Uponor SYSTEMpro 311 Installation Manual

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SYSTEMpro™311

Installation Manual

Page 2

SYSTEMpro™311

Installation Manual is published by Uponor Wirsbo 5925 148th Street West Apple Valley, MN 55124 (952)-891-2000

First Edition First Printing July 2002 Printed in the United States of America

Page 3

TABLE OF CONTENTS

INTRODUCTION

Control Overview .................................................................... 3

Navigating the Control ........................................................ 4-6

Viewing the Status of the System Performance .......... 7-12

Mixing Reset Mode ........................................ 7-9

Snow Melt Mode ........................................10-12

INSTALLATION

Step 1 – Checking Contents ................................................ 14

Step 2 – The Control Base .............................................. 15-17

Step 3 – Rough-In Wiring...................................................... 18

Step 4 – Attaching the Control to the Base ...................... 19

Step 5 – Mounting the Sensors .................................... 20-22

Step 6 – Electrical Connections to the Control............ 23-28

Powered Input Connection ............................ 23

Output Connections .................................. 24-25

Sensor Connections ........................................ 26

Unpowered Input Connections .................... 27

Temperature Resistance Chart ...................... 28

Step 7 – Testing the Wiring ............................................ 29-32

Test the Sensors .............................................. 29

Test the Power Supply .................................... 30

Test the Powered Demand Inputs ................ 30

Test the Outputs ........................................ 30-32

Step 8 – Completing the Installation .................................. 33

PROGRAMMING

Step 1 – Programming the Control .............................. 35-55

DIP Settings ................................................ 35-36

Programming the "Misc" Menu .................... 37

Programming the "Adjust" Menu............ 38-55

A. Boiler/High Temp Zone Settings.... 38-41

B. DHW Settings.................................... 42-43

C. Mixing Device Settings.................... 44-49

D. Snow Melting Settings.................... 50-53

E. Boiler Operation Settings ................ 54-55

Step 2 – Test Sequence.................................................... 56-57

CONTROL FUNCTION OVERVIEW

Section A – General .............................................................. 59

Section B – Boiler / High Temp Zones .......................... 60-62

Section B1 – General ................................ 60-62

Section B2 – Boiler Demands ........................ 62

Section C – Domestic Hot Water (DHW) ...................... 63-66

Section C1 – General ................................ 63-64

Section C2 – DHW Priority ........................ 65-66

Section D – Mixing Zones .............................................. 67-71

Section D1 – General ................................ 67-69

Section D2 – Mixing Devices.................... 69-70

Section D3 – Mixing Demands ................ 70-71

(Continued on page 2)

INTRODUCTION

INTRODUCTION - Table of Contents

IMPORTANT NOTE:

If you are not familiar with how the Wirsbo SYSTEMpro 311 operates, or the theory behind settings for a radiant system it is important you review the Control Function Overview. It will help with understanding the functions of the control within the hydronic radiant heating system.

Quick Guide

If you are only INSTALLING the SYSTEMpro 311 go to:

INSTALLATION Steps 1-8

If you are only PROGRAMMING the SYSTEMpro 311 go to:

PROGRAMMING Steps 1-2

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Section E – Snow Melting .............................................. 72-79

Section E1 – General.................................. 72-75

Section E2 – With Slab Sensor ................ 76-77

Section E3 – Without Slab Sensor .......... 77-78

Section E4 – Snow Melt Enable .............. 78-79

Section F – Boiler Operation .......................................... 80-81

Section F1 – Boiler Supply Sensor.......... 80-81

Section G – Troubleshooting .......................................... 82-83

APPENDIX

IVariable Speed Injection Mixing.............................. 85-87

II SYSTEMpro 311 Menu Tree .................................... 88-89

III Application Drawings ................................................ 90-97

IV Error Message Overview ........................................ 98-101

V SYSTEMpro 311 Program Setup ........................ 102-103

INTRODUCTION

INTRODUCTION - Table of Contents

TABLE OF CONTENTS (cont.)

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INTRODUCTION

CONTROL OVERVIEW

The SYSTEMpro™311 is a multi-temperature reset

control that maximizes the comfort and efficiency of

a hydronic heating system. This weather-responsive

control uses outdoor reset to automatically adjust

boiler and mixed-loop water temperatures supplied

to the heating system. It can be used to supply

mixed-loop water temperature heat to a radiant

floor or snowmelt application and is specifically

created to operate efficiently as part of a Wirsbo

radiant/snow melt heating system. For a mixing

device, either a variable speed injection pump or

floating action mixing valve may be used. As an

added benefit, the SYSTEMpro 311 has the ability

to control an indirect Domestic Hot Water (DHW)

storage tank and a semi-automatic snow melt zone.

INTRODUCTION

INTRODUCTION - Control Overview

Page 6

INTRODUCTION

NAVIGATING THE CONTROL

The SYSTEMpro 311 (also referred to as "control") has

a Liquid Crystal Display (LCD) that lets users setup the

operation of the system. The SYSTEMpro 311 has four

push buttons for selecting and adjusting settings.

(See fig. a)

NOTE: It is recommended that the user record control settings (for later review) on the Program Setup Sheet provided in Appendix V.

Menu (See fig. b)

• All items displayed by the control are organized into various menus

• Menus are listed on the left side of the display (Menu Field)

• To select a menu, use the Menu button

• By pressing and releasing the Menu button, the display will advance to the next available menu

• Within specific menu selections, a group of items can be viewed and selected

Item (See fig. c)

• The abbreviated name of the selected item will be displayed in the item field of the display

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

• Once you have reached the last available item in a menu, press and release the Item button to return the display to the first item in the same menu

Adjustments (See fig. d)

• To make an adjustment to a control setting, first select the appropriate menu with the Menu button

• Then select the item you want using the Item button

• Finally, use the up and/or down button to make the change

NOTE: You can get more information by viewing the Status field of the LCD. The status field shows which of the control’s outputs are active. Most symbols in the status field can only be seen when the View Menu is selected.

INTRODUCTION

INTRODUCTION - Navigating the Control

Minimum

Maximum

WWSD

Melting

DHW Demand

Boiler Demand

Mix Demand

Open Close

Misc

Adjust

min hr

DHW

sec

View

Menu Item

Start Stop

Ma Me

Open Close

DHW

Menu Item

Start Stop

Ma Me

Open Close

DHW

Menu Item

Start Stop

Ma Me

Open Close

DHW

Menu Item

Start Stop

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INTRODUCTION

INTRODUCTION - Navigating the Control

Minimum

Maximum

WWSD

Melting

DHW Demand

Boiler Demand

Mix Demand

Open Close

Misc

Adjust

min hr

DHW

sec

View

Menu Item

Start Stop

Item Field

Displays an abbreviated name of the selected item

Menu Field

Displays the current menu

Status Field

Displays the current status or the control’s inputs, outputs and operation

Buttons

Select menus, items and adjust settings

Numbers Field

Displays the current value of the selected item

}

Display

Symbol Description

Open/Close

Displays when the actuator is opening or closing.

Mixing Device Output Scale

Shows output of injection pump or mixing valve. Arrows show whether the output is increasing or decreasing.

Burner

Displays when the boiler relay is turned on.

Pump

Indicates specific pump operation

1 - boiler pump (P3) 2 - boiler demand pump (P7) 3 - mixing pump (P1)

DHW Pump/Valve

Displays when the DHW pump or valve is on.

Warning

Displays when an error exists or when a limit has been reached.

Lock/Unlock

Displays when the access levels are locked or unlocked.

Units of Measurement

Pointer

Displays the control operation as indicated by the text.

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Access Levels

• The SYSTEMpro 311 comes with four Access Level settings

• Access Levels restrict the number of Items and Adjustments that can be accessed by the user

• The access level of the control is found in the Miscellaneous (Misc) Menu when the Lock/Unlock DIP switch is set to the Unlocked position

The four access levels include:

1) Limited (LTD) (See fig. a)

• The most restricted access level

2) User (USER) (See fig. b)

• Allows access to only a few of the items within a menu

3) Installer (INST) (See fig. c)

• Sufficient for the normal set up of the control

NOTE: This is how the control arrives from the factory.

4) Advanced (ADV) (See fig. d)

• Allows access to all of the control settings available

How to Set The Access Level (ACCESS) (See fig. e)

1) With a small screwdriver, or similar tool - Set the “Lock/Unlock” DIP switch on control front to Unlock

2) Go to ACCESS item field in MISC Menu

3) Select the level of access that you wish to be used by the control

RANGE: ADV (Advanced), INST (Installer),

USER (User), LTD (Limited)

DEFAULT: INST (Installer)

INTRODUCTION

INTRODUCTION - Navigating the Control

MiscaMiscbMisccMisc

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

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INTRODUCTION

VIEWING THE STATUS OF THE SYSTEM PERFORMANCE

• The View Menu is available for viewing the current status of the system performance

• By selecting the View Menu, and then pushing the item button, you can scroll through the available menu items showing the current settings and temperatures in the system

OUTDOOR (See fig. a)

Shows actual outside temperature at outdoor sensor S4 location

RM TRG (See fig. b)

Targeted room temperature for the mixing zone.

NOTE: This screen will be available in the View Menu only when the Indoor (INDR) sensor is selected under the MIX 10K screen in the ADJUST Menu.

ROOM (See fig. c)

Actual room temperature as read by the room sensor (MIX 10K).

NOTE: This screen will be available in the View Menu only when the Indoor (INDR) sensor is selected under the MIX 10K screen in the ADJUST Menu.

Mixing Reset Mode

INTRODUCTION

INTRODUCTION - Viewing the Status of the System Performance

View

Access Level

LTD

USER

INST

ADV

View

Access Level

LTD

USER

INST

ADV

View

Access Level

LTD

USER

INST

ADV

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SLAB (See fig. d)

Actual slab temperature as read by the slab sensor S7 (MIX 10K)

NOTE: This screen will be available in the View Menu only when the Slab (SLAB) sensor is selected under the MIX 10K screen in the ADJUST Menu.

MIX TRG (See fig. e)

The targeted mixed supply water temperature the control has calculated in order to meet current conditions

MIX SUP (See fig. f)

Shows actual mix supply water temperature to the system at mix supply sensor S1 location

Boil TRG (See fig. g)

The targeted boiler supply temperature the control has calculated in order to meet the current conditions

INTRODUCTION

INTRODUCTION - Viewing the Status of the System Performance

View

Access Level

LTD

USER

INST

ADV

View

Access Level

LTD

USER

INST

ADV

View

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

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Boil SUP (See fig. h)

Shows actual boiler supply water temperature at boiler supply sensor S3 location

DHW TRG (See fig. i)

The targeted DHW tank temperature the control has calculated in order to meet the current DHW demand.

NOTE: This screen will be available in the View Menu only when a DHW device is selected in the DHW THRU screen in the ADJUST Menu.

DHW (See fig. j)

Shows the actual DHW tank temperature at the DHW sensor (S6) location.

NOTE: This screen will be available in the View Menu only when a DHW device is selected in the DHW THRU screen in the ADJUST Menu.

INTRODUCTION

INTRODUCTION - Viewing the Status of the System Performance

View

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

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INTRODUCTION

VIEWING THE STATUS OF THE SYSTEM PERFORMANCE

• The View Menu is available for viewing the current status of the system performance

• By selecting the View Menu, and then pushing the item button, you can scroll through the available menu items showing the current settings and temperatures in the system

OUTDOOR (See fig. a)

Shows actual outside temperature at outdoor sensor S4 location

SLAB TRG (See fig. b)

The targeted temperature the control has calculated in order to meet current conditions

SLAB (See fig. c)

Shows actual slab temperature at slab sensor S7 location

STATUS (See fig. d)

Shows current snow melt operating status. See Control Function Overview section page 72 for more detailed information.

Snow Melt Mode

INTRODUCTION

INTRODUCTION - Viewing the Status of the System Performance

View

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

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MIX TRG (See fig. e)

The targeted mixed supply water temperature the control has calculated in order to meet current conditions

MIX SUP (See fig. f)

Shows actual mix supply water temperature to the system at mix supply sensor S1 location

MIX ∆T (See fig. g)

Shows actual temperature differential (Delta-T) between mix supply sensor S1 and mix return sensor S5 locations

Boil TRG (See fig. h)

The targeted boiler supply temperature the control has calculated in order to meet the current conditions

INTRODUCTION

INTRODUCTION - Viewing the Status of the System Performance

View

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

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Boil SUP (See fig. i)

Shows actual boiler supply water temperature at boiler supply sensor S3 location.

DHW TRG (See fig. j)

The targeted DHW tank temperature the control has calculated in order to meet the current DHW demand. This screen is available only when a sensor is selected in the DHW SENS screen in the ADJUST Menu.

DHW (See fig. k)

Shows actual DHW tank temperature at DHW sensor S6 location. This screen is available only when a sensor is selected in the DHW SENS screen in the ADJUST Menu.

INTRODUCTION

INTRODUCTION - Viewing the Status of the System Performance

View

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

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INSTALLATION

TABLE OF CONTENTS

Step 1 – Checking Contents ................................................ 14

Step 2 – The Control Base .............................................. 15-17

Step 3 – Rough-In Wiring...................................................... 18

Step 4 – Attaching the Control to the Base ...................... 19

Step 5 – Mounting the Sensors .................................... 20-22

Step 6 – Electrical Connections to the Control............ 23-28

Powered Input Connection ............................ 23

Output Connections .................................. 24-25

Sensor Connections ........................................ 26

Unpowered Input Connections .................... 27

Temperature Resistance Chart ...................... 28

Step 7 – Testing the Wiring ............................................ 29-32

Test the Sensors .............................................. 29

Test the Power Supply .................................... 30

Test the Powered Demand Inputs ................ 30

Test the Outputs ........................................ 30-32

Step 8 – Completing the Installation .................................. 33

INSTALLATION

INSTALLATION - Table of Contents

Page 16

INSTALLATION

INSTALLATION - Step 1 - Checking Contents

INSTALLATION - STEP 1

CHECKING CONTENTS

Check the contents of this package. The Wirsbo SYSTEMpro 311 should have:

One SYSTEMpro 311

(A3040311)

One Outdoor Sensor

(A3040070)

Two Universal Sensors

(A3060071)

One Product Manual

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

Control Optional Components

(sold separately)

DHW Sensor

(A3060071)

Remote Display

(A3040040)

Snow Melt Enable Kit

(A3040039)

CAUTIONS AND DISCLAIMERS

Failure to install and/or operate this control properly could result in:

• Damage to the equipment

• Personal injury

• Property damage

It is up to you to make sure this control is installed safely in a way that meets all codes and standards that apply. Do not use this electronic control as a primary limit control. Other controls that are meant to be used and certified to be used as safety limits must be placed into the control circuit.

Carefully read the Control Overview (page 3) to make sure you have chosen the proper control for your application.

Warning Symbol: Indicates presence of hazards which can cause severe personal injury, death or substantial property damage if ignored

SYSTEMpro

™

311

Installation Manual

Page 17

INSTALLATION - STEP 2

THE CONTROL BASE

Removing the Control from the Base

Press down at the fingertip grips on top of the front cover and pull out and down.

(See fig. a)

Lift the front cover up and away from the control.

(See fig. b)

Loosen the screws at the front of the wiring cover.

(See fig. c)

The wiring cover pulls straight out from the wiring chamber.

(See fig. d)

INSTALLATION

INSTALLATION - Step 2 - The Control Base

Page 18

Remove the safety dividers from the wiring chamber by pulling them straight out of their grooves.

(See fig. e)

Press the control release clip on the base inside the wiring chamber and slide the control upwards.

(See fig. f)

The control lifts up and away from the base.

(See fig. g)

Mounting the Base (See fig. h)

1) Find a convenient and accessible location typically in the mechanical room

2) Following the hole pattern, mount the control base using the appropriate screws

INSTALLATION

INSTALLATION - Step 2 - The Control Base

Mounting holes

Knockout

Locking Clip

Release Clip

Page 19

The control can also be mounted on a standard DIN rail. (See fig. i)

First remove the control from its base and then, using the hooks and spring clip on the back of the control (ordered separately), mount it onto the DIN rail. This will be a popular option for those who prefer to mount the control inside a larger electrical panel.

The wiring can enter the bottom or the back of the enclosure. Knock-outs provided in the base allow the wiring to be run in conduit up to the enclosure. The base also has holes that line up with the mounting holes of most common electrical boxes.

INSTALLATION

INSTALLATION - Step 2 - The Control Base

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INSTALLATION - STEP 3

ROUGH-IN WIRING

Things to note before you start wiring:

• All electrical wiring should end in the control base wiring

chamber

• The base has standard 7/8” (22 mm) knockouts

• Knockouts accept common wiring hardware and conduit

fittings

• Before removing knockouts, check wiring diagram and

select those sections of the chamber with common voltages

• Do not allow the wiring to cross between low/high voltage

sections or else wires will interfere with safety dividers (these dividers should be installed at a later time)

• Do not apply power to any of the wires during rough-in

wiring stage

• All wires should be stripped to 3/8"L (9 mm) for the correct

connection to the control

Wiring Components:

1) Install the various sensors indicated below as per instructions

listed and run the wiring back to the control base and label all wires for later installation

Main Sensors:

• Outdoor Sensor S4

• Boiler Sensor S3

• Mixing Sensor S1

Optional Sensors:

• DHW Sensor S6

• Mixing Return Sensor S5

• Slab Sensor S7

Optional Modules:

• Remote Display Module (RDM)

• Snow Melt Enable Kit

2) Run appropriate wire from all other system components

(pump, boiler, etc.) to the control base

3) Run wires from the 120 VAC power to the control base

• Use a clean power source to ensure proper operation

• Comply with local codes for minimum gauge and breaker requirements

INSTALLATION

INSTALLATION - Step 3 - Rough-In Wiring

CAUTION

All wiring must be performed by a licensed professional and comply with local trade practices and codes.

Wirsbo does not take responsibility for any damage caused due to failure to comply.

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INSTALLATION - STEP 4

ATTACHING THE CONTROL TO THE BASE

1) Push the SYSTEMpro 311 control into the base you mounted in Step 2

2) Slide the control down until it snaps firmly into place

(See fig. a)

INSTALLATION

INSTALLATION - Step 4 - Attaching the Control to the Base

Page 22

INSTALLATION - STEP 5

MOUNTING THE SENSORS

Outdoor Sensor (S4)

(See fig. a)

The Outdoor Sensor includes a 10 kΩ thermistor which provides an accurate measurement of the outdoor temperature. The sensor is protected by a white U.V. resistant PVC plastic enclosure.

Step One – Mounting (See fig. b)

NOTE: The temperature sensor (thermistor) is built into the 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 sensor is wall mounted, the wiring should enter through the back or bottom of the enclosure. Do not mount the sensor with the conduit knockout facing upwards as rain could enter the enclosure and damage the sensor.

• 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 an exterior wall which best represents actual outdoor temperature (a north facing wall). It should not be exposed to heat sources such as solar gain, exhaust ventilation or window openings.

• The outdoor sensor should be installed at an elevation above the ground that will prevent accidental damage or tampering. Installing the sensor in the shadow of the roof eave is common.

Step Two – Wiring and Testing (See fig. c)

• 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.

CAUTION: Do not run sensor wires parallel to telephone or power cables. If the sensor wires are located in an area with strong sources of electromagnetic interference (EMI), shielded cable or twisted pair should be used or the wires can be run in a grounded metal conduit. If using shielded cable, the shield wire should be connected to the Com 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 as per installation – step 6.

• Replace the front cover of the sensor enclosure.

INSTALLATION

INSTALLATION - Step 5 - Mounting the Sensors

Wires from outdoor sensor to control terminals (Com Sen - Out Sen)

Sensor is built into the enclosure

Sensor with rear entry wiring

Sensor with bottom entry wiring

Sensor mounted onto 2” x 4” electrical box

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Universal Sensors (S1, S3, S5 & S6)

(See fig. d)

These Universal Sensors have a zinc sleeve for fast response and a wide operating range. They can be used in a multitude of applications. They are supplied with 10 inches (250 mm) of 2 conductor wire.

Step One – Mounting (See figs. e thru g)

NOTE: The Sensor is designed to mount on a pipe or in a temperature immersion well.

• 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.

• The Universal Sensor should be placed downstream of a pump or after an elbow or similar fitting. Proper sensor location requires that the fluid is thoroughly mixed within the pipe before it reaches the sensor.

Step Two – Wiring and Testing

• If it is necessary to connect 18 AWG wire to the two sensor wires, wire nuts can be used to hold the wires together.

• Follow the sensor testing instructions given in this brochure and then connect the wires to the control.

INSTALLATION

INSTALLATION - Step 5 - Mounting the Sensors

Page 24

Slab Sensor (S7) (See fig. h)

The Slab Sensor has a PVC plastic sleeve which is designed for use in soils or concrete. It is supplied with 20 ft (6 m) of 2 conductor cable.

Step One – Mounting (See fig. i)

NOTE: Proper placement of this sensor is critical for correct operation of the control.

This sensor is designed to be embedded in the slab material. It is highly recommended the sensor be installed in a plastic or metal conduit embedded in the slab. If there is ever a sensor failure, this allows the sensor to be removed and replaced. The sensor should be placed 1” (25 mm) below the slab surface and half way between the pipes. Access to the conduit after leaving the slab should be available for replacing the sensor in the future if required.

(See fig. j)

Step Two – Wiring and testing

CAUTION: Do not run sensor wires parallel to telephone or power cables. If the sensor wires are located in an area with strong sources of electromagnetic interference, shielded cable or twisted pair should be used or the wires can be run in a grounded metal conduit. The ground wire should be connected to the common sensor terminal on the control and not to earth ground.

The Slab Sensor is supplied with 20' (6 m) of cable. If a longer length is required, 18 AWG wire can be spliced onto the two wires from the sensor. The splices should be properly soldered and protected in an accessible, waterproof junction box. Follow the sensor testing instructions given in this brochure and then connect the wires to the control.

INSTALLATION

INSTALLATION - Step 5 - Mounting the Sensors

Sensor half way between the pipes/cables

1”

(25 mm)

Conduit w/sensor

Sensor wire

Access panel

Page 25

INSTALLATION - STEP 6

ELECTRICAL CONNECTIONS TO THE CONTROL

IMPORTANT: Test to be certain no voltage is present in any wires.

120 VAC Power (See fig. a)

• Provides power to microprocessor and control display as well as power to Boil P3 terminal (8) from Power L terminal (7)

• Connect 120 VAC power supply to Power L and Power N terminals (6 and 7)

Demand Connections

Demand to the control is generated from a thermostat zone control module or external relay. This connection must have 24 VAC supplied to the demand terminals

Mixing Demand (See fig. b)

• Apply a voltage between 24 VAC and 240 VAC across Mixing Demand terminals (1 and 2)

Mixing Demand with Wirsbo Thermostat

NOTE: When connecting a Wirsbo Thermostat WT1 or WT2 directly to the Mix Demand Terminals 1 and 2, a 0.5 watt 1000 ohm resistor needs to be installed parallel as shown. A packet with the resistor and schematic is included in the box.

Boiler Demand (See fig. c)

• Apply a voltage between 24 VAC and 240 VAC across Boil Dem and Com Dem terminals (3 and 4)

DHW Demand (See fig. d)

• Apply a voltage between 24 VAC and 240 VAC across DHW and the Com Dem terminals (4 and 5)

Powered Input Connections

INSTALLATION

INSTALLATION - Step 6 - Electrical Connections to the Control

120 VAC

Power

Mix

Demand

24 to 240 VAC

Boil

Dem

Com

Dem

24 to 240 VAC

Com

Dem

DHW Dem

24 to 240 VAC

24 VAC

TRANSFORMER

120 VAC

WIRSBO

RH W

NOTE:

0.5w 1000 Ohm Resistor

54321

Mix

Demand

Boil Com DHW

Dem

WIRSBO

THERMOSTAT

WT 1

(A3030101)

WT 2

(A3030102)

Page 26

1) Boiler Contact (See fig. e)

Boiler terminals (15 and 16) are an isolated output. No power is available on these terminals from the control.

• Use terminals as switch to make or break the boiler circuit

• When the SYSTEMpro 311 requires the boiler to fire, contact closes between terminals 15 and 16

2) DHW Pump/Valve Contact (See fig. f)

DHW P6/Vlv terminals (13 and 14) are an isolated output. No power is available on these terminals from the control.

• Use terminals as switch to either make or break power to DHW pump or valve

• As an isolated contact it may switch a voltage between 24 VAC and 240 VAC

3) Primary Pump Contact (Boil P3) (See fig. g)

Boil P3 output terminal (8) is a powered output. When relay in the SystemPro 311 closes, 120 VAC is provided to Boil P3 terminal (8) from Power L terminal (7).

• To operate primary pump, connect one side of primary pump circuit to terminal (8) and second side of pump circuit to neutral N terminal (6) side of 120 VAC power supply

4) Boiler Demand Pump (Boil Dem Pmp P7)

(See fig. h)

Boil Dem Pmp P7 terminals (9 and 10) are an isolated output. No power is available on these terminals from the control.

• Use terminals as a switch to make or break power to the boiler system pump

• As an isolated contact, it may switch a voltage between 24 VAC and 240 VAC

Output Connections (1-7)

INSTALLATION

INSTALLATION - Step 6 - Electrical Connections to the Control

Boil

Pow

120 VAC

Boil Dem Pmp P7

120 VAC

Boiler

DHW

P6/Vlv

24 to 240 VAC

Page 27

5) Mixing System Pump (Mixing Pmp P1)

(See fig. i)

Mixing Pmp P1 terminals (11 and 12) are isolated outputs. No power is available on these terminals from the control.

• Use terminals as a switch to either make or break power to mixing system pump

• As an isolated contact, it may switch a voltage between 24 VAC and 240 VAC

6) Variable Speed Injection Pump (Cls/P4)

(See fig. j)

The SYSTEMpro 311 can vary the speed of a pump motor with locked rotor current of less than 2.4 A (most small wet rotor circulators may be used as described in APPENDIX I - page 85).

• If using a variable speed injection pump, connect one of the wires from variable speed injection pump to Cls/P4 terminal (19)

• Connect other wire on variable speed injection pump to live (L) side of 120 VAC power supply

• Connect Pwr Mix terminal (17) to neutral (N) side of 120 VAC power source

7) Mixing Valve Actuator (See fig. k)

If a mixing valve is used:

• Connect one side of 24 VAC power to Pwr Mix terminal (17) on control

• Connect output relay Opn (18) to the "open" terminal of actuating motor

• Connect output relay Cls/P4 (19) to the "close" terminal of actuating motor

• Connect second side of 24 VAC circuit to common terminal of actuating motor

NOTE: The SYSTEMpro 311 has an internal overload fuse rated at 2.5 A 250 VAC — contact your Wirsbo sales representative for repair information if fuse is blown.

INSTALLATION

INSTALLATION - Step 6 - Electrical Connections to the Control

Mixing

Pmp P1

120 VAC

Mix

Opn

Cls/

Mix

Opn

Cls/

24 or 1

20 VAC

Com

Page 28

WARNING: Do not apply power to these terminals as this will damage the control.

Connect the two wires from sensors to terminals described below:

8) Outdoor Sensor S4 wires to Com and Out terminals (27 and 29) (See fig. l)

• Measures outdoor air temperature

9) Boiler Sensor S3 wires to Com and Boil S3 terminals (24 and 26) (See fig. m)

• Measures supply water temp from boiler

10) Mixing Supply Sensor S1 wires to Com

and Mix S1 terminals (20 and 23) (See fig. n)

• Measures the supply temperature after the mixing device

NOTE: Sensor is normally attached downstream of mixing system pump (P1).

11) Mixing Return Sensor S5 wire to Com

and Ret S5 terminals (20 and 22) (See fig. o)

• Measures fluid return temperature from snow melting slab

NOTE: This sensor is only used when the Snow Melting/Mixing Reset DIP switch is set to the Snow Melting position

12) Mix 10K Sensor to Com and Mix 10K

terminals (20 and 21) (See fig. p)

• Works with indoor sensor, slab sensor, or zone control

sensor

13) DHW Sensor S6 to Com and DHW S6

terminals (27 and 28) (See fig. q)

• Measures temperature in DHW (Domestic Hot Water) tank

Sensor Connections (8-13)

INSTALLATION

INSTALLATION - Step 6 - Electrical Connections to the Control

Com

DHW

Com

Mix

10K

Com

DHW

Out

Com

Boil

Zo in

Boil

Boiler

Sensor

Com

Mix

10K

Ret

Mix

Com

Mix

10K

Ret

Mix

Page 29

WARNING: Wires from unpowered input connections are polarity sensitive. The communication of these devices will not operate correctly if the wires are reversed.

14) Mixing Zone Control Input (See fig. r)

An external tekmar zone control may be used to control mixing zones.

• Connect wire from Com Sen terminal on zone control to Com terminal (20) on SYSTEMpro 311

• Connect ZoOut terminal on zone control to Mix 10K terminal (21) on SYSTEMpro 311

15) Boiler Zone Control Input (See fig. s)

An external tekmar zone control may be used to control boiler zones.

• Connect wire from Com Sen terminal on zone control to Com terminal (24) on the SYSTEMpro 311

• Connect the ZoOut terminal on zone control to Boil ZoIn terminal (25) on the SYSTEMpro 311

16) tN2 Device (See fig. t)

A Remote Display Module or Snow Melt Enable may be connected to the tN2 input on the SYSTEMpro 311.

• Connect the Com terminal from Remote Display Module or Snow Melt Enable to Com terminal (27) on SYSTEMpro 311

• Connect the tN2 terminal from Remote Display Module or

Snow Melt Enable to the tN2 terminal (30) on SYSTEMpro 311

Unpowered Input Connections (14-16)

INSTALLATION

INSTALLATION - Step 6 - Electrical Connections to the Control

Out

Com

Sen

Com

Mix

10K

SYSTEMpro 311

Zone Control

Out

Com Sen

Com

Boil

Zo in

SYSTEMpro 311

Zone Control

Com

DHW

Out

tN2

Page 30

INSTALLATION

INSTALLATION - Step 6 - Electrical Connections to the Control

ΩΩΩΩ

100

105

110

115

120

125

130

135

140

145

150

155

160

165

170

175

180

185

190

195

200

205

210

215

220

225

-7

-4

-1

102

104

107

490,813

405,710

336,606

280,279

234,196

196,358

165,180

139,402

118,018

100,221

85,362

72,918

62,465

53,658

46,218

39,913

34,558

29,996

26,099

22,763

19,900

17,436

15,311

13,474

11,883

10,501

9,299

8,250

7,334

6,532

5,828

5,210

4,665

4,184

3,760

3,383

3,050

2,754

2,490

2,255

2,045

1,857

1,689

1,538

1,403

1,281

1,172

1,073

983

903

829

763

703

648

598

553

Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance

°F °C °F °C °F °C °F °C

-50

-45

-40

-35

-30

-25

-20

-15

-10

-5

-46

-43

-40

-37

-34

-32

-29

-26

-23

-21

-18

-15

-12

-9

Temperature Resistance Chart

Page 31

INSTALLATION - STEP 7

TESTING THE WIRING

NOTE: The following tests are to be performed using standard testing practices and procedures. They should only be carried out by properly trained and experienced installers.

Things to note before you start ANY testing:

• Before supplying power for testing, each terminal block

must be unplugged from its header on the control

• To remove the terminal block, pull straight down from

the control (See fig. a)

• The following tests should only be carried out by

properly trained and experienced installers

• When testing, use standard testing practices and

procedures

• To properly test wiring and sensors, a good quality

electrical test meter capable of reading at least 0 – 300 VAC and at least 0 – 2,000,000 Ohms is essential

Test the Sensors

To test the sensors, the actual temperature at each sensor location must be measured.

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 on the previous page, estimate the temperature measured by the sensor. The sensor and thermometer readings should be close. If the test meter reads a very high resistance, there may be a broken wire, a poor wiring connection or a defective sensor. If the resistance is very low, the wiring may be shorted, there may be moisture in the sensor or the sensor may be defective. To test for a defective sensor, measure the resistance directly at the sensor location.

Do not apply voltage to a sensor at any time as damage to the sensor may result.

INSTALLATION

INSTALLATION - Step 7 - Testing the Wiring

Power

Boil P3

Boil Dem Pmp P7

Page 32

Test the Power Supply

1) Make sure exposed wires and bare terminals are not in contact with other wires or grounded surfaces

2) Turn on the power and measure the voltage between the Power L and Power N terminals (6 and 7) using an AC voltmeter, the reading should be between 108 and 132 VAC

Test the Powered Demand Inputs

Voltage Readings for ALL Demand Devices (described below)

1) When any of the demand devices described above calls for heat, you should measure between 20 and 260 VAC at the terminals

2) When these demand devices are off, you should measure less than 5 VAC

Mixing Demand (if used)

• Measure voltage between Mix Demand terminals (1 and 2)

Boiler Demand (if used)

• Measure voltage between Boil Dem and Com Dem terminals

(3 and 4)

DHW Demand (if used)

• Measure voltage between DHW Dem and Com Dem

terminals (4 and 5)

Test the Outputs

IMPORTANT NOTE FOR ALL OUTPUT DEVICES:

Once you have verified a device operates properly, shut off the power to the device and remove the jumper installed during the testing procedure below. If any device fails to start, see troubleshooting information on page 32.

Primary Pump (Boil P3) — connected to terminal (8) (See fig. a)

1) Make sure that power to terminal block is off

2) Install a jumper between Power L and Boil P3 terminals (7 and 8)

3) When power is applied to the Power L and Power N terminals (7 and 6) the primary pump should start

INSTALLATION

INSTALLATION - Step 7 - Testing the Wiring

120 VAC

Boil

Power

Page 33

Boiler Demand Pump (Boil Dem Pmp P7) — terminals (9 and 10) (See fig. b)

1) Make sure power to the pump circuit is off

2) Install a jumper between terminals (9 and 10)

3) When pump circuit is powered up, boiler demand pump should start

Mixing System Pump (Mixing Pmp P1) — terminals (11 and 12) (See fig. c)

1) Make sure power to the pump circuit is off

2) Install a jumper between terminals (11 and 12)

3) When the pump circuit is powered up, mixing system pump should start

DHW Pump or Valve (DHW P6/ Vlv) — (13 and 14) (See fig. d)

• Make sure power to the pump or valve circuit is off

• Install a jumper between terminals (13 and 14)

• When the DHW circuit is powered up, the DHW pump should

turn on or the DHW valve should open completely

Boiler — connected to the Boiler terminals (15 and 16) (See fig. e)

• Make sure power to the boiler circuit is off

• Install a jumper between the terminals (15 and 16)

• When the boiler circuit is powered up, the boiler should fire

NOTE: Boiler may have a flow switch that prevents firing until the primary pump (P3) is running.

Variable Speed Injection Pump (VSP P4) — (17 and 19) (See fig. f)

• Make sure power to terminal block is off

• Install a jumper between the Pwr Mix and Cls/P4 terminals

(17 and 19)

• When the variable speed pump circuit is powered up, the

variable speed pump should operate at full speed

INSTALLATION

INSTALLATION - Step 7 - Testing the Wiring

Boil Dem Pmp P7

120 VAC

Mixing

Pmp P1

120 VAC

DHW

P6/Vlv

120 VAC

Boiler

120 VAC

Pwr

Mix

Opn

Cls/ P4

Page 34

Mixing Valve Actuator — connected to Pwr Mix, Opn and Cls / P4 terminals (17, 18 and 19)

STEP 1: (See fig. g)

• Make sure power to the motor circuit is off

• Install a jumper between the Pwr Mix and Opn terminals (17 and 18)

• Power up circuit , actuator should move in opening direction

NOTE: If the motor closes instead of opens, wiring of actuating motor must be reversed

• If valve opens correctly, turn off the power to circuit and remove the jumper before proceeding to STEP 2

STEP 2: (See fig. h)

• Install a jumper between the Pwr Mix and Cls/ P4 terminals (17 and 19)

• Power up circuit , actuator should move in closing direction

• If motor closes correctly, turn off power to circuit and remove jumper

Troubleshooting for ALL Output Devices (described above)

• If the device does not start, check all wiring connections

• If the device still fails to start you may need to refer to the manufacturers installation or troubleshooting information supplied with the device

INSTALLATION

INSTALLATION - Step 7 - Testing the Wiring

24 or 1

20 VAC

Com

Pwr

Mix

Opn

Cls/ P4

Pwr Mix

Opn

Cls/ P4

24 or 1

20 VAC

Com

Page 35

INSTALLATION - STEP 8

COMPLETING THE INSTALLATION

Once you have successfully tested all of the wiring and found that everything is operational, you are ready to complete the installation.

1) Make sure all power to the devices and terminal blocks is off, and remove any remaining jumpers from the terminals

2) Reconnect the terminal blocks to the control by carefully aligning them with their respective headers on the control

3) Push the terminal blocks into the headers — they should snap firmly into place

(See fig. a)

4) Install supplied safety dividers between unpowered sensor inputs and powered or 120 VAC wiring chambers

5) Apply power to the control

NOTE: The operation of the control on power up is described in the Control Function Overview section of this manual (page 58).

Cleaning The Control

• Moisten cloth with water and wring out prior to wiping control

• Do not use solvents or cleaning solutions on the control

INSTALLATION

INSTALLATION - Step 8 - Completing the Installation

Power

Boil

Boil Dem Pmp P7

Page 36

PROGRAMMING

TABLE OF CONTENTS

Step 1 – Programming the Control .............................. 35-55

DIP Settings ................................................ 35-36

Programming the "Misc" Menu .................... 37

Programming the "Adjust" Menu............ 38-55

A. Boiler/High Temp Zone Settings.... 38-41

B. DHW Settings.................................... 42-43

C. Mixing Device Settings.................... 44-49

D. Snow Melting Settings.................... 50-53

E. Boiler Operation Settings ................ 54-55

Step 2 – Test Sequence.................................................... 56-57

PROGRAMMING

PROGRAMMING - Table of Contents

Page 37

PROGRAMMING - STEP 1

PROGRAMMING THE CONTROL

GENERAL NOTE: This section is dedicated to guiding you through the programming of each function in a logical order based on area of control. For more detailed functions of any particular item, please refer to the Control Overview Section.

IMPORTANT (PLEASE READ): The SYSTEMpro 311 is

now fully installed and ready for a trained, qualified individual to begin entering the settings that will help it control a hydronic radiant heating system at its most efficient level.

Before you start PROGRAMMING you should:

1) REVIEW DIP Switch Settings below, as they affect what items are available to be viewed and controlled through the User Interface.

2) REVIEW The Control Function Overview if you are not familiar with how the control functions operate in conjunction with the specific systems installed.

DIP SWITCH SETTINGS:

About DIP Switch Settings

• DIP switch settings on the control are very important and

should be set to appropriate settings prior to making any adjustments to the control

• DIP switch settings change the items that are available to be

viewed and/or adjusted in the control

• If a DIP switch is changed while control is powered up, the

control responds to the setting change by returning the display to the View menu. This is true for all the DIP switches except for the Lock / Unlock DIP switch

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Page 38

Lock/Unlock DIP Switch Setting (Factory Setting is Unlock)

• Lock/Unlock DIP switch is used to lock and unlock the access level of the control

(See fig. a)

• In locked mode, access levels cannot be changed

• A small icon representing a padlock is shown in the bottom right hand corner of the display, indicating if control is locked or unlocked

(See fig. b)

• To change the access level, set the DIP switch to the unlocked, or down position. The current access level of the control is viewed in its Miscellaneous (Misc) Menu.

• While viewing the access level, use the “up” and “down” buttons to select between the Limited (LTD), User (USER), Installer (INST) or Advanced (ADV) access levels

• To lock the access level, select the appropriate access level in the Miscellaneous (Misc) Menu and move the DIP switch from unlocked position to the locked position

• As long as the DIP switch is in the locked position, the access level of the control can no longer be viewed or adjusted in its Miscellaneous (Misc) Menu

Snow Melting / Mixing Reset (Factory Setting is Mixing Reset)

• The Snow Melting / Mixing Reset DIP switch sets the operating mode of the mixing system

• When DIP switch is set to the Mixing Reset setting, the mixing system is used to supply heat to a building’s heating system

• The control uses a reset ratio method of outdoor reset that matches the heating load

• When this setting is used, a desired indoor air setting, design outdoor setting and a design supply setting must be entered into the control to create the reset ratio curve

• When the DIP switch is set to the Snow Melting setting, the mixing system is used to supply heat to a single zone snow melting system

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Max

Melt

Sto

Snow Melting

Mixing Reset

Test

Page 39

PROGRAMMING THE “MISC” MENU

UNITS (See fig. a)

1) Go to UNITS item field in Miscellaneous (MISC) Menu

2) Select the temperature measurement units you wish all temperatures to be displayed in

RANGE: °F, °C

DEFAULT: °F

BACKLITE (See fig. b)

1) Go to BACKLITE item field in Miscellaneous (MISC) Menu

2) Select the operating mode for the backlighting function of the LCD as well as the time of keypad inactivity until the control automatically returns to the default display

RANGE: OFF, 90 sec., ON

DEFAULT: ON

ACCESS (See fig. c)

1) Go to ACCESS item field in Miscellaneous (MISC) Menu

2) Select the level of access that you wish to be used by the control

RANGE: ADV (Advanced), INST (Installer), USER (User), LTD (Limited)

DEFAULT: INST (Installer)

NOTE: For more information on Access Levels refer to Navigating the Control in the Introduction section (page 4).

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Misc

sec

Misc

Access Level

LTD

USER

INST

ADV

Misc

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Page 40

PROGRAMMING THE

“ADJUST” MENU

A. BOILER / HIGH TEMP ZONE SETTINGS

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Page 41

OUTDOOR DESIGN (OUT DSGN) (See fig. a)

1) Go to OUT DSGN item field in Adjust Menu

2) Set to the outdoor design temperature used in the heat-loss calculation

RANGE: -60 to 50°F (-51 to 10°C)

DEFAULT: 10°F (-12°C)

BOILER ROOM (Boil ROOM) (See fig. b)

1) Go to Boil ROOM item field in Adjust Menu

2) Set to the desired room temperature for the boiler/high temp zones

RANGE: 35 to 100°F (2 to 38°C)

DEFAULT: 70°F (21°C)

NOTE: There is only a ±3°F (±1°C) adjustment in the LTD Access Level.

BOILER INDOOR (Boil INDR) (See fig. c)

1) Go to Boil INDR item field in Adjust Menu

2) Set to the room temperature used in original building heatloss calculations of the building

RANGE: 35 to 100°F (2 to 38°C)

DEFAULT: 70°F (21°C)

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Page 42

BOILER DESIGN (Boil DSGN) (See fig. d)

1) Go to Boil DSGN item field in Adjust Menu

2) Set to the design supply water temperature calculated in the heat-loss to satisfy the boiler/high temp zones

RANGE: 70 to 220°F (21 to 104°C)

DEFAULT: 190°F (88°C)

BOILER MAXIMUM (Boil MAX) (See fig. e)

1) Go to Boil MAX item field in Adjust Menu

2) Set to the lowest water temperature that the control is allowed to use as a boiler target temperature (Refer to the boiler manufacturer’s literature)

RANGE: 120 to 225°F, OFF (49 to 107°C, OFF)

DEFAULT: 210°F (99°C)

BOILER MINIMUM (Boil MIN) (See fig. f)

1) Go to Boil MIN item field in Adjust Menu

2) Set to the lowest water temperature the boiler is capable of receiving without condensing (Refer to the boiler manufacturer’s literature)

RANGE: OFF, 80 to 180°F (OFF, 27 to 82°C)

DEFAULT: 130°F (54°C)

NOTE: If boiler is designed for condensing operation, set the Boil MIN adjustment to OFF.

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Page 43

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

WARM WEATHER SHUT DOWN (WWSD)

(See fig. g)

The control enters into WWSD when slab and outdoor temperatures exceed MELTING temperature by more than

1.5°F (1°C).

1) Go to WWSD item field in the Adjust Menu

2) Set to an outdoor temperature at which the system no longer needs to heat the zone to maintain a comfortable temperature inside

RANGE: 35 to 100°F, OFF (2 to 38°C, OFF)

DEFAULT: 68°F (21°C)

Page 44

PROGRAMMING THE

“ADJUST” MENU

B. DHW SETTINGS

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Page 45

DHW DEVICE (DHW THRU) (See fig. h)

1) Go to DHW THRU item field in Adjust Menu

2) Select the type of DHW device you are using to supply flow to the heat exchange in the DHW tank

RANGE: NONE, PUMP, VALV

DEFAULT: PUMP

DHW SENSOR (DHW SENS) (See fig. i)

1) Go to DHW SENS item field in Adjust Menu

2) Select whether or not a DHW Sensor is being used to

measure the DHW TANK temperature

RANGE: NONE, DHW

DEFAULT: NONE

DHW TANK (DHW TANK) (See fig. j)

1) Go to DHW THRU item field in Adjust Menu (This needs to be set to VALV or PUMP before DHW TANK temperature can be selected)

2) Go to DHW SENS item field in Adjust Menu

3) Set DHW SENS to DHW

4) Go To DHW TANK item field in Adjust Menu

5) Set the desired DHW storage tank temperature

RANGE: OFF, 70 to 190°F (OFF, 21 to 88°C)

DEFAULT: 140°F (60°C)

NOTE: If DHW THRU is set to NONE, this menu will not be available.

NOTE: DHW TANK should only be selected if a universal sensor is used in the tank.

DHW PRIORITY (DHW PRI) (See fig. k)

1) Go to DHW THRU item field in Adjust Menu (This needs to be set to VALV or PUMP before priority can be selected)

2) Go to DHW PRI item field in Adjust Menu

3) Select the portions of the heating system that the DHW will have priority over. Your choices are Mixing Priority or NONE

RANGE: NONE, MIX

DEFAULT: NONE

NOTE: If DHW THRU is set to NONE, this menu will not be available.

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Page 46

PROGRAMMING THE

“ADJUST” MENU

(DIP set to Mixing Reset)

C. MIXING DEVICE SETTINGS

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Page 47

MIXING ROOM (MIX ROOM) (See fig. l)

1) Go to MIX ROOM item field in Adjust Menu

2) Set to the desired room temperature for mixing zones

NOTE: There is only a ±3°F (±1°C) adjustment in the LTD Access Level.

DIP SETTING: Mixing Reset

RANGE: 35 to 100°F (2 to 38°C)

DEFAULT: 70°F (21°C)

NOTE: Used to shift the reset ratio parallel for temporarily higher/lower room temperature.

10K INDOOR SENSOR (MIX 10K ) (See fig. m)

1) Go to MIX 10K item field in Adjust Menu

2) To add an indoor sensor for temperature control of a single zone mixing system, set to INDR

3) To add indoor temperature feedback control from a tekmar zone control, set to ZoIn

4) To add a slab sensor for temperature control for snow melting, set to SLAB

RANGE: NONE, INDR, ZoIn, SLAB (only if MIX MIN = OFF)

DEFAULT: NONE

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Page 48

SLAB MINIMUM (SLAB MIN) (See fig. n)

1) Go to MIX 10K item field in Adjust Menu

2) Set MIX 10K to SLAB

3) Go to SLAB MIN item field in Adjust Menu

4) Set the minimum allowed core temperature of slab as long as the control is not in WWSD

NOTE: Caution should be used when adjusting SLAB MIN setting as this may lead to overheating of zone during mild conditions.

RANGE: OFF, 35 to 120°F (OFF, 2 to 49°C)

DEFAULT: 70°F (21°C)

NOTE: The SLAB MIN and the SLAB MAX screens are only available if SLAB is selected in the MIX 10K screen

SLAB MAXIMUM (SLAB MAX) (See fig. o)

1) Go to MIX 10K item field in Adjust Menu

2) Set MIX 10K to SLAB

3) Go to SLAB MAX item field in Adjust Menu

4) Set the maximum allowed core temperature of slab

NOTE: If slab is to be maintained at a fixed core temperature, set SLAB MAX and SLAB MIN items to the same setting.

RANGE: 40 to 150°F (4 to 66°C)

DEFAULT: 90°F (32°C)

MIXING MINIMUM (MIX MIN) (See fig. p)

1) Go to MIX MIN item field in Adjust Menu

2) Set to the lowest temperature control is allowed to use as MIX TRG temperature

DIP SETTING: Mixing Reset

RANGE: OFF, 35 to 150°F (OFF, 2 to 66°C)

DEFAULT: OFF

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Page 49

MIXING INDOOR (MIX INDR) (See fig. q)

1) Go to MIX INDR item field in Adjust Menu

2) Set to the room temperature used in original heat-loss calculations for the building (Normally 65 to 70°F)

DIP SETTING: Mixing Reset

RANGE: 35 to 100°F (2 to 38°C)

DEFAULT: 70°F (21°C)

MIXING DESIGN (MIX DSGN) (See fig. r)

1) Go to MIX DSGN item field in Adjust Menu

2) Set to the design supply water temperature calculated in heat-loss calculation for the mixing zones

DIP SETTING: MIXING RESET

RANGE: 70 to 220°F (21 to 104°C)

DEFAULT: 110°F (43°C)

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

Page 50

MIXING MAXIMUM (MIX MAX) (See fig. s)

1) Go to MIX MAX item field in Adjust Menu

2) Set to highest water temperature the control is allowed to use as MIX TRG temperature

RANGE: 80 to 210°F, OFF (27 to 99°C, OFF)

DEFAULT: 180°F (82°C)

NOTE: Do not exceed the water temperatures shown for the following construction methods.

OUTDOOR DESIGN (OUT DSGN) (See fig. t)

1) Go to OUT DSGN item field in Adjust Menu

2) Set to the outdoor design temperature used in the heat-loss calculation

RANGE: -60 to 50°F (-51 to 10°C)

DEFAULT: 10°F (-12°C)

MIXING DEVICE SELECTION (MIXING) (See fig. u)

1) Go to MIXING item field in Adjust Menu

2) Set the type of mixing device used (floating action mixing valve “FLOT” or variable speed injection pump “VAR”)

RANGE: FLOT (Floating), VAR (Variable Speed)

DEFAULT: VAR

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

Adjust

Access Level

LTD

USER

INST

ADV

Adjust

Access Level

LTD

USER

INST

ADV

• Concrete 150°F

• Poured Underlayment 140°F

• Radiant Wall/Ceiling 120°F

(using drywall)

• Joist No Plates 180°F

• Joist w/Plates 165°F

• Quik Trak

180°F

Adjust

Access Level

LTD

USER

INST

ADV

Page 51

MOTOR SPEED (MOTR SPD) (See fig. v)

NOTE: For a Floating Action Valve Mixing Device only.

1) Go to MIXING item field in Adjust Menu

2) Set MIXING to FLOT

3) Go to MOTR SPD item field in Adjust Menu

4) Set the time the actuating motor requires to operate from fully closed to fully open

RANGE: 30 to 230 sec

DEFAULT: 150 sec

WARM WEATHER SHUT DOWN (WWSD)

(See fig. w)

The control enters into WWSD when slab and outdoor temperatures exceed MELTING temperature by more than

1.5°F (1°C).

1) Go to WWSD item field in the Adjust Menu

2) Set to an outdoor temperature at which the system no longer needs to heat the zone to maintain a comfortable temperature inside

RANGE: 35 to 100°F, OFF (2 to 38°C, OFF)

DEFAULT: 68°F (21°C)

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PROGRAMMING THE

“ADJUST” MENU

D. SNOW MELTING SETTINGS

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

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MELTING MODE (MELTING) (See fig. x)

1) Go to MELTING item field in View Menu

2) Set the slab surface temperature to be maintained while the control is in melting mode

DIP SWITCH: Snow Melting

RANGE: 32 to 95°F (0 to 35°C)

DEFAULT: 36°F (2°C)

IDLING MODE (IDLING) (See fig. y)

Idle feature decreases melting start up time maintaining slab at an “Idling” temperature.

1) Go to IDLING item field in View Menu

2) Set the slab surface temperature that you wish to maintain

while control is in idling mode

DIP SWITCH: Snow Melting

RANGE: OFF, 20 to 95°F (OFF, -7 to 35°C)

DEFAULT: OFF

RUNNING TIME (RUN TIME) (See fig. z)

The length of time the snow melting system operates once the slab has reached melting temperature.

1) Go to RUN TIME item field in Adjust Menu

2) Set the time in which slab is to be operated at Melting temperature during a melting demand

RANGE: 0:30 to 17:00 hr, INF (Infinite)

DEFAULT: 4:00 hr

SLAB PROTECTION (∆T MAX) (See fig. aa)

1) Go to ∆T MAX item field in Adjust Menu

2) Set ∆T MAX (delta T) — the temperature difference between slab supply and slab return temperature

NOTE: The rate at which heat is applied to slab can be controlled and thermal stresses in slab can be minimized by limiting this temperature difference.

DIP SWITCH: Snow Melting

RANGE: 10 to 70°F, OFF (6 to 39°C, OFF)

DEFAULT: 30°F (17°C)

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COLD WEATHER CUT OUT (CWCO) (See fig. bb)

Maintaining slab at either melting or idling temperature during extremely cold temperatures can be expensive or impossible. To set a Cold Weather Cut Out:

1) Go to CWCO item field in Adjust Menu

2) Set CWCO to the temperature which you wish the snowmelt system to turn off once the outdoor temperature drops below that point

DIP SWITCH: Snow Melting

RANGE: OFF, -30 to 50°F (OFF, -34 to 10°C)

DEFAULT: 10°F (-12°C)

10K INDOOR SENSOR (MIX 10K ) (See fig. cc)

1) Go to MIX 10K item field in Adjust Menu

2) To add a slab sensor for temperature control for snow melting, set to SLAB

RANGE: NONE, SLAB

DEFAULT: NONE

MIXING MAXIMUM (MIX MAX) (See fig. dd)

1) Go to MIX MAX item field in Adjust Menu

2) Set to highest water temperature control is allowed to use as MIX TRG temperature

RANGE: 80 to 210°F, OFF (27 to 99°C, OFF)

DEFAULT: 180°F (82°C)

NOTE: Do not exceed the water temperatures shown for the following construction methods.

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• Concrete 150°F

• Poured Underlayment 140°F

• Radiant Wall/Ceiling 120°F

(using drywall)

• Joist No Plates 180°F

• Joist w/Plates 165°F

• Quik Trak

180°F

Page 55

OUTDOOR DESIGN (OUT DSGN) (See fig. ee)

1) Go to OUT DSGN item field in Adjust Menu

2) Set to the outdoor design temperature used in the heat-loss calculation

RANGE: -60 to 50°F (-51 to 10°C)

DEFAULT: 10°F (-12°C)

MIXING DEVICE SELECTION (MIXING) (See fig. ff)

1) Go to MIXING item field in Adjust Menu

2) Set the type of mixing device used (floating action mixing valve “FLOT” or variable speed injection pump “VAR”)

RANGE: FLOT (Floating), VAR (Variable Speed)

DEFAULT: VAR

MOTOR SPEED (MOTR SPD) (See fig. gg)

NOTE: For a Floating Action Valve Mixing Device only.

1) Go to MIXING item field in Adjust Menu

2) Set MIXING to FLOT

3) Go to MOTR SPD item field in Adjust Menu

4) Set the time the actuating motor requires to operate from fully closed to fully open

RANGE: 30 to 230 sec

DEFAULT: 150 sec

WARM WEATHER SHUT DOWN (WWSD)

(See fig. hh)

The control enters into WWSD when slab and outdoor temperatures exceed MELTING temperature by more than

1.5°F (1°C).

1) Go to WWSD item field in the Adjust Menu

2) Set to an outdoor temperature at which the system no longer needs to heat the zone to maintain a comfortable temperature inside

RANGE: 35 to 100°F, OFF (2 to 38°C, OFF)

DEFAULT: 68°F (21°C)

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PROGRAMMING THE

“ADJUST” MENU

E. BOILER OPERATION

PROGRAMMING

PROGRAMMING - Step 1 - Programming the Control

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BOILER MAXIMUM (Boil MAX) (See fig. ii)

1) Go to Boil MAX item field in Adjust Menu

2) Set to the highest water temperature the boiler is allowed to use as a Boil TRG temperature (Refer to the boiler manufacturer’s literature)

RANGE: 120 to 225°F, OFF (49 to 107°C, OFF)

DEFAULT: 210°F (99°C)

BOILER MINIMUM (Boil MIN) (See fig. jj)

1) Go to Boil MIN item field in Adjust Menu

2) Set to the lowest water temperature that the control is allowed to use as a boiler target temperature (Refer to the boiler manufacturer’s literature)

RANGE: OFF, 80 to 180°F (OFF, 27 to 82°C)

DEFAULT: 130°F (54°C)

NOTE: If boiler is designed for condensing operation, set the Boil MIN adjustment to OFF.

DIFFERENTIAL (Boil DIFF) (See fig. kk)

An on/off heat source such as a boiler must be operated with a differential to prevent short cycling. With the SYSTEMpro 311, it has either a fixed or automatic differential setting that may be selected.

1) Go to Boil DIFF item field in Adjust Menu

2) Select Auto (for automatic operation) or enter a differential temperature manually

RANGE: AUTO, 2 to 42°F (AUTO, 1 to 23°C)

DEFAULT: AUTO

WARM WEATHER SHUT DOWN (WWSD)

(See fig. ll)

The control enters into WWSD when slab and outdoor temperatures exceed MELTING temperature by more than

1.5°F (1°C).

1) Go to WWSD item field in the Adjust Menu

2) Set to an outdoor temperature at which the system no longer needs to heat the zone to maintain a comfortable temperature inside

RANGE: 35 to 100°F, OFF (2 to 38°C, OFF)

DEFAULT: 68°F (21°C)

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PROGRAMMING - STEP 2

TEST SEQUENCE

The SYSTEMpro 311 has a built-in test routine which is used to test the main control functions. The control monitors the sensors and displays an error message whenever a fault is found. See Appendix IV (page 98) for a list of the SYSTEMpro's error messages and possible causes. When the test button is pressed, the test light is turned on. The outputs and relays are tested in the following sequence:

• Each step in the test sequence lasts 10 seconds.

• During the test routine, the test sequence is paused by pressing the test button

• While paused, the control displays the testing step as well as the abbreviation PAUS

• If the Test button is not pressed again for 5 minutes while the test sequence is paused, the control exits the entire test routine

• If the test sequence is paused, the Test button can be pressed again to advance to the next step (this can also be used to rapidly advance through the test sequence)

• To reach the desired step, repeatedly press and release the Test button until the appropriate device and segment in the display turn on

Step 1

• If FLOT is selected in MIXING item, mixing valve is run fully

open

• If VAR is selected in MIXING item, injection pump is ramped

over 10 seconds to 100%

Step 2

• If FLOT is selected in MIXING item, mixing valve is run fully

closed

• If VAR is selected in MIXING item, injection pump is ramped

down

over 10 seconds

Step 3

• The mixing system pump (P1) is turned on for 10 seconds and then shuts off

NOTE: The control can only be paused in step 3 if there is a mixing demand.

Step 4

• The boiler demand pump (P7) is turned on for 10 seconds and then shuts off

NOTE: The control can only be paused in Step 4 if there is a boiler demand.

PROGRAMMING

PROGRAMMING - PROGRAMMING - Step 2 - Test Sequence

NOTE:

Before you begin testing, all appropriate settings must be entered into the control using the LCD screen. If you are unfamiliar with the theory behind a hydronic radiant heating system, please refer to the Control Function Overview for more help.

Page 59

Step 5

• The primary pump (P3) is turned on and remains on

Step 6

• The Boiler contact is turned on for 10 seconds

• After 10 seconds, the Boiler and Boil P3 contacts are shut off

NOTE: The control can only be paused in step 6 if there is a boiler or mixing demand.

Step 7

• If PUMP is selected in DHW THRU item, DHW P6/Vlv contact is closed for 10 seconds

• If VLV is selected in DHW THRU item, DHW P6/Vlv and Boil P3 contacts are closed for 10 seconds.

• If NONE is selected in DHW THRU item, N/A is displayed in the LCD

NOTE: The control can only be paused in step 7 if there is a DHW demand.

Step 8

• After test sequence is completed, the word COMPLETE is displayed for 1 second and control resumes normal operation

MAX HEAT (See fig. a & b)

The SYSTEMpro 311 has a function called Max Heat. In this mode, the control turns on and operates the system up to the maximum set temperatures, and the mixing device at the set percentage, as long as there is a demand for heat.

• This mode may be used for running all circulators during system start-up in order to purge air from the piping

• Once started, control continues to operate in MAX HEAT mode for up to 24 hours or until either the Item, Menu or Test button is pressed

• To enable the Max Heat feature, use the following procedure:

1) Press and hold the Test button for more than 3 seconds.

At this point, control displays the words MAX HEAT and the word NO

2) Using the up and down buttons, select the word YES. After

3 seconds, the control flashes the word MANUAL and the number 100. This number represents the desired output from the mixing device

3) Set desired output of mixing device by using the up and/or

down buttons on the control.

4) To cancel Max Heat mode, press either Item, Menu, or

Test button

5) Once Max Heat mode ends or is cancelled, control resumes

normal operation

PROGRAMMING

PROGRAMMING - Step 2 - Test Sequence

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Page 60

CONTROL FUNCTION OVERVIEW

TABLE OF CONTENTS

Section A – General .............................................................. 59

Section B – Boiler / High Temp Zones .......................... 60-62

Section B1 – General ................................ 60-62

Section B2 – Boiler Demands ........................ 62

Section C – Domestic Hot Water (DHW) ...................... 63-66

Section C1 – General ................................ 63-64

Section C2 – DHW Priority ........................ 65-66

Section D – Mixing Zones .............................................. 67-71

Section D1 – General ................................ 67-69

Section D2 – Mixing Devices.................... 69-70

Section D3 – Mixing Demands ................ 70-71

Section E – Snow Melting .............................................. 72-79

Section E1 – General.................................. 72-75

Section E2 – With Slab Sensor ................ 76-77

Section E3 – Without Slab Sensor .......... 77-78

Section E4 – Snow Melt Enable .............. 78-79

Section F – Boiler Operation .......................................... 80-81

Section F1 – Boiler Supply Sensor.......... 80-81

Section G – Troubleshooting .......................................... 82-83

POWERING UP THE CONTROL

When the SYSTEMpro 311 is powered up:

1) It displays the control type number in the LCD for 2 seconds

2) It displays the software version for another 2 seconds

3) It defaults to normal operating mode by displaying current outdoor air temperature

CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - CONTROL FUNCTION OVERVIEW - Table of Contents

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CONTROL FUNCTION OVERVIEW - SECTION A

GENERAL

This section explains the operation of each menu function on the SYSTEMpro 311 in order of control area.

WARM WEATHER SHUT DOWN (WWSD)

(See fig. a)

• When the outdoor air temperature rises above WWSD setting, the SYSTEMpro 311 turns on the LCD's WWSD pointer

• When control is in Warm Weather Shut Down, Mix Demand and Boiler Demand pointers are still displayed if there is a demand

NOTE: The control does not operate the heating system to satisfy Mix or Boiler demands. The control will respond to a DHW demand and operates as described in Section C.

EXERCISING

• The SYSTEMpro 311 has a built-in pump and valve exercising function

• If a pump or valve output on the control has not been operated at least once during every exercising period, the control turns on the output for 10 seconds

• Exercising reduces possibility of a pump or valve seizing during a long period of inactivity

NOTE: If a mixing valve is being used as the mixing device, the SYSTEMpro 311 makes sure the valve operates over its entire range at least once each exercising period (every 70 hours). The exercising function will not work if power to the control, pumps or valves is disconnected.

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CONTROL FUNCTION OVERVIEW - SECTION B

BOILER / HIGH TEMP ZONES

The SYSTEMpro 311 can provide a reset supply water temperature from the primary boiler loop to high temp mix loops. Boiler zones piped into the primary loop will receive the same water temperature as the current boiler supply temperature. The boiler supply temperature is automatically adjusted by the SYSTEMpro 311 based on the following information you must enter into the control's Adjust Menu.

NOTE: The SYSTEMpro 311 will automatically calculate a reset ratio based on the data you input.

OUTDOOR DESIGN (OUT DSGN) (See fig. a)

• The OUT DSGN is set to the outdoor design temperature used on the heat-loss analysis for the project

BOILER DESIGN (Boil DSGN) (See fig. b)

• The Boil DSGN temperature is the temperature the supply water must be heated to heat the boiler zones when the outdoor air is at the OUT DSGN temperature

BOILER MINIMUM (Boil MIN) (See fig. c)

• The Boil MIN is the lowest water temperature that the control is allowed to use as a boiler target temperature (Refer to the boiler manufacturer’s literature)

• During mild conditions, if the control calculates a Boil TRG temperature below the Boil MIN setting, the Boil TRG temperature adjusts to at least the Boil MIN setting

NOTE: During this condition, if the boiler is operating near the Boil MIN setting, the Minimum pointer turns on while the Boil TRG or Boil SUP temperature is viewed

• If the installed boiler is designed for condensing operation, set the Boil MIN adjustment to OFF

Section B1: General

CONTROL FUNCTION

OVERVIEW

CONTROL FUNCTION OVERVIEW - CONTROL FUNCTION OVERVIEW - Section B - Boiler / High Temp Zones

Boil MAX

Boil DSGN

OUT DSGN

WWSD

Boil ROOM

210

(99)

190

(88)

170

(77)

150

(66)

130

(54)

110

(43)

(32)

(21)

50°F

(10°C)

-20

(-29)

(-18)

(-7)

40 (5)

(16)

(27)

Outdoor Air Temperature

Water Tem

erature

Boiler Reset Ratio

Boil MIN

Boil INDR

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BOILER MAXIMUM (Boil MAX) (See fig. d)

• The Boil MAX is the highest water temperature the control is allowed to use as a Boil TRG temperature

• At no time does the control operate the boiler above 248°F (120°C).

NOTE: If the control calculates target Boil MAX and the Boil SUP temperature is near the Boil MAX temperature, the Maximum pointer turns on while the Boil TRG or the Boil SUP temperature is viewed.

WARM WEATHER SHUT DOWN (WWSD)

(See fig. e)

• When the outdoor air temperature rises above WWSD setting, the SYSTEMpro 311 turns on the LCD's WWSD pointer

• When control is in Warm Weather Shut Down, Mix Demand and Boiler Demand pointers are displayed if there is a demand

NOTE: The control does not operate the heating system to satisfy Mix or Boiler demands. The control will respond to a DHW demand and operates as described in Section C.

BOILER INDOOR (Boil INDR) (See fig. f)

• Boil INDR is the room temperature used in original building heat-loss calculations

• Setting establishes the beginning of the reset ratio for the boiler zones

BOILER ROOM (Boil ROOM) (See fig. g)

• The Boil ROOM is the desired room temperature for the boiler zones

• This setting provides a parallel shift of the reset ratio

NOTE: The room temperature desired by the occupants is often different from the designed indoor temperature (Boil INDR). If the room temperature is not correct, adjusting Boil ROOM setting increases or decreases amount of heat available to the building.

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BOILER DEMAND PUMP (P7) OPERATION

• The boiler demand pump (Boil Dem Pmp P7) contact (terminals 9 and 10) closes if there is a boiler demand and the control is not in WWSD

• After boiler demand is removed, the boiler system pump runs an additional 20 seconds

NOTE: Boiler demand can be an external demand or a boiler zone control as described in section B2.

EXTERNAL BOILER DEMAND

External boiler demand is generated by applying a voltage between 24 and 240 VAC across Boil Dem (3) and Com Dem (4) terminals.

• Once voltage is applied, Boiler Demand pointer is displayed in the LCD

• If control is not in WWSD, it closes the Boil P3 contact, which starts the primary pump and closes the Boil Dem Pmp P7 contact, which starts the boiler system pump

• The control turns on the primary pump and boiler system pump segments in the LCD

• The control calculates a Boil TRG supply temperature, then fires the boiler (if required) to reach and/or maintain target supply temperature

BOILER ZONE CONTROL

A tekmar zone control can be used to control the temperature in the boiler zones connected to the boiler demand pump (P7).

• Connects to SYSTEMpro 311 using Boil ZoIn terminal and Com terminal (24 and 25)

• Provides its own internal boiler demand to SYSTEMpro 311

NOTE: In this case, there is no need to provide external boiler demand.

• Can adjust the Boil TRG temperature (if required) to provide improved building occupant comfort and system performance

Section B2: Boiler Demands

CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - CONTROL FUNCTION OVERVIEW - Section B - Boiler / High Temp Zones

Page 65

CONTROL FUNCTION OVERVIEW - SECTION C

DOMESTIC HOT WATER

A DHW demand is generated on the SYSTEMpro 311 by one of two methods:

1) an external DHW demand from an aquastat

2) an internal demand from a universal sensor

External Demand (Aquastat)

• The SYSTEMpro 311 registers an external demand for DHW when voltage between 24 and 240 VAC is applied across DHW Dem and Com Dem terminals (4 and 5)

• A DHW aquastat or setpoint control is used as a switch in the DHW demand circuit

• Once the control detects a DHW demand, the LCD's DHW Demand icon turns on and the control operates as described in section “BOILER TRG DURING DHW GENERATION”

Internal Demand (Universal Sensor)

• If the DHW SENS item is set to DHW, the control looks for a DHW sensor connected to the DHW S6 and the Com terminals (27 and 28)

• The DHW TANK setting is used to set the desired indirect DHW tank temperature

• When the temperature at the DHW sensor drops 3°F (1.5°C) below DHW TANK setting, the LCD's DHW Demand pointer turns on and the control operates as described in section “BOILER TRG DURING DHW GENERATION”

NOTE: An advantage to using the DHW sensor is that the control can display the current DHW TANK temperature. Also, SYSTEMpro 311 can control the DHW temperature with more accuracy compared to an aquastat.

DHW DEVICE (DHW THRU) (See fig. a)

When the control receives a DHW demand, the sequence of operation depends on the type of DHW device selected. The DHW device is selected using the DHW THRU item in the Adjust Menu.

Section C1: General

CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - Section C - Domestic Hot Water

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DHW Valve (VALV) (See fig. b)

• If VALV is selected as DHW device and a DHW demand exists, the control closes the DHW P6/Vlv contact (13 and 14) and the Boil P3 contact (7 and 8)

• The primary pump provides flow through DHW tank’s heat exchanger once the DHW valve is opened

• The control operates the Boiler contact to provide a sufficient boiler supply temperature to DHW tank

DHW Pump (PUMP) (See fig. c)

• If PUMP is selected as the DHW device, the control assumes the DHW pump provides adequate flow through both the DHW tank heat exchanger and the boiler

• To provide heat to DHW tank, the control closes DHW P6/Vlv contact (13 and 14).

• The control operates the Boiler contact to provide sufficient boiler supply temperature to DHW tank

• If using a primary loop with DHW tank piped in primary/secondary, select DHW valve

BOILER TARGET DURING DHW GENERATION (Boil TRG) (See fig. d)

The Boil TRG temperature during DHW operation depends on whether an external or internal demand is occurring. The DHW demand then overrides the reset water temperature.

External Demand (Aquastat)

• If the control receives a DHW demand through an external device such as an aquastat, the Boil TRG temperature is at least 180°F

Internal Demand (Universal Sensor)

If the control receives a DHW demand from a DHW sensor connected to the DHW S6 and the Com terminals (27 and 28), the Boil TRG temperature is at least as hot as the DHW TANK setting plus 40°F (22°C).

CONTROL FUNCTION

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Often, it is desirable to limit or stop the flow of heat to the heating system when the DHW tank calls for heat. This allows for faster recovery of the DHW tank. The control has several features that it can use when dealing with DHW priority. The features available depend on the type of DHW device being used and the type of DHW demand the control receives.

Mixing Priority (DHW PRI = MIX) (See fig. e)

It can be set up so the DHW tank has priority over mixing zones. In this case:

• The mixing device is throttled back on a call for DHW

• The mixing system pump (P1) continues to operate based on the mix demand

• The reduction of the mixing device's output directs more heat to the DHW tank

NOTE: Boiler zones will continue to operate without change.

DHW PRIORITY OVERRIDE

To prevent the building from cooling off too much or from a potential freeze up during DHW priority, the control limits the amount of time for DHW priority.

• As the outdoor air temperature becomes colder, the length of time that the control provides DHW priority is reduced

• Once the allowed time for priority has elapsed, the control overrides the DHW priority and operates DHW and heating simultaneously

CONDITIONAL DHW PRIORITY

During DHW generation, if the boiler supply temperature holds at or above the required temperature the boiler has enough capacity for DHW and possibly the heating system.

• DHW and heating occurs simultaneously as long as the boiler supply temperature is maintained near its target

Section C2: DHW Priority

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CONTROL FUNCTION OVERVIEW - Section C - Domestic Hot Water

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DHW POST PURGE

After DHW demand is removed, control performs a purge on the boiler.

• Control shuts off boiler and continues to operate either the DHW pump or DHW valve and primary pump (P3)

• Control purges residual heat from boiler into the DHW tank

• Control continues purge for a maximum of four minutes or until boiler supply temperature drops 20°F (11°C) below DHW Boil TRG temperature

• Control stops purge if boiler supply temperature drops below current Boil TRG temperature

DHW MIXING PURGE

After DHW operation, the boiler is extremely hot, while heating zones may have cooled off considerably after being off for a period of time.

• To avoid thermally shocking the boiler after DHW priority, the control shuts off the boiler, but continues to operate the DHW while restarting the heating system

• Above step allows some of the DHW return water to mix with the cool return water from the zones and temper the boiler return water

CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - CONTROL FUNCTION OVERVIEW - Section C - Domestic Hot Water

Page 69

CONTROL FUNCTION OVERVIEW - SECTION D

MIXING ZONES

The SYSTEMpro 311 can provide a reset supply water temperature from the primary boiler loop to a secondary mixed loop via a variable speed injection mixing or a floating action valve. The mixing supply temperature is determined using a reset ratio. In order for the control to set up a reset ratio, the following information must be entered into the Adjust Menu.

OUTDOOR DESIGN (OUT DSGN) (See fig. a)

• OUT DSGN is the outdoor air temperature used when doing heat-loss calculations for the building

MIXING DESIGN (MIX DSGN) (See fig. b)

• MIX DSGN temperature is the supply water temperature required to heat mixing zones when the outdoor temperature is at OUT DSGN temperature

MIXING MAXIMUM (MIX MAX) (See fig. c)

• MIX MAX sets highest water temperature control is allowed to use as MIX TRG temperature

• If control calculates target MIX MAX setting, and MIX SUP temperature is near MIX MAX temperature, the LCD's Maximum pointer turns on while either the MIX TRG temperature or the MIX SUP temperature is viewed

WARM WEATHER SHUT DOWN (WWSD)

(See fig. d)

• When outdoor air temperature rises above WWSD setting, the SYSTEMpro 311 goes into WWSD and turns on the LCD's WWSD pointer

• When control is in WWSD, Mix Demand and Boiler Demand pointers are displayed if there is a demand

NOTE: The control does not operate the heating system to satisfy Mix or Boiler demands. The control will respond to a DHW demand and operates as described in Section C.

Section D1: General

CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - Section D - Mixing Zones

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Mix MAX

Mix DSGN

OUT DSGN

WWSD

Mix ROOM

210

(99)

190

(88)

170

(77)

150

(66)

130

(54)

110

(43)

(32)

(21)

50°F

(10°C)

-20

(-29)

(-18)

(-7)

40 (5)

(16)

(27)

Outdoor Air Temperature

Water Tem

erature

Mixing Reset Ratio

Mix MIN

Mix INDR

Page 70

MIXING INDOOR (MIX INDR) (See fig. e)

• MIX INDR is room temperature used in original heat-loss calculations for the building

• Setting establishes beginning of reset ratio for mixing zones

MIXING MINIMUM (MIX MIN) (See fig. f)

• MIX MIN is lowest temperature control is allowed to use as MIX TRG temperature.

• During mild conditions, if control calculates a MIX TRG temperature below MIX MIN setting, MIX TRG temperature is adjusted to match MIX MIN setting

• If mixing supply temperature is near MIX MIN setting, the LCD's Minimum pointer turns on (when MIX TRG or MIX SUP temperature is being viewed)

• If using an indoor sensor and control is operating at MIX MIN temperature, the mixing system pump (P1) is cycled using Pulse Width Modulation (PWM) with a 15 minute cycle length

• The Control provides an average supply water temperature to the mixing system by cycling the mixing system pump (P1) and controlling the flow of supply water (average temperature is equal to the original MIX TRG)

NOTE: This step minimizes overheating the zone while control is operating at MIX MIN temperature.

MIXING ROOM (MIX ROOM) (See fig. g)

• MIX ROOM is desired room temperature for mixing zones

NOTE: There is only a ±3°F (±1°C) adjustment in the LTD Access Level.

• Provides a parallel shift of reset ratio

NOTE: Room temperature desired by occupants is often different from designed indoor temperature (MIX INDR). If room temperature is not correct, adjusting MIX ROOM setting increases or decreases the amount of heat available to the building.

MIXING TARGET TEMPERATURE (MIX TRG)

(See fig. h)

• MIX TRG temperature is determined from reset ratio settings and outdoor air temperature

• The Control displays the temperature it is currently trying to maintain as mixing supply temperature

• If control does not presently have a requirement for heat, it displays “---“ in LCD

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CONTROL FUNCTION OVERVIEW - CONTROL FUNCTION OVERVIEW - Section D - Mixing Zones

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MIXING PUMP (P1) OPERATION

• Mixing pump (P1) contact (terminals 11 and 12) closes whenever there is mixing demand and the SYSTEMpro 311 is not in WWSD

• After mixing demand is removed, Mixing Pmp P1 contact remains closed for 20 seconds

• During WWSD, the mixing pump (P1) is operated based on EXERCISE function

BOILER MINIMUM PROTECTION (Boil MIN)

(See fig. i)

• The SYSTEMpro 311 can offer boiler protection from cold mixing system return water temperature entering the boiler while firing. This helps reduce possible flue gas condensation.

• If boiler water temperature is cooler than Boil MIN setting while boiler is firing, control reduces output from mixing device (limits amount of cool return water to boiler and allows boiler water temperature to recover)

MIXING DEVICE SELECTION (MIXING)

• The SYSTEMpro 311 can supply a lower water temperature to part of the heating system by varying the speed of an injection pump or modulating a mixing valve.

• This selection is made under the MIXING item in the Adjust Menu.

VARIABLE SPEED INJECTION (VAR) (See fig. j)

• A standard wet rotor circulator is connected to the SYSTEMpro 311 on Cls/P4 terminal (19)

• Control increases or decreases power output to circulator when there is mix demand

• Circulator speed varies to maintain correct mixed supply water temperature at mix supply sensor

• For correct sizing and piping of variable speed injection driven circulator, refer to essay Appendix I, Variable Speed Injection Mixing on page 85.

• A visual indication of current variable speed output is displayed in the LCD as a segmented bar graph. Two small indicators at the top of the graph indicate whether the output is increasing or decreasing.

Section D2: Mixing Devices

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FLOATING ACTION (FLOT) (See fig. k)

• A floating action actuator motor is connected to control on Opn and Cls/P4 terminals (18 and 19)

• The control pulses actuator motor open or closed to maintain correct supply water temperature at mix supply sensor during mix demand

• The mixing valve actuator can be connected to a 2-way, 3-way or 4-way valve

• A visual indication as to whether control is currently opening or closing the mixing valve is displayed in the LCD with the words Open and Close (also, a visual indication of the valve's current position is displayed in the form of a segmented bar graph)

EXTERNAL MIXING DEMAND (See fig. l)

An external mixing demand allows use of a conventional thermostat system for zoning. Demand is generated by applying a voltage between 24 and 240 VAC across the Mix Demand terminals (1 and 2).

• Once voltage is applied, the Mix Demand pointer is displayed in the LCD

• If the SYSTEMpro 311 is not in WWSD, it closes the Mixing Pmp P1 contact

• The Mixing system pump segment is displayed in the LCD

• Control calculates a MIX TRG temperature based on outdoor air temperature and settings

• If required, control operates Boiler contact (as described in Section B2, page. 62) to provide heat to mixing device

10K INDOOR SENSOR (MIX 10K = INDR)

(See fig. l)

Set MIX 10K item to INDR to add an indoor sensor that offers temperature control of a single zone mixing system. The indoor sensor is connected to Com and Mix 10K terminals (20 and 21). Power must also be applied to Mix Demand terminals (1 and 2).

• With indoor sensor connected, control can sense the actual room temperature

• Using this information, the control offers more constant water flow through mixing system

• Indoor feedback fine-tunes supply water temperature in

mixing system to prevent overheating or underheating

NOTE: To adjust room temperature for the mixing zone, use MIX ROOM setting in the Adjust Menu.

Section D3: Mixing Demands

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NOTE: If connecting a Wirsbo

thermostat (WT1 or WT2) directly

to the Mix Demand terminals,

refer to Mixing Demand with

Wirsbo Thermostat on page 23.

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10K ZONE CONTROL (MIX 10K = ZoIn)

(See fig. m)

Set MIX 10K item to ZoIn to add indoor temperature feedback control of multiple mixing zones

• Control of mixing zones can be provided by connecting a tekmar zone control to the SYSTEMpro 311

• The zone control provides its own internal mix demand to the SYSTEMpro 311 control

NOTE: In this case, there is no need to provide an external mix demand. The zone control is capable of automatically adjusting the MIX TRG temperature to improve building occupant comfort and system performance.

10K SLAB SENSOR (MIX 10K = SLAB) (See fig. n)

Set the MIX 10K item to SLAB to add a slab sensor for temperature control of a single zone mixing system. Power must be applied to the Mix Demand terminals (1 and 2).

• SYSTEMpro 311 can use a slab sensor to control the actual slab temperature

• Slab sensor is placed in the slab and connected to Com and Mix 10K terminals (20 and 21)

• With slab sensor connected, the control will limit the mixing supply temperature to keep the slab sensor between the SLAB MIN and SLAB MAX settings

Slab Minimum (SLAB MIN) (See fig. o)

• SLAB MIN sets minimum allowed core temperature of slab as long as the control is not in WWSD

NOTE: Caution should be used when adjusting SLAB MIN setting as this may lead to overheating of zone during mild conditions.

Slab Maximum (SLAB MAX) (See fig. p)

• SLAB MAX sets maximum allowed core temperature of slab

NOTE: If slab is to be maintained at a fixed core temperature, set SLAB MAX and SLAB MIN items to the same setting.

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CONTROL FUNCTION OVERVIEW - SECTION E

SNOW MELTING (DIP set to Snow Melt)

The SYSTEMpro 311 can control a single zone snow melting system. To provide the best control of the snow melting system, control should be equipped with an optional Slab Sensor (A3060072) and optional Universal Sensor (A3060071) to measure slab return temperature. These can be purchased separately or as part of the Snow Melt Enable Kit (A3040039).

NOTE: When operating in snow melt mode, the Snow Melting/Mixing Reset DIP switch must be set to Snow Melting position.

SLAB PROTECTION (∆T MAX) (See fig. a)

A mixing device is installed between snow melting slab and boiler(s) to control rate at which heat is transferred to snow melting system and to protect slab from thermal stress damage. The control limits the rate at which heat is applied to slab through ∆T MAX setting.

• ∆T (delta T) is the temperature difference between slab supply temperature and slab return temperature

• The rate at which heat is applied to slab can be controlled and thermal stresses in slab can be minimized by controlling this temperature difference

• When slab is operating, control ensures slab supply temperature does not exceed slab return temperature by more than ∆T MAX setting

NOTE: When control is operating and actual ∆T is near ∆T MAX, the Maximum pointer can be seen when viewing the MIX ∆T item in the View Menu.

Section E1: General

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VISCOSITY COMPENSATION (EXCEEDING ∆T MAX)

At low temperatures, glycol solutions used in snow melting systems become very viscous and difficult to pump. In order to overcome this condition during a cold start of a snow melting system, the control is allowed to exceed ∆T MAX setting for a time to warm the glycol solution.

• Allows control to compensate for the high viscosity of the glycol solution

• Used when return temperature is below 30°F (-1°C)

NOTE: When control exceeds the ∆T MAX setting, Maximum pointer flashes when viewing MIX ∆T item in the View Menu.

RAMPING OF THE ∆T

When control starts applying heat to slab, supply temperature to snow melting system is ramped up over a period of time until it reaches maximum allowed ∆T.

OPERATING STATUS (STATUS) (See fig. b)

While in snow melting mode, an additional item is available in the View Menu called STATUS. It displays current operating status of snow melting system.

STRT (See fig. c)

Displayed after snow melting system has been enabled and remains on until slab reaches melting temperature. If the slab is at melting temperature, STRT is displayed for five seconds after snow melting system has started operation. This is to verify that the control has entered into snow melting mode.

STOP (See fig. d)

Displayed after the snow melt system is disabled

IDLE (See fig. e)

Displayed as long as the control is operating slab at idling temperature

EXT (See fig. f)

Displayed when RUN TIME has reached 0:00 and control still has an external demand for melting. In this situation, control continues melting until snow melting demand is removed or the control is stopped.

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0:30 to 17:00 hr (See fig. g)

RUN TIME is displayed as long as slab is up to temperature and the control is in the melting mode.

INF (See fig. h)

Displayed if an infinite run time is selected and the control is in the melting mode.

WWSD (See fig. i)

Displayed when control is in a Warm Weather Shut Down

CWCO (See fig. j)

Displayed when control is in a Cold Weather Cut Out

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RUNNING TIME (RUN TIME) (See fig. k)

Run time is the length of time the snow melting system operates once the slab has reached melting temperature.

• During the time slab approaches melting temperature, run time does not decrease

• Once the slab has reached melting temperature, run time begins counting down

• When run time reaches 0:00 (displayed by the STATUS item in the View Menu) the control has finished the melting process

NOTE: If a slab sensor is not used, the run time begins counting down as soon as the melting mode is enabled.

COLD WEATHER CUT OUT (CWCO) (See fig. l)

Maintaining a slab temperature at either a melting or idling temperature when outdoor conditions has dropped below system design parameters can be both expensive and impossible. Cold Weather Cut Out (CWCO) is a feature that allows the control to automatically shut the system down at a particular outdoor temperature setting to save energy.

• When the control is not in melting mode and the outdoor temperature drops below the CWCO setting, the control goes into CWCO mode which prevents any melting events to take place until the outdoor temperature rises above the CWCO setting.

• When the control is already in melting mode, the CWCO only occurs when the outdoor temperature is less than CWCO setting and slab surface is less than 29°F. This allows the control to finish the current melting cycle and helps prevent refreezing of left over moisture on the slab surface.

BOILER OPERATION

Refer to Section F (page 80) for a description of the boiler operation.

BOILER PROTECTION

The SYSTEMpro 311 ensures the boiler water temperature remains above Boil MIN setting

• If boiler water temperature begins to drop due to slab return temperature, the mixing device is throttled back to allow the boiler to recover

• Throttling back minimizes time boiler operates below its

condensing temperature and prolongs life expectancy of boiler

MIXING SYSTEM PUMP (P1) OPERATION

The mixing system pump (Mixing Pmp P1) contact closes and remains closed as long as control is either in the melting or idling mode. The mixing system pump contact shuts off if control is in WWSD or CWCO, or if there is no call for melting or idling.

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SLAB OUTDOOR RESET

When using a slab sensor, the control assumes sensor is approximately 1 inch below surface of snow melting slab. Since this point is closer to the source of heat, it is warmer than the surface of the slab. So, the sensor must be maintained at a higher temperature to ensure the surface of slab is maintained at correct temperature.

• Amount of temperature difference between surface of slab and slab sensor changes with outdoor air temperature

• Slab core temperature is increased as outdoor air temperature drops

• Temperature displayed as slab temperature is the temperature of the slab sensor

• Sensor temperature will be higher than the actual surface temperature of the slab

MELTING MODE (MELTING) (See fig. m)

The SYSTEMpro 311 is a manual snow melting control.

• For snow melting system to start, one of four methods described in section E4 must be used

• The MELTING setting in the Adjust Menu sets slab surface temperature that is maintained while control is in melting mode

NOTE: When control is in melting mode, Melting pointer is visible in the View Menu and either EXT, INF or a running time may be read under STATUS item in View Menu.

IDLING MODE (IDLING) (See fig. n)

Extra time may be required when the snow melting system starts from a cold temperature.

• To decrease melting start up time, slab can be maintained at an “Idling” temperature

• Idle feature is also useful for preventing frost and light ice formation

• The IDLING setting in the Adjust Menu sets slab surface temperature that is maintained while control is in the idling mode

NOTE: When control is in idling mode, the word IDLE can be read under STATUS item in the View Menu.

Section E2: With Slab Sensor

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WARM WEATHER SHUT DOWN (WWSD)

(See fig. o)

The control enters into WWSD when:

• Slab and outdoor temperatures exceed MELTING temperature by more than 1.5°F (1°C)

• In WWSD, the snow melting system is shut down to conserve energy

In cases where a slab sensor has not been or cannot be installed in snow melting slab, it is still possible for the SYSTEMpro 311 to operate the snow melting system. In this mode the control supplies a calculated mixed supply water temperature to the slab.

NOTE: This mode of operation is generally not recommended since the control can no longer regulate slab temperature. As a result, it can cause the slab to operate at surface temperatures that are higher or lower than required. A higher surface temperature can lead to excessive energy usage and fuel costs. A lower surface temperature can cause the slab to freeze over.

WARM WEATHER SHUT DOWN (WWSD)

(See fig. p)

When a slab sensor is not in use:

• The Warm Weather Shut Down is determined only from the outdoor temperature

• If outdoor temperature rises above MELTING setting by more than 2°F (1°C), control goes into WWSD and ignores any demand for melting or idling

MELTING MODE (MELTING) (See fig. q)

The SYSTEMpro 311 is a manual snow melting control:

• For the snow melting system to be started, one of four methods described in section E4 must be used

• When the control is in melting mode, the Melting pointer is visible in View Menu

• Either EXT, INF or a running time can be read when viewing STATUS item in View Menu

• The MELTING setting in Adjust Menu sets the theoretical slab surface temperature that is maintained while control is in melting mode

Section E3: Slab Without Slab Sensor

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IDLING MODE (IDLING) (See fig. r)

Extra time may be required when the snow melting system starts from a cold temperature.

• To decrease the start up time, the slab can be maintained at an “Idling” temperature

• Idle feature is also useful for preventing frost and light ice formation

• When control is in idling mode, the word IDLE appears in the STATUS item in the View Menu

• IDLING setting in the Adjust Menu sets the theoretical slab surface temperature that is kept while control is in idling mode

There are four ways in which the snow melting system can be enabled on the SYSTEMpro 311:

• External Mix Demand

• Snow Melt Enable Module

• Remote Display Module

• Using Start / Stop buttons on the SYSTEMpro 311

EXTERNAL MIX DEMAND

An external snow melting demand is generated when a voltage between 24 and 240 VAC is applied across the Mix Demand terminals (1 and 2).

• An external demand must be present for at least 4 seconds to start snow melting system

• Once started, slab temperature is increased to MELTING setting and maintained at MELTING temperature until RUN TIME reaches 0:00

• If RUN TIME reaches 0:00 and external demand is still present, control continues at MELTING temperature until external demand is removed or system is stopped

Section E4: Snow Melt Enable

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SNOW MELT ENABLE MODULE (See fig. s)

A snow melt enable module can be used to start and stop the snow melting system. The snow melting system is enabled by pressing the button on the front of the snow melt enable module.

• As the slab is coming up to temperature, a green light flashes on the front of the snow melt enable module

• Once the slab is at melting temperature and RUN TIME is counting down, green indicator light turns solid

• To disable snow melting system when in melting mode, press the button on the face of the snow melt enable module

• When system is stopped, a solid red indicator light is displayed on the face of the snow melt enable module for 5 seconds

REMOTE DISPLAY MODULE (See fig. t)

A Remote Display Module can be used to start and stop snow melting system.

• The snow melting system is enabled by pressing the

Start

(See fig. u)

button on the Remote Display Module while in

the View Menu

• Once snow melting system is enabled, the word STRT is displayed in the LCD for at least 5 seconds

• The Remote Display Module then displays RUN TIME setting to allow user to adjust it

• To disable snow melting system when it is in melting mode, press the

Stop (See fig. v)

button on the Remote Display

Module

• The word STOP will be displayed

USING START / STOP BUTTONS ON THE SYSTEMPRO 311

If there are no external demand modules connected to the SYSTEMpro 311, the SYSTEMpro 311 will be used to operate the snow melt system.

• The snow melting system is enabled by pressing the

Start

(See fig. w)

button on the SYSTEMpro 311 while in the View

Menu.

• Once snow melting system is enabled, the word STRT is displayed in the LCD for at least 5 seconds

• The SYSTEMpro 311 then displays RUN TIME setting to allow user to adjust it

• To disable snow melting system when it is in melting mode, press the

Stop (See fig. x)

button on the SYSTEMpro 311

• The word STOP will be displayed

CONTROL FUNCTION OVERVIEW - Section E - Snow Melting

Minimum

Maximum Melting

DHW

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Start Stop

Minimum

Maximum Melting

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CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - CONTROL FUNCTION OVERVIEW - Section F - Boiler Operation

CONTROL FUNCTION OVERVIEW - SECTION F

BOILER OPERATION

BOILER TARGET TEMPERATURE (Boil TRG)

(See fig. a)

The Boil TRG temperature is determined from the demands that currently require heat.

• Boiler target temperature is set at least as high as the highest temperature requirements of the current demands

• The control displays the temperature that it is currently trying to maintain as the boiler supply temperature in Boil TRG item in the View Menu

• If the control does not have a current requirement for heat, it displays “---” in the LCD

BOILER MINIMUM (Boil MIN) (See fig. b)

The Boil MIN is the lowest water temperature that the SYSTEMpro 311 is allowed to use as a Boil TRG temperature.

• During mild conditions, if the control calculates a Boil TRG temperature below Boil MIN setting, Boil TRG temperature is adjusted to at least the Boil MIN setting

• In this mode, if boiler is operating, and boiler supply temperature is near Boil MIN setting, the Minimum pointer appears in the LCD while the Boil TRG or the Boil SUP temperature is viewed

• If installed boiler is designed for low temperature operation, set Boil MIN adjustment to OFF

BOILER MAXIMUM (Boil MAX) (See fig. c)

The Boil MAX is the highest water temperature the control is allowed to use as a Boil TRG temperature.

• If control calculates target Boil MAX, and Boil SUP temperature is near Boil MAX temperature, the Maximum pointer turns on in the LCD while the Boil TRG or the Boil SUP temperature is viewed

• At no time does the control operate the boiler above 248°F (120°C).

Section F1: Boiler Supply Sensor

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DIFFERENTIAL (Boil DIFF) (See fig. d)

An on/off heat source such as a boiler must be operated with a differential to prevent short cycling. This differential is centered around the Boil TRG temperature

• If boiler supply temperature drops 1/2 of the differential setting below Boil TRG temperature, the control closes Boiler contact to fire boiler

• If boiler supply temperature rises 1/2 of the differential setting above the Boil TRG temperature, the control opens Boiler contact to turn off boiler

• The SYSTEMpro 311 offers either a fixed or automatic differential setting

• If AUTO differential is selected, the control automatically adjusts boiler differential setting under current load conditions to minimize short cycling

BOILER OPERATION

When the SYSTEMpro 311 notices that boiler operation is required, Boiler contact terminals (15 and 16) close. While the Boiler contact is closed, the burner segment in the LCD is displayed.

BOILER PURGE

After all demands are satisfied, the SYSTEMpro 311 continues to operate primary pump (P3, terminal 8) for 20 seconds.

• Allows any excess heat to be purged out of boiler after burner is shut off

• Helps prevent water in the boiler from flashing into steam after boiler is shut off

• There must not be any motorized valves to restrict water flow through pump and boiler

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CONTROL FUNCTION OVERVIEW - SECTION G

TROUBLESHOOTING

When troubleshooting any heating system, it is a good idea to establish a set routine to follow. Below is an example of a sequence you can use when diagnosing or troubleshooting problems in a hydronic heating system.

Establish the problem

Get as much information from the customer as possible about the problem:

• Is there too much heat, not enough heat or no heat?

• Is the problem only in one zone or does the problem affect the entire system?

• Is this a consistent problem or only intermittent?

• For how long has the problem existed?

This information is critical in correctly diagnosing the problem.

Understand the sequence of operation of the system

If a particular zone is not receiving enough heat, check:

• Which pumps or valves in the system must operate to deliver heat to the affected zone?

If the zone is receiving too much heat, check:

• Which pumps, valves or check valves must operate to stop delivery of heat?

NOW, Press the Test button on the control and follow it through the test sequence as described in the Testing section. Pause the control as necessary to make sure the correct device is operating as it should

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CONTROL FUNCTION

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CONTROL FUNCTION OVERVIEW - Section G - Troubleshooting

Sketch the piping of the system

Making a sketch of the system piping before installation is a simple step that is often overlooked. This sketch can save hours of troubleshooting by identifying some of the following:

• Flow directions in the system, the location of the pumps, check valves, pressure bypass valves and mixing valves

• The correct flow direction of all pumps

This is also a very useful step if additional assistance is required.

Document the control for future reference

Before making any adjustments to the control, write down all of the items that the control is currently displaying. Include items such as:

• Error messages

• Current temperatures

• Settings

• Which devices should be operating as indicated by the LCD

This information is an essential step if additional assistance is required to diagnose the problem.

Isolate the problem between the control and the system

Now that the sequence of operation is known and the system is sketched:

• Is the control operating proper pumps and valves at the correct times?

• Is the control receiving correct signals from the system about when it should be operating?

• Are proper items selected in menus of the control for the device that is to be operated?

Test the contacts, voltages and sensors

Using a multimeter:

• Ensure that the control is receiving adequate voltage to the power terminals and the demand terminals as noted in the technical data

• Determine if the internal contacts on the control are opening and closing correctly

• Follow the instructions in the Testing the Wiring section to simulate the closed contacts on the terminal blocks as required

• Test the sensors and their wiring as described in earlier section

Page 86

APPENDIX

TABLE OF CONTENTS

IVariable Speed Injection Mixing.............................. 85-87

II SYSTEMpro 311 Menu Tree .................................... 88-89

III Application Drawings ................................................ 90-97

IV Error Message Overview ........................................ 98-101

V SYSTEMpro 311 Program Setup ........................ 102-103

NOTES:

APPENDIX

APPENDIX - APPENDIX - Table of Contents

Page 87

APPENDIX I

APPENDIX I - Variable Speed Injection Mixing

Variable Speed Injection Mixing For Hydronic Heating Systems

The purpose of this section is to discuss the use of variable speed injection mixing to precisely transfer heat from the high temperature boiler (primary) loop to the lower temperature radiant (secondary) loop in hydronic heating systems.

Various devices and plumbing arrangements can be used to accomplish this transfer. In the past, it was common to use a mixing valve in order to temper the water between the primary and secondary loops in a system. In some instances, the heat source (condensing or electric boiler, geo-thermal heat pump, etc.) can be operated at lower temperatures and dedicated solely to operating a low temperature radiant heating system. In the vast majority of systems, mixing is required because:

• A boiler minimum operating temperature is required

• High temperature water is required for other system needs

• Water temperatures vary over a wide range (e.g. solar heat sources, waste heat utilization, wood fired boilers, etc.)

When the available heat source produces higher water temperatures than is required by the radiant heating system, a tempering device is required. To achieve the lower water temperature required for the radiant system, the high temperature boiler water must be blended or injected into the return side of the radiant system to a level that meets the required supply water temperature for the radiant side. Technologies have evolved to the point of using small "wet rotor" pumps to accurately adjust the secondary radiant supply water temperature regardless of the flow activities on either primary or secondary loops.

(See fig. a)

The speed of the injection pump is automatically adjusted to deliver the desired volume of hot boiler water to the lower temperature radiant loop. The injection pump speed is constantly adjusted as the radiant heating system demand and the supply water temperature change. If the boiler return temperature becomes too cold, the injection pump can be slowed down to reduce the heat injection rate, resulting in an increased boiler return temperature.

Wirsbo offers a variety of controls that utilizes variable speed injection pump output. This output modulates the power supply to the circulator to vary its rotational speed. For residential and many commercial systems, the controls have a 120 VAC 50/60Hz output to directly power small circulators.

Radiant System

a Mixing with variable speed pump

System

Pump

High Te mperature (Primary) Loop

Valve

Injection

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Primary

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Boiler

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A permanent capacitor, impedance protected motor (no start switch) on the circulator is required. The maximum allowable amperage for this output is 2.2 amps, which limits the allowable circulator size to 1/6 HP.

This type of system can use a small circulator to inject a high BTU input into a relatively large system flow. Typically, the injection pump need only deliver 1/6 to 1/4 of the system flow for low temperature radiant panels if high temperature water is available for injection. In small hydronic systems, the smallest available circulator for variable speed injection may be too large. It is important to properly size the injection pump and use a globe valve on the return injection leg.

For proper injection pump sizing, the designer must know the following information:

(See fig. b)

= Flow Rate (Injection Loop) in GPM

= Radiant (Secondary Loop) Flow Rate in GPM

= Boiler (Primary Loop) Supply Temperature

= Radiant (Secondary Loop) Supply Temperature

= Radiant (Secondary Loop) Return Temperature

= Radiant (Secondary Loop) Temperature

Differential (

- TR)

Note: All values are to be given at design conditions. The formula used for sizing the injection pump is shown below.

= (F1x TD) / (T1- TR)

Example:

If values at design conditions are:

= Radiant (Secondary) Flow = 30 GPM

= Boiler (Primary) Supply = 180°F

= Radiant (Secondary) Supply = 140°F

= Radiant (Secondary) Return = 120°F

= Radiant (Secondary) Differential = 20°F

To find the injection pump flow rate:

= (30 x 20) / (180 - 120)

= (600) / (60)

= 10 GPM

APPENDIX I

APPENDIX I - Variable Speed Injection Mixing

b Direct Injection Mixing

“FV” to be calculated

Variable

Speed

Injection

Pump

Supply To LOW

Temperature Loop

2F1

Supply From HIGH

Temperature Loop

TRF

“DIRECT” INJECTION

Direct Injection

= (F1x TD) / (T1- TR)

Page 89

In order to provide the proper amount and temperature of supply water on the radiant heating loop, the variable speed injection pump needs only to inject 10 GPM at design conditions.

Figures c and d

show the two most common piping layouts for variable speed injection mixing. Pay particular attention to the drop lines (or thermal traps) shown in the injection legs. These are particularly important to prevent "thermal siphoning" from the primary loop into the secondary loop. Consult the pump manufacturers' chart (below) to assist in the selection of the proper injection pump for the project.

In the piping arrangement shown, the variable speed injection pumps are plumbed in such a way as to limit head pressure in the injection legs to only a few feet at most. Use standard pressure drop calculations and equivalent length of feet charts for exact calculations if required.

APPENDIX I

APPENDIX I - Variable Speed Injection Mixing

To LOW Te mperature Heating System

c Injection into a horizontal loop

System

Pump

Balancing

Valve

Variable

Speed

Injection

Pump

Primary

Pump

From HIGH

Temperature

Loop

}

Note #2

Note #1

Note #3

}

Note #2

}

Note #2

Note #1

}

Note #2

To LOW

Te mperature

Heating System

d Injection into a vertical loop

System

Pump

Balancing

Valve

Variable

Speed

Injection

Pump

Primary

Pump

From HIGH

Temperature

Loop

}

Note #1

Note #3

}

Note #2

}

Note #2

Note #1

}

Note #2

Note #1 - Maximum 4 Pipe Diameters Apart Note #2 - Minimum 6 Pipe Diameters Apart Note #3 - Drop line to be longer than 1 foot

– 1.5 - 2.0 20 0.5 X X X X X

2.5 2 100 0.5 X

4 - 5.5 3.0 - 4.5 100 0.5 X X X X X X

4.5 - 6.5 4 - 5.5 100 0.75 X X 9 - 10.5 7.5 - 8.5 100 0.75 X X X X

98100 1 X

14 - 15 12 - 13 100 1 X X X

19 17 100 1.25 X 22 - 24 19 - 21 100 1.25 X X X 26 - 28 – 100 1.5 X X X 35 - 37 31 - 32 100 1.5 X X

33 30 100 2 X 41 - 45 39 - 42 100 2 X X

Design Injection Flow Rate (US GPM) Turns open of Nominal Pipe Grundfos (F) Taco B&G Armstrong

Without With the Globe Valve Diameter 15-42 Astro

Globe Valve Globe Valve (%) (inches)

2* 3**

26-64

003

007

0010

0012

NRF9NRF22NRF

33 30 50

43-75

* Speed 2, ** Speed 3 (Brute) Table courtesy of tekmar - This table assumes there are 5 feet of pipe, 4 elbows, and branch trees of the listed diameter. These circulators have been tested and approved by the manufacturers for use with the tekmar variable speed electronics.

Manufacturer Approved Pump Models

Variable Speed Injection Design Flow Rates

Page 90

APPENDIX II

APPENDIX II - SYSTEMpro 311 Menu Tree

Page 91

APPENDIX II

APPENDIX II - SYSTEMpro 311 Menu Tree

Page 92

APPENDIX III

APPENDIX III - Application Drawings

Page 93

APPENDIX III

APPENDIX III - Application Drawings

Page 94

APPENDIX III

APPENDIX III - Application Drawings

Page 95

APPENDIX III

APPENDIX III - Application Drawings

Page 96

APPENDIX III

APPENDIX III - Application Drawings

Page 97

APPENDIX III

APPENDIX III - Application Drawings

Page 98

APPENDIX III

APPENDIX III - Application Drawings

Page 99

APPENDIX III

APPENDIX III - Application Drawings

Page 100

Error Messages

The control was unable to store a piece of information into its EEPROM. This error can be caused by a noisy power source. The control will display the error message and will continue to operate as normal. Pressing either the Menu or Item button will clear this error.

(See fig. a)

The control was unable to read a piece of information stored in the Adjust Menu. Because of this, the control was required to load the factory settings into all of the items in the Adjust Menu. The control will stop operation until all of the items available in the Adjust Menu of the control have been checked by the user or installer.

(See fig. b)

NOTE: Access level must be set to ADV in order to clear the error.

The control was unable to read a piece of information stored in the Miscellaneous Menu. Because of this, the control was required to load factory settings into all of the items in the Miscellaneous Menu. The control will continue to display the error message until all of the items available in the Misc Menu of the control have been checked by the user or installer.

(See fig. c)

NOTE: Access level must be set to ADV in order to clear the error.

An incorrect device has been connected to the (tN2) input terminal. To correct this error, ensure that the correct device is being used. Once the problem has been corrected, press either the Menu or Item button to clear the error message from the control.

(See fig. d)

APPENDIX IV

APPENDIX IV - Error Message Overview