Grundfos MAGNA3 Series Installation And Operating Instructions Manual
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Grundfos MAGNA3 Series Installation And Operating Instructions Manual

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Date:
January 8, 2015.
Project:
Jackson Home Office Expansion.
3 – Office Building / Connector.
Phase:
Product:
Snow Melt System.
Document:
Warranty.
Notes:
No Notes.

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Summary of Contents for Grundfos MAGNA3 Series

  • Page 1 Date: January 8, 2015. Project: Jackson Home Office Expansion. 3 – Office Building / Connector. Phase: Product: Snow Melt System. Document: Warranty. Notes: No Notes.
  • Page 2 Date of substantial completion or 18 months from date of shipment.
  • Page 4 Date: January 8, 2015. Project: Jackson Home Office Expansion. 3 – Office Building / Connector. Phase: Product: Snow Melt System. Document: Installation, Operation, and Maintenance Manuals. Notes: No notes.
  • Page 5 The Christman Company Construction Manager: Limbach Company LLC Mechanical Contractor: SUBMITTED BY: ATTACHMENT INCLUDES REF # Grundfos Magna3 Pump O + M 984594080-0614 Manual Alfa- Laval Heat exchangers 1644725-01 01/10 T5-BFG - Plate Heat Exchanger Viega PRO Radiant warranty HRH WARR 6/10/10...
  • Page 6 GRUNDFOS INSTRUCTIONS MAGNA3 Installation and operating instructions...

  • Page 7: Table Of Contents

    English (US) Installation and operating instructions Original installation and operating instructions. Selection of control mode Fault finding CONTENTS 16.1 Grundfos Eye operating indications 16.2 Signalling communication with remote control Page 16.3 Fault finding Limited warranty Sensor Symbols used in this document 17.1 Sensor specifications...

  • Page 8: Limited Warranty

    2. Symbols used in this document Products manufactured by GRUNDFOS PUMPS CORPORATION Warning (Grundfos) are warranted to the original user only to be free of defects in material and workmanship for a period of 24 months If these safety instructions are not observed, from date of installation, but not more than 30 months from date it may result in personal injury.

  • Page 9: General Information

    3. General information Max. 95 % RH The Grundfos MAGNA3 is a complete range of circulator pumps Enclosure Type 2 with integrated controller enabling adjustment of pump performance to the actual system requirements. In many systems, this will reduce the power consumption considerably, reduce noise from thermostatic radiator valves and similar fittings and improve the control of the system.

  • Page 10: Operating Conditions

    3.3 Operating conditions 3.5 Insulating shells Insulating shells are available for single-head pumps only. Limit the heat loss from the pump housing and Note Note pipework. Min./Max. +14 °F - 230 °F The heat loss from the pump and pipework can be reduced by (-10 °C - +110 °C) insulating the pump housing and the pipework.

  • Page 11: Nameplate

    3.7 Nameplate The pump nameplate provides the following information: TYPE 2 BOITIER DE TYPE 2 THERMALLY PROTECTED Nonsubmersible Pump For use with maximum 230° F water RISK OF ELECTRIC SHOCK. DE-ENERGIZE EQUIPMENT BEFORE REMOVAL OF COVER & SERVICING. FOR SUPPLY CONNECTION USE COPPER WIRE SUITABLE FOR 90 °C OR EQUIVALENT.

  • Page 12: Radio Communication

    The wireless radio in this product is class B. Intended use This product incorporates a radio for remote control. The product can communicate with Grundfos Go Remote and with other MAGNA3 pumps of the same type via the built-in radio. Only Grundfos-approved external antennae may be connected to 4.1 Installing the pump...

  • Page 13: Positioning

    To ensure adequate cooling, the control box must be in horizontal pipework, pay special attention when fitting the pump head to the position with the Grundfos logo in vertical position. See fig. 8. pump housing: 3. Visually check that the floating ring in the sealing system is centered.

  • Page 14: Changing The Control Box Position

    Position the control box in horizontal position so that the Grundfos logo is in vertical position. The motor shaft must be horizontal. Due to the drain hole in the stator housing, position the gap of the Fig.

  • Page 15: Electrical Installation

    5. Electrical installation Step Action Illustration Single-head pump. Note: The gap of the clamp can also be in position 6 o'clock for the following pump sizes: • MAGNA3 65-XX • MAGNA3 80-XX Carry out the electrical connection and protection according to •...

  • Page 16: Supply Voltage

    5.1 Supply voltage Step Action Illustration 1 x 115 V ± 10 %, 50/60 Hz, PE. 1 x 208-230 V ± 10 %, 50/60 Hz, PE. See pump nameplate for rated supply voltage Connect the cable The voltage tolerances are intended for mains voltage variations. conductors to the They should not be used for running pumps at other voltages than power supply plug.

  • Page 17: Connection To The Power Supply (Models 32-Xx)

    5.3 Connection to the power supply (models 32-XX) Step Action Illustration Step Action Illustration Remove two screws. Refit the front Remove the front cover. cover from the control box and access the power connection. L (L1) N (L2) Locate the power plug inside.

  • Page 18: Connection Diagram

    5.4 Connection diagram External switch GFCI Fuse (min. 10 A, time lag) Fig. 14 Example of typical connection, 1 x 230 V ± 10 %, 50/60 Hz Note Note All cables used must be connected in accordance with local regulations. 5.4.1 Connection to external controllers Analog input signal...
  • Page 19 Fig. 16 Wiring diagram, 32-XX versions The connection terminals of 32-XX versions differ from those of terminal-connected versions, but they have the same function and connection options. Use screened cables for external on/off switch, digital input, sensor and setpoint signals. Connect screened cables to the ground connection as follows: •...

  • Page 20: Input/Output Communication

    NC NO C • The pump is running. The function of the signal relay can be set to "Alarm", "Ready" or "Operation" on the pump control panel or with Grundfos GO Signal relay Operating signal Remote.
  • Page 21 Max. curve Min. curve Normal duty Min. curve On/off timer Select the function of the digital input on the pump control panel or with Grundfos GO Remote. Start/stop Fig. 18 Digital input Contact symbol Function Max. curve 100 % speed Min.

  • Page 22: Analog Input For External Sensor

    The electrical signal for the input can be 0-10 VDC or 4-20 mA. Signal The selection of electrical signal (0-10 V or 4-20 mA) can be changed on the control panel or with Grundfos GO Remote. signal sensor Fig. 19 Analog input for external sensor or control Fig.

  • Page 23: Electrical Connection For External Sensor

    Grundfos GO Remote. However, the pump can always be set to max. curve duty or to stop on the pump control panel or with Grundfos GO Remote. If two or more functions are enabled at the same time, the pump will operate according to the setting with the highest priority.

  • Page 24: First Start-Up

    6. First start-up Do not start the pump until the system has been filled with liquid and vented. Furthermore, the required minimum inlet pressure must be available at the pump inlet. See section 19. Technical data. The system cannot be vented through the pump. The pump is self-venting.

  • Page 25: Settings

    7. Settings 7.1 Overview of settings All settings can be made on the pump control panel or with Grundfos GO Remote. Menu Submenu Further information Setpoint See section 13.1 Setpoint. Operating mode See section 13.2 Operating mode. • Normal • Stop •...

  • Page 26: Menu Overview

    8. Menu overview Status Settings Assist Operating status Setpoint Assisted pump setup Operating mode, from Operating mode Setting of pump Control mode Control mode Setting of date and time Pump performance Date format, date and time FLOW LIMIT Max. curve and duty point Enable FLOWLIMIT function Date only Resulting setpoint...

  • Page 27: Control Panel

    9. Control panel 10. Menu structure The pump incorporates a start-up guide which is started at the Warning first start-up. After the start-up guide, the four main menus will At high liquid temperatures, the pump housing appear in the display. See section 6. First start-up. may be very hot.

  • Page 28: Status" Menu

    12. "Status" menu 13. "Settings" menu Navigation Navigation Home > Status Home > Settings Press and go to the "Status" menu with Press and go to the "Settings" menu with "Status" menu "Settings" menu This menu offers the following status information: This menu offers the following setting options: Operating status Setpoint...

  • Page 29: Operating Mode

    13.2 Operating mode 13.3 Control mode Navigation Navigation Home > Settings > Operating mode Home > Settings > Control mode Operating mode Control mode Normal (control mode) • • AUTO ADAPT Stop • • FLOW ADAPT Min. (min. curve) Prop. press. (proportional pressure) •...
  • Page 30 13.3.1 AUTO 13.3.2 FLOW ADAPT ADAPT The AUTO control mode continuously adapts the pump When FLOW is selected, the pump will run AUTO ADAPT ADAPT ADAPT performance according to the actual system characteristic. ensure that the flow never exceeds the entered FLOW value.
  • Page 31 +266 °F (+130 °C). Changing K and T values are only possible with Note Note Grundfos GO. To ensure that the pump is able to control, we Note Note recommend to set the sensor range between Changing the K...
  • Page 32 See table, fig. 33. 13.3.7 Constant curve The table shows the suggested controller settings: The pump can be set to operate according to a constant curve, like an uncontrolled pump. See fig. 34. The desired speed can be set in % of maximum speed in the range from 25 to 100 %.

  • Page 33: Flowlimit

    13.5 Automatic Night Setback 13.4 FLOW LIMIT Navigation Navigation Home > Settings > FLOW Home > Settings > Automatic Night Setback LIMIT Automatic Night Setback FLOW LIMIT Enable FLOWLIMIT function • To enable the function, select "Active" with and press Set FLOWLIMIT.

  • Page 34: Relay Outputs

    13.6 Relay outputs 13.7 Setpoint influence Navigation Navigation Home > Settings > Relay outputs Home > Settings > Setpoint influence Relay outputs Setpoint influence Relay output 1 External setpoint function • • Relay output 2. Temperature influence. • • 13.7.1 External setpoint function The relay outputs can be set to the following: Not active •...

  • Page 35: Bus Communication

    13.8 Bus communication 13.7.2 Temperature influence When this function is enabled in proportional- or 13.8.1 Pump number constant-pressure control mode, the setpoint for head will be reduced according to the liquid temperature. Temperature influence can be set to function at liquid temperatures below +176 °F or +122 °F (80 °C or 50 °C).
  • Page 36 13.9.2 Set date and time 13.9.3 Units Navigation Navigation Home > Settings > General settings > Set date and time Home > Settings > General settings > Units Set date and time Units Select date format SI or US units •...
  • Page 37 13.9.4 Enable/disable settings 13.9.6 Define Home display Navigation Navigation Home > Settings > General settings > Enable/disable settings Home > Settings > General settings > Define Home display Define Home display Enable/disable settings Select Home display type • In this display, the possibility of making settings can be disabled Define Home display contents.
  • Page 38 13.9.7 Display brightness 13.9.9 Run start-up guide Navigation Navigation Home > Settings > General settings > Display brightness Home > Settings > General settings > Run start-up guide Brightness Run start-up guide 1. Press [OK] to start the setting. It is possible to run the start-up guide again. The start-up guide will guide the user through the general settings of the pump, such 2.

  • Page 39: Assist" Menu

    The pump is designed for multi-pump connection via the wireless GENIair connection or wired via a bus system (Building Management System). The built-in wireless GENIair module enables communication between pumps and with Grundfos Go Remote without the use of add-on modules: • Multi-pump function.

  • Page 40: Selection Of Control Mode

    15. Selection of control mode Select this control System application mode Recommended for most heating systems, especially in systems with relatively large pressure losses in the AUTO ADAPT distribution pipes. See description under proportional pressure. In replacement situations where the proportional-pressure duty point is unknown. The duty point has to be within the AUTO operating range.
  • Page 41 Select this control System application mode Constant temperature In heating systems with a fixed system characteristic, for example domestic hot-water systems, the control of the pump according to a constant return-pipe temperature may be relevant. FLOW can be used with advantage to control the maximum circulation flow. LIMIT Differential temperature...

  • Page 42: Fault Finding

    The pump is currently being accessed by indication). Grundfos GO Remote. 16.2 Signalling communication with remote control The center indicator light in the Grundfos Eye will indicate communication with Grundfos GO Remote. The table below describes the desired function of the center indicator light. Case Description...

  • Page 43: Fault Finding

    Check if the pump is running in turbine operation. electronics. See code (29) Forced pumping. Switch off the pump on the main switch. If the light in the Grundfos Eye is on, the pump is Other pumps or sources force running in forced-pumping mode. Forced pumping (29)

  • Page 44: Sensor

    17. Sensor Nose downwards 5 Nm Fig. 39 Correct position of sensor During maintenance and replacement of the sensor, it is important that the sealing cap is fitted correctly on the sensor housing. Tighten the screw holding the clamp to 3.7 ft-lbs (5 Nm). Warning Before replacing the sensor, make sure that the pump is stopped and that the system is not...

  • Page 45: Accessories

    Note Grundfos GO Remote is encrypted to protect against misuse. The Grundfos GO Remote app is available from Apple AppStore and Android market. The Grundfos GO Remote concept replaces the Grundfos R100 remote control. This means that all products supported by the R100 are supported by Grundfos GO Remote.
  • Page 46 18.2.1 Description of CIM modules Fieldbus Module Description Functions protocol CIM 050 CIM 050 is a Grundfos communication interface GENIbus module used for CIM 050 has terminals for the GENIbus connection. communication with a GENIbus network. CIM 100 CIM 100 has terminals for the LonWorks connection.
  • Page 47 18.2.3 Reuse of CIM modules solution for wireless monitoring and management of Grundfos A CIM module in a CIU unit used together with GRUNDFOS products. It is based on a centrally hosted database and a web MAGNA can be reused in MAGNA3.

  • Page 48: Fitting The Cim Module

    18.3 Fitting the CIM module Warning Before fitting the module, switch off the power supply. Make sure that the power supply cannot be accidentally switched on. Step Action Illustration Remove the front cover from the control box. Fit the CIM module as illustrated and click it on. Fit and tighten the screw holding the CIM module and secure the earth connection.

  • Page 49: Technical Data

    The pump mains filter will cause a discharge current to earth during operation. I < 3.5 mA. leakage Consumption when the pump is stopped 1 to 10 W, depending on activity, i.e. reading the display, use of Grundfos GO Remote, interaction with modules, etc.
  • Page 50 GRUNDFOS Kansas City GRUNDFOS Canada GRUNDFOS México 17100 West 118th Terrace 2941 Brighton Road Boulevard TLC No. 15 Olathe, Kansas 66061 Oakville, Ontario L6H 6C9 Canada Parque Industrial Stiva Aeropuerto Phone: (913) 227-3400 Phone: +1-905 829 9533 C.P. 66600 Apodaca, N.L. México...
  • Page 51 L-MAG-TL-09 98459408 0614 ECM: 1133339 www.grundfos.com www.grundfos.us...
  • Page 52 Instruction Manual Plate Heat Exchangers M3 M6 M10 TS6 Part number 1644725-01 0810...
  • Page 53 Table of contents English Table of contents Description ..................1 Main components ..............1 Function ..................2 Semi-welded PHE..............2 Installation ..................3 Requirements ................3 Lifting ..................4 Raising ..................4 Operation ..................5 Start-up ..................5 Unit in operation ................ 6 Shut-down .................
  • Page 54 English Environmental compliance Environmental compliance AlfaLaval endeavours to perform its own op- Maintenance erations as cleanly and efficiently as possi- • During maintenance oil and wear parts in the ble, and to take environmental aspects into machine are replaced. considerattion when developing, designing, manufacturing, servicing and marketing its •...

  • Page 55: Description

    Description English Description Main components Bolt Carrying bar Support Frame plate protection column Carries the channel plates and the pressure plate. Tightening bolts Press the channel plates together. Connections Holes through the frame plate, permitting the media to enter into the heat exchanger.

  • Page 56: Function

    English Description Function The plate heat exchanger consists of a pack of tightening bolts. The plates are fitted with a gasket corrugated metal plates with portholes for the pas- which seals the channel and directs the fluids into sage of the two fluids between which heat transfer alternate channels.

  • Page 57: Installation

    Installation English Installation Requirements Multi-pass units: Connections on the Pipes pressure plate Caution! It is important that the plate pack has been tight- ened to the correct measurement (check against Make sure the pipe connections are drawing) before the pipe is connected. locked when working on the piping.

  • Page 58: Lifting

    English Installation Lifting Warning! Never lift by the connections or the studs around them. Straps should be used when lifting. Place straps according to picture. Raising Place two timber beams on the floor. Place straps around one bolt on each side. Lift the heat exchanger off pallet using e.g.

  • Page 59: Operation

    Operation English Operation Start-up Note! If there is a valve at the exit, make sure it is fully open. If several pumps are included in the system, make sure you know which one should be Open the vent and start the pump. activated first.

  • Page 60: Unit In Operation

    English Operation Unit in operation Shut-down Note! Note! Adjustments of flowrates should be made If several pumps are included in the system, slowly in order to protect the system make sure you know which one should be against sudden and extreme variations of stopped first.

  • Page 61: Maintenance

    Maintenance English Maintenance Cleaning-In-Place (CIP) The Cleaning-In-Place (CIP) equipment permits CIP performs cleaning of the plate heat exchanger without opening • cleaning of fouling and descaling of lime deposits If CIP cannot be done, cleaning must be performed • passivation of cleaned surfaces to reduce sus- manually, see section “Manual cleaning”.

  • Page 62: Manual Cleaning

    English Maintenance Manual cleaning Opening Warning! To avoid hand injuries owing to sharp Warning! edges, protective gloves should always be worn when handling plates and protective If the heat exchanger is sheets. hot, wait until it has cooled down to about 40 °C (104 °F).
  • Page 63 Maintenance English Mark the plate assembly on the outside by a diagonal line. Mark See also point 5 under part “Closing”. Measure and note down the dimension A. Open the plate pack by letting the pressure plate glide on the carrying bar. If plates are to be numbered, do this before removing the plates.
  • Page 64 English Maintenance Manual cleaning of opened units Note! Caution! Never use hydrochloric acid with Be careful not to damage the gasket dur- stainless steel plates. Water of more ing manual cleaning. than 330 ppm Cl may not be used for the preparation of cleaning solutions.
  • Page 65 Maintenance English Cleaning agents – Incrustation, scaling Concentration max 4 % Temperature max 60 °C (140 °F) Incrustation – Scaling Sediment Cleaning agent Calcium carbonate Corrosion products Nitric acid Calcium sulphate Metal oxides Sulfamic acid Silicates Silt Citric acid Alumina Phosphoric acid Diatomic organisms and Complexing agents (EDTA, NTA)
  • Page 66 English Maintenance Closing Check that all the sealing surfaces are Press the plate assembly together. Tight- clean. ening is done in two steps, see figures be- low. Be careful so that the frame plate and the pressure plate are always in parallel. Brush the threads of the bolts clean, using a steel wire brush.

  • Page 67: Pressure Test After Maintenance

    Maintenance English Pressure test after maintenance Finally the middle pair of bolts, and upper and lower bolts are tightened. Before start-up of production, whenever plates or gaskets have been removed, inserted or exchanged, it is strongly recommended to perform a pressure test to confirm the internal and external sealing func- tion of the PHE.

  • Page 68: Regasketing

    English Maintenance Regasketing Glued gaskets Open the plate heat exchanger according to page 8, and remove the plate that is to Separate gluing instructions will be delivered togeth- have a new gasket. er with the glue. Remove the old gasket. Assure that all sealing surfaces are dry, clean and free of foreign matter.
  • Page 69 - Data Brochure D 664 Snow Detector & Melting Control 664 07/09 The Snow Detector and Melting Control 664 is designed to control up to two zones in a snow melting system. The control automatically adjusts the mixed supply water to the snow melting system by controlling up to two boilers and a single mixing device. For mixing, the 664 can use a variable speed injection pump, a fl...
  • Page 70 How To Use The Data Brochure This brochure is organized into four main sections. They are: 1) Sequence of Operation, 2) Installation, 3) Control Settings, and 4) Troubleshooting. The Sequence of Operation section has 6 sub-sections. We recommend reading Section A: General of the Sequence of Operation, as this contains important information on the overall operation of the control.
  • Page 71 Display Number Field Item Field Displays the current value of the selected item Displays an abbreviated name of the selected item Menu Field Displays the current menu Status Field Displays the current status of the control's inputs, outputs and operation Buttons Selects Menus, Items and adjust settings...

  • Page 72: Sequence Of Operation

    Definitions The following defined terms and symbols are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning the life of the product. - Warning Symbol: Indicates presence of hazards which can cause severe personal injury, death or substantial property damage if ignored.

  • Page 73: Section B: Snow Melting

    MIXING TARGET (MIX TRG) The mixing target temperature is the supply fluid temperature calculated by the control. The control will operate the snow melt system so that the mix supply temperature reaches the mixing target except while providing boiler return protection for the boiler. MIXING MAXIMUM (MIX MAX) The Mix Max sets the highest fluid temperature that the control is allowed to calculate as the mixing target temperature.
  • Page 74 SOFT START When the control starts applying heat to the slab, the supply temperature to the snow melting system is ramped up over a period of time until it reaches the target mixed supply temperature. This feature helps reduce thermal stresses in the slab. Note: This operation only occurs if the Boil SENS item is set to RET or NONE.

  • Page 75: Section C: Boiler Operation

    • DET The word DET is displayed after the snow melting system has been automatically enabled by the Snow / Ice Sensor 090 and the zone is at its slab target temperature. DET is also displayed once the control is manually enabled after automatic detection by the 090 and the running time has counted down to 0:00.
  • Page 76 STAGING The 664 controls up to two stages in order to supply the required temperature. After the first stage is turned on in the firing sequence, the control waits a minimum amount of time before turning on the next stage. After the minimum time delay between stages has expired, the 664 examines the control error to determine when the next stage is to fi...

  • Page 77: Section D: Melting Enable / Disable

    ROTATION (ROTATE) The ROTATE item is an adjustable setting that is factory set at 48 hours. The firing order of the boiler changes whenever one stage’s accumulated running time exceeds the other stage’s accumulated running time by more than the ROTATE setting. After each rotation, the stage with the least running hours is the fi...
  • Page 78 Remote Start / Stop Module 039 The snow melting system is enabled by pressing the button on the front of the 039. While the zone(s) is coming up to temperature, a green indicator light fl ashes on the front of the 039.
  • Page 79 Section D2: Snow Melting Disable The snow melting system can be disabled manually or automatically. A melting disable signal applied to the control takes both zones out of the Melting mode. Once the snow melting system is disabled, the zone(s) operates in the Idling mode. The Idling mode allows the zone(s) to be either operated at a lower temperature or turned off.

  • Page 80: Section E: Melting Operation

    Section E: Melting Operation Section E1 General Melting Operation Section E1: General Melting Operation The Snow Detector and Melting Control 664 provides up to two zones of snow melting. In order for the snow melting system to be started, one of the methods described in Section D1 must be used. Once a melting enable signal is applied and the zone(s) is not in WWSD or the system is not in CWCO, the Melting mode begins.
  • Page 81 ADDITIONAL MELTING TIME (ADD MELT) In cases where areas of the snow melting system haven’t completely melted after the Melting mode has fi nished and the 090 is dry, the 664 has a function in which additional time can be added to melt the zone(s). This Snow Ice Sensor is an adjustable time through the ADD MELT item in the ADJUST menu of the control.

  • Page 82: Section F: Idling Operation

    Section F: Idling Operation Section F1 Section F2 General Idling Temporary Operation Idle Section F1: General Idling Operation When the snow melting system starts from a cold temperature, the time required for the zone(s) to reach its melting temperature may be excessive.

  • Page 83: Installation

    Installation CAUTION Improper installation and operation of this control could result in damage to the equipment and possibly even personal injury. It is your responsibility to ensure that this control is safely installed to all applicable codes and standards. This electronic control is not intended for use as a primary limit control.
  • Page 84 Melt / Idle Demand To generate a melt demand or idle demand, a voltage between 24 V (ac) and 230 V (ac) must be applied across the Melt / Idle Demand terminals (19 and 20). 24 to 230 V (ac) Output Connections Boiler Contacts The Stage 1 and Stage 2 terminals (21, 22 and 23, 24) are isolated...
  • Page 85 Mixing Valve Actuator If a mixing valve is used, connect one side of the 24 V (ac) power to the Pwr Mix terminal (4) on the control. The output relay Opn / Var (3) is then connected to the open terminal of the actuating motor and the output relay Cls (5) is connected to the close terminal of the 24 to 115 V (ac) actuating motor.

  • Page 86: Testing The Wiring

    EITHER: Snow / Ice Sensor 090 (Zone 1) If a Snow / Ice Sensor 090 is used, connect the red wire from the sensor cable to the Red terminal (6), connect the black wire from the sensor cable to the Blk / Com terminal (7), connect the blue wire from the sensor cable to the Blu terminal (8), connect the yellow wire from the sensor cable to the Yel terminal (9) and connect the brown wire from the sensor cable to the Brn / Slab1 terminal (10).
  • Page 87 Test The Power Supply 103.5 to 126.5 V (ac) Make sure exposed wires and bare terminals are not in contact with other wires or grounded surfaces. Turn on the power and measure the voltage between the Power L and Power N terminals (29 and 30) using an AC voltmeter, the reading should be between 103.5 and 126.5 V (ac).

  • Page 88: Dip Switch Settings

    4–20 mA Device The 4–20 mA output terminals (1 and 2) can not be tested without power applied to the control. Since no power is supplied to the control at this point, the 4–20 mA output cannot be tested. Please refer to the operation test below. Connecting The Control Make sure all power to the devices and terminal blocks is off, and remove any remaining jumpers from the terminals.

  • Page 89: Access Levels

    Access Levels The tekmar Snow Detector and Melting Control 664 comes with four Access Level settings. These Access Levels restrict the number of Menus, Items and Adjustments that can be accessed by the user. The four access levels are Limited (LTD), User (USER), Installer (INST) and Advanced (ADV). 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.

  • Page 90: View Menu

    664 View Menu (1 of 2) Access Level Item Field Description Range Outdoor Current outdoor air temperature as measured by -67 to 149°F the outdoor sensor. (-55 to 65°C) Slab 1 Target Slab sensor target temperature of zone 1. – – –, -58 to 167°F ZONE 1 = AUTO (–...

  • Page 91: Adjust Menu

    664 View Menu (2 of 2) Access Level Item Field Description Range Boil Supply Current boiler supply water temperature as -31 to 266°F measured by the boiler sensor. (-35 to 130°C) Boil SENS = SUP Boil Return Current boiler return water temperature as -31 to 266°F measured by the boiler sensor.
  • Page 92 664 Adjust Menu (2 of 3) Access Level Actual Item Field Description Range Setting Melt 2 The desired slab surface temperature of 32 to 95°F zone 2 while in the Melting mode. (0 to 35°C) Zone 2 = AUTO Default = 36°F (2°C) Idle 2 The desired slab surface temperature of OFF, 20 to 95°F zone 2 while in the Idling Mode.
  • Page 93 664 Adjust Menu (3 of 3) Access Level Actual Item Field Description Range Setting ΔT Maximum The maximum ΔT for the snow 10 to 70°F, OFF melting system. (5 to 39°C, OFF) PRIORITY ≠ NONE Default = OFF Differential The differential for the snow AUTO, 2 to 42°F melting system.

  • Page 94: Monitor Menu

    664 Monitor Menu (1 of 2) ▲ ▼ Note: To clear the recorded information in the specific item field, press and hold Access Level Item Field Description Range Outdoor High The highest recorded outdoor air temperature -85 to 170°F since this item was last cleared. (-65 to 77°C) Outdoor Low The lowest recorded outdoor air temperature -85 to 170°F...
  • Page 95 664 Monitor Menu (2 of 2) ▲ ▼ Note: To clear the recorded information in the specific item field, press and hold Access Level Item Field Description Range Boiler 1 Fire The total number of running hours for Stage 1 since this item was last cleared.
  • Page 96 664 Schd (Schedule) Menu (1 of 1) Access Level Item Field Description Range Override The setback override that is in effect for the snow NONE, AWAY (Ovr) melting system. Default = NONE 664 Misc (Miscellaneous) Menu (1 of 1) Access Level Item Field Description...
  • Page 97 Testing the Control The Snow Detector and Melting Control 664 has a built-in test routine which is used to test the main control functions. The 664 continually monitors the sensors and displays an error message whenever a fault is found. See the following pages for a list of the 664’s error messages and possible causes.
  • Page 98 Troubleshooting When troubleshooting any heating system, it is always a good idea to establish a set routine to follow. By following a consistent routine, many hours of potential headaches can be avoided. Below is an example of a sequence that can be used when diagnosing or troubleshooting problems in a hydronic heating system.

  • Page 99: Miscellaneous Menu

    664 Error Messages (1 of 3) Error Displayed Description of Error 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.
  • Page 100 664 Error Messages (2 of 3) Error Displayed Description of Error The control is no longer able to read the mixing supply sensor due to an open circuit. In this case, the control does not operate the snow melting system. Locate and repair the problem as described in the Data Brochure D 070.
  • Page 101 664 Error Messages (3 of 3) Error Displayed Description of Error The control is no longer able to read the water detection circuit due to an open circuit. In this case, if the control is currently in the Melting mode, the control will fi nish the snow melting cycle. The snow melting system can only be operated using an external melt demand, Remote Display Module 040, Remote Start / Stop Module 039 or the Start button on the control.
  • Page 102 Notes © 2009 D 664 - 07/09 34 of 36...
  • Page 103 Notes 35 of 36 © 2009 D 664 - 07/09...
  • Page 104 Technical Data Snow Detector & Melting Control 664 Two Zone, Two Stage Boiler, Mixing Literature — D 664, A 664’s, D 001, D 070, E 021, U 664. Control — Microprocessor PID control; This is not a safety (limit) control. Packaged weight —...
  • Page 105 Date: January 8, 2015. Project: Jackson Home Office Expansion. 3 – Office Building / Connector. Phase: Product: Snow Melt System. Document: Shop Drawings. Notes: No shop drawings available.
  • Page 106 Date: January 8, 2015. Project: Jackson Home Office Expansion. 3 – Office Building / Connector. Phase: Product: Snow Melt System. Document: Product Data. Notes: No notes.
  • Page 107 Performance Engineering Group, Inc. 32995 Industrial Road Livonia, MI 48150-1617 Phone: 734.266.5300 Fax: 734.266.5310 SUBMITTAL PACKAGE CONTROLS Jackson National Life Phase 3.1 Job: Gresham Smith and Partners Architect: Edwards & Zuck Engineer: The Christman Company Construction Manager: Limbach Company LLC Mechanical Contractor: SUBMITTED BY: ATTACHMENT INCLUDES...
  • Page 108 Submittal C 664 Snow Detector & Melting Control 664 0/ ATC Contractor to coordinate with Snow Melting Replaces: New Limbach and Snow melting system Job __________________________ Contact _______________________ Designer ______________________ vendor for additional monitoring The Snow Detector & Melting Control 664 is designed to operate mechanical equipment to melt snow off of up to 2 outdoor slabs. It can sensors, and install of all devices be used in hydronic snow melting applications consisting of up to 2 zones and 2 boilers where each zone can operate at an independent and output to BMS.
  • Page 109 Sample application Drawing Below is a sample application drawing for this product. This application may include other tekmar products that are required for installation. More sample applications can be found at www.tekmarcontrols.com. Sample Mechanical diagram Sample Electrical diagram legend Idle Demand Melt Demand Idle Demand B1 = On/Off Boiler...
  • Page 110 - Data Brochure D 090 Snow / Ice Sensor 090 / 094, Sensor Socket 091 08/05 The tekmar Snow / Ice Sensor 090 / 094 and 3-1/2” (89 mm) tekmar Sensor Socket 091 are used with all 3-1/8” (80 mm) 3-7/16”...
  • Page 111 Conduit Place the sensor socket at the chosen location and run a conduit for the cable from the socket to the snow / ice detection control. If more than 210’ (64 m) of cable is required to reach the control, run the conduit to a weatherproof junction box. The sensor cable should be run in its own conduit and not in combination with high voltage wiring.

  • Page 112: Testing And Troubleshooting

    Installing Brick Pavers If using brick pavers instead of concrete, it is recommended to mortar surrounding brick pavers to the side of the socket. This ensures good thermal conduction from the brick pavers to the socket. The top of the brick pavers should be level with the socket when the plastic plug is installed.

  • Page 113: Technical Data

    Technical Data Snow / Ice Sensor 090 / 094 Literature D 090 090 Packaged weight 4.4 lbs (2000 g) 094 Packaged weight 10.5 lbs (4762 g) Dimensions 1-3/4” H x 3-7/16 O.D. (45 x 87 O.D. mm) Material Brass, epoxy Cable material 18 AWG, 5 conductor stranded wire with polyethylene jacket 090 Cable length...
  • Page 114 DRAWN BY: Gordon Faustich REVIEWED BY: APPROVED BY: ISSUED FOR 12/09/14 APPROVAL INCREASED FLOW 12/31/14 AND BTU/SF ADDED SENSOR 02/24/15 WELLS TO SKID UPDATED 03/23/15 CONTROLS UPDATED 03/24/15 SENSORS ON SKID PROPERTY OF THAW-PAK This drawing is the property of THAW-PAK, it has been prepared to assist in the installation of our system.
  • Page 115 Performance Engineering Group, Inc 32995 Industrial Road Livonia, MI 48150-1617 Phone: 734.266.5300 Fax: 734.266.5310 SUBMITTAL PACKAGE HEAT DISTRIBUTION Jackson National Life Phase 3.1 Job: Gresham Smith and Partners Architect: Edwards & Zuck Engineer: The Christman Company Construction Manager: Limbach Company LLC Mechanical Contractor: SUBMITTED BY: ATTACHMENT INCLUDES...
  • Page 116 TechData PRODUCT SPECIFICATION SHEET ViegaPEX™ Cross-linked Polyethylene (PEX) Scope This material specification designates the requirements for ViegaPEX hot and cold water distribution tubing. All ViegaPEX tubing is copper tube size dimension (CTS), SDR-9 wall thickness and meets the respective requirements of ASTM F876 and F877.
  • Page 117 TechData PRODUCT SPECIFICATION SHEET ViegaPEX™ SDR-9 PEX Tubing ASTM F876/F877/CTS-OD SDR-9 Quality Assurance STOCK TUBING WALL NOM. WEIGHT VOLUME (Gal.) CODE SIZE O.D. THICKNESS I.D. PER FT PER 100 FT When the product is marked with the ASTM F876/F877 3/8" 0.500±.003 0.070+.010 0.350 .0413 0.50 designation, it affirms that the product was manufactured,...
  • Page 118 ® ASTM Ecoflex Potable HDPE Submittal Information Revision E: Feb. 3, 2014 Project Information Job Name: Location: Part No. Ordered: Engineer: Date Submitted: Contractor: Submitted By: Manufacturer’s Representative: Approved By: Technical Data Service Pipe: High-density polyethylene (HDPE); NSF certified SDR-11 Insulation: Multilayered, closed-cell, crosslinked polyethylene (PEX) foam insulation with a thermal conductivity of 0.26 BTU in./sq.
  • Page 119 ® Ecoflex Connection Vault Submittal Information Revision A: August 24, 2009 Project Information Jackson National Life phase 3.1 Job Name: Okemos, MI Location: Part No. Ordered: Edwards & Zuck 12-11-14 Engineer: Date Submitted: Limbach LLC Contractor: Submitted By: Performance Engineering Manufacturer’s Representative: Approved By: Technical Data...
  • Page 120 ® ASTM Ecoflex Rubber End Cap, Single Submittal Information Revision C: Feb. 3, 2014 Project Information Job Name: Jackson National Life phase 3.1 Location: Okemos, MI Part No. Ordered: Engineer: Edwards & Zuck Date Submitted: 12-11-14 Contractor: Submitted By: Limbach LLC Manufacturer’s Representative: Approved By: Performance Engineering...
  • Page 123 Underground Handhole Enclosure Selection Guide PG Style PC Style Straight sides permit easy movement of box should Stackable for increased depth. Straight sides for easy grade level change. Gasketing also available. All sizes adjustment of box to grade. are stackable. •...
  • Page 124 Material Safety Data Sheet Product Name: 8406-40% Revision Date: March 18, 2013 Page Section #1: Chemical Product and Company Identification Product Name: 8406-40% Manufacturer / Distributor: Enerco Corporation Address: 317 N. Bridge St., Grand Ledge, MI 48837 Telephone: (800) 292-5908 Fax: (517) 627-8037 For chemical emergency - spill, leak, fire, exposure or accident - call CHEMTREC - day or night - (800) 424-9300...
  • Page 125 Material Safety Data Sheet Product Name: 8406-40% Revision Date: March 18, 2013 Continued from previous page... Page Section #5: Fire-Fighting Measures NFPA Code Legend NFPA Hazard Codes - (Health / Flammability / Reactivity): 4 - Severe Hazard 3 - Serious Hazard 2 - Moderate Hazard Flash Point: Greater than 200°F.
  • Page 126 Material Safety Data Sheet Product Name: 8406-40% Revision Date: March 18, 2013 Continued from previous page... Page Section #8: Exposure Controls / Personal Protection Good general ventilation should be sufficient to control airborne levels of vapor and mist. Ventilation: Eye Protection: Chemical safety goggles.
  • Page 127 Material Safety Data Sheet Product Name: 8406-40% Revision Date: March 18, 2013 Continued from previous page... Page Section #14: Transport Information Not hazardous as regulated by DOT. DOT Proper Shipping Name: DOT Hazard Class: Not Applicable. DOT UN Number: DOT Label: Not Applicable DOT Packing Group: None...
  • Page 128 PIPE MATERIALS UNION INSTALLATION INSTRUCTIONS 1. ALL PIPING SHOULD BE SIZED AND INSTALLED AS SHOWN ON THE THAW-PAK PRESSURE GAUGE SYSTEM DRAWING. 1-1/2" ALUMINUM 1-1/2" BLACK BUSHING FLUSH PLUG 2. NO CHANGES SHALL BE MADE TO THE SYSTEM LAYOUT OR PIPE SIZE WITHOUT 1.
  • Page 129 Jackson National SIM Design Criteria for PEX Heated Area: 7,899 Max. Heat Load 1,761,477 MBTU Temp. Difference: ° ∆T ∆P HX: 13.57 BTU's / sf: Flow: 105.0 PEX Headloss: 17.77 ft. Tubing Type: 3/4" Centers: 9 " Tubing Rato: Longest Loop: Shortest Loop: Difference: # Loops:...
  • Page 130 313' 311' 313' 312' 317' 317' 314' 319' 316' 317' 325' 315' 326' 321' 320' 321' 316' 329' 323' DRAWN BY: Gordon Faustich REVIEWED BY: APPROVED BY: ISSUED FOR 12/09/14 APPROVAL INCREASED FLOW 12/31/14 AND BTU/SF ADDED SENSOR 02/24/15 WELLS TO SKID UPDATED RADIANT HEAT SCHEDULE 03/23/15...
  • Page 131 DRAWN BY: 319' Gordon Faustich 313' REVIEWED BY: 312' 312' APPROVED BY: 313' ISSUED FOR 12/09/14 APPROVAL INCREASED FLOW 12/31/14 AND BTU/SF ADDED SENSOR 02/24/15 WELLS TO SKID UPDATED RADIANT HEAT SCHEDULE 03/23/15 CONTROLS UPDATED 03/24/15 SENSORS ON SKID ZONE MANIFOLD LOCATION AREA...
  • Page 134 Coordinate power and control requirements with respective trades...
  • Page 139 Contractor has verified proper space is provided for installation including required clearances.
  • Page 141 Contractor has verified proper space is provided for installation including required clearances.
  • Page 153 EQUIPMENT LIST ITEM QTY. DESCRIPTION GRUNDFOS MAGNA3 D 65-150 F 60 Hz MATERIAL # 98126863 CAPACITY: 105 GPM AT 46' TDH NEMA 12 CONTROL PANEL Contractor has verified proper space is provided for equipment. WATTS 3" BRASS FP BALL VALVE...

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