Tekmar Boiler Control 275 Installation & Operation Manual
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Tekmar Boiler Control 275 Installation & Operation Manual

Tekmar Boiler Control 275 Installation & Operation Manual

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Boiler Control 275
The Boiler Control 275 is designed to stage up to four condensing or non-condensing, modulating or on-off boilers using
P.I.D. staging to accurately maintain temperature. The control supports hybrid boiler plants that contain both condensing
and non-condensing boiler groups. Water temperature is controlled by outdoor reset for space heating applications or a
fixed setpoint for Domestic Hot Water (DHW) tank heating or industrial process heating applications. The control will also
accept an analog signal from an Energy Management System (EMS) to control the water temperature. Boiler equal run-time
rotation, pump exercising and stand-by system pump operation increase boiler plant reliability. The control is tekmarNet
communication compatible allowing for internet connectivity using an optional Gateway 483.
Additional functions include:
•
tN4 Compatible
•
BTC I Compatible
•
24 Hour, 5-11, 5-2, 7 Day Schedule
•
Flow or Combustion Air Proof
•
Four Modulating or On/Off Boilers
Boiler Control 275
One tN4, Four Modulating Boiler & DHW / Setpoint
tN4
tN4
Boiler
Bus
Input
Outdoor Sensor
Included
OR
0-10 or 2-10 V (dc)
from EMS
Input
Input
Universal
Universal
Sensor
Sensor
Included
Included
Installation & Operation Manual
Menu
Item
Do not apply power
1
2
3
4
5
6
7
8
9
10
11
Com
Out
Boil
Com
BRet/
Mod1
Mod2
Mod3
+
+
+
+
–
–
–
Sup
DHW
Output
Output
Up to 4
Up to 4
Modulating
Boiler Pumps
OR Boiler Enable
Boilers
Boiler Demand
DHW / Setpoint Demand
Proof Demand
Zone Load Shedding
Priority Override
EMS Input Signal
12
13
14
15
16
17
18
19
20
Relay
Relay
Relay
Relay
Mod4
+
1
2
3
4
OR
OR
Output
Combustion
Air Damper
OR Alert
1 of 48
Multi-Staging
•
Equal Run Time Rotation
•
Primary Pump Sequencing
•
DHW Operation
•
Optional DHW Sensor
•
Setpoint Operation
EMS
Setback
BTC I
Pump Sequencer
Fixed Last
Off
Rotate
Fixed Lead
First On / Last Off
First On / First Off
Off
Exercise
Demands
Test
off
red
red
For maximum heat,
press and hold Test
button for 3 seconds.
Designed and assembled in Canada by
tekmar Control Systems Ltd
tektra 1020-01
Power
115 V ±10% 60 Hz 7 VA, 1150 VA max.
Relays
230 V (ac) 5 A 1/3 hp
Demands
20 to 260 V (ac) 2 VA
Signal wiring must be rated at least 300 V.
21
22
23
24
25
26
27
28
29
30
C.A. /
DHW
Prim
Power
Boiler
DHW
Com
Alert
/ P2
P1
L
N
Demand
/Setp
Dem
Output
Output
DHW Pump
Primary
OR
Pump
Power Supply
Primary Pump
© 2012
D 275
01/12
Replaces:03/09
®
not testing
testing
testing paused
Meets Class B:
Canadian ICES
FCC Part 15
31
Pr.
Dem
Input
Flow OR
C.A. Proof
Input
DHW OR
Setpoint
Demand
Signal
Input
Boiler
Demand
Signal
Input
115 V (ac)
D 275 - 01/12

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Summary of Contents for Tekmar Boiler Control 275

  • Page 1 Multi-Staging Replaces:03/09 The Boiler Control 275 is designed to stage up to four condensing or non-condensing, modulating or on-off boilers using P.I.D. staging to accurately maintain temperature. The control supports hybrid boiler plants that contain both condensing and non-condensing boiler groups. Water temperature is controlled by outdoor reset for space heating applications or a fixed setpoint for Domestic Hot Water (DHW) tank heating or industrial process heating applications.

  • Page 2: Table Of Contents

    How to Use the Data Brochure This brochure is organized into three main sections. The Control Settings section of this brochure describes the various items that are adjusted and displayed by the They are: 1) Sequence of Operation, control. The control functions of each adjustable item are 2) Installation, described in the Sequence of Operation.

  • Page 3: Display And Symbol Description

    Display Number Field Item Field Displays the current value Displays the current of the selected item item selected 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 adjusts settings Menu Item...

  • Page 4: Access Level

    Access Level The access level restricts the number of Menus, Items, • Installer (INST): Select this access level to limit some of the settings available to the installer. This is the factory and Adjustments that can be accessed by the user. The default access level.
  • Page 5 Terminal Unit Setting in Adjust Menu Radiator (RAD) A radiator terminal unit has a large heated surface that is Select the appropriate terminal unit in the adjust menu. exposed to the room. A radiator provides heat to the room This will change the shape of the characterized heating through radiant heat transfer and natural convection.

  • Page 6: Section C: Boiler Operation

    Outdoor Design Setting in Adjust Menu Boiler Design Setting in Adjust Menu The outdoor design temperature is typically the coldest The boiler design supply temperature is the boiler water outdoor air temperature of the year. This temperature is temperature required to heat the zones at the outdoor design used when doing the heat loss calculations for the building temperature, or on the typical coldest day of the year.
  • Page 7 Stage Delay Setting in Adjust Menu The boiler differential can be fixed or automatically determined by the control. The Auto Differential setting The Stage Delay is the minimum time delay between the balances the amount of temperature swing in the boiler firing of each stage.

  • Page 8: Section D: Modulating Boilers

    Modulating Boilers Section D The 275 can operate up to four modulating boilers. The control also provides dry contacts for either burner ignition or boiler pump. Selection is made through Boiler Relay setting in the Adjust menu. Once a boiler is required to operate, the control outputs an analog signal corresponding to the Start Modulation Boiler Start Modulation Setting in Adjust Menu setting and then turns on the boiler relay.
  • Page 9 Boiler Minimum Modulation Setting in Adjust Menu For boilers with electronic operators, the boiler’s input signal range may not match the output signal range of the 275 (per boiler) control. The Maximum Modulation setting limits the control The Minimum Modulation setting is the lowest modulation output range in order to match the boiler’s input range.

  • Page 10: Section E: On / Off Boilers

    16 stages. For information on BTC I equipped boilers and is connected to the 275 using two wires connected to the how to installed with the 275, please see tekmar Service Mod + and - wiring terminals for each boiler stage. The 275 Bulletin SB 055.

  • Page 11: Section I: Domestic Hot Water Operation

    Domestic Hot Water Operation Section I DHW operation is only available when the Pump Sequencer Boiler Target Temperature during a DHW Demand DIP Switch is set to Off. If a Powered DHW Demand is present, the boilers are operated to maintain the DHW Exchange temperature. If a DHW Demand DHW sensor demand is present, the boilers are operated DHW Demands come from one of three sources: an external...
  • Page 12 Mode 1 - DHW in Parallel with No Priority Mode 4 - DHW in Primary/Secondary with Priority When a valid DHW Demand is present, the DHW relay When a valid DHW Demand is present, the DHW relay (terminal 23) and Primary Pump relay (terminal 24) turn (terminal 23) turns on.
  • Page 13 Mode 6 – Dedicated DHW DHW Post Purge When a valid DHW Demand is present from the DHW After the DHW Demand is removed, the control performs Sensor, the primary pump relay turns on. The DHW Relay a purge. The control shuts off the boilers and continues to in this mode is used as the DHW recirculation pump and operate the DHW Pump and the primary pump if applicable.

  • Page 14: Section J: Setpoint Operation

    Setpoint Operation Section J Setpoint operation is only available when DHW Mode is DIP Switch must be set to Setback to view UnOccupied set to Off. items. The control can operate to satisfy the requirements of a During the Away Scene, Setpoint demands are ignored. setpoint load in addition to a space heating load.
  • Page 15 Automatic Priority Override Mode 3 Setpoint in Primary/Secondary with No Priority Whenever a Setpoint Demand is present, the primary pump 2 hours is turned on and the boilers are operated to maintain the setpoint target. Mode = 3 Setpoint 15 mins Primary Pump 70°F (21°C)

  • Page 16: Section K: Energy Management System (Ems)

    Energy Management System (EMS) Section K The control can accept an external DC signal from an Energy CONVERSION TABLE 0 - 10 Management System (EMS) in place of the outdoor sensor. 0 - 20 mA* 0 - 10 V (dc) Boiler Target The control converts the DC signal into the appropriate –...

  • Page 17: Section L: Pump Operation

    Pump Operation Section L Primary Pump Operation Stand-by Operation The control includes two primary pump outputs with The control only operates one primary pump at a time. A capability for sequencing. Primary pump sequencing is flow proof device can be used to detect when stand-by activated through a DIP switch.

  • Page 18: Section M: Combustion Air And Alert Settings

    Flow Proof Demand Test the purge, the zone override is removed so the zone is allowed to close and turn off the primary pump. If the last The control includes a flow proof demand test in order to demand came from a non-tN4 zone, the purge period for determine if the flow/pressure device has failed.

  • Page 19: Section N: Setting The Schedule

    Combustion Air Proof Demand Test The control includes a C.A. proof demand test in order to determine if the proving device has failed. If the C.A. damper contacts are opened, the flow proof demand should not be present after 4 minutes. If the flow proof demand remains, the control will display an error message.

  • Page 20: Section O: Time Clock

    Boiler Control 275 (thermostats, Reset Module and Expansion Modules). Each The Boiler Control 275 is the system control for a hydronic tN4 device is connected to a tN4 communication bus using heating system. The 275 operates up to 4 modulating boilers, two wires.

  • Page 21: Section S: Scene Operation

    Zone Load Shedding (tN4) Indoor Temperature Feedback (tN4) Zone load shedding helps protect non-condensing boilers Indoor feedback applies when the 275 is connected to a from sustained flue gas condensation damage. Zone load tN4 Thermostat network operating on a boiler bus. Indoor shedding starts when the boiler supply temperature is below temperature feedback fine tunes the water temperature of the boiler minimum setting and all boilers are operating...

  • Page 22: Installation

    Type 275 includes: One Boiler Control 275, One Outdoor Sensor 070, Two Universal Sensors 082, One 500 Ohm resistor, Data Brochures D 275, D 070, D 001, Application Brochure A 275. Step Two — Mounting the Base Remove the control from its base by pressing on the release clip in the wiring chamber and sliding the control away from it.
  • Page 23 Step Four — Electrical Connections to the Control General The installer should test to confirm that no voltage is present at any of the wires. Push the control into the base and slide it down until it snaps firmly into place. Terminals 25 - 31 Powered Input Connections Power...
  • Page 24 Sensor is used by the control to measure the boiler supply water temperature. DHW or Boiler Return Sensor (tekmar 082) Connect the two wires from the DHW Sensor 082 to the Com and BRet / DHW (5 and 6) terminals. The DHW...
  • Page 25 Terminals 7 – 22 Non-Powered Output Connections Wiring the Modulating Boiler Outputs The control provides a 0-10 V (dc) modulating output to Mod1 Mod2 Mod3 Mod4 four modulating boilers. • Polarity is important. • Connect the + wire from boilers 1, 2, 3 and 4 to terminals Modulating Boiler 1 7, 9, 10 and 12 respectively.
  • Page 26 Step Five — Testing the Wiring General The following tests are to be performed using standard testing practices and procedures and should only be carried out by properly trained and experienced persons. A good quality electrical test meter, capable of reading from at least 0-300 V (ac), 0-30 V (dc), 0-2,000,000 Ohms, and testing for continuity is essential to properly test the wiring and sensors.
  • Page 27 Terminals 13 – 20 Testing Relay 1 – 4 1. Shut off power to the control and the boiler circuit or • If the relay is set to boiler pump: boiler pump circuit. • When the appropriate boiler pump symbol is displayed in the LCD, there should be continuity.

  • Page 28: Control Settings

    Exercise Demands EMS / Demands The EMS / Demands DIP switch selects whether a tekmar Off / Exercise outdoor sensor 070 or an external 0-10 or 2-10 V (dc) input Use the Off / Exercise DIP switch to select whether or not...
  • Page 29 Rotate / Off Fixed Last / Off Use the Rotate / Off DIP switch to enable the Equal Run Use the Fixed Last / Off DIP switch to exclude the last boiler Time Rotation feature. This feature Changes the firing in the rotation sequence.

  • Page 30: View Menu

    Display Menus View Menu (1 of 2) The View menu items display the current operating temperatures and status information of the system. Item Field Range Access Description VIEW OUTDOOR USER Current outdoor air temperature as measured by -76 to 149°F INST the outdoor sensor.
  • Page 31 View Menu (2 of 2) Item Field Range Access Description BOILER 2 MODULATION / STG SECTION D VIEW Current percent modulation of the boiler 2 burner. 0 to 100 % If the BTC I / Off DIP is set to BTC I, the BTC I number of stages is displayed.

  • Page 32: Adjust Menu

    Adjust Menu (1 of 7) The Adjust Menu items are the programmable settings used to operate the mechanical equipment. Item Field Range Access Description Actual Setting ROOM OCCUPIED SECTION B 35 to 100°F ADJUST The desired room air temperature during the (2.0 to 38.0°C) INST occupied period.
  • Page 33 Adjust Menu (2 of 7) Item Field Range Access Description Actual Setting Mod, OnOF BOILER 2 MODE SECTION D, E, F ADJUST Select whether boiler 2 is modulating (Mod) or on-off (OnOF). If the BTC I / Off DIP switch is 1, 2, 3, 4, Mod set to BTC I, then select the number of boiler Default = Mod...
  • Page 34 Adjust Menu (3 of 7) Item Field Range Access Description Actual Setting CONDENSING LEAD SECTION H Select whether or not the lead group of boilers are condensing or not. When set to On, the boiler OFF or On minimum setting is not applied to the lead group of boilers.
  • Page 35 Adjust Menu (4 of 7) Item Field Range Access Description Actual Setting DAMPER DELAY SECTION M 0:10 to 3:00 ADJUST The time delay for the boiler to operate once minutes the combustion air damper relay closes. Note: Only available when Relay is set to Damper Default = 1:00 and Proof Demand is set to Combustion Air (CA).
  • Page 36 Adjust Menu (5 of 7) Item Field Range Access Description Actual Setting BOILER 1 MOTOR SPEED SECTION D 10 to 230 The amount of time required for the modulating ADJUST seconds actuating motor to fully open the gas valve or operate the fan speed from a stopped position to full speed.
  • Page 37 Adjust Menu (6 of 7) Item Field Range Access Description Actual Setting DHW OCCUPIED SECTION I OFF, 70 to The temperature of the DHW tank during the 190°F (OFF, ADJUST INST wake and occupied periods. 21.0 to 87.5°C) Note: This item is only available when DHW Default = 140°F Mode is 1, 2, 3 or 4, the DHW Sensor is set to (60.0°C)
  • Page 38 Adjust Menu (7 of 7) Item Field Range Access Description Actual Setting SETPOINT UNOCCUPIED SECTION J Selects whether the control should respond to ADJUST OFF, On Setpoint demands while in unoccupied mode. Note: This item is only available when DHW Default = OFF UnOcc Mode is set to Off, and Setback / Off DIP is...

  • Page 39: Time Menu

    Time Menu (1 of 2) Note: The Setback / Off switch setting must be in the Setback position in order to have access to the TIME menu. The Time menu items set the time clock, day and date. Item Field Range Access Description...

  • Page 40: Schedule Menu

    Time Menu (2 of 2) Item Field Range Access Description YEAR SECTION O TIME 2000 ... 2255 INST Set the current year. Default = 2005 Note: This item is only available when Daylight Savings Time is set to Mode 1 or 2. TIME MODE SECTION O...
  • Page 41 Schedule Menu (2 of 3) Item Field Range Access Description – –:– – to 11:50 PM SCHD ALL DAYS OF THE WEEK SECTION N Wake UnOcc Sleep Select the times for the scheduled events. – –:– – to 23:50 USER Note: This item is only available when the Setback INST / Off DIP is set to On and the Heat Schedule is set...
  • Page 42 Schedule Menu (3 of 3) Item Field Range Access Description – –:– – to 11:50 PM SCHD MONDAY SECTION N Wake UnOcc Sleep – –:– – to 23:50 Select the times for the scheduled events. USER Note: This item is only available when the Setback INST / Off DIP is set to On and the Heat Schedule is set Default = 6:00 AM...

  • Page 43: Misc Menu

    Misc (Miscellaneous) Menu (1 of 1) The Miscellaneous menu items set display and control options such as access level and temperature units. Item Field Range Access Description ACCESS LEVEL PAGE 4 USER USER, The access level of the control. The access column INST, ADV INST shows which items are visible in each access level.

  • Page 44: Testing The Control

    Testing the Control IF DHW mode = 1, 2, 5, or 6, the primary pump is turned off The control has a built-in test routine that tests the main Step 7 The DHW relay is closed. control functions. The control continually monitors the The C.A.

  • Page 45: Error Messages

    To Enable Zone Test: 4. Pressing the Up button will turn off stage 1, and turn on stage 2 of the same device (if that device has a second 1. Press and hold the Test button for more than 6 seconds. stage) or turn on stage 1 of the device with the next lowest The control displays ZONE TEST OFF and the Test LED address.
  • Page 46 Error Messages (2 of 3) Error Message Description VIEW SCHEDULE MASTER ERROR ® More than one tekmarNet device has been assigned the same master number. BOILER SUPPLY SENSOR SHORT CIRCUIT VIEW Due to a short circuit, the control failed to read the boiler supply sensor. When there is a call for heat, the control no longer controls the boiler(s).
  • Page 47 Error Messages (3 of 3) Error Message Description VIEW PRIMARY PUMP P1 & P2 FAILURE Both the primary pump P1 and P2 have failed or the flow proof demand signal was not detected before the proof demand delay time elapsed. To clear the error code, press and hold the up and down buttons together for 5 seconds while viewing this error message.

  • Page 48: Technical Data

    Representative. tekmar Control Systems Ltd., Canada, tekmar Control Systems, Inc., U.S.A. Head Offi ce: 5100 Silver Star Road, Vernon, B.C. Canada V1B 3K4, 250-545-7749, Fax. 250-545-0650 Web Site: www.tekmarcontrols.com Product design, software and literature are Copyright ©...

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