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Eco-Propel
Variable Speed Pump Kit
Instruction and Operation
Manual
, P/N: 107065-01, Revision 1
March 03, 2017
Contents
Introduction
Installation
Pre-installation
Installation Procedure
Electrical
Front Panel
General Navigation
Setup & Tuning
Manual Operation
Concert Parameter Adjustment
Pump Parameter Adjustment
Trouble Shooting
Specifications
General
Ordering Information
Replacement Parts
Eco-Propel Variable Speed Pump Kit Instruction and Operation
TM
Application
The Eco-Propel
been designed for Apex Condensing High
Efficiency Boiler models with Concert
2
Control:
3
4
5
Intent
9
This
functional, installation and setup information.
The intended users are application engineers,
installing contractors.
10
11
13
14
15
16
16
P.O. Box 3244
Lancaster PA 17604-3244
Telephone 717-239-7642
Fax 877-501-5212
www.ThermalSolutions.com
TM
Variable Speed Pump Kit has
APX425C
APX525C
APX625C
APX725C
APX825C
instruction
manual
Figure 1:
Grundfos Variable Speed Pump
Figure 2:
Taco Variable Speed Pump
TM
Boiler
includes
detailed
Page 1 of 16
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Summary of Contents for Thermal Solutions Eco-Propel 107058-01
- Page 1 P.O. Box 3244 Eco-Propel Lancaster PA 17604-3244 Telephone 717-239-7642 Variable Speed Pump Kit Fax 877-501-5212 Instruction and Operation www.ThermalSolutions.com Manual , P/N: 107065-01, Revision 1 March 03, 2017 Application The Eco-Propel Variable Speed Pump Kit has Contents been designed for Apex Condensing High Efficiency Boiler models with Concert Boiler Introduction...
- Page 2 Variable Speed Pump), control hardware and Introduction wiring harness. The Eco-Propel Variable Speed Pump Kit uses a standard 0-10Vdc Functionality output to interface with the variable speed The Eco-Propel is pre- Variable Speed Pump Kit boiler pump. engineered to integrate with boiler firing rate control ensuring efficient temperature control Fault Tolerant Design while maximizing electrical energy savings.
- Page 3 Installation Pre-Installation NOTE: Before installing read this installation manual and keep for feature reference. WARNING Eco-Propel Kit must be installed and serviced by a professional service technician. Improper connections could create an electrical hazard, which could cause series injury, property damage, or death.
- Page 4 Installation Procedure Mechanical 1. Install Primary/Secondary Piping: Boiler MUST be installed in a Primary/Secondary piping configuration to ensure sufficient flow through the boiler’s heat exchanger. The primary loop must isolate the boiler from system piping via a closely spaced tee. For more information refer to the “Piping” section in the Apex Boiler Installation and Operation Manual.
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Page 5: Installation
Installation Installation Procedure 6. The pump can be installed vertically or horizontally to fit existing pipe structure. It can also be suspended directly in the pipes, provided the pipework can support the pump weight. Refer to figures 4 and 5. 7. - Page 6 Installation Installation Procedure Figure 7: Enclosure Mounting Locations 5. Insert the factory supplied locking grommet into holes on the side of enclosure. 6. Once enclosure is properly secured in place, connect the appropriate wiring to the Eco-Propel Control terminals. Then slide Eco-Propel control onto din-rail. 7.
- Page 7 Installation: Taco Variable Speed Pump Electrical Figure 8: Taco Variable Speed Pump Wiring Schematic Factory supplied wiring harness connections: (Factory harness uses 18 AWG, type TEW/AWM Stranded Wire, 105C.) Wire From Wire To Wire Type Component Terminal Component Terminal Horner [ D - ] Boiler Control J3 MB1 B...
- Page 8 Installation: Grundfos Variable Speed Pump Electrical Figure 9: Grundfos Variable Speed Pump Wiring Schematic Factory supplied wiring harness connections: (Factory harness uses 18 AWG, type TEW/AWM Stranded Wire, 105C.) Wire Wire From Wire To Type Component Terminal Component Terminal Horner [ D - ] Boiler Control J3 MB1 B...
- Page 9 Front Panel General Navigation Visable when Eco-Propel has been enabled Figure 10: Concert Display Home Screen Home Screen The Home screen shows provides the following Eco-Propel features: Status: When the Horner Eco-Propel Control, (control), is connected and communicating the display shows the Eco-Propel logo and differential temperature status. Adjust Page Link: Adjust icon provides access to the Adjust menu and the Variable Speed Pump adjustment screen.
- Page 10 Setup & Tuning Manual Operation The pump speed may be adjusted manually using the Operation screen. The user may select Low or High speeds, or adjust pump speed anywhere between low and high; Figure 11: Variable Speed Pump (VSP) Operating Screens Bar Graph &...
- Page 11 Setup & Tuning Concert Parameter Adjustment Login to Adjust Parameters Control operation may be tailored to suit the application by adjusting parameters. To adjust parameters select the ADJUST icon located throughout the display. Press ADJUST icon to review and adjust all parameters. Parameters are password protected to discourage unauthorized or accidental changes to settings.
- Page 12 Setup & Tuning Concert Parameter Adjustment From the ADJUST menu select the following buttons to view and adjust parameters. Variable Speed Press to adjust the following parameters. Pump Grundfos VSP Figure 14: Variable Speed Pump Adjustment Screen Factory Range / Setting Choices Parameter and Description...
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Page 13: Troubleshooting
Figure 17: Press “Ok” to select Constant curve Taco Setup: For Taco Variable Speed Pump, Not Provided by Thermal Solutions. The following selections must be made when using the Taco Variable Speed Pump: Located under the bottom cover of the variable speed pump is a control mode knob. Remove bottom two screws to take away the cover. - Page 14 Faults are investigated by selecting the “Help” button from the “Home” screen. When a fault is active the “Help” button flashes red. Continue selecting the flashing buttons to be directed to the Fault cause. When a Variable Speed Pump related fault is present the “Variable Speed Pump Status” icon will flash. Select the icon to determine the cause of fault and suggested correction.
- Page 15 Troubleshooting (continued) The following screen is intended to help in the setup of the Variable Speed Pump option: Figure 21: Eco-Propel System Setup Screen The following screen is shown when there is an active variable speed pump fault: Figure 22: Fault Alarm Screen Eco-Propel Variable Speed Pump Kit Instruction and Operation Page 15 of 16...
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Page 16: Specifications
Specifications General Figure 23: Grundfos Variable Speed Pump Dimensions DIMENSTIONS [IN] Part Weight Voltage Max Amp Pipe Size Number (lbs.) 107058-01 115 VAC 3.88 1-1/2” 9.8” 14.5” 4.2” 6.5” 12” Figure 24: Dimensions Taco Variable Speed Pump Part Weight Voltage Max Amp Pipe Size Number... - Page 17 Specifications Ordering Information Part Number Description 107068-01 Eco Propel Grundfos VSP Kit 107068-02 Eco Propel Taco VSP Kit Repair Parts List Part Number Description 107059-01 Taco Variable Speed Pump 107058-01 Grundfos Variable Speed Pump 107061-01 2 Channel analog output Smart-Mod, 4-20/0-10V 107048-01 Junction Box Assembly 107051-01...
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