- Data Brochure D 263 Boiler Control 263 03/09 The tekmar Boiler Control 263 can control the supply water temperature from a single modulating boiler or up to 2 on / off stages based on outdoor temperature, domestic hot water requirements, or setpoint requirements. A large easy to read display provides current system temperatures and operating status. The control has an internal setback timer, which can have 2 events per day on a 24 hour, 5-1-1 day or 7 day schedule.
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) Testing and Troubleshooting. The Sequence of Operation section has six 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. Then read the sub sections that apply to your installation.
Display Number Field Displays the current value of the selected item Menu Field Displays the current menu Boiler Demand DHW Demand Setpoint Demand Modulation Priority Override Item Field Displays an abbreviated name of the selected item Status Field Displays the current status of the control's inputs, outputs and operation Buttons Selects Menus, Items and adjust settings Symbol Description Burner Displays when Relay 1 and / or Relay 2 is turned on.
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.
TYPES OF DEMANDS The control stages or modulates the boiler(s) to control supply water temperature to a hydronic system. The supply water temperature is based on outdoor reset, a fixed temperature for DHW, or a fixed temperature for setpoint. Boiler Reset When a boiler demand signal from the heating system is present, the control operates the boiler(s) to maintain the supply temperature based on the outdoor air temperature and the Characterized Heating Curve settings. Refer to section D.
Section B: Boiler Operation Section B1 Section B2 Boiler Operation Mode 1 Two Stage Operation Section B3 Mode 2 Modulating Boiler Operation Section B1: Boiler Operation BOILER TARGET TEMPERATURE The boiler target temperature is determined by the type of demand received by the control. A boiler demand calculates a boiler target based on the characterized heating curve settings and the outdoor air temperature.
ROTATION The control’s Equal Run Time Rotation function is fixed at 48 hours. The firing order of the boilers changes whenever one boiler accumulates 48 hours more running time than the other boiler. After each rotation, the boiler with the least running hours is the first to fire and the boiler with the most running hours is the last to fire. This function ensures that both boilers receive equal amounts of use.
Auto Differential If the Auto Differential is selected, the control automatically determines the best differential as the load changes. This reduces potential short cycling during light load conditions. Differential Increasing Load Off On Time Section B3: Mode 2 - One Modulating Boiler and Pump Operation MODULATION When operating in Mode 2, the control provides a modulating output signal to operate a single modulating boiler.
Example 1: A boiler requires a 1.8 V (dc) signal to fire the boiler at low fire. The boiler can be modulated to 10 V (dc) where it reaches high fire. This means the boiler’s input signal range is 1.8 to 10 V (dc). The 263 control has an output signal range of 0 to 20 mA which can be externally converted to 0 to 10 V (dc) using a 500 Ω resistor (Refer to Modulation Output section in Step 4 of the Installation section). To make the two signal ranges the same, the Minimum Modulation required is: 0 V – 1.
DIFFERENTIAL A modulating boiler must be operated with a differential while operating in low fire. The boiler differential is divided around the boiler target temperature. The boiler burner ignites at low fire when the supply water temperature is ½ of the Boiler Differential setting below the boiler target temperature. The boiler is shut off in low fire as the supply temperature reaches at least ½ of the differential above the boiler target temperature.
Section C: Pump Operation Section C1 Pump Operation Section C1: Pump Operation PRIMARY PUMP OPERATION The primary pump operates under the following conditions: • A boiler demand is present and the control is not in Warm Weather Shut Down (WWSD). • A DHW demand is present and DHW MODE is set to 3 or 4. • A setpoint demand is present and Setpoint MODE is set to 3. Primary Pump Purge After a demand is removed, the control continues to operate the primary pump for a period of time.
Section D: Boiler Reset Operation Section D1 Boiler Reset Section D1: Boiler Reset Operation BOILER DEMAND A boiler demand is required in order for the control to provide heat to the heating system. A boiler demand is generated by applying a voltage between 24 and 230 V (ac) across the Boiler Demand terminals (1 and 2). Once voltage is applied, the Boiler Demand pointer is displayed in the LCD. If the control is not in Warm Weather Shut Down (WWSD), the control closes the primary pump contact.
TERMINAL UNITS The control provides for a selection between six different terminal unit types: two types of radiant floor heat, fancoil, fin-tube convector, radiator and baseboard. When a terminal unit is selected, the control automatically loads the design supply temperature, maximum supply temperature, and minimum supply temperature. The factory defaults are listed below. These factory defaults can be changed to better match the installed system.
Typical settings for the boost function vary between 30 minutes and two hours for buildings that have a fast responding heating system. For buildings that have a slow responding heating system, a setting between four hours and eight hours is typical. After a boost time is selected, the setback timer must be adjusted to come out of setback some time in advance of the desired occupied time. This time in advance is normally the same as the BST setting.
DHW MODE AND PRIORITY OPERATION The control has four different modes of DHW operation, which depends on the piping arrangement of the DHW tank. It is often desirable to limit or even stop the flow of heat to the heating system when the DHW tank calls for heat. This allows for a faster recovery of the DHW tank. DHW Mode 1 - DHW in Parallel no Priority When a DHW Demand is present, the DHW Pmp / Vlv contact (terminals 9 and 10) closes.
CONDITIONAL DHW PRIORITY The Conditional DHW Priority Override applies to DHW MODE 2 and 4. If the boiler supply temperature is maintained at or above the required temperature during DHW generation, this indicates that the boiler(s) has enough capacity for DHW and possibly heating as well. As long as the boiler supply temperature is maintained near its target, DHW and heating occurs simultaneously. DHW POST PURGE After the DHW Demand is removed, the control performs a purge on the boiler(s).
For correct operation, close attention must be paid to the mechanical layout of the system. When the control turns off the primary pump (Prim P1), flow to the heating system must stop. If flow is not stopped, the temperature in the heating system can exceed the maximum desired temperature and can result in damage to the heating system. DHW MODE 4 OPERATION In DHW MODE 4, the space heating zones must be prevented from coming on during DHW demands using external wiring.
SETPOINT PRIORITY OVERRIDE The setpoint has a Priority Override while in SETP MODE 2. In order to prevent the building from cooling off too much or the possibility of a potential freeze up during setpoint priority, the control limits the amount of time for setpoint priority. As the outdoor air temperature becomes colder, the length of time the control provides setpoint priority is reduced.
STEP FOUR General ELECTRICAL CONNECTIONS TO THE CONTROL 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. 7 8 Powered Input Connections Power N L 115 V (ac) Power 115 V (ac) Connect the 115 V (ac) power supply to the Power L and Power N terminals (7 and 8). This connection provides power to the microprocessor and display of the control.
Relay 1 Contact Mode 1 - Two ON / OFF Stages The Relay 1 terminals (11 and 12) are isolated outputs in the control. There is no power available on these terminals from the control. These terminals are to be used as a switch to either make or break power to a boiler or a Lo fire stage on a single boiler. Since this is an isolated contact, it may switch a voltage between 24 V (ac) and 230 V (ac).
15 16 Mod 1 mA – + The 0 to 20 mA output can be converted to 0 to 10 V (dc) using an external 500 Ω resistor across the Modulation Output terminals (15 and 16). 500 Ω resistor 0 - 20 mA converted to 0 - 10 V (dc) output OR 250 Ω resistor 0 - 20 mA converted to 0 - 5 V (dc) output The 0 to 20 mA output can be converted to 0 to 5 V (dc) using an external 250 Ω resistor across the Modulation Output terminals.
17 18 Com UnO Sw UnOccupied Switch If an external timer (tekmar Timer 032) or switch is used, connect the two wires from the external switch to the Com and UnO Sw terminals (17 and 18). When these two terminals are shorted together, the control registers an unoccupied (UNOCC) signal. Timer Switch STEP FIVE —————— TESTING THE WIRING General Each terminal block must be unplugged from its header on the control before power is applied for testing.
Setpoint Demand If a setpoint demand is used, measure the voltage between the Setp Dem and the Com Dem terminals (5 and 4). When the setpoint demand device calls for heat, between 20 and 260 V (ac) should be measured at the terminals. When the setpoint demand device is off, less than 5 V (ac) should be measured.
DHW Pump Or Valve (DHW Pmp / Vlv) If a DHW pump or DHW valve is connected to the DHW Pmp / Vlv terminals (9 and 10), make sure the power to the pump or valve circuit is off and install a jumper between those terminals. When the DHW circuit is powered up, the DHW pump should turn on or the DHW valve should open completely.
DIP Switch Settings GENERAL DIP Switches Installer None Setpoint Demand Rotate DHW Sensor Off Off Exercise Test Priority Override not testing testing testing pausedd off red red Modes 1 2 Menu If a DIP switch is changed while the control is powered up, the control responds to the change in setting by returning the display to the VIEW menu. Soft Stop Setback Advanced Boiler Demand DHW Demand Modulation Item Item Made in Canada byy tekmar Control Systems Ltd.
Display Se c In tion s Ad talle va r nc ed View Menu (1 of 1) Description Outdoor Current outdoor air temperature as measured by the outdoor sensor. Room Occupied Current room air temperature as measured by the indoor sensor. This item is only available when an indoor sensor is connected to the control. B3 © 2009 D 263 - 03/09 Range -76 to 149°F (-60 to 65°C) 23 to 113°F (-5 to 45°C) Boiler Supply Current boiler supply water temperature as measured by the boiler supply sensor.
Display Se c In tio st n Ad alle va r nc ed Adjust Menu (1 of 3) Description Range Mode Selects the control mode of operation. 1 (2 on / off) 2 (1 mod & pump) Default = 1 Room Occupied The desired room air temperature during the occupied period. 35 to 100°F (2 to 38°C) Default = 70°F (21°C) D1 Room Unoccupied The desired room air temperature during the unoccupied period. This item is only available when the Setback / None DIP switch is set to Setback.
Display Se c In tio st n Ad alle va r nc e d Adjust Menu (2 of 3) B2 B3 Description Boiler Differential The temperature differential that the control is to use when it is operating the boiler(s). Boiler 1 Selects whether or not boiler 1 is operational. This item is only available in operating mode 1. Boiler 2 Selects whether or not boiler 2 is operational. This item is only available in operating mode 1.
Display Se c In tio st n Ad alle va r nc ed Adjust Menu (3 of 3) Description Range DHW Exchange Unoccupied Selects whether or not a DHW demand will be responded to during the UnOccupied period. This item is only available when the DHW Sensor / Off DIP switch is set to Off and the Setback / None DIP switch is set to Setback. OFF, On Default = OFF DHW Boilers Selects how many boilers are to be operated during DHW generation. This item is only available in operating mode 1.
Time Menu (1 of 1) Note: The Setback / Off DIP switch must be in the Setback position in order to have access to the TIME menu. SETTING THE TIME Step One Press and release the Menu button until the TIME menu is reached. Step Two Press the Item button. While the minutes are flashing, use the ▲ or ▼ button to set the proper minutes. Step Three Press and release the Item button. While the hours are flashing, use the ▲ or ▼ button to set the proper hour. Step Four Press and release the Item button.
Schedule Menu (1 of 1) Note: The Setback / Off DIP switch must be in the setback position in order to have access to the SCHEDULE menu. SETTING THE SCHEDULE A schedule allows the timer to automatically change between two preset events based on the time of day. The schedule divides the day into Occupied and UnOccupied periods. To set the time of day at which each period is to begin, use the following procedure.
Testing the Control The control has a built-in test routine that is used to test the main control functions. The control continually monitors the sensors and displays an error message whenever a fault is found. See the following pages for a list of the control’s error messages and possible causes. When the Test button is pressed, the Test light is turned on. The individual outputs and relays are tested in the following test sequence. TEST SEQUENCE Each step in the test sequence lasts 10 seconds.
MAX HEAT The control has a function called Max Heat. In this mode, the control turns on and operates the system up to the maximum set temperatures as long as there is a demand for heat. The control continues to operate in this mode for up to 24 hours or until the Item, Menu or Test button is pressed. This mode may be used for running all circulators during system start-up in order to purge air from the piping. To enable the Max Heat feature, use the following procedure.
Error Messages (2 of 2) The control is no longer able to read the boiler supply sensor due to an open circuit. The control will not operate the boiler(s) until the sensor is repaired. Locate and repair the problem as described in the Data Brochure D 070. To clear the error message from the control after the sensor has been repaired, press either the Menu or Item button. The control is no longer able to read the DHW sensor due to a short circuit.
Notes 35 of 36 © 2009 D 263 - 03/09
Technical Data Boiler Control 263 Two Stage / One Modulating, DHW & Setpoint — — — — — — Power supply Relay capacity Modulation Output Demands Sensors included — — — — — Optional devices — D 263, A 263’s, D 001, D 070. Microprocessor PID control; This is not a safety (limit) control. 3.3 lb.
