D 406 Installation & Operation Manual 12/11 tekmarNet®2 House Control 406 Alternative Energy Replaces: New Introduction The tN2 House Control 406 is designed to operate the equipment in a 2-pipe, single tank, hydronic heating and cooling system. It operates two heat pump stages (waterto-water or air-to-water) with a backup heat source (boiler or electric resistance). The heat pump provides either hot or chilled water to a storage tank loop and optional mixed temperature loop.
Table of Contents Installation .........................................................................2 Preparation ....................................................................2 Physical Dimensions .....................................................3 Installation Location.......................................................3 Rough-In Wiring.............................................................3 Sizing the Transformer ..................................................4 Control Wiring ...
Power Required ------------------------------------------------------------------------------------------------------------------------------------------------------• 115 V (ac), 1-phase, 15 A service from circuit breaker panel (potentially up to two circuits) • Power disconnect (optional) Physical Dimensions Front View Side View 1/2” Knock-out (x 4) Control designed to mount on 4” x 4” electrical box (not included).
Pull two conductor 18 AWG LVT cable, up to 500 feet (150 m) for the following equipment: • tekmarNet®2 Thermostats • Heat Pump Compressor Stage 1 • Heat Pump Compressor Stage 2 (if applicable) • Heat Pump Reversing Valve (O or B) • Modulating Boiler 0-10 V (dc) or 4-20 mA (if applicable) • On/Off Boiler or Backup Heat Source (if applicable) • • • • • • • • Outdoor Temperature Sensor HP Return Temperature Sensor Tank Supply Temperature Sensor Boiler Supply Temperature Sensor (if applicable) Mix Supply Temp
Figure 3 - Connect Neutral Wires for Power Source 2 Figure 5 - System Pumps (Left) Tank System Pump Mix System Pump Boil System Pump DHW Pump HP Loop Pump Transfer Pump Variable Speed Pump Power Source 2 Figure 6 - System Pumps (Right) Figure 4 - Line Voltage Mix System Pump DHW Pump Transfer Pump Power Source 1 Power Source 2 Rear Line Voltage Wiring Diagram ----------------------------------------------------------------------------------------------------------------------------------Back of
Front Low Voltage Wiring Diagram ---------------------------------------------------------------------------------------------------------------------------------tekmarNet ®2 Thermostats tN2 tN2 Mix Supply / DHW Universal Sensor tN2 tN2 tN2 tN2 tN2 tN2 Tank Supply Universal Sensor Zone 3 C Vlv Modulating Boiler Backup + H8009B Zone 2 C Vlv Expansion — 1 Rc2 Y2 DHW Call House Control 406 Zone 1 C Vlv tN4 Boil/Mix tN4 Item tN4 Tank Expansion C Menu tN4 Setpoint Call Setpoint Call M
Wiring the Heat Pump The 406 can operate a single heat pump with a two-stage compressor in heating or cooling mode. • Connect the Rc1 and Y1 terminals on the 406 to the R and Y1 terminals on the heat pump. • Connect the Rc2 and Y2 terminals on the 406 to the R and Y2 terminals on the heat pump. • Connect the Rc1 and O/B terminal on the 406 to the R and O or B terminal on the heat pump. Wiring the Auxiliary Backup The 406 can operate an auxiliary backup other than a boiler.
Mounting the Universal Sensor -----------------------------------------------------------------------------------------------------------------------------------Note: These sensors are designed to mount on a pipe or in a temperature immersion well. The Universal Sensor should be placed downstream of a pump or after an elbow or similar fitting. This is especially important if large diameter pipes are used as the thermal stratification within the pipe can result in erroneous sensor readings.
Testing the Control Wiring Testing the Power ------------------------------------If the control display does not turn on, check the Input Power wiring terminals using an electrical multimeter. The voltage should measure between 21.6 to 26.4 V (ac). If the voltage is below this range, measure the line voltage side of the transformer. The voltage should measure between 103.5 to 126.5 V (ac).
Testing the HP Loop Pump ---------------------- Testing the DHW Pump ----------------------------------- Activate the User Test sequence and pause at Step 10 by pressing the Item button once the HP Loop pump turns on. Using an electrical meter, measure the voltage between the HP Loop pump and a neutral. The voltage should measure between 103.5 V (ac) and 126.5 V (ac). Activate the User Test sequence and pause at Step 16 by pressing the Item button once the DHW pump turns on.
Applications Mechanical A406-1 Description: The House Control 406 operates a two stage air source heat pump in heating or cooling mode to supply an outdoor reset water temperature to 4 on board tank temperature zones. Additional zones can be added using the Tank tN4 and C Expansion terminals. Domestic Hot Water pre-heat is achieved by maintaining the DHW sensor S5 in the preheat storage tank at an adjustable temperature, 90°F (32°C) default, using the DHW pump P6.
Electrical A406-1 tekmarNet ®2 Thermostats tN2 tN2 DHW Sensor (S5) tN2 tN2 tN2 tN2 tN2 tN2 R Y1 Y2 O Two Stage Air to Water Heat Pump Tank Sensor (S4) Item DHW Call H8009B House Control 406 Zone 1 C Vlv Zone 2 C Vlv Zone 3 C Vlv L1 L2 L N C (Z2) (Z3) (Z4) 24 V (ac) Transformer 009 Back of House Control 406 (P4) Tank Sys (black) (black) Tank Sys Pump Mix Sys Pump Boil Sys Pump DHW Pump 6 5 4 3 7 8 1 2 003 Relay Zone 4 Input Power C Vlv C R R (Z1) A1 A2 Stor.
Mechanical A406-2 Description: The House Control 406 operates two air source heat pumps in heating or cooling mode to supply an outdoor reset water temperature to 4 on board mix temperature zones and 4 tank zones connected to the Tank expansion terminals with a Wiring Center 314. An electric boiler supplies backup heat using the Backup relay and the Transfer Pump P7.
Electrical A406-2 Two Air to Water Heat Pumps tekmarNet ®2 Thermostats tN2 tN2 Mix Sensor (S5) tN2 tN2 tN2 tN2 tN2 tN2 R Y O C R Y O C Tank Sensor (S4) Boiler Sensor (S4) 7 8 1 2 Backup DHW Call H8009B Zone 2 C Vlv Zone 3 C Vlv tN4 Tank Expansion 314 T T Rc2 Y2 Item House Control 406 Zone 1 C Vlv tN4 Setpoint Call Menu 6 5 4 3 003 Relay C Outdoor Sensor (S1) Sensors - No Power Tank Com Boil HPRt Com Out Heat Pump Return Sensor (S2) Mod dc/mA Boil / Mix Tank + tN4 C tN4
Mechanical A406-3 Description: The House Control 406 operates a water source heat pump in heating or cooling mode to supply an outdoor reset water temperature to 4 on board tank temperature zones. The 406 also operates a modulating condensing boiler to supply an outdoor reset water temperature to 4 boiler zones connected to the Boil expansion terminals with a Wiring Center 313. The boiler supplies backup heat to the tank loop using the transfer pump P7.
Electrical A406-3 tekmarNet ®2 Thermostats tN2 tN2 DHW Sensor (S5) tN2 tN2 tN2 tN2 tN2 tN2 O Y R Water-to Water Heat Pump Tank Sensor (S4) Boiler Sensor (S3) DHW Call H8009B House Control 406 Zone 1 C Vlv Zone 2 C Vlv Zone 3 C Vlv T (Z3) (P3) Tank Sys Boil Sys (black) (black) Tank Sys Pump Mix Sys Pump Boil Sys Pump + - L N (Z4) Back of House Control 406 (P4) 313 Mod Con Boiler C (Z2) T Zone 4 Input Power C Vlv C R R (Z1) tN4 Boil Expansion Backup Item Rc2 Y2 Menu t
Mechanical A406-4 Description: The House Control 406 operates a two stage water source heat pump in heating or cooling mode to supply an outdoor reset water temperature to 4 on board tank temperature zones. The 406 also operates an on/off boiler to supply an outdoor reset water temperature to 4 boiler zones connected to the Boil expansion terminals with a Wiring Center 314. The boiler supplies backup heat to the tank loop using the variable speed pump P1.
Electrical A406-4 tekmarNet ®2 Thermostats tN2 tN2 DHW Sensor (S5) tN2 tN2 tN2 tN2 tN2 tN2 R Y1 Y2 O Two Stage Water to Water Heat Pump Tank Sensor (S4) Boiler Sensor (S3) Backup DHW Call H8009B Zone 2 C Vlv Zone 3 C Vlv T (Z3) L N (Z4) Back of House Control 406 (P4) Tank Sys (black) (P3) Boil Sys (black) Tank Sys Pump Mix Sys Pump Boil Sys Pump On/Off Boiler Zone 4 Input Power C Vlv C R C (Z2) 314 T R (Z1) tN4 Boil Expansion Rc2 Y2 Item House Control 406 Zone 1 C Vlv t
Mechanical A406-5 Description: The House Control 406 operates two water source heat pumps in heating or cooling mode to supply an outdoor reset water temperature to 4 on board mix temperature zones and 4 tank zones connected to the Tank expansion terminals with a Wiring Center 313. The 406 also operates a modulating condensing boiler to supply an outdoor reset water temperature to 4 boiler zones connected to the Boil expansion terminals with a Wiring Center 314.
Electrical A406-5 Two Water to Water Heat Pumps R Y O C R Y O C tekmarNet ®2 Thermostats tN2 tN2 Mix Sensor (S5) tN2 tN2 tN2 tN2 tN2 tN2 Boiler Sensor (S3) 003 Mix/DHW tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2 Rc1 Y1 O/B No Power Zone 1 Zone 2 Zone 3 Zone 4 H8009B Zone 3 C Vlv T Boil Sys (P3) (black) (black) Tank Sys Pump Mix Sys Pump Boil Sys Pump 314 - (Z4) Back of House Control 406 Tank Sys tN4 Boil Expansion L N C (Z3) 313 Mod Con Boiler R (Z2) + Zone 4 Input Power C Vlv C
User Interface Display Item Field Menu Field Displays the name of the selected item Displays the current menu Number Field Status Fields Displays the current status of the control’s inputs, outputs and operation. Most symbols in the status field are only visible when the VIEW Menu is selected Displays the current value of the selected item Var Setpoint Aux Xfr Symbols Calls CALLS Displays any call for heat or cool the control is receiving. Pumps PUMPS Displays any pump currently operating.
Item Button --------------------------------------------------------------------------------------------------------------------------------------------------------Each menu contains a list of Items that can be viewed and, in some cases, adjusted. Press the item button to scroll through the list in each Menu. • To view the next available item, press and release the Item button. • To view the previous item, hold down the Item button, and press and release the Up button.
View Menu (2 of 3) Item Field Range Description 0-100% BOILER MODULATION SECTION G Current percent modulation of the boiler’s burner. The boiler modulation increases when the boiler supply is less than the boiler target. The boiler modulation decreases when the boiler supply is greater than the boiler target. Note: This item is only available when the BOIL TYPE setting is set to 0-10 or 4-20.
View Menu (3 of 3) Item Field Range Description PRECOOL TANK The heat pump is cooling the storage tank while the zones remain off. This may continue for up to 30 minutes and then the zones are allowed to call for cooling. PURGING COOL Cool water is being purged from the storage tank and the heat pump is not allowed to come on. This may continue for up to 30 minutes and then preheat will begin. PREHEAT TANK The heat pump is heating the storage tank while the zones remain off.
Adjust Menu (2 of 6) Item Field Range Description BACKUP NONE, AUX, XFER, VAR Default = NONE Access: Installer Set to: 1STG, 0-10, 4-20, EMS1, EMS2 Default = 1STG Access: Installer Set to: -60 to 45°F (-51 to 7°C) Default = 10°F (-12°C) Access: Installer Set to: SECTION B NONE - No backup heat source is available. AUX - An auxiliary heat source (electric or instantaneous water heater) is either inside or in-line with the storage tank. XFER - A boiler is the backup heat source.
Adjust Menu (3 of 6) Item Field Range Description BOILER DESIGN 70 to 200°F (21 to 93.5°C) Default = 180°F (82°C) Access: Installer Set to: OFF, 80 to 180°F (26.5 to 82°C) Default = 140°F (60°C) if BOIL TYPE = 1STG SECTION D The supply water temperature required for the boiler zones to heat the building on the typical coldest day of the year.
Adjust Menu (4 of 6) Item Field Range 35 to 70°F (4 to 21°C) Default = 50°F (10°C) Access: Installer Set to: Description COOL SETPOINT SECTION D Tank setpoint that will be maintained when in cooling mode (not for floor cooling). ON, OFF Default = ON Access: Installer Set to: DEW POINT SECTION C ON - a humidity sensor is required in order to operate floor cooling. OFF - no humidity sensor is required to perform floor cooling. The floor-cooling supply target will be the value of the COOL MINIMUM setting.
Adjust Menu (5 of 6) Item Field Range 30 to 70°F (1 to 21°C) Default = 40°F (4.5°C) Access: Installer Set to: OFF, -10 to 60°F (-23.5 to 15.5°C) Default = OFF Access: Installer Set to: OFF, 35 to 100°F (-12 to 15.
Adjust Menu (6 of 6) Item Field Range 70 to 180°F (21 to 82°C) Default = 125°F (51.5°C) If DHW MODE = 1-4 Default = 90°F (32°C) If DHW MODE = 5 Access: Installer Set to: ON, OFF Default = ON Access: Installer Set to: 60 to 200°F (15.5 to 93.5°C) Default = 180°F (82°C) Access: Installer Set to: °F or °C Default = °F Access: User Set to: Description DHW OCCUPIED SECTION F Selects the temperature of the indirect DHW tank when DHW MODE = 1-4.
Monitor Menu (2 of 2) Item Field Range 0 to 9999 Hours Default = 0 hr Access: Installer RUN TIME (AUXILIARY) 0 to 9999 Hours Default = 0 hr Access: Installer RUN TIME (TRANSFER PUMP) 0 to 9999 Hours Default = 0 hr Access: Installer RUN TIME (VARIABLE SPEED PUMP) 0 to 9999 Hours Default = 0 hr Access: Installer RUN TIME (HP LOOP PUMP) 0 to 9999 Hours Default = 0 hr Access: Installer RUN TIME (TANK PUMP) 0 to 9999 Hours Default = 0 hr Access: Installer RUN TIME (MIX SYSTEM PUMP) 0 to 9999 Hours D
Toolbox Menu (1 of 1) The Toolbox Menu is a location for system information and Test functions. If any errors are present on the system, they will be located at the beginning of this menu.
Sequence of Operation tekmarNet® System Section A tekmarNet® is a family of products that use communication to operate the HVAC system in a comfortable and efficient manner. The House Control is the central component in a tekmarNet® system and requires tekmarNet ®2 (tN2) Thermostats to be directly connected to the control.
VAR (Variable Speed Pump) A boiler is the backup heat source. Backup heat is transferred from the boiler loop to the tank loop with the Variable Speed Pump. This is only selectable if a boiler water temperature has been selected and no mixing water temperature has been selected. Once enabled, the Variable Speed Pump will operate to maintain the desired tank target. Note: Boiler return protection is available when selecting this type of backup.
Section C Heat Cool Operation Mode --------------------------------------------There are five different modes that the heat pump and backup can operate in. Use the MODE setting in the Adjust Menu to select one of the following modes: AUTO The heat pump and backup will automatically switchover between heat and cool mode. COOL While in cool mode, the heat pump will satisfy any cooling calls from the zones on the Tank and Mix bus.
Without Humidity Sensor Floor cooling may be performed without a humidity sensor. This operation is only recommended in dry areas where humidity is not a concern. Set the DEW POINT item in the Adjust Menu to OFF for floor cooling without a humidity sensor on the network. Conditions For Floor Cooling The House Control 406 will enter into floor cooling when the following conditions have been met: 1. The 406 is in Warm Weather Shut Down (WWSD) 2. There has been no heat calls for 2 hours 3.
Boiler Minimum Protection -----------------------When operating a non-condensing boiler, it is important to prevent cool water from returning to the boiler. Cold return water temperatures create flue gas condensation, which if left too long, can severely damage the boiler. If VAR is selected as a backup type, the variable speed pump will reduce its speed in order to maintain the boiler sensor above the BOIL MIN setting.
• B = Heat pump normally operates in cool mode. Energize B to operate the heat pump in heat mode R Y B Rc1 Y1 O/B 406 Use the SWITCHOVR setting in the Adjust Menu to select the proper operation of the O/B terminal. Backup Delay -----------------------------------------To allow the heat pump to operate at full output for some adjustable amount of time before the backup heat source is allowed to come on, a backup delay is used.
DHW MODE 1 - DHW in Parallel no Priority When a DHW Call is present, the DHW Pump is activated. The Boiler System Pump does not turn on, but may operate based on either a Boiler, Setpoint or Backup Call. It is assumed that the DHW Pump will provide adequate flow through the heat exchanger and the boiler. DHW MODE 4 - DHW in Primary / Secondary with Priority When a DHW Call is present, the DHW Pump and the Boiler System Pump are operated.
DHW Priority Override ---------------------------------- DHW Post Purge --------------------------------------------------------------- To prevent the building from cooling off too much or the possibility of a potential freeze up during DHW priority, the control limits the amount of time for DHW priority during cold weather. During warm weather the DHW priority is 120 minutes. During cold weather the DHW priority is 15 minutes.
Modulating Boiler Operation -------------------The 406 can operate a single hot-water modulating boiler using the Mod dc/mA output and the Backup contact. Not all boilers require the use of the Backup contact. The control operates the boiler by first switching the Backup contact to allow the modulating boiler to go through the ignition sequence. A 0-10 V (dc) or 4-20 mA analog signal is then used to modulate the boiler firing rate starting from 50% (5 V (dc) or 12 mA signal) for 30 seconds.
Boiler Minimum Modulation --------------------The Minimum Modulation is the lowest signal the control can send to modulate the boiler. This operates the boiler at low fire. Use the MIN MOD setting in the Adjust Menu to select an appropriate boiler minimum modulation. • Refer to the boiler manufacturer’s literature to determine the minimum output voltage V (dc) or current (mA) that the boiler will successfully operate at. Boiler’s Minimum Input Signal - 4mA x 100% 16 mA Example: A boiler requires a 1.
Section I Mixing Operation The House Control 406 operates the variable speed pump output for mixing. The Variable % bar graph in the “Zones” box of the status field indicates the approximate speed of the pump. Status Field Var Variable Speed Pump A standard wet rotor circulator can be connected to the Variable Speed Pump output on the back of the control. The control varies the circulator speed to maintain the correct mixed supply water temperature at the mix supply sensor.
Troubleshooting It is recommended to complete all wiring to ensure trouble free operation. Should an error occur, simply follow these steps: 1. Find: If the House Control or tekmarNet ® Thermostat flashes on the screen, it is indicating a problem on the system. 2. Identify: Use the Menu button to locate the Toolbox Menu. The Error code should appear as the first item. 3. Solve: Using the lookup chart below, match the Error code to the one on the control.
Error Messages (2 of 3) Error Message Description HEAT PUMP RETURN SENSOR OPEN CIRCUIT Due to an open circuit (disconnected or broken wire), the control failed to read the heat pump return sensor. The control still operates the heat pump, but the HP RETURN MAX and HP RETURN MIN settings are no longer used. Locate and repair the problem as described in the “Test the Sensor Wiring” section. TANK SENSOR SHORT CIRCUIT Due to a short circuit, the control failed to read the tank sensor.
Error Messages (3 of 3) Error Message Description TANK DEVICE LOST (T:01 TO T:24) Each tekmarNet® device (thermostat, setpoint control, timer) has an address. The device with this address on the tank water temperature is no longer reporting back to the 406. The device can be located by either the address, or by going to each device in the building, checking that the LCD is on, and the tekmarNet® communication symbol is on.
Frequently Asked Questions Symptom LCD display is off Look For...
Job Record Item Setting Item MODE DEW POINT WATERTEMP COOL MIN ZONES 1-4 SWITCHOVER HP SOURCE HP DIFF HP TYPE HP2 DELAY BACKUP HP LOOP BOIL TYPE HP RETURN MAX OUT DSGN HP RETURN MIN TANK DSGN BALNCE PT TANK MIN Y COOLING CWSD MIX DSGN Y MIN RUN BOIL DSGN Y MIN OFF BOIL MIN BKUP DLY BOIL MOTR DHW MODE MIN MOD DHW XCHG MOD DELAY DHW OCC WWSD OCC DHW UNOCC WWSD UNOCC SETPOINT INTERLOCK UNITS Setting COOL SETP 47 of 48 © 2011 D 406 - 12/11
Technical Data tekmarNet ®2 House Control 406 Heat Pump & Backup, Four Zone Valves Literature Control Packaged weight Dimensions Enclosure Approvals Ambient conditions Power supply Control Load Zone, Y1 and O/B Relays Y2, Backup Relays Pump Relays Variable Power Pump Power Boil/Mix modulating output Sensors - Included Warranty D406, Q406, U406 Microprocessor control. This is not a safety (limit) control 1.4 lb. (640 g) 5.5” H x 5.5” W x 2.
