Tekmar 402 tN2 House Control - Boiler, DHW, Mixing and Setpoint, Four Zone Valves

Installation & Operation Manual D 402
tekmarNet®2 House Control 402 09/10

HVAC Systems Replaces: 01/10
Introduction
The House Control 402 is designed to operate as part of a
complete hydronic heating system with tekmarNet ®2 (tN2)
thermostats. It can provide operation of two outdoor reset
water temperatures such as radiant floor heating on the first
temperature and baseboard or fan coil heating on the second
temperature. In addition the control has Domestic Hot Water Features
and Setpoint capabilities. It is easy to add more zones, add • Single on-off, two-stage or modulating boiler
schedules or other convenient accessories through the use
• Boiler outdoor reset temperature
of the tekmarNet ®4 (tN4) Expansion terminals.
• Mixing outdoor reset temperature
• Domestic Hot Water tank operation
• Setpoint operation
• Mix with variable speed injection, floating action,
or proportional 0-10 V (dc), proportional 4-20 mA
• For use with tekmarNet ®2 Thermostats
• Four 24 V (ac) powered zone valve outputs
• Expand to 24 zones per temperature using
tekmarNet®4 expansion ports
• CSA C US Certified for use in USA and Canada
VIEW
Calls Pumps
Boil Exp Boil System
Zones
1234
Menu Item
House Control 402
Benefits
• Energy efficiency through Outdoor Temperature
Reset with Indoor Feedback
• Indoor Feedback minimizes the water temperature
(increasing energy savings), and the efficiency of
your mechanical equipment through integrated
tekmarNet ® Thermostats
• Zone Synchronization reduces equipment cycling
• Auto Differential - Reduces boiler cycling
• Compact enclosure for flexible installation
• Simple zone expansion using Wiring Centers
1 of 32 © 2010 D 402 - 09/10

Table of Contents
Installation ......................................................................2 Monitor Menu ...........................................................19
Preparation ................................................................ 2 Toolbox Menu .......................................................... 20
Physical Dimensions ................................................. 3 Sequence of Operation ................................................ 21
Installation Location .................................................. 3 tekmarNet® System ..................................................21
Rough-In Wiring ........................................................ 3 Mix Temperature Reset Operation ...........................21
Sizing the Transformer .............................................. 4 Boiler Temperature Reset Operation ....................... 22
Control Wiring ........................................................... 4 Domestic Hot Water Tank Operation ....................... 23
Sensor Wiring............................................................ 7 Setpoint Operation .................................................. 25
Testing the Sensor Wiring ......................................... 9 Boiler Operation ...................................................... 25
Testing the Control Wiring ......................................... 9 Domestic Hot Water Heat Source ............................27
Max Heat ..................................................................10 Pump Operation .......................................................27
Applications .................................................................. 11 Energy Saving Features .......................................... 28
User Interface ............................................................... 13 Troubleshooting ............................................................28
Display......................................................................13 Error Messages .................................................. 28-30
Symbols ...................................................................13 Frequently Asked Questions .............................. 30-31
Navigating The Display ............................................14 Job Record ...............................................................31
Access Levels and Thermostat Lock........................14 Technical Data..............................................................32
Programming and Settings .......................................14
Limited Warranty and Product Return Procedure ........32
View Menu ...............................................................15
Adjust Menu ........................................................16-18
Getting Started
Congratulations on the purchase of your new tekmarNet ® House Control!
This manual covers the complete installation, programming and sequence of operation for this control. You will also find
instruction on testing, commissioning, and troubleshooting the control and system that it operates.
Installation
Caution
Improper installation and operation of this control could the control circuit. Do not attempt to service the control.
result in damage to the equipment and possibly even Refer to qualified personnel for servicing. There are no
personal injury or death. It is your responsibility to ensure user serviceable parts. Attempting to do so voids warranty
that this control is safely installed according to all applicable and could result in damage to the equipment and possibly
codes and standards. This electronic control is not intended even personal injury or death.
for use as a primary limit control. Other controls that are
intended and certified as safety limits must be placed into
Radio Frequency Interference

The installer must ensure that this control and its wiring are to correct the interference by re-orientating or relocating
isolated and/or shielded from strong sources of electromagnetic the receiving antenna, relocating the receiver with respect
noise. Conversely, this Class B digital apparatus complies to this control, and/or connecting the control to a different
with Part 15 of the FCC Rules and meets all requirements of circuit from that to which the receiver is connected.
the Canadian Interference-Causing Equipment Regulations. Cet appareil numérique de la classe B respecte toutes
However, if this control does cause harmful interference les exigences du Règlement sur le matériel brouilleur du
to radio or television reception, which is determined by Canada.
turning the control off and on, the user is encouraged to try
Preparation
Tools Required ---------------------------
------------------------------
-----
-----
---
---
---
---
---
--
--
---
---
---
---
---
---
--
--
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
--
---
--
---
--
---
• tekmar or jeweller screwdriver • Needle-nose Pliers
• Phillips head screwdriver • Wire Stripper
© 2010 D 402 - 09/10 2 of 32

Materials Required ----------------------
-------------------------
----
------
--
--
--
---
--
---
---
---
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
--
--
---
----
----
------
--
--
--
-----
• (2) #10 x 1” Wood Screws • 14 AWG Solid Wire (Line Voltage Connections)
• (3) Wire Nuts • tekmar 009K (24 V (ac) transformer with 4” x 4” junction box)
• 18 AWG LVT Solid Wire (Low Voltage Connections) • Cable or Conduit Connectors
Power Required ----

------------------------
---------------------
--
----
----
-------
------
------
------
------
------
-----
-----
------
-----
-----
------
------
-------
--------
----
-------
--
• 120 V (ac), 1-phase, 15 A service from circuit breaker • Power disconnect (optional)
panel
Physical Dimensions
Cover Off Front View Side View Back View

1/2” Knock-out (x 4)
Control designed to mount on 4” x 4”
electrical box (not included).
Electrical box shown comes with 009K
Made in Canada tN2 tN2 tN2 tN2 tN2 tN2 tN2 tN2 C Opn Cls
Zone 1 Zone 2 Zone 3 Zone 4 Floating Action
Mix Com Boil Out Com DHW
Stage 2 Mod dc/mA Boil Exp. Mix Exp.

tN4 C tN4 C
Sensors - No Power
5–1/2”
Pump Power L
Speed Pump
Variable
DHW Pump
Boil System Pump
Mix System Pump

(140 mm)
+
Setpoint
Call
Menu Item
DHW
Stage 1
Call
House Control 402

H8007B
Zone 1 Zone 2 Zone 3 Zone 4 Input Power Use at least 167°F

C Vlv C Vlv C Vlv C Vlv C R (75°C) conductors
7/8”
(22 mm)
CL
1–1/8”
(30 mm) 2–1/4” 2–1/4” 1/2” x 5/8”
5–1/2” (12 mm x 16 mm) ∅1/8” 7/8” x 1/2” (23 mm x 12 mm)
(57 mm) (57 mm) (3 mm)
(140 mm) Knock-out (x 4) Knock-out (x 4)
Installation Location
• When choosing the location for the control, consider the • Locate the control near pumps and/or zone valves if
following: possible.
• Keep dry. Avoid potential leakage onto the control. • Provide easy access for wiring, viewing and adjusting
RH 90% to 104°F (40°C). the control.
Non-condensing environment. • Mount approximately 5 ft. (1.5 m) off the finished floor.
• Do not expose to operating temperatures beyond 32- • Install the electrical junction box to a wall using #10
104°F (0-40°C) x 1” wood screws. Wall anchors are recommended
• Provide adequate ventilation. when mounting to sheet rock wallboard or masonry.
• Keep away from equipment, appliances or other
sources of electrical interference.
Rough-In Wiring
Line Voltage Wiring----
---------------------
------------------
--
----
----
------
--
--
--
---
---
---
---
---
---
---
---
----
----
----
--
--
---
---
---
---
--
--
---
---
---
----
--
--
--
-----
---
-----
The control operates a number of pumps through wiring Each cable must be pulled from the equipment to the
on the back of the control. The control must be mounted electrical junction box. It is recommended to label each
to a 4” x 4” electrical junction box so that these electrical cable for easy identification. All line voltage wires should
connections are safely contained. be stripped to a length of 1/2” (13 mm).
For ease of service, the circuit breaker or power disconnect Pull a three conductor 14 AWG cable for the following
should be located in reasonably close proximity to the equipment:
equipment. • Circuit Breaker or Power Disconnect
All line voltage wire connections are recommended to • Mix System Pump
be pulled inside a flexible or solid conduit. Always follow • Boiler System Pump
proper wiring practices, building and electrical codes for • DHW Tank Pump (if applicable)
your jurisdiction. • Variable Speed Injection Pump (if applicable)
3 of 32 © 2010 D 402 - 09/10

Low Voltage Wiring -----------------------
-------------------------
-------
---
--
----
---
---
---
----
--
---
---
---
---
----
--
---
--
---
--
---
--
---
--
----
--
----
--
--
--
--
---
--
---
--
--
Each cable must be pulled from the equipment to the • Boiler Stage 2 T-T (if applicable)
control’s plastic enclosure. All low voltage wiring connections • Modulating Boiler 0-10 V (dc) or 4-20 mA (if applicable)
enter the enclosure through conduit knockouts on the • Outdoor Temperature Sensor
sides, or through the square knockouts on the rear. It is • Boiler Supply Temperature Sensor
recommended to label each cable for easy identification. • Mix Supply Temperature Sensor
All low voltage wires are to be stripped to a length of 3/8” • DHW Tank Temperature Sensor (if applicable)
(9 mm) to ensure proper connection to the control.
• DHW Tank Aquastat (if applicable)
Pull two conductor 18 AWG LVT cable, up to 500 feet • Setpoint Devices (if applicable)
(150 m) for the following equipment: Pull three conductor 18 AWG LVT cable for the following
• tekmarNet ®2 Thermostats equipment:
• Zone Valves • Mixing Valve Actuator Floating Action
• Mixing Valve Actuator Proportional 0-10 V (dc) • tekmarNet ®4 Accessories (User Switch, Timer)
• Boiler Stage 1 T-T
Sizing the Transformer

The control requires an external transformer. A tekmar • If using a Floating Action mixing valve, add the VA
Transformer 009 (or 009K which includes a 4”x 4” electrical draw for the actuating motor. A tekmar Actuating Motor
box) can supply up to 40 VA, and includes an in-line fuse 741 draws 1.5 VA during normal operation.
to protect the transformer and control. The total power capacity of the power supply should be
In order to correctly size the external transformer, all loads larger than the total load of all the devices connected
connected to the control must be taken into account. to the control. This total load must not exceed 100 VA.
When adding up the loads, consider the following: Multiple tekmar Transformer 009’s can be wired together
to increase total VA capacity.
• tekmarNet®2 Thermostats draw approximately 2 VA each.
• Each zone valve must be sized for peak load. This can The following chart is provided to simplify transformer
be obtained by multiplying the peak current draw (in sizing:
Amps) by 24 V (ac).
Zone 1 2 3 4
Thermostat Load Transformer

Floating Control must exceed:
Zone Valve Load Action (VA) Load (VA)
Total Zone Load + + + + + 2 VA
Control Wiring
Line Voltage Wiring----
-----------------------
----------------------
----
------
--
--
--
---
---
---
---
---
---
---
---
----
----
----
--
--
---
---
---
---
--
--
---
---
---
----
--
--
--
-----
---
-----
CAUTION: TURN ALL POWER OFF BEFORE PERFORMING ANY WIRING.
Ground the Pumps Wire the Pump Power (L)
• Connect the pump grounds to the power supply • Connect the 115 V (ac) line voltage (L) wire to the red
ground as shown in Figure 1. The ground wire must Pump Power (L) wire on the back of the House Control
also be grounded to the electrical box. and to the 115 V (ac) side of the transformer. Use a
Wire the Pump Neutrals wire nut or approved connector. See Figure 3.
• Connect the Neutral (N) wires from each pump and wire Wire the Pumps
to the 115 V (ac) Neutral (N) wire. If the transformer has • Wire each remaining line voltage pump wire into the
been mounted to this electrical box, connect its neutral push-in wire connector of the corresponding pump
wire with this group. This is shown in Figure 2. lead on the back of the House Control. This is shown
in Figure 4.
© 2010 D 402 - 09/10 4 of 32

Figure 1 - Connect Figure 2 - Connect
Ground Wires Neutral Wires
Variable Speed Pump Variable Speed Pump
Pump Pump
Pump Pump
DHW Pump Pump DHW Pump Pump
Boil System Pump Boil System Pump
Mix System Power Source Mix System Power Source

Pump
Pump
(L,N) Pump
Pump
(L,N)
Figure 3 - Connect Figure 4 - Connect

Line Voltage (Hot) Pump Line (Hot)
V. S. Pump
V. S. Pump
402
DHW Pump 402
DHW Pump Mix System Pump
Boil System Pump

Mix System Pump
Boil System Pump
DHW Pump
Boil Sys Pump DHW Pump
Boil Sys Pump Variable Strip wires

1/2 inch (13 mm).
Variable Strip wires
1/2 inch (13 mm).
Speed Pump Installed wires are Speed Pump Installed wires are
not removable. not removable.
Pump Power L 12-18 AWG
Pump Power L 12-18 AWG
Power
Mix System
Power Source
Mix System Pump
Source (L,N)
Pump
(L,N)
Rear Line Voltage Wiring Diagram -

------
---------
----
----
-----
----
-------
----
-------
----
-------
------
-----
------
------
------
-----
---
---
-----
------
--
Back of House Control 402

Mix (black)
Mix System Pump
Boil
(black)
Boil System Pump
DHW
(black)
DHW Pump
(red)
Pump Power L
Strip wires
L 1/2 inch (13 mm).
Installed wires are
(blue) Variable not removable.
12-18 AWG
Variable Speed Pump
N Speed
to pump grounds
L NG
115 V (ac)
5 of 32 © 2010 D 402 - 09/10

Install The Enclosure -------
---------------------
---------------
----
--------
---------
------
------
------
------
-----
------
-----
-----
-----
-----
-------
-----
-----
----
• Ensure that the pump wires are neatly tucked inside
the electrical box. Figure 5
• Using 2 of the 4 holes in the back of the enclosure, se-
curely fasten it to the electrical junction box with 2 #10
screws as shown in Figure 5.
Low Voltage Wiring -----------------------

-------------------------
-------
---
--
----
---
---
---
----
--
---
---
---
---
----
--
---
--
---
--
---
--
---
--
----
--
----
--
--
--
--
---
--
---
--
--
External Power Supply Domestic Hot Water (DHW) or Setpoint Call
It is strongly recommended that a transformer with an in-line When the control receives a DHW Call or Setpoint Call for
fuse be used in order to protect the transformer from high heat it will override Outdoor Reset and Indoor Feedback
currents. The tekmar Transformer 009 includes a fuse. and operate the boiler to heat the DHW tank or the Setpoint
• Connect the 24 V (ac) leads from the transformer to the equipment.
C and R terminals marked “Input Power” on the 402. • To create a DHW call, wire a dry contact OR apply 24
tN2 Thermostats V (ac) to the DHW call terminals.
The 402 is designed to operate with tekmarNet®2 Thermostats. • To create a Setpoint call, wire a dry contact OR apply
They provide the heating and cooling control for each zone, 24 V (ac) to the Setpoint call terminals.
and communicate with any other tekmarNet ® device on Wiring the Boiler
the system. The 402 can operate a single modulating boiler, single
• Connect the tN2 terminals from each thermostat to the on-off, or a single two-stage on-off boiler.
corresponding tN2 terminals for each zone on the 402. On/Off Boiler
Zone Valves • Connect the Boiler Stage 1 terminals on the 402 to the
• Wire the zone valves to the C and Vlv terminals on the T-T (or R-W) terminals on the boiler.
402. • If required, connect the Boiler Stage 2 terminals on the
• End switches on zone valves are not required when 402 to the second stage T-T (or R-W) terminals on the
using the 402. boiler.
tN4 Expansion Terminals Modulating Boiler
The 402 uses the Expansion tN4 and C terminals to • Wire the Mod (dc/mA) positive (+) and negative (-) ter-
communicate with additional thermostats, setpoint controls, minals on the 402 to the input signal terminals on the
and other tekmarNet ® devices. There are two sets of tN4 boiler. Correct polarity of the wires is important.
and C terminals on the 402. • In some cases, the modulating boiler also requires
Boil Exp. contact closure on the T-T terminals to fire the boiler. If
required, connect the Boiler Stage 1 terminals on the
To add additional boiler water temperature zones (typically
402 to the T-T (or R-W) terminals on the boiler.
baseboard or fan coil zones) to the system, install a
tekmarNet ® Wiring Center. Floating Action Terminals
• Connect the tN4 and C Boil Exp. terminals on the 402 Applications that use a floating action mixing valve actuator
to the corresponding tN4 and C Expansion terminals (tekmar type 741) will use the Floating Action Opn, Cls, and
on the external Wiring Center. C terminals. This is a powered output (24 V (ac)).
Mix Exp. • Wire the Opn, Cls, and C terminals on the 402 to the
open, close, and C terminals on the floating action
The 402 has the capacity to expand the number of mixing
actuator.
zones in the system beyond the four on board zones. To
add additional mix water temperature zones (typically Proportional Mixing (0-10 V (dc) or 4-20 mA)
radiant floor zones) to the system, install a tekmarNet ® Applications that use a proportional mixing valve actuator
Wiring Center. will use the Mod (dc/mA) terminals. Proportional mixing can
• Connect the tN4 and C Mix Exp. terminals on the 402 only be used when a modulating boiler is not installed.
to the corresponding tN4 and C Expansion terminals • Wire the Mod positive (+) on the 402 to the positive (+)
on the external Wiring Center. terminal on the actuator.
• Wire the Mod negative (-) on the 402 to the negative (-)
or common terminal on the actuator.
© 2010 D 402 - 09/10 6 of 32

Front Low Voltage Wiring Diagram ---------
------
------
----
-------
----
-------
----
-------
------
-------
------
------
------
--------
----------
----
----
tekmarNet ®2 Thermostats
24 V (ac) Floating
Action Actuator
Com
Open
Close
Mix Supply
Sensor 082
Outdoor Zone 1 Zone 2 Zone 3 Zone 4 Floating Action
Boiler Supply tekmarNet ®4
Sensor
C
tN4 Mix

Sensor 082
tN4 C tN4 C
Expansion WC
Expansion to
070
tN4
Sensors - No Power
Wiring Centers,
C
tN4 Boil Timers, or
Expansion WC
tN4
User Switch
DHW Tank
—
Modulating
Sensor 082 Boiler
+
Setpoint
Call
Setpoint Call Menu Item

2
DHW
Stage 1
Call
House Control 402

H8007B

One or Two Stage

Boiler T-T
DHW Call
R L
from DHW
C N
Tank Aquastat
(optional)
Zone Valves
24 V (ac) Transformer 009
Sensor Wiring
Mounting the Outdoor Sensor 070 --
-------
-------
----
----
-----
----
------
-----
--------
---------
------
------
------
------
-----
-----
-----
---
--
-----
----
-----
Note: The temperature sensor (thermistor) is built into the • In order to prevent heat transmitted through the wall
070 enclosure. from affecting the sensor reading, it may be necessary
• Remove the screw and pull the front cover off the to install an insulating barrier behind the enclosure.
sensor enclosure. • The 070 should be mounted on a wall which best rep-
• The 070 can either be mounted directly onto a wall or resents the heat load on the building (a northern wall
a 2” x 4” electrical box. When the 070 is wall mounted, for most buildings and a southern facing wall for build-
the wiring should enter through the back or bottom of ings with large south facing glass areas). The 070
the enclosure. Do not mount the 070 with the conduit should not be exposed to heat sources such as venti-
knockout facing upwards as rain could enter the enclo- lation or window openings.
sure and damage the sensor. • The 070 should be installed at an elevation above
the ground that will prevent accidental damage or
tampering.
Sensor with rear Sensor with bottom Sensor mounted

entry wiring entry wiring onto 2" x 4"
electrical box
7 of 32 © 2010 D 402 - 09/10

Wiring the Outdoor Sensor 070 ------------
-------------
---
---
-----
--
---
--
-----
--
--
--
-----
---
---
---
---
---
---
---
---
---
---
--
--
--
--
---
---
---
---
---
---
--
-----
--
--
--
-
• Connect 18 AWG or similar wire to the two terminals Wires from outdoor
provided in the enclosure and run the wires from the sensor to control
terminals
070 to the control. Do not run the wires parallel to tele- (Com Sen - Out Sen)
phone or power cables. If the sensor wires are located
in an area with strong sources of electromagnetic in-
terference (EMI), shielded cable or twisted pair should
be used or the wires can be run in a grounded metal
conduit. If using shielded cable, the shield wire should
be connected to the Com or Com Sen terminal on the
control and not to earth ground.
• Follow the sensor testing instructions in this brochure
and connect the wires to the control. Sensor is built into
• Replace the front cover of the sensor enclosure. the enclosure
Mounting the Boiler and Mix Sensor 082 ---

--
--
--
--
--
--
--
---
--
--
--
--
--
---
--
----
--
---
--
-----
--
--
--
---
---
---
---
----
--
---
--
---
--
---
--
----
--
---
--
--
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. Proper sensor location requires that the fluid
is thoroughly mixed within the pipe before it reaches the
sensor.
Strapped to Pipe
The Universal Sensor can be strapped directly to the pipe
using the cable tie provided. Insulation should be placed
around the sensor to reduce the effect of air currents on
the sensor measurement.
Immersion Well Retaining Clip

If a Universal Sensor is mounted onto 1” (25 mm) diameter Universal
L type copper pipe, there is approximately an 8 second Sensor 082
delay between a sudden change in water temperature and
the time the sensor measures the temperature change.
This delay increases considerably when mild steel (black
iron) pipe is used. In general, it is recommended that
a temperature well be used for steel pipe of diameter
greater than 1-1/4” (32 mm). Temperature wells are also
Sensor Well
recommended when large diameter pipes are used and
fluid stratification is present.
Conduit Connection
The Universal Sensor 082 and Universal Sensor Enclosure
080 (sold separately) are specifically designed to mount
onto a 3/8” (10 mm) ID temperature well that is supplied
with an end groove. To install the well, plumb a ‘T’ into the
pipe and fix the well into the ‘T’. The 080 enclosure has Bottom of
a 7/8” (22 mm) back knockout that must be removed and Enclosure 080
fitted over the temperature well. The 082 is then inserted
into the well and the retaining clip supplied with the
enclosure is snapped onto the well end groove. If the well
has a threaded end, the installer must supply a standard
threaded conduit retaining ring. The two wires from the
sensor are connected to the terminal block provided in the Universal
enclosure. The other side of the terminal block is used to Sensor 082 Cable Tie
connect wires from the control.
© 2010 D 402 - 09/10 8 of 32

Testing the Sensor Wiring
A good quality test meter capable of measuring up to 5,000 estimate the temperature measured by the sensor. The
kΩ (1 kΩ = 1000 Ω) is required to measure the sensor sensor and thermometer readings should be close. If the
resistance. In addition to this, the actual temperature must test meter reads a very high resistance, there may be a
be measured with either a good quality digital thermometer, broken wire, a poor wiring connection or a defective sensor.
or if a thermometer is not available, a second sensor can If the resistance is very low, the wiring may be shorted,
be placed alongside the one to be tested and the readings there may be moisture in the sensor or the sensor may
compared. be defective. To test for a defective sensor, measure the
First measure the temperature using the thermometer and resistance directly at the sensor location.
then measure the resistance of the sensor at the control. Do not apply voltage to a sensor at any time as damage
The wires from the sensor must not be connected to the to the sensor may result.
control while the test is performed. Using the chart below,
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
°F °C °F °C °F °C °F °C
-50 -46 490,813 20 -7 46,218 90 32 7,334 160 71 1,689
-45 -43 405,710 25 -4 39,913 95 35 6,532 165 74 1,538
-40 -40 336,606 30 -1 34,558 100 38 5,828 170 77 1,403
-35 -37 280,279 35 2 29,996 105 41 5,210 175 79 1,281
-30 -34 234,196 40 4 26,099 110 43 4,665 180 82 1,172
-25 -32 196,358 45 7 22,763 115 46 4,184 185 85 1,073
-20 -29 165,180 50 10 19,900 120 49 3,760 190 88 983
-15 -26 139,402 55 13 17,436 125 52 3,383 195 91 903
-10 -23 118,018 60 16 15,311 130 54 3,050 200 93 829
-5 -21 100,221 65 18 13,474 135 57 2,754 205 96 763
0 -18 85,362 70 21 11,883 140 60 2,490 210 99 703
5 -15 72,918 75 24 10,501 145 63 2,255 215 102 648
10 -12 62,465 80 27 9,299 150 66 2,045 220 104 598
15 -9 53,658 85 29 8,250 155 68 1,857 225 107 553
Testing the Control Wiring

Testing the Power -----------------------
------------------------
------
--- If the thermostat display continues to be off, or is cycling
If the control display does not turn on, check the Input on and off, there may be a fault on the thermostat.
Power wiring terminals using an electrical multimeter. If a fault is suspected, contact your tekmar sales
The voltage should measure between 21.6 to 26.4 V representative for assistance.
(ac). If the voltage is below this range, measure the User Test --
--
--
--
---
--
--
--
--
--
--
--
---
---
------
--
--
--
-----
--
-------
--
--
line voltage side of the transformer. The voltage should The User Test is found in the Toolbox menu of the control.
measure between 103.5 to 126.5 V (ac). Press the Menu button to access the Toolbox Menu. Press
Testing the Thermostats ---------------
-------------------
------ the Item button to locate the User Test.
If the thermostat display turns on, this indicates that Start the test sequence by going to the User Test item and
the thermostat is operating correctly and there are no pressing the ‘Up’ arrow button.
electrical issues. In the event that the display is off, or Pause the test sequence by pressing the Item button. To
the display is cycling on and off, follow this procedure. advance to the next step, press the Item button again.
1. Remove the tN2 wires from the thermostat. If the test sequence is paused for more than five minutes,
2. Use an electrical meter to measure DC voltage between the control exits the entire test routine and returns to normal
the tN2 terminals. operation.
To advance to a particular step, repeatedly press and
If the DC voltage is 0 V (dc) for 20 seconds, then there is
release the Item button to display the appropriate device.
an open or short circuit in the tN2 wires. If the DC voltage
is 0 V (dc) for 10 seconds and then is 23 to 24 V (dc) for 5 User Test Sequence
seconds, this indicates the wiring is correct. Step 1 The Mix 1 device ramps up to 100% over 30 seconds
or according to the motor speed setting.
3. Connect the thermostat to the tN2 wires from a zone
on a House Control, Wiring Center, or Zone Manager. Step 2 The Mix 1 device ramps down to 0% over 30 seconds
or according to the motor speed setting.
4. If the thermostat display is off, or is cycling on and off,
move the thermostat to the next available zone on the Step 3 Zone 1 turns on for 10 seconds.
House Control, Wiring Center, or Zone Manager. Step 4 Zone 2 turns on for 10 seconds.
If the thermostat display remains permanently on, there Step 5 Zone 3 turns on for 10 seconds.
may be a fault with the previously tried zone on the House Step 6 Zone 4 turns on for 10 seconds.
Control, Wiring Center, or Zone Manager. Step 7 The mix system pump turns on for 10 seconds.
9 of 32 © 2010 D 402 - 09/10

Step 8 The DHW pump turns on for 10 seconds. Testing the DHW Pump -
--
---
--
--
--
--
--
---
---
-----
--
------
--
--
Step 9 The boiler system pump turns on for 10 Activate the User Test sequence and pause at Step 8 by
seconds. pressing the Item button once the DHW pump turns on.
Step 10 During the boiler test step, zone relays 1 through 4 Using an electrical meter, measure the voltage between
turn on, the mix system pump turns on, and the boil the DHW pump and a neutral. The voltage should
system pump turns on. The mixing device operates measure between 103.5 V (ac) and 126.5 V (ac).
up to 20%. This ensures there is a location for heat Testing the Boiler System Pump ---
--
--
--
---
--
-----
--
--
to move when the boiler is turned on. Activate the User Test sequence and pause at Step 9 by
• If the Boil Type is 1 Stage, the boiler stage 1 relay is pressing the Item button once the boiler system pump turns
closed for 10 seconds and then opened. on. Using an electrical meter, measure the voltage between
• If the Boil Type is 2 Stage, the boiler stage 1 relay is the boiler system pump and a neutral. The voltage should
closed for 10 seconds, then the boiler stage 2 relay is measure between 103.5 V (ac) and 126.5 V (ac).
closed for 10 seconds and then both relays are opened.
Testing the Boiler Stage 1 Contact-
--
--
---
---
-----
--
---
• If Boiler Type is modulating 0 - 10, the boiler stage
Activate the User Test sequence and pause at Step 10 by
1 relay is closed for 10 seconds and the modulating
pressing the Item button once the boiler stage 1 turns on.
output operates at 50 % [5 V (dc)].
Using an electrical meter, measure for continuity over the
• If Boiler Type is modulating 4 - 20, the boiler stage
boiler stage 1 terminals.
1 relay is closed for 10 seconds and the modulating
output operates at 50 % (12 mA). Testing the Boiler Stage 2 Contact-
--
--
---
---
-----
--
---
Step 11 Control returns to normal operation. This test applies for 2 stage on-off boilers only.
Testing the Variable Speed Injection Pump -
--
--
--
- Activate the User Test sequence and pause at Step 10 by
Activate the User Test sequence and pause at Step 1 pressing the Item button once the boiler stage 2 turns on.
by pressing the Item button once the injection pump is Using an electrical meter, measure for continuity over the
operating at 100%. Using an electrical meter, measure the boiler stage 2 terminals.
voltage between the variable speed pump and a neutral. Testing the Boiler Modulating Output --
--
-----
--
---
The voltage should measure between 103.5 V (ac) and This test applies for modulating boilers only.
126.5 V (ac). Active the User Test sequence and pause at Step 10 by
pressing the Item button once the boiler stage 1 turns on.
Testing the Zone Output -----------------
------------------
---
--
-- Using an electrical meter, measure for either a 5 V (dc) or
Activate the User Test sequence and pause at Step 3 by 12 mA signal. The Boil Type setting selects whether the
pressing the Item button once Zone 1 turns on. Using an signal is V (dc) or mA.
electrical meter, measure the voltage between the zone
valve and the common (C) terminals. The voltage should Testing the DHW Call -
--
--
--
---
--
--
--
--
--
--
--
--
--
------------
measure between 21.6 V (ac) and 26.4 V (ac). Repeat for Remove all wires from the DHW Call terminals. The control
Zones 2, 3, and 4. display should show no DHW Call. Reconnect wires. Then
apply either a short circuit or 24 V (ac) over the DHW Call
Testing the Mix System Pump -------------
--------------
--
--
-- terminals. The control should now show a DHW Call.
Activate the User Test sequence and pause at Step 7 by
pressing the Item button once the mix system pump turns Testing the Setpoint Call -
--
--
--
--
--
---
--
--
--
----
---
----
--
----
on. Using an electrical meter, measure the voltage between Remove all wires from the Setpoint Call terminals. The
the mix system pump and a neutral. The voltage should control display should show no Setpoint Call. Reconnect
measure between 103.5 V (ac) and 126.5 V (ac). wires. Then apply either a short circuit or 24 V (ac) over
the Setpoint Call terminals. The control should now show
a Setpoint Call.
Max Heat
The control has a function called Max Heat. In this mode, the boiler un-powered. This will prevent heat from en-
the control turns on and operates the system up to the tering the system during the purge.)
maximum set temperatures as long as there is a call for • When a DHW Call or Setpoint Call is present, the
heat. Use this mode to run the circulators during system boiler will operate at the DHW exchange or Setpoint
start-up and commissioning, purging air from the piping. temperature settings.
This feature is useful when drying sheet rock and paint in • WWSD and DHW Priority is disabled during Max Heat
the building. mode.
To enable Max Heat, enter the Toolbox Menu and find Max • When Max Heat is on the display will show ‘Max Heat
Heat. Use the up arrow to select ‘On’. Test’.
• Max Heat will automatically turn off after 24 hours.
• When a space heating call is present, the boiler will
run to maintain a target of Boil Design + 10°F (+ 6°C). To Cancel Max Heat, go to Max Heat in the Toolbox menu
(One can purge the system using this test and leave and use the down arrow to select ‘Off’.
© 2010 D 402 - 09/10 10 of 32

Applications
Single Boiler, DHW Tank, Variable Speed Mixing, 4 Mix Zones A402-1
Description: The House Control 402 operates an On/Off boiler with indirect Domestic Hot Water. Mixing is performed with
variable speed injection, which supplies an outdoor reset water temperature to the 4 onboard mix temperature hydronic
zones. Additional zones (boiler or mix) can be added using the tN4 Expansion terminals.
S3 070 tekmarNet ®2 Thermostats

402
Z1 Z2 Z3 Z4
P2
S1 S2
P1 P3 P4
Mix Sensor (S2)

Zone 1 Zone 2 Zone 3 Zone 4 Floating Action tekmarNet ®4
Boiler Sensor (S1)
C
tN4 Mix
Expansion to
tN4 C tN4 C
Expansion
tN4
Sensors - No Power
Outdoor
C
Wiring Centers,
tN4 Boil
Expansion Timers, or
tN4
Sensor
(S3) User Switch
+
Setpoint
Call
Menu Item
DHW
1
Stage 1
Call
House Control 402

H8007B

Boiler T-T
DHW Call R L 24 V (ac)

C N Transformer 009
Zone Valves (Z1 to Z4)

(black)
Mix System Pump
(P4) Mix (black)
Boil System Pump
(P1) Boil
(black)
DHW Pump
(P2) DHW
(red)
Pump Power L
Strip wires
L 1/2 inch (13 mm).
Installed wires are
12-18 AWG
Variable Speed Pump
N Speed
(P3)
to pump grounds
L NG
115 V (ac)
11 of 32 © 2010 D 402 - 09/10

Single Boiler, 2 Boiler Zones, DHW, 3 Way Mix, 4 Mix Zones A402-2
Description: The House Control 402 operates a modulating boiler with indirect Domestic Hot Water. Mixing is performed with
a three-way floating action mixing valve, which supplies a reset water temperature to four mix temperature hydronic zones.
Two boiler water temperature zones shown are operated by a Wiring Center through the tN4 Boil Expansion terminals.
tekmarNet ®2 Thermostats S3 070 tekmarNet ®2 Thermostats

313 402
Z1 Z2 Z3 Z4
P2
S4
S1 S2
P1 P3
Com
Open
Close
Mix Sensor (S2)
Zone 1 Zone 2 Zone 3 Zone 4 Floating Action
Boiler Sensor (S1)
C
tN4 Mix
tN4 C tN4 C
Expansion tekmarNet ®4
tN4
Sensors - No Power
Outdoor C tN4 Boil Expansion to

Expansion 313 Wiring Centers,
tN4
Sensor
(S3) Timers, or
—
Modulating
Boiler User Switch
+
+
Setpoint
Call
DHW Sensor (S4) Menu Item

DHW
1
Stage 1
Call
House Control 402

H8007B

R L 24 V (ac)
C N Transformer 009
Zone Valves (Z1 to Z4)

(black)
Mix System Pump
(P3) Mix
(black)
Boil System Pump
(P1) Boil
(black)
DHW Pump
(P2) DHW (red)
Pump Power L
Strip wires
L 1/2 inch (13 mm).
Installed wires are
12-18 AWG
Speed Pump
to pump grounds
L NG
115 V (ac)
© 2010 D 402 - 09/10 12 of 32

User Interface
Display
Menu Field Item Field

Displays the Displays the name
current menu of the selected item
VIEW
ADJUST
Status Fields MONITOR minhr Number Field

Displays the current sec Displays the
status of the control’s MINMAX PMAM current value of
inputs, outputs and Calls Pumps WWSD Saving the selected item
operation. Most symbols
in the status field are Boil Exp Boil System Cls
only visible when the Mix Exp Mix System Zones Opn
VIEW Menu is selected DHW Setp DHW Var 1 2 3 4 1 2 Mix
Symbols
CALLS °F°C °F, °C, %, HOURS, MINUTES, SECOND

Calls Displays any call for heat the control is minhr Units of measurement for current number.
receiving. sec%
UNOCCUPIED
PUMPS
Pumps Displays any pump currently operating.
Indicates that a User Switch or Timer has
put the system into UnOccupied.
BOILER
Zones ZONES
Indicates that the boiler should be
1234 Displays if an on-board zone is operating.
heating.
DEVICE OUTPUT SCALE
WARNING
Displays output of the mixing valve or
Displays if an error exists on the system.
injection pump.
ENERGY SAVING INDICATOR CLOSE / OPEN
Cls
Saving Displays when the system is saving energy.
Opn Displays whether the mixing valve motor
See the Energy Saving Features section. is opening or closing.
WWSD MIN / MAX
WWSD Displays when the system is in Warm MINMAX Displays when an operating temperature
Weather Shut Down. reaches a minimum or maximum value.
13 of 32 © 2010 D 402 - 09/10

Navigating The Display
The 402 uses a simple user interface to accomplish a are used to change the menu, sort through Items, and
variety of functions. The four buttons beneath the display adjust each setting as required.
Menu Button ------------------------------

------------------------------------
------
----
---
---
---
---
---
----
---
---
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
---
---
---
-----
--
--
--
----
The menus display in the Menu Field at the top left side of • The Monitor menu keeps track of run times and
the LCD. Four menus are available: View, Adjust, Monitor other important data that is collected during system
and Toolbox (identified by the wrench symbol). operation.
• The View menu allows the user to view the current • The Toolbox menu is a source of system information
status of various system parameters. and includes useful tools for commissioning and test-
• The Adjust menu allows the installer to adjust settings ing the system.
to ensure control operation matches requirements of
the mechanical system.
Item Button ------------------------------

--------------------------------
-----
----
-----
----
---
---
--
--
---
---
--
--
---
---
--
--
---
---
---
---
--
--
---
---
--
--
--
--
--
--
---
---
--
--
----
----
--
---
--
----
--
-
Each menu contains a list of Items that can be viewed and, • To view the next available item, press and release the
in some cases, adjusted. Press the item button to scroll Item button.
through the list in each Menu. • To view the previous item, hold down the Item button,
and press and release the Up button.
Up and Down Buttons --------------------

---------------------
-----
----
--
-----
--
--
--
--
---
---
---
---
---
----
--
---
---
---
--
----
--
---
--
---
--
---
--
---
--
-----
--
---
--
---
--
-
The Up and Down buttons are primarily used for adjusting To adjust a setting:
settings. • Select the appropriate menu using the Menu button.
• Select the item using the Item button.
• Use the Up or Down button to make the adjustment.
Default Item --------

----------------------------
--------------------------
-----
----
--
--
---
---
---
---
--
--
----
----
--
--
---
---
---
---
--
--
---
---
---
---
--
---
---
---
--
--
---
---
--
---
--
---
--
---
--
--
When navigating menus, the display reverts back to the • To set the default item in the View menu, display the
default item (View Menu) after 60 seconds of button item for more than five seconds.
inactivity.
Access Levels and Thermostat Lock

The 402 is shipped pre-programmed with common settings. To change to the ‘Installer’ access level and Unlock the
The 402 has an ‘Installer’ access level that allows full access thermostats:
to all settings and a ‘User’ access level that restricts the • In the Toolbox menu, locate Access
number of settings to only the Warm Weather Shut Down • Adjust the access level to ‘Installer’ by pressing the
and the temperature units. The 402 defaults to the ‘User’ up or down button. This prevents unwanted setting
access level after 12 hours of operation. changes to the control.
All thermostats are locked while the 402 is in the ‘User’
access level. Certain settings on the thermostat will be
unavailable while the thermostat is locked.
Programming and Settings

The 402 settings can be found in the ‘Adjust’ menu. When All settings are stored in permanent memory and will be
changing the items value, the setting is saved to the control’s kept correctly during any loss of power.
memory once the Item button is pressed to advance to the
next item, or after 60 seconds, the control times out and
reverts back to the ‘View’ menu.
© 2010 D 402 - 09/10 14 of 32

View Menu (1 of 1)
The View menu items display the current operating temperatures and status information
of the system.
Item Field Range Description

VIEW
OUTDOOR SECTION B, C
-76 to 149°F Current outdoor air temperature as measured by the outdoor sensor. The
Calls Pumps (-60.0 to 65.0°C) outdoor air temperature is shared to all thermostats in the tekmarNet ®
Zones system.
VIEW
MIX SUPPLY SECTION B

-22 to 266°F Current mix supply water temperature as measured by the mix supply
Calls Pumps (-30.0 to 130.0°C) sensor. The control operates the mixing device so that the mix supply
Zones is equal to the mix target temperature.
VIEW
MIX TARGET SECTION B
– – –, 35 to 180°F The temperature the control is currently trying to maintain at the mix
supply sensor. The mix target is calculated based on the outdoor
Calls Pumps (1.5 to 82.0°C)
design and mix design settings. “– – –” is displayed when no heat is
Zones
required for mix zones.
VIEW
BOILER SUPPLY SECTION C
-22 to 266°F Current boiler supply water temperature as measured by the boiler
sensor. The control operates the boiler so that the boiler supply is
Calls Pumps (-30.0 to 130.0°C)
within the boiler differential of the boiler target. ‘MIN’ is shown when
VIEW MENU
Zones
the control is providing boiler minimum protection to the boiler.
VIEW BOILER TARGET SECTION C
The boiler target is the temperature the control is currently trying to
– – –, 35 to 200°F maintain at the boiler supply sensor. The boiler target is calculated based
Calls Pumps (1.5 to 93.0°C) on the outdoor design, boiler design, and boiler minimum settings. “– – –”
Zones is displayed when no heat is required for boiler zones. ‘MIN’ is shown
when the control is providing boiler minimum protection to the boiler.
VIEW
BOILER MODULATION SECTION F
Current percent modulation of the boiler’s burner. The boiler modulation
increases when the boiler supply is less than the boiler target. The
0-100% boiler modulation decreases when the boiler supply is greater than the
Calls Pumps
boiler target.
Zones
Note: This item is only available when the Boil Type setting is set to
0-10 or 4-20.
DHW TANK SECTION D
Current Domestic Hot Water tank temperature as measured by the optional
-22 to 266°F DHW sensor. If the DHW tank temperature falls 6°F (3.0°C) below the
(-30.0 to 130.0°C) DHW Occ setting, a DHW call is created and the tank is heated.
Note: This item is only available when a DHW sensor is installed and
DHW Mode is set to 1 to 4.
DHW SUPPLY SECTION D
Current supply water temperature to the indirect DHW tank heat
-22 to 266°F
exchanger as measured by the DHW sensor.
(-30.0 to 130.0°C)
Note: This item is only available when a DHW sensor is installed and
DHW Mode is set to 5.
SYSTEM IN AWAY SECTION I

The heating system is in the Away scene. The DHW tank will not be
--
heated. Setpoint calls are still responded to.
Use the User Switch to change scene out of Away.
After the last item, the control returns to the first item in the menu.
15 of 32 © 2010 D 402 - 09/10
Adjust Menu (1 of 3)
The Adjust menu items are the programmable settings used to operate
the mechanical equipment.
Item Field Range Access Description Set to
ADJUST
-60 to 45°F OUTDOOR DESIGN SECTION B, C
(-51.0 to 7.0°C) Typically set to the temperature of the coldest day
Installer of the year. The outdoor air temperature used in the
Default = 10°F boiler and mixing heating curves that determine the
(-12.0°C) boiler target and the mix target temperatures.
MIX DESIGN SECTION B

The supply water temperature required for the mix
zones to heat the building on the typical coldest day
ADJUST
70 to 180°F of the year. Recommendations:
(21.0 to 82.0°C) High mass radiant floor = 120°F (50°C)
Installer
Default = 120°F Low mass radiant floor = 140°F (60°C)
(49.0°C) Fancoil or air handling unit = 190°F (90°C)
Copper fin-tube convector = 180°F (80°C)
Radiators = 160°F (70°C)
Low profile baseboard = 150°F (65°C)
ADJUST MENU
MIX TYPE SECTION B

ADJUST
4-20 mA, Select the type of mixing device.
0-10 V (dc) VAR = Variable speed injection pump
FLOT, Installer FLOT = Floating action motor for mixing valves
VAR 0-10 = 0 -10 V (dc) analog signal for mixing valves
Default = VAR 4-20 = 4-20 mA analog signal for mixing valves
Note: 0-10 and 4-20 are only available when Boiler
Type = 1 Stage or 2 Stage.
MIX MOTOR SECTION B

ADJUST The time that the mix actuating motor requires to
30 to 230 seconds operate from fully closed to fully open.
sec
Installer tekmar actuating motors = 105 sec.
Default = 105 seconds
Refer to actuating motor for correct setting.
Note: This item is only available when the Mix Type
is set to FLOT (floating action motor), 0-10, or 4-20.
BOILER TYPE SECTION F

The type of boiler connected to the control.
EMS2, 1STG = single one-stage on-off boiler
EMS1, 2STG = single two-stage on-off boiler
4-20 0-10 = 0-10 V (dc) modulating boiler
0-10, Installer 4-20 = 4-20 mA modulating boiler
2STG, EMS1 = tekmar boiler staging controls
1STG EMS2 = Viessmann modulating boilers with
Default = 1STG OpenTherm
Note: Only 1STG and 2STG are available when the
Mix Type is set to 0-10 V (dc) or 4-20 mA.
Continued on next page.
© 2010 D 402 - 09/10 16 of 32

BOILER DESIGN SECTION C
The supply water temperature required for the boiler
VIEW zones to heat the building on the typical coldest day
70 to 200°F of the year. Recommendations:
(21.0 to 93.5°C) High mass radiant floor = 120°F (50°C)
Installer
Default = 180°F Low mass radiant floor = 140°F (60°C)
(82.0°C) Fancoil or air handling unit = 190°F (90°C)
Copper fin-tube convector = 180°F (80°C)
Radiators = 160°F (70°C)
Low profile baseboard = 150°F (65°C)
BOILER MINIMUM SECTION B, C

The minimum allowed boiler target temperature and
temperature at which the mixing device begins to
provide boiler protection against cold return water
temperatures. The mixing valve or variable speed
OFF, 80 to 180°F injection pump operate at low percent output when
the boiler supply temperature drops below this
(26.5 to 82.0°C)
Installer setting.
Default = 140°F Recommendations:
(60.0°C) Condensing gas or electric boiler = OFF
Non-condensing gas and oil boilers = 140°F (60°C)
ADJUST MENU
Note: If Boiler Type is 0-10 V (dc), 4-20 mA, EMS1

or EMS2, this setting is defaulted to Off. The mixing
device does not provide boiler protection when Boiler
Type is set to EMS1 or EMS2.
BOILER MOTOR SECTION F

ADJUST
The time required for the modulating actuating motor
10 to 230 seconds to fully open the gas valve or ramp the burner fan
sec Default = 30 from off to full speed on a modulating boiler. Set to
Installer
seconds 30 seconds unless otherwise recommended by the
boiler manufacturer.
Note: This item is only available when the Boiler
Type is 0-10 V (dc) or 4-20 mA.
ADJUST MINIMUM MODULATION SECTION F

0 to 50% The minimum percent modulation of the boiler
Installer burner.
Default = 0%
Note: This item is only available when the Boiler
ADJUST MODULATION DELAY SECTION F

0 to 3:00 minutes Delay time between the burner firing and the boiler
sec
Default = 10 Installer releasing to modulation.
seconds Note: This item is only available when the Boiler
ADJUST FLUSHING SECTION G

Off or On Set to On when a domestic hot water tank is used
Installer to heat the building. When On, the control ensures
Default = Off
that each zone is operated at least once daily to
prevent stagnation.
Continued on next page.
17 of 32 © 2010 D 402 - 09/10

ADJUST
40 to 100°F WWSD OCCUPIED SECTION I
(4.5 to 38.0°C) Installer The system’s Warm Weather Shut Down temperature
Default = 70°F User during Occupied periods or when a schedule is not
(21.0°C) used.
ADJUST
40 to 100°F WWSD UNOCCUPIED SECTION I
(4.5 to 38.0°C) The system’s Warm Weather Shut Down temperature
Installer during Unoccupied periods.
Default = 60°F
Note: Item is only available when a schedule or User
(15.5°C) Switch is present on the system.
DHW MODE SECTION D

Off, 1, 2, 3, 4, 5 Selects the DHW mode of operation. The
Installer mode determines the zone and boiler system
Default = 2
pumps operation whenever the DHW pump is in
operation.
DHW EXCHANGE SECTION D

ADJUST MENU
100 to 200°F Selects the minimum boiler target to the DHW heat
(38.0 to 93.5°C) exchanger.
Installer
Default = 180°F Note: Item is only available in DHW Modes 1 through 4
(82°C) when a DHW sensor is not connected. It is available in
DHW Mode 5 when a DHW sensor is connected.
70 to 180°F DHW OCCUPIED SECTION D

(21.0 to 82.0°C) Selects the temperature of the indirect DHW tank.
Installer
Default = 125°F Note: Item is only available when an optional DHW
(51.5°C) sensor is installed except in DHW Mode 5.
DHW UNOCCUPIED SECTION I

ADJUST
Selects whether or not the indirect DHW tank should
Off or On be heated to during Unoccupied time periods.
Installer
Default = On Note: Item is only available when Schedule #1
is available or a User Switch is present on the
system.
ADJUST
60 to 200°F
SETPOINT SECTION E
(15.5 to 93.5°C)
Installer The minimum boiler target temperature when a
Default = 180°F
Setpoint Call is present.
(82.0°C)
ADJUST
°F or °C Installer UNITS
Default = °F User Selects units for temperature display.
© 2010 D 402 - 09/10 18 of 32

Monitor Menu (1 of 1)
The Monitor menu items provide information about the system’s operation and performance.
To clear any item back to default, press and hold the Up and Down buttons while viewing
that item.
OUTDOOR HIGH
MONITOR
-76 to 149°F Records the highest outdoor temperature since the item was
(-60.0 to 65.0°C) last cleared. Press and hold the Up and Down buttons while
viewing to reset.
OUTDOOR LOW
MONITOR
-76 to 149°F Records the lowest outdoor temperature since the item was
(-60.0 to 65.0°C) last cleared. Press and hold the Up and Down buttons while
viewing to reset.
RUN TIME (BOILER)

MONITOR hr 0 to 9999 Hours The total ‘on’ time of the boiler relay since the item was last
Default = 0 hr cleared. Press and hold the Up and Down buttons while
viewing to reset.
MONITOR MENU
RUN TIME (DHW PUMP)

MONITOR hr 0 to 9999 Hours The total running time of the DHW Pump since this item was
Pumps Default = 0 hr last cleared. Press and hold the Up and Down buttons while
viewing to reset.
DHW
RUN TIME (BOIL SYSTEM PUMP)

MONITOR hr 0 to 9999 Hours The total running time of the Boil System Pump since this item
Pumps Default = 0 hr was last cleared. Press and hold the Up and Down buttons
Boil System
while viewing to reset.
RUN TIME (MIX SYSTEM PUMP)

MONITOR hr 0 to 9999 Hours The total running time of the Mix System Pump since this item
Pumps Default = 0 hr was last cleared. Press and hold the Up and Down buttons
Mix System while viewing to reset.
RUN TIME ($AVING)

MONITOR hr 0 to 9999 Hours Maintains a record of the total length of time the $aving icon
Saving Default = 0 hr has been active. Press and hold the Up and Down buttons
while viewing to reset.
BOILER ENERGY USE

MONITOR hr 0 to 9999 Hours Multiply this value by the BTU rating (input BTU/hr) of the boiler
to get an approximate energy consumption (in BTU’s) for the
Default = 0 hr
boiler. Press and hold the Up and Down buttons while viewing
to reset. Not available when Boiler Type is EMS1 or EMS2.
19 of 32 © 2010 D 402 - 09/10

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.
USER TEST TESTING

On or Off Begins the test routine which tests the main control’s functions.
Default = Off See the Testing the Control section for more details. Use the
up button to turn the User Test On.
MAX HEAT TESTING

On or Off When selected, control operates the system up to maximum set
temperatures. Will operate up to 24 hours, or can be manually
Default = Off
turned Off. See Max Heat in the Testing the Control section
for more details.
TYPE AND SOFTWARE VERSION

402
Displays the type number of the product, followed by the current
J12 06B
software version beneath.
TOOLBOX MENU
ACCESS LEVEL
INST (Installer) Selects the Access Level of the control, which determines the
or USER Menu items available. USER provides the most limited level of
access and shows the fewest possible items.
Default = INST
When set to USER, all thermostats are locked and the number
of thermostat settings available are reduced.
FACTORY DEFAULTS
OFF, SEL
Loads the factory default settings. Hold the Up and Down
Default = Off buttons for 1 second until SEL is shown.
MIX DEVICES
0 to 24 devices Displays the number of devices on the Mix bus (Water
Temperature). This is made up of thermostats connected to
the House Control, and to the Mix Expansion terminals.
BOIL DEVICES
0 to 24 devices Displays the number of devices on the Boil Expansion bus
(Water Temperature). This is made up of thermostats connected
to the Boil Expansion terminals on the House Control.
HISTORY - 1 THROUGH 5
See Troubleshooting Displays a history of any past errors that have occurred on the
Guide system. Will clear after 30 days, or press Up and Down buttons
for 1 second to manually clear. The last 5 history items will
display if present.
© 2010 D 402 - 09/10 20 of 32
Sequence of Operation
tekmarNet® System Section A
®
tekmarNet is a family of products that use communication • Wiring Centers 313, 314, 315, 316 - Add additional zones
to operate the HVAC system in a comfortable and efficient • tN2 and tN4 Thermostats - Add thermostats
manner. The House Control is the central component in • tN4 Timer 033 - Adds 4 programmable schedules
a tekmarNet ® system and requires tekmarNet ® 2 (tN2) • tN4 User Switch 479 - Provides a system override for
Thermostats to be directly connected to the control. vacations and holidays
The tekmarNet ® 4 (tN4) Expansion terminals can link the • tN4 Setpoint Control 161 - Control hot tubs, pools and
House Control with other tekmarNet ® components: more
Mix Temperature Reset Operation Section B
Mix Call or Mix Expansion Call ----------

-----------
--
---
---
-----
--
--
--
-----
--
--
--
-----
---
----
--
---
---
---
---
---
---
---
---
----
--
---
--
-----
-----
--
---
--
----
--
-
When an onboard tN2 Thermostat calls for heat, the House
Control registers a Mix call for hydronic heating. Calls Calls
When a device connected to the tN4 Mix Expansion
terminals calls for heat, the House Control registers a Mix Mix Mix Exp
Expansion Call for hydronic heating on the mix loop.
Mix Target -------------------------------

--------------------------------
------
------
----
---
----
--
---
--
---
--
---
--
----
--
---
--
---
--
---
--
---
--
----
--
---
--
-----
----
--
---
--
----
--
--
When there are no Mix or Mix Expansion calls, the mix
target in the View menu on the display will show ‘– – –’ to Mix Heating Curve
indicate there is no requirement for mixing operation.
Once a Mix Call or Mix Expansion Call is present, a mix (Outdoor Design,
Mix Design)
target is determined by the control using the mixing heating
Increasing Water Temperatures

curve (mix design and outdoor design settings) together
with indoor temperature feedback from the thermostats.
The heating curve operates based on the principle that
a buildings heat loss increases with colder outdoor
temperatures. The calculated Mix Target will be shown in
the View menu on the display.
Mix Maximum
(70°F Outdoor,
The control has a fixed mix maximum temperature of +10°F
70°F Mix Supply)
(+5.5°C) higher than the Mix Design setting. When this
occurs, the “MAX” segment will display when viewing the Decreasing Outdoor Temperatures
mix target or mix supply temperature in the view menu.
Mix Supply ------

-----------------------------
-------------------------- ----
------
-------
---
---
----
--
---
---
---
---
---
---
---
--
--
---
---
---
---
--
--
--
--
--
--
--
--
---
---
-----
------
--
--
--
-----
--
-
Once a Mix Target water temperature has been calculated, Boiler Minimum Protection
the House Control measures the temperature at the mix If the boiler supply water temperature is cooler than the
supply sensor location and then operates the mixing device boiler minimum setting, the control reduces the output of the
to maintain the mix supply temperature. The heat source will mixing device. This limits the amount of cool return water
also be turned on and operated so that the mixing device to the boiler and allows the boiler return water temperature
is able to maintain the mix target temperature. to recover. Once the boiler supply temperature exceeds
the boiler minimum setting, the mixing device will return
to normal operation.
Note: The mixing device does not provide boiler minimum
protections when the Boiler Type setting is EMS1 or EMS2.
21 of 32 © 2010 D 402 - 09/10

Mixing Device Type -----------------------
--------------------------
-------
---
--
----
--
---
---
---
---
---
---
---
---
----
--
---
--
---
--
----
--
---
--
---
--
----
--
--
--
--
----
--
---
--
-
The House Control can operate a mixing device such as Modulating 0-10 V (dc)
a mixing valve or variable speed injection pump based *Only available if a one or two stage on-off boiler is
upon one of four output signals. The device output bar used.
graph on the display indicates the approximate position A modulating 0-10 V (dc) actuating motor can be used to
of the mixing device. operate the mixing valve. The control uses the Mod dc/mA
Variable Speed Injection Pump output to provide an analog 0-10 V (dc) signal to the actuator
A standard wet rotor circulator can be connected to the in order to maintain the correct mix supply temperature.
Variable Speed Pump output on the back of the control. Modulating 4-20 mA
The control varies the circulator speed to maintain the *Only available if a one or two stage on-off boiler is
correct mixed supply water temperature at the mix supply used.
sensor. For correct sizing and piping of the variable speed
A modulating 4-20 mA actuating motor can be used to
injection circulator, refer to essay E 021. Note: Pumps
operate the mixing valve. The control uses the Mod dc/mA
manufactured with an internal variable speed controller
output to provide an analog 4-20 mA signal to the actuator
are not compatible with the House Control.
in order to maintain the correct mix supply temperature.
Floating Action 24 V (ac)
A 24 V (ac) floating action actuator motor and mixing valve
Mixing Device Exercising
can be connected to the Floating Action outputs on the The control operates the mixing device from 0 to 100% output
front of the House Control. The control pulses the actuator every 3 days to help prevent corrosion and / or precipitate
motor open or closed to maintain the correct supply water build up on the mixing valve or pump that could lead to
temperature at the mix supply sensor when there is a seizure of the mixing device. The control ensures that no
requirement for mixing. heat is supplied to the zones during exercising.
Boiler Temperature Reset Operation Section C

Boiler Expansion Call ----
---------------------
--------------------
----
--------
----
------
------
------
------
------
------
------
-----
-----
------
-----
------
-----
--------
----
When a device connected to the tN4 Boil Expansion Calls
terminals calls for heat, the House Control registers a Boil Boil Exp
Expansion call for hydronic heating on the boiler loop.
Boiler Target -----------------------------

------------------------------
----
-----
-----
----
--
--
---
---
---
---
--
--
--
--
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
---
---
--
--
---
-----
--
---
--
--
When there are no Boiler Expansion or Mix calls, the boiler Boiler Heating Curve
target in the View menu on the display will show ‘– – –’ to
indicate there is no requirement for boiler operation. (Outdoor Design,
Boiler Design)
Once a Boiler Expansion Call is present, a boiler target
Increasing Water Temperatures

is determined by the control using the boiler heating
curve (boiler minimum, boiler design and outdoor design
settings) together with indoor temperature feedback from
the thermostats. The heating curve operates based on the
principle that a buildings heat loss increases with colder
outdoor temperatures. The calculated Boiler Target will be
shown in the View menu on the display.
(70°F Outdoor,
When a Mix or Mix Expansion Call is present, the control Boiler Minimum)
calculates a boiler target that is higher than the mix target
using Boiler Load Reset. Decreasing Outdoor Temperatures
Boiler Minimum Boiler Maximum

The House Control protects non-condensing boilers from The control has a fixed boiler maximum temperature of +
sustained flue gas condensation and thermal shock through 10°F (+5.5°C) higher than the Boiler Design setting for the
the Boiler Minimum setting. The boiler minimum is the Boiler Heating Curve. When this occurs, the “MAX” segment
lowest temperature that the control is allowed to use as a will display when viewing the boiler target or boiler supply
boiler target temperature. If the boiler is operating at the temperature in the view menu. The control will operate
boiler minimum temperature, the “MIN” segment is turned the boiler so that the boiler supply temperature will never
on in the display when viewing either the boiler supply exceed 210°F (99.0°C).
temperature or the boiler target temperature.
© 2010 D 402 - 09/10 22 of 32

Domestic Hot Water Tank Operation Section D
DHW Call -------
------------------------------
-------------------------
-----
-----
----
--
--
---
---
---
---
--
--
--
--
---
---
---
---
--
--
---
---
---
---
--
--
--
--
--
--
--
--
---
---
---
---
---
-----
--
---
--
---
--
--
A DHW Call is required in order for the control to provide
heat to a DHW tank. Once the control registers a DHW Call,
it will display the “DHW” icon under Calls in the display. Calls
This can be done in three ways:
DHW Tank Aquastat
• If a DHW aquastat (mechanical switch) is used to
DHW
apply a DHW Call, the tank is heated to the aqua-
stat temperature setting. A dry contact or 24 V (ac)
signal is applied across the DHW Call terminals on the
House Control. tekmarNet ® Setpoint Control with Sensor
DHW Tank Sensor • A DHW Call is provided through the tekmarNet ®
• A DHW tank sensor provides superior temperature system. This can be done through the Boil Expansion
control of the tank compared to an aquastat. The tN4 terminals with a tekmarNet ® setpoint device such
House Control automatically detects whether a DHW as a Setpoint Control 161.
sensor is installed. The upper limit of the DHW tem-
perature is set by the DHW setting. The DHW tank dif-
ferential is fixed to 6°F (3°C).
DHW - Boiler Target ---------------------

-----------------------
-------
---
--
-----
---
---
---
----
---
---
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
---
---
--
--
---
------
--
--
--
---
When a DHW Call is present, a boiler target is • When using a tekmarNet ® Setpoint Control, the boiler
determined. target is set to the devices Exchange Supply setting.
• When using a DHW Tank Aquastat, the boiler target is If there are multiple devices calling for heat, the boiler target
set to the DHW Exchange setting. is set to the highest temperature requirement.
• When using a DHW Tank Sensor, the boiler target is
set to the DHW Occupied setting plus 40°F (22°C).
DHW Mode -----------------------------

------------------------------
----
---
----
---
---
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
---
---
--
--
---
---
--
--
---
---
---
---
---
---
--
-----
--
--
--
---
The control has five different settings available for DHW
Mode that affect pump operation. The required DHW DHW Mode = 1
Mode setting will depend on the piping arrangement of the
DHW tank and whether or not priority for the DHW tank
is necessary. DHW Priority stops or limits the delivery of DHW Zone
Pump Valve
heat to the building heating system while the DHW tank ON ON Or
calls for heat. This allows for quick DHW tank temperature OFF
recovery.
Boiler System
DHW MODE 1 - DHW in Parallel no Priority Pump
ON Or OFF
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, Mixing, or Setpoint Call.
It is assumed that the DHW pump will provide adequate DHW Mode = 2
flow through the heat exchanger and the boiler.
DHW MODE 2 - DHW in Parallel with Priority

DHW Zone
When a DHW Call is present, the DHW pump is activated. Pump Valve
The boiler system pump and all boiler temperature zones ON OFF
are shut off through tekmarNet ® communication to achieve
DHW priority. Boiler System
It is assumed that the DHW pump will provide adequate Pump
OFF
23 of 32 © 2010 D 402 - 09/10

DHW MODE 3 - DHW in Primary / Secondary no DHW Mode = 3
Priority
When a DHW Call is present, the DHW pump and the boiler
system pump is operated. Boiler temperature zones can
turn on if required.
Zone
DHW MODE 4 - DHW in Primary / Secondary with DHW Valve
Pump ON Or
Priority ON OFF
When a DHW Call is present, the DHW pump and the
Boiler System
boiler system pump is operated. All boiler temperature Pump
zones are shut off through tekmarNet ® communication to ON
achieve DHW priority.
DHW Mode 5 - DHW in Near Boiler Piping with DHW Mode = 4
Priority
DHW Mode 5 requires that a DHW sensor be located on
the boiler outlet pipe and a DHW call from an aquastat
inside the DHW tank. The aquastat operates the DHW
tank temperature while the DHW sensor is used to control Zone
DHW Valve
the boiler temperature delivered to the DHW indirect heat Pump OFF
exchanger. ON
When a DHW Call is present, the DHW pump is activated. Boiler System
Pump
The boiler system pump and all boiler temperature zones ON
are shut off through tekmarNet ® communication to achieve
DHW priority.
It is assumed that the DHW pump will provide adequate DHW Mode = 5
Zone
DHW Priority Override --------------------
---------------------
------
-- DHW Valve
To prevent the building from cooling off too much or the Pump OFF
ON Boiler
possibility of a potential freeze up during DHW priority, Sensor
the control limits the amount of time for DHW priority
during cold weather. During warm weather the DHW DHW Boiler Boiler System
Sensor Pump Pump
priority is 120 minutes. During cold weather the DHW
OFF OFF
priority is 15 minutes. Once the allowed time for priority
has elapsed, the control overrides the DHW priority and
resumes space heating for 15 minutes. It will then revert
back to DHW Priority and repeat. DHW Priority Override Time
DHW Post Purge --------------------------

---------------------------
----
After the DHW Call is removed, the control performs a purge
on the boiler. The control shuts off the boiler and continues
Increasing Time
to operate the DHW pump and the Boiler System pump if

applicable. This purges the residual heat from the boiler
into the DHW tank. The control continues this purge for a
maximum of two minutes. The control also stops the purge
if the boiler supply temperature drops below the current
boiler target temperature.
Decreasing Outdoor Air Temperature
© 2010 D 402 - 09/10 24 of 32

Setpoint Operation Section E
A Setpoint Call is required in order for the control to provide When the control receives a Setpoint Call:
heat to a setpoint load, such as a spa, pool, or snowmelt • All Boil zones are turned off.
load. This can be done in two ways: • The Mix device is ramped down to a minimum level.
Contact Closure ------------------------
--------------------------------
-- • The boiler will operate to maintain the Setpoint tem-
A dry contact or 24 V (ac) signal is applied across the perature as set in the Adjust menu, or as set on the
Setpoint Call terminals on the 402. tekmarNet ® Setpoint control if one is being used.
tekmarNet ® Setpoint Control with Sensor--
--
---
--
-- Calls
®
A Setpoint Call is provided through the tekmarNet
system. This can be done through the tN4 Expansion
terminals with a setpoint device such as a Setpoint Setp
Control 161.
Once the control registers a Setpoint Call, it will display It is assumed that the Setpoint pump will provide adequate
the “Setp” icon under Calls in the display. flow through the heat exchanger and the boiler.
Note: Setpoint operation has a fixed priority of on. Setpoint calls will also be responded to when the system
is in Away, which can be set using a 479 User Switch.
Setpoint Operation ---------------------
---------------------------
----
--
The control can operate to satisfy the requirements of a Setpoint Priority Override --
--
--
--
---
--
--
--
---
--
----
--
------
setpoint load in addition to a space heating load and a To prevent the building from cooling off too much or
DHW load. A setpoint load overrides the current outdoor the possibility of a potential freeze up during setpoint
reset temperature and WWSD setting in order to provide priority, the control attempts to limit the amount of time
heat to the setpoint load. for setpoint priority.
As the outdoor air temperature becomes colder, the length
Setpoint Priority of time the control provides setpoint priority is reduced.
Once the allowed time for priority has elapsed, the control
Setpoint
will check the space heating target.
• If there is a space heating target, the boiler operates at
Setpoint Zone
Pump Valve that target for 15 minutes.
ON OFF • If after 15 minutes there is still a Setpoint Call, the con-
trol will reduce mixing outputs, shut off all boiler heat-
Boiler System Pump ing zones and target the Setpoint temperature.
If Mix demand = On
Otherwise = Off • Note: It is possible to disable Setpoint Priority by using
a tekmarNet ® Setpoint control and turning the priority
to Off in the Setpoint control.
Boiler Operation Section F

The 402 is able to operate a single 1-stage or 2-stage on- The control displays the temperature that it is currently
off boiler or a single modulating boiler as a heat source. trying to maintain as the boiler supply temperature in the
For proper operation of the boiler, the 402 must be the only View menu. If the control does not presently have a call for
control that determines when the boiler is to fire. heat, it does not show a boiler target temperature. Instead,
*Important note: The operating control in the boiler, also ‘– – –’ is displayed on the LCD.
known as an aquastat, remains in the burner circuit and acts Boiler Minimum --
--
---
--
--
--
---
--
--
--
--
--
--
--
-----
---
--------
--
---
as a secondary upper limit on the boiler temperature. The When operating non-condensing boilers, it is important
boiler operator temperature setting can be adjusted above to prevent cool water from returning to the boiler. Cold
210°F, which is the fixed Boiler Maximum on the 402. return temperatures create flue gas condensation, which
Boiler Target Temperature ---------------
----------------
----
--
--- if left too long, can severely damage the boiler.
The boiler target temperature is the temperature which The 402 protects the boiler through the Boiler Minimum
the control is trying to operate the boiler at. There are setting. The boiler minimum is the lowest temperature that
four items that determine the boiler target temperature: the control is allowed to use as a boiler target temperature.
• Mix Call If the boiler is operating at the boiler minimum temperature,
• Boil Exp Call the “MIN” segment is turned on in the display when viewing
either the boiler supply temperature or the boiler target
• DHW Call
temperature.
• Setpoint Call
If the control receives more than one call for heat at the
same time, it will operate the boiler at the highest of the
four calls.
25 of 32 © 2010 D 402 - 09/10
Boiler Maximum --------------------------
-----------------------------
---- Minimum Modulation
The 402 will operate the boiler so that the boiler The Minimum Modulation is the lowest signal the control
supply temperature will never exceed 210°F (99.0°C). can send to modulate the boiler. This operates the boiler
The highest allowed boiler target is the boiler design at low fire.
temperature + 10°F (5.5°C). • Refer to the boiler manufacturer’s literature to deter-
Boiler Type -------------------------------
---------------------------------
-----
--- mine the minimum output voltage V (dc) or current
The 402 can operate either of the following types of (mA) that the boiler will successfully operate at.
boilers: For 0-10 V (dc):
• One single-stage on-off boiler
Minimum Modulation =
• One two-stage on-off boiler
Boiler’s Minimum Input Signal x 100%
• Modulating boiler using a 0-10 V (dc) signal
10 V (dc)
• Modulating boiler using a 4-20 mA signal
• tekmar EMS signal (for use with multiple boiler For 4-20 mA:
stagers) Minimum Modulation =
• EMS signal for Viessmann modulating boilers Boiler’s Minimum Input Signal - 4mA x 100%
On-Off Operation --------------------------
-------------------------------
-- 16 mA
The 402 operates a single hot-water on-off boiler to Example:
maintain the boiler target within a differential. The boiler A boiler requires a 1.8 V (dc) signal to fire the boiler at
target is the average temperature and the boiler supply low fire. The boiler can be modulated to 10 V (dc) where
temperature can fluctuate by 1/2 of the differential above it reaches high fire.
and below of the boiler target. Minimum Modulation = 1.8 V x 100% = 18%
Modulation Boiler Operation -------------
--------------
--
--
---- 10 V
The 402 can operate a single hot-water modulating
boiler using the Mod dc/mA output and the Boiler Stage 10 V (dc)
contact. Not all boilers require the use of the Boiler
Stage contact.
Control
Range
Range
Boiler
The control operates the boiler by first switching the boiler
stage contact to allow the modulating boiler to go through
the ignition sequence (the boiler stage contact may not
be required on all modulating boilers). A 0-10 V (dc) or 4-
20 mA analog signal is then used to modulate the boiler 18% 1.8 V (dc)
firing rate starting from 50% (5 V (dc) or 12 mA signal) for 0 Vdc
30 seconds.
After the 30 second delay has elapsed, the control will
then allow the boiler to modulate down to the minimum tekmar EMS Signal Operation
modulation setting and hold it there for the Modulation Delay The 402 can provide a 0-10 V (dc) signal proportional to
time setting. The Modulation Delay setting is determined the boiler target which is compatible with tekmar Boiler
by the boiler manufacturer. It is the amount of time that Staging controls that accept an EMS input.
the burner must operate before the internal boiler control • To use the tekmar EMS signal operation, the Boil Type
allows an external signal to operate the burner. setting in the Adjust menu must be set to EMS1.
After the Modulation Delay has elapsed, the control uses Viessmann EMS Signal
PID logic to change the boiler firing rate signal in order The 402 has a special 0-10 V (dc) signal proportional to
to satisfy the boiler target temperature. When the firing the boiler target that is designed to be compatible with
rate signal is reduced down to the Minimum Modulating Viessmann Open Therm 0-10 V (dc) inputs.
setting and the boiler supply temperature exceeds the • To use the Viessmann EMS signal operation, the Boil
boiler target by 1/2 of the differential, the control will shut Type setting in the Adjust menu must be set to EMS2.
off the burner. The signal is 0 V (dc) when the boiler is off. The voltage
is 2.2 V (dc) to provide a boiler target of 81°F (27°C),
up to maximum of 10 V (dc) to provide a boiler target of
176°F (80°C).
© 2010 D 402 - 09/10 26 of 32

Auto Differential -------------------------
-----------------------------
------ In order to decrease temperature swings and increase boiler
Both on-off and modulating boilers are operated with efficiency, the Auto Differential feature automatically adjusts
a differential. In some cases, a modulating boiler must the operating differential of the boiler based on the heating
be operated with a differential while operating at low load. As the load increases, the differential will decrease
fire because this indicates the load is smaller than to minimize temperature swings. As the load decreases,
the minimum modulation of the boiler. For modulating the differential will increase to prevent short cycling. This
boilers, the differential no longer applies once operating can significantly improve operating efficiency and prevent
the boiler above low fire. equipment failures through excessive cycling.
The differential operates by closing the boiler contact
when the boiler supply water temperature is 1/2 of the
differential below the boiler target temperature. As the Off
supply temperature reaches 1/2 of the differential above
the boiler target temperature, the boiler is shut off.
Boiler Off
Heating Load
+1/2 Differential
Differential
On
Boiler Target
Time
Boiler On - 1/2 Differential
Domestic Hot Water Heat Source Section G

The 402 can use a high-efficiency water heater as a source 070
402
of heat for space heating zones in addition to providing
domestic hot water. This is an open-loop system in which
potable water is circulated through the zones. When the
flushing feature is set to on, the mixing valve is moved to the
fully open position, all four zone valves are opened, and the
mix system pump is turned on for 5 minutes each day. This
prevents stagnation of the water in the heating system.
Pump Operation Section H

Mix System Pump ----------------------
--------------------------
------ Variable Speed Injection Pump -
--
--
--
---
--
-----
--
----
--
--
The mix system pump operates whenever all the The variable speed pump operates whenever the
following conditions are met: following conditions are met:
• A Mix Call is present. • A Mix Call is present.
• The thermostat calling for heat has the Heat 1 pump • The heating system is not in Warm Weather Shut
setting set to On. Down.
• The heating system is not in Warm Weather Shut Down. Note: The variable speed pump operates at minimum
speed whenever the boiler supply temperature falls below
Boiler System Pump --------------------
---------------------
--
--
------
--
the boiler minimum setting and whenever there is a DHW
The boiler system pump operates whenever all the
Call and DHW priority has been selected.
following conditions are met:
• A Mix or a Boiler Call is present. Pump Exercising ---
-----
----
----
----
----
-----
----
---
-----
--------
• The thermostat calling for heat has the Heat 1 pump The control operates each pump every three days for 10
setting set to On. seconds to help prevent corrosion and / or precipitate build
• There is no DHW priority. up on the pump components that can lead to pump seizure.
• The heating system is not in Warm Weather Shut Down. The control ensures that no heat is supplied to the zones
during exercising.
DHW Pump --
-------------
-------------------------
----------------------
----
--
The DHW pump operates whenever all the following
conditions are met:
• A DHW Call is present.
• The heating system is not in DHW priority override.
• DHW post purge.
27 of 32 © 2010 D 402 - 09/10
Energy Saving Features Section I
The “$aving” icon is displayed when energy is being saved. Further Savings!
The following features reduce energy consumption. Use a Timer 033 with programmable schedule #1 to
Network Schedules----
-----------------------
----------------------
----
-- gain the WWSD Unoccupied setting. This provides an
Adding a schedule to a tekmarNet® system is both easy additional WWSD temperature that can be set even lower
and valuable. A Timer 033 provides scheduling with up to for Unoccupied and Sleep time periods.
4 events per day for every tekmarNet® Thermostat. Turning • This setting will appear after WWSD in the Adjust
down the room temperatures when they are unoccupied menu if a Timer 033 or User Switch is present on the
reduces boiler on-time and energy consumption which system.
helps save money and the environment. Zone Synchronization ---
--
--
--
--
--
--
--
---
--
--
--
---
--
--------
One-Touch Economy ----------------------
------------------------
---- Another feature of the House Control is Zone Synchronization.
A User Switch 479 allows for one-touch overrides of the In typical zoned systems, the thermostats operate on a stand-
system. For example, if leaving the building for vacation, alone basis. This means that a zone turns on and off as
simply press the “Away” button and all the thermostats required without any regard for other zones. The net effect
will immediately operate at a lower temperature, instead is random operation of the zones causing short cycling of
of having to walk around the building lowering the heating the heat source. tekmarNet® thermostats communicate to
temperature setting and raising the cooling temperature ensure that their cycles are synchronized. Energy is saved
setting on each thermostat. by ensuring zones requiring heat operate on the same cycle,
therefore reducing short cycling of the boiler.
DHW Tank During Away ------------------
--------------------
-----
In addition to the One-Touch setback, a User Switch 479
Zone Post Purge --
--
--
--
---
--
--
--
--
--
--
--
---
--
--
--
-----
--
-------
also allows the user to press the ‘Away’ button and tell the When the last zone is nearly satisfied for heating, the boiler is
House Control 402 to ignore DHW Calls, preventing the shut off and the zone continues to operate together with the
DHW tank from unnecessarily heating up when no one is boiler system pump and / or mix system pump. This purges
living in the building. the residual heat from the boiler into this zone. The control
continues this purge for a maximum of two minutes. The
Warm Weather Shut Down (WWSD)--------
---------
--
--
-- control will stop the purge if the boiler supply temperature
During warmer weather, heating of the rooms is typically no drops below the boiler minimum setting.
longer required. To prevent energy waste from unnecessary
boiler operation, the control goes into Warm Weather Shut
Down (WWSD) when the outdoor temperature rises above
the WWSD temperature set in the Adjust menu.
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. Use the Description in the chart
to solve the problem.
Error Messages (1 of 3)
Error Message Description
ADJUST ERROR
The control failed to read the Adjust menu settings, and reloaded the factory default settings.
Operation stops until all the Adjust menu settings are checked.
Note: To clear the error, the access level must be set to Installer and each setting in the Adjust
menu must be checked.
OUTDOOR SENSOR SHORT CIRCUIT

Due to a short circuit, the control failed to read the outdoor sensor. As a result, the control
assumes an outdoor temperature of 32°F (0°C) and continues operation. Locate and repair
the problem as described in the “Test the Sensor Wiring” section.
© 2010 D 402 - 09/10 28 of 32

OUTDOOR SENSOR OPEN CIRCUIT
Due to an open circuit (disconnected or broken wire), the control failed to read the outdoor
sensor. As a result, the control assumes an outdoor temperature of 32°F (0.0°C) and
continues operation. Locate and repair the problem as described in the “Test the Sensor
Wiring” section.
MIX SENSOR SHORT CIRCUIT

Due to a short circuit, the control failed to read the Mix supply sensor. As a result, the control
operates the mixing device at a fixed output as long as there is a call for heat. Locate and
repair the problem as described in the “Test the Sensor Wiring” section.
MIX SENSOR OPEN CIRCUIT

Due to an open circuit (disconnected or broken wire), the control failed to read the Mix supply
sensor. The control operates the mixing device at a fixed output as long as there is a call for
heat. Locate and repair the problem as described in the “Test the Sensor Wiring” section.
BOILER SENSOR SHORT CIRCUIT

Due to a short circuit, the control failed to read the boiler sensor. When there is a call for heat,
the control no longer controls the boiler. Instead, the control provides a boiler enable and the
boiler operates on its aquastat/limit until the sensor is repaired. The control will not operate
the boiler contact if the Boil Minimum setting is set to Off. Locate and repair the problem as
described in the “Test the Sensor Wiring” section.
BOILER SENSOR OPEN CIRCUIT
Due to an open circuit, the control failed to read the boiler sensor. The control no longer
controls the boiler. Instead, the control provides a boiler enable and the boiler operates on its
aquastat/limit until the sensor is repaired. The control will not operate the boiler contact if the
Boil Minimum setting is set to Off. Locate and repair the problem as described in the “Test
the Sensor Wiring” section.
DOMESTIC HOT WATER SENSOR SHORT CIRCUIT
Due to a short circuit, the control failed to read the DHW sensor. As a result, the control no
longer heats the DHW tank. Locate and repair the problem as described in the “Test the
Sensor Wiring” section. DHW tank heating will resume once the sensor problem is corrected.
The error message self clears once the error condition is corrected.
DOMESTIC HOT WATER SENSOR OPEN CIRCUIT

Due to an open circuit, the control failed to read the DHW sensor. As a result, the control
no longer heats the DHW tank. Locate and repair the problem as described in the “Test the
Sensor Wiring” section. DHW tank heating will resume once the sensor problem is corrected.
The error message self clears once the error condition is corrected.
DOMESTIC HOT WATER CALL ERROR

A DHW sensor and a DHW call have been applied at the same time. The DHW tank will not
be heated until the DHW call signal is removed. The error message self clears once the error
condition is corrected.
BOILER DEVICE LOST (b:01 TO b:24)

Each tekmarNet ® device (thermostat, setpoint control, timer) has an address. The device with
this address on the boiler water temperature is no longer reporting back to the 402.
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. Trace the wires
from the control to the lost device looking for loose or damaged wires.
Note: If you deliberately remove a tekmarNet ® device, hold the Up and Down buttons to clear
this error.
29 of 32 © 2010 D 402 - 09/10

MIX DEVICE LOST (1:01 TO 1:24)
Each tekmarNet ® device (thermostat, setpoint control, timer) has an address. The device with
this address on the mix water temperature is no longer reporting back to the 402.
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. Trace the wires
from the control to the lost device looking for loose or damaged wires.
Note: If you deliberately remove a tekmarNet ® device, hold the Up and Down buttons to clear
this error.
MASTER DEVICE ERROR

More than one master has been detected on the tekmarNet ®4 expansion terminals. The 402
is a “Master Device” and no other tekmarNet ® reset controls can be added to the tekmarNet ®4
expansion terminals. If one has been added, remove it from the system.
DEVICE ERROR AT ADDRESS b:01 to b:24

Each tekmarNet ® device (thermostat, setpoint control, timer) has an address. One of the
devices on the boiler water temperature has an error. If there is a record of the device
address together with the room name, go to that device to correct the error. Otherwise, go
to each device in the building, checking for the flashing Warning symbol. Once the error on
the device is corrected, the error message will clear.
DEVICE ERROR AT ADDRESS 1:01 to 1:24

Each tekmarNet ® device (thermostat, setpoint control, timer) has an address. One of the
devices on the mix water temperature has an error. If there is a record of the device address
together with the room name, go to that device to correct the error. Otherwise, go to each
device in the building, checking for the flashing Warning symbol. Once the error on the device
is corrected, the error message will clear.
MIX MODULE ERROR

A Mixing Module has been connected to the Mix Exp. tN4 terminals. The 402 controls mixing
devices through outputs on the control and cannot operate tekmarNet ® mixing expansion
modules. Remove the device and connect the mixing actuator or pump directly to the appropriate
output terminals on the 402.
Frequently Asked Questions (1 of 2)

Symptom Look For... Corrective Action
Control power supply has a 24 V (ac) fuse which if blown, requires
Fuse holder
replacement.
LCD display is off
Use electrical meter to measure 24 V (ac) voltage on input power R and C
Power to control
terminals.
DHW Call on LCD If a DHW call is present, the control is aware that the DHW tank requires heat.
DHW tank reading Ensure the DHW tank temperature is accurate and replace if necessary.
Burner symbol on If the burner symbol is on the LCD, there is a problem with the boiler. Ensure
LCD the boiler aquastat manual limit is reset to the on position.
No DHW tank
heating DHW pump symbol If the DHW pump symbol is on, check to ensure the DHW pump is in operation
on LCD by checking for pump vibration or voltage on the pump wiring terminals.
If DHW pump and boiler are operating, the system may require the boiler system
DHW pump in
pump to operate to heat the DHW tank. Ensure the DHW Mode setting is set
operation
correctly.
© 2010 D 402 - 09/10 30 of 32

Frequently Asked Questions (2 of 2)
Symptom Look For... Corrective Action
Burner symbol on If the burner symbol is on the LCD, there is a problem with the boiler. Ensure
LCD the boiler aquastat manual limit is reset to the on position.
Warm Weather Shut Down (WWSD) is an energy saving feature that prevents
WWSD symbol on central heating during the summer. Ensure the outdoor temperature reading
LCD is accurate and replace outdoor sensor if necessary. WWSD setting can be
increased if heating is required.
Mix or Boil Calls on
No central If there are no Mix or Boil Calls, there are no thermostats calling for heat.
LCD
heating
DHW Call on LCD During DHW tank heating, the central heating may not be heated.
During AWAY, the thermostats operate at a lower temperature. Locate a ‘User
System in AWAY
Switch’ and set to Normal to resume heating.
“MIN” shown
Boiler is operating below the boiler minimum setting and the mixing valve is
together with boiler
closed or the mix injection pump is operating at low speed. The mixing device
target or boiler
will operate normally once the boiler warms up.
supply on LCD
Mixing using variable speed injection pumps requires the balancing valve to
Boiler short Burner symbol
be set correctly. Lack of head pressure can lead the injection pump speed to
cycling cycling on and off
ramp up and down.
Thermostats have a differential of +/- 1.5°F of the temperature setting. Due to
LCD shows zone on the display rounding numbers up, heating can appear on when the temperature
Single zone over is 2°F above the setting. This is normal operation.
heating Ensure zone valve terminals measure 0 V (ac). Measuring 0 V (ac) indicates
LCD shows zone off mechanical zone valve may have failed in open position. Measuring 24 V (ac)
indicates control relay may have failed.
Single zone under LCD shows zone on Ensure zone valve terminals measure 24 V (ac). Measuring 24 V (ac) indicates
heating mechanical zone valve may have failed in closed position. Measuring 0 V (ac)
indicates control relay may have failed.
LCD shows zone off Check for calls
Job Record
Item Setting Item Setting
OUTDOOR DESIGN FLUSHING
MIX DESIGN WWSD OCCUPIED
MIX TYPE WWSD UNOCCUPIED
MIX MOTOR DHW MODE
BOILER TYPE DHW EXCHANGE
BOILER DESIGN DHW OCCUPIED
BOILER MINIMUM DHW UNOCCUPIED
BOILER MOTOR SETPOINT
MINIMUM MODULATION UNITS
MODULATION DELAY
31 of 32 © 2010 D 402 - 09/10

Technical Data
tN2 House Control 402 Boiler, DHW & Setpoint, Mixing, Four Zone Valves
Literature D402, Q402, SB057
Control Microprocessor control. This is not a safety (limit) control.
Packaged weight 1.4 lbs (640 g)
Dimensions 5.5” H x 5.5” W x 2.25” D (140 x 140 x 57 mm)
Enclosure NEMA 1 rated, blue PC+ABS plastic
Approvals CSA C US, meets class B: ICES & FCC Part 15
Ambient conditions Indoor use only, 32 to 104°F (0 to 40°C), RH 90% Non-condensing
Power supply 24 V (ac) ±10% 60 Hz, 100 VA max, Class 2
Control load 2 VA
Zone valve / floating action load 89 VA, 24 V (ac), 3.7 A for zones 1 to 4 plus floating action output
Boiler stage 1, 2 relays 24 V (ac) 5 A
Boiler system pump relay 115 V (ac) 5 A, 1/6 hp
Mix system pump relay 115 V (ac) 5 A, 1/6 hp
DHW pump relay 115 V (ac) 5 A, 1/6 hp
Variable speed pump relay 115 V (ac) 2.4 A
Pump power 115 V (ac) 12 A max
Setpoint and DHW calls Short, 0 - 32 V (ac)
Boil/Mix modulating output 0 - 10 V (dc) 500 Ω min load impedance, 4 - 20 mA 1 kΩ max load impedance
Sensors NTC thermistor, 10k @ 77°F (25°C ± 0.2°C) ß=3892
- Included Outdoor Sensor 070 and 2 of Universal Sensors 082
Warranty Limited 3 Year
Limited Warranty and Product Return Procedure

Limited Warranty The liability of tekmar under this warranty is lim- Any representations or warranties about the Products made by Purchaser
ited. The Purchaser, by taking receipt of any tekmar product (“Prod- to its customers which are different from or in excess of the tekmar Lim-
uct”), acknowledges the terms of the Limited Warranty in effect at ited Warranty are the Purchaser’s sole responsibility and obligation. Pur-
the time of such Product sale and acknowledges that it has read chaser shall indemnify and hold tekmar harmless from and against any
and understands same. and all claims, liabilities and damages of any kind or nature which arise
The tekmar Limited Warranty to the Purchaser on the Products sold out of or are related to any such representations or warranties by Pur-
hereunder is a manufacturer’s pass-through warranty which the chaser to its customers.
Purchaser is authorized to pass through to its customers. Under The pass-through Limited Warranty does not apply if the returned Prod-
the Limited Warranty, each tekmar Product is warranted against uct has been damaged by negligence by persons other than tekmar,
defects in workmanship and materials if the Product is installed and accident, fire, Act of God, abuse or misuse; or has been damaged by
used in compliance with tekmar’s instructions, ordinary wear and modifications, alterations or attachments made subsequent to purchase
tear excepted. The pass-through warranty period is for a period of which have not been authorized by tekmar; or if the Product was not
twenty-four (24) months from the production date if the Product is installed in compliance with tekmar’s instructions and/or the local codes
not installed during that period, or twelve (12) months from the docu- and ordinances; or if due to defective installation of the Product; or if the
mented date of installation if installed within twenty-four (24) months Product was not used in compliance with tekmar’s instructions.
from the production date. THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS
The liability of tekmar under the Limited Warranty shall be limited to, at OR IMPLIED, WHICH THE GOVERNING LAW ALLOWS PARTIES TO
tekmar’s sole discretion: the cost of parts and labor provided by tekmar CONTRACTUALLY EXCLUDE, INCLUDING, WITHOUT LIMITATION,
to repair defects in materials and/or workmanship of the defective prod- IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR
uct; or to the exchange of the defective product for a warranty replace- A PARTICULAR PURPOSE, DURABILITY OR DESCRIPTION OF THE
ment product; or to the granting of credit limited to the original cost of the PRODUCT, ITS NON-INFRINGEMENT OF ANY RELEVANT PATENTS
defective product, and such repair, exchange or credit shall be the sole OR TRADEMARKS, AND ITS COMPLIANCE WITH OR NON-VIOLA-
remedy available from tekmar, and, without limiting the foregoing in any TION OF ANY APPLICABLE ENVIRONMENTAL, HEALTH OR SAFETY
way, tekmar is not responsible, in contract, tort or strict product liabil- LEGISLATION; THE TERM OF ANY OTHER WARRANTY NOT HEREBY
ity, for any other losses, costs, expenses, inconveniences, or damages, CONTRACTUALLY EXCLUDED IS LIMITED SUCH THAT IT SHALL NOT
whether direct, indirect, special, secondary, incidental or consequential, EXTEND BEYOND TWENTY-FOUR (24) MONTHS FROM THE PRODUC-
arising from ownership or use of the product, or from defects in work- TION DATE, TO THE EXTENT THAT SUCH LIMITATION IS ALLOWED BY
manship or materials, including any liability for fundamental breach of THE GOVERNING LAW.
contract. Product Warranty Return Procedure All Products that are believed to
The pass-through Limited Warranty applies only to those defective Prod- have defects in workmanship or materials must be returned, together
ucts returned to tekmar during the warranty period. This Limited War- with a written description of the defect, to the tekmar Representative
ranty does not cover the cost of the parts or labor to remove or transport assigned to the territory in which such Product is located. If tekmar
the defective Product, or to reinstall the repaired or replacement Product, receives an inquiry from someone other than a tekmar Representative,
all such costs and expenses being subject to Purchaser’s agreement and including an inquiry from Purchaser (if not a tekmar Representative) or
warranty with its customers. Purchaser’s customers, regarding a potential warranty claim, tekmar’s
sole obligation shall be to provide the address and other contact informa-
tion regarding the appropriate Representative.
tekmar Control Systems Ltd., Canada, tekmar Control Systems, Inc., U.S.A. Head Office: 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 © 2010 by: All specifications are subject to change without notice.
tekmar Control Systems Ltd. and tekmar Control Systems, Inc.
32 of 32 Printed in Canada. D 402 - 09/10.

Tekmar 402 tN2 House Control - Boiler, DHW, Mixing and Setpoint, Four Zone Valves

Diunggah oleh

Informasi Dokumen

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

Tekmar 402 tN2 House Control - Boiler, DHW, Mixing and Setpoint, Four Zone Valves

Diunggah oleh

Hak Cipta:

Format Tersedia

Installation & Operation Manual D 402

tekmarNet®2 House Control 402 09/10

House Control 402

1 of 32 © 2010 D 402 - 09/10

Radio Frequency Interference

© 2010 D 402 - 09/10 2 of 32

Power Required ----

Cover Oﬀ Front View Side View Back View

Stage 2 Mod dc/mA Boil Exp. Mix Exp.

Boil System Pump

Mix System Pump

House Control 402

Zone 1 Zone 2 Zone 3 Zone 4 Input Power Use at least 167°F

3 of 32 © 2010 D 402 - 09/10

Sizing the Transformer

Thermostat Load Transformer

© 2010 D 402 - 09/10 4 of 32

DHW Pump Pump DHW Pump Pump

Boil System Pump Boil System Pump

Mix System Power Source Mix System Power Source

Figure 3 - Connect Figure 4 - Connect

DHW Pump Mix System Pump

Boil System Pump

Boil System Pump

Boil Sys Pump Variable Strip wires

Rear Line Voltage Wiring Diagram -

Back of House Control 402

5 of 32 © 2010 D 402 - 09/10

Low Voltage Wiring -----------------------

© 2010 D 402 - 09/10 6 of 32

Mix Com Boil Out Com DHW

Stage 2 Mod dc/mA Boil Exp. Mix Exp.

Setpoint Call Menu Item

House Control 402

Zone 1 Zone 2 Zone 3 Zone 4 Input Power Use at least 167°F

One or Two Stage

Sensor with rear Sensor with bottom Sensor mounted

7 of 32 © 2010 D 402 - 09/10

Mounting the Boiler and Mix Sensor 082 ---

Immersion Well Retaining Clip

© 2010 D 402 - 09/10 8 of 32

Testing the Control Wiring

9 of 32 © 2010 D 402 - 09/10

© 2010 D 402 - 09/10 10 of 32

S3 070 tekmarNet ®2 Thermostats

Mix Sensor (S2)

House Control 402

Zone 1 Zone 2 Zone 3 Zone 4 Input Power Use at least 167°F

DHW Call R L 24 V (ac)

Zone Valves (Z1 to Z4)

Back of House Control 402

11 of 32 © 2010 D 402 - 09/10

tekmarNet ®2 Thermostats S3 070 tekmarNet ®2 Thermostats

Outdoor C tN4 Boil Expansion to

DHW Sensor (S4) Menu Item

House Control 402

Zone 1 Zone 2 Zone 3 Zone 4 Input Power Use at least 167°F

Back of House Control 402

© 2010 D 402 - 09/10 12 of 32

Menu Field Item Field

Status Fields MONITOR minhr Number Field

CALLS °F°C °F, °C, %, HOURS, MINUTES, SECOND

13 of 32 © 2010 D 402 - 09/10

Menu Button ------------------------------