Watts Tekmar 294EXP User manual

Installation, Operation and Maintenance Manual

Smart Boiler Expansion 294EXP

IOM-T-294EXP

WARNING

Please read carefully before proceeding with

installation. Your failure to follow any attached

instructions or operating parameters may lead to the

product’s failure.

Keep this Manual for future reference.

Important Safety Information .........................3

Radio Frequency Statement .........................4

Installation .......................................5

Installation Location .............................5

Wiring Schematic ...............................6

Wiring Instructions ..............................7

User Interface ....................................9

Status Icons ...................................9

Labels for Boilers 9 to 12 or 13 to 16 ................9

Sequence of Operation ............................10

DIP Switches .................................10

Power On LED ................................10

Communication LED ............................10

Boiler Output Operation .........................10

Troubleshooting..................................11

Technical Data ...................................12

Limited Warranty & Product Return Procedure...........12

Table of Contents

This is a safety-alert symbol. The safety alert sym-

bol is shown alone or used with a signal word

(DANGER, WARNING, or CAUTION), a pictorial

and/or a safety message to identify hazards.

When you see this symbol alone or with a signal

word on your equipment or in this Manual, be alert

to the potential for death or serious personal injury.

• It is the installer's responsibility to ensure that this control

is safely installed according to all applicable codes and

standards.

• Improper installation and operation of this control could

result in damage to the equipment and possibly even

personal injury or death.

• This control is not intended for use as a primary limit

control. Other controls that are intended and certified as

safety limits must be placed into the control circuit.

Do not attempt to service the control. There are no user

serviceable parts inside the control. Attempting to do so

voids warranty.

To avoid serious personal injury and damage to the equipment:

It is your responsibility to ensure that this control is safely

installed according to all applicable codes and standards.

tekmar®is not responsible for damages resulting from

improper installation and/or maintenance.

• Read Manual and all product labels BEFORE

using the equipment. Do not use unless you

know the safe and proper operation of this

equipment.

• Keep this Manual available for easy access by

all users.

• Replacement Manuals are available at

tekmarControls.com

Important Safety Information

This pictorial alerts you to electricity, electrocution,

and shock hazards.

Double insulated.

This symbol identifies hazards which, if not

avoided, could result in death or serious injury.

This symbol identifies hazards which, if not

avoided, could result in minor or moderate

injury.

This symbol identifies practices, actions, or

failure to act which could result in property

damage or damage to the equipment.

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC

Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in

a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used

in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment

in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his

own expense.

This device complies with part 15 of the FCC Rules and with Industry Canada license-exempt RSS standard(s). Operation is

subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any

interference received, including interference that may cause undesired operation.

The antenna used for this radio must be properly installed and maintained and must provide a separation distance of at least

7.9 inches (20 cm) from all persons.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to

operate the equipment.

Le présent appareil est conforme aux CNR d’Industrie Canada applicables aux appareils radio exempts de license. L’exploitation

est autorisée aux deux conditions suivantes:

(1) l’appareil ne doit pas produire de brouillage, et

(2) l’utilisateur de l’appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d’en compromettre

le fonctionnement.

Radio Frequency Statement

Use a Phillips screwdriver to remove

the two screws on the cover.

Pull the front cover towards you. The

top of the cover will pivot on a hinge.

Remove the cover by releasing the

pivot hooks.

Mount the enclosure to a wall using

#6 wood screws in the four mounting

holes. Use screw anchors if drilling

into masonry.

Use the 24 knock-outs to install

connecting conduits and cabling to

the control.

To install the cover, hook the top

of the cover to the enclosure, then

pivot the bottom to shut.

Use a Phillips screwdriver to fasten

the two bottom screws.

When choosing the location for the control, consider the following:

• Keep dry. Avoid potential leakage onto the control.

RH 90% to 104°F (40°C).

Non-condensing environment.

• Do not expose to operating temperatures beyond 32-104°F

(0-40°C)

• Provide adequate ventilation.

• Keep away from equipment, appliances or other sources of

electrical interference.

• Provide easy access for wiring, viewing, & adjusting the

display screen.

• Mount approximately 5 ft. (1.5 m) off the finished floor.

• Locate the control near pumps &/or zone valves if possible.

• Provide a solid backing to mount the enclosure to. For

example: plywood, studs, etc

• Use the conduit knockouts provided on the upper, lower,

back & sides of the enclosure.

Installation

Installation Location

This section provides a wiring schematic for the control.

Wiring Schematic

• Before wiring, ensure all power is turned off and take all

necessary precautions.

• Strip all wiring to a length of 3⁄8in. or 10 mm for all terminals.

• A circuit breaker or power disconnect that provides power

to the control should be located nearby & clearly labeled.

• Refer to the current and voltage ratings at the back of this

brochure before connecting devices to this control.

• Only qualified personnel should install or service the control.

CAN ICES-3 (A)/NMB-3(A)

Class 2 Circuits

Boiler Mod:

Class 2 Circuits

Input Power:

115 V (ac) ±10%, 60 Hz, 6 W

Relays:

230 V (ac), 5 A, 1/3 hp

Operating Temperature:

32°F to 122°F (0°C to 50°C)

Use Copper Conductors Only

H2062B

Boiler 6

Boiler 5

Mod

Boiler 7

1110

Boiler 8

1312

Boiler 5

Enable

1514

Boiler 6

Enable

1716

Boiler 7

Enable

1918

Boiler 8

Enable

2120

Boiler 5

Pump/Vlv

2322

Boiler 6

Pump/Vlv

2524

Boiler 7

Pump/Vlv

2726

Boiler 8

Pump/Vlv

2928

Power

To Reduce the Risk of Electric

Shock - Do not connect to a

circuit operating at more than

150 volts to ground.

Pour réduire les risques

d'électrocution choc - ne pas

raccorder à un circuit

fonctionnant à plus de 150 V à

la terre.

231

+Gnd

Expansion

Expansion 5 to 8

Set switches: 1 to Off, 2 to Off

+Mod

Smart Boiler Expansion 294EXP

For product literature:

Pour la documentation

du produit:

Watts.com/tekmar

tektra 1152-01

Designed and assembled

in Canada

DANGER

Boiler Pump/Valve

Boiler Expansion 5 to 8

LNG LNG

+-+-+-+-TT TT TT TT

-+Gnd

Modulating Boilers (Terminals 4 to 11)

The control provides either a 0-10 V (dc) or a 4-20 mA output to each boiler. Polarity is important.

• Connect the control Mod (+) terminals 4, 6, 8, 10 to boilers 5, 6, 7 and 8 analog signal input (+)

respectively.

• Connect the control Mod (-) terminals 5, 7, 9, 11 to boilers 5, 6, 7 and 8 analog signal input (-)

respectively.

Some modulating boilers may also require a boiler on/off enable signal in addition to the

modulating signal. Please consult the boiler manual.

Modutrol IV

tekmar

V9055

Modutrol IV™

0 - 135 Ω

Actuating

Motor

Mod +

Modutrol IV

tekmar

V9055

V9055™

0 - 135 Ω

Actuating

Motor

Mod +

The 4 to 20 mA output can be converted to a 0 - 135 Ω

output for a Modutrol IV™ gas valve actuating motor using a

0 - 135 Ω tekmar Converter 005 (sold separately).

The 4 to 20 mA output can be converted to a 0 - 135 Ω

output for a V9055™ gas valve actuating motor using a

0 - 135 Ω tekmar Converter 005 (sold separately).

Boiler

Control

294

Boiler

Control

294

Modutrol IV™ and V9055™ are trademarks of Honeywell, Inc.

Boiler Enable (Terminals 12 to 19)

A single stage condensing or non-condensing boiler is enabled through the TT contacts.

• For Boiler 5 connect the Boiler Enable terminals 12 and 13 to the boiler TT contacts.

• For Boiler 6 connect the Boiler Enable terminals 14 and 15 to the boiler TT contacts.

• For Boiler 7 connect the Boiler Enable terminals 16 and 17 to the boiler TT contacts.

• For Boiler 8 connect the Boiler Enable terminals 18 and 19 to the boiler TT contacts.

Boiler Expansion (Terminals 1, 2, 3)

The control operates 4 on board boilers and is expandable in groups of 4 up to a

maximum of 16 through the use of boiler expansions. The control connects to the

expansion through a wired three-wire connection. The maximum bus cable length is

100 feet (30 m) using 18 AWG solid conductor cable.

• Connect the 294 terminal 18 (-) to the 294EXP terminal 1 (-).

• Connect the 294 terminal 19 (+) to the 294EXP terminal 2 (+).

• Connect the 294 terminal 20 (Gnd) to the 294EXP terminal 3 (Gnd). 18 19 20

Gnd

Expansion

123

Gnd

Expansion

This section explains how to wire individual devices to the Smart Boiler Expansion 294EXP.

Wiring Instructions

Boiler Pump / Valve (Terminals 20 to 27)

Boiler pumps or valves requiring up to 230 V (ac) 5 A, 1/3 hp can be switched through terminals 20

to 27. If a single power source is used for multiple pumps, ensure they are not tied together at any

point between the pumps and the control. For simplicity in wiring and troubleshooting, a separate

breaker for each pump is recommended.

For pumps:

•

Connect the power source line wire (L) to terminal 20.

• Connect a wire from terminal 21 to the pump Line In terminal.

• Connect the pump Neutral (N) to the power source neutral.

• Repeat for additional boiler pumps 6 (terminals 22, 23), boiler pump 7 (24, 25) and boiler pump

8 (terminals 26, 27).

• Ensure each pump is connected to earth ground.

Ground

Boiler 1

20 21

Pump/Valve

Boiler 1

20 21

Pump/V

alve

For 120 V (ac) valves:

•

Connect the power source line wire (L) to terminal 20.

• Connect a wire from terminal 21 to the valve Line In terminal.

• Connect the valve Neutral (N) to the power source neutral.

• Repeat for additional valves 6 (terminals 22, 23), valve 7 (24, 25) and valve 8 (terminals 26, 27).

• Ensure each pump is connected to earth ground.

For 24 V (ac) valves:

• Connect the power source Red wire (R) to terminal 20.

• Connect a wire from terminal 21 to the valve power terminal.

• Connect the valve power common to the power source common (C).

• Repeat for additional boiler valves 6 (terminals 22, 23), boiler valve 7 (24, 25) and boiler valve

8 (terminals 26, 27).

Ground

Boiler 1

20 21

Pump/Valve

Provide a 15 Amp circuit for the input power.

• Connect the 115 V (ac) line wire (L) to terminal 28.

• Connect the neutral wire (N) to terminal 29.

Input Power (Terminals 28, 29)

Power In

28 29



POWER

LED is on when powered.

COMMUNICATION

LED is on when communicating to 294.

Boiler Pump/Valve

Boiler Expansion 5 to 8

Status Icons

User Interface

Labels for Boilers 9 to 12 or 13 to 16

The 294EXP is assembled from the factory with labels to operate boilers 5 through 8. Included in the packaging are labels for

boilers 9 to 12 and another set for boilers 13 to 16. If operating one of these boiler groups, locate the correct label, peel the label

from the backing, and using the plastic oval shape as a guide, apply the label to on top of the existing label.

CAN ICES-3 (A)/NMB-3(A)

Class 2 Circuits

Boiler Mod:

Class 2 Circuits

Input Power:

115 V (ac) ±10%, 60 Hz, 6 W

Relays:

230 V (ac), 5 A, 1/3 hp

Operating Temperature:

32°F to 122°F (0°C to 50°C)

Use Copper Conductors Only

H2062B

Boiler 6

Boiler 5

Mod

Boiler 7

1110

Boiler 8

1312

Boiler 5

Enable

1514

Boiler 6

Enable

1716

Boiler 7

Enable

1918

Boiler 8

Enable

2120

Boiler 5

Pump/Vlv

2322

Boiler 6

Pump/Vlv

2524

Boiler 7

Pump/Vlv

2726

Boiler 8

Pump/Vlv

2928

Power

To Reduce the Risk of Electric

Shock - Do not connect to a

circuit operating at more than

150 volts to ground.

Pour réduire les risques

d'électrocution choc - ne pas

raccorder à un circuit

fonctionnant à plus de 150 V à

la terre.

231

+Gnd

Expansion

Expansion 5 to 8

Set switches: 1 to Off, 2 to Off

+Mod

Smart Boiler Expansion 294EXP

For product literature:

Pour la documentation

du produit:

Watts.com/tekmar

tektra 1152-01

Designed and assembled

in Canada

DANGER

CAN ICES-3 (A)/NMB-3(A)

Class 2 Circuits

Boiler Mod:

Class 2 Circuits

Input Power:

115 V (ac) ±10%, 60 Hz, 6 W

Relays:

230 V (ac), 5 A, 1/3 hp

Operating Temperature:

32°F to 122°F (0°C to 50°C)

Use Copper Conductors Only

H2063B

Boiler 10

Boiler 9

Mod

Boiler 11

1110

Boiler 12

1312

Boiler 9

Enable

1514

Boiler 10

Enable

1716

Boiler 11

Enable

1918

Boiler 12

Enable

2120

Boiler 9

Pump/Vlv

2322

Boiler 10

Pump/Vlv

2524

Boiler 11

Pump/Vlv

2726

Boiler 12

Pump/Vlv

2928

Power

To Reduce the Risk of Electric

Shock - Do not connect to a

circuit operating at more than

150 volts to ground.

Pour réduire les risques

d'électrocution choc - ne pas

raccorder à un circuit

fonctionnant à plus de 150 V à

la terre.

231

+Gnd

Expansion

Expansion 9 to 12

Set switches: 1 to On, 2 to Off

+Mod

Smart Boiler Expansion 294EXP

For product literature:

Pour la documentation

du produit:

Watts.com/tekmar

tektra 1152-01

Designed and assembled

in Canada

DANGER

Boiler Pump/Valve

Boiler Expansion 5 to 8

Boiler Pump/Valve

Boiler Expansion 9 to 12

The power LED operates as follows.

LED Operation

On Power applied and control is operating correctly

Off No power or the control is faulty

When powered on, the Smart Boiler Expansion 294EXP communicates to the Smart Boiler Control 294. The communication LED

operates as follows.

LED Operation

On Communication with 294

Off No communication with 294

All boiler relays are normally off and the modulating outputs at 0 V (dc) or 4 mA. The Smart Boiler Control 294EXP responds to

commands from the 294 to turn on a boiler, the modulating signal, and the boiler pump or valve. The status on the 294EXP

display will match the 294 Boiler Status menu.

Output LED Operation

Boiler 5, 9, 13 On Boiler enable 5, 9, 13 relay is closed

Off Boiler enable 5, 9, 13 relay is open

Boiler 6, 10, 14 On Boiler enable 6, 10, 14 relay is closed

Off Boiler enable 6, 10, 14 relay is open

Boiler 7, 11, 15 On Boiler enable 7, 11, 15 relay is closed

Off Boiler enable 7, 11, 15 relay is open

Boiler 8, 12, 16 On Boiler enable 8, 12, 16 relay is closed

Off Boiler enable 8, 12, 16 relay is open

Boiler Pump/Valve 5, 9, 13 On Boiler pump/valve 5, 9, 13 relay is closed

Off Boiler pump/valve 5, 9, 13 relay is open

Boiler Pump/Valve 6, 10, 14 On Boiler pump/valve 6, 10, 14 relay is closed

Off Boiler pump/valve 6, 10, 14 relay is open

Boiler Pump/Valve 7, 11, 15 On Boiler pump/valve 7, 11, 15 relay is closed

Off Boiler pump/valve 7, 11, 15 relay is open

Boiler Pump/Valve 8, 12, 16 On Boiler pump/valve 8, 12, 16 relay is closed

Off Boiler pump/valve 8, 12, 16 relay is open

Two DIP switches located on the top left side of the control. The DIP switch positions determine the boiler groups that the Smart

Boiler Expansion 294EXP operates.

Boilers DIP Switch 1 DIP Switch 2

5 to 8 Off Off

9 to 12 On Off

13 to 16 Off On

Sequence of Operation

Power On LED

Communication LED

Boiler Output Operation

DIP Switches

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