Grundfos MAGNA3 Series, Installation And Operating Instructions Manual

Page 1: ...Date January 8 2015 Project Jackson Home Office Expansion Phase 3 Office Building Connector Product Snow Melt System Document Warranty Notes No Notes ...

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Page 4: ...Date January 8 2015 Project Jackson Home Office Expansion Phase 3 Office Building Connector Product Snow Melt System Document Installation Operation and Maintenance Manuals Notes No notes ...

Page 5: ...ger The Christman Company Mechanical Contractor ATTACHMENT INCLUDES REF Grundfos Magna3 Pump O M 984594080 0614 Manual Alfa Laval Heat exchangers 1644725 01 01 10 T5 BFG Plate Heat Exchanger Viega PRO Radiant warranty HRH WARR 6 10 10 Tekmar TE664 manual D 664 SUBMITTED BY SUBMITTAL PACKAGE WARRANTIES AND O M MANUALS Jackson National Life Phase 3 1 Edwards Zuck Limbach Company LLC ...

Page 6: ...GRUNDFOS INSTRUCTIONS MAGNA3 Installation and operating instructions ...

Page 7: ... 2 Operating mode 24 13 3 Control mode 24 13 4 FLOWLIMIT 28 13 5 Automatic Night Setback 28 13 6 Relay outputs 29 13 7 Setpoint influence 29 13 8 Bus communication 30 13 9 General settings 30 14 Assist menu 34 14 1 Assisted pump setup 34 14 2 Setting of date and time 34 14 3 Multi pump setup 34 14 4 Setup analog input 34 14 5 Description of control mode 34 14 6 Assisted fault advice 34 14 7 Wirele...

Page 8: ...orized service station for instructions Any defective product to be returned to Grundfos or a service station must be sent freight prepaid documentation supporting the warranty claim and or a Return Material Authorization must be included if so instructed GRUNDFOS WILL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES LOSSES OR EXPENSES ARISING FROM INSTALLATION USE OR ANY OTHER CAUSES THE...

Page 9: ...water systems we recommend to keep the liquid temperature below 150 F 65 C to eliminate the risk of lime precipitation Fig 1 Pumped liquids 3 2 1 Glycol The pump can be used for pumping water glycol mixtures up to 50 Example of a water ethylene glycol mixture Maximum viscosity 50 cSt 50 water 50 ethylene glycol mixture at 14 F 10 C The pump has a power limiting function that protects against overl...

Page 10: ...mp see fig 3 For pumps in air conditioning and cooling systems down to 14 10 C it is required to apply a silicon sealant to the internal contours of the shell in order to eliminate any air gaps and prevent condensation between the insulation shell and pump housing Alternatively the pump can also be insulated manually in accordance with standard insulating requirements for heating and cooling syste...

Page 11: ...SHOCK DE ENERGIZE EQUIPMENT BEFORE REMOVAL OF COVER SERVICING FOR SUPPLY CONNECTION USE COPPER WIRE SUITABLE FOR 90 C OR EQUIVALENT THIS PUMP HAS NOT BEEN INVESTIGATED FOR USE IN SWIMMING POOL OR MARINE AREAS TO REDUCE THE RISK OF ELECTRIC SHOCK SEE INSTRUCTION MANUAL FOR PROPER INSTALLATION ACCEPTABLE FOR INDOOR USE ONLY PSI For use with maximum 230 F water Contains FCC ID OG3 RADIOM01 2G4 Pos De...

Page 12: ...cs the following must be observed Position the pump in such a way that sufficient cooling is ensured The temperature of the ambient air must not exceed 104 F 40 C TM05 6472 4712 Pos Tool Size 1 Screwdriver straight slot 1 2 x 8 0 mm 2 Screwdriver straight slot 0 6 x 3 5 mm 3 Screwdriver torx bit TX20 4 Hexagon key 5 0 mm 5 Open end wrench Depending on flange bolt size 6 Wire cutter 7 Pipe wrench 1...

Page 13: ...pump housing 1 Gently lower the pump head with rotor shaft and impeller into the pump housing 2 Make sure that the contact face of the pump housing and that of the pump head are in contact before the clamp is tightened See fig 9 Fig 9 Fitting the pump head to the pump housing 4 4 Pump head position If the pump head is removed before the pump is installed in the pipework pay special attention when ...

Page 14: ... escaping vapor Step Action Illustration 1 Loosen the screw in the clamp holding the pump head and pump housing together Warning If the screw is loosened too much the pump head will be completely disconnected from the pump housing TM05 2867 0612 2 Carefully rotate the pump head to the desired position If the pump head is stuck loosen it with a light blow of a rubber mallet TM05 2868 0612 3 Positio...

Page 15: ...7 1912 6 Fit and tighten the screw holding the clamp to minimum 6 0 7 ft lbs 8 1 Nm TM05 2872 0612 7 Fit the insulating shells Note For air conditioning and cooling systems a silicone sealant must be applied inside the insulation shell to eliminate all air gaps and prevent condensation between the pump housing and insulation shell Alternatively the pump may be insulated manually in accordance with...

Page 16: ...rom the control box TM05 2875 0612 2 Locate the power supply plug and conduit adapter in the box supplied with the pump TM05 2876 0612 3 Connect the conduit adapter to the control box TM05 2877 0612 4 Pull the power supply cable through the conduit adapter TM05 2878 0612 5 Strip the cable conductors as illustrated TM05 5534 3812 6 Connect the cable conductors to the power supply plug L L or L1 Gro...

Page 17: ...g inside TM06 1103 1614 3 Connect the conduit to the control box Pull the power supply cable through the conduit TM06 1104 1614 5 Strip the cable as illustrated Connect the cable conductors to the power supply plug L L or L1 Ground Ground N N or L2 TM06 1105 1614 6 Insert the power plug into its mating connector Tighten the conduit TM06 1106 1614 L L1 N L2 7 Refit the front cover TM06 1107 1614 St...

Page 18: ... sensor and setpoint signals TM03 2397 0312 External switch Fuse min 10 A time lag GFCI Note Note All cables used must be connected in accordance with local regulations TM05 2673 3812 NC NO C NC NO C N L S S M I M A signal sensor Vcc 24V IN Mains connection Alarm Operation Start stop On off timer Analog input Warning Wires connected to supply terminals outputs NC NO C and start stop input must be ...

Page 19: ...round connection as follows Terminal connected versions Connect the cable screen to ground via the digital input terminal earth Plug connected versions Connect the cable screen to ground via cable clamp TM05 8539 2413 Warning Wires connected to supply terminals outputs NC NO C and start stop input must be separated from each other and from the supply by reinforced insulation Note Note All cables u...

Page 20: ...ontrol panel or with Grundfos GO Remote The relays can be used for outputs up to 250 V and 2 A Fig 17 Relay output The functions of the signal relays appear from the table below TM05 3338 1212 Contact symbol Function NC Normally closed NO Normally open C Common NC NO C NC NO C Alarm Operation Relay 1 Relay 2 Signal relay Alarm signal Not activated The power supply has been switched off The pump ha...

Page 21: ...ed via the digital input External forced max or min curve The pump can be forced to operate on the max or min curve via the digital input Select the function of the digital input on the pump control panel or with Grundfos GO Remote TM05 3339 1212 Contact symbol Function M A Max curve 100 speed M I Min curve 25 speed S S Start Stop Frame connection Start stop Normal duty Note Factory setting with j...

Page 22: ...g 21 Examples of external sensors For further details visit WebCAPS and reference Magna3 Data booklet 98439208 Fig 22 Example of external signal for the control via BMS or PLC TM05 3221 1112 Function control mode Sensor type Heat energy meter Temperature sensor Constant temperature Temperature sensor Differential pressure Pressure sensor TM06 0882 1114 PIN Description Load IN Analog input 150 Ω 4 ...

Page 23: ...setting with the highest priority The priority of the settings is as shown in the table below Example If the pump has been forced to stop via an external signal the pump control panel or Grundfos GO Remote can only set the pump to max curve As illustrated in the table the pump does not react to external signals max curve and min curve when it is controlled via bus For further details please contac...

Page 24: ...T after approx 5 seconds TM05 2884 0612 2 Pump display at first start up After a few seconds the pump display will change to the start up guide TM05 2885 0612 3 The start up guide will guide you through the general settings of the pump such as language date and time If the buttons on the pump control panel are not touched for 15 minutes the display will go into sleep mode When a button is touched ...

Page 25: ...3 5 Automatic Night Setback Not active Active Relay outputs See section 13 6 Relay outputs Relay output 1 Relay output 2 Setpoint influence See section 13 7 Setpoint influence External setpoint function See section 13 7 1 External setpoint function Temperature influence See section 13 7 2 Temperature influence Bus communication See section 13 8 Bus communication Pump number See section 13 8 1 Pump...

Page 26: ...ult Heat power General settings Internal fault Heat energy Language Internal sensor fault Flow rate Set date and time Dry running Volume Select date format Forced pumping Hours counter Set date Undervoltage Temperature 1 Select time format Overvoltage Temperature 2 Set time External sensor fault Differential temp Units Work log SI or US units Operating hours Customized units Trend data Pressure Du...

Page 27: ...up provides a short description of the control modes and offers fault advice See section 14 Assist menu 11 Home menu Navigation Home Press to go to the Home menu Home menu factory setting Shortcut to control mode settings Shortcut to setpoint settings Flow rate Head Navigate in the display with or and change between the two shortcuts with or The Home display can be defined by the user See section ...

Page 28: ...tions Setpoint Operating mode Control mode FLOWLIMIT Automatic Night Setback Relay outputs Setpoint influence Bus communication General settings Navigate between submenus with or 13 1 Setpoint Navigation Home Settings Setpoint Setpoint Set the setpoint so that it matches the system Setting 1 Press OK to start the setting 2 Select digit with and and adjust with or 3 Press OK to save A too high sett...

Page 29: ...ting mode is for instance suitable for hot water priority 13 3 Control mode Navigation Home Settings Control mode Control mode AUTOADAPT FLOWADAPT Prop press proportional pressure Const press constant pressure Const temp constant temperature Constant curve Setting 1 Select control mode with or 2 Press OK to enable The setpoint for all control modes except AUTOADAPT and FLOWADAPT can be changed in ...

Page 30: ...tory settings 13 3 2 FLOWADAPT When FLOWADAPT is selected the pump will run AUTOADAPT and ensure that the flow never exceeds the entered FLOWLIMIT value The setting range for the FLOWLIMIT is 25 to 90 of the Qmax of the pump The factory setting of the FLOWLIMIT is the flow where the AUTOADAPT factory setting meets the max curve See fig 27 Fig 27 FLOWADAPT 13 3 3 Proportional pressure The pump head...

Page 31: ...lla in the system It is possible to set the sensor range min 14 F 10 C max 266 F 130 C Fig 30 Constant temperature 13 3 6 Differential temperature This control mode ensures a constant differential temperature drop across a heating system The pump should be installed in the flow pipe so the built in sensor measures the liquid temperature going out to the load An external temperature sensor must be ...

Page 32: ...l the motor becomes unstable 4 Set the integral time Ti to twice the value which made the motor unstable This is the correct setting of the integral time General rules of thumb If the controller is too slow reacting increase Kp If the controller is hunting or unstable dampen the system by reducing Kp or increasing Ti 13 3 7 Constant curve The pump can be set to operate according to a constant curv...

Page 33: ...matic Night Setback Navigation Home Settings Automatic Night Setback Automatic Night Setback To enable the function select Active with or and press OK Once Automatic Night Setback has been enabled the pump automatically changes between normal duty and night setback duty at low performance Changeover between normal duty and night setback depends on the flow pipe temperature The pump automatically c...

Page 34: ...t is ready to run Alarm The signal relay is activated together with the red indicator light on the pump Operation The signal relay is activated together with the green indicator light on the pump 13 7 Setpoint influence Navigation Home Settings Setpoint influence Setpoint influence External setpoint function Temperature influence 13 7 1 External setpoint function The external setpoint function is ...

Page 35: ...mperature Systems with almost constant flows for example one pipe heating systems and underfloor heating systems in which variable heating demands cannot be registered as changes in the head as is the case with two pipe heating systems In such systems the pump performance can only be adjusted by enabling the temperature influence function Selection of Tmax In systems with a dimensioned flow pipe t...

Page 36: ...hour clock Setting 1 Select Set time 2 Press OK to start the setting 3 Select digit with and and adjust with or 4 Press OK to save 13 9 3 Units Navigation Home Settings General settings Units Units SI or US units Customized units Select whether the display should shows SI or US units or select the desired units for the parameters below Pressure Differential pressure Head Level Flow rate Volume Tem...

Page 37: ...ncel 13 9 6 Define Home display Navigation Home Settings General settings Define Home display Define Home display Select Home display type Define Home display contents The Home display can be set to show up to four user defined parameters or a graphical illustration of a performance curve Select Home display type 1 Select List of data or Graphical illustration with or 2 Press OK to save To specify...

Page 38: ...menus will be set back to the factory settings This also includes language units possible setup of analog input multi pump function etc To overwrite the current settings with the factory settings select Yes with or and press OK 13 9 9 Run start up guide Navigation Home Settings General settings Run start up guide Run start up guide It is possible to run the start up guide again The start up guide ...

Page 39: ... twin head pumps without the use of external controllers The pumps in a multi pump system communicate with each other via the wireless GENIair connection A multi pump system is set up via a selected pump i e the master pump first selected pump All Grundfos pumps with a wireless GENIair connection can be connected to the multi pump system The multi pump functions are described in the following sect...

Page 40: ...t lower than the balancing valve setting the pump will ramp down instead of losing energy by pumping against a balancing valve Cooling surfaces in air conditioning systems can operate at high pressure and low flow FLOWADAPT In systems with relatively large pressure losses in the distribution pipes and in air conditioning and cooling systems Two pipe heating systems with thermostatic valves and a d...

Page 41: ...ue of the external signal The pump can also be set to operate according to the max or min curve like an uncontrolled pump The max curve mode can be used in periods in which a maximum flow is required This operating mode is for instance suitable for hot water priority The min curve mode can be used in periods in which a minimum flow is required This operating mode is for instance suitable for manua...

Page 42: ... simultaneously Alarm Pump stopped One green indicator light in the middle permanently on in addition to another indication Remote controlled The pump is currently being accessed by Grundfos GO Remote Case Description Signalling by the center indicator light Wink The pump in question is highlighted in the Grundfos GO Remote display To inform the user of the location of the highlighted pump the cen...

Page 43: ...e pump or call GRUNDFOS SERVICE for assistance High motor temperature 64 Alarm Temperature in stator windings too high No Check the winding resistance according to the MAGNA3 service instructions Internal fault 72 84 155 157 Warning alarm Internal fault in the pump electronics Yes Replace the pump or call GRUNDFOS SERVICE for assistance Overvoltage 74 Alarm Supply voltage to the pump too high Yes ...

Page 44: ...or specifications 17 1 1 Pressure Full scale 17 1 2 Temperature TM05 3036 0812 Nose downwards 5 Nm Warning Before replacing the sensor make sure that the pump is stopped and that the system is not pressurized Maximum differential pressure during operation 29 psi 2 bar 0 2 MPa Accuracy 32 to 185 F 0 to 85 C 2 Accuracy 14 to 32 F and 185 to 266 F 10 to 0 C and 85 to 130 C 3 Temperature range during ...

Page 45: ...esired type of Grundfos GO Remote setup 18 2 Communication The pump can communicate via the wireless GENIair connection or a CIM module This enables the pump to communicate with other pumps and with different types of network solutions The Grundfos CIM modules CIM Communication Interface Module enable the pump to connect to standard fieldbus networks Fig 40 Building management system BMS with four...

Page 46: ...ROFIBUS communication status CIM 200 TM05 3815 1612 Modbus RTU CIM 200 is a Grundfos communication interface module used for communication with a Modbus RTU network CIM 200 has terminals for the Modbus connection DIP switches are used to select parity and stop bits to select transmission speed and to set line termination Two hexadecimal rotary switches are used to set the Modbus address Two LEDs a...

Page 47: ...mputer You will get a complete status overview of the entire GRM system It allows you to plan maintenance and service based on actual operating data CIM 300 TM05 3815 1612 BACnet MS TP CIM 300 is a Grundfos communication interface module used for communication with a BACnet MS TP network CIM 300 has terminals for the BACnet MS TP connection DIP switches are used to set transmission speed and line ...

Page 48: ...Action Illustration 1 Remove the front cover from the control box TM05 2875 0912 2 Fit the CIM module as illustrated and click it on TM05 2914 1112 3 Fit and tighten the screw holding the CIM module and secure the earth connection TM05 2912 1112 4 For connection to fieldbus networks see separate installation and operating instructions for the desired CIM module TM05 2913 1112 ...

Page 49: ...lectromagnetic compatibility EN 55014 1 2006 EN 55014 2 1998 EN 61800 3 3 2008 and EN 61000 3 2 2006 Sound pressure level The sound pressure level of the pump is lower than 43 dB A Leakage current The pump mains filter will cause a discharge current to earth during operation Ileakage 3 5 mA Consumption when the pump is stopped 1 to 10 W depending on activity i e reading the display use of Grundfos...

Page 50: ...7 3500 www grundfos us GRUNDFOS Canada 2941 Brighton Road Oakville Ontario L6H 6C9 Canada Phone 1 905 829 9533 Telefax 1 905 829 9512 www grundfos ca GRUNDFOS México Boulevard TLC No 15 Parque Industrial Stiva Aeropuerto C P 66600 Apodaca N L México Phone 011 52 81 8144 4000 Fax 011 52 81 8144 4010 www grundfos mx ...

Page 51: ...08 0614 ECM 1133339 The name Grundfos the Grundfos logo and be think innovate are registered trademarks owned by Grundfos Holding A S or Grundfos A S Denmark All rights reserved worldwide Copyright Grundfos Holding A S www grundfos com ...

Page 52: ...EN DE FR NL DA SV FI ES PT IT RU PL NO Instruction Manual Plate Heat Exchangers M3 M6 M10 TS6 T2 T5 TL3 TL6 Part number 1644725 01 0810 ...

Page 53: ...leaning In Place CIP 7 Manual cleaning 8 Pressure test after maintenance 13 Regasketing 14 Except for this Instruction Manual the following documents are also included in this shipment Plate Heat Exchanger PHE drawing Plate hanging list Parts list with exploded view drawing How to contact Alfa Laval Contact details for all countries are continually updated on our website Please visit www alfalaval...

Page 54: ...censed waste incineration plant Metal straps should be sent for material recy cling Maintenance During maintenance oil and wear parts in the machine are replaced All metal parts should be sent for material recy cling Worn out or defective electronic parts should be sent to a licensed handler for material recycling Oil and all non metal wear parts must be taken care of in agreement with local regul...

Page 55: ... used to protect the holes against corrosion Connections can also be pipes for welding or threaded Tightening bolts Press the channel plates together Pressure plate Moveable steel plate In some cases pipes may be connected to the pres sure plate Channel plates Heat is transferred from one medium to the other through the thin channel plates The number of plates deter mines the total heat transfer s...

Page 56: ...ed plates Cassettes available The function of the semi welded PHE is the same as that of the con ventional PHE Chapters Installation and Opera tion of this manual are applicable to full extent Chapter Maintenance is fully applicable when it comes to the parts Cleaning in Place and Pres sure test after maintenance and partially applica ble for the remaining part To cover the specific requirements o...

Page 57: ...king on the piping Turning of the connections will dam age the gaskets on the end plate and cause leakage Shut off valves To be able to open the heat exchanger shut off valves should be provided in all connections Space 600 mm minimum free space is needed for lifting plates in and out Multi pass units Connections on the pressure plate It is important that the plate pack has been tight ened to the ...

Page 58: ... beams on the floor Lift the heat exchanger off pallet using e g straps Place the heat exchanger on the timber beams Place straps around one bolt on each side Lift the heat exchanger off the timber beams Lower the heat exchanger to horizontal position and place it on the floor Warning Never lift by the connections or the studs around them 1 2 3 4 5 6 ...

Page 59: ... all air is expelled close the vent Repeat steps 1 6 for the second media Note If several pumps are included in the system make sure you know which one should be activated first Note Adjustments of flowrates should be made slowly in order to avoid the risk of water hammer Water hammer is a shortlasting pressure peak that can appear during start up or shut down of a system causing liquids to travel...

Page 60: ...ium is to be proc essed in the PHE Shut down Slowly close the valve controlling the flow rate of the pump you are about to stop When the valve is closed stop the pump Repeat steps 1 2 for the other side If the heat exchanger is shut down for sev eral days or longer it should be drained Draining should also be done if the proc ess is shut down and the ambient temper ature is below freezing temperat...

Page 61: ...lization of cleaning liquids before draining Follow the instructions of the CIP equipment CIP equipment CIP model Maximum number of plates M3 M6 M6 M M10 B M10 M TS6 M CIP 20 90 89 62 40 27 56 CIP 40 178 124 81 53 110 Cleaning liquids Cleaning liquid Description AlfaCaus A strong alkaline liquid for removing paint fat oil and biological deposits AlfaPhos An acid cleaning liquid for removing metall...

Page 62: ...ger Inspect the sliding surfaces of the carrying bar and wipe clean Warning To avoid hand injuries owing to sharp edges protective gloves should always be worn when handling plates and protective sheets Warning If the heat exchanger is hot wait until it has cooled down to about 40 C 104 F 1 2 Inspect ...

Page 63: ...ross the with and 25 mm 5 turns per bolt vertically See also point 5 under part Closing Open the plate pack by letting the pressure plate glide on the carrying bar If plates are to be numbered do this before removing the plates Plates need not to be removed if cleaning is done using only water i e without clean ing agent Step Bolt No To dimension 1 1 2 3 4 1 05A 2 1 2 or 3 4 Opening 3 Mark 4 5 6 R...

Page 64: ... hose Deposits not removable with water and brush Plates must be removed from the plate heat exchanger during cleaning Brush with cleaning agent Rinse with water Caution Never use hydrochloric acid with stainless steel plates Water of more than 330 ppm Cl may not be used for the preparation of cleaning solutions It is very important that carrying bars and support columns in aluminium are protected...

Page 65: ...rowth Slime Cleaning agent Bacteria Sodium hydroxide Nematodes Sodium carbonate Protozoa Cleaning effect can be considerably increased by the addition of small quantities of hypochlorite or agents for the formation of com plexes and surfactants Cleaning agents Oil residues asphalt fats Deposit Cleaning agent Oil residues Asphalt Fats Paraffinic naphta based solvent e g kerosine Note Gaskets in EPD...

Page 66: ...nd with the gaskets turned towards the frame plate Press the plate assembly together Tight ening is done in two steps see figures be low Be careful so that the frame plate and the pressure plate are always in parallel Tighten the two diagonal pair of bolts alter nately until the plate package measures 1 10A After that bolts are tightened alternately and diagonally as shown in the figure be low 1 2...

Page 67: ...on of the PHE At this test one media side at the time must be tested with the other side open to the atmosphere The pressure testing shall be performed at a pres sure equal to the operating pressure of the actual unit but never above the design pressure as stated on the nameplate The recommended test time is 10 minutes Please note that PHE units for refrigeration applica tions and units with media...

Page 68: ...an and free of foreign matter Attach the clip on gasket to the plate Slip the gasket prongs under the edge of the plate Proceed with the next plate to be regasket ed until all plates in need of regasketing are done with Close the plate heat exchanger according to page 12 Glued gaskets Separate gluing instructions will be delivered togeth er with the glue 1 2 3 4 Note Make sure the two gasket prong...

Page 69: ...ess and hold Test button for 3 seconds Made in Canada by tekmar Control Systems Ltd tektra 900 01 Power 115 V 10 50 60 Hz 600 VA Relays 230 V ac 5 A 1 6 hp Stage Zn P1 Relays 230 V ac 5 A 1 3 hp Var Pump 230 V ac 2 4 A max FLA 5 A max LRA fuse T2 5 A 250V Demand 20 to 260 V ac 2 VA Meets Class B Canadian ICES FCC Part 15 off red red Do not apply power 1 kΩ max Output 4 20 mA device Output Variable...

Page 70: ...face The 664 uses a Liquid Crystal Display LCD as the method of supplying information You use the LCD in order to setup and monitor the operation of your system The 664 has four push buttons Menu Item for selecting and adjusting settings As you program your control record your settings in the ADJUST Menu table which is found in the second half of this brochure Menu All of the items displayed by th...

Page 71: ...m pump is operating Pointer Displays the control operation as indicated by the text Override Displays when the control is in override mode F C min hr sec Units of measurement Warning Displays when an error exists or when a limit has been reached Zone Displays when a zone is in operation Melt Demand Idle Demand WWSD Minimum Maximum Water Melting Item Field Displays an abbreviated name of the select...

Page 72: ...or a modulating 4 20 mA device The selection is made under the Mixing item in the ADJUST menu Variable Speed Injection VAR A standard wet rotor circulator is connected to the 664 on the Pwr Mix and Opn Var terminals 4 and 3 The 664 increases or decreases the power output to the circulator based on the system requirements For correct sizing and piping of the variable speed injection pump refer to E...

Page 73: ...l operate the snow melt system so that the mix supply temperature reaches the mixing target except while providing boiler return protection for the boiler MIXING MAXIMUM MIX MAX The Mix Max sets the highest fluid temperature that the control is allowed to calculate as the mixing target temperature If the control does target the Mix Max setting and the mix supply temperature is near the MIX MAX the...

Page 74: ...useful where high slab temperatures are required to melt the snow or ice A good example of this is installations using paving bricks on top of sand and concrete layers COLD WEATHER CUT OUT CWCO Maintaining the zone s at either the melting or idling temperature during extremely cold temperatures can be expensive or impossible The control turns the snow melting system off when the outdoor air temper...

Page 75: ...hat the control is allowed to use as a boiler target temperature If the boiler s is operating and the boiler supply temperature is near the Boil Min setting the Minimum pointer turns on in the LCD while the Boil SUP temperature is being viewed If the installed boiler s is designed for condensing or low temperature operation set the Boil MIN adjustment to OFF SNOW MELTING OVERRIDE If the Away setti...

Page 76: ...ss This means that the boiler s has a very small water content and has very little metal in the heat exchanger A boiler that has a low thermal mass comes up to temperature quite rapidly when fired This is typical of many copper fin tube boilers Medium MED The MED setting is selected if the boiler s that is used has a medium thermal mass This means that the boiler s either has a large water content a...

Page 77: ...setting when required If this mode of operation is selected the boiler pump should either operate continuously or be operated in parallel with the System Pump contact Sys P1 When the mixing device begins to ramp up the Stage 1 contact closes on the 664 The Stage 1 contact remains closed until the mixing device no longer requires heat With the sensor on the boiler return the 664 is still capable of...

Page 78: ...e button on the 040 while in the VIEW menu The 040 then displays the RUN TIME setting to allow the user to adjust it Once the snow melting system is enabled the word STRT is displayed for at least 5 seconds in the Status item of the appropriate zone while in the VIEW menu External Melt Demand DIP switch set to Melt Demand The snow melting system is enabled when a voltage between 24 and 240 V ac is...

Page 79: ...plays a solid red indicator light until the external demand is removed Remote Display Module 040 A Remote Display Module 040 can be used to stop the snow melting system The snow melting system is disabled by pressing the button on the 040 while in the VIEW menu Once the snow melting system is disabled the word STOP is displayed for 5 seconds in the STATUS item of the appropriate zone while in the ...

Page 80: ...tes in the Idling mode The table on page 14 describes how the control responds to enable and disable signals ZONE 1 and 2 ZONE The Zone 1 and 2 setting may be selected to AUTO or OFF When AUTO is selected the zone is activated and the control operates the appropriate zone When OFF is selected the control does not operate the zone SLAB TEMPERATURE CONTROL The 664 uses a sensor in zone 1 and zone 2 ...

Page 81: ... 1 If at any time while zone 2 is melting and the system is restarted either manually or automatically the control turns off zone 2 and begins melting zone 1 If the slab temperature of zone 2 is warm enough when the system is restarted the control provides any extra heat to zone 2 that zone 1 is not using If the slab temperature of zone 2 is not warm enough when the system is restarted the control...

Page 82: ...le allows the control to enter the idle state for a set amount of time If the snow ice detector does not detect snow during the temporary idle period the control then leaves the idle state and returns to the OFF state This is useful in applications where there is the possibility of snow and the slab can be pre heated in order to have a short heat up time if snow is detected To enable a temporary i...

Page 83: ...er time Power must not be applied to any of the wires during the rough in wiring stage All wires are to be stripped to a length of 3 8 9mm to ensure proper connection to the control Install the Outdoor Sensor 070 Boiler Sensor 082 and Mixing Sensor s 082 according to the installation instructions in the Data Brochure D 070 and run the wiring back to the control Install the Snow Ice Sensor 090 acco...

Page 84: ...e on these terminals from the control If zone 1 is used connect the zone pump or zone valve circuit to the Com Zn and Zn 1 terminals 26 and 25 If zone 2 is used connect the zone pump or zone valve circuit to the Com Zn and Zn 2 terminals 26 and 27 Variable Speed Injection Pump The 664 can vary the speed of a permanent capacitor impedance protected or equivalent pump motor that has a locked rotor c...

Page 85: ...nd Boil terminals 16 and 17 The boiler sensor is used by the 664 to measure the water temperature of the boiler Mixing Supply Sensor Connect the two wires from the Mixing Supply Sensor 082 to the Com and Mix Sup terminals 12 and 15 The mixing supply sensor is used by the 664 to measure the fluid supply temperature after the mixing device Normally the sensor is attached downstream of the mixing pump...

Page 86: ...wo wires from the slab sensor to the Slab 2 and Com terminals 11 and 12 The slab sensor is used by the 664 to measure the slab temperature of zone 2 tekmar Net tN2 Device A Remote Display Module RDM 040 or Remote Start Stop Module 039 can be connected to the tekmar Net tN2 input Connect the Com terminal from the appropriate tN2 device to the Com terminal 12 on the 664 Connect the tN2 terminal from...

Page 87: ...r to the boiler circuit is off and install a jumper between the terminals When the boiler circuit is powered up the boiler should fire If the boiler does not turn on refer to any installation or troubleshooting information supplied with the boiler The boiler may have a flow switch that prevents firing until the boiler pump is running If the boiler operates properly disconnect the power and remove the...

Page 88: ... 4 20 mA modulation increases the initial percentage output is zero and the meter should read 4 mA As the Output increases the meter reading should increase until 100 Output is reached at which point the meter should read 20 mA When the 4 20 mA modulation decreases the meter should start at 20 mA and eventually reach 4 mA when the display shows 0 Output Note The 4 20 mA output can only be tested i...

Page 89: ...he Miscellaneous Misc menu when the Lock Unlock DIP switch is set to the Unlocked position In the Advanced access level all of the control settings are available to the user In the User access level only a few of the menus and items are available The Limited access level is the most restricted of them all The control s factory setting is Installer INST This access level is sufficient for the normal...

Page 90: ...e of zone 2 ZONE 2 AUTO 58 to 167 F 50 to 75 C B1 Status 2 Operating status of zone 2 STRT STOP IDLE EXT 0 00 to 23 59 hr INF WWSD CWCO DET IDLE A Mix Target The current mix target temperature as calcu lated by the control 25 to 248 F 32 to 120 C B1 Mix Supply Current mixed supply water temperature as measured by the mixing supply sensor 31 to 266 F 35 to 130 C B1 Mix Return Current mixed return w...

Page 91: ...resent AUTO 20 to 80 Default AUTO E1 Zone 1 Selects zone 1 as operational or not OFF AUTO Default AUTO E1 Melt 1 The desired slab surface temperature of zone 1 while in the Melting mode Zone 1 AUTO 32 to 95 F 0 to 35 C Default 36 F 2 C F1 Idle 1 The desired slab surface temperature of zone 1 while in the Idling mode Zone 1 AUTO OFF 20 to 95 F OFF 7 to 35 C Default OFF E1 Zone 2 Selects zone 2 as o...

Page 92: ...lt 10 F 12 C E1 Priority Selects priority of zone 1 over zone 2 ΔT MAX OFF NONE COND FULL Default COND E1 Priority Selects priority of zone 1 over zone 2 ΔT MAX OFF COND FULL Default COND A Mix Maximum The maximum supply water temperature for the mixing system 80 to 210 F OFF 27 to 99 C OFF Default 150 F 66 C A Mixing The type of mixing device that is to be used FLOT Floating VAR Variable Speed 4 ...

Page 93: ...inutes Default 0 10 min C1 Boiler Mass The thermal mass characteristics of the boiler s that is being used Boil SENS SUP LITE MED HEVY Default MED C1 Stage 1 Selects stage 1 as operational or not Boil SENS SUP AUTO OFF Default AUTO C1 Stage 2 Selects Stage 2 as operational or not Boil SENS SUP AUTO OFF Default OFF C1 Rotate Sets the rotation time for the stages This item is used by the Equal Run T...

Page 94: ...he lowest recorded temperature at the slab sensor of zone 2 since this item was last cleared Zone 2 Auto 85 to 170 F 65 to 77 C Mix High The highest recorded temperature at the mixing supply sensor since this item was last cleared 25 to 230 F 32 to 110 C Mix Low The lowest recorded temperature at the mixing supply sensor since this item was last cleared 25 to 230 F 32 to 110 C Zone 1 Pump or Valve...

Page 95: ...w The lowest temperature recorded at the boiler sensor since this item was last cleared Boil SENS NONE 25 to 230 F 32 to 110 C No Heat This item is an adjustable warning If a zone s slab temperature does not reach its slab target temperature within the set time the control displays a warning message 1 to 24 hr OFF Default OFF Cop The number of times that the microprocessor in the control has reset...

Page 96: ...em Field Description Range Access Level L T D U S E R I N S T A D V Units The units of measure that all of the temperatures are to be displayed in by the control F C Default F Backlite The operating mode for the back lighting on the LCD as well as time of keypad inactivity until the control automatically returns to the default display OFF 30 sec ON Default ON Access The access level that is to be ...

Page 97: ... item the injection pump is ramped down over 10 seconds If 4 20 is selected in the MIXING item the 4 20 mA device is modulated down in the time set by the MOTR SPD item Step 3 If the Zone 1 item is set to AUTO the Zone 1 contact Zn 1 is turned on for 10 seconds After 10 seconds the Zone 1 contact Zn 1 is turned off Step 4 If the Zone 2 item is set to AUTO the Zone 2 contact Zn 2 is turned on for 1...

Page 98: ...troubleshooting a system Note flow directions in the system paying close attention to the location of pumps check valves pressure bypass valves and mixing valves Ensure correct flow direction on all pumps This is also a very useful step if additional assistance is required Document the control for future reference Before making any adjustments to the control note down all of the items that the con...

Page 99: ...Because of this the control was required to load the factory settings into all of the items in the MISCELLANEOUS menu The control will continue to display the error message until all of the items available in the MISCELLANEOUS menu of the control have been checked by the user or installer Note Access level must be ADV in order to clear the error An incorrect device has been connected to the tekmar...

Page 100: ...ror message from the control after the sensor has been repaired press either the Menu or Item button The control is no longer able to read the slab sensor of zone 1 due to a short circuit In this case if the control is currently in the Melting mode the control will target a fixed mixing water temperature until the melting cycle is finished Locate and repair the problem as described in the Data Broch...

Page 101: ...ng mode the control will target a fixed mixing water temperature until the melting cycle is finished Locate and repair the problem as described in the Data Brochure D 070 To clear the error message from the control after the sensor has been repaired press either the Menu or Item button The control is no longer able to read the slab sensor of zone 2 due to an open circuit In this case if the control ...

Page 102: ...34 of 36 2009 D 664 07 09 Notes ...

Page 103: ...35 of 36 2009 D 664 07 09 Notes ...

Page 104: ... VIOLATION OF ANY APPLICABLE ENVIRONMENTAL HEALTH OR SAFETY LEGISLATION THE TERM OF ANY OTHER WARRANTY NOT HEREBY CONTRACTUALLY EXCLUDED IS LIMITED SUCH THAT IT SHALL NOT EXTEND BEYOND TWENTY FOUR 24 MONTHS FROM THE PRODUCTION DATE TO THE EXTENT THAT SUCH LIMITATION IS ALLOWED BY THE GOVERNING LAW Product Warranty Return Procedure All Products that are believed to have defects in workmanship or ma...

Page 105: ...Date January 8 2015 Project Jackson Home Office Expansion Phase 3 Office Building Connector Product Snow Melt System Document Shop Drawings Notes No shop drawings available ...

Page 106: ...Date January 8 2015 Project Jackson Home Office Expansion Phase 3 Office Building Connector Product Snow Melt System Document Product Data Notes No notes ...

Page 107: ...t Gresham Smith and Partners Engineer Construction Manager The Christman Company Mechanical Contractor ATTACHMENT INCLUDES REF Tekmar 664 Control D 664 Tekmar 090 Sensor and Socket D 090 Electrical panel skid PEG 14 009S E1 SUBMITTED BY Edwards Zuck SUBMITTAL PACKAGE CONTROLS Jackson National Life Phase 3 1 Limbach Company LLC ...

Page 108: ...ing Literature D664 A664 U664 D001 D070 E021 Control Microprocessor control This is not a safety limit control Packaged weight 3 5 lb 1600 g Dimensions 6 5 8 H x 7 9 16 W x 2 13 16 D 170 x 193 x 72 mm Enclosure Blue PVC plastic NEMA type 1 Approvals CSA C US meets class B ICES FCC Part 15 Ambient conditions Indoor use only 32 to 122 F 0 to 50 C RH 90 Non condensing Power supply 115 V ac 10 50 60 H...

Page 109: ...6 Com 17 Boil 18 Out 19 Melt Idle Demand 20 21 Stage 1 22 23 Stage 2 24 25 Zn 1 26 Com Zn 27 Zn 2 28 30 Sys P1 29 Power L N Menu Test Snow Detector Melting Control 664 Two Zone Two Stage Boiler Mixing Item Start Stop Idle Demand Signal wiring must be rated at least 300 Melt Demand not testing testing testing paused For maximum heat press and hold Test button for 3 seconds Made in Canada by tekmar ...

Page 110: ... may occur near buildings hot air exhaust ducts or other heat sources or sunny areas within a larger slab area As well as reading temperatures the sensor also detects surface water The installer should be careful not to place the sensor where standing water could accumulate on its surface This may cause the snow melt system to be held on far longer than necessary as the control will be getting a s...

Page 111: ...rock or a styrofoam or wooden block can be used to elevate the socket A hole must be punched or drilled in the styrofoam or wooden block in order to provide drainage Mounting Plate 1 Drainage hole 2 Socket screw holes 3 Rebar holes 4 Rebar tie holes 5 Conduit tie holes 3 3 3 3 4 4 4 4 5 2 1 2 2 2 Failure to provide adequate drainage under the socket may reduce the life expectancy of the snow ice s...

Page 112: ...eating element This reading should be close to 50 Ohms Testing and Troubleshooting Temperature Resistance F C 49 45 472 000 40 40 337 000 31 35 243 000 22 30 177 000 13 25 130 000 4 20 97 000 Temperature Resistance F C 5 15 72 900 14 10 55 300 23 5 42 300 32 0 32 600 41 5 25 400 50 10 19 900 Temperature Resistance F C 59 15 15 700 68 20 12 500 77 25 10 000 86 30 8 060 95 35 6 530 104 40 5 330 Repl...

Page 113: ... damages whether direct indirect special secondary incidental or consequential arising from ownership or use of the product or from defects in workmanship or materials including any liability for fundamental breach of contract The pass through Limited Warranty applies only to those defective Products returned to tekmar during the warranty period This Limited Warranty does not cover the cost of the...

Page 114: ...IEWED BY DRAWN BY THAW PAK DISTRIBUTOR PROJECT NAME MICHIGAN CITY CONSULTANTS MICHIGAN AD AD 12 31 14 INCREASED FLOW AND BTU SF 02 24 15 ADDED SENSOR WELLS TO SKID 03 23 15 UPDATED CONTROLS 03 24 15 UPDATED SENSORS ON SKID LIABILITY This drawing and our recommendations and suggestions are intended to assist our customers Our design represents our best judgment based on our experience and the best ...

Page 115: ...T INCLUDES REF ViegaPEX TM Polyethylene Tubing TD PFVP 0307 Uponor Pre Insulated Pipe System Uponor Connection Vault Uponor End cap 1 1 2 Manifold Sets with 7 8 Ball Valves BAM00 15 2 Quazite Manifold Box and Cove Enerco Corporation Propylene Glycol 40 8406 40 Thaw Pak tubing layout Installation info PEG 014 009S M1 thru M 5 SUBMITTED BY Edwards Zuck SUBMITTAL PACKAGE HEAT DISTRIBUTION Jackson Nat...

Page 116: ...ViegaPEX is also certified to meet the Uniform Plumbing Code IAPMO CSA B137 5 Warnock Hersey the ICBO Evaluation Service and HUD Housing and Urban Development Recommended Uses ViegaPEX tubing is intended and recommended for use in hot and cold potable water distribution systems Design temperature and pressure ratings for ViegaPEX is 160 psi 73 F and 100 psi 180 F ViegaPEX tubing can also be used i...

Page 117: ...MR 1276 Minimum Bend Radius CORRECT 8 x O D INCORRECT PIPE FLATTENS AT THE BEND Pressure Drop Table Expressed as PSI ft Pressure Drop SIZE GPM 3 8 1 2 3 4 1 1 070 016 1 5 149 034 2 2 303 069 2 5 385 087 3 539 122 023 3 5 717 162 030 4 208 039 5 314 059 6 440 082 024 7 586 109 032 8 140 041 9 174 051 10 211 062 11 252 074 12 296 087 13 343 101 14 116 16 148 18 184 20 224 22 267 Indicates 8 fps maxi...

Page 118: ...Foam Thickness Insulation Value1 Bend Radius Weight lb ft 1 Potable HDPE with 5 5 Jacket 300 ft coil 5115513 1 660 1 368 1 54 R 7 57 14 1 0 lbs 1 Potable HDPE with 5 5 Jacket 300 ft coil 5115515 1 900 1 554 1 42 R 6 75 18 1 0 lbs 2 Potable HDPE with 5 5 Jacket 300 ft coil 5115520 2 375 1 943 1 18 R 5 36 30 1 4 lbs 3 Potable HDPE with 6 9 Jacket 300 ft coil 5116930 3 500 2 860 1 18 R 5 27 32 2 4 lb...

Page 119: ...t Number Access Cover D1 Height Overall H1 Height Top to Centerline H2 Height Top to Centerline H3 Width W1 W2 Length L1 Weight Ecoflex Connection Vault 6 outlet 1018326 30 29 19 11 52 W1 66 108 lbs Ecoflex Connection Vault 8 outlet 1018327 30 29 19 11 65 W2 66 112 lbs Installation The Connection Vault is designed for burial Position the Connection Vault in the trench to achieve proper pipe alignm...

Page 120: ... HDPE Pipe with 5 5 Jacket 5855520 140mm 5 5 3 5 1 0 lbs 5115513 5115515 5115520 End Cap 1 2 2 PEX and 3 HDPE Pipe with 6 9 Jacket 5856930 175mm 6 9 3 5 1 0 lbs 5016915 5016920 5016925 5116930 5216915 5216920 End Cap 3 3 4 PEX and 4 HDPE Pipe with 7 9 Jacket 5857940 200mm 7 9 3 5 1 0 lbs 5017930 5017935 5017940 5117940 5217930 Installation The End Cap includes an O ring and clamp device for a wate...

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Page 123: ...ations without notice Copyright 2008 Application Tiers Static Vertical Wheel Load Ratings per ANSI SCTE 77 2007 Specification for Underground Enclosure Integrity NOTE QUAZITE products are not intended for use in deliberate traffic areas Loading Requirements PG and PT style enclosure and cover assemblies up to 30 x 48 and PC style in sizes 6 x8 8 x18 11 x18 and 12 x12 with standard covers CA and st...

Page 124: ...unconscious person Enerco Corporation 317 N Bridge St Grand Ledge MI 48837 800 292 5908 517 627 8037 Section 1 Chemical Product and Company Identification Product Name Manufacturer Distributor Address Telephone Fax For chemical emergency spill leak fire exposure or accident call CHEMTREC day or night 800 424 9300 Section 2 Composition Information on Ingredients Indicates hazardous substances Remai...

Page 125: ... when not in use Do not ingest Store in a cool dry place Store below 120 F Normal shelf life 1 year Do not store with or near food supplies or potable water Section 5 Fire Fighting Measures Flash Point Flammable Limits Extinguishing Media Special Fire Fighting Procedures Unusual Fire and Explosive Hazards NFPA Hazard Codes Health Flammability Reactivity NFPA Code Legend 4 Severe Hazard 3 Serious H...

Page 126: ...life Insignificant toxic hazard to aquatic organisms and fish Best route is to use product for its originally intended purpose Dispose of in accordance with applicable environmental standards Clear Liquid Unless Dye Specified Little Or No Odor 9 0 10 0 Section 8 Exposure Controls Personal Protection Ventilation Eye Protection Skin Protection Respiratory Protection Other Protection Equipment Permis...

Page 127: ...T UN Number TSCA RCRA Hazard Class CERCLA RQ SARA Title III Extremely Hazardous Substance STATE RIGHT TO KNOW Section 313 Chemicals Hazardous Substance Hazard Catagorization The shipping name listed above applies to a 55 gallon drum of the product This product may have more than one proper shipping name depending on packaging product properties and mode of shipment No components of this product ar...

Page 128: ...NSTALLED 3 ALL PIPING FROM BOILER TO MANIFOLDS SUPPLIED BY OTHERS 4 DUE TO UNFORESEEN CONDITIONS AT TIME OF INSTALLATION RUNS MAY VARY FROM GIVEN LENGTH 5 LAY PLASTIC TUBING BEFORE CUTTING FROM ROLL 6 KEEP TUBING 6 MAX FROM SIDES DRAINS 7 NOT RESPONSIBLE FOR SYSTEM OPERATION IF NOT INSTALLED AS SHOWN ON PRINT 8 KEEP TUBING 6 AWAY FROM ALL TOILETS 9 ALL CIRCUIT LENGTHS INCLUDE A 10 ALLOWANCE FOR RI...

Page 129: ...ommendations and suggestions are intended to assist our customers Our design represents our best judgment based on our experience and the best facts provided to us any use thereof is at the sole risk of the customer It is assumed that the customer will install the THAW PAK system in compliance with all local state and national codes RADIANT HEAT SCHEDULE ZONE MANIFOLD LOCATION AREA LOOPS GPM HEAD ...

Page 130: ...dential and not disclose this drawing or copies thereof without our written consent APPROVED BY REVIEWED BY DRAWN BY THAW PAK DISTRIBUTOR PROJECT NAME MICHIGAN CITY CONSULTANTS MICHIGAN AD AD 12 31 14 INCREASED FLOW AND BTU SF 02 24 15 ADDED SENSOR WELLS TO SKID 03 23 15 UPDATED CONTROLS 03 24 15 UPDATED SENSORS ON SKID LIABILITY This drawing and our recommendations and suggestions are intended to...

Page 131: ...omer agrees to keep confidential and not disclose this drawing or copies thereof without our written consent APPROVED BY REVIEWED BY DRAWN BY THAW PAK DISTRIBUTOR PROJECT NAME MICHIGAN CITY CONSULTANTS MICHIGAN AD AD 12 31 14 INCREASED FLOW AND BTU SF 02 24 15 ADDED SENSOR WELLS TO SKID 03 23 15 UPDATED CONTROLS 03 24 15 UPDATED SENSORS ON SKID LIABILITY This drawing and our recommendations and su...

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Page 153: ...hereof is at the sole risk of the customer It is assumed that the customer will install the THAW PAK system in compliance with all local state and national codes MODEL LF25S 1 2 4 WESSELS AIR SEPERATOR WATTS TEMP PRESSURE GAUGE 1 2 LFDPTG3 3 0 200 60 320 F MODEL NO 0121662 2 HONEYWELL CONTROL VALVE W ACTUATOR WATTS PRESSURE RELIEF VALVE NEMA 12 CONTROL PANEL VALVE BODY MODEL V5011N1099 SIZE 3 4 MO...