GEOTHERMAL HYDRONIC CONTROL MODULE By TERRA-THERM, INC. Physical Dimensions: 15-11/16 H x 11-13/16 W x 6-19/32 D M2-0152 HEAT PUMP HYDRONIC CONTROL MODULE With 2-stage heat, 2-stage cooling setpoint controls ARL Certified \\Tt\common\Assemblies\Hydronic Control Module\HCM Instructions\2007.3 Hydronic Control Module Instructions
2
INTRODUCTION The Terra-Therm Geothermal Hydronic Control Module is designed as a controller for ECONAR geothermal heat pump systems with a buffer tank, either one or two heat pumps, or one heat pump with a backup boiler. It will control up to 3 zones with any combination of one or more fan coils and radiant floor zones. The 24V control wiring for the fan coils, thermostats, heat pumps and 110 V power for the fan coil or radiant floor circulating pumps all report to this module and connect to their respective terminals. For dealer convenience, all board terminals are coded the same as the components which connect to them. The Terra-Therm Geothermal Hydronic Control Module has been ARL Certified. Local and state codes for installation must be observed. INSTALLATION The hydronic control module should be installed within 8 of the buffer tank. 8-wire thermostat wire is required from the master fan coil thermostat (the master thermostat is the one that you intend to select whether the system is in cooling or heating mode) and connect to the thermostat per manufacturer s instructions. (See enclosed diagram) All other thermostats can be connected with 6-wire thermostat wire. (You may wish to use 8 Conductor wire to all thermostats in case you would decide to change which stat will be the master stat.) Run 6 conductor thermostat wire from each heat pump and each fan coil to the controller. We recommend wiring holes be installed on the left upper side of the control box behind the lid opening for all 24 V wiring and the 110 V wiring holes be installed in the right bottom area of the box. Be sure that the hole locations do not interfere with internal components or full door opening. (See diagram 1) 1. The 2 temperature sensors for the buffer tank are pre installed in the sensor well and sealed. The sensor well should be installed in the anode hole on the top of the 52 gallon buffer tank, and in the lower ¾ port on the side of the 80 & 120 gallon buffer tanks. Install the sensor leads through the panel low voltage wiring hole (field drilled see Diagram 1) and connect them to the tekmar set point control sensor terminals. Sensors are connected to terminals 7 & 8 on Tekmar 152s. Discussion: It is best to mount the controller within 8 of the buffer tank, as the tekmar leads are 10 long. If necessary, the control unit can be mounted farther than 8 from the buffer tank and the leads can be lengthened. 2. Connect the wiring from each fan coil to the respective fan coil connector on the control board observing the terminal coding on the board. If only 1 fan coil is used, it must be connected to fan coil #1 location. W should be jumpered to W2 on the fan coil terminal strip so that the all of the resistance heat comes on together on second stage (W2) call. (See diagram 2) Discussion: The function of the terminals is as follows: R and C are transformer power, G is fan call, and W2 is electric (second stage) heat call. The AP terminal is not used in standard installations. 3. Connect each fan coil thermostat to the respective connector on the control board. Remember that the thermostat that is connected to the master thermostat #1 location on the board is the one that will select if the system will operate in heating or cooling mode. If only one fan coil is being used, it must be connected to the master thermostat location. (see diagram 2) Our Terra-Therm fan coil thermostat is shown. If a different fan coil thermostat is being used, follow the thermostat manufacturer s installation instructions. 3
4. Connect each radiant floor thermostat to its respective connector using only the R and W1 terminals. Some thermostats will require the C terminal be connected as well. Be sure to set the jumpers for a radiant floor zone in step 8. 5. Connect the wiring from each heat pump to the control board observing the terminal letters. (See diagram 2) If only one heat pump is being used, it must be connected to the heat pump #1 location. ( see Diagram 3 for GW 980/1200 - Note: the Y2 terminal in the heat pump is connected to the Y terminal of the Heat Pump #2 connector) If only one heat pump is used but the second stage heat call is to be used to turn on a backup boiler, the boiler control is wired to terminals R and Y on the Heat Pump #2 connector. When using a Takagi or Seisco boiler for second stage heat, second stage cool must be disabled. (See diagram 4) Discussion: The heat pump R and X terminals are transformer power, G is hydronic pump relay, Y is compressor and O is reversing valve, which is activated in cooling mode. Terminal L is the lockout indicator. 6. Connect the 110V terminals on the lower terminal strip to the 110V, minimum 15 amp power supply. 7. Connect each 110V fan coil circulating pump to its respective terminals. (Bottom of control panel) Be certain that fan coil #1 pump is connected to pump #1 terminals and fan coil #2 pump is connected to pump #2 terminals, etc. When each fan coil thermostat calls, if it is in the same mode as the master stat (heating or cooling), the related pump will be powered up through these terminals. If the thermostat is not in the same heating or cooling mode as the master stat, the circulating pump will not operate. Discussion: If there is a call from radiant floor thermostat while the master thermostat is in the cooling mode, the heating call will be ignored. This insures that the radiant floor system is disabled when the system is in cooling mode. 8. At the top right of the circuit board, you can configure each zone to fan coil or radiant zones. Zone 1 will always be a fan coil but zones 2 and 3 can be set up to be fan coils or radiant floor zones by installing the jumpers beneath the fan coil connection as shown below. IMPORTANT: If the jumpers are set for a radiant zone (like J6 and J7 above), then there should be no wires connected to the terminals AP, C, W2, G, and R for that zone. 9. If there are radiant floor zones in this application with thermostats that do not report directly to this module, the radiant floor must be locked out when the system is in the cooling mode. The B1 terminals connect to an internal relay on the hydronic control, which opens in the cooling mode. This terminal pair can be used with 24V or 110V circuits. (See diagram 6) Discussion: The radiant floor must be locked out in the cooling mode or the floor will 4
sweat with potential mold issues. There are a number of different approaches to accomplish radiant floor lock out. If there is only one radiant zone, the 110V wire from the radiant zone control to the manifold circulating pump is interrupted and connected to the B1 terminals. If there are multiple zones, a relay is controlled by the B1 terminals so that each 110V circulating pump is interrupted when the system is in the cooling mode. OPERATION The system should now be ready to operate. Verify the heat pump loops and hydronic systems are filled and purged and ready for operation. Turn on power to the heat pumps and fan coils. Turn on the power switch on the lower left corner of the control module. Verify that the Control Module Power light is lit. There will be a warm up period for the thermostats and heat pumps of approximately 5 minutes. After that period, the heat pump(s) will begin operating in the mode selected by the master stat to begin heating or cooling the water in the buffer tank. Use the master stat to put the system in heating mode. The System Status lights should indicate that the system is in heating mode, if there is a buffer tank call to the heat pump(s) and if there are any thermostat calls. The buffer tank controls are set from the factory to the following settings: MODEL M2-0152 HYDRONIC CONTROL MODULE INITIAL SETTINGS Single Unit (GW 290 770) (GW 980-X-TOTO & 1200-X-TOTO) (2 stage heat, 2 stage cool) Set point Differential Delay Mode Heating Tekmar Prgm 1 103ºF 10ºF 10 sec. Heat (Comp1) Heating Tekmar Prgm 2 100ºF 12ºF 5 min. Heat (Comp2 980-1200) Other 2 nd Stage Cooling Tekmar Prgm 1 47ºF 6ºF 10 sec. Cool (Comp1) Cooling Tekmar Prgm 2 51ºF 10ºF 5 min. Cool (Comp2 980-1200) Alternative program for 2 single compressor units. This will balance compressor run time. (GW 290 770) (2 stage heat, 2 stage cool) Set point Differential Delay Mode Heating Tekmar Prgm1 103ºF 10ºF 10 sec. Heat (unit 1) Heating Tekmar Prgm 2 100ºF 12ºF 5 min. Heat (unit 2) Cooling Tekmar Prgm 1 51ºF 10ºF 5 min. Cool (unit 1) Cooling Tekmar Prgm 2 47ºF 6ºF 10 sec. Cool (unit 2) 5
The cooling setting for the Alternate Program are not programmed from the factory and will need to be changed for proper operation. Observe and verify the operation of the system. The heat pump(s) should shut off once the buffer tank settings have been achieved in heating or cooling modes. The fan coil(s) and circulating pump(s) should also shut off once their respective thermostat calls are satisfied. Each thermostat should operate only in the mode selected by the master stat; That is, if the master stat is in heat mode, and thermostat #2 is in the cooling mode, fan coil #2 fan will still operate but its circulating pump will not operate. Switch the master stat to the opposite mode (from heating to cooling) and verify the heat pump operation and buffer tank settings. Verify that the fan coils and pumps operate according to their thermostat calls and that the radiant floor system (if equipped) locks out in cooling mode. WARRANTY This unit is warranted against manufacturing defects for a period of 2 years from the date of purchase. In the event of a component failure, Terra Therm will, at our discretion, provide a replacement unit or repair components to the dealer for installation. At our request, the defective parts must be returned to Terra Therm to receive credit. This warranty covers parts only. Damage resulting from abuse, water damage or faulty installation is specifically excluded. Terra Therm s maximum liability shall be limited to the replacement cost of the unit. Manufactured exclusively for Terra Therm, Inc. By Electro Industries, Inc www.terratherm.info 507-463-3213 Version 2007.1 Hydronic Control Module Instructions Common Assemblies / 2-2007 6
CONTROL PANEL WIRING POINTS DIAGRAM 1 7
8
9
10
11
12