Aegis Pavilion Control 410 User manual

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© 2006
D 410 - 01/06
- Data Brochure
Boiler Control 410
D 410
01/06
The Pavilion Control 410 can control the supply water temperature from a single modulating boiler based on outdoor temperature or
domestic hot water requirements. A large easy to read display provides current system temperatures and operating status.
Additional functions include:
•
• Outdoor Reset
•
• Primary pump output
•
• Pump exercising
•
• Pump purging
•
• Boiler demand for space heating loads
•
• DHW demand for domestic hot water loads
•
• Test sequence to ensure proper component operation
•
• Setback input for energy savings
•
• CSA C US certified
Input
Boiler
Sensor
Included
Input
Boiler
Demand
Input
DHW
Demand
Output
Boiler Pump
Input
115 V (ac)
Power Supply
Output
Primary
Pump
Input
Timer
Output
DHW Pump or
DHW Valve
OR
M
1
Boil
Dem
2
Com
Dem
3
DHW
Dem
Prim
P1
4 5
NL
6
Power
7 8 9 10 11
+
12
-
13 14 15 16
Com Boil Out UnO
Sw
Boiler Control 410
Outdoor Reset & DHW
Mod V (dc)
Boil
P2
DHW
Pmp/Vlv
HXXXXA
Menu Item
Boiler Demand
DHW Demand
Modulation
DHW Priority Override Test
off not testing
red testing
red testing paused
Made in Canada by
tekmar Control Systems Ltd.
tektra 969-02K
Power 115 V ±10% 50/60 Hz 600 VA
Relays 230 V (ac) 5 A 1/3 hp, pilot duty 240 VA
Demands 20 to 260 V (ac) 2 VA
Signal wiring must be rated at least 300 V.
For maximum heat
press & hold Test
button for 3 seconds.
Meets Class B:
Canadian ICES
FCC Part 15
Date Code
Advanced
Exercise
Off
Installer
Do not apply power
Input
Outdoor
Sensor
Included
Output
Boiler

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© 2006 D 410 - 01/06
How To Use The Data Brochure
Control Settings..............................................Pg 17
View Menu.....................................................Pg 17
Adjust Menu..................................................Pg 17
Testing the Control.........................................Pg 19
Error Messages...............................................Pg 20
10K Sensors ....................................................Pg 21
Outdoor Sensor 00228................................Pg 21
Boiler Sensor 00229....................................Pg 22
Sensor Testing Instructions..........................Pg 23
Technical Data ................................................Pg 24
User Interface..................................................Pg 2
Display .............................................................Pg 3
Sequence of Operation ..................................Pg 4
Section A: General Operation ....................Pg 4
Section B: Boiler Operation........................Pg 5
Section C: Pump Operation ........................Pg 6
Section D: Outdoor Reset Operation.........Pg 7
Section E: Domestic Hot Water Operation ...Pg 8
Installation.......................................................Pg 10
DIP Switch Settings........................................Pg 16
This brochure is organized into four main sections. They are: 1) Sequence of Operation, 2) Installation, 3) Control Settings, and 4)
Testing and Troubleshooting. The Sequence of Operation section has five sub-sections. We recommend reading Section A: General
of the Sequence of Operation, as this contains important information on the overall operation of the control. Then read the sub
sections that apply to your installation.
The Control Settings section (starting at DIP Switch Settings) of this brochure describes the various items that are adjusted and
displayed by the control. The control functions of each adjustable item are described in the Sequence of Operation.
The control 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 control 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 the control are organized into two menus (View, Adjust).
These menus are listed on the top left hand side of the display (Menu Field). To select
a menu, use the Menu button. By pressing and releasing the Menu button, the display
sequences between the four menus. Once a menu is selected, there will be a group of
items that can be viewed within the menu.
Item
The abbreviated name of the selected item will be displayed in the item field of the
display. To view the next available item, press and release the Item button. Once you
have reached the last available item in a menu, pressing and releasing the Item button
will return the display to the first item in the selected menu.
The items can be quickly scrolled through by holding the Item button and then press-
ing the button. To rapidly scroll through the items in the reverse order, hold the Item
button and press the button.
Adjust
To make an adjustment to a setting in the control, begin by selecting the ADJUST menu
using the Menu button. Then select the desired item using the Item button. Finally, use
the , and / or button to make the adjustment.
Additional information can be gained by observing the Status field of the LCD. The status
field will indicate which of the control’s outputs are currently active. Most symbols in the
status field are only visible when the VIEW menu is selected.
Menu Item
Menu Item
Menu Item
Table of Contents
User Interface

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D 410 - 01/06
Symbol Description
Burner
Displays when the ignition
sequence is initiated.
Warning
Displays when an error exists or
when a limit has been reached.
Pump
Displays when the primary
or boiler pump is operating.
°F, °C, min, hr, %
Units of measurement.
DHW
Displays when the DHW
pump is on.
Pointer
Displays the control operation
as indicated by the text.
Occupied
Displays when the control is
in occupied mode.
Modulating Output Scale
Displays the total modulation
output level of the boiler.
UnOccupied
Displays when the control is
in Unoccupied mode.
Boiler Demand
DHW Demand
Modulation
DHW Priority Override
Menu Field
Displays the
current menu
Item Field
Displays an
abbreviated
name of the
selected item
Status Field
Displays the
current status
of the control's
inputs, outputs
and operation
Number Field
Displays the current value
of the selected item
Buttons
Selects Menus, Items
and adjust settings
Display

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POWERING UP THE CONTROL
When the control is powered up, all segments in the LCD are turned on for 2 seconds. Next, the software version is displayed for 2
seconds. Finally, the control enters into the normal operating mode.
OPERATION
The control modulates the boiler to control the supply water temperature to a hydronic system. The supply water temperature is
based on outdoor reset or a fixed temperature for DHW.
Outdoor Reset
When a boiler demand signal from the heating system is present, the control operates the boiler to maintain the supply temperature
based on the outdoor air temperature and the Reset Ratio settings. Refer to section D.
DHW
When a DHW demand is present, the control operates the boiler to maintain the supply water temperature at least as hot as the
DHW exchange setting. Refer to section E.
SETBACK (Occ and UnOcc)
To provide greater energy savings, the control has a setback feature. With setback, the
supply water temperature in the system is reduced when the building is unoccupied. By
reducing the supply water temperature, the air temperature in the space may be reduced
even when thermostat(s) are not turned down. Any time the UnO Sw (14) and the Com (13)
are shorted together, the control operates in the unoccupied mode. When in the unoccupied
mode, the UNOCC segment is displayed in the LCD. The control adjusts the supply water
temperature based on the UNOCC settings made in the control.
EXERCISING
The control has a built-in exercising feature that is selected through the Exercise / Off DIP switch. To enable the exercising feature
set the Exercise / Off DIP switch to Exercise. If exercising is enabled, the control ensures that each pump is operated at least
once every 3 days. If a pump has not been operated at least once every 3 days, the control turns on the output for 10 seconds.
This minimizes the possibility of the pump seizing during a long period of inactivity. While the control is exercising, the Test LED
flashes quickly.
Note: The exercising function does not work if power to the control or pumps is disconnected.
RUNNING TIMES
The control displays the accumulated running time of the boiler in the VIEW menu.
Resetting the Running Times
To reset the running time for the boiler, select the running time in the VIEW menu. Next, press the and buttons simultaneously
until CLR is displayed.
FACTORY DEFAULTS
The control comes preset with several factory defaults. To fine-tune building requirements, these defaults may be changed.
To reload the factory default, power down the control and wait for 10 seconds. Power up the control while simultaneously
holding the Menu and buttons. An E01 error occurs forcing the installer to go through the ADJUST menu to ensure the
settings are correct.
Section A: General Operation

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BOILER TARGET TEMPERATURE
The boiler target temperature is determined by the type of demand received by the control. A boiler demand calculates a boiler
target based on the reset ratio settings and the outdoor air temperature. A DHW demand uses a fixed setpoint temperature as the
boiler target temperature.
The control displays the temperature that it is currently trying to maintain as the boiler supply temperature. If the control does not
presently have a requirement for heat, it does not show a boiler target temperature. Instead, “– – –” is displayed in the LCD.
BOILER MINIMUM
The boiler minimum is the lowest temperature that the control is
allowed to use as a boiler target temperature. During mild conditions,
if the control calculates a boiler target temperature that is below the
Boiler Minimum setting, the boiler target temperature is adjusted to at least
the Boiler Minimum setting. During this condition, if the boiler is operating,
the minimum segment is turned on in the display when viewing either the
boiler supply temperature or the boiler target temperature. Set the Boiler
Minimum setting to the boiler manufacturer’s recommended temperature.
BOILER MAXIMUM
The boiler maximum is the highest temperature that the control is
allowed to use as a boiler target temperature. If the control does target
the Boiler Maximum setting, and the boiler temperature is near the boiler
maximum temperature, the maximum segment will be displayed in the
LCD while either the boiler target temperature or the boiler temperature
is being viewed. At no time does the control operate the boiler above
248°F (120°C).
MODULATION
The control provides a 0 - 5 V (dc) output signal to the P125 burner module to control burner modulation. The P125, in turn, drives the
fan at a speed (RPM) which is proportional to the control’s modulating output signal. The control displays the current percentage
modulation using the BOIL Modulation item in the VIEW menu.
When boiler operation is required, the control first provides the minimum modulation percentage required to initiate the burner’s
ignition sequence. The burner is then modulated from the minimum modulation percentage using Proportional, Integral and
Derivative (PID) logic in order to satisfy the boiler target temperature. The control will always modulate the burner down to the
minimum modulation percentage prior to turning off the boiler. In the event the burner is operating above the low fire position and
the demands are removed, the control will also modulate the burner down to the minimum modulation percentage prior to turning
off the boiler.
Proportional compares the actual supply temperature to the boiler target temperature.
Integral compares the actual supply temperature to the boiler target temperature over a period of time.
Derivative compares how fast or slow the supply water temperature is changing.
DIFFERENTIAL
A modulating boiler must be operated with a differential while operating in low fire. The boiler differential is divided around the boiler
target temperature. The boiler burner ignites at low fire when the supply water temperature is 1/2 of the Boiler Differential setting
below the boiler target temperature. The boiler is shut off in low fire as the supply temperature reaches at least 1/2 of the differential
above the boiler target temperature. With the control, either a fixed or an auto differential may be selected.
When the boiler is modulating above low fire, the differential does not apply. Instead, the modulation output signal is determined
using Proportional, Integral and Derivative (PID) logic in order to satisfy the boiler target temperature.
MIN Segment On
MAX Segment
On
MAX Segment
On
Section B: Boiler Operation

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Fixed Differential
If the user desires to have a fixed differential, this is set using the
Boiler Differential setting in the ADJUST menu.
Auto Differential
If the Auto Differential is selected, the control automatically determines
the best differential as the load changes. This reduces potential short
cycling during light load conditions.
PRIMARY PUMP OPERATION
The primary pump operates under the following conditions:
•
• A boiler demand is present and the control is not in Warm Weather Shut Down (WWSD).
•
• A DHW demand is present and DHW MODE is set to 3 or 4.
Primary Pump Purge
After the demands are removed, the control continues to operate the primary pump for a period of time. The maximum
length of time that the primary pump continues to run is adjustable using the Primary Pump Purge setting. The primary pump
continues to run until either the purging time has elapsed or the boiler supply temperature drops more than a differential below
the Boiler Minimum setting.
Primary
Pump
Primary
Pump
Boiler
Pump
Boiler
Pump
or
Boiler
Pump
Primary
Pump
BOILER PUMP OPERATION
The control can operate the boiler pump on the boiler in addition to the primary pump. The boiler pump turns on 5 seconds prior to
the boiler firing (pre-purge) and continues to run after the boiler is turned off (post-purge).
Boiler Pump Purge
The amount of time that the boiler pump continues to run after the boiler turns off is adjustable using the Boiler Pump Purge setting.
Primary
Pump Boiler
Pump
Primary
Pump Boiler
Pump
Primary
Pump Boiler
Pump
T
e
m
p
e
r
a
t
u
r
e
f
a
l
l
T
e
m
p
e
r
a
t
u
r
e
r
i
s
e
Time
Desired temperature
160°F (71°C) Differential
10°F (6°C)
Boiler Off
Boiler On
155°F (68°C)
165°F (74°C)
Increasing Load
Time
Differential On
Off
Section C: Pump Operation

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BOILER DEMAND
A boiler demand is required in order for the control to provide heat to the heating system.
A boiler demand is generated by applying a voltage between 24 and 230 V (ac) across the
Boil Dem and Com Dem terminals (1 and 2). Once voltage is applied, the Boiler Demand
pointer is displayed in the LCD. If the control is not in Warm Weather Shut Down (WWSD),
the control closes the primary pump contact. The control calculates a boiler target supply
temperature based on the outdoor air temperature and the reset ratio settings. The control
then modulates the burner firing rate, if required, to maintain the target supply temperature.
RESET RATIO
The reset ratio establishes the relationship between the outdoor
air temperature and the supply water temperature. The reset ratio
determines the amount the supply water temperature is raised for every
1 degree outdoor temperature drop. The control automatically calculates
the reset ratio based on the outdoor design temperature, boiler design
temperature and the boiler indoor design temperature.
OUTDOOR DESIGN TEMPERATURE (OUT DSGN)
The outdoor design temperature is the outdoor air temperature that is
the typical coldest temperature of the year where the building is located.
This temperature is used when doing the heat loss calculations for the
building. If a cold outdoor design temperature is selected, the boiler
supply temperature rises gradually as the outdoor temperature drops.
If a warm outdoor design temperature is selected, the boiler supply
temperature rises rapidly as the outdoor temperature drops.
BOILER DESIGN TEMPERATURE (BOIL DSGN)
The boiler design supply temperature is the supply water temperature
required to heat the building when the outdoor air temperature is as cold
as the outdoor design temperature.
BOILER INDOOR DESIGN TEMPERATURE (BOIL INDR)
The indoor design temperature is the room temperature that was used in the original heat loss calculations for the building. This
setting establishes the beginning of the reset ratio.
ROOM (OCC / UNOCC)
The Room setting is the desired room temperature for the building and provides a parallel shift of the reset ratio. The room
temperature desired by the occupants is often different from the design indoor temperature. If the room temperature is not correct,
adjusting the Room setting increases or decreases the amount of heat available to the building. A Room setting is available for both
the occupied (day) and unoccupied (night) periods.
WARM WEATHER SHUT DOWN (OCC AND UNOCC)
The warm weather shut down (WWSD) disables the space heating system during warm outdoor weather. There is a separate
WWSD for both the occupied and the unoccupied periods. When the outdoor air temperature rises above the WWSD setting, the
control turns on the WWSD pointer in the display. When the control is in WWSD, the Boiler Demand pointer is displayed if there is
a boiler demand. However, the control does not operate the heating system to satisfy this demand. The control does respond to a
DHW demand and operates as described in section E.
12
Boil
Dem
Com
Dem
24 to 230 V (ac)
N
L
50°F
(10°C)
210
(99)
190
(88)
170
(77)
150
(66)
130
(54)
110
(43)
90
(32)
70
(2)
-20
(-29)
0
(-18)
20
(-7)
40
(5)
60
(16)
80
(27)
Outdoor Air Temperature
Supply Water Temperature
BOIL MAX
BOIL MAX
BOIL MAXBOIL DSGN
BOIL DSGN
BOIL DSGN
OUT DSGN
OUT DSGN
OUT DSGN
ROOM UNOCC
ROOM UNOCC
ROOM UNOCC
Reset RatioReset Ratio
Reset Ratio
Reset RatioReset Ratio
BOIL MIN
BOIL MIN
BOIL MIN
ROOM OCC
ROOM OCC
ROOM OCC
BOIL INDR
BOIL INDR
BOIL INDR
WWSD OCC
WWSD OCC
WWSD OCC
WWSD UNOCC
WWSD UNOCC
WWSD UNOCC
Section D: Outdoor Reset Operation

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DHW DEMAND
A DHW Demand is required in order for the control to provide heat to the DHW system. A
DHW aquastat or setpoint control is used as a switch in the DHW demand circuit. Once
the control detects a DHW demand, the DHW Demand pointer turns on in the LCD and the
control operates the boiler to provide a sufficient boiler supply water temperature to the
DHW tank. The control operates the pumps as described below.
The control registers a DHW Demand when a voltage between 24 and 230 V (ac) is applied
across the Com Dem and DHW Dem terminals (2 and 3).
BOILER TARGET DURING DHW GENERATION
The boiler target (BOIL TARG) temperature during DHW operation is at least as hot as the DHW heat exchange setting (DHW XCHG).
The DHW demand overrides the reset water temperature, except when the reset water temperature requirement is higher than that
of the DHW tank.
DHW MODE AND PRIORITY OPERATION
The control has four different modes of DHW operation, which depends on the piping arrangement of the DHW tank. It is often
desirable to limit or even stop the flow of heat to the heating system when the DHW tank calls for heat. This allows for a faster
recovery of the DHW tank.
23
Com
Dem
DHW
Dem
24 to 230 V (ac)
L
N
DHW
Pump
Primary
Pump Boiler
Pump
DHW
Pump
Primary
Pump Boiler
Pump
DHW
Pump
Primary
Pump Boiler
Pump
Section E: Domestic Hot Water Operation
DHW Mode 1 - DHW in Parallel no Priority
When a DHW Demand is present, the DHW Pmp / Vlv contact
terminals (7 and 8) closes. The primary pump contact does not turn
on, but may operate based on a boiler demand.
DHW Mode 2 - DHW in Parallel with Priority
When a DHW Demand is present, the DHW Pmp / Vlv contact
terminals (7 and 8) closes and the primary pump contact is opened.
DHW Mode 3 - DHW in Primary / Secondary no Priority
When a DHW Demand is present, the DHW Pmp/ Vlv contact
terminals (7 and 8) is closed and the primary pump contact is closed.
This mode can be used if a DHW tank is piped in direct return and
a DHW valve is installed.
MODE 1
MODE 2
MODE 3

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DHW Mode 4 - DHW in Primary / Secondary with Priority
When a DHW Demand is present, the DHW Pmp / Vlv contact terminals (7 and 8) is closed and the primary pump contact is
closed. Priority can only be obtained using external wiring. During a priority override, the DHW Pmp / Vlv contact is opened until
the heating system has recovered before returning to DHW operation.
This mode can be used if a DHW tank is piped in direct return and a DHW valve is installed.
DHW MODE 4
External Priorit
y
Interlock
Power to External
Boiler Zones
N.C.
L
DHW
Pump
N
N.O.
L
N
COIL
Power from
DHW Pump / Vlv
Contact
DHW PRIORITY OVERRIDE
The DHW Priority Override applies when DHW MODE is set to 2 or 4.
To prevent the building from cooling off too much or the possibility of a
potential freeze up during DHW priority, the control limits the amount of
time for DHW priority. As the outdoor air temperature becomes colder,
the length of time that the control provides DHW priority is reduced.
Once the allowed time for priority has elapsed, the control overrides the
DHW priority and resumes space heating.
To provide external DHW priority, the space heating zones must be
interlocked with the DHW Pmp / Vlv contact. During demands, the
DHW Pmp / Vlv contact must remove any power to all space heating
zone valves or zone pumps.
CONDITIONAL DHW PRIORITY
The Conditional DHW Priority Override applies when DHW MODE is set to 2 and BOIL MIN is not set to OFF. If the boiler supply
temperature is maintained at or above the required temperature during DHW generation, this indicates that the boiler has enough
capacity for DHW and possibly heating as well. As long as the boiler supply temperature is maintained near its target, DHW and
heating occurs simultaneously.
DHW POST PURGE
After the DHW Demand is removed, the control performs a purge on the boiler. The control shuts off the boiler and continues
to operate either the DHW pump or the DHW valve and the system and boiler pump if applicable. This purges the residual heat
from the boiler into the DHW tank. The control continues this purge for a maximum of four minutes or until the boiler supply water
temperature drops 20°F (11°C) below the boiler target temperature during the DHW operation. The control also stops the purge if
the boiler supply temperature drops below the current boiler target temperature.
DHW MIXING PURGE
After DHW operation, the boiler is extremely hot. At the same time,
the heating zones may have cooled off considerably after being off for
a period of time. To avoid thermally shocking the boiler after DHW in
parallel with priority (DHW MODE 2), the control shuts off the boiler, but
continues to operate the DHW pump while restarting the heating system.
This allows some of the DHW return water to mix with the cool return
water from the zones and temper the boiler return water.
DHW DURING UNOCCUPIED
The control can either continue operation of the DHW system as it would during the occupied period or the control can ignore a call
for DHW as long as the control is in the unoccupied mode. For this function to operate, the control must have the Setback / None
DIP switch set to Setback.
DHW
Pump
Primary
Pump Boiler
Pump
Disable
Using External
Wiring
Increasing Air Temperature
Increasing Time
DHW priority demand time limit
Outdoor Air Temperature
DHW Priority OverrideDHW Priority Override
DHW
Pump
Primary
Pump Boiler
Pump
MODE 4

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DHW WITH LOW TEMPERATURE BOILERS
If DHW is to be incorporated into a low temperature system such as a
radiant heating system, a mixing device is often installed to isolate the
high DHW supply temperature from the lower system temperature. If a
mixing device is not installed, high temperature water could be supplied
to the low temperature system while trying to satisfy the DHW demand.
This may result in damage to the low temperature heating system. The
control is capable of providing DHW in such a system while maximizing
the chance that the temperature in the heating system does not exceed
its allowed Boiler Maximum setting.
To prevent high temperature water from being introduced into the
heating system, flow to the space heating system must stop during a
call for DHW. To do this, the control must be set to DHW MODE 2 or
DHW MODE 4and BOIL MIN must be set to OFF.
DHW Mode 2 Operation
On a call for DHW, the control provides DHW priority by shutting off the primary pump (Prim P1) for a period of time. This time
is based on the outdoor air temperature as described in the DHW Priority Override section. However, if the DHW Demand is not
satisfied within the allotted time, the boiler shuts off and the heat of the boiler is purged into the DHW tank.
Once the boiler supply temperature is sufficiently reduced, the DHW Pmp / Vlv contact shuts off. The heating system is turned on
for a period of time to prevent the building from cooling off. After a period of heating, and if the DHW Demand is still present, the
control shuts off the heating system and provides heat to the DHW tank once again.
For correct operation, close attention must be paid to the mechanical layout of the system. When the control turns off the primary
pump (Prim P1), flow to the heating system must stop. If flow is not stopped, the temperature in the heating system can exceed
the maximum desired temperature and can result in damage to the heating system.
DHW Mode 4 Operation
In DHW MODE 4, the space heating zones must be prevented from coming on during DHW demands using external wiring. This
can be done using an external relay to remove power from zone pumps or zone valves while a DHW Demand is present. This
external relay is interlocked with the DHW Pmp / Vlv contact.
During a DHW Demand, the control closes the primary pump (Prim P1) contact and the DHW Pmp / Vlv contact. Once the DHW
Demand is removed, or during a DHW priority override, the DHW Pmp / Vlv contact is opened, and the external wiring should
allow the space heating zones to operate.
There is no mixing purge available in DHW MODE 4. After DHW priority, the boiler supply water temperature may exceed the
design water temperature of the space heating system and can result in damage to the heating system.
DHW
Pump
Primary
Pump Boiler
Pump
Installation
CAUTION
Improper installation and operation of this control could result in damage to the equipment and possibly even personal injury. It is
your responsibility to ensure that this control is safely installed according to all applicable codes and standards. This electronic
control is not intended for uses as a primary limit control. Other controls that are intended and certified as safety limits must be
placed into the control circuit. Do not open the control. Refer to qualified personnel for servicing. Opening voids warranty and could
result in damage to the equipment and possibly even personal injury.
STEP ONE GETTING READY
Check the contents of this package. If any of the contents listed are missing or damaged, please contact your wholesaler or tekmar
sales representative for assistance.
Type 410 includes: One Pavilion Control 410 (00263), One Outdoor Sensor 00228, One Boiler Sensor 00229, Data Brochure D410.
Note: Carefully read the details of the Sequence of Operation to ensure that you have chosen the proper control for your application.

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The control can be mounted
on a standard DIN rail. First
remove the control from its
base and then, using the hooks
and spring clip on the back of
the control, mount it onto the
DIN rail. This will be a popular
option for those who prefer to
mount the control inside a larger
electrical panel.
The wiring can enter the
bottom or the back of the
enclosure. Knock-outs pro-
vided in the base allow the
wiring to be run in conduit
up to the enclosure. The
base also has holes that
line up with the mounting
holes of most common
electrical boxes.
Press down at the fingertip grips
on top of the front cover and pull
out and down.
Lift the front cover up and away
from the control.
Loosen the screws at the front
of the wiring cover.
The wiring cover pulls straight out
from the wiring chamber.
The base is ready for mounting.The control lifts up and away
from the base.
Press the control release clip
on the base inside the wiring
chamber and slide the control
upwards.
Remove the safety dividers
from the wiring chamber by
pulling them straight out of their
grooves.
There are 10 conduit knock-outs at the back
and bottom of the wiring chamber.
13 Mounting holes
Control
release
clip
Control release clip
STEP TWO MOUNTING THE BASE
STEP THREE ROUGH-IN WIRING
All electrical wiring terminates in the control base wiring chamber. The base has standard 7/8 ” (22 mm) knockouts, which accept
common wiring hardware and conduit fittings. Before removing the knockouts, check the wiring diagram and select those sections
of the chamber with common voltages. Do not allow the wiring to cross between sections, as the wires will interfere with safety
dividers which should be installed at a later 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” (9 mm) to ensure proper connection to the control.
•
• Install the Outdoor Sensor 00228 according to the installation instructions in this brochure and run the wiring back to the control.
•
• Install the Boiler Sensor 00229 according to the installation instructions in this brochure and run the wiring back to the control.
•
• Run wire from other system components (pumps, boilers, etc.) to the control.
•
• Run wires from the 115 V (ac) power to the control. Use a clean power source with a 15 A circuit to ensure proper operation.
Multi-strand 16 AWG wire is recommended for all 115 V (ac) wiring due to its superior flexibility and ease of installation into
the terminals.

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5
6
115 V (ac)
L
N
Power
LN
1
3
2
54
78
910
11 13
12 14
15
16
6
24 VAC TO 230 VAC
SUPPLY
120 VAC SUPPLY
PRIMARY
CIRCULATOR
PAVILION
410 BOILER
CONTROL
DHW
CIRCULATOR
BOILER
CIRCULATOR
UNOCCUPIED
SWITCH
SUPPLY
SENSOR
P125 CONTROL BOARD
LT BLUE
10 PIN WIRING BLOCK
20 PIN WIRING BLOCK
L
N
R or L
C or N
PINK
x8 x4
OUTDOOR
SENSOR
ROOM
T’STAT
DHW
TEMP SW
BOIL
DEM
DHW
DEM
LP1
DHW PUMP/
VALVE
BOIL
MOD
(+)
MOD
(-)
P2
BOIL
OUT
N
COM
DEM
STEP FOUR ELECTRICAL CONNECTIONS TO THE CONTROL
General
The installer should test to confirm that no voltage is present at any of the wires. Push the control into the base and slide it down
until it snaps firmly into place.
Powered Input Connections
115 V (ac) Power
Connect the 115 V (ac) power supply to the Power L and Power N terminals (5 and 6).
This connection provides power to the microprocessor and display of the control.
As well, this connection provides power to the Prim P1 terminal (4) from the Power L
terminal (5).
Note: Refer to the Pinnacle boiler manual for control board parameter changes.

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12
Boil
Dem
Com
Dem
24 to 230 V (ac)
N
L
23
Com
Dem
DHW
Dem
24 to 230 V (ac)
L
N
L
115 V (dc)
N
Prim
P1
Power
L
6
N
45
78
M
24 to 230 V (ac)
DHW
Pmp/Vlv
or
N
L
Boiler Demand
To generate a Boiler Demand, a voltage between 24V (ac) and 230 V (ac) must be
applied across the Boil Dem and Com Dem terminals (1 and 2).
DHW Demand
To generate a DHW Demand, a voltage between 24V (ac) and 230 V (ac) must be
applied across the Com Dem and DHW Dem terminals (2 and 3).
Caution: The same power supply must be used to power both the DHW Demand and
the Boiler Demand circuits since they both share the Com Dem terminal.
Output Connections
Primary Pump Contact (Prim P1)
The Prim P1 output terminal (4) is a powered output. When the relay in the control
closes, 115V (ac) is provided to the Prim P1 terminal (4) from the Power L terminal (5).
To operate the primary pump, connect one side of the primary pump circuit to
terminal (4) and the second side of the pump circuit to the neutral (Power N) side of
the 115 V (ac) power supply.
DHW Pmp / Vlv Contact
The DHW Pmp / Vlv terminals (7 and 8) are an isolated output. There is no power
available on these terminals from the control. These terminals are to be used as a
switch to either make or break power to the DHW pump or the DHW valve. Since this
is an isolated contact, it may switch a voltage between 24V (ac) and 230 V (ac).
Boiler Pump Contact (Boil P2)
The Boil P2 terminals (9 and 10) are isolated output in the control. There is no power
available on these terminals from the control. These terminals are to be used as
a switch to either make or break power to a boiler pump. Since this is an isolated
contact, it may switch a voltage between 24V(ac) and 230 V(ac).
Modulation Output
The Modulation Output Mod V (dc) terminals (11 and 12) provide a 0 - 5 V (dc) output to
the P125 burner control board in the boiler.
10
9
115 V (ac)
L
N
P2
Boil
Pink Lt Blue
P125 CONTROL BOARD
10 PIN WIRING BLOCK
20 PIN WIRING BLOCK
x8 x4
11
+
12
–
Mod V (dc)
Note: Refer to the Pinnacle boiler manual for control board parameter changes.

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14
UnO
Sw
15
Boil
16
Out
13
Com
13
Com
14
UnO
Sw
15
Boil
13
Com
14
UnO
Sw
Timer Switch
14
UnO
Sw
15
Boil
13
Com
6
Power
5
V
103.5 to 126.5 V (ac)
N
L
Sensor and Unpowered Input Connections
Do not apply power to these terminals as this will damage the control.
Outdoor Sensor 00228
Connect the two wires from the Outdoor Sensor to the Com and Out terminals (13 and
16). The outdoor sensor is used by the control to measure the outdoor air temperature.
Boiler Sensor 00229
Connect the two wires from the Boiler Sensor to the Com and Boil terminals
(13 and 15). The boiler sensor is used by the control to measure the boiler supply
water temperature.
UnOccupied Switch
If an external timer or switch is used, connect the two wires from the external switch
to the Com and UnO Sw terminals (13 and 14). When these two terminals are shorted
together, the control registers an unoccupied (UNOCC) signal.
STEP FIVE TESTING THE WIRING
General
Each terminal block must be unplugged from its header on the control before power is applied for testing. To remove the terminal
block, pull straight down from the control.
The following tests are to be performed using standard testing practices and procedures and should only be carried out by
properly trained and experienced persons.
A good quality electrical test meter, capable of reading from at least 0 to 300 V (ac) and at least 0 to 2,000,000 , is essential to
properly test the wiring and sensors.
Test The Sensors
In order to test the sensors, the actual temperature at each sensor
location must be measured. A good quality digital thermometer with
a surface temperature probe is recommended for ease of use and
accuracy. Where a digital thermometer is not available, a spare
sensor can be strapped alongside the one to be tested and the
readings compared. Test the sensors according to the instructions in
this brochure.
Test The Power Supply
Make sure exposed wires and bare terminals are not in contact with
other wires or grounded surfaces. Turn on the power and measure
the voltage between the Power L and Power N terminals (5 and 6)
using an AC voltmeter, the reading should be between 103.5 and
126.5 V(ac).

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20 to 260 V (ac)
2
1
Boil
Dem Com
Dem
20 to 260 V (ac)
3
2
Com
Dem
DHW
Dem
66
Power
NL
Prim
P1
4
5
L
N
115 V (ac)
10
9
Boil
P2
L
N
115 V (ac)
Test the Powered Inputs
Boiler Demand
If a boiler demand is used, measure the voltage between the
Boil Dem and Com Dem terminals (1 and 2). When the boiler
demand device calls for heat, between 20 and 260 V(ac) should be
measured at the terminals. When the boiler demand device is off,
less than 5 V(ac) should be measured.
DHW Demand
If a DHW demand is used, measure the voltage between the
Com Dem and DHW Dem terminals (2 and 3). When the DHW
demand device calls for heat, between 20 and 260 V(ac) should be
measured at the terminals. When the DHW demand device is off,
less than 5 V(ac) should be measured.
L
N
8
7
DHW
Pmp/Vlv
24 to 230 V (ac)
M
or
Test The Outputs
Primary Pump (Prim P1)
If a primary pump is connected to the Prim P1 terminal(4), make sure that
power to the terminal block is off and install a jumper between the Power L
and Prim P1 terminals (5 and 4). When power is applied to the Power L and
Power N terminals (5 and 6), the primary pump should start. If the pump does not turn
on, check the wiring between the terminal block and pump and refer to any installation
or troubleshooting information supplied with the pump. If the pump operates properly,
disconnect the power and remove the jumper.
Boiler Pump (Boil P2)
If a boiler pump is connected to the Boil P2 terminals (9 and 10), make sure that
power to the terminal block is off and install a jumper between the terminals. When
power is applied to circuit, the boiler pump should start. If the pump does not turn on,
check the wiring between the terminal block and pump and refer to any installation or
troubleshooting information supplied with the pump. If the pump operates properly,
disconnect the power and remove the jumper.
DHW Pump Or Valve (DHW Pmp / Vlv)
If a DHW pump or DHW valve is connected to the DHW Pmp / Vlv terminals (7 and 8),
make sure the power to the pump or valve circuit is off and install a jumper between
those terminals. When the DHW circuit is powered up, the DHW pump should turn on
or the DHW valve should open completely. If the DHW pump or valve fails to operate,
check the wiring between the terminals and the pump or valve and refer to any instal-
lation or troubleshooting information supplied with these devices. If the DHW pump or
valve operates correctly, disconnect the power and remove the jumper.

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GENERAL
The DIP switch settings on the control are very important and should be set
to the appropriate settings prior to making any adjustments to the control
through the User Interface. The DIP switch settings change the items that
are available to be viewed and / or adjusted in the User Interface.
If a DIP switch is changed while the control is powered up, the control responds
to the change in setting by returning the display to the VIEW menu.
Advanced / Installer
The Advanced / Installer DIP switch selects the access level of the
control. In the Installer access level, a limited number of items may be
viewed and / or adjusted. In the Advanced access level, all items may
be viewed and / or adjusted.
Off / Exercise
The Off / Exercise DIP switch selects whether or not the control is to
exercise the primary pump and boiler pumps. If the DIP switch is set
to Exercise, the pumps are operated for 10 seconds after every three
days of inactivity.
13 14 15 16
Com Boil Out UnO
Sw
Boiler Control 410
Outdoor Reset & DHW
Boiler Demand
DHW Demand
Modulation
DHW Priority Override Test
off not testing
red testing
red testing paused
Signal wiring must be rated at least 300 V.
For maximum heat
press & hold Test
button for 3 seconds.
Advanced
Exercise
Off
Installer
Do not apply power
DIP Switches
Advanced
Exercise
Off
Installer
Advanced
Exercise
Off
Installer
Dip Switch Settings
Connecting The Control
Make sure all power to the devices and terminal blocks is off, and remove any remaining
jumpers from the terminals.
Reconnect the terminal blocks to the control by carefully aligning them with their
respective headers on the control, and then pushing the terminal blocks into the headers.
The terminal blocks should snap firmly into place.
Install the supplied safety dividers between the unpowered sensor inputs and the
powered or 115 V (ac) wiring chambers.
Apply power to the control. The operation of the control on power up is described in the
Sequence of Operation section of the brochure.
12
11
Mod V (dc)
-
+
67
48
Prim
P1
LN
DHW
Pmp/Vlv
Power
5
Test The Modulating Output
If a modulating device is used, connect a voltmeter to the modulat-
ing output Mod V (dc) terminals (11 and 12) and observe the read-
ing during operation. The initial percentage output is zero and the
meter should read 0 V (dc). As the BOIL Modulation in the VIEW menu
increases, the meter reading should increase until the BOIL Modu-
lation reaches 100% at which point the meter should read 5 V (dc).
When the 0 - 5 V (dc) modulation decreases, the meter should start
at 5 V (dc) and eventually reach 0 V (dc) when the display shows 0%
BOIL Modulation.

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View Menu (1 of 1)
Outdoor Current outdoor air temperature as measured by the outdoor
sensor.
-76 to 149°F
(-60 to 65°C)
Boiler Supply Current boiler supply water temperature as measured by
the boiler supply sensor.
-22 to 266°F
(-30 to 130°C)
Boiler Target Boiler target temperature is the temperature the control
is currently trying to maintain at the boiler supply sensor +/- ½ of the
differential.
– – –, 35 to 230°F
(– – –, 2 to 110°C)
Boiler Modulation Current percent modulation of the boiler’s burner. 0 to 100%
Boiler Hours The total running time of the boiler since this item was last
cleared. To clear this item, press the and button simultaneously
while viewing this item.
0 to 1999 hr
Display Description Range
Installer
Advanced
Adjust Menu (1 of 2)
Room Occupied The desired room air temperature
during the occupied period.
35 to 100°F
(2 to 38°C)
Default = 70°F (21°C)
Room Unoccupied The desired room air temperature
during the unoccupied period.
35 to 100°F
(2 to 38°C, OFF)
Default = 65°F (18°C)
Outdoor Design The design outdoor air temperature
used in the heat loss calculations for the heating system.
-60 to 45°F
(-51 to 7°C)
Default = 10°F (-12°C)
Boiler Indoor The design indoor air temperature used in
the heat loss calculation for the heating system.
35 to 100°F
(2 to 38°C)
Default = 70°F (21°C)
Boiler Design The design supply water temperature
used in the heat loss calculations for the heating system.
70 to 220°F
(21 to 104°C)
Default = 180°F (82°C)
RangeDisplay Description
Installer
Advanced
Actual
Setting

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Adjust Menu (2 of 2)
Boiler Minimum The minimum allowed boiler target
temperature.
OFF, 80 to 180°F
(OFF, 27 to 82°C)
Default = OFF
Boiler Maximum The maximum allowed boiler target
temperature.
120 to 225°F, OFF
(49 to 107°C, OFF)
Default = 200°F (93°C)
Boiler Differential The temperature differential that the
control is to use when it is operating the boiler(s).
Au, 2 to 42°F
(Au, 1 to 23°C)
Default = Au
DHW Mode Selects the DHW mode of operation.
1(parallel, no priority),
2(parallel, priority),
3(pri-sec, no priority),
4(pri-sec, priority)
Default = 2
DHW Exchange Occupied The minimum boiler supply
temperature to the DHW heat exchanger during the
Occupied period.
OFF, 100 to 220°F
(OFF, 38 to 104°C)
Default = 180°F (82°C)
DHW Exchange Unoccupied Selects whether or
not a DHW demand will be responded to during the
UnOccupied period.
OFF, On
Default = OFF
WWSD Occupied The system’s warm weather shut down
temperature during the Occupied period.
35 to 100°F, OFF
(2 to 38°C, OFF)
Default = 70°F (21°C)
WWSD Unoccupied The system’s warm weather shut
down temperature during the Unoccupied period.
35 to 100°F, OFF
(2 to 38°C, OFF)
Default = 60°F (16°C)
WWSD Unoccupied The system’s warm weather shut
down temperature during the Unoccupied period.
35 to 100°F, OFF
(2 to 38°C, OFF)
Default = 60°F (16°C)
Primary Pump Purge The maximum length of time that
the primary pump will continue to operate after the boiler
demand has been removed.
OFF, 0:10 to 19:55
minutes
(5 second increments)
Default = 0:20 min
Boiler Pump Purge The length of time that the boiler
pump will continue to run after the last stage in the boiler
has turned off.
This item is only available in operating MODE 2.
OFF, 0:10 to 19:55
minutes
(5 second increments)
Default = 0:20 min
The units of measure that all of the temperatures are to be
displayed in by the control.
°F,°C
Default = °F
RangeDisplay Description
Installer
Advanced
Actual
Setting

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Testing the Control
The control has a built-in test routine that is used to test the main control functions. The
control continually monitors the sensors and displays an error message whenever a fault is
found. See the following pages for a list of the control’s error messages and possible causes.
When the Test button is pressed, the Test light is turned on. The individual outputs and
relays are tested in the following test sequence.
TEST SEQUENCE
Each step in the test sequence lasts 10 seconds.
During the test routine, if a demand from the system is present, the test sequence may be paused by pressing the Test button.
If the Test button is not pressed again for 5 minutes while the test sequence is paused, the control exits the entire test routine. If
the test sequence is paused, the Test button can be pressed again to advance to the next step. This can also be used to rapidly
advance through the test sequence. To reach the desired step, repeatedly press and release the Test button until the appropriate
device and segment in the display turn on.
Step 1 – The primary pump contact is closed.
Step 2 – The boiler pump contact is closed.
Step 3 – The modulation output is set to the minimum modulation percentage.
Step 4 – If there is a demand present, the modulation output increases to 100% Modulation.
Step 5 – If there is a demand present, the modulation output decreases to the minimum modulation percentage.
Step 6 – The modulation output decreases to 0% and the boiler pump contact is opened.
– If DHW MODE is set to 1 or 2, the DHW Pmp / Vlv contact is closed and the primary pump contact is opened.
– If DHW MODE is set to 3 or 4, the DHW Pmp / Vlv contact is closed and the primary pump contact remains closed.
Step 7 – After the test sequence is completed, the control resumes its normal operation.
MAX HEAT
The control has a function called Max Heat. In this mode, the control turns on and operates the system up to the maximum set
temperatures as long as there is a demand for heat. The control continues to operate in this mode for up to 24 hours or until the
Item, Menu or Test button is pressed. This mode may be used for running all circulators during system start-up in order to purge
air from the piping. To enable the Max Heat feature, use the following procedure.
1) Press and hold the Test button for more than 3 seconds. At this point, the control
flashes the MAX segment and displays the word OFF
2) Using the or buttons, select the word On. After 3 seconds, the control turns on all
outputs. However, the max heat mode is still limited by the BOIL MAX setting.
3) To cancel the Max Heat mode, press the Item, Menu, or Test button.
4) Once the Max Heat mode has either ended or is cancelled, the control resumes normal
operation.
Menu Item
Menu Item

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Error Messages (1 of 1)
The control was unable to read a piece of information stored in its memory. Because of this, the control
was required to reload the factory settings into all of the items in the ADJUST menu. The control will
stop operation until all of the items in the ADJUST menu of the control have been checked by the user
or installer.
Note: The Advanced / Installer DIP switch must be set to Advanced in order to clear the error.
The control is no longer able to read the outdoor sensor due to a short circuit. In this case the control
assumes an outdoor temperature of 32°F (0°C) and continues operation. 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 outdoor sensor due to an open circuit. In this case the control
assumes an outdoor temperature of 32°F (0°C) and continues operation. 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 boiler supply sensor due to a short circuit. The control will not
operate the boiler(s) until the sensor is repaired. 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 boiler supply sensor due to an open circuit. The control will not
operate the boiler(s) until the sensor is repaired. To clear the error message from the control after the
sensor has been repaired, press either the Menu or Item button.