ComfortPro Systems AquaHeat ProZone User manual

AquaHeat
www.ComfortProSystems.com
A systems approach integrating established and emerging technologies
AquaHeat Installation Guide
Control Systems

2
AquaHeat
www.ComfortProSystems.com
Preface
System Design and Installation
The Mains
PEX pipe mains are recommended to reduce labor and architectural impact. For a slab-on-grade installation, the
mains can be buried below or within the slab. For below slab installation refer to insulated supply and returns like
ComfortPro Systems Microex product range. For a wet or dry on plywood application, the mains can be installed
within the joist cavity. Always allow for the expansion and contraction of the mains, as the temperature uctuates. It
is recommended that the pipe be allowed free movement and is not fastened directly to the oor joists.
Requirements of a hydronic control system
The intent of a hydronic heating control system is to achieve heating comfort, system protection, energy saving and
ease of use.
Heating comfort is achieved by:
• keeping proper system temperatures
• directing the right amount of heat when and where you want it
System protection is achieved by:
• protecting the primary heat source (e.g. boiler) from corrosion and thermal shock
• reducing equipment cycling
Energy saving is achieved by:
• running the system at the lowest water temperature possible
• turning o the system when no heat is demanded
• minimizing boiler short cycling.
Ease of use is achieved by:
• running automatic functions in lieu of manual settings
• providing easy and consistent wiring and installation procedures
AquaHeat Installation Guide Philosophy
A hydronic system can get quiet complicated and with the rapid introduction higher integrated solutions keeping up is chal-
lenging more than ever. To keep the basic installation order we have build this series of guides to reect the typical steps in the
implementation of a project.

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AquaHeat
Control Systems
AquaHeat Control System
AquaHeat ProZone Control Systems 4
AquaHeat ProZone Control System components 4
Zone Denition 5
Recommended Control System per Loop count 5
Step - by - step Installation at a glance 6
General Installation Guidelines 7
Wiring 7
Component Locations 7
Pro Thermostat Installation Locations 8
AquaHeat Actuators 9
ProMix Manifold actuators 9
Actuator Operation 10
Mechanical Installation of ProZone Actuator 10
Connecting the ProZone Actuator 11
Combining the Pro Zone Master/Slave 12
Pro 4 and 6 Zone Master with Pump Relay Box 13
Pro 4 and 6 Zone Slave Box 14
AquaHeat Thermostats
Pro Basic and “Dual Sensing” 15
Pro Digital Dual Sensing 15
Thermostat Features Overview 16
Thermostat Dimensions 17
Thermostat Wiring 18-19
Conguring Pro Series Thermostats for dual sensor applications 20-21
Installing External Sensors 22

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AquaHeat
Control Systems
AquaHeat ProZone Control System
AquaHeat ProZone Control Systems
AquaHeat ProZone control systems come in various scalable building blocks which makes the systems suitable for every applica-
tion.
System Components are grouped into
- Actuators
- Control Box
- Timer Box
- Thermostats
- Sensors
The ComfortPro AquaHeat ProZone control system allows for various combinations of these individual components to t budget,
size, and user convenience.
AquaHeat ProZone Control System components
Basic T-Stat
Digital dual sensing T-Stat
Master 4 or 6 zones Slave 4 or 6 zones
Actuators
Manifolds up to 12 zones

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AquaHeat
Control Systems
AquaHeat ProZone Control System
Zone Denition
A Heating Zone is dened as an individual or grouped section of the whole heating system, which is controlled at once.
In the simplest case a zone is characterized by a single oor loop of PEX pipe connected to a manifold. A Zone can also comprise
of several oor heating loops connected to a manifold and controlled by a single controller/thermostat. Ultimately, a Zone can
comprise of a complete manifold which is controlled by a single zone valve in front of the manifold injection loop.
Manifolds are typically operated by electro-mechanical servo motors to open and close individual oor loops water circulation at
the supply side loop valves which in turn are controlled through the ProZone control box and/or directly through thermostats.
Recommended Control System per Loop count
The ProZone heating control system can be scaled for every project. Key indicator for the requirements of a oor heating system
is the number of PEX pipe oor heating loops used in the project.
Examples are:
1. Simple, one zone system
A very basic system comprises of a manifold like the AquaHeat ProMix or ProLock manifold with one or more oor PEX pipe loops
combined to a single zone. In this case, the oor heating system can be controlled by a single thermostat like AquaHeat Pro Basic
thermostat. One actuator is controlled by the thermostat and regulates the ow of heat into the manifold loops through a zone
valve in front of the manifold supply line.
2. Multiple Zone System
For a multiple zone system each zone is controlled by a thermostat and/or a ProZone control box. In this case, the actuators
mounted to the manifold are grouped to its individual zone and typically connected to a ProZone control box. The ProZone
control box allows for a clean installation without extensive wiring. The control box connects again the Zone to the individual
thermostat.
3. Multiple Zone system with multiple manifolds and timer control
In larger projects it is often required to use several manifolds for many oor loops. The following considerations should be ob-
served:
If more than one manifold is used (based on large living area coverage or higher than usual zone division) group manifolds ac-
cording to controlled zones. Make sure that control box and actuators receive enough power to support the operation (i.e. size
the supply power transformer accordingly).
Loop actuators can be con-
nected as single or indi-
vidual zones
Single loop actuator
to control a whole
manifold
Fig 2 - Zone Denitions

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AquaHeat
Control Systems
ProZone Control System
Radiant Heating Floor Loops
Part # 1 - 3 4 6 10 12 18
Pro Thermostats ProBasic 450008 • • • • • •
Pro Digital Dual Sensor 450010 × × × × × ×
ProZone Control Box Pro 4 Zone Master 450003 •×
Pro 6 Zone Master 450004 • • • •
Pro 4 Zone Slave 450005 •
Pro 6 Zone Slave 450006 ו •
• Required/recommended components
× Alternative components
Table 1 - Control System Recommendation per Floor loop count
Step - by - step Installation at a glance
1. Mount all components of the system, i.e. Control Boxes, Transformer, Timer boxes, thermostats, actuators, external
sensors
2. Connect the actuators to the control box or in a simple case to the thermostats directly
3. Connect the thermostats and sensors
4. Connect the pump power cable to the Master control module
5. Connect the transformer to either thermostat or AquaHeat ProZone master control box
6. After completed electrical wiring power-up the system
7. Check whether all zones are opening the actuators and the injection loop starts pumping
8. Set thermostats minimum and maximum temperature range
9. Calibrate thermostats for exact temperature

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AquaHeat
Control Systems
Installation Instructions
General Installation Guidelines
These step - by - step instructions explain the full installation for the ProZone Control System. Before an installation can occur the
following general guidelines and pre-requisites have to be maintained:
Wiring
Wiring of the system is divided into two groups of wires needed for the operation of the system. ComfortPro recommends using the
following minimum wire diameters as dened by the American Wire Guide (AWG):
Thermostat wiring
Thermostat AWG Diameter
Pro Basic (2 wire) 24 0.0201”
Pro Basic (4 wire) 18 0.0403”
Pro Digital (2 wire) 24 0.0201”
Pro Digital (4 wire) 18 0.0403”
Actuator Wiring
AquaHeat ProZone actuators come with a 3ft pre-sealed 2-pole cable. If the length of the cable needs to be extended use AWG
size 18 or better 17 type wiring.
Control Box Power supply
For power line wiring the usual AWG sizes should be used. If the low voltage side after the transformer has to be extended to reach
the Control Box or thermostat, caution should be taken to use a strong copper cable in order to minimize power loss along a longer
wire.
Table 2 - Wire Sizes
Component Locations
All system components should be installed in the most reasonable distance to their connected modules. Caution should be taken
in small spaces so that the system components (like power transformers) are not overheating.
Control Boxes should be mounted on a DIN rail above the Manifold within 1-3ft of the manifold. There should be a power outlet to
the left side of the DIN rail for most convenient installation. We recommend the thermostat wiring sparing on top of the DIN rail. If
a manifold cabinet is used it is recommended to size the cabinet with respect to the Control boxes size.

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AquaHeat
Control Systems
Pro Series Control System
Pro Series Thermostat Installation Locations
When installing thermostats in a new development the following aspects have to be taken in consideration.
Select the location of the thermostat conveniently for the user
Install thermostat on the inside walls of the building/dwelling
Install thermostat minimum 8 inches away from doors.
Thermostats should be mounted approximately 54 - 60 inches from the oor
Note: Avoid mounting thermostats close to windows, on outside walls, behind doors, close to the oor or ceiling and other cool-
ing or heating devices
Minimum 8 inches
54” - 60”
Maximum DIN rail length or wall space used is approx. 25 inches.
4 Zone 6 1/2”
6 Zone 8 7/8”
4 Zone 6 1/2”
6 Zone 8 7/8”
17 3/4”
Fig 3 - ProZone Module Dimensions
Fig 4 - Thermostat Installation Location
3 1/2”

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AquaHeat
Control Systems
ProZone Actuators
AquaHeat Actuators (P/N 450001, 2 - wire) or (P/N 450002, 4 - wire)
AquaHeat oers two kind of actuators for Promix and ProLock manifolds. AquaHeat actuators operate on 24VAC supply voltage and
can be controlled through the ProZone Control Box or directly through the thermostat. Actuators come as 2 and 4 wire models. 4
wire models include an additional end switch (black and grey cable) which can be used to control a pump. AquaHeat oers both
models to give optimal system versatility to the systems design.
Wiring Diagram - 2-wire Wiring Diagram - 4-wire
NC Actuators (Normally Closed)
AquaHeat actuators are operated as normally closed (NC) versions, i.e. during normal or stand-by operation the manifold loop sup-
ply valve is closed and no water is pumped throught the loop. Upon request from either the ProZone Control box or the thermostat
the actuator drives open the manifold loop supply valve and fresh heating water is pumped through the oor loop. When the room
temperature in the room or oor reaches the desired target temperature the thermostat or ProZone Control Box closes the loop
supply valve through the drive of the actuator into the NC position.
ProMix Manifold actuators
Actuator Operation
(Gray)
Fig 5 - Actuator wiring diagrams
Fig 6 - ProZone Actuator Dimensions
1 1/2” (38mm)
2” (51mm)
2” (50mm)
2” (51mm)

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AquaHeat
Control Systems
ProZone Actuators
When the thermostatic element expands, it supplies the thrust required for automatic movement of the valve. The 4-wire version is
provided with an auxiliary contact for additional commands (metering, control of pump, fan or other equipment). The actuator has
a transparent window that allows to check the status of the actuator on the actuator cover.
Mechanical Installation of the ProZone Actuator
Transparent Zone Valve
Red Closed
Black Open
1. Remove handle or cap from the body valve.
2. Position the actuator and tighten the ring nut of the actuator
manually onto the body valve.
Do NOT use pipe wrenches, spanners or similar.
3. Connect electrical wiring.
Important maintenance notes
Do not replace the connected cable. Opening the ProZone actuator
will cause irreparable damage to the device.
Faulty actuators must be replaced as complete units.
Technical Characteristics
Action Open/Close
Power supply 24 VAC (+10% / -15%)
Frequency 60 Hz
Power consumption (normal operation) 2.5 VA
Peak starting current 0.35 A x 30 sec (24V)
Initial opening (NC) or closing (NA) time (power ON) 24V 3 min
Final opening (NC) or closing (NA) time (power ON) 5 min
Actuator stroke max 3.5 mm
Valve stroke 2.5 mm
Protection class IP44 to EN60529
Electrical Protection class II
Safety (contamination level) 2
Cable length 3ft
2-pole x 0.75 mm2
4-pole x 0.75 mm2
Operation temperature limit 32 - 122°F
Storage temperature limit -13 - 140°F
Fluid temperature limit Max 230°F
Nominal closing force (power OFF) (Closed type) 140 N (±10%)
Auxiliary microswitch (4-wire model) max 700 mA - 24Vac
Valve connection Threaded ring nut M30x1.5
Fig 7 - Actuator Indicator
Fig 8 - ProZone Actuator Mount

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AquaHeat
Control Systems
ProZone Actuators
blue
blue
Connecting the ProZone Actuator
ProZone Master Module
brown
brown
Actuator 1
Actuator 2
Actuators can either be connected directly to thermostats in a single zone environment or for multiple zones we emphasize the
use of the ProZone Master control box. By using a ProZone master control box one or more actuators are being connected to a
single zone at the zone connector bench. Each Zone connector bench can connect up to 4 actuators, i.e. two cables per screw
connector.
Fig 9 - ProZone Actuator Connection

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AquaHeat
Control Systems
Combining the Pro Zone Master/Slave
Before connecting the thermostats and actuators the control boxes have to be properly connected. The following combinations
and positions mounted on a DIN-rail are possible. The units snap into each other after the Master cover is being removed.
Pro Zone Control Boxes
Pro 6 Zone MASTER
Pro 6 Zone MASTER + Pro 4 Zone SLAVE
Pro 6 Zone MASTER + Pro 6 Zone SLAVE
Quick Installation Instructions for ProZone Module assemblies
1. Open ProZone Master module cover by unscrewing three screws from the Master module
cover front. Note that the fourth screw is delivered in a plastic bag within the package.
2. Slide the male connector clips from either the Slave or the Timer box sideways over the edge
of the circuitboard. Note you can adjust the height of the male connector clamps by hand. See
Fig 11.
3. Clip into the DIN rail or use screws to screw housings directly to the drywall (4 screws /mod-
ule)
Fig 11 - ProZone Module con-
nectors
Fig 10 - ProZone Module combinations

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AquaHeat
Control Systems
Pro 4/6 Zone Master Control Box
Pro 4 and 6 Zone Master with Pump Relay Box
LED Zone Indicator
1 Zone connection benchPump & Auxiliary
Connectors
Power Supply Con-
nector
Pro 4 Zone Master
Pro 6 Zone Master
ProZone Master modules are the essential modules for any sophisticated control system. A Master module provides power supply
to multiple zones. On-board pump relay controls the circulator and or mixing pumps directly. Activity in one zone is indicated by
a green LED diode. The master module conveniently allows to connect thermostats and actuators and assign zones to your proj-
ects. The Master Module comes as 4 (P/N 450003) and 6 Zone (P/N 450004) control box.
Operating temperature 32°F - 122°F
Circuit Protection Class I - IP20
Power supply 24 VAC +/- 10%
Output
Pump & accessories:
Relay => 2 free contact 8A 120Vac
Zones:
4 or 6independent zones => the maximum
output power of each zone depends on
thermostat connecting on this zone. The
maximum current for all connected actuators is
2.5A
LED Zone Indicator (green) heating indicator shows water circulation
Technical Characteristics
Fig 12 - ProZone Master Modules
Fig 13 - ProZone Master Module PCB

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AquaHeat
Control Systems
Pro 4/6 Zone Slave Control Box
ProZone Slave modules allow for the Zone extension of the Master module functionality. The easy clip-in extender provides a fast
and reliable connection to the Master module. Two extension modules (P/N 450005 - 4 Zone, P/N 450006 - 6 Zone) are available if
additional thermostats and actuators are needed for the system design.
Pro 4 Zone Slave
Pro 6 Zone Slave
1 Zone connection bench
Master Module Con-
nector
Technical Characteristics
Operating temperature 32°F - 122°F
Protection Clase I - IP20
Power supply 24 VAC +/- 10% 60Hz
Output
Zones:
4 or 6 independent zones => the maximum
output power of each zone depends on the
number of thermostats connecting to this
zone. The maximum current for all connected
actuators is 2.5A
LED Zone Indicator (green) heating indicator shows water circulation
LED Zone indicator
Pro 4 and 6 Zone Slave Box
Fig 14 - ProZone Slave Module
Fig 15 - ProZone Slave Module PCB

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AquaHeat
Control Systems
Pro Series Thermostats
Selecting Thermostats
ComfortProSystems oers a wide range of Thermostat solutions which will t your design. In order to easily identify the combina-
tion of products for your complete Heating project please look at the following table (chpt 2-1)
Pro Basic (P/N 450008)
Thermostats contain a temperature dial which can be calibrated to reect the correct room temperature. Pro Basic Stats can drive
an actuator directly through the on-board quiet triac.
Pro Digital Dual Sensing (P/N 450010)
Pro Digital thermostats contain a display through which all interaction with the oor heating system is controlled. The functions
are similar to Pro Basic thermostats and come with on-board sensor (part # 450010).
Measured temperature
precision 0.2°F
Operating temperature 32°F – 122°F (0°C - 50°C)
Setting temperature range 41°F - 99°F in 0.5°F increments (5°C - 37°C)
Regulation
characteristics
Proportional Integral regulation (adjustable, see
installation menu) Cycle: 15 minutes or
Static dierential 0.5°F
Anti-short cycle: 3min in OFF, 2min in ON.
Electrical Protection Class II - IP30
Power Supply 24 VAC +/- 10%
Output TRIAC output 24 VAC, 15 W max.
( 4 CPS ProZone actuators Part #450014 )
External Floor sensor NTC (10K Ohms) 9ft
Measured temperature
precision 0.2°F
Operating temperature 32°F – 122°F (0°C - 50°C)
Setting temperature range 41°F - 86°F (5°C – 30°C)
Floor limiting temperature
range 50°F - 104°F (10°C – 40°C)
Regulation
characteristics
Proportional band 10min for 3.6°F
or Static dierential 0.9°F
Electrical Protection Class II - IP30
Power Supply 24 VAC +/- 10%
Output TRIAC output 24 VAC, 15 W max. ( 4 CPS ProZone
actuators)
External Floor sensor NTC (10K Ohms) 9ft
Soft version V 1.4x
Fig 16 - ProBasic Ther-
mostat
Fig 17 - ProDigital Ther-
mostat

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AquaHeat
Control Systems
Pro Series Thermostats
Thermostat Features Overview
Features Pro Basic Pro Digital
Dual Sensor
Part # 450008 450010
Sensor
On-Board • •
External Probe
(Sensor)
•
Direct Drive
(Actuator)
Triac (24VAC)• •
Relay
Mode
Selector
Day - Comfort •
Night - Reduc-
tion
•
Duty Cycle
Heating/Cool-
ing Control
Heating • •
Cooling
Clock Timer
Digital
Display
•
Proportional
Adjustment
(Hysteresis)
•
Temperature
Dial
•
Digital Button
Control
•
Auxiliary Relay
hockup (4 wire
operation)
Table 3 - Pro Series Thermostat Features

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AquaHeat
Control Systems
Thermostat Dimensions
Pro Basic (P/N 450008)
Pro Digital Dual Sensor (P/N 450010)
1 1/4” (31mm)
2 3/8” (60mm)
3 1/8” (80mm)
1 1/4” (31mm)
2 3/8” (60mm)
3 1/8” (80mm)
Installation Steps (see also product instructions in
package)
1. Lift temperature dial from thermostat
2. Loosen visible screw to open thermostat body
3. Pull connection wiring through appropriate bottom
hole (optional external sensor wiring as well)
4. Use appropriate wall screws to ax thermostat body
at desired location.
5. Connect wiring according to connector ID in section
“Thermostat Wiring”
6. Close thermostat cover by tightening screw
7. Push temperature dial on potentiometer half moon
stub
Installation Steps (see also product instructions in pack-
age)
1. Lift center rubber lid from thermostat
2. Loosen visible screw to open thermostat body
3. Pull connection wiring through appropriate bottom
hole (optional external sensor wiring)
4. Use appropriate wall screws to ax thermostat body at
desired location.
5. Connect wiring according to connector ID’s in section
“Thermostat Wiring”
6. Close thermostat cover by tightening cover screw
7. Push protective center rubber lid back onto opening

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AquaHeat
Control Systems
Thermostat Wiring
All AquaHeat ProZone Control System thermostats are wired via two or four cables. Two cables are required for supply power and
signaling to the thermostat and two wires are for driving the actuator directly to the actuator or through the ProZone Box. For wir-
ing of the thermostat the following AWG sizes are required:
Minimum AWG size 24 for thermostat signaling
Minimum AWG size 18 or lower for driving the actuators directly
For dual sensor thermostats the wiring is typically provided with the probe.
Pro Series Thermostats
Connector # Signal
1 Thermostat (24V)
2 Actuator (24V)
4Grd
4Grd
Connecting Pro Basic Thermostats to the ProZone master/slave zone module
External Sensor Connector
Fig 19 - Pro Basic Wiring
Table 4 - Pro Series Thermostat Wiring

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AquaHeat
Control Systems
Pro Series Thermostats
Connecting Pro Digital Thermostats to the ProZone master/slave zone module
A/B time zoning pilot wire(See ProClock Timer
Box for details). Connect either zone A/B
External Sensor Connector
Fig 20 - Pro Digital Wiring

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AquaHeat
Control Systems
Pro Series Thermostats
Conguring Pro Series Thermostats for dual sensor applications
Dual sensor thermostats allow to regulate between two separate temperature measurements. For proper adjustment of room and
oor temperature it might become necessary to deviate from the pre-congured thermostat settings.
AquaHeat ProBasic and ProDigital Dual Sensor thermostat both are congurable for either only internal, only external sensor or
both, in which case the external (oor) sensor is used as a temperature limiter.
Pro Basic Conguration
Pro Basic Dual Sensor thermostats are congured by dip switches (conguration switch) located on the inside PC board and are
best adjusted during the installation of the thermostat. Basic adjustments as the actuator type, regulation mode (static dierential/
proportional, and the sensor modes).
Conguration Switch Switch Position
State Function 1 2 3 4
1Actuator NC down
2Actuator NO up
3Static Dierential Regulation down
4Proportional Regulation up
5Internal (Room) Sensor only down down
6External (Floor) Sensor only down up
7 Both Sensors - oor lower limit up down
8 Both Sensors - oor upper limit up up
Conguration Switch Selection Pro Basic
1. Select the actuator type (Choose between 2 - wire and 4 - wire with end
switch)
2. Select regulation method preferred
3. Select which sensors are to be used and whether the oor sensor should
limit the measurement to the lower or higher temperature
Please see table below for available congurations
Conguration
Switch
Floor Sensor Temperature Limi-
tation setting screw
Fig 22 - Pro Basic Conguration
Table 5 - Pro Basic Conguration Dip Switch