ComfortPro Systems AquaHeat ProZone User manual

AquaHeat
www.ComfortProSystems.com
Radiant Heating and Snowmelting products
AquaHeat
A better
approach to
radiant Heating
systems
Installation
Guide
Control System

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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 challenging more than ever. To keep the basic installation order we have build this guide to reect the typical
steps in the implementation of a project:
Chapter 1 - Hydronic oor installation
Chapter 2 - Manifold installations
Chapter 3 - Boiler room installations
Chapter 4 - Control system installation
Chapter 5 - System start-up, warranty requirements and maintenance

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Table of Contents
Chapter 4 - 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/Timer Control Box 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
ProChronotherm 16
Thermostat Features Overview 17
Thermostat Dimensions 18
Thermostat Wiring 19
Conguring Pro Series Thermostats for
dual sensor applications 21
Connecting the ProZone Transformer 23
Installing External Sensors 24

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CHAPTER 4
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 application.
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
Fig 1 - AquaHeat System Components

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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/ther-
mostat. 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 di-
rectly 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 ther-
mostat 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 observed:
If more than one manifold is used (based on large living area coverage or higher than usual zone division) group
manifolds according to controlled zones. Make sure that control box and actuators receive enough power to sup-
port the operation (i.e. size the supply power transformer accordingly).
Loop actuators can be
connected as single or
individual zones
Single loop ac-
tuator to control
a whole manifold
Fig 2 - Zone Denitions

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CHAPTER 4
ProZone Control System
Radiant Heating Floor Loops
Part # 1 - 3 4 6 10 12 18
Pro Thermostats ProBasic 450008 • • • • • •
Pro Basic Dual Sensor 450009 × × × × × ×
Pro Digital Dual Sensor 450010 × × × × × ×
Pro Chronotherm 45 0 011 × × × × × ×
ProZone Control Box Pro 4 Zone Master 450003 •×
Pro 6 Zone Master 450004 • • • •
Pro 4 Zone Slave 450005 •
Pro 6 Zone Slave 450006 ו •
Pro Clock Timer 450007 × × • • •
Pro Zone Power Supply Pro Zone Transformer
(60 VA)
450014 • • • • • •
• 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. Program the ProZone Timer Box (if available) for desired duty cycles and night reduction.
9. Set thermostats minimum and maximum temperature range
10. Calibrate thermostats for exact temperature

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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”
Pro Chronotherm 15 0.0571”
Actuator Wiring
AquaHeat ProZone actuators come with a 3ft pre-sealed 2-pole cable. If the length of the cable needs to be ex-
tended 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 and Pro Clock Timer should be mounted on a DIN rail above the Manifold within 1-3ft of the mani-
fold. 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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CHAPTER 4
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 cooling or heating devices
Minimum 8
inches
54” - 60”
Maximum DIN rail length or wall space used is approx. 25 inches.
6 1/2”
4 Zone 6 1/2”
6 Zone 8 7/8”
4 Zone 6 1/2”
6 Zone 8 7/8”
24 1/4”
Fig 3 - ProZone Module Dimensions
Fig 4 - Thermostat Installation Location
3 1/2”

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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 supply valve is closed and no water is pumped throught the loop. Upon request from either the Pro-
Zone 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 tem-
perature 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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CHAPTER 4
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.
Warning
The actuator must not be installed below the body valve.
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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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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CHAPTER 4
Combining the Pro Zone Master/Slave/Timer Control Box
Before connecting the thermostats and actuators the control boxes have to be properly connected. The fol-
lowing 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 Clock TIMER
Pro 6 Zone MASTER + Pro 4 Zone SLAVE + Pro Clock TIMER
Pro 6 Zone MASTER + Pro 6 Zone SLAVE + Pro Clock TIMER
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 con-
nector clamps by hand. See Fig 11.
3. Clip into the DIN rail or use screws to screw housings directly to the drywall (4
screws /module)
Fig 11 - ProZone Module
connectors
Fig 10 - ProZone Module combinations

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Pro 4/6 Zone Master Control Box
Pro 4 and 6 Zone Master with Pump Relay Box
LED Zone Indicator
1 Zone connection
bench
Pump & Auxiliary
Connectors
Power Supply
Connector
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 projects. 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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CHAPTER 4
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
Connector
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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Pro Clock Timer Box
ProZone timer box (PN 450007) features 7 day programing, 2 channels A and B, 1 user program per channel, 9 built in programs,
program graphics display, automatic or manual operation, key pad lock function for child safety, and in the event of a power
outage hours and parameters are saved . The easy clip-in extender provides a fast and reliable connection to the Master or slave
module.
Pro Clock Timer Box
Mode description
Use the keys < & > in order to change the mode in the operating
menu.
Set CLOCK Menu
Use this menu to adjust the Timer clock to the actual time.
Use < / > to adjust the minutes Press OK
Use < / > to adjust the hours Press OK
Use < / > to adjust the day Press OK
Manual REDUCED operating load
Force reduced temperature operation indenately on
the 2 channel.
Manual COMFORT operating load
Force comfort temperature operation indenately on
the 2 channel.
Manual AUTOMATIC operating load
The timer follows automatically the selected program
according to the actual time.
IMPORTANT:
in order to control your thermo-
stats with the TIMER please put your thermostat in
position.
Technical Characteristics
Operating temperature 32°F - 122°F
Protection IP30
Power supply 24 VAC +/- 10% 60Hz
Master 4 or 6 zones
Pro Clock Timer Box
Pro Clock Timer Display
1 : Operating mode menu
2 : Days of the week
3 : Time
4 : Program graphic
5 : Channel A or B
Timer box
1
2
3
5
4

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CHAPTER 4
Pro Clock Timer Box
PROGRAM MENU :
By pressing +or - keys you select the channel ChA or ChB to the program then validate with OK button.
If you select a built -in program P1 to P9 and press OK this program will be followed in the mode.
BUILT IN PROGRAMS DESCRIPTION
P1: Morning, evening week-end P6: Morning, afternoon, week-end
P2: Morning, midday, evening, week-end P7: 7h - 19h (oce)
P3: Day & week-end P8: 8h - 19h Saturday (shop)
P4: Evening & week-end P9: Week-end secondary house
P5: Morning, evening (bathroom)
You can also select a user program U1 for channel A and U2 for channel B.
USER PROGRAM EDITION
The +key sets temperature at the current blinking program hour.
The -key sets temperature at the current blinking program hour.
Use the <& >keys to slide the blinking curser position in the day and modify or
correct the program easily.
When the displayed day is correct press OK to save it and then you jump to the
following day. When you press OK on day 7 you return to the top menu.
Now once automatic operating mode is selected, the timer will look for the channels A and B the desired
programs.
SPECIAL FUNCTION:
KEYPAD LOCK function :
Function to prevent any modications or changes of the parameters.
In , , , operating modes you should maintain the OK key pressed and simultaneously on the +or -
key to (Loc codE) or unlock (Un Loc) the key pad.
Shows the daily program Use < &> to see the
other days in the program
Then press +or - to change the
program
Hour of the curser
Day

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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 combination of products for your complete Heating project please look at the following table (chpt
2-1)
Pro Basic (P/N 450008) and “Dual Sensing” (P/N 450009)
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. The Dual Sensing Thermostat Part-
Nr. 450009 picks up the room and oor temperature to correctly control the manifold ow.
Pro Digital Dual Sensing (P/N 450010)
Pro Digital thermostats contain a display through which all interaction with the oor heating system is con-
trolled. 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
Thermostat
Fig 17 - ProDigital
Thermostat

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CHAPTER 4
ProChronotherm (P/N 450011)
Pro Chronotherm thermostats contain an on-board clock to adjust temperature based on certain time of day.
The functions are similar to Pro Basic thermostats and come with on-board sensor.
Operating temperature 32°F – 122°F (0°C - 50°C)
Comfort / Reduction mode
setting temperature range 41°F - 95°F (5°C – 35°C)
Daily clock programmable 24H with 15 minutes step
Weekly clock programmable 7 days with 1 hour step
Regulation
characteristics Proportional band 2°K for 10min cycle
Electrical Protection Class II - IP30
Power Supply
Battery operated life
2 x AA LR06 1.5V
> 1 year (For Alkaline type)
Output Relay output => 1RT Free contact (8(3)A 24Vac )
Pro Series Thermostats
Fig 18 - Pro Chronotherm
Thermostat

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Pro Series Thermostats
Thermostat Features Overview
Features Pro
Basic
Pro Basic
Dual Sen-
sor
Pro Digital
Dual Sen-
sor
Pro
Chrono-
therm
Part # 450008 450009 450010 450011
Sensor
On-Board • • • •
External
Probe (Sen-
sor)
• •
Direct Drive
(Actuator)
Triac (24VAC)• • • •
Relay
Mode
Selector
Day - Comfort • •
Night - Re-
duction
• •
Duty Cycle
Heating/
Cooling
Control
Heating • • • •
Cooling
Clock Timer •
Digital
Display
•
Proportional
Adjustment
(Hysteresis)
• •
Temperature
Dial
• •
Digital But-
ton Control
•
Auxiliary Re-
lay hockup (4
wire opera-
tion)
•
Table 3 - Pro Series Thermostat Features

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CHAPTER 4
Thermostat Dimensions
Pro Basic (P/N 450008)/ Dual Sensor (P/N 450009)
Pro Digital Dual Sensor (P/N 450010)
Pro Chronotherm (P/N450011)
1 1/4” (31mm)
2 3/8” (60mm)
3 1/8” (80mm)
1 1/4” (31mm)
2 3/8” (60mm)
3 1/8” (80mm)
1 1/2” (38mm)
2 3/8” (60mm)
3 1/4” (83mm)
2 3/8” (60mm)
3 7/8” (98mm)
5 1/4” (135mm)
Installation Steps (see also product instruc-
tions 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 thermo-
stat 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 package)
1. Lift center rubber lid from thermostat
2. Loosen visible screw to open thermostat body
3. Pull connection wiring through appropriate bot-
tom 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
Installation Steps (see also product instructions
in package)
1. Open thermostat ip cover and remove battery
compartment lid
2. Loosen visible screws (2x) to open thermostat
body
3. Pull connection wiring through appropriate bot-
tom 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. Set batteries (right polarity) and close compart-
ment cover