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