HBX EXP-0100 User manual

HBX Control Systems Inc.
Installation Manual
Expansion Module 0100
Version 1.0
EXP-0100

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
E X P - 0 1 0 0 a n u a l P a g e 1
###!
 ! 

The EXP-0100 Expansion odule is designed to be integrated with the HBX CPU-1000 HVAC Controller, it
is not a stand alone control device. The purpose and function of the EXP-0100 is to provide system
expansion capabilities. Its primary use is to add additional boiler stages. For example, 1 CPU-1000 + 1
EXP-0100 can provide a total of 4 boiler stages (when configured as a staging control).
If the Control is configured as a mixing control and more than one boiler is required, the program within
the CPU-1000 anticipates (defaults) that boiler stages are connected through the Expansion odules
(refer to drawing IX 1000-05 of this manual). The EXP-0100 has a spare thermistor input with no fixed
function. The installer may choose to run the spare thermistor as a; room sensor, setpoint sensor, or a
return water temp sensor. The spare demand signal has no dedicated function at the time of print.
The position of setpoint sensors (thermistors) are critical to the correct operation of the Control. Pay
special attention to the wiring of setpoint sensors in relation to actuators, pumps, and multiple boiler
stage relays. Example shown in Application Drawing IX 1000-04.
HBX has developed a series of Expansion odules. At time of product introduction the EXP-0100
(Staging) and EXP-0300 (Pump) odules are made available. These will be followed by the release of
the ZON-0500 (Zone Control), and the OD-0100 ( odulating Output odule) odule.
A combination of these odules are designed to tackle a variety of applications, using a maximum of
six odules in unison with a single CPU-1000 Control Unit. The sequence in which the odules are
connected is very important. Install the odules that you are utilizing in the following order: CPU-1000,
Staging Controls, Pump Controls, odulating Controls, Zone Controls.
The EXP-0100 is designed to be wall mounted, DIN rail mounted, or installed inside a separate electrical
enclosure. The unit should be mounted inside and be protected from falling water and high humidity
conditions. With all the covers in place it is designed to protect any individual from accidental electrical
shock.
 35*7-&26.;%32*3)80*6
(&2'*(322*(7*)737-*!
&67-*%32*3)80*6&5*
237)*4*2)*27327-*!73
43:*57-*5*0&<6

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
;75& -*51.6735Gives you many choices.
E.g. Room sensor or setpoint sensor.
;75&*1&2).,2&0 Any heat demand
signal powered by 20 - 240VAC.
E.g. 24VAC thermostat (future applications).
-*51.6735.24876&5*)*6.,2*)
+35-17-*51.67356&2)
18672*9*5'*68'/*(7*)73&2<
*;7*52&043:*568440<9307&,*
35(855*27
;75&*0&<This relay is the default relay for
bringing on multiple boiler stages.
E.g Boiler (stage) 4, 6, 8 etc. depending on the
number of odules connected together.
;75&*0&<This relay is the default relay for
bringing on multiple boiler stages.
E.g Boiler (stage) 3, 5, 7, etc. depending on the
number of odules connected together.
;75&*0&<6&5*)5<(327&(76
&2)5&7*)+35&1&;3+146
Extra Thermistor 1
Extra Demand Signal 1 Extra Relay 1
Extra Relay 2
  !
Place the CPU-1000 and desired Expansion odules on a flat surface. Align the 32-Pin connector into
the holes on the Expansion odule and gently push into place. Next slide the CPU-1000 onto the 32-Pin
connection by carefully matching up the holes and pins. When installed correctly there is virtually no
gap between units. With power applied to the assembly, the first (green) LED should be illuminated on
each Expansion odule. This lit, green LED serves as confirmation of both electrical and
communications continuity.
32- Pin Connector
P/N 033-0037
 
E X P - 0 1 0 0 a n u a l P a g e 2
© H B X C o n t r o l S y s t e m s I n c . 2 0 14

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
2. Power and
Communications
LED
7. Thermistor
6. Input Signal A
5. Aux. Relays /
Extra Boiler Stages
4. Relay 2 LED
3. Relay 1 LED
1. 32 Pin Connector Port
4*(.+.(&7.326
1 x Thermistor Input
(10K Ohm)
1 x isc. Input Signal
(20-240VAC)
2 x Aux. Output Relays
(240VAC 10Amps)
"*.,-7
0.408Kg
.1*26.326
100mm W x 170mm H x 70mm D
 .67.2,6
eets CSA C22.2 No. 24
eets UL Standard 873
ETL Control No. 3068143
735&,*
10ºC to 40ºC
70mm 66mm17
Side View Front View
Rear View Top View
168mm
100mm
63.2mm
86mm
Bottom View
$
 
E X P - 0 1 0 0 a n u a l P a g e 3

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXPANSION MODULE
TH Hi Temp
System
Pump 1
120VAC
24VAC
Boiler
Sensor
Outdoor
Sensor
Apply Control
Signal or
Program for
Permanent Heat
Demand
Boiler 1
Stage 1
Boiler 2
Stage 2
Boiler 3
Stage 3
Boiler 4
Stage 4
C
R
L
N
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Central ProcessingUnit
1000
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
120VAC
Heat
Load
Boiler
Sensor
P1 Hi Temp
System Pump
1000 100
 
814*,*2)
• P1 - Hi-Temp System Pump

   
• 4 stage boiler control
• One system pump piped reverse return
© H B X C o n t r o l S y s t e m s I n c . 2 0 14E X P - 0 1 0 0 a n u a l P a g e 4
327530 <4*
Staging Utilized

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
   
• 1x Hi/Lo boiler (2 stage) with 1 main hi-temp system pump
• Boiler pump is being controlled directly from the internal boiler (staging) contacts
• Outdoor reset of boiler target temp is controlled via the outdoor sensor and the
boiler sensor on the supply pipe
• An additional setpoint load in the form of a fan coil, fan coil high-speed controlled
at the same time as fan coil actuator
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXPANSION MODULE
TH
V
V
Boiler 1
Stage 1
Boiler 1
Stage 2
Fan Coil
Hi Speed
Motor
Enable
R W
Fan Coil
Actuator
Setpoint
Sensor
Outdoor
Sensor
Boiler
Sensor
Primary
Heat Load
Thermostat
Primary
Heat Load
Actuator
120VAC
24VAC
C
R
L
N
P2 System
Pump
TH
120VAC
Outdoor
Sensor
Balancing
Valve
Fan Coil
2 Stage
Boiler
NB. Design Heat Load must be a
High Temp Radiant System
Eg. Baseboard/Panel Radiators
Room (Setpoint)
Sensor
Boiler
Sensor
Heat
Load
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Central ProcessingUnit
1000
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
P1 Boiler
Pump
P2 System
Pump
1000 100
 
814*,*2)
• P1 - Boiler Pump
• P2 - System Pump

E X P - 0 1 0 0 a n u a l P a g e 5
327530 <4*
Staging Utilized

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
   
• 4x Hi/Lo fire boilers (8 stages) with 2x hi-temp system pumps controlled on a pump
sequencer
• Boiler pumps are being controlled directly from the internal boiler (staging)
contacts
• Outdoor reset of boiler target temp is controlled via the outdoor sensor and the
boiler sensor on the supply pipe
• Optional DHW shown using DHW pump on DHW priority
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXP. MODULE EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXP. MODULE EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXP. MODULE
Boiler
Sensor
Boiler 1
Stage 1
Boiler 1
Stage 2
Boiler 2
Stage 3
Boiler 2
Stage 4
Boiler 3
Stage 5
Boiler 3
Stage 6
Boiler 4
Stage 7
Boiler 4
Stage 8
24VAC
120VAC
Outdoor
Sensor
P1/P2 Hi Temp
System Pump
Sequencing
P3 DHW
Pump
TH
Apply Control
Signal or
Program for
Permanent Heat
Demand
C
R
L
N
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Central ProcessingUnit
1000
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
CertifiedtoCSA C22.2 No 24
ConformstoULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
120VAC
Boiler
Sensor
DHW
Sensor
P1 and P2
Pump Sequencing
2 Stage Boiler 2 Stage Boiler 2 Stage Boiler 2 Stage Boiler
Heat
Load
P3 DHW
Pump
P4 Boiler Pump P5 Boiler Pump P6 Boiler Pump P7 Boiler Pump
1000 100100100
 
814*,*2)
• P1 + P2 - High Temp
System Pumps setup to
sequence every 48 hours
• P3 - DHW
• P4-P7 - Boiler Pumps

327530 <4*
Staging Utilized
E X P - 0 1 0 0 a n u a l P a g e 6
© H B X C o n t r o l S y s t e m s I n c . 2 0 14

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
# #
• 2 stage boiler, controlling boiler pump and mixed system pump
• Radiant injection valve using P Iv, maintaining a setpoint, Eg. ramp heating
• Outdoor reset of boiler target temp is controlled via the outdoor sensor and the boiler sensor on the
supply pipe
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXPANSION MODULE
Boiler
Sensor
System
Sensor
Setpoint
Sensor
Outdoor
Sensor
P1 Boiler
Pump
P2 System
Pump
Boiler 1
Stage 1
Boiler 1
Stage 2
120VAC
24VAC
V
C
L
N
R
PMIv
Injection
Valve
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Central ProcessingU nit
1000
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
120VAC
System
Sensor
Balancing
Valve
Injection
Valve
Setpoint
Sensor
Ramp Heating
Boiler
Sensor
P2 System
Pump
P1 Boiler
Pump
1000 100
 

814*,*2)
• P1 - Boiler Pump
• P2 - System Pump
327530 <4*
ixing Utilized
E X P - 0 1 0 0 a n u a l P a g e 7

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
CENTRAL PROCESSING UNITCPU-1000
1 2
DS
1
DS
1
3 4
DS
2
DS
2
5 6
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXPANSION MODULE
Boiler 1
Stage 1
Boiler 1
Stage 2
DHW
Actuator
Valve
Boiler
Sensor
System
Sensor
Outdoor
Sensor
P1 Boiler
Pump
P2 System
Pump
P3 PMIp
Injection
Micing
Pump
120VAC
24VAC
Apply Control
Signal or
Program for
Permanent Heat
Demand
A
TH
V
C
L
N
R
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Central ProcessingUnit
1000
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
120VAC
Boiler
Sensor
System
Sensor
Boiler 1
Boiler 2
Balancing
Valve
Balancing
Valve
Heat
Load
A
P2 Mixed
System
Pump
P3 PMIp
Injection
Pump
P1 Boiler
System
Pump P4 Boiler
Pump
P5 Boiler
Pump
1000 100

# #
• ixing systems using more than 1 boiler stage must be connected via 1 or more
EXP-0100 units, note boiler contact terminations.
• Setup shows primary/secondary mixing via P Ip (injection pump), plus optional DHW
control using an actuator valve (terminals 15 and 16)
• Outdoor reset of boiler target is controlled via the outdoor sensor and boiler sensor with
DHW priority
 
814*,*2)
• P1 - Boiler System Pump
• P2 - ixed System Pump
• P3 - Injection Pump, P Ip
• P4-P5 - Boiler Pumps
327530 <4*
ixing Utilized
E X P - 0 1 0 0 a n u a l P a g e 8
© H B X C o n t r o l S y s t e m s I n c . 2 0 14

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
# #
• Single stage boiler, controlling boiler pump and mixed system pump
• Radiant injection pump using P Ip, maintaining a setpoint, Eg. ramp heating
• Outdoor reset of boiler target temp is controlled via the outdoor sensor and the
boiler sensor on the supply pipe
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXPANSION MODULE
Boiler
Sensor
System
Sensor
Outdoor
Sensor
Boiler
Setpoint
Sensor
120VAC L
G
P1 Boiler
Pump
P2 System
Pump
P3 PMIp
Injection
Pump
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Central ProcessingU nit
1000
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
120VAC
Boiler
Sensor
System
Sensor
Setpoint
Sensor
Ramp Heating Balancing
Valve
P1 Boiler
Pump
P3 Injection
Pump
P2 System
Pump
1000 100
 
814*,*2)
• P1 - Boiler Pump
• P2 - System Pump
• P3 - Injection Pump

327530 <4*
ixing Utilized
E X P - 0 1 0 0 a n u a l P a g e 9

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
  "  "
• DHW Control / 4 stage boiler control
• Boiler pumps controlled by boiler
• 1 DHW circulating pump, using 1x EXP-0100
• Single stage boilers
EXP-0100
34
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXPANSION MODULE
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
L
N
Boiler
Sensor
Boiler 1 Boiler 2 Boiler 3 Boiler 4
DHW
Sensor
P1 DHW
Circ. Pump
120VAC
120VAC
Boiler
Sensor P1 DHW
Circ. Pump
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Central ProcessingUnit
1000
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
Single Stage Boiler
Single Stage Boiler
Single Stage Boiler
Single Stage Boiler
DHW
Sensor
P2 Boiler Pump
P3 Boiler Pump
P4 Boiler Pump
P5 Boiler Pump
1000 100
 
814*,*2)
• P1 - DHW Circ. Pump
• P2-P5 - Boiler Pumps

327530 <4*
DHW Utilized
E X P - 0 1 0 0 a n u a l P a g e 1 0
© H B X C o n t r o l S y s t e m s I n c . 2 0 14

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
CENTRAL PROCESSING UNITCPU-1000
12
DS
1
DS
1
34
DS
2
DS
2
56
DS
3
DS
3GR
120
28
NL
2726
GR
120
25
NL
2423
GRGR
120
22
NL
2120
120
19
NL
1817
RL
2
RL
1615
2
RL
1
RL
1413
1
TM
3
TM
1211
3
TM
2
TM
109
2
TM
1
TM
87
1
20-240 v 20-240 v 20-240 v
DO NOT CONNECT POWER HERE
10 A 10 A
10 A 10 A 10 A
EXP-0100
3 4
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXP. MODULE EXP-0100
3 4
DS
1
DS
1
20-240 v 10 A
RL
1
RL
65
1
10 A
RL
2
RL
87
2
DO NOT
CONNECT
POWER
HERE
TM
1
TM
21
1
EXP. MODULE
C
L
120VAC
24VAC
DHW
Boiler
Boiler 1
Stage 1
Boiler 1
Stage 2
Boiler 2
Stage 3
Boiler 2
Stage 4
P1 Hi
Temp
System
Pump
P2 Hi
Temp
System
Pump
DHW
Boiler
Sensor
DHW
Sensor
Outdoor
Sensor
Boiler
Sensor
Apply Control
Signal or
Program for
Permanent Heat
Demand
P1 and P2 are
Automatically
Sequenced by
the CPU-1000
N
R
BBC
CD
D
Input:120VAC 60Hz 5A
Relays: 240VAC 10A
DemandSignal: 20 - 240V
Model: CPU - 1000
CAUTION, RISKOF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Central ProcessingUnit
1000
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
Certifiedto CSA C22.2 No 24
Conformsto ULStandard 873
Input:120VAC 60Hz 5A
Relays: 240VAC10A
DemandSignal: 20 - 240V
Model: EXP-0100
CAUTION, RISKOF ELECTRICAL SHOCK -
DISCONNECTPOWER PRIOR TO SERVICING
EXP-0100
Expansion Module
120VAC
Boiler
Sensor
DHW
Sensor
DHW Boiler
Sensor
2 Stage
Boiler
2 Stage
Boiler
P1 and P2
Hi-Temp
System Pumps
(Sequencing)
P4 Boiler Pump P5 Boiler Pump
Heat
Load
1000 100100
ELECTRICAL
814*,*2)
• P1 - Boiler Pump
• P2 - System Pump
• P3 - Injection Pump
 P4›P5 Boiler Pumps

!   
• Dual system (multi-purpose)
• 2 Hi/Lo fire heating boilers
• 1 dedicated DHW boiler
• System pumps are sequenced
327530 <4*
Dual System Utilized
E X P - 0 1 0 0 a n u a l P a g e 1 1

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
.1.7*)"&55&27<
HBX Controls warrants each of its products to be free from defects in workmanship and materials under normal
use and service for a period of 24 months from date of manufacture or 12 months from date of purchase from an
HBX Authorized Dealer, if within the above documented period after date of manufacture.
If the product proves to be defective within the applicable warranty period, HBX on its sole discretion will repair or
replace said product. Replacement product may be new or refurbished of equivalent or better specifications,
relative to the defective product. Replacement product need not be of identical design or model. Any repair or
replacement product pursuant to this warranty shall be warranted for not less than 90 days from date of such
repair, irrespective of any earlier expiration of original warranty period. When HBX provides replacement, the
defective product becomes the property of HBX Controls.
Warranty Service, within the applicable warranty period, may be obtained by contacting your nearest HBX
Controls office via the original Authorized Agent and requesting a Return aterial Authorization Number (R A #).
Proof of purchase in the form a dated invoice/receipt must be provided to expedite the issuance of a Factory
R A.
After an R A number has been issued, the defective product must be packaged securely in the original or other
suitable shipping package to ensure that it will not be damaged in transit. The R A number must be visible on
the outside of the package and a copy included inside the package. The package must be mailed or otherwise
shipped back to HBX with all costs of mailing/shipping/insurance prepaid by the warranty claimant.
Any package/s returned to HBX without an approved and visible R A number will be rejected and shipped back
to purchaser at purchaser’s expense. HBX reserves the right, if deemed necessary, to charge a reasonable levy
for costs incurred, additional to mailing or shipping costs.
.1.7&7.323+"&55&27.*6
If the HBX product does not operate as warranted above the purchasers sole remedy shall be, at HBX’s option,
repair or replacement. The foregoing warranties and remedies are exclusive and in lieu of all other warranties,
expressed or implied, either in fact or by operation of law, statutory or otherwise, including warranties of
merchantability and fitness for a particular purpose/application. HBX neither assumes nor authorizes any other
person to assume for it any other liability in connection with the sale, installation maintenance or use of HBX
Controls products.
HBX shall not be liable under this warranty; if its testing and examination discloses that the alleged defect in the
product does not exist or was caused by the purchasers or third persons misuse, neglect, improper installation or
testing, unauthorized attempts to repair or any other cause beyond the range of intended use, or by accident,
fire, lightning or other hazard.
.1.7&7.323+.&'.0.7<
In no event will HBX be liable for any damages, including loss of data, loss of profits, costs of cover or other
incidental, consequential or indirect damages arising out of the installation, maintenance, commissioning,
performance, failure or interruption of an HBX product, however caused and on any theory of liability. This
limitation will apply even if HBX has been advised of the possibility of such damage.
3(&0&:
This limited warranty statement gives the purchaser specific legal rights. The purchaser may also have other rights
which vary from state to state in the United States, from Province to Province in Canada and from Country to
Country elsewhere in the world.
To the extent this Limited Warranty Statement is inconsistent with local law, this statement shall be deemed
modified to be consistent with such local law. Under such local law, certain disclaimers and limitations of this
statement may not apply to the purchaser. For example, some states in the United States, as well as some
governments outside the United States (including Canadian Provinces), may:
Preclude the disclaimers and limitations in this statement from limiting the statutory rights of a consumer (e.g.
United Kingdom);
Otherwise restrict the ability of a manufacturer to enforce such disclaimers or limitations; or
Grant the purchaser additional warranty rights which the manufacturer cannot disclaim, or not allow limitations on
the duration of implied warranties.
E X P - 0 1 0 0 a n u a l P a g e 1 2
© H B X C o n t r o l S y s t e m s I n c . 2 0 14

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
E X P - 0 1 0 0 a n u a l P a g e 1 3
 

Control Systems Inc.
HBX EXP 0100 Expansion Module
Version 1.0
© H B X C o n t r o l S y s t e m s I n c . 2 0 14E X P - 0 1 0 0 a n u a l P a g e 1 4
 

©HBX Control Systems Inc. 2014
Phone: [phone] Fax: [phone]
Email: inf
[e-mail] Web: www.hbxcontrols.com
HBX Control Systems Inc.
4516 - 112th Avenue SE
Calgary, AB Canada T2C 2K2