TEC 100 User manual

TEC 100/200 Programming
& Installation Manual
As of software v7.2
Total Energy Controls

2
Contents
Description Page
Installation Instructions
GeneralNotes 3
MainsWiring 3
Control Wiring 4
Other Wiring Options 5
Fitting and Wiring Temperature Sensors 6
Temperature Display Calibration 8
Commissioning Instructions
Introduction 9
Keypad Overview 9
Establishing the System Max Flow Temp 11
Setting the Programs 12
Setting the Calendar 12
Programming the On / Off Times 14
Frequency (How the Time Clock works) 16
SelectDays 17
OptimiseOnTime 18
Optimise Off Time 19
Setting the Maximum Flow Temperature 20
Setting the Minimum Flow Temperature 21
Setting the Minimum Return Temperature 22
Setting the Mid Temperature 23
Setting the Night Temperature 24
Setting the Frost Temperature 25
Setting the External Cut-Off Temperature 26
The Plant Relay 27
HotWaterPriority 28
Internal / External Optimisation 29
Calibration 30
Rotation 32
Exiting Programming Mode 33
TEC 100/200 with Monitoring Socket
Monitor Installation and Operation 34

3
Installation
General Notes
The installation of all TEC units should be carried out by a qualified electrical
engineer familiar with heating systems and control wiring.
All control circuits of TEC units are ‘volt free’ and may be used to switch
240V AC or low voltage control systems.
Extreme care must be taken to ensure that all wiring is correct before applying
power, as irrepairable damage to the PCB could result due to incorrect
connections.
Mains Wiring
Unscrew the four screws of the TEC 100/200 and remove the lid to gain access
to the PCB and wiring connections.
A 240V AC 1Ph 50Hz supply may be taken from the existing time clock
switched or permanent supply, or direct from the boiler mains input connections
(where available), which ever is the most suitable. The 240V connection to the
TEC 100/200 is shown in Fig.1 below.
240 V Supply as described
TEC 100/200 PCB
EL
N
Fig. 1

4
Control Wiring
NOTE: If a wiring harness is provided in the rear of the enclosure please
follow cables to TEC 100/200 PCB to determine connections as described in
the following sections.
Many boilers are provided with an accessible mains terminal block. Most
have a pair of connections (usually unused) for use with external controls.
These connections will have a link which needs to be removed so that the
TEC 100/200 control wires can be connected as shown in Fig.2.
TEC 100/200 PCB
NL E
Remove link
To boiler 2
(
TEC 200
)
To boiler
If the boiler is a simple
permanent pilot type, i.e.
Ideal Concord, Potterton,
Kingfisher etc, the
connections may be made
into the mains supply of
the boiler if more
convenient.
Fig. 2
Note: A 5-core heat resistant flex is ideal for connecting the TEC 100/200 to the
boiler. The recommended connection method is via a flexible nylon
conduit to house the cable.
Where a terminal block arrangement as shown in Fig.2 is not available, the
control wiring should be connected directly into the boiler thermostat wiring
as shown in Fig.3.

5
TEC 100/200 PCB
Boiler Thermostat
Boiler 2 (TEC200):
Connections as per
Boiler 1
NL E
Live in
p
ut
Live to Burner
Fig. 3
Other Wiring Options
The TEC 100/200 has three control relays. On the TEC 100 the left hand relay
is the Plant Relay which may be used to control a circulating pump and the
right hand relay is the boiler control circuit. The centre relay (Tec 100 only)
make and breaks on RTN/HW settings and may be used to control a HW pump,
solenoid etc, see Fig 4. On the TEC 200 the left hand relay is the Plant Relay,
the middle relay is boiler 2 control circuit and the right hand relay is boiler 1
control circuit.
Pump
TEC 100/200 PCB
NL E
1P 2
Make on
RTN/HW
temperature
drop.
Neutral
Live
Fig. 4

6
Fitting and Wiring Temperature Sensors
The TEC 100/200 has three temperature sensor inputs, these being Flow,
Return/Hot Water and External. Connections are as shown in Fig.5.
FLOW Sensor
TEC 100/200 PCB
AuxExtnFlow Retn
P 2 1 N E
L
EXTERNAL Sensor
RETURN / HW Sensor
Fig. 5
Flow / Return Temperature Sensors (Cable Type)
Using heat resistant cloth tape, tightly strap the sensors to the relevant
flow and return pipes, close to boiler, before any branching connections.
Cover the sensors with heating pipe insulation and strap with ty-wraps or
similar. See Fig.6.
Heat Resistant Cloth Tape Sensor Head
Securing Ty-Wraps
Pipe Insulation fixed over Sensor
Flow / Return Pipe
Fig. 6

7
Optional Hot Water Tank Sensor connections (replaces Return Temperature
Sensor) are shown in Fig.7.
Fix Tank Sensor
with expanding
wire (supplied
with optional
Tank Sensor).
TEC 100/200 Return
Temperature Sensor
co
nn
ec
ti
o
n
s
Optional HW Tank Sensor.
Connect in place of Return
Temperature Sensor.
Mount 1/3 to 1/2 way up
tank.
Fig. 7
If the hot water tank is a distance from the boiler, wiring to it may be
impractical.
If hot water priority is important then the Return Sensor should be fitted
to the Hot Water Tank Return Pipe. If this is also impractical, then fit
as normal to the main Return Pipe and set the Minimum Return
Temperature to provide an adequate level of hot water supply.
Where the tank option is used, set the Minimum Return Temperature
to the stored water temperature requirement.
External Sensor
The External Sensor should preferably be positioned on a north facing
exterior wall, and connected to the appropriate terminals of the TEC 100/200.
If it is not possible to mount the sensor on a north facing wall, then mount
in a shaded position, under eaves, and away from boiler house vent grilles etc.
Note A special reflective, insulated external sensor is available when fitting
in a position where solar heat is unavoidable.

8
Temperature Display Calibration
When required, the temperatures as displayed on the TEC 100/200 may be
adjusted to cater for heat losses on pipework, losses on external temperature
sensor etc. Program 17 (see page 30) can be used to calibrate the temperature
display by -10ºC/+20ºC.

9
C ommissioning - Introduction
The TEC 100/200 Digital has 18 main programs, these being:
1. Calendar
2. On/Off Times (Two On/Off Periods per day)
3. Frequency (Once, Twice, 24 Hours)
4. Select Days (Every Day, Weekends, Week Days)
5. Optimise On Time ( 0 to 240 minutes)
6. Optimise Off Time ( 0 to 240 minutes)
7. Maximum Flow Temperature (30ºC to 85ºC)
8. Minimum Flow Temperature (25ºC to 85ºC)
9. Minimum Return Temperature (20ºC to 65ºC)
10. Mid Temperature (0ºC to 85ºC)
11. Night Temperature (0ºC to 85ºC)
12. Frost Temperature (0ºC to 35ºC)
13. External Cut Off Temperature (0ºC to 35ºC)
14. Differential (1ºC to 5ºC)
15. Hot Water Priority (Yes / No)
16. Internal/External Optimisation (Yes / No)
17. Calibration (-10ºC/+20ºC)
18. Rotation (Yes / No)
Certain Differentials and the Compensation Slope are fixed within the software,
i.e. Return Temp 2ºC, External Temp 2ºC, Compensation Slope 1.5.
Keypad and Running Mode Overview
Used to enter Programming Mode from normal running mode,
and to access Change Mode for the selected program.
P
PROGRAM
Used to cycle through the program list when in Programming
SELECT
Mode and to change program settings when in Change Mode.
Used to cycle through the program list when in Programming
Mode and to change program settings when in Change Mode.
RETURN

10
E Used to confirm a programming change and to exit from the
Programming Mode.
ENTER
The TEC 100/200 will go into Boost mode from a cold BOOST
S57 F20 R20 E12
start. It will stay in this mode for 15 minutes, or
until the Return Temp is within10ºC of the Flow
Temp If a Hot Water Sensor is fitted then the
TEC 100/200 will go into Boost mode if the HW Tank
is cold.
FIRING
S57 F50 R42 E12
Firing mode indicates that the boiler is firing.
Temp Set indicates that the actual Flow Temp is
above the system set temperature**. The boiler will TEMPERATURE SET
S57 F59 R53 E12
not be firing at this point.
Economising indicate that the TEC 100/200 has entered ECONOMISING
S57 F59 R53 E12
self learning mode and is making economies. The
boiler will not be firing at this point.
EXT
S57 F36 R34 E16
Ext ‘flashing’ indicates that the external temp
is above the level set in the Ext Cut-Off program.
** The system set temperature as indicated in the display, represents the
heating system aiming temperature based on current climatic conditions,
as determined by the TEC 100/200’s weather compensation circuitry.

11
Establishing the System Maximum Flow Temp
Switch on the power to the TEC 100/200.
1. Set the Bypass Switch to the bypass position.
Allow the heating system to cycle twice at the normal winter setting of the
boiler thermostat (see plant engineer, caretaker, maintenance manger etc to
establish winter thermostat position).
2. The display will show:
FIRING Tu 10:05
S57 F50 R42 E05
Current Mode
Set Temp
Actual Flow Temp
Actual Return / HW Temp
Actual External Temp
3. When the actual Flow Temperature exceeds the Set Temperature, the display
will change:
TEMP.SET Tu 10:05
S57 F58 R48 E05
4. When the boiler has cycled twice with the TEC 100/200 in bypass, observe the
actual flow temperature as shown on the display:
In this example, the winter setting for the heating system (TEC 100/200
maximum flow setting) should be set to 72ºC (73ºC - 1ºC).
The Boiler Thermostat should now be set to a higher setting to ensure correct
operation of the TEC 100/200.
TEMP.SET Tu 10:05
S57 F73 R65 E05

12
Setting the Programs
P1. Setting the Calendar (Factory Set)
1. Press to change display to:
2. Press again to display:
3. Press or to set the year.
4. Press to change display to:
5. Press or to set the month.
6. Press to change display to:
7. Press or to set the date.
P
PROGRAM
1 CALENDAR
21/11/03 11:29
P
PROGRAM
SET YEAR
21/11/03 11:29
E
ENTER
RETURNSELECT
SET MONTH
21/11/03 11:29
RETURNSELECT
E
ENTER
SET DATE
21/11/03 11:29
RETURNSELECT

13
8. Press to change display to:
E SET HOUR
21/11/03 11:29
ENTER
9. Press or to set the hour.
SELECT RETURN
8. Press to change display to:
E
ENTER
SET MINS
21/11/03 11:29
9. Press or to set the minutes.
SELECT RETURN
10. Press to change display to:
SET DAY Fr
E
ENTER
11. Press or to set the day.
SELECT RETURN
12. Press to confirm the program change and return to main menu.
E
ENTER
13. Press to advance to next program.
SELECT

14
P2. Programming the Time Clock (On/Off Times)
1. Press or to select program 2:
SELECT RETURN 2 ON/OFF TIMES
2. Press again to display:
P MO 1 07:30-00:00
2 00:00-16:30
PROGRAM
There are two (2) programmable On/Off times per day.
The second OFF time must ALWAYS be programmed, and set to a time
after, but in the same 24 hour period as the first ON time.
3. To change On/Off Times select the required day with
SELECT RETURN
4. Press to enter programming mode for the chosen day:
P
PROGRAM MO 1 07:30-00:00
* 2 00:00-16:30
5. Press to set first ON time:
P MO 1 07:30-00:00
* 2 00:00-16:30
PROGRAM
6. Press or to set the hour as required.
SELECT RETURN
7. Press to set first ON time minutes:
E
ENTER MO 1 07:30-00:00
* 2 00:00-16:30

15
8. Press or to set the minutes as required.
SELECT RETURN
9. Press to set first OFF** time: MO 1 07:30-00:00
* 2 00:00-16:30
E
ENTER
** If the FIRST OFF time is not required leave at 00:00.
Adjust HOUR and MINUTES in the same way as previously described.
10. Press to set the second ON time and repeat as above.
E
ENTER
11. Press to set the second OFF time and repeat as above.
E
ENTER
If different On/Off times are required for each day, then repeat the above
instructions for each day’s times.
To repeat a days On/Off times into the next day, select the next day as
described above and press followed by .
PE
PROGRAM ENTER
12. Press to confirm program changes and return to main menu.
E
ENTER

16
P3. Frequency (How the Time Clock operates)
1. Press or to select program 3:
3 FREQUENCY
CURRENT ONCE
SELECT RETURN
2. Press to display:
P UP/DN TO CHANGE
CURRENT ONCE
PROGRAM
3. Press or to set as described below:
SELECT RETURN
ONCE The time clock operates from the first ON time to the second
OFFtime.
TWICE The time clock operates on both ON and OFF times i.e. two
On/Off periods per day.
24 HOUR The time clock operates 24 hours a day regardless of the
On/Off settings.
4. Press to confirm program changes and return to main menu.
E
ENTER

17
P4. Select Days
1. Press or to select program 4:
4 SELECT DAYS
CURRENT EVERY DAY
SELECT RETURN
2. Press to display:
P UP/DN TO CHANGE
CURRENT EVERY DAY
PROGRAM
3. Press or to set as described below:
EVERY DAY The heating will operate everyday as set by the time
clockOn/Offtimes.
WEEK ENDS The heating will operate at week ends only as set by
time clock On/Off time for Sat – Sun. If reduced
heating is required at week ends then set the time clock
for reduced hours during Saturday and Sunday, and then
set program 4 to EVERY DAY.
WEEK DAYS The heating will operate during week days only as set
by the time clock On/Off times Mon – Fri. The heating
will be OFF at weekends.
4. Press to confirm program changes and return to main menu.
RETURNSELECT
E
ENTER

18
P5. Optimise On (Pre-Heat)
1. Press or to select program 5:
SELECT RETURN
5 OPTIMISE ON
CURRENT 000 MINS
When programming a Variable Pre-Heat period (Optimum On) the first switch
on time (P2) should be set to the buildings occupation time. If a variable pre-
heat period is not required, then the first switch on time must allow for a
sufficient warm-up period before occupation time.
When selected, the full programmed variable pre-heat period will occur at 0ºC
external temperature. At temperatures above 0ºC the system will calculate the
required pre-heat time.
Note: To assure adequate temperatures are achieved by occupation time
the maximum pre-heat period must satisfy the building’s thermal
characteristics.
If Optimum On is not required then set to 000 mins.
UP/DN TO CHANGE
CURRENT 000 MINS
2. Press to display:
P
PROGRAM
3. Press or to set the required number of minutes.
SELECT RETURN
4. Press to confirm program changes and return to main menu.
E
ENTER

19
P6. Optimise Off
1. Press or to select program 6:
Optimum Off periods will, when selected, switch off a boiler / heating system
earlier than the programmed off time.
At 15ºC external temperature the full optimum off period will occur and the
boilers will switch off early. At 0ºC external temperature there will be no
optimum off and the boilers will switch off at the normal programmed time. At
external temperatures between 0ºC and 15ºC the system will calculate the
required off time.
If Optimum Off is not required then set to 000 mins.
2. Press to display:
3. Press or to set the required number of minutes.
4. Press to confirm program changes and return to main menu.
RETURNSELECT 6 OPTIMISE OFF
CURRENT 000 MINS
P
PROGRAM
UP/DN TO CHANGE
CURRENT 000 MINS
RETURNSELECT
E
ENTER

20
P7. Setting the Maximum Flow Temperature
1. Press or to select program 7:
2. Press to change display to:
3. Press or to change the temperature setting to that
required (i.e. 73ºC).
4. Press to confirm the program changes and return to main menu.
7 MAX FLOW TEMP
CURRENT 60
E
ENTER
RETURN
SELECT
P
PROGRAM
UP/DN TO CHANGE
CURRENT 73
SELECT RETURN