Tekmar Mixing Control 354 User manual

C
Permanent
External
(1 & 2)
Indoor Sensor
Zone Control
13 14
Sen
RTU
2K10K
0.4
2.0
3.
Heating Curve
Dem R
12 345
Mixing Control 354
Dem
10 11 12 15
Sen
Com
Sen
Com
Sw
UnO
1 17
Sen
Sup Out
150°F
100
Minimum
Boiler Return
Motor
Speed
Test
Do not apply power here!
24 V (ac) only
Boiler Sen
Occupied
35
(2)
105
(41)
70°F
(21°C)
Unoccupied
35
(2)
105
(41)
70°F
(21°C)
Boiler enabled
10% open
H10712
Heat Demand
25% open
123
O
R
Boiler
Closing
Power
Heat Demand
WWSD
Unoccupied
Minimum Return
Maximum Supply
Floating Action
Heat Demand
18 19 20789
Mix
Com Opn Cls
Mix Mix Sen
Com
Sen
Ret
140 sec.
30 250Off
100°F
150
0
M
Opening
Power 24 V 50/ 0 Hz 3 VA
Pump Relay
1 2 0 V (ac) 10 A 1/3 hp, pilot duty 240 VA 2 A
Boiler Relay
1 2 0 V (ac) 10 A 1/3 hp, pilot duty 240 VA 2 A
Mix Relay
1 2 0 V (ac) A 1/4 hp, pilot duty 240 VA 2 A
Made in Canada by
tekmar Control Systems Ltd.
Pump
Heat Power
Max. Supply
190
Pump
Off
Jun 95
12345 7
- Data Brochure
Mixing Control 354
D 354
08/95
Heating
is required
Operating Mode
selector switches
Test button and
LED to test main
control functions
24Vac power
supply is on
Terminal Plugs:
Power and out-
put connections
Occupied
temperature
setting
Control is
maintaining
Maximum Supply
Unoccupied
temperature
setting
Terminal Plug:
Sensor and
timer input
Heating Curve
setting
Input: Supply
Universal Sensor 071
Included
Outdoor Reset Strategy pg 2 Testing pg 9
Sequence of Operation pg 3 Error Messages pg 11
Installation pg 5 Technical Data pg 12
Settings pg 8 Limited Warranty pg 12
Input:
Heat Demand
signal
Input: Indoor
Sensor 074
Output:
Turn on boiler
24Vac
power
supply
Output: Turn on
pump
Output: Open / Close
Mixing Valve
Input: Return
Sensor 071
System is in
Warm Weather
Shut Down
System is
switched to
Unoccupied
Control is
maintaining
Minimum Return
Valve is opening
Valve is closing
Minimum Boiler
Return tempera-
ture setting
Actuating
Motor Speed
setting
Maximum Supply
temperature
setting
Input: 2k RTU
Mixing Control 354
Power
Heat Demand
WWSD
Unoccupied
Min. Return
Max. Supply
Boiler
Occupied
35
(2)
105
(41)
70°F
(21°C)
Unoccupied
35
(2)
105
(41)
70°F
(21°C)
Closing
Opening
Floating Action
Pump
The tekmar Mixing Control 354 is a microprocessor-based control with a floating action output
intended to operate a mixing valve. This valve regulates the supply water temperature to a heating
system based on the outdoor air temperature, and optionally, the indoor air temperature. The
pump is shut down and the valve is closed when there is no Heat Demand signal or when the
outdoor temperature is warm enough so that the system no longer requires heat (WWSD). The
pump runs continuously when a zone control is selected. Maximum supply temperature and
minimum boiler return temperature can be constrained for protection of system components.
Boiler is on
Pump is on
Input: Unoccupied
signal. or
Timer 030
Input: Outdoor
Sensor 070
Included

Shifting the Heating Curve
(a) Manually, at the control:
The Occupied and Unoccupied dials on this control can shift the WWSD
point up or down from 35 to 105°F (2 to 41°C).
(b) Automatically, using room temperature feedback:
In addition to a Supply Sensor and an Outdoor Sensor, this control can use
a tekmar RTU, Zone Control or Indoor Sensor to provide room temperature
feedback for added comfort and system flexibility.
The control still calculates a desired supply temperature based on the
Heating Curve setting and the outdoor temperature.
If the air temperature in the room is too cold, the control will shift the heating
curve (and WWSD point)
up, which raises the supply temperature until the
room warms up again.
If the air temperature in the room is too warm, the control will shift the heating
curve (and WWSD point)
down, which lowers the supply temperature until
the room cools down.
Correct setting and shifting of the Heating Curve the key to More Comfort and Energy Savings
Heating Curve
As outdoor temperatures get colder, heat losses from a building increase, requiring the addition of more heat to prevent the indoor
air temperature from also getting colder. This tekmar reset control measures the outdoor temperature and as the outdoor
temperature gets colder, it balances the heat loss by making the heating supply water hotter.
The Heating Curve is used to calculate exactly how hot to make the supply water at different outdoor temperatures, and illustrates
the Reset Ratio. (the number of degrees the supply water temperature is raised for each degree the outdoor temperature falls.)
Setting the Heating Curve
Two examples of how the Heating Curve works (see illustration)
—With a 2.4 Curve, the supply water temperature is raised 2.4 degrees for every degree of outdoor temperature drop.
If: WWSD point = 70°F and Outdoor temperature = 30°F, then supply temperature = 1 °F
—With a 0. Curve, the supply water temperature is raised 0. degrees for every degree of outdoor temperature drop.
If: WWSD point = 70°F and Outdoor temperature = 30°F, then supply temperature = 94°F
2
To provide heat to the building, this control turns on the pump and opens the mixing valve, delivering heat at the low output required
by the Heating Curve near the WWSD point. If the outdoor temperature rises above the WWSD point, the control shuts the system
off again, and because the system was operating at a low heat output level, overheating and temperature swings in mild weather
are avoided.
When the system is operating near the WWSD point and the building is too cold; the WWSD point should be raised.
When the system is operating near the WWSD point and the building is too warm; the WWSD point should be lowered.
• If the Heating Curve selected is too low; the heating system will not be
able to raise the supply temperature high enough to keep the room
temperature warm during colder weather.
• If the Heating Curve selected is too high; too much heat is delivered and
the building will overheat during colder weather.
Warm Weather Shut Down (WWSD)
At warm outdoor temperatures, the indoor space of a building gains heat
from the outdoors; additional heat is not required, and if the heating
system is running (even on standby), enough excess heat can be
produced to overheat the building, causing discomfort and wasting
valuable energy.
This control closes the mixing valve and turns off the pump, when the
outdoor temperature is above the WWSD point.
As outdoor temperatures get colder, there comes a point where the heat
gain turns into heat loss; the heat loss causes the indoor temperature to
fall below the comfort level, and the heating system must be turned on to
start delivering heat.
Outdoor air temperature
Supply water temperature
50
(10)
30
(-1)
10
(-12)
-10°F
(-23)°C
11 0
(43)
70
(21)
70
(21)
90
(32)
210
(99)
170
(77)
150
( 5)
130
(54)
190
(88)
3. 3.0 2.4 2.0 1.
0.8
0.4
1.0
0.
90
(32)
50°F
(10)°C
Heating
Curve
WWSD
Point
1.2
Outdoor air temperature
Supply water temperature
50
(10)
30
(-1)
10
(-12)
-10°F
(-23)°C
11 0
(43)
70
(21)
70
(21)
90
(32)
210
(99)
170
(77)
150
( 5)
130
(54)
190
(88)
3. 3.0 2.4 2.0 1.
0.8
0.4
1.0
90
(32)
50°F
(10)°C
Heating
Curve
WWSD
Point
will
shift
up and
down
with
shift of
Heating
Curve
1.2
UP DOWN
UP DOWN
Parallel Shift of Heating Curve
0.
A very cool room temperature can shift the curve far enough up to bring the control out of WWSD at warm outdoor temperatures.
A very warm room temperature can shift the curve far enough down to put the control into WWSD at cool outdoor temperatures.
Refer to the tekmar Essays E 001 and E 002 for more detailed information regarding control strategy and integration of control functions.
Outdoor Reset Strategy

Unoccupied mode
Connect (short circuit) terminals
UnO Sw — Com Sen (14 and 15) together.
Heat Demand signal
(a) -
switch the Heat demand switch to the "External (1 & 2)" position, and
supply a 24Vac signal to terminals
Heat Dem — Heat Dem (1 and 2),
(b) - switch the the Heat demand switch to the "Permanent" position.
3
When the Mixing Control 354 is powered-up, the "Power" light will come on and the control will turn on all LED's for five seconds.
If no errors are detected, the control closes the mixing valve for the time set on the Motor Speed dial (this is the last step of
the test program, see page 11). Once the mixing valve is closed, the control enters the operating mode. Once in operating
mode, the control uses:
• an Outdoor Sensor 070 to continually monitor the outdoor temperature.
• an Universal Sensor 071 to continually monitor the system supply water temperature.
• Option, an Universal Sensor 071 to continually monitor the boiler return water temperature.
•
Option, Indoor temperature can be monitored through the use of;
(a) - a tekmar 2K RTU or Indoor Sensor 074 (switch selector switch to "Indoor Sensor" position) or;
(b) - a tekmar Zone Control (switch selector switch to "Zone Control" position)
• While monitoring all of these temperatures, the control recognizes the following temperature conditions and inputs and will
respond as described. During operation, the lights of the control will indicate operational status as illustrated.
Indoor Sensor 074 function Selector switch = Indoor Sensor
The control will monitor the indoor, outdoor and supply temperatures, and shift the Heating Curve (and the
WWSD point) up or down to fine adjust the system supply water temperature whenever the room temperature
is different than the setting of the Occupied dial. When switched into Unoccupied mode, the "Unoccupied"
light will come on, and the control will operate at the temperature of the Unoccupied dial setting.
2K RTU function Selector switch = Indoor Sensor
The control will monitor the indoor, outdoor and supply temperatures, and shift the Heating Curve (and the
WWSD point) up or down to fine adjust the system supply water temperature whenever the room
temperature is different than the setting of the RTU dial. The Occupied and Unoccupied dials are not
functional, and a setback RTU must be used if Unoccupied schedules are desired.
WWSD function
When WWSD occurs, the "WWSD" and "Closing" lights will come on, the mixing valve will
close and the boiler and pump will shut down. The control will continue to monitor the
outdoor and supply temperatures. Whenever 3 days pass, the mixing valve will be run open
and closed and then the pump will be cycled on for 15 seconds to help prevent seizing.
External
(1 & 2)
Permanent
Indoor Sensor
Zone Control
Boil
e
10%
Heat Demand
25%
tekmar Zone Control function Selector switch = Zone Control
The control will monitor the indoor temperatures of all zones, as well as the outdoor and supply
temperatures, and shift the Heating Curve (and the WWSD point) up or down to fine adjust the system supply
water temperature for whichever zone requires the hottest supply water. The pump relay is continuously
on when Zone Control is selected except during the valve and pump exercising period. The Occupied and
Unoccupied dials are not functional.
Valve and Pump Exercising
Exercising of the valve and pump is done to ensure long life of these components. Every three days the control checks to see if the
valve has been operated to the fully open and close positions. If the valve has been operated to these positions, the control continues
normal operation. If not, the control will open the valve to the fully open position and then return the valve to its previous position. If
the valve has not been closed in the last three days, the valve will also cycle fully closed and then return to its operating location.
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Heat Demand
Boiler
Closing
Pump
Opening
Heat Demand light
may also be on
Unoccupied light
may also be on
External
(1 & 2)
Permanent
Indoor Sensor
Zone Control
Boil
e
10%
Heat Demand
25%
External
(1 & 2)
Permanent
Indoor Sensor
Zone Control
Boil
e
10%
Heat Demand
25%
Occupied/Unoccupied dial function
The control will monitor the outdoor and supply temperatures. The Occupied and Unoccupied dial settings become the WWSD point.
When the outdoor temperature is warmer than the setting of the Occupied dial, the control enters WWSD. When switched into
Unoccupied mode, the "Unoccupied" light will come on, and the control will operate at the temperature of the Unoccupied dial setting.
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
12
Dem Dem
Heat
External
(1 & 2)
P
Zone Control
Boiler enabled
Heat Demand
25% open
()
Permanent
Boiler enabled
10% open
Heat Demand
Outdoor temperature cold enough to require heating
Occupied/Unoccupied dial, no Heat demand signal
When the outdoor temperature is colder than the WWSD point, the control will leave
WWSD. Whenever the control leaves WWSD, the "WWSD" light will go out and the
control will continue to monitor the outdoor and supply temperatures, but no further
control action will take place until there is a heat demand signal.
Unoccupied light
may also be on
Sequence of Operation
OR
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Heat Demand
Boiler
Closing
Pump
Opening

Notes on operation of Minimum Return and Maximum Supply functions
At times, the control may be trying to control both the Maximum Supply and Minimum Return temperatures (ie. when leaving a
deep setback). When this occurs, the control is programmed to give priority to the Minimum Boiler Return function, and only the
"Min. Return" light will be displayed.
When the control is in WWSD, the "Min. Return" and "Max. Supply" lights will not be displayed.
When using a Return Sensor for Minimum Boiler Return protection, it is essential that there always be water flow past the boiler
return sensor whenever there is a heat demand. See Brochure A 354.
Caution:
The tekmar Mixing Control 354 is an operating control and is not certified or intended for use as a primary safety device
Under normal operating conditions, the control will provide excellent protection against excessive supply temperatures
and low boiler return temperatures, however, if failsafe protection against either of these conditions is essential then
separate certified safety limit devices should be employed
4
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Opening
(c)
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Opening
(b)
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Opening
(a)
Maximum Supply temperature operation
To provide a measure of protection to system components that may be damaged by
excessive heat, (eg. some types of plastic hydronic radiant floor tubing) this control has
a setting for Maximum Supply temperature. Maximum supply can be turned off by
rotating the dial fully clockwise.
When the supply temperature gets close to the setting on the Max. Supply dial, the Max
Supply light will come on an the control will begin closing the valve, in order to reduce
the temperature before it overshoots. The control will operate the valve to maintain the
temperature slightly below the Maximum.
The control may operate for a long time at the Maximum supply temperature if :
(a) - it is coming out of a deep setback or just starting up from a cold start.
(b) - an RTU (or Occupied dial when Indoor Sensor 074 is used) is turned up suddenly.
(c) - the maximum setting is too low for system design conditions.
Minimum Boiler Return temperature operation
To provide a measure of protection to boilers that may be damaged by low return water
temperatures, this control has a setting for Minimum Boiler Return temperature.
When the boiler return temperature gets close to the setting on the Minimum Boiler
Return dial, the "Min Return" light will come on and the control will begin closing the valve
in order to raise the boiler return temperature before it undershoots. The control will
operate the valve to maintain the boiler return temperature slightly warmer than the
Minimum Boiler Return temperature setting.
The control may operate for a long time at the Minimum Return temperature if:
(a) - it is coming out of a deep setback or just starting up from a cold start.
(b) - an RTU (or Occupied dial when Indoor Sensor 074 is used) is turned up suddenly.
(c) - the minimum setting is too high for system design conditions.
Outdoor temperature cold enough to require heating (cont )
With Heat demand signal
The "Heat Demand" light will come on, the control will switch on the
pump, and calculate the desired supply temperature based on the
requirements of the Heating Curve.
The control will operate the actuating motor which positions the mixing
valve to deliver the correct supply temperature.
When positioning the mixing valve, the control uses the following control
actions;
(a) - Open the valve. The "Opening" light will come on and the control
will power the valve towards the fully open position.
(b) - Close the valve. The "Closing" light will come on and the control
will power the valve towards the fully closed position.
(c) - No valve movement. "Opening" and "Closing" lights are both off
and the valve remains in a fixed position.
Boiler light may also be on
Min Return light may also be on
Max Supply light may also be on
Unoccupied light may also be on
Opening or Closing
light may also be on
Boiler light may also be on
Unoccupied light may also be on
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Opening
Opening or Closing
light may also be on
Unoccupied light may also be on
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Test
Opening

Step Four Electrical connection to the control
Power and output connections
The installer should test to confirm that no voltage is present at any of the wires
• Install the control into the base, sliding it down until it snaps into place.
• All electrical connections are made directly to the plug terminals.
• Connect the 24Vac power supply from the secondary side of a 24Vac class II transformer to
terminals Power C — Power R (3 and 4). Do not connect either of the transformer terminals
to ground.
• Connect the Pump circuit to terminals Pump (5 and ). These terminals lead to a 10 amp dry relay
contact which closes when the control requires pump operation.
Note: The type 354 is approved for low voltage only (Maximum 24Vac). The pump should be
switched through an isolation relay approved for the line voltages required to operate the pump.
• Connect the boiler circuit to terminals Boiler (10 and 11). These terminals lead to a 10 amp
dry relay contact which closes when the control requires boiler operation. Boilers with a 24Vac
control circuit can be switched directly through the control. If higher voltages are used, an
isolation relay should be added.
Caution
Improper installation and operation of this control could result in damage to equipment and possibly even personal injury
It is your responsibility to ensure that this control is safely installed according to all applicable codes and standards
Step One Getting ready
Check the contents of this package. If any of the contents listed are missing or damaged, please refer to the Limited Warranty
and Product Return Procedure on the back of this brochure and contact your wholesaler or tekmar sales agent for assistance.
Type 354 includes: •One Control 354 • One Outdoor Sensor 070 • One Supply Sensor 071
• One Data Brochure D 354 • One Data Brochure D 001 • Application Brochures A 354
Other information available: • Essay E 001 • Essay E 002
Read brochures A 354 and select the correct Application for your job.
Note:
Carefully read the details of the Application, and the Sequence of Operation sections in all applicable brochures to ensure that you
have chosen the proper control and understand its functions within the operational requirements of your system. Some applications
feature boiler return protection and require ordering an additional Universal Sensor 071.
Step Two Mounting of the base
The control should be removed from its base by pressing down on the release clip in the wiring chamber and sliding upwards
on the control. The base is then mounted in accordance with the instructions in the Data Brochure D 001.
Step Three Rough-in Wiring
All electrical wiring terminates in the control base wiring chamber. It has standard 7/8" (22mm) knock-outs that will accept
common wiring hardware and conduit fittings. Before breaking out the knock-outs, check the wiring diagram and select those
sections of the chamber with common voltages, since the safety dividers will later prevent wiring from crossing between sections.
Power should not be applied to any of the wires during this rough-in wiring stage
• Install the Outdoor Sensor 070, and the Supply Sensor 071 according to the instructions in the Data Brochure D 001 and
run the wiring back to the control.
Option: A Universal Sensor 071 can be installed to provide Minimum Boiler Return protection. See Brochures A 354.
Option: An Indoor Sensor 074, RTU or Zone control can also be connected. See individual sensor instructions.
• Install the wiring from the other system components (Boiler, Pump, Actuating Motor, Heat Demand circuit) to the base.
• Install a 24Vac Class II transformer with a minimum 12VA rating close to the control, and run the wiring from the transformer
to the base.
A Class II transformer must be used. Do not connect any of the transformer terminals to ground, as damage to
the control may result.
5
34
CR
Power
5
Pump
Installation
Maximum 24 Volts
5
Pump
34
CR
Power
10 11
Boiler
789
Com
Mix
Opn
Mix
Cls
Mix

OR
Sensor and unpowered input connections
Power should never be applied to these terminals Damage to the
control will result
Connect the two wires from the Outdoor Sensor 070 to terminals
Com Sen — Out Sen (18 and 20).
Connect the two wires from the Supply Sensor 071 to terminals
Com Sen — Sup Sen (18 and 19).
Option: Boiler Return temperature sensor: (Ordered separately)
Connect the two wires from the Universal Sensor 071 to terminals
Com Sen — Ret Sen (12 and 13).
Option: Indoor temperature feedback sensor. (One option only)
(1) Connect the two wires from the Indoor Sensor 074 or the tekmar
10K Zone Control to terminals Com Sen — 10K Sen (15 and 1 ).
OR
(2) Connect the two wires from the tekmar 2K RTU to terminals
Com Sen — 2K RTU (15 and 17).
Option: Occupied/Unoccupied switch input.
Connect the two wires from the Occupied/Unoccupied dry contact
switch (timer, relay, etc.) to terminals UnO Sen — Com Sen (14 and 15).
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
Do not apply power here!
Maximum 24 Volts
• Connect the power supply for the actuating motor to terminal Com Mix (7).
If a tekmar Actuating motor 010 is used , a 24Vac 12VA power supply for the
control is adequate for operating the motor. Install a jumper wire between
terminal Power R (4) and Com Mix (7).
• Connect the wire from the OPEN circuit of the actuating motor to the terminal
Opn Mix (8) of the control. This terminal leads to a 10 amp relay contact
which closes to bring power from terminal
Com Mix (7) to open the valve.
• Connect the wire from the CLOSE terminal of the actuating motor to the terminal
Cls Mix (9) of the control. This terminal leads to a 10 amp relay contact which
closes to bring power from terminal
Com Mix (7) to close the valve.
35 4
CR
10 11
Boiler
789
Com
Mix
Opn
Mix
Cls
Mix
Pump
Power
Power supply
connection to tekmar
Actuating Motor 010
Output
to Motor
Maximum 24 Volts
Powered input connections
If a 24Vac external heat demand signal is used, (zone valve end switches, etc.) connect the
wiring from the Heat Demand circuit to terminals Heat Dem — Heat Dem (1 and 2). When
24Vac is applied to these terminals, the control will respond to a "call for heat" from the system.
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
12
Dem Dem
Heat
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
UnO
Sw
Com
Sen
18 19 20
Com
Sen
10K
Sen
2K
RTU
Sup
Sen
Out
Sen
Com
Sen
Ret
Sen
12 13 14 15 1 17
Note: This is not a wiring diagram
For a detailed wiring schematic of your specific application, refer to the Application Brochure A 354
type 354
Do not apply
power here!
Maximum 24 Volts
10A
10A
Safety Divider
24
Vac
External
24Vac
0Hz class II
transformer
OR
Outdoor
Sensor
070
Supply
Sensor
071
12 13 14 15
UnO
Sw
Com
Sen
10K
Sen
2K
RTU
Com
Sen
1
Sup
Sen
17
Out
Sen
89107
Com
Mix
Opn
Mix
Cls
Mix
12
Dem Dem
453
CR
11
18 19 20
Com
Sen
Ret
Sen
10A 10A
Boiler
Unoccupied
Switch (optional)
to switch control to
Unoccupied mode
or Timer 030
Return
Sensor 071
(optional)
2K RTU
(optional)
10K Indoor
Sensor or
Zone Control
(optional)
Heat Demand
Deliver 24Vac signal
when heat requested
from system
120/240Vac
Boiler Relay
closes to turn
on boiler
Actuating Motor
Relay
Closes to operate
Mixing Valve motor
(refer to A-354 for
wiring)
Pump Relay
closes to turn on
System Pump
Pump
Heat Power
Electrical connections to the terminal plugs of the type 354 control Control relays are shown in "power down" condition

Test the outputs
If a Pump circuit is connected to the Pump (5 and ) terminals, make sure power to the circuit is off and install a jumper in the
terminal plug between terminals 5 and . When the circuit is powered-up, the pump should operate.
If it does not come on, check the circuit wiring for errors and ensure that it is powered up and the voltage is correct. Check the
devices in the circuit (pump, switching relay, etc.) for faults. If the pump operates properly when the circuit is powered up disconnect
the power, remove the jumper and proceed to the next step.
Note: When a Return Sensor 071 is used, the boiler loop pump must operate with the pump See Brochures A 354
If you are using the control to operate the boiler, make sure power to the boiler circuit is off and install a jumper in the terminal
plug between the Boiler (10 and 11) terminals. When the circuit is powered-up, the boiler should operate. If it does not come
on, check the circuit wiring for errors and ensure that it is powered up and the voltage is correct. Check the devices in the circuit
(limits, flow switches, etc.) for faults. If the boiler operates properly when the circuit is powered up, disconnect the power, remove
the jumper and proceed to the next step.
Make sure power to the Actuating Motor circuit is off and install a jumper in the terminal plug between the Com Mix — Opn Mix
(7 and 8) terminals. When the circuit is powered-up, the valve should open. If it does not open, check the circuit wiring for errors
and ensure that it is powered up and the voltage is correct. Check the valve to make sure it is not jammed or already fully open.
If the valve closes instead of opens, reverse the motor OPEN and CLOSE wiring. If the valve operates properly when the circuit
is powered up, disconnect the power, remove the jumper and install it in the terminal plug between the Com Mix — Cls Mix (7 and 9)
terminals. When the circuit is powered-up, the valve should close. If it does not close, check the circuit wiring and valve operation
as described above. Disconnect the power, remove the jumper and proceed to the next step.
Connect the control
• Turn the power off and make sure all test jumpers have been removed from the plugs
• Connect the plugs to the control by carefully aligning them with their respective headers and pushing them upwards into the
headers. The plugs should snap firmly into place.
• The control is now ready for set-up and operation.
Caution
The tekmar Mixing Control 354 is an operating control and is not certified or intended for use as a safety device Under
no circumstances should safety limit devices be left disconnected after installation of this control The installer shall
check all applicable code requirements and obtain necessary inspections to ensure that the installation is in
compliance with those requirements
Step Five Testing the wiring
Caution
These tests are to be performed using standard electrical testing practices
and procedures and should only be carried out by properly trained and
experienced persons
Before applying power to the control for testing, each terminal plug must be
unplugged from its header on the control Pull straight down to unplug
A good quality electrical test meter, capable of reading from at least 0 — 200
Volts AC, and at least 0 — 1,000,000 Ohms, is essential to properly test this
control
Test the sensors
These test must be made before turning on the power supply, and with the terminals
unplugged. The sensors are to be tested according to the instructions in brochure
D 001. If a tekmar RTU or Zone Control is used, check the applicable data brochure
for the product used.
Test the power supply
Make sure exposed wiring or bare terminals are not in contact with any other wires or
grounded surfaces. Turn on the power to the transformer and use an AC voltmeter
to measure the voltage between terminals C — R (3 and 4). Between 22 and 2 Volts
AC should be measured at these terminals.
Test the powered inputs
If an external Heat Demand signal is used, power up the Heat Demand circuit and
supply a Heat Demand signal to the control. Use an AC voltmeter to measure the
voltage between terminals Heat Dem — Heat Dem (1 and 2). Between 22 and 2
Volts AC should be measured at these terminals.
7
13
14
15
17
1
18
19
20
2K
RTU
Sup
Sen
Ret
Sen
Uno
Sw
10K
Sen
Com
Sen
Out
Sen
12
Com
Sen
Com
Sen
Terminal plug disconnected
from its header on the control
Terminal plug pushed into
its header on the control
13
14
15
17
1
18
19
20
2K
RTU
Sup
Sen
Ret
Sen
Uno
Sw
10K
Sen
Com
Sen
Out
Sen
12
Com
Sen
Com
Sen

8
Step Six Essential control settings
To obtain the best operation from a reset control, it is important to measure the system supply temperature as accurately
as possible Whenever the control receives a heat demand signal, the system pump must be operated to maintain
continuous water flow across the supply temperature sensor Whenever the control uses a boiler return sensor, the boiler
pump must also be operated to maintain continuous water flow across the boiler return sensor
For specific application details refer to Brochures A 354.
A more detailed technical description of the effect of control settings on overall system operation is described in the tekmar Essay, E 002.
0.4
2.0
3.
Heating Curve
design supply temperature – room temperature
room temperature – design outdoor temperature
Heating Curve =
For example: • Design outdoor temperature = 5°F (-15°C)
• Room temperature = 70°F (21°C)
• Design supply temperature = 160°F (71°C)
Heating curve = = = 1 4
160°F - 70°F
70°F - 5°F
90°F
65°F
For more information regarding the Heating Curve, refer to page 2 of this
brochure. If the actual designed supply water temperature for a system
is unknown, a trial setting can be calculated using these typical supply
temperatures:
• Fan coils …180° to 210°F (82° to 99°C)
• Baseboard convectors …1 0° to 190°F (71° to 88° C)
• Hydronic radiant floors …100° to 130°F (38°to 54°C).
Outdoor air temperature
Supply water temperature
50
(10)
30
(-1)
10
(-12)
-10°F
(-23)°C
11 0
(43)
70
(21)
70
(21)
90
(32)
210
(99)
170
(77)
150
( 5)
130
(54)
190
(88)
3. 3.0 2.4 2.0 1.
0.8
0.4
1.0
0.
90
(32)
50°F
(10)°C
Heating
Curve
WWSD
Point
1.2
Occupied temperature
When there is no room temperature feedback to the control, the Occupied dial setting determines the
starting point of the heating curve (WWSD point) and the heating curve setting will reset the water
temperature as described in the Heating Curve instructions above.
When an Indoor Sensor 074 is connected to the control, the Occupied dial setting becomes the actual
controlled temperature of the room. This valuable feature allows the control to compensate for an
incorrectly set heating curve or for unexpected internal heat gains or losses. If the room temperature
is too high or too low, the indoor sensor allows the heating curve to be shifted up or down accordingly.
When a tekmar Zone Control or RTU (Room Temperature Unit) is connected to the control, the RTU
setting becomes the controlled temperature and the Occupied dial becomes inactive.
Unoccupied temperature
The Unoccupied dial operates in the same way as the Occupied dial, but at a different temperature.
When the terminals
UnO Sw — Com Sen (14 and 15) are shorted out, the control switches from
operating at the Occupied dial setting to operating at the Unoccupied dial setting. When a tekmar
Zone Control or RTU (Room Temperature Unit) is connected to the control, the RTU setting becomes
the controlled temperature and the Occupied/Unoccupied dials become inactive, making it necessary
to control Unoccupied temperatures at each individual zone.
Zone Control/Indoor Sensor switch
Set this selector switch to the "Indoor Sensor" position when a tekmar Indoor Sensor 074 or a tekmar
RTU is connected. The control will receive room temperature feedback from the room that has the
Sensor or RTU.
Set the switch to the "Zone Control" position when a tekmar Zone control is connected, the control
receives information from the Zone Control that allows the heating curve to be shifted so the supply
water temperature is hot enough to satisfy the requirements of the zone with the highest heat demand.
Occupied
35
(2)
105
(41)
70°F
(21°C)
35
(2)
105
(41)
70°F
(21°C)
Unoccupied
External
(1 & 2)
Permanent
Indoor Sensor
Zone Control
Boiler enabled
10% open
Heat Demand
25% open
Settings
Heating Curve
As outdoor temperatures drop, heat losses from a space become greater and the heating system
supply water temperature must be raised to maintain a constant room temperature. The heating curve
value describes how many degrees the supply water temperature is raised for a one degree drop in
outdoor temperature. The supply temperature starts to increase when the outdoor temperature falls
below the WWSD point. To calculate the correct setting for the heating curve, use the following formula.

9
Heat Demand switch
When the heating system uses zone valve end switches or some other means of delivering an
external heat demand signal to terminals
Heat Dem — Heat Dem (1 and 2), set this switch to
"External (1 & 2)" and the control will only be able to operate the mixing valve when it receives a
24Vac signal from the heat demand circuit.
If an external heat demand signal is not used, set the switch to "Permanent" and the control will be
enabled all the time.
Maximum Supply temperature
This setting determines the maximum allowable supply temperature to be delivered to the system.
When the supply temperature gets too hot, the mixing valve closes until the temperature is stabilized
at the maximum. To get the fastest system heat up times, this setting should be set as high as
allowable. Refer to page 4 for more details on maximum supply operation and requirements.
Minimum Boiler Return temperature
When a Return Sensor 071 is connected to the control, and the dial is turned up from "Off", this
setting determines the minimum allowable boiler return temperature. When the return temperature
becomes too cold, the mixing valve is closed until the temperature is stabilized at the minimum. To
get the fastest system heat up times, this setting should be set as low as allowable. Refer to page
4 for more details on minimum boiler return operation and requirements.
Boiler Enable switch
The position of this switch determines at which valve position the control will fire the boiler under
normal conditions. If there is a Return Sensor 071 installed and the boiler return temperature is too
cold, the control will override this setting in order to raise the water temperature more quickly.
• At the "10% open" position, the control will not fire the boiler until the valve has opened at least
10%, and will turn the boiler off when the valve closes to 0% open. This setting would normally be
chosen for high mass boilers (cast iron, steel fire tube, etc.), or systems with a large thermal mass
in the loop between the boiler and the mixing valve.
Motor
Speed
140 sec.
30 250
tekmar
motor
External
(1 & 2)
Permanent
Indoor Sensor
Zone Control
Boiler enabled
10% open
Heat Demand
25% open
External
(1 & 2)
Permanent
Indoor Sensor
Zone Control
Boiler enabled
10% open
Heat Demand
25% open
(1) Set the Motor Speed dial to the longest (fully clockwise) position.
(2) Power up the control and let it run the actuating motor/mixing valve to the fully closed position.
(3) When the test light turns off, push the test button.
(4) Observe the motor as it is driven open by the test routine. When the motor reaches its fully open position by stopping against
its end switch, turn the Motor Speed dial down just until the control cycles through to the next step in the test routine.
(5) The Motor speed dial is now calibrated to the motor. Let the control cycle through to the end of the test routine.
Motor Speed
The control determines the position of the mixing valve by timing the actuating motor, and comparing
the elapsed time of open signal against the elapsed time of close signal. Selecting the correct Motor
Speed setting is essential for proper valve and boiler operation. The tekmar Actuating Motor 010
takes 210 seconds to move from the fully closed to the fully open position and the Motor Speed dial
on the control is labeled with a mark indicating the correct position.
If you are using a different make of actuating motor and you know its opening time, set the Motor
Speed dial to match. If you are unsure of the exact opening time, complete the following procedure:
• At the "25% open" position, the control will not fire the boiler until the valve has opened at least 25%, and will turn the boiler off
when the valve closes to 15% open. This setting would normally be chosen for low mass boilers (copper fin tube, low mass
cast iron, etc.), and systems with low thermal mass in the loop between the boiler and the mixing valve.
Note:
Some heating systems combine high input, low mass boilers with very little thermal mass in the loop between the boiler
and mixing valve In some extreme cases, erratic boiler action (short cycling and tripping of high limits) may result from
this type of system even at the "25% open" position To prevent this type of operation it may be necessary to add thermal
mass to the system by installing a storage tank or making the loop larger
150°F
100 Off
Max. Supply
190
Minimum
Boiler Return
Off
100°F
150
0
Test button
With the settings made and the terminal plugs firmly seated, power up the control. The control will
do the last step of the following test routine. It is adviseable to re-check the power supply voltage
while the control is powered and operating.
The control can be made to cycle through the test routine whenever the Test button is pushed. The
test can be halted at certain times during the test by pushing the button a second time. For details
of the test routine, refer to the test routine description starting on the next page.
Testing the Control Functions
Test

Indicator lights
There are eleven LEDs on the front of the control that will aid in testing and troubleshooting. During normal operation, these lights
indicate the following functions:
Power light on
• the 24Vac power supply has been connected and the control is energized.
Heat Demand light on • the control is receiving an external heat demand signal at terminals Heat Dem — Heat Dem
(1 and 2) or the heat demand selector switch is in the "Permanent" position or a 10K Zone
Control causes a Heat Demand.
WWSD light on • the control has calculated that the outdoor temperature is warm enough to not require heat.
Unoccupied light on • the terminals Uno Sw —Com Sen (14 and 15) are shorted together, switching the control into
Unoccupied (setback) mode.
Min. Return light on • the control is operating the mixing valve to satisfy the minimum boiler return requirement.
Max. Supply light on • the control is operating the mixing valve to prevent maximum supply temperature overshoot.
Pump light on • the pump relay is on, closing the contacts between the Pump (5 and ) terminals.
Boiler light on • the boiler relay is on, closing the contacts between the Boiler (10 and 11) terminals.
Closing light on • the close relay is on, closing the contacts between the Com Mix — Cls Mix (7 and 9) terminals.
Opening light on • the open relay is on, closing the contacts between the Com Mix — Opn Mix (7 and 8) terminals.
Test light on • the control is going through the programmed test routine
Step Seven Operational test of control functions - Test button
The Mixing Control 354 has a Test button which can be used to test all of the main control functions at any time. When the Test
button is pushed, the control automatically runs through the following test procedure. If a fault in a sensor occurs, the lights will
flash an error message and the test routine will be exited until the fault is located and corrected. The error messages are listed
on page 11.
10
All red status lights on
On power-up, and at the start of each test routine, all of the red status lights are switched on
for approximately 5 seconds.
The control searches for sensor faults and, if no faults are found, proceeds to the next step.
If a sensor fault occurs, the control suspends the test routine and indicates the fault by flashing
some of the lights in an error message. These error messages are listed on page 11.
When the test button is pushed, one or two of the yellow operation lights may also be on, but
these lights have no effect and no significance during the test routine.
Note: Whenever the control exits the test routine, there is a 3 second delay before the
control will be able to re-enter. Pushing the test button during this 3 seconds will have no effect.
Power light on — Test light on — Opening light on
The control turns on the open relay for the time span set on the Motor Speed dial. (See motor
speed calibration procedure on page 9.)
If the Test Button is pushed once during the time the valve is driving open, the "Test" light will
flash and the control will be held in a pause mode for 5 minutes, after which time it will
automatically exit the test routine and return to normal operating mode. During the 5 minute
pause, the valve will continue to drive open until it reaches the fully open position.
Pushing the Test button during the 5 minute pause will allow the control to resume the test
routine at the next step.
Power light on — Test light on — Pump Light on
The opening relay is turned off and the control turns on the pump for 10 seconds and cycles
to the next step.
During the 10 seconds,
if there is a heat demand signal , and the Test button is pressed once,
the test routine will be halted and the pump will remain on. The "Test" light will flash, and the
control will be held in a pause mode for 5 minutes, after which time it will automatically exit the
test routine and cycle into normal operating mode.
Pushing the Test button during the 5 minute pause will allow the control to resume the test
routine at the next step.
Power light on — Test light on — Pump Light on — Boiler light on
The pump is running; the control turns on the boiler for 10 seconds.
During the 10 seconds,
if there is a heat demand signal , and the Test button is pressed, the
test routine will be halted and the pump and boiler will remain on.
The "Test" light will flash, and the control will be held in a pause mode for 5 minutes, after which
time it will automatically exit the test routine and cycle into normal operating mode.
Pushing the Test button during the 5 minute pause will allow the control to resume the test
routine at the next step.
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Test
Opening
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Test
Opening
Heat Demand
light may
also be on
Heat Demand
light may
also be on
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Test
Opening
Boiler
Closing
Power
WWSD
Unoccupied
Min. Return
Max. Supply
Pump
Heat Demand
Test
Opening
Heat Demand
light may
also be on