Tekmar 540 User manual

1 of 8 © 2009 W 540 - 03/09
W540
03/09
tekmarNet®4 Thermostat 540
- Wiring Brochure
Overview
Information
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Choose controls
to match
application
1Application
Brochure
Design your
mechanical
applications
2Layout
Brochure
Rough-in
wiring
instructions
3Wiring
Brochure
Wiring and
installation of
specific control
4Job
Record
Record settings &
wiring details for
future reference
6
Data
Brochure
Control settings
and sequence of
operation
5
The following brochure describes how to wire the tekmarNet®4 (tN4) thermostat 540. The 540 has outputs for one stage
of heat, one stage of cooling, and one fan.
Table of Contents:
Definitions.......................................................................2
Rough-In Wiring .............................................................2
Remove the Wiring Cover ..............................................3
Mounting the Thermostat ...............................................3
Wiring Symbols...............................................................3
Electrical Drawings ......................................................3-5
Wiring the Thermostat ....................................................6
Troubleshooting the Wiring .............................................7
Testing the Wiring....................................................... 7, 8
Technical Data................................................................8
12 34
Fan
Heating
DIP
Switch
Settings
tN4
Network
24 V (ac)
Power
Cooling
Cooling & Fan Power

© 2009 W 540 - 03/09 2 of 8
Definitions
The following defined terms and symbols are used throughout this manual to bring attention to the presence of hazards of
various risk levels, or to important information concerning the life of the product.
– Caution: Refer to accompanying documents.
– Caution: Refer to accompanying documents.
INSTALLATION
CATEGORY II – Local level appliances.
Caution
Improper installation and operation of this control could result
in damage to the equipment and possibly even personal
injury or death. It is your responsibility to ensure that this
control is safely installed according to all applicable codes
and standards. This electronic control is not intended for
uses as a primary limit control. Other controls that are
Choose the placement of the thermostats early in the
construction process to enable proper wiring during
rough-in.
Consider the following:
•
Interior Wall.
•
Keep dry. Avoid potential leakage onto the control.
•
Relative Humidity 92% to 104°F (40°C), and 50%
above 104°F (40°C). Non-condensing environment.
•
No exposure to extreme temperatures beyond 36-122°F
(2-50°C).
Rough-In Wiring
24 V (ac) Power for Cooling and Fan
Fan 1
1 Cond. / 18 AWG
1 Cond. / 18 AWG
1 Cond. / 18 AWG
4 Cond. / 18 AWG
1st Stage Cool
Note: When multiple wires
run to the same equipment
location, wiring conductors
can share one wire jacket.
1st Stage Heat
24 V (ac) Power
tN4 Network
Zone Manager
•
No draft, direct sun, or other cause for inaccurate
temperature readings.
•
Away from equipment, appliances, or other sources of
electrical interference.
•
Easy access for wiring, viewing, and adjusting the display
screen.
•
Approximately 5 ft. (1.5 m) off the finished floor.
Use standard 18 AWG wire for the thermostat power, stages,
tN4 and sensor connections.
Refer to the diagram below to determine the number of
conductors to run from each piece of equipment to the
thermostat location.
intended and certified as safety limits must be placed into
the control circuit. Do not attempt to service the control.
Refer to qualified personnel for servicing. There are no
user serviceable parts. Attempting to do so voids warranty
and could result in damage to the equipment and possibly
even personal injury or death.

3 of 8 © 2009 W 540 - 03/09
Mounting the Thermostat
If a single gang switch box is used, an Adaptor Plate 007
is required to mount the thermostat to the box.
•
Fasten the base of the thermostat to the adaptor plate.
•
Feed the wiring through the openings in the back of the
adaptor plate and thermostat.
•
Use the upper and lower screw holes to fasten the
adaptor plate to the box.
Remove the Wiring Cover
To remove the wiring cover:
•
Place a small slot screwdriver or similar tool into the slot
located on the top of the thermostat.
•
While pushing against the plastic tab, pull the top of the
front cover so that it pivots around the bottom edge of
the thermostat’s base.
The electrical drawing examples on the following pages show
the 540 in common applications. Choose the drawing that
most accurately depicts the components in your system and
use that drawing as a guide to aid in wiring your system.
These are only concept drawings, not engineered drawings.
They are not intended to describe a complete system nor
any particular system. It is up to the system designer to
determine the necessary components for and configuration
Electrical Drawings
OR
Wiring Symbols
Dry contact switch. Operates a device.
Do not apply power to these terminals.
Serious control damage will result.
Powered switch. 24 V (ac), switched
output to valve, pump relay etc. tekmarNet®4
If a switch box was not used, mount the thermostat directly
to the wall.
•
Feed the wiring through the openings in the back of the
thermostat.
•
Use screws in the screw holes to fasten the thermostat
to the wall. At least one of the screws should enter a
wall stud or similar rigid material.
of the particular system being designed including additional
equipment isolation relays (for loads greater than the
controls specified output ratings) and any safety devices
which in the judgement of the designer are appropriate in
order to properly size, configure and design that system
and to ensure compliance with building and safety code
requirements.
Stud
Switch
Box
Thermostat
Base
007 Adaptor
Plate
Thermostat 31/4”
(83 mm)
Stud
23/8”
(60 mm)
screwhole
23/8”
(60 mm)
screwhole
Thermostat
Thermostat
Base
Wall
Mounted on wallboardMounted on switch box
Remove cover
Push tab
1
2

© 2009 W 540 - 03/09 4 of 8
Electrical Application 540 E1
Description:
540 operates a hydronic heating system zone together with a
cooling system and fan.
12 34
Zone Manager
540 tNt
Cooling Equipment
1 Stage Cooling
1 Stage Fan
C G Y R
tN4 C W
R
Test
Item
Menu
Cooling System
Heating System
Reset
Module
Zone
Manager
540

5 of 8 © 2009 W 540 - 03/09
Electrical Application 540 E2
Description:
540 operates a furnace and air conditioning system.
12 34
daisy chain
to other tN4 thermostats
for communication
540 tNt
HVAC Equipment
1 Stage Heat
1 Stage Cooling
1 Stage Fan
Install jumper wire
from terminal 3 to
terminal 5.
CR W Y G
tN4 C
Furnace and Air Conditioning System 540
D
X
H

© 2009 W 540 - 03/09 6 of 8
Terminals tN4 and C provide tN4 communication.
If a Zone Manager is used:
•
Connect tN4 on the thermostat to tN4 on the proper
zone of the Zone Manager used for the first stage of
heat. The C terminal is already connected.
If a Zone Manager is not used:
•
Connect tN4 on the thermostat to tN4 on another tN4
device on the same tN4 bus.
•
Connect C on the thermostat to the C terminal on another
tN4 device on the same tN4 bus.
tN4 Communication Terminals 1, 2
The W terminal is used to turn on the heating equipment.
The heating equipment must use the same power source
as the R and C terminals.
If a Zone Manager is used:
•
Connect W on the thermostat to W on the proper zone
of the Zone Manager.
If a Zone Manager is not used:
•
Connect W on the thermostat to the heating equipment
(such as a furnace).
Heat Contact Terminal 4
Terminals R and C provide 24 V (ac) power.
If a Zone Manager is used:
•
Connect C on the thermostat to C on the proper zone
of the Zone Manager.
•
Connect R on the thermostat to R on the proper zone
of the Zone Manager.
If a 24 V (ac) transformer is used:
•
Connect C on the thermostat to C on the transformer.
•
Connect R on the thermostat to R on the transformer.
Power (24 V (ac)) Terminals 2, 3
Note: This connection is polarity sensitive.
Wiring the Thermostat:
Zone Manager
tN4 C RW
Terminals Rc and Y are used to turn on the cooling.
•
Rc-Y is an isolated switch. No power is available from
these terminals.
•
Connect Rc on the thermostat to R on the cooling
equipment.
•
Connect Y on the thermostat to Y on the cooling
equipment.
Cooling Contact Terminals 5, 6
1st Stage Cooling
Zone Manager
CRW
234
tN4 C RW
CR
23
Thermostat
Zone Manager
tN4 C RW
tN4 C
12
Thermostat
Thermostat
RY
Thermostat
6Y
5Rc

7 of 8 © 2009 W 540 - 03/09
Terminals Rc and G are used to turn on the fan.
•
Rc-G is an isolated switch. No power is available from
these terminals.
•
Connect Rc on the thermostat to R on the fan equipment.
•
Connect G on the thermostat to G on the fan equipment.
Fan 1 Contact Terminals 5, 7
Testing the Wiring
Testing 24 V (ac) Power Supply
1. Remove the front cover from the thermostat.
2. Use an electrical test meter to measure (ac) voltage
between the R and C terminals. The reading should
be 24 V (ac) +/– 10%.
1. Remove the front cover from the thermostat.
2. Press Mode button until Mode is set to OFF.
3. Set electrical test meter to continuity.
4. Place probes between R (3) and W (4), then between
Rc (5) and Y (6), then between Rc (5) and G (7). In all
cases there should be no continuity.
5. Press Mode button until Mode is set to HEAT.
6. Increase the Set Room temperature. The “H1” symbol
should appear.
7. There should be continuity between the R (3) and W
(4) terminals.
8. Press Mode button until Mode is set to COOL.
9. Lower the Set Room temperature. The “C1” symbol
should appear.
10. There should be continuity between the Rc (5) and Y
(6) terminals.
Testing the Relays
Thermostat
7G
6Y
5Rc
Fan
RG
11. Press Mode button until Mode is set to VENT.
12. Set VENT to On. The “Fan” symbol should appear.
13. There should be continuity between the Rc (5) and G
(7) terminals.
3. Install the front cover.
Troubleshooting the Wiring
The following tests are to be performed using standard
testing practices and procedures and should only be carried
out by properly trained and experienced persons.
A good quality electrical test meter, capable of reading
from at least 0-300 V (ac), 0-2,000,000 Ohms, and testing
for continuity is essential to properly test the wiring and
sensors.
General
1234
tN4 C R W
###
C1H1
OFF VENTAUTO
HEATCOOL
Cool
540 LCD Display Segments
Heat
Fan

tekmar Control Systems Ltd., Canada
tekmar Control Systems, Inc., U.S.A.
Head Office: 5100 Silver Star Road
Vernon, B.C. Canada V1B 3K4
[phone] Fax. [phone]
Web Site: www.tekmarcontrols.com
Product design, software and literature are Copyright © 2009 by:
tekmar Control Systems Ltd. and tekmar Control Systems, Inc. 8 of 8 All specifications are subject to change without notice. Printed in Canada. W540 - 03/09.
The symbol is shown on the display when communication
is present. If the thermostat is connected in a network and
the communication is missing, there may be an open or
short circuit on the tN4 and C bus wires.
1. Remove the front cover from the thermostat.
2. To test for short circuits:
•
Disconnect the tN4 bus wires on one end.
•
Install wire nuts on each wire to ensure the wire ends
are not touching.
•
Disconnect the tN4 bus wires on the other end.
•
Measure for continuity using an electrical meter.
•
If continuity is present, there is a short circuit fault along
the wires. It is recommended to replace the tN4 bus
wires.
Testing the tN4 Buses
3. To test for open circuits:
•
• Disconnect the tN4 bus wires on one end and connect
them together.
•
• Disconnect the tN4 bus wires on the other end.
•
• Use an electrical meter to measure for continuity.
•
• If there is no continuity, there is an open circuit fault
along the wires. It is recommended to replace the tN4
bus wires.
Technical Data:
tekmarNet®4 Thermostat 540: One Stage Heat, One Stage Cool, One Fan
Control Microprocessor PID control; This is not a safety (limit) control
Packaged weight 0.8 lb. (380 g)
Enclosure White PVC plastic
Dimensions 2-7/8” H x 2-7/8” W x 13/16” D (73 x 73 x 21 mm)
Approvals CSA C US, CSA/UL 61010-1, meets Class B: ICES and FCC Part 15
Ambient conditions Indoor use only, 36 to 122°F (2 to 50°C)
RH max 92% to 104°F (40°C), and 50% above 104°F (40°C)
Altitude <9840 feet (3000 m), Installation Category II, Pollution Degree 2
Power supply 24 V (ac) ± 10% 50/60 Hz, 1.8 VA Standby, 56 VA fully loaded, NEC / CEC Class 2
W Relay 24 V (ac) 2 A
Y Relay 24 V (ac) 2 A
G Relay 24 V (ac) 2 A
Technical Data
The installer must ensure that this control and its wiring are isolated and / or shielded from strong sources of electromag-
netic noise. Conversely, this Class B digital apparatus complies with Part 15 of the FCC Rules and meets all requirements
of the Canadian Interference-Causing Equipment Regulations. However, if this control does cause harmful interference to
radio or television reception, which is determined by turning the control off and on, the user is encouraged to try to correct
the interference by re-orientating or relocating the receiving antenna, relocating the receiver with respect to this control,
and / or connecting the control to a different circuit from that to which the receiver is connected.
Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.