654_D Installation & Operation Manual 06/13 Snow Melting Control 654 Snow Melting Replaces: New Introduction The Snow Melting Control 654 is designed to operate electric or hydronic equipment to melt snow or ice from any surface including driveways, walkways, patios, business entrances, parking ramps, loading docks, hospital entrances, helipads or car wash bays. The surface temperature for snow melting is controlled automatically to reduce operating energy costs.
Table of Contents Important Safety Information.............................................3 Installation .........................................................................4 Preparation .................................................................... 4 Physical Dimensions ..................................................... 4 Installation Location....................................................... 4 Rough-In Wiring.............................................................
Important Safety Information It is your responsibility to ensure that this control is safely installed according to all applicable codes and standards. tekmar is not responsible for damages resulting from improper installation and/or maintenance. To avoid serious personal injury and damage to the equipment: • Read Manual and all product labels BEFORE using the equipment. Do not use unless you know the safe and proper operation of this equipment. • Keep this Manual available for easy access by all users.
Installation Preparation Tools Required -----------------------------------------------------------------------------------------------------------------------------------------------------• tekmar or jeweller screwdriver • Phillips head screwdriver • Needle-nose Pliers • Wire Stripper Materials Required -----------------------------------------------------------------------------------------------------------------------------------------------• 18 AWG LVT Solid Wire (Low Voltage Connections) • tekmar 2
Sizing the Transformer The control requires an external transformer. A tekmar Transformer 009 can supply up to 40 VA, and includes an in-line fuse to protect the transformer and control. The total power capacity of the power supply should be larger than the total load of all the devices connected to the control. This total load must not exceed 100 VA. Control Wiring See Application Brochure 654_A for specific application wiring diagrams.
tN4 Wiring Center or Zone Manager ------------------- Alert Relay Output ----------------------------------------------------------- No Power Aux Ht R C tN4 Mod Brn Yel Blu Red Blk Out/ Sup – + Slab Com Bret tN4 C R W tN4 C R W No Power Aux Ht R C tN4 Mod Brn Yel Blu Red Blk Out/ Sup – + Slab Com Bret Zone 1 Zone 2 tN4 Wiring Center or Zone Manager Alert Equipment Transformer and Relays -------------------------------------------------------------------------------------------------------------------
Sensor Wiring Mounting the Outdoor Sensor ----------------------------------------------------------------------------------------------------------------------------------------Notice: The temperature sensor (thermistor) is built into the sensor enclosure. • Remove the screw and pull the front cover off the sensor enclosure. • The outdoor sensor can either be mounted directly onto a wall or a 2" x 4" electrical box.
Immersion Well If a Universal Sensor is mounted onto 1" (25 mm) diameter L type copper pipe, there is approximately an 8 second delay between a sudden change in water temperature and the time the sensor measures the temperature change. This delay increases considerably when mild steel (black iron) pipe is used. In general, it is recommended that a temperature well be used for steel pipe of diameter greater than 1-1/4" (32 mm).
Testing the Relay Outputs ------------------------------The control includes an Override menu to check if the control’s relays are operating and that the control is wired correctly to the snow melting equipment. Step 1: Press and hold the Home button for 3 seconds. Step 2: Press NEXT to navigate to the Override menu. Step 3: Press ENTER to enter the Override menu. Step 4: Select Manual Override to Hand. Step 5: For hydronic systems, set System Pump to On. The system pump should now be operating.
User Interface Display Touch to display Run Time, Outdoor & Slab Temperature Status Field Touch to quickly enter the View menu Operation Field Touch to turn system off while away Touch to go to the next setting Touch to Melt or Stop Touch to adjust settings Home Button Return to the Home Screen ENTER Press and hold for 3 seconds to access the programming menus. Home Button Operation Field MELT System is melting snow or ice. IDLE System is idling. STRM OFF System is in storm operation.
Programmable Settings Programming Menus Press and hold the Home button for 3 seconds to enter the programming menus. The control returns to the last programming menu previously used. Press and hold for 3 seconds to access the programming menus. Select a Programming Menu -------------------- Setting Items --------------------------------------------------------------------- • Touch “NEXT” to advance (clockwise in above illustration) to the next menu.
View Menu (1 of 2) The View menu items display the current operating temperatures and status information of the system. Item Field Range Access 1 to 12 User Installer SNOW ZONE The snow melt zone number on the tekmarNet ® system. Conditions: tekmarNet ® communication available. User Installer OUTDOOR Current outdoor air temperature as measured by the local or remote outdoor sensor. The outdoor air temperature is shared to all devices in the tekmarNet ® system.
View Menu (2 of 2) Item Field Range Access Description User Installer HEAT RELAY Current status of the heat relay. The boiler, pump or electric cable is on when ON is displayed. The boiler, pump or electric cable is off when OFF is displayed. Conditions: Application Mode is set to PWM, Boil, Mix, or Elec. 0 to 100% Installer PWM RATE Current duty cycle rate of the zone or boiler for each 20 minute cycle. Conditions: Application Mode is set to PWM or Elec.
Set Temp Menu The Set Temp menu items select the operating temperatures of the snow melt system. Item Field Range 32 to 95°F (0.0 to 35.0°C) Default = 36°F (2.0°C) Access Description MELTING User Installer Select the desired surface temperature of the snow melt surface when melting. Conditions: Application Mode is set to PWM, Boil, Mix or Elec. IDLING OFF, 20 to 95°F (-6.5 to 35.0°C) Default = OFF Installer Select the desired surface temperature of the snow melt surface when idling.
Time Menu Time settings are only required when using a programmable schedule. The Time menu is not available when the Application Mode is set to 090.
Schedule Menu The Schedule menu can operate on a 24 hour or 7 day repeating schedule. When a 24 hour schedule is selected, “SuMoTuWeThFrSa” is shown on the top of the screen to show that the event time applies to all days of the week. When a 7 day schedule is selected, each individual day of the week is shown with the event time. The Schedule menu is not available when the Application Mode is set to 090.
Display Menu The Display menu items select the temperature units and backlight options. Item Field Range Access Description °F or °C Default = °F User Installer UNITS Select Fahrenheit or Celsius as the temperature units. User Installer BACKLIGHT Select how the display backlight operates. ON = Always on. ON MELT = On when melting, off when not melting. This provides a visual indicator to occupants that the snow melting system is currently melting. OFF = Always off.
Monitor Menu The Monitor menu items provide information about the system’s operation and performance. The Monitor menu is not available when the Application Mode is set to 090. Item Field Range Access 0 to 9999 hours User Installer Description HEAT HOURS Records the number of running hours since the item was last reset. Touch the number and then the ENTER key to reset to zero.
Toolbox Menu The Toolbox Menu is a location for system information and Test functions. If any errors are present on the system, they will be located at the beginning of this menu. Item Field Range Access Description ACCESS LEVEL Installer (INST) User (USER) Default = INST User Installer Software J1226A Type 654 User Installer Not applicable Installer Select the access level of the control, which determines which menus and items are available.
Override Menu The Override Menu allows an operator to manually test each relay and manually start the system. Item Field Range Access Hydronic AUTO, HAND, MAX, PRGE, OFF Electric AUTO, HAND, TEST, OFF MANUAL OVERRIDE Installer Default = AUTO Manually override the normal automatic operation of the control to test the equipment or operate the system at the maximum temperature limits.
System Menu The System Menu provides settings on how to configure and operate the mechanical equipment. Item Field Range Access Description Set to APPLICATION MODE PWM, BOIL, MIX, ELEC, 090 Default = PWM Installer NONE, 090 (or 094), 095 Default = 090 Installer OFF or ON Default = ON Select the control application mode. PWM = Hydronic Pulse Width Modulation. BOIL = Hydronic boiler heats snow melting system. MIX = Hydronic mixing valve or injection pump heats snow melting system.
Boiler Menu The Boiler Menu provides settings on how to configure and operate the boiler. Item Field Range Access App Mode = Boil MOD, 1STG, EMS1, EMS2 Default = MOD App Mode = Mix OFF, ENBL, CTRL Default = OFF Description BOILER TYPE Installer App Mode = PWM OFF, CTRL Default = OFF The type of boiler connected to the control. MOD = Modulating boiler. 1STG = Single one-stage on-off boiler. EMS1 = tekmar boiler staging controls. EMS2 = Viessmann modulating boilers with 0-10 V OpenTherm Module.
Mix Menu The Mix Menu provides settings on how to configure and operate the mixing valve or mixing injection pump. The Mix menu is only available when the Application Mode is set to Mix. Item Field Range Access Description Set to MIX TYPE 0-10 or 4-20 Default = 0-10 Installer Select the type of mixing analog signal. 0-10 = 0 to 10 V (dc) 4-20 = 4 to 20 mA MIX MOTOR SPEED 30 to 230 seconds Default = 105 seconds Installer 80 to 180°F (26.5°C to 82.
tekmarNet® Menu The tekmarNet® menu includes settings of how the snow melting control communicates and operates together with other controls. The tekmarNet® menu is only available when communication is detected. Item Field Range Access Range: AUTO, 01 to 24, b:01 to b:24, 1:01 to 1:24, 2:01 to 2:24, 3:01 to 3:24 Installer Description ADDRESS The tekmarNet® address of this control. To manually set the address, use the up or down arrow buttons.
Sequence of Operation Snow Melting Overview A snow melting system can offer a safe, convenient, and cost effective way of removing snow and ice from the snow melting slab and similar surfaces. Safety is increased by activating the snow melting system as soon as the snow falls rather than waiting for mechanical snow removal after snow has accumulated. This eliminates slip hazards and reduces the risk of injury by mechanized snow melting equipment, thereby reducing potential liability costs.
Melt - Manual Start and Timed Stop The snow melting system can be started manually in one of three different methods: • Touch the Melt key on the control display. • Press the Setpoint Enable button on a User Switch. • Activate through a Gateway webpage or home automation system. Once manually started, the snow melting system continues to operate until the time set by the Manual Melt Run Time setting in the Set Temp menu elapses.
Melt - EconoMelt When a Snow / Ice Sensor 090 or 094 is installed, the installer can choose to select to either automatically or manually start the snow melting system. Selecting EconoMelt to On provides the option to remove the snow using a snow plow or shovel and then use the snow melting system to melt the remaining thin layer of snow or ice that mechanical snow removal methods are unable to remove. The snow melting system stops when the sensor is dry. The factory default for EconoMelt is Off.
Melt - Tracked Start and Stop The snow melting system can have multiple zones. Zones have the option to track the melting run time of zone 1. This is useful in cases where zone 1 has an automatic Snow / Ice Sensor installed and the remaining zones do not. This allows zones 2 to 12 to gain the functionality of automatic starting and stopping with only one Snow / Ice sensor installed in the system. When zone 1 detects snow or ice, it starts melting.
Additional Melting Time A Snow / Ice Sensor 090 or 094 automatically shuts off the snow melting system when the water sensor is dry. Due to the construction of the slab and the layout of the heating pipe or electrical cable, there may be areas that do not melt completely. The Additional Melt Time setting in the Set Temp menu allows the installer to set addition melting time after the sensor is dry.
Warm Weather Shut Down During warm weather, the slab is warm enough to naturally melt snow or ice. The control has a Warm Weather Shut Down (WWSD) setting in the Set Temp menu that prevents the control from entering Melt, Idle or Storm operation in order to conserve energy. The control shows WWSD on the display when WWSD is in effect. Automatic (Auto) The control enters WWSD when both the slab temperature of a zone and the outdoor temperature exceed the Melt temperature setting by more than 2°F (1°C).
Programmable Schedules To provide greater energy savings, the control can operate on a programmable schedule. The schedule is stored in memory and is not affected by loss of power to the control. If tekmarNet® communication is detected the control can become either a schedule member or schedule master. Zone Schedule ---------------------------------------The schedule only applies to the control. The control follows its own schedule and the events are not communicated to the tekmarNet ® system.
Hydronic Priority Levels -------------------------------------------------------------------------------------------------------------------------------------------Priority = None All zones have the same priority and can operate at the same time. This setting is recommended when the boiler plant capacity is sized larger than the heat loss of all zones at design conditions.
Slab Protection In a hydronic snow melting system, the boiler or heating plant capacity may be much larger than the load of the snow melting zones. This can result in large temperature differentials between the supply water temperature and the slab creating large tensile stresses on the slab. Concrete is weak to tensile forces and when repeatedly exposed to tensile loads the concrete may crack. This may be prevented by selecting the Protect Slab setting in the System menu to On.
Single Stage On/Off Boiler (1STG) --------------------- EMS2 ------------------------------------------------------------------------------------- The control turns on or off the heat relay to fire the boiler in order to maintain the Boiler Target temperature. The boiler supply temperature operates on a differential that is half above and half below the boiler target. The status of the boiler is shown by the Boil Relay item in the View menu.
Mixing Operation The Application Mode can be set to Mix when a mixing valve or a mixing injection pump is installed to regulate the supply water temperature to the snow melting system. The boiler or heat plant can be either dedicated or non-dedicated to the snow melting system. The mixing device position or speed is controlled by an analog 0-10 V (dc) or a 4-20 mA signal so that the supply temperature maintains the Mix Target temperature.
Tandem Snow / Ice Detection Step 3: In the tekmarNet ® menu, select the Snow Zone that the 654 is to operate. There can be up to 12 different Snow Zones. Both 654 controls must be set to the same Snow Zone number. Step 4: On one of the 654, select the Application Mode to PWM, Boil, Mix or Elec. This control is the Snow Zone Master and it will operate the snow melting equipment. Step 5: On the other 654, select the Application Mode to 090. This control is the Snow Zone Member.
Melt and Storm Groups The snow melting control is able to respond to a setpoint enable signal from a User Switch or Gateway to remotely activate or deactivate the storm or melt operation. The tekmarNet ® communication system supports setpoint enable signals 1 through 12. When the snow melting control receives a setpoint enable signal that is the same as the Melt Group number, the control enters Melt operation.
Troubleshooting It is recommended to complete all wiring to ensure trouble free operation. Should an error occur, simply follow these steps: 1. Find: If the control flashes on the screen, it is indicating a problem on the system. 2. Identify: Hold the Home button for 3 seconds, touch the NEXT key to locate the Toolbox Menu, then touch the ENTER key. The error code should appear as the first item. 3. Solve: Use the chart below to match the error code to the one on the control.
Error Messages (2 of 4) Error Message Description ADDRESS TAKEN ERROR Two devices (thermostats, setpoint controls, snow melting controls) have been manually set to the same address. The device continues to operate with this error but does not communicate with the tekmarNet® system. To clear this error, select an unused tekmarNet® address or select automatic addressing.
Error Messages (3 of 4) Error Message Description BOILER RETURN SENSOR SHORT CIRCUIT ERROR Due to a short circuit, the control is unable to read the Boiler Return Sensor 082. The control continues operation but does not provide any boiler return protection. Check the boiler return sensor wire for short circuits according to the sensor installation manual. It may be necessary to replace the boiler return sensor. Once the error has been corrected, the error message automatically clears.
Error Messages (4 of 4) Error Message Description SNOW / ICE SENSOR ERROR The control is unable to properly detect the Snow / Ice Sensor 090 or 094. The control can no longer automatically detect snow or ice but manual start of the snow melting system is still available. Check the Snow / Ice Sensor brown, yellow, red and black wires according to the sensor installation manual. It is important to check any cable splices for loose wiring connections. It may be necessary to replace the sensor.
Frequently Asked Questions Symptom Look For... Corrective Action LCD display is off Power to control Use electrical meter to measure 24 V (ac) voltage on input power R and C terminals. System pump always on Display shows Idle Idle operation requires that the system pump operate continuously while below the melting temperature setting. Blue short Dirt or salt on snow/ The snow/ice sensor requires regular cleaning. Avoid using road salt on the snow ice sensor melting slab.
Set Temp Menu Settings Item Item Setting Setting MELTING STORM RUN TIME IDLING WATER SENSITIVITY STORM WARM WEATHER SHUT DOWN MANUAL MELT RUN TIME COLD WEATHER CUT OUT ADDITIONAL MELT TIME System Menu Settings Item Item Setting APPLICATION MODE ECONOMELT SNOW / ICE SENSOR tekmarNet® SYSTEM PUMP SLAB SENSOR AUXILIARY RELAY SLAB PROTECTION MAXIMUM MELT TIME Setting OUTDOOR OR BOILER RETURN SENSOR Boiler Menu Settings Item Item Setting BOILER TYPE BOILER MOTOR SPEED BOILER MODULA
Technical Data Snow Melting Control 654 tekmarNet ® Electric or Hydronic Boiler / Mixing Literature 654_A, 654_C, 654_D, 654_Q, 654_U Control Microprocessor control. This is not a safety (limit) control Packaged weight 1.3 lb.
