Transcript
Installation Manual
Expansion Module 0300 Version 1.0
EXP-0300 HBX Control Systems Inc.
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
HBX EXP-0300 EXPANSION MODULE INTRODUCTION The EXP-0300 Expansion Module is designed to be integrated wi w th the HBX CPU-1000 HVA V C Controller, it is not a stand alone devi v ce. The purpose and fu f ncti t on of the EXP-0300 is to provi v de greater control of pumps in larger mechanical heati t ng sytems. It’s primary use is to take control of multi t ple boiler pumps and allow you to take fu f ll advantage of the post purge fe f ature of the Control. For example, 1 CPU-1000 + 1 EXP-0100 + 1 EXP-0300 can provi v de 2, 2 stage boiler controls wi w th 2 boiler pumps, setup using post purge on the boiler pumps. The EXP-0300 has a spare thermistor input wi w th no fi f xed fu f ncti t on. The installer may a choose to run the spare thermistor as a; room sensor, setpoint sensor, or return water temperature sensor. The spare demand signal has no dedicated fu f ncti t on at ti t me of print. In large systems (Eg. 6 and 8 stages of boilers) using additi t onal setpoint loads vi v a setpoint sensors (thermistors), the order and sequence of stagi g ng relay a s (EXP-0100), thermistor terminal locati t on and additi t onal pump relay a s (EXP-0300) is criti t cal (See Draw awings STG 1000-11 and STG 1000-13). * If there are an odd number / or unused pump relays (EXP-0300), a setpoint demand will trigger the 1st unassigned 2 or 3 wire relay held in series. Under certain specifi f c circumstances the setpoint sensor will be programmed as setpoint 2 or even 3 in the programming menu.
HBX has developed a series of Expansion Modules. At ti t me of product introducti t on the EXP-0100 (Stagi g ng) g and EXP-0300 (Pump) Modules are made av a ailable. These wi w ll be fo f llowed by the release of the ZON-0100 (Zone Va V lv l e) Module, ZON-0200 (Zone Pump) Module, VFD-0100 (V (Variable Frequency Driv i e) Module, and the MOD-0100 (M ( odulati t ng Output Module) Module.
* More than six Zone Modules can be connected to the CPU1000 as the Zone Modules are not dependent on the CPU to power the internal relays.
The EXP-0300 is designed to be wall mounted, DIN rail mounted, or installed inside a separate electrical enclosure. The unit should be mounted inside and be protected fr f om fa f lling water and high humidity t condi d ti t ons. Wi W th t al all th t e cove v rs in place it is desig igned to protect any n indi dividual a fr f om accidental a electri r cal a shock.
© HBX Control Systems Inc. 2013
EXP-0300 Manual Page 1
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
INSTA TALLA LATION PROCEDURE Place the CPU-1000 and desired Expansion Modules on a fl f at surfa f ce. Align the 32-Pin connector into the holes on the Expansion Module and gently push into place. Next slide the CPU-1000 onto the 32-Pin connecti t on by carefu f lly matching up the holes and pins. When installed correctly there is vi v rtually no gap betw t een units. Wi W th power applied to the assembly, y the fi f rst (g ( reen) n LED should be illuminated on each Expansion Module. This lit, green LED serves as confi f rmati t on of both electrical and communicati t ons conti t nuity ty.
32- Pin Connector P/N 033-0037
TERMINA NAL DESIGNA NATIONS
Extra Thermistor 1 Extra Demand Signal 1
Supply Power 120 VAC Extra Pump 2 Extra Pump 1
Extra Thermistor 1 - Giv i es you many choices, E.g. room sensor or setpoint sensor. Extra Demand Signal 1 - Any heat demand signal powered by 20 - 240VA V C. E.g. 24VA V C thermostat (Future Applicati t ons). Thermistor inputs are designed fo f r 10K Ohm thermistors and must never be subjected to any n external power supply ( oltage or current). (v
EXP-0300 Manual Page 2
Supply Power 120VA V C - In order to power the extra pumps, a seperate line, neutral and ground must be supplied here and protect by at least a 20Amp breaker. Extra Pump 2 - This relay a is the defa f ult relay a fo f r pump 2 (Eg. BP2). Extra Pump 1 - This relay a is the defa f ult relay a fo f r pump 1 (Eg. BP1).
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
MAIN PA P RT R S AN A D LA L BELS 1. 32 Pin Connector Port
Specifi f cations: 1 x Thermistor Input (10K Ohm) m
2. Power and Communications LED
1 x Misc. Input Signal (20-240VA V C)
3. Relay 1 LED 4. Relay 2 LED
2 x Aux. Output Re R lay a s (240VA V C 10Amps) 1 x Power Input (120 VA V C)
5. Supply Power 120VAC
Weight: W K 6. Aux. Relay/Extra Pump 0.408Kg 7. Aux. Relay/Extra Pump Dimensions: 100mm W x 170mm H x 70mm D 8. Input Signal A ETL Listings: Meets CSA C22.2 No. 24 Meets UL Standard 873 ETL Control No. 3068143
9. Thermistor
Storage: 10ºC to 40ºC HYSICAL A DIMENSIONS Side View 70mm
Front View 17
Rear View
66mm
Top View
168mm
Bottom View
63.2mm
100mm
© HBX Control Systems Inc. 2013
86mm
EXP-0300 Manual Page 3
EXP-0300 Manual Page 4
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
STA T GING CONTROL STG 1000-11 • • • • •
1 x Hi/Lo fi f re boilier (2 ( stag a es) wi w th t a mai a n system pump Use of 1 x EXP X -0300 to run post purg r e on th t e boilier pump Opti t onal a DHW H is show own runni n ng n a DHW H pump th t roug ugh an indi d rect hot wa w ter tank 2 hi h -temp loads are sati t sfi f ed and contr t ollled vi v a 24V 4VAC va valve actu t ators Outdoor reset of boilier targ r et temp al a so accomplilshes low ower temp to each of th t e h -temp loads hi ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
1
2
3
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2
EXP-0100
EXP. MODULE
10 A
20-240 v
DO NOT CONNECT
10 A
3
1
2
120
120 L
N
GR
L
120
120
N
GR
L
N
GR
L
N
GR
1
2
3 4
TM TM
DS DS
1
1
EXP. MODULE
20-240 v
10 A
2
3 4
5 6
7
TM TM
DS DS
RL RL
RL RL
10 A
POWER HERE
POWER HERE
DO NOT CONNECT POWER HERE
8
EXP-0300 DO NOT CONNECT
10 A
10 A
1
5
6 7
8
N
L
120
120
1
L
GR
1
9 10 11 12 13 N
120 GR
L
N
1
1
GR
Primary Heat Load Actuator
1
1
1
1
2
8 2
Setpoint 2 Sensor: Must be programmed as setpoint 2 in the CPU Program Menu
V
Boiler Sensor
TH
Setpoint Sensor
Outdoor Sensor
V Fan Coil Actuator
Primary Heat Load Thermostat A
Boiler 1 Boiler 1 Stage 1 Stage 2
P2 Hi-Temp System Pump
24VAC
P3 DHW Pump
P1 Boiler Pump
C R 120VAC L N
MECHAN A ICAL A Control Ty Type: Stagi g ng Uti t lized
EXP-0300
Outdoor Sensor Central Processing Unit CAUTION,
Expansion Module
D
C
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A
120VAC
Relays: 240VAC 10A Demand Signal: 20 - 240V
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
Pump Legend: • P1 - Boiler Pump • P2 - Hi-Te T mp System Pump • P3 - DHW Pump
EXP-0100
Expansion Module B
1000
300
100
120VAC
P2 Hi-Temp System Pump
Room (Setpoint) Sensor
Boiler Sensor P1 Boiler Pump
Heat
2 Stage Boiler
NB. Design Heat Load must be a High Temp Radiation System Eg. Baseboard/ Panel Radiators
P3 DHW Pump
TH
Load
Fan Coil
Balancing Valve
A
© HBX Control Systems Inc. 2013
EXP-0300 Manual Page 5
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
STA T GING CONTROL STG 1000-12 •
4 x Hi/Lo fi f re boiliers (8 stag a es) wi w th t 2 system pumps setu t p fo f r pump sequ q encing, opti t onal a fl f ow o proof sensor wi w red back to th t e Control Stag a es 3-8 are controllled vi v a th t e 3 EXP X -0100s Each boilier pump is al a so controllled using post purg r e vi v a th t e 2 EXP X -0300 modul u es Optitonal a DHW H is show own usin ing a DHW H pum ump an a d an a in i di direct hot wa w ter ta tank wi w th t pri r ori r ty t Outd t oor reset of boilier ta target temp m is contr t ollled usin ing th t e outd t oor sensor
• • • •
ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
2
3
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1
2
20-240 v
10 A
3
1
2
120
120 L
N
GR
L
N
120
120 GR
L
N
GR
L
N
GR
EXP-0100 DO NOT CONNECT
10 A
POWER HERE
DS DS 1
EXP-0100 EXP. MODULE DO NOT CONNECT
10 A
DO NOT CONNECT POWER HERE
EXP. MODULE
20-240 v
10 A
EXP-0300
EXP-0100 EXP. MODULE DO NOT CONNECT
10 A
POWER HERE
20-240 v
10 A
DO NOT CONNECT
10 A
2
3 4
5 6
7
2
3 4
5 6
7
2
3 4
5 6
7
2
3 4
DS DS
RL RL
RL RL
TM TM
DS DS
RL RL
RL RL
TM TM
DS DS
RL RL
RL RL
TM TM
DS DS
1
2
1
1
2
1
1
2
1
1
1
1
1
1
8
1
2
1
1
1
1
8
1
2
EXP-0300 DO NOT CONNECT
10 A
1
1
1
1
1
8 2
1
EXP. MODULE
10 A
20-240 v
10 A
POWER HERE
TM TM
1
EXP. MODULE
10 A
20-240 v
POWER HERE
POWER HERE
1
1
5
6 7
8
N
L
GR
1
9 10 11 12 13 120
120 L
120
N
GR
L
N
2
3 4
TM TM
DS DS
1
GR
1
1
5
6 7
8
N
L
L
9 10 11 12 13 120
120
1
GR
N
120 GR
L
N
GR
Optional Flow Proof Switch
Boiler DHW Outdoor Sensor Sensor Sensor
TH
Apply Control Signal or Program for Permanent Heat Demand
Boiler 1 Boiler 1 Stage 1 Stage 2
P1 Hi Temp System and P2 Sequencing
Boiler 2 Boiler 2 Stage 3 Stage 4
Boiler 3 Boiler 3 Stage 5 Stage 6
Boiler 4 Boiler 4 Stage 7 Stage 8
P4 Boiler P5 Boiler Pump Pump
P6 Boiler P7 Boiler Pump Pump
P3 DHW Pump 24VAC C R
L
120VAC
N
MECHAN A ICAL A Control Ty Type: Stagi g ng Uti t lized
EXP-0100
EXP-0100
Expansion Module B
C
1000
Central Processing Unit CAUTION,
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100 Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
EXP-0300
Expansion Module
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
EXP-0300
Expansion Module
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Expansion Module
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A Relays: 240VAC 10A Demand Signal: 20 - 240V
120VAC
120VAC
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
Pump Legend: • P1-P2 - Setu t p as Sequ q encing • P3 - DHW Pump • P4-P7 - Boiler Pumps
100
100
100
300
300
Boiler Sensor
P1 / P2 Pump Sequencing
Heat
EXP-0100
Expansion Module
D
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
120VAC
P4 Boiler Pump 1
P5 Boiler Pump 2
P6 Boiler Pump 3
P7 Boiler Pump 4
Flow Proof SW
2 Stage Boiler
Load P3 DHW Pump DHW Sensor
EXP-0300 Manual Page 6
2 Stage Boiler
2 Stage Boiler
2 Stage Boiler
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
STA T GING CONTROL STG 1000-13 •
4 x Hi/Lo fi f re boiliers (8 stag a es) wi w th t 2 system pumps setu t p fo f r pump sequ q encing, opti t onal a fl f ow o proof sensor wi w red back to th t e Control Stag a es 3-8 are controllled vi v a th t e 3 EXP X -0100s Each boilier pump is al a so controllled using post purg r e vi v a th t e 2 EXP X -0300 Modul u es Optitonal a DHW H is show own usin ing a DHW H pum ump an a d an a in i di direct hot wa w ter ta tank wi w th t pri r ori r ty t Addi d titonal a setp t oin i t load (m ( ak ake-up u ai air un unit) t satitsfi f ed usin ing pum ump (P ( 5) 5 th throug ugh fa fancoili, vi va t e 3rd EX th EXP-0300 Outd t oor reset of boilier ta target temp m is contr t ollled usin ing th t e outd t oor sensor
• • • • •
ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
2
3
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1
2
20-240 v
10 A
3
1
2
120 L
N
120 GR
L
N
120
120 GR
L
N
GR
L
N
GR
Optional Flow Proof Switch
1
2
3 4
5 6
7
DS DS
RL RL
RL RL
1
20-240 v
10 A
1
1
1
1
2
8 2
1
2
3 4
5 6
7
DS DS
RL RL
RL RL
1
1
20-240 v
10 A
DO NOT CONNECT
10 A
1
1
1
1
2
8 2
1
2
3 4
5 6
7
TM TM
DS DS
RL RL
RL RL
1
1
EXP. MODULE
10 A
20-240 v
1
1
1
1
2
8 2
1
EXP. MODULE
10 A
20-240 v
EXP-0300 DO NOT CONNECT
10 A
POWER HERE
2
3 4
TM TM
DS DS
1
EXP-0300 DO NOT CONNECT
10 A
POWER HERE
POWER HERE
TM TM
EXP-0300
EXP-0100 EXP. MODULE DO NOT CONNECT
10 A
POWER HERE
TM TM 1
EXP-0100 EXP. MODULE DO NOT CONNECT
10 A
POWER HERE
DS DS 1
EXP-0100 EXP. MODULE DO NOT CONNECT
10 A
10 A
DO NOT CONNECT POWER HERE
1
1
1
5
6 7
8
N
L
9 10 11 12 13 120
120 L
GR
N
120 GR
L
N
GR
1
2
3 4
TM TM
DS DS
1
EXP. MODULE
10 A
20-240 v
10 A
POWER HERE
1
1
5
6 7
8
N
L
L
GR
1
9 10 11 12 13 120
120
1
N
120 GR
L
N
2
3 4
TM TM
DS DS
1
GR
1
1
5
1
6 7
8
N
L
9 10 11 12 13 120
120 L
GR
N
120 GR
L
N
GR
Make-Up Air Setpoint Sensor
Boiler DHW Outdoor Sensor Sensor Sensor
Setpoint Sensor
TH
Boiler 1 Boiler 1 Stage 1 Stage 2
Apply Control Signal or Program for Permanent Heat Demand
Boiler 2 Boiler 2 Stage 3 Stage 4
P1 Hi Temp System and P2 Sequencing
Boiler 3 Boiler 3 Stage 5 Stage 6
Boiler 4 Boiler 4 Stage 7 Stage 8
P4 Boiler P5 Boiler Pump Pump
P6 Boiler P7 Boiler Pump Pump
P8 Make-Up Air Coil Pump
P3 DHW Pump 24VAC C R
L
120VAC
N
MECHAN A ICAL A Control Ty Type: Stagi g ng Uti t lized
EXP-0100
C
Demand Signal: 20 - 240V Model: EXP-0100
P1 / P2 Pump Sequencing
Flow Proof SW
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
EXP-0300
Expansion Module
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
EXP-0300
Expansion Module
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Expansion Module
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
120VAC
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
100
100
100
300
300
300
Boiler Sensor
P4 Boiler Pump
P5 Boiler Pump
2 Stage Boiler
Load
EXP-0300
Expansion Module
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A Relays: 240VAC 10A Demand Signal: 20 - 240V
1000
Heat
Input: 120VAC 60Hz 5A Relays: 240VAC 10A
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Central Processing Unit
EXP-0100
Expansion Module
D
CAUTION,
1000
CAUTION,
Pump Legend: • P1-P2 - Setu t p as Sequ q encing • P3 - DHW Pump • P4-P7 - Boiler Pumps • P8 - Make-up air (coil pump)
EXP-0100
Expansion Module B
120VAC
2 Stage Boiler
P6 Boiler Pump
P7 Boiler Pump
2 Stage Boiler
2 Stage Boiler
P8 Make-Up Air Coil Pump
DHW Sensor
Setpoint Sensor
© HBX Control Systems Inc. 2013
P3 DHW Pump
EXP-0300 Manual Page 7
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
STA T GING CONTROL STG 1000-15 • •
2 stag a e (H ( i/Lo) boilier control Boilier pump controllled by EXP X -0300 & 1 hi h -temp system pump
ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
2
3
8 1
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2
EXP. MODULE
10 A
20-240 v
10 A
POWER HERE
DS DS 1
EXP-0300 DO NOT CONNECT
10 A
10 A
DO NOT CONNECT POWER HERE
3
1
2
120 L
N
120 GR
L
N
120
120 GR
L
N
GR
L
N
2
3 4
TM TM
DS DS
1
GR
1
1
5
6 7
8
120
1
L
9 10 11 12 13 120
N
GR
L
N
120 GR
L
N
GR
Boiler 1 Boiler 1 Stage 1 Stage 2
TH
Apply Control Signal or Program for Permanent Heat Demand
Boiler Sensor
Outdoor Sensor
24VAC C
P1 Hi Temp System Pump
R
P2 Boiler Pump
120VAC L N
MECHAN A ICAL A Control Ty Type: Stagi g ng Uti t lized
EXP-0300
Expansion Module B
C
D Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
1000
Central Processing Unit CAUTION,
Relays: 240VAC 10A Demand Signal: 20 - 240V
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
Pump Legend: • P1 - Hi-Te T mp System Pump • P2 - Boiler Pump
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A
300
120VAC
Boiler Sensor
P1 Hi-Temp System Pump P2 Boiler Pump
Heat
2 Stage Boiler
Load
EXP-0300 Manual Page 8
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
MIXING CONTROL MIX 1000-09 • • •
2 stag a e boilier, mixi x ng control Using PMIp Supply lying DHW vi v a DHW pump, using 1x EXP X -0100 and EXP X -0300
ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
2
3
8 1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2
20-240 v
10 A
3
1
2
120 L
N
120 GR
L
120
120
N
GR
L
N
GR
L
N
GR
1
EXP-0300 DO NOT CONNECT
10 A
POWER HERE
DS DS 1
EXP-0100 EXP. MODULE DO NOT CONNECT
10 A
10 A
DO NOT CONNECT POWER HERE
2
3 4
5 6
7
2
3 4
TM TM
DS DS
RL RL
RL RL
TM TM
DS DS
1
2
1
1
EXP. MODULE
10 A
20-240 v
10 A
POWER HERE
1
1
1
1
8 2
1
1
1
1
5
6 7
8
N
L
9 10 11 12 13 120
120 L
GR
120
N
GR
L
N
GR
TH
Apply Control Signal or Program for Permanent Heat Demand
Boiler System Outdoor Sensor Sensor Sensor
DHW Sensor
P1 Boiler P2 System P3 PMIp Pump Pump Inj. Mixing Pump
Boiler #1 Boiler #2
P4 DHW Pump
Please Note: In this example the DHW load and demand function, and behave as a setpoint load and must be programmed accordingly. The DHW options menu in the Control do not function in this configuration. Must be programmed as setpoint # 1.
24VAC C R 120VAC L N
MECHAN A ICAL A Control Ty Type: Mixing Uti t lized
EXP-0100
C
Central Processing Unit
Expansion Module
D Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
CAUTION,
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
120VAC Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A Relays: 240VAC 10A Demand Signal: 20 - 240V
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
Pump Legend: • P1 - Boiler Pump • P2 - System Pump • P3 - PMIp Inj. Mi M xi x ng Pump • P4 - DHW Pump • P5-P6 - Boilier Pumps
EXP-0300
Expansion Module B
1000
100
300
120VAC
P4
Boiler Sensor
P1 P5
P2 Boiler 1
Heat
System Sensor P3
Load
Balancing Valve
DHW Sensor
P6 Boiler 2
Please Note: In this example the DHW load and demand function, and behave as a setpoint load and must be programmed accordingly. The DHW options menu in the Control do not function in this configuration. Must be programmed as setpoint # 1.
© HBX Control Systems Inc. 2013
EXP-0300 Manual Page 9
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
MIXING CONTROL MIX 1000-20 • • •
Singl g e stag a e mixi x ng control runni n ng 1 mixed loop and 1 setp t oint load vi v a a plate heat exchanger Mixed in Mi injectiton usin ing PMI M p(p ( um ump in injectiton) n , 1 boilier pum ump, an a d 1 lo-temp m system pum ump Setp t oin i t load fo f r a hot tu tub requ quires th t e use of 1 EX EXP-0300 wh which c al a so contr t ols 2 pum umps(P ( 4 an a d P5) 5 fo f r both t th t e left f an a d ri right side of th t e heat exc xchan anger ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
EXP-0300 DO NOT CONNECT
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
1
2
3
8 1
1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2
EXP. MODULE
10 A
20-240 v
10 A
POWER HERE
DO NOT CONNECT POWER HERE
3
1
2
120 L
N
120 GR
L
N
120
120 GR
L
N
GR
L
N
2
3 4
TM TM
DS DS
1
1
GR
1
5
6 7
8
N
L
120
1
L
9 10 11 12 13 120
GR
N
120 GR
L
N
GR
Boiler
TH
Apply Control Signal or Program for Permanent Heat Demand
Boiler Supply Outdoor Sensor Sensor Sensor
Setpoint Sensor
24VAC C
P1 Boiler Pump
R
P2 System Pump
P3 PMIp Injection Pump
P4 Heat Exchanger Pump Boiler Side P/S
120VAC
P5 Heat Exchanger Pump Hot Tub Side
L N
MECHAN A ICAL A Control Ty Type: Mixing Uti t lized
EXP-0300
Expansion Module B
C
D Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION, RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
1000
Central Processing Unit CAUTION,
Pump Legend: • P1 - Boiler Pump • P2 - System Pump • P3 - Injecti t on Pump • P4 - Heat Exchanger Boilier Side • P5 - Heat Exchanger Hot Tu Tub Side
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A Relays: 240VAC 10A Demand Signal: 20 - 240V
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
300 120VAC
120VAC
Hot Tub Setpoint Sensor
P2 System Pump
Heat System Sensor
P3 Inj. pump
P1 Boiler Pump
Boiler Sensor P5 Heat Exchanger Hot Tub Side
Load Heat Exchanger P4 Heat Exchanger Boiler Side
EXP-0300 Manual Page 10
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
MIXING CONTROL MIX 1000-21 • • • •
4 stag a e boilier M xi Mi x ng wi w th t 1 boilier system pump, 1 mixed system pump and PMIp injecti t on Addi d ti t onal a setp t oint load fo f r hot tu t b or pool using EXP X -0300 runni n ng 2 extra pumps 2 x EXP X -0100 to stag a e boiliers ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
2
3
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
1
2
20-240 v
EXP. MODULE
EXP-0100 DO NOT CONNECT
10 A
10 A
POWER HERE
DS DS 1
EXP-0100 DO NOT CONNECT
10 A
10 A
DO NOT CONNECT POWER HERE
3
1
2
120
120 L
N
GR
L
N
120
120 GR
L
N
GR
L
N
GR
1
2
3 4
5 6
7
TM TM
DS DS
RL RL
RL RL
1
EXP. MODULE
20-240 v
1
1
1
1
1
2
8
1
2
EXP. MODULE
10 A
20-240 v
10 A
POWER HERE
2
3 4
5 6
7
TM TM
DS DS
RL RL
RL RL
1
EXP-0300 DO NOT CONNECT
10 A
10 A
POWER HERE
1
1
1
1
1
2
8
2
3 4
TM TM
1
DS DS
2
1
1
1
1
5
6 7
8
N
L
9 10 11 12 13 120
120 L
GR
N
120 GR
L
N
GR
TH
Apply Control Signal or Program for Permanent Heat Demand
Boiler System Outdoor Sensor Sensor Sensor
Setpoint Sensor
P1 Boiler Pump
Boiler 1 Boiler 1 Stage 1 Stage 2
P2 System P3 PMIp Pump Inj. Pump
Boiler 2 Boiler 2 Stage 3 Stage 4
P4 Heat P5 Heat Exchanger Exchanger Boiler Side Pump Hot P/S Tub Side
24VAC C R
120VAC
L G
MECHAN A ICAL A Control Ty Type: Mixing Uti t lized
EXP-0100
C
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
1000
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Expansion Module
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Relays: 240VAC 10A
Central Processing Unit CAUTION,
EXP-0300
Expansion Module
D
CAUTION,
120VAC
Demand Signal: 20 - 240V
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
Pump Legend: • P1 - Boiler Pump • P2 - System Pump • P3 - PMIp Injecti t on Pump • P4 - Heat Exchanger Boiler Side P/S • P5 - Heat ExchangerPump Hot Tu T b Side • P6-P7 - Boiler Pumps
EXP-0100
Expansion Module B
Input: 120VAC 60Hz 5A
100
100
300 120VAC
P6 Boiler Pump
Boiler Sensor
Hot Tub / Pool Setpoint Sensor
System Sensor
Heat
P1 Boiler Pump P2 System Pump 2 Stage Boiler
Load
P3 PMIp Inj. Pump
P5 Heat Exchanger Pump Hot Tub Side
P7 Boiler Pump Heat Exchanger 2 Stage Boiler
P4 Heat Exchanger Boiler Side P/S
© HBX Control Systems Inc. 2013
EXP-0300 Manual Page 11
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0
DOMESTIC HOT WA WATER CONTROL DHW 1000-03 • • • •
DHW control, 4 stag a e boilier control Boilier pumps controllled by EXP X -0300, programmed as 1 pump/boilier 1 DHW circ. pump, using 1 x EXP X -0100 Singl g e stag a e boiliers ELECTRICAL A CPU-1000
CENTRAL PROCESSING UNIT 10 A
20-240 v
20-240 v
20-240 v
10 A
10 A
1 2
3 4
5 6
7
DS DS
DS DS
TM TM
TM TM
TM TM
RL RL
RL RL
1
2
3
1
2
3
1
2
2
3
8 1
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 2
20-240 v
EXPANSION MODULE 10 A
EXP-0300 DO NOT CONNECT
10 A
POWER HERE
DS DS 1
EXP-0100 DO NOT CONNECT
10 A
10 A
DO NOT CONNECT POWER HERE
3
1
2
120 L
N
120 GR
L
N
120
120 GR
L
N
GR
L
N
GR
1
2
3 4
5 6
7
TM TM
DS DS
RL RL 1
1
1
EXPANSION MODULE
10 A
20-240 v
10 A
POWER HERE
1
1
Boiler 1 Boiler 2
1
8
1
2
3 4
RL RL
TM TM
DS DS
2
1
2
1
1
5
6 7
8
N
L
L
9 10 11 12 13 120
120
1
GR
N
120 GR
L
N
GR
Boiler 3 Boiler 4
Boiler DHW Sensor Sensor
P2 Boiler P3 Boiler P1 DHW Pump Pump Circ. Pump
120VAC
P4 Boiler P5 Boiler Pump Pump
L N
MECHAN A ICAL A Control Ty Type: DHW Uti t lized
EXP-0100
C
Input: 120VAC 60Hz 5A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0100
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Central Processing Unit CAUTION,
Expansion Module
D
CAUTION,
1000
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Input: 120VAC 60Hz 2A
Demand Signal: 20 - 240V
Relays: 240VAC 10A
Model: EXP-0300
CAUTION,
RISK OF ELECTRICAL SHOCK DISCONNECT POWER PRIOR TO SERVICING
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
120VAC
Input: 120VAC 60Hz 5A Relays: 240VAC 10A Demand Signal: 20 - 240V
Certified to CSA C22.2 No 24 Conforms to UL Standard 873
Model: CPU - 1000
RISK OF ELECTRICAL SHOCK - DISCONNECT POWER PRIOR TO SERVICING
1000
Pump Legend: • P1 - DHW Circ. Pump • P2-P5 - Boiler Pumps
EXP-0300
Expansion Module B
120VAC
Boiler Sensor
100
300
P1 DHW Circ. Pump P2 Boiler Pump
P3 Boiler Pump
Single Stage Boiler
Single Stage Boiler
DHW Sensor P4 Boiler Pump Single Stage Boiler
P5 Boiler Pump Single Stage Boiler
EXP-0300 Manual Page 12
Control Systems Inc. HBX EXP 0300 Expansion Module Version 1.0 Limited Wa W rranty HBX Controls warrants each of its products to be fr f ee fr f om defe f cts in workmanship and materials under normal use and servi v ce f r a period of 24 months fr fo f om date of manufa f cture or 12 months fr f om date of purchase fr f om an HBX Authorized Dealer, if w thin the above documented period aft wi f er date of manufa f cture. If the product proves to be defe f cti tive wi w thin the applicable warranty t period, HBX on its sole discreti t on wi w ll repair or replace said product. Re R placement product may a be new or refu f rbished of equiv i alent or better specifi f cati t ons, relati tive to the defe f cti tive product. R placement product need not be of identi Re t cal design or model. Any repair or replacement product pursuant to this warranty t shall be warranted fo f r not less than 90 day a s fr f om date of such repair, irrespecti tive of any earlier expirati t on of origi g nal warranty t period. When HBX provi v des replacement, the defe f cti tive product becomes the property t of HBX Controls. Warranty W t Servi v ce, wi w thin the applicable warranty t period, may a be obtained by contacti t ng your nearest HBX Controls off ffice vi v a the origi g nal Authorized Agent and requesti t ng a Re R turn Material Authorizati t on Number (RM RMA #). Proof of purchase in the fo f rm a dated inv n oice/receipt must be provi v ded to expedite the issuance of a Factory RM RMA. Aft f er an RM R A number has been issued, the defe f cti tive product must be packaged securely in the origi g nal or other suitable shipping package to ensure that it wi w ll not be damaged in transit. The RM RMA number must be vi v sible on the outside of the package and a copy included inside the package. The package must be mailed or otherw rwise shipped back to HBX wi w th all costs of mailing/shipping/insurance prepaid by the warranty t claimant. Any package/s returned to HBX wi w thout an approved and vi v sible RM R A number wi w ll be rejected and shipped back to purchaser at purchaser’s expense. HBX reserves the right, if deemed necessary, y to charge a reasonable levy v fo f r costs incurred, additi t onal to mailing or shipping costs. Limitation of Wa W rranties. If the HBX product does not operate as warranted above the purchasers sole remedy shall be, at HBX’s opti t on, repair or replacement. The fo f regoing warranti t es and remedies are exclusiv i e and in lieu of all other warranti t es, expressed or implied, either in f ct or by operati fa t on of law aw, statutory or otherw rwise, including warranti t es of merchantability t and fi f tness fo f r a parti t cular purpose/applicati t on. HBX neither assumes nor authorizes any other person to assume fo f r it any other liability t in connecti t on wi w th the sale, installati t on maintenance or use of HBX Controls products. HBX shall not be liable under this warranty t ; if its testi t ng and examinati t on discloses that the alleged defe f ct in the product does not exist or was caused by the purchasers or third persons misuse, negl g ect, improper installati t on or testi t ng, unauthorized attempts to repair or any other cause beyond the range of intended use, or by accident, fi f re, lightning or other hazard. Limitation of Liability. y In no event wi w ll HBX be liable fo f r any damages, including loss of data, loss of profi f ts, costs of cover or other incidental, consequenti t al or indirect damages arising out of the installati t on, maintenance, commissioning, perfo f rmance, fa f ilure or interrupti t on of an HBX product, however caused and on any theory of liability ty. This limitati t on wi w ll apply even if HBX has been advi v sed of the possibility t of such damage. Local Law aw. This limited warranty t statement gi gives the purchaser specifi f c legal rights. The purchaser may a also hav a e other rights which vary fr f om state to state in the United States, fr f om Provi v nce to Provi v nce in Canada and fr f om Country to Country elsewhere in the world. To the extent this Li T L mited Wa W rranty t Statement is inconsistent wi w th local law aw, this statement shall be deemed modifi f ed to be consistent wi w th such local law aw. Under such local law aw, certain disclaimers and limitati t ons of this statement may a not apply to the purchaser. For example, some states in the United States, as well as some governments outside the United States (i ( ncluding Canadian Provi v nces), may a : Preclude the disclaimers and limitati t ons in this statement fr f om limiti t ng the statutory rights of a consumer (e.g. United Ki K ngdom) m; Otherw rwise restrict the ability t of a manufa f cturer to enfo f rce such disclaimers or limitati t ons; or Grant the purchaser additi t onal warranty t rights which the manufa f cturer cannot disclaim, or not allow limitati t ons on the durati t on of implied warranti t es.
© HBX Control Systems Inc. 2013
EXP-0300 Manual Page 13
Phone: +1 (403) 720-0029 Fax: +1 (403) 720-0054 Email: info @ hbxcontrols.com Web: www.hbxcontrols.com
HBX Control Systems Inc. 4516 - 112th Avenue SE Calgary, AB Canada T2C 2K2
© HBX Control Systems Inc. 2013
