tekmar 4 Thermostat 545 is a versatile and feature-rich thermostat designed to provide precise temperature control for various applications. With its two-stage heating, one-stage cooling, and one-fan operation, it offers flexible temperature management options. It includes inputs for two auxiliary sensors, allowing you to monitor additional temperature sources such as outdoor or floor sensors. The 545's compatibility with tekmarNet 4 technology enables integration with other tekmar devices for a comprehensive control system.
tekmar 4 Thermostat 545 is a versatile and feature-rich thermostat designed to provide precise temperature control for various applications. With its two-stage heating, one-stage cooling, and one-fan operation, it offers flexible temperature management options. It includes inputs for two auxiliary sensors, allowing you to monitor additional temperature sources such as outdoor or floor sensors. The 545's compatibility with tekmarNet 4 technology enables integration with other tekmar devices for a comprehensive control system.
1 of 12 © 2008 W 545 - 12/08
W 545
12/08
tekmarNet
®
4 Thermostat 545
- Wiring Brochure
tNt 545
Two Stage Heat, One Stage Cool, One Fan
Power: 24 V (ac) ±10% 60 Hz 1.5 VA
Relays: 24 V (ac) 2 A
G1
G1
Rc
Y1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Fan 1 Relay
Fan 1 Relay
Power Cooling
Cool 1 Relay
Sensor Common
Sensor 2
Sensor 1
tekmarNet 4
Power Neutral
Power 24 V (ac)
Heat 1 Relay
Heat 1 Relay
Heat 2 Relay
Heat 2 Relay
DIP Switch Functions
992-02
Meets Class B: Canadian ICES, FCC Part 15
®
No Power
To isolate
relay, cut
jumper
Terminal Functions
Y1 Rc G1 G1
R
C
tN4
S1
S2
Com
W1
Rh1 Rh2
W2
Overview
Information
Brochure
Choose controls
to match
application
1
Application
Brochure
Design your
mechanical
applications
2
Layout
Brochure
Rough-in
wiring
instructions
3
Wiring
Brochure
Wiring and
installation of
specific control
4
Job
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 tekmar tekmarNet
®
4 (tN4) thermostat 545. The 545 has outputs for: two
heat stages, one cooling stage and one fan. The 545 has inputs for two auxiliary sensors. The wiring of 545 thermostat is
simple and cost effective.
Table of Contents:
Definitions ....................................................................... 2
Rough-In Wiring .............................................................2
Remove the Wiring Cover ..............................................3
Mounting the Thermostat ...............................................3
Wiring Symbols ...............................................................3
Electrical Drawings ......................................................3-8
Wiring the Thermostat ...............................................9-10
Troubleshooting the Wiring ........................................... 11
Testing the Wiring .................................................... 11-12
Technical Data .............................................................. 12
DIP
Switches
1st Stage
Cooling
Auxiliary
Sensors
1st Stage
Fan
Wiring
Cover
24 V (ac)
Power
tN4
Network
1st Stage
Heating
2nd Stage
Heating
© 2008 W 545 - 12/08 2 of 12
Sensor 2
Sensor 1
Fan 1
2 Cond. / 18 AWG
2 Cond. / 18 AWG
2 Cond. / 18 AWG
2 Cond. / 18 AWG
2 Cond. / 18 AWG
4 Cond. / 18 AWG
2nd Stage Heat
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
Zone Manager
or 2nd Stage
Equipment
Defi nitions
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.
RH 80% to 88°F (31°C), down to 50% from 104 to
122°F (40 to 50°C). Non-condensing environment.
•
No exposure to extreme temperatures beyond 32 - 122°F
(0 - 50°C).
•
No draft, direct sun, or other cause for inaccurate
temperature readings.
Rough-In Wiring
•
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 12 © 2008 W 545 - 12/08
Mounting the Thermostat
If a single or double gang switch box is used, mount the
thermostat directly to the box.
•
Feed the wiring through the openings in the back of the
thermostat.
•
Use the upper and lower screw holes to fasten the
thermostat 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 right side of the thermostat.
•
While pushing against the plastic tab, lift off the wiring cover.
The electrical drawing examples on the following
pages show the 545 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
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
Factory jumper.
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 upper and lower screw holes to fasten
the thermostat to the wall. At least one of the screws
should enter a wall stud or similar rigid material.
determine the necessary components for and configuration
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
Thermostat
Base
Terminal
Cover
3
1
/4”
(83 mm)
Switch Box
Stud
Wall
Thermostat
Base
Terminal
Cover
© 2008 W 545 - 12/08 4 of 12
tNt 545
Two Stage Heat, One Stage Cool, One Fan
Power: 24 V (ac) ±10% 60 Hz 1.5 VA
Relays: 24 V (ac) 2 A
G1
G1
Rc
Y1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Fan 1 Relay
Fan 1 Relay
Power Cooling
Cool 1 Relay
Sensor Common
Sensor 2
Sensor 1
tekmarNet 4
Power Neutral
Power 24 V (ac)
Heat 1 Relay
Heat 1 Relay
Heat 2 Relay
Heat 2 Relay
DIP Switch Functions
992-02
Meets Class B: Canadian ICES, FCC Part 15
®
No Power
To isolate
relay, cut
jumper
Terminal Functions
10
9
8
7
6
5
1211 13 14
4321
545 tNt
Slab Sensor
079
tN4 C R W tN4 C R W
Zone Manager 337
Zone A1 Zone B1
Factory installed jumper
connects R to Rh1
(terminals 10 to 11) To
isolate Rh1-W1 relay,
cut jumper
using same 24 V
power supply
Cooling Equipment
1 Stage Cooling
1 Stage Fan
Rc
Y1
G1
Outdoor Sensor
070
Y1
Rc
G1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
G1
Electrical Application 545 E1
Description:
Two Stage Heating (H1 = Radiant, H2 = Fin-tube Convector), One Stage Cooling (C1 = Compressor), One A/C Fan (F1 = C1),
Fan Mode = 1.
Legend:
Sensor 1 = Floor
Sensor 2 = Outdoor
5 of 12 © 2008 W 545 - 12/08
10
9
8
7
6
5
1211 13 14
4321
545 tNt
tN4 C R W
tN4 C R W
Zone Managers
Factory installed jumper
connects R to Rh1
(terminals 10 to 11) To
isolate Rh1-W1 relay,
cut jumper
Cooling Equipment
Y1
Rc G1
G1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Universal Sensor
071
Rc Y1 G1
1 Stage Cooling
1 Stage Fan
Indoor Sensor
076
tNt 545
Two Stage Heat, One Stage Cool, One Fan
Power: 24 V (ac) ±10% 60 Hz 1.5 VA
Relays: 24 V (ac) 2 A
G1
G1
Rc
Y1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Fan 1 Relay
Fan 1 Relay
Power Cooling
Cool 1 Relay
Sensor Common
Sensor 2
Sensor 1
tekmarNet 4
Power Neutral
Power 24 V (ac)
Heat 1 Relay
Heat 1 Relay
Heat 2 Relay
Heat 2 Relay
DIP Switch Functions
992-02
Meets Class B: Canadian ICES, FCC Part 15
®
No Power
To isolate
relay, cut
jumper
Terminal Functions
Electrical Application 545 E2
Description:
Two Stage Heating (H1 = Radiant, H2 = Fan Coil), One Stage Cooling (C1= Compressor), One HVAC Fan (F1= H2 & C1),
Fan Mode = 2.
Legend:
Sensor 1 = Room
Sensor 2 = Coil
© 2008 W 545 - 12/08 6 of 12
tNt 545
Two Stage Heat, One Stage Cool, One Fan
Power: 24 V (ac) ±10% 60 Hz 1.5 VA
Relays: 24 V (ac) 2 A
G1
G1
Rc
Y1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Fan 1 Relay
Fan 1 Relay
Power Cooling
Cool 1 Relay
Sensor Common
Sensor 2
Sensor 1
tekmarNet 4
Power Neutral
Power 24 V (ac)
Heat 1 Relay
Heat 1 Relay
Heat 2 Relay
Heat 2 Relay
DIP Switch Functions
992-02
Meets Class B: Canadian ICES, FCC Part 15
®
No Power
To isolate
relay, cut
jumper
Terminal Functions
10
9
8
7
6
5
1211 13 14
4321
545 tNt
tN4 C R W
Zone Manager
Factory installed jumper
connects R to Rh1
(terminals 10 to 11) To
isolate Rh1-W1 relay,
cut jumper
HVAC Equipment
R
Y1
G1
W
Y1
Rc
G1
Com
S2
S1
tN4
C
R
Rh1
W1 W2
Slab Sensor
079
1 Stage Heat
1 Stage Cooling
1 Stage Fan
G1
Rh2
Universal Sensor
071
Electrical Application 545 E3
Description:
Two Stage Heating (H1 = Radiant, H2 = Furnace), One Stage Cooling (C1 = Compressor), One HVAC Fan (F1 = H2 & C1),
Fan Mode = 2.
Legend:
Sensor 1 = Remote
Sensor 2 = Floor
7 of 12 © 2008 W 545 - 12/08
tNt 545
Two Stage Heat, One Stage Cool, One Fan
Power: 24 V (ac) ±10% 60 Hz 1.5 VA
Relays: 24 V (ac) 2 A
G1
G1
Rc
Y1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Fan 1 Relay
Fan 1 Relay
Power Cooling
Cool 1 Relay
Sensor Common
Sensor 2
Sensor 1
tekmarNet 4
Power Neutral
Power 24 V (ac)
Heat 1 Relay
Heat 1 Relay
Heat 2 Relay
Heat 2 Relay
DIP Switch Functions
992-02
Meets Class B: Canadian ICES, FCC Part 15
®
No Power
To isolate
relay, cut
jumper
Terminal Functions
1211 13 14
4321
10
9
8
7
6
5
545 tNt
tN4 C R W
tN4 C R W
Zone Managers
Factory installed jumper
connects R to Rh1
(terminals 10 to 11) To
isolate Rh1-W1 relay,
cut jumper
A/C Equipment
Y1
Rc G1
G1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Universal Sensor
071
Rc Y1 G1
1 Stage Cooling
Indoor Sensor
076
Ventilation
Equipment
G1
G1
Electrical Application 545 E4
Description:
Two Stage Heating (H1 = Radiant, H2 = Fin-tube Convector), One Stage Cooling (C1 = Compressor), One Ventilation Fan
(F1 = HRV or Vent), Fan Mode = None.
Legend:
Sensor 1 = Remote
Sensor 2 = Room
© 2008 W 545 - 12/08 8 of 12
tNt 545
Two Stage Heat, One Stage Cool, One Fan
Power: 24 V (ac) ±10% 60 Hz 1.5 VA
Relays: 24 V (ac) 2 A
G1
G1
Rc
Y1
Com
S2
S1
tN4
C
R
Rh1
W1
Rh2
W2
Fan 1 Relay
Fan 1 Relay
Power Cooling
Cool 1 Relay
Sensor Common
Sensor 2
Sensor 1
tekmarNet 4
Power Neutral
Power 24 V (ac)
Heat 1 Relay
Heat 1 Relay
Heat 2 Relay
Heat 2 Relay
DIP Switch Functions
992-02
Meets Class B: Canadian ICES, FCC Part 15
®
No Power
To isolate
relay, cut
jumper
Terminal Functions
10
9
8
7
6
5
1211 13 14
4321
545 tNt
Factory installed jumper
connects R to Rh1
(terminals 12 to 13) To
isolate W1 relay,
cut jumper
External Class 2
Transformer
24 V (ac)
tN4 C
Other
tN4 Thermostat
or Zone Mana
g
er
HVAC Equipment
R
Y1
G1
W
R C
Indoor Sensor
076
Y1
Rc
G1
Com
S2
S1
tN4
R
Rh1
W1 W2
C
G1
1 Stage Heat
1 Stage Cooling
1 Stage Fan
Rh2
Duct Sensor
083
Electrical Application 545 E5
Description:
Two Stage Heating (H1 = Fan Coil, H2 = Furnace), One Stage Cooling (C1 = Compressor), One HVAC Fan (F1 = H1 & H2,
C1), Fan Mode = 2.
Legend:
Sensor 1 = Room
Sensor 2 = Duct
9 of 12 © 2008 W 545 - 12/08
Wire the tN4 communication to terminals tN4 and C.
If a Zone Manager is used:
•
Connect the tN4 on the thermostat to the 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 the tN4 on the thermostat to the tN4 on another
tN4 device on the same tN4 bus.
•
Connect the C on the thermostat to the C terminal on
another tN4 device on the same tN4 bus.
tN4 Communication Terminals 8, 9
Wire the first stage of heating to the Heat 1 Relay.
(Rh1 - W1)
•
Use these terminals as a switch to operate the first stage
of heating.
If a Zone Manager is used:
•
Connect W1 on the thermostat to W on the proper
zone of the Zone Manager.
If a Zone Manager is not used:
•
Determine if the factory jumper must be cut.
•
When the factory jumper is not cut, W1 is a powered
output that is internally connected to R.
•
When the factory jumper is cut, Rh1- W1 is an isolated
switch. No power is available from these terminals.
Heat 1 Relay Terminals 11, 12
Wire the second stage of heating to the Heat 2 Relay.
(RH2 - W2)
•
Use these terminals as a switch to operate the second
stage of second.
If a Zone Manager is used:
•
Connect RH2 to R on the proper zone of the Zone
Manager. Connect W2 to W on the proper zone of the
Zone Manager.
If a Zone Manager is not used:
•
Rh2 - W2 is an isolated switch. No power is available
from these terminals.
Heat 2 Relay Terminals 13, 14
Wire 24 V (ac) to terminals C and R.
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 9, 10
Zone Manager
Thermostat
Zone Manager
or Thermostat
Thermostat
Zone Manager
Thermostat
*
Factory installed jumper connects terminals R to Rh1
(To isolate Rh1-W1 relay, cut jumper)
2nd Zone Manager or
2nd Stage Equipment
Thermostat
Note: This connection is polarity sensitive.
Wiring the Thermostat:
9
C
10
R
tN4 C R W
8
tN4
9
C
10
R
tN4 C R W
9
C
10
R
Rh1 W1
11 12
tN4 C R W
Rh2 W2
13 14
tN4 C R W
© 2008 W 545 - 12/08 10 of 12
Wire the first stage of fan to the Fan 1 Relay. (G1 - G1)
•
G1 - G1 is an isolated switch. No power is available from
these terminals.
•
Use these terminals as a switch to operate the first stage
of fan.
•
If the fan is part of the cooling equipment you may be able
tojumper power from Rc (3) to G1 (2) (not shown).
Fan 1 Relay Terminals 1, 2, 3
Thermostat
Wire the first stage of cooling to the Cool 1 Relay.
(Rc - Y1)
•
Rc - Y1 is an isolated switch. No power is available from
these terminals
•
Use these terminals as a switch to operate the first stage
of cooling.
Cool 1 Relay Terminals 3, 4
Thermostat
The auxiliary sensors are connected to the thermostat on
terminals Com, S1 and S2.
•
• Connect sensor 1 to terminals S1 and Com.
•
• Connect sensor 2 to terminals S2 and Com.
Do not apply power
to terminals 5 - 7, permanent
damage to the sensors and / or thermostat will result!
Auxiliary Sensors Terminals 5 - 7
Do Not Apply Power
Thermostat
Universal
Sensor
Outdoor
Sensor
To various tekmar
sensors
43
Y1 Rc
321
Rc G1 G1
5
Com
6
S2
7
S1
1st Stage
Cooling
1st Stage
Fan
11 of 12 © 2008 W 545 - 12/08
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
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%.
3. Install the front cover.
1. Remove the front cover from the thermostat.
2. Disconnect the wires from the relay that is to be
tested.
3. Place the thermostat into the test routine.
4. Use an electrical test meter and check for continuity
across the relay.
•
• When the relay’s symbol is displayed in the LCD,
there should be continuity.
•
• When the relay’s symbol is not displayed in the
LCD, there should be no continuity.
5. Reconnect the wires to the relay.
6. Repeat steps 2 to 5 for each relay that is to be tested.
7. Install the front cover on the thermostat.
Cool 1
Fan 1
545 LCD Display Segments
Heat 1 Heat 2
Testing the Relays
To test the sensors, the actual temperature at each sensor
location must be measured.
Use a good quality digital thermometer with a surface
temperature probe for ease of use and accuracy. Where
a digital thermometer is not available, place a spare
sensor alongside the one to be tested and compare
the readings.
Testing the Sensors
1. Remove the front cover from the thermostat.
2.
Disconnect the wires from the sensor that is to be
tested.
3. Test the sensor’s resistance according to the
instructions in the sensor Data Brochure D 070, D 074,
D 079 or D 083.
4. Reconnect the wires.
5. Install the front cover on the thermostat.
5
Com
6
S2
7
S1
8
tN4
9
C
10
R
Rh1 W1 Rh2 W2
11 12 13 14
4321
Y1 Rc G1 G1
###
For an explanation on the use of the ‘Test’ sequence or any error messages, refer to the Data Brochure.
tekmar Control Systems Ltd., Canada
tekmar Control Systems, Inc., U.S.A.
Head Office: 5100 Silver Star Road
Vernon, B.C. Canada V1B 3K4
(250) 545-7749 Fax. (250) 545-0650
Web Site: www.tekmarcontrols.com
Product design, software and literature are Copyright © 2008 by:
tekmar Control Systems Ltd. and tekmar Control Systems, Inc.
12 of 12
All specifications are subject to change without notice.
Printed in Canada. W 545 - 12/08.
To test the tN4 Network, check the wires for continuity.
1. Remove the front cover from the thermostat.
2. Disconnect the two wires (tN4 and C) at one end and
connect them together.
Testing the tN4 Network
3. Go to the other end of the wires and disconnect them.
4. Using an electrical test meter, check for continuity.
5. Reconnect the wires.
6. Install the front cover on the thermostat.
Technical Data:
tekmarNet
®
4 Thermostat 545: Two Stage Heat, One Stage Cool, One Fan
Control Microprocessor PID control; This is not a safety (limit) control
Packaged weight 1.15 lb. (522 g)
Enclosure White PVC plastic
Dimensions 4-1/2” H x 4-3/4” W x 7/8” D (114 x 120 x 22 mm)
Approvals CSA C US, CSA/UL 61010-1, meets Class B: ICES and FCC Part 15
Ambient conditions Indoor use only, 32 to 122°F (0 to 50°C)
RH
80% to 88°F (31°C), down to 50% from 104 to 122°F (40 to 50°C)
Altitude <6560 feet (2000 m), Installation Category II, Pollution Degree 2
Power supply 24 V (ac) ± 10% 60 Hz, 1.5 VA, NEC / CEC Class 2
W1 Relay 24 V (ac) 2 A
W2 Relay 24 V (ac) 2 A
Y1 Relay 24 V (ac) 2 A
G1 Relay 24 V (ac) 2 A
Sensors: NTC thermistor, 10 k @ 77°F (25°C ± 0.2°C) ß = 3892
– Included None
– Optional tekmar type # 070, 071, 072, 073, 076, 077, 078, 079, 083, 083, 084
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.
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tekmar 545 User guide
- Type
- User guide
- This manual is also suitable for
tekmar 4 Thermostat 545 is a versatile and feature-rich thermostat designed to provide precise temperature control for various applications. With its two-stage heating, one-stage cooling, and one-fan operation, it offers flexible temperature management options. It includes inputs for two auxiliary sensors, allowing you to monitor additional temperature sources such as outdoor or floor sensors. The 545's compatibility with tekmarNet 4 technology enables integration with other tekmar devices for a comprehensive control system.
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