AERCO BMS 168 User Manual

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Boiler Management

System

Installation

Instructions

Boiler Management

System

Operation &

Troubleshooting

DISPLAY MODE

HDR

TEMP

AIR

TEMP

LOAD

FOR USE W/ INDOOR TEMP. SENS.

SET

POINT

OFF SET

PROP BAND

CONFG

SYS

Hold Key for

Display Header

Header Set

Temp., oF

Display Outside Air Temp., oF

Display % Load & No. of Units Operating

Display/Change Indoor Sensor Reference Temp.,

Display/Change Setpoint Temp when Activated

Display/Change Hdr. Temp. / Indoor Ref. Temp.

System Configuration

FIELD ADJUSTMENT MODE

FIELD

L.E.D. "On" Enables Field Adjustment

ADJ

Select System Start Option

SYS

Display/Change Outside Air

START

Temp. for System Start

TEMP

Display/Change Bldg Ref Temp — Indoor/Outdoor

REF

TEMP

Hdr Set Temp — Constant Set

HDR

Display/Change

TEMP

Minimum Or Maximum

LIMIT

Header Temp. Display/Change

RESET

Header Temp. / Outside Air Temp.

RATIO

(Alarm Cancel) Reset Alarm Contact

Set Date

LOAD

And Time

Set Up

OFF

Set Back

SET

Clock Select Fault

CONFG

Alarm Relay

SYS

Options

Enable BMS

Disable BMS

OFF

Reset Mode Point Mode

Raise/Lower

To Change

HEADER SET INDOOR AIR

DISPLAY

ADJ

HDR

TEMP

SYS

REF

START

TEMP

LEVEL

PROP

SET

BAND

POINT

OFF SET

ON OFF

CONFIG

AERCO INTERNATIONAL INC., NORTHVALE, N.J.

AIR

SYS

HDR TEMP LIMIT

RESET RATIO

LOAD

FIELD

ADJ

Applicable to Serial Numbers 329985 and above (EPROM Rev. K and above)

AERCO International, Inc.

159 Paris Avenue

159 Paris Avenue Northvale, NJ 07647-0128

Northvale, NJ 07647-0128

GF-108M

REVISED 3/13/08

Telephone Support

Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday):

1-800-526-0288

AERCO International, Inc. 159 Paris Avenue Northvale, NJ 07647-0128

www.aerco,com

The information contained in this installation, operation and maintenance manual is subject to change without notice from AERCO International, Inc.

AERCO makes no warranty of any kind with respect to this material, including but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in connection with the furnishing, performance, or use of this material.

Page

SECTION 1 ABOUT YOUR NEW BOILER MANAGEMENT SYSTEM (BMS) 1-1

SECTION 2 FEATURES OF THE BMS 2-1

SECTION 3 INSTALLING THE BMS 3-1

3.1 MOUNTING THE BMS 3-1

3.2 GENERAL WIRING 3-1

3.3 PULSE WIDTH MODULATION WIRING 3=2

3.3.1 PWM Wiring at BMS 3-2

3.3.2 PWM Wiring at Boilers 3-2

3.4 RS485 (MODBUS) WIRING 3-2

3.4.1 RS485 Wiring at BMS 3-2

3.4.2 RS485 Wiring at Boilers 3-3

3.5 SENSOR INSTALLATION AND WIRING 3-3

3.5.1 Header Sensor 3-3

3.5.2 Outside Air Sensor 3-3

3.6 INTERLOCK WIRING 3-4

3.6.1 Interlock 1 Wiring 3-4

3.6.2 Interlock 2 Wiring 3-4

3.7 RELAY WIRING 3-4

3.7.1 System Start Relay 3-4

3.7.2 Fault Alarm Relay 3-4

3.7.3 Auxiliary Relay 3-4

3.8 SET BACK 3-4

SECTION 4 FAMILIARIZING YOURSELF WITH THE BMS 4-1

4.1 ABOUT BMS MODES 4-1

4.1.1 Selecting and Viewing Functions 4-1

4.1.2 Changing Function Settings 4-1

4.2 NORMAL MODE FUNCTIONS 4-4

4.2.1 HDR TEMP 4-4

4.2.2 AIR TEMP 4-4

4.2.3 % LOAD 4-4

4.2.4 SYS START TEMP 4-4

4.2.5 REF TEMP 4-4

4.2.6 HDR TEMP LIMIT 4-4

4.2.7 FIELD ADJ 4-4

4.2.8 SET POINT 4-4

4.2.9 PROP BAND 4-4

4.2.10 OFF SET 4-4

4.2.11 RESET RATIO 4-4

4.2.12 ▲ and ▼ Arrow Keys 4-5

Table of Contents

(Continued)

4.2.13 ON and OFF Keys 4-5

4.2.14 CONFIG SYS 4-5

4.3 FIELD ADJUST MODE FUNCTIONS 4-5

4.3.1 HDR TEMP 4-5

4.3.2 AIR TEMP 4-6

4.3.3 % LOAD 4-6

4.3.4 Setting the Internal Clock With the % LOAD Key 4-6

4.3.5 SYS START TEMP 4-7

4.3.6 REF TEMP 4-7

4.3.7 HDR TEMP LIMIT 4-7

4.3.8 FIELD ADJ 4-8

4.3.9 SET POINT 4-8

4.3.10 PROP BAND 4-8

4.3.11 OFFSET 4-8

4.3.12 Setting Up a Reset Schedule 4-8

4.3.13 Manual Set Back 4-9

4.3.14 RESET RATIO 4-9

4.3.15 ▲ and ▼ Arrow Keys 4-9

4.3.16 ON and OFF Keys 4-9

4.3.17 CONFIG SYS 4-9

4.4 SYSTEM CONFIGURATION MODE FUNCTIONS 4-10

4.4.1 TEMP FAIL MODE 4-10

4.4.2 SYS ENABLE 4-11

4.4.3 MAX PWR INPUT 4-11

4.4.4 START AND STOP LEVEL Keys 4-12

4.4.5 BLR OP MODE 4-12

4.4.5.1 Sequential Mode 4-12

4.4.5.2 Parallel Mode 4-13

4.4.5.3 Combination Mode 4-13

4.4.5.4 Designating the Number of Combination Boilers 4-13

4.4.6 HDR SET MODE 4-13

4.4.7 INTGL RATE GAIN and DERIV GAIN Keys 4-13

4.4.7.1 TEMP BANDWIDTH 4-14

4.4.7.2 INTGL RATE GAIN 4-14

4.4.7.3 DERIV GAIN 4-14

4.4.8 AUX RELAY 4-15

4.4.9 ▲ and ▼ Arrow Keys 4-15

4.4.10 ON and OFF Keys 4-15

4.4.11 CONFIG SYS 4-15

Table of Contents

(Continued)

SECTION 5 PROGRAMMING THE BMS MODE OF OPERAT

5.1 INDOOR/OUTDOOR RESET MODE 5-1

5.1.1 Selecting Indoor/Outdoor Reset Mode 5-1

5.1.2 Entering System Start Temperature 5-1

5.1.3 Determining the Reset Schedule 5-1

5.1.4 Entering the Building Reference Temperature 5-2

5.1.5 Entering the Reset Ratio 5-2

5.2 SETUP FOR REMOTE SETPOINT MODE 5-2

5.2.1 Entering Header Set and Boiler Operating Modes 5-2

5.2.2 Entering Remote Signal Type and Header Temperature Limits 5-2

5.3 SETUP FOR CONSTANT SETPOINT MODE 5-3

5.3.1 Entering Header Set and Boiler Operating Mode 5-3

5.3.2 Entering Header Reference Temperature 5-3

5.4 CONFIGURING BOILERS FOR PULSE WIDTH MODULATION (PWM) 5-3

5.4.1 C-More Control System PWM Setup 5-4

5.4.2 Configuring the Temperature Controller 5-4

5.5 SYSTEM INITIALIZATION AND POLLING 5-4

5.6 TESTING THE SYSTEM 5-5

ION

APPENDICES

Appendix A Specifications A-1 Appendix B Methods for Determining Reset Schedule and Indoor/Outdoor Reset Ratio Charts B-1 Appendix C Normal (Read-Only) Mode Display Messages and Defaults C-1 Appendix D Field Adjust Mode Display Messages and Defaults D-1 Appendix E Config Sys Mode Display Messages and Defaults E-1 Appendix F Sensor Resistance Data Sheet F-1 Appendix G Parts List G-1 Appendix H Troubleshooting H-1 Appendix I General BMS Wiring I-1 Appendix J Programming the BMS Using RS-232 Communication J-1

iii

List of Figures

Figure 1 Typical BMS Installation 3-5 Figure 2 BMS Mounting 3-6 Figure 3 Wire Routing Locations at the BMS 3-7 Figure 4 PWM Communication Outputs at the BMS 3-8 Figure 5 Pulse Width Modulation Connections at KC Series Boiler Boiler With Modular Control Box 3-9 Figure 6 PWM & RS485 Connections at KC Series Boiler With C-More Control Box 3-10 Figure 7 Pulse Width Modulation Connections at the Benchmark Boiler With Modular Control Box 3-11 Figure 8 PWM & RS485 Connections at the Benchmark Boiler With C-More Control Box 3-12 Figure 9 BMS RS485 & RS232 Connector Locations 3-13 Figure 10 BMS RS485 & RS232 Connector Pin Assignments 3-14 Figure 11 Header Sensor Installation With Well 3-15 Figure 12 Outside Air Sensor Mounting and Connections 3-16 Figure 13 Normal and Field Adjust Mode Overlay 4-2 Figure 14 System Configuration Mode Overlay 4-3

Section 1 ______________________________

SIMPLE INSTALLATION AND

About Your New Boiler Management System (BMS)

AERCO’s Boiler Management System (BMS), stages and modulates AERCO KC Series and Benchmark Boilers, allowing them to operate efficiently as a system. It provides a broad array of operating modes, so that the nuances of specific applications can be easily accommodated. The BMS can control up to 40 boilers; 8 via pulse width modulation (PWM) and up to 32 via Modbus (RS485) communication. For Modbus control, the AERCO Boilers must be equipped with C-More Control Systems.

PRECISE CONTROL

Utilizing PWM or Modbus control, the BMS fully exploits the condensing and modulating ability and efficiency of each boiler and regulates the output of the boiler plant with water supply temperature variation of no more than ±2°F

Staging can be performed sequentially or in parallel. The BMS can sample building reference temperatures to modulate boiler plant output, and will perform water supply temperature night setback automatically referenced to its internal clock.

OPERATION

Installation of the BMS is simple, and lowvoltage wiring is employed between the BMS panel and boiler modules. There are no complex design steps to be performed, since a keypad in conjunction with the LCD allows the operator to acquire, change, and program settings through easy-to-use labeled buttons. Each BMS function consists only of selecting the function and toggling values, which generally requires no more than pressing four keys.

The instant a parameter is programmed, it is automatically entered into the BMS memory, avoiding multiple programming steps to store information. In the event of power loss, most factory default settings remain in nonvolatile memory for up to 10 years and need not be reprogrammed. However, date and time remain in memory for about 30 days.

BMS PROGRAMMING VIA RS232 PORT

If desired, the BMS can be programmed by connecting a Laptop Computer, or other type of terminal emulation device, to the RS232 connector on the left side of the BMS. See Appendix J for programming using RS232 communication.

1-1

Section 2 ______________________________

SEQUENTIAL OR PARALLEL

Features of

OPERATION

the BMS____

APPLICATION FLEXIBILITY

Three different system or control options can be selected at setup to match the needs of any closed-loop system - Indoor/Outdoor Reset, 4-to-20 mA Remote Setpoint, and Constant Setpoint.

CONTINUOUS COMMUNICATIONS

The BMS continually sends information to the boilers and receives information from them, providing total control of boiler plant dynamics.

EXCEPTIONAL ACCURACY

The BMS control system uses a PID (Proportional Integral Derivative) control algorithm to respond dynamically to system changes. Water temperatures are precisely controlled by modulating energy in put. A supply water temperature of ±2°F is assured.

BUILDING INDOOR AIR TEMPERATURE INPUTS

The BMS accepts building indoor air temperatures directly from a thermistor sensor or from a 4-to-20 mA signal. Adjustments can be made to the header setpoint temperature to compensate for varying building temperatures and conditions.

Modules can be either sequenced on, or run in parallel, by selection from the front panel. In sequential mode, boilers are brought on one at a time, so turn-down ratio is 14 multiplied by the number of KC Series boilers, or 20 multiplied by the number of Benchmark boilers. This provides higher energy savings and seasonal efficiency. In parallel mode, all of the boilers are modulated together at the same firing rate. The turn-down ratio of the system is fixed at 14:1 for the KC Series boilers and 20:1 for the Benchmark boilers.

BUMPLESS TRANSFER

When in sequential mode, the BMS stages boilers on and off, one at a time, at selectable percentages of firing rate. The result is a seamless transition and undetectable room temperature changes. Sequential mode has several other unique features:

Run-Time Equalization: The BMS se-

quences boilers on a first on-first off basis, which automatically equalizes the run time of all boilers in the plant.

Automatic Load Distribution: The BMS

continuously monitors the number of modules that are available for operation. In the event of a boiler malfunction or when service is performed, the BMS automatically compensates for a lack of response from any unit and brings on the next available boiler to satisfy demand. This feature operates in both parallel and sequential modes.

2-1

Time Delay Between Boiler Starts:

A fixed, 30-second time delay between boiler starts ensures smooth energy input without spikes in electrical, gas, or venting conditions.

AUTOMATIC SYSTEM START

Automatic system start contacts for controlling auxiliary equipment such as pumps and dampers can be selected to close between 32°F and 100°F outside air temperature, eliminating the need for the plant operator to turn auxiliary equipment on and off.

MINIMUM AND MAXIMUM HEADER SET CLAMPING

The supply water temperature can be clamped at a maximum high temperature or minimum low temperature, to ensure that the building temperature is optimal for the greatest comfort.

Two Interlock Circuits (Enable/Disable Contacts)

The BMS contains two normally-open interlock circuits that require only a set of dry contacts to enable or disable the boiler plant. They can be used to monitor pumps, combustion air dampers, or other equipment. Out-of-limit conditions trip the interlocks, shutting down the boiler plant, and providing a high level of protection.

ADJUSTABLE OFFSET

The Offset feature can allow the temperature of the supply water to be offset in 1° increments over a range of -50°F below to +50°F above its current temperature. This feature is employed for night setback or morning warmup. The BMS lets you select, over a 7-day period, the time when the offset begins and ends.

CONTROL OF AUXILIARY EQUIPMENT

The auxiliary relay uses a dry set of contacts to operate auxiliary equipment. For example, when the boiler plant is at 100% load, these contacts close and can start an auxiliary boiler, or notify an energy management system of a full-load condition.

FAULT ALARM SURVEILLANCE

The BMS continually monitors its sensors for opens and shorts and the interlock circuits for opens. However, the BMS fault alarm relay does not close or indicate a fault when a boiler has failed. The fault alarm circuit consists of a dry set of 120 VAC contacts rated at 5 A.

SIMPLE INSTALLATION

The BMS operates from 120 VAC, 50 to 60 Hz, and uses Belden 9841 or equivalent wiring between modules for control and monitoring. The lightweight panel can be mounted up to 200 feet from the boilers when using pulse width modulation communication.

RUGGED AND RELIABLE

The BMS is housed in a NEMA 13-grade enclosure and operates in ambient temperatures as high as 131°F (55°C).

POWER-OFF MEMORY

Most system configuration values are retained in nonvolatile memory for up to 10 years. Date and time remain in memory for approximately 30 days.

MODBUS COMMUNICATION

The BMS can monitor or control C-More Boilers using Modbus communication via its RS485 port. It can also be monitored or controlled by a Building Automation System (BAS) or a PC connected to its RS232 port.

2-2

Section 3 ______________________________

3.2 GENERAL WIRING

Installing the BMS________

Please follow the installation procedure in the order presented. Incorrect wiring may damage the unit and void the AERCO warranty Do not omit steps, and do not substitute other types of wiring for those specified. Figure 1 shows a typical BMS installation.

3.1 MOUNTING THE BMS

Use the mounting plate (Figure 2) supplied with the BMS to securely mount the unit away from moisture, and at an appropriate height for easy reading of the display. To reduce the possibility of electrical noise entering the system, mount the BMS at least 6 feet away from electrical devices such as power panels, high voltage transformers and transmission lines, motors, and fluorescent lights.

All wiring and fusing must be in compliance with the National Electrical Code and with local electrical codes. Control wiring for the sensors and communications links must run in separate conduit and not in the conduit providing line voltage in order to ensure immunity from electrical noise.

All wiring should be installed in conduit leading up to the bottom of the BMS panel. There are five knock-outs in the bottom of the panel by which wiring must enter the BMS.

Shielded, twisted-pair cable should be used for sensor and communication wiring. This wiring should be 18 to 24 AWG. Examples of suitable sensor and communication wire are: Belden 9841, 8761, 3105A or equivalent. AC power wiring should be 16 to 18 AWG. A BMS wiring diagram is included in Appendix I. Once mounting is complete and the BMS is secured in place, loosen the two captive screws on the wiring cover plate with a Phillips screwdriver. Feed all wiring through the knock-outs provided on the bottom of the panel. All pulse width modulation (PWM) and RS485 control wires should be fed through the two knock-outs furthest to the left.

Shock Hazard!

Extreme caution must be exercised when connecting power wiring to the BMS. The external circuit breaker supplying Line voltage to the the BMS must be turned off to avoid electrical shock

Power wiring should be fed through the right-most knock-out in the bottom of the panel (Figure 3). The remaining knockouts are for control wiring located on the middle terminal block. The terminal blocks can be detached from the BMS headers to simplify field wiring.

Once power wiring is completed, apply line voltage to the BMS, and press the ON key on the BMS keypad to verify proper connection. The display should show INITIALIZING EPROM REV. n where n is the current EPROM version.

3-1

WARNING!

Turn off AC input power to the BMS to avoid electrical shock.

3.3 PULSE WIDTH MODULATION WIRING

Pulse width modulation (PWM) wiring connections are made between the BMS JP2 terminal block and the Relay or I/O Box terminals at each AERCO Boiler. Shielded twisted-pair wire is recommended.

3.3.1 PWM Wiring At BMS

To wire boilers for pulse width modulation (PWM), connect the boiler control wires in ascending order according to the numbers on the BMS (Figure 4). For example, the control wiring for boiler 1 at the BMS would be connected as follows:

• Positive control wire connects to JP 2, terminal 1 (+).

• Negative control wire connects to JP 2, terminal 2 (-).

• Shield wiring connects to the negative (-) control wire at Section BLR 1, terminal 2. The shield is not terminated at the boiler. All shields must be terminated on the BMS end. The wiring terminals labeled SHIELD at terminal block JP3 of the BMS are not internally connected to ground and are only used as a place to terminate the sensor shields. The pulse width modulation shield can be connected to any minus (-) terminal of the PWM terminal strip (JP2).

3.3.2 PWM Wiring At The Boilers

The pulse-width modulation (PWM) control wiring from the BMS to each boiler is connected at each boiler’s relay box or input/output (I/O) box, depending on the type of control system used. Modular control systems utilize a relay box as shown in Figure 5 (KC1000) and Figure 7 (Benchmark). The newer C-More control system utilizes an I/O box as shown in Figure 6 and Figure 8.

Regardless of the type of control system used, the PWM wiring is connected to the BMS + and – terminals as shown in the respective illustrations. It is imperative that positive (+) and negative (-) polarity be observed when making these connections. All boilers follow the same control wiring scheme.

When using pulse width modulation, the BMS may be mounted up to 200 feet from the boilers.

3.4 RS485 (MODBUS) WIRING

All Modbus Networks are implemented using a “Master - Slave” technique. The BMS can function as either a “Master” controlling C-More Slaves or a “Slave” controlled by a “Master” Energy Management System (EMS) or Building Automation System (BAS). Therefore, the following paragraphs provide only an overview of the required wiring connections. Detailed information and setup procedures for RS485 Modbus networks are provided in Modbus Communication Manual GF-114. Refer to GF-114 prior to implementing any RS485 networks using Modbus.

RS485 wiring connections are made using a “Daisy-Chain” configuration. Shielded twisted-pair wire from 18 to 24 AWG is required for all RS485 wiring.

3.4.1 RS485 Wiring At BMS

RS485 wiring connections are made at the BMS at connector JP11 which is labeled RS485 TO BLRS. The location of this RS485 connector is shown in Figure 9. In addition, Figure 9 also shows the locations of the external and internal RS232 connectors which are used to interface the BMS to an EMS Master if required. The pin assignments for the RS485 and RS232 connectors are shown in Figure 10.

3-2

Connect the RS485 wiring at the BMS as follows:

• Connect the positive (+) lead to the +(B) terminal of JP11.

• Connect the negative (-) lead to the -(A) terminal of JP11.

• Connect the shield to the SHLD terminal of JP11.

3.4.2 RS485 Wiring At Boilers

RS485 wiring connections are made at the RS485 COMM terminals of each boiler’s I/O Box as shown in Figures 6 (KC1000) and Figure 8 (Benchmark). Connect the wiring as follows:

• Connect the positive lead to the + terminal

• Connect the negative lead to the terminal

• DO NOT terminate the shields to the Ground (G) terminal at the Boiler end of the RS485 loop. Connect the shields of the incoming and outgoing leads together. The RS485 loop should only be terminated at the BMS.

RS485 loops should not exceed 4000 feet.

Detailed wiring diagrams for RS485 Modbus communication networks are provided in the Modbus Communication Manual GF-114.

3.5 SENSOR INSTALLATION

AND

There are two types of sensors that may be installed -- header sensors and outside air sensors. While an outside air sensor is required for Indoor/Outdoor Reset mode, it is not required for Constant Setpoint or 4-to20-mA modes of operation. However, it is recommended to take full advantage of all BMS features. The header sensor is required for all modes of operation.

Sensor wiring and power wiring should be run separately to reduce the chance of electrical noise entering the sensor wiring.

WIRING

3.5.1 Header Sensor

The header sensor to be used with the BMS is a sensor that requires a well as shown in Figure 11. When installing the sensor, use a 1/2 inch NPT tapped coupling or a 4 x 4 x 1/2 Tee fitting. Use heat-conductive grease when installing to aid in its response. The sensor probe must be inserted at least 2 inches into the flow of water for proper response. The header sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the plant’s supply water header.

The header sensor is a thermistor type sensor. The Resistance vs. Temperature Chart for the sensor is provided in Appendix F. See Figure 11 for installation details.

Shielded pair 18 AWG cable (Belden # 8760 or equiv.) is recommended for header sensor wiring. There is no polarity to be observed. Connect the wires from the sensor to BMS terminals 4 and 5 on JP3. The ground for the shield is at BMS end of the link, not the header sensor. Connect the ground to JP3, terminal 8 (SHIELD). The header sensor can be installed up to 600 feet from the BMS.

3.5.2 Outside Air Sensor

The Outside Air Sensor, AERCO part no. 122662, must be mounted on the North side of the building, shielded from direct sunlight, and away from air intakes or outlets from the building. See Figure 12 for a typical installation. The sensor includes a plate for wall mounting. Shielded pair 18 AWG cable (Belden # 8760 or equiv.) is recommended for sensor wiring. There is no polarity to be observed. Connect the sensor wires to BMS terminals 1 and 2 on JP3. Connect the shield to JP3, terminal 3 (SHIELD) at the BMS. The shield must not be grounded on the sensor end. The sensor can be mounted up to 600 feet from the BMS.

3-3

3.6 INTERLOCK WIRING

The BMS is equipped with two interlocks designated Interlock 1 (INT 1) and Interlock 2 (INT 2). Since both interlocks must be closed for the BMS to operate the boiler plant, the associated wiring terminals are jumpered, prior to shipment. If desired, proving device switches can be connected to either used, interlock wiring connections are made as described in the following paragraphs.

3.6.1 Interlock 1 Wiring

Interlock 1 is often used with auxiliary equipment, such as air dampers or flow switches. If used, connect the end proving switch to INT 1 terminals 11 and 12 as shown in the wiring diagram in Appendix I.

3.6.2 Interlock 2 Wiring

Interlock 2 is a general purpose interlock which can be used with a variety of devices or equipment or conditions that must be proved prior to enabling the boiler plant. If used, connect the end proving switch to INT 2 terminals 13 and 14 as shown in the wiring diagram in Appendix I.

interlock in place of the jumper. If

NOTE

If necessary, Interlock 1 can be programmed to operate the boilers only when the outside air temperature falls below the system start temperature. See para. 4.4.2 for details. Interlock 2 cannot programmed with this feature.

3.7 RELAY WIRING

The BMS contains a System Start Relay, a Fault Alarm Relay and an Auxiliary Relay which can be connected to external monitoring or control devices. The contacts for each of these relays are rated at 120 VAC, 5A and are fused internally at 5A with replaceable fuses. The contact terminals for these relays are shown in the wiring diagram in Appendix I.

3.7 1 System Start Relay

The state of the System Start (SYS START) relay contacts are controlled by the value set for the SYS START TEMP function in the Field Adjust Mode (para. 4.3.5). The contacts are closed only when the outside air temperature is less than the System Start Temperature (SYS START TEMP) which is set in the Field Adjust Mode. The default for this temperature setting is 70°F.

3.7.2 Fault Alarm Relay

The state of the Fault Alarm (FLT ALARM) relay contacts are controlled by the option selected by pressing the CONFIG SYS key when in the Field Adjust mode (para.

4.3.16). Contact closure can be set to ALL FAULTS, INTERLOCK 1, INTERLOCK 2, or NO INTERLOCK.

3.7.3 Auxiliary Relay

The state of the Auxiliary (AUX) relay contacts are controlled by the AUX RELAY CLOSE option selected when in the System Configuration mode (para. 4.4.8). Contact closure can be set to occur either when all available boilers are at the maximum power input or no boilers are available (all boilers faulted or turned off).

NOTE

The SET BACK function is used only if the header supply temperature will be offset manually as described in para. 4.3.13. Disregard para. 3.8 if an automatic header temperature reset schedule is used as described in para. 4.3.12.

3.8 SET BACK

The SET BACK terminals shown in the wiring diagram in Appendix I are used only when implementing a manually-controlled header temperature offset. If used, connect a dry contact switch across SET BACK terminals 15 and 16 on JP3.

3-4 3-5

Figure 2

BMS MOUNTING

3-6

Figure 3

RECOMMENDED WIRE ROUTING LOCATIONS AT THE BMS

3-7

Figure 4

PWM COMMUNICATION OUTPUTS AT THE BMS

3-8

Figure 5

PULSE WIDTH MODULATION CONNECTIONS AT

KC SERIES BOILER WITH MODULAR CONTROL BOX

3-9

Remove sheet metal cover to access I/O Box

OUTDOOR SENSOR IN

SENSOR COMMON

AUX SENSOR IN

NOT USED

ANALOG IN

B.M.S. (PWM) IN

SHIELD

mA OUT

RS-485 COMM.

NOT USED

REMOTE INTL'K IN

EXHAUST SWITCH IN

DELAYED INTL'K IN

NOT USED

FAULT RELAY

COM

120 VAC, 5A, RES

AUX RELAY

COM NO

120 VAC, 5A, RES

NOT USED

PWM Connections

RS485 COMM Connections

Figure 6

PWM & RS485 CONNECTIONS AT

KC SERIES BOILER WITH C-MORE CONTROL BOX

3-10

Figure 7

PWM CONNECTIONS AT

BENCHMARK BOILER WITH MODULAR CONTROL BOX

3-11

Open Door To Access I/O Box

OUTDOOR SENSOR IN

SENSOR COMMON

AUX SENSOR IN

NOT USED

ANALOG IN

B.M.S. (PWM) IN

SHIELD

mA OUT

RS-485 COMM.

NOT USED

REMOTE INTL'K IN

EXHAUST SWITCH IN

DELAYED INTL'K IN

NOT USED

FAULT RELAY

COM

120 VAC, 5A, RES

AUX RELAY

COM NO

120 VAC, 5A, RES

NOT USED

PWM Connections

RS485 COMM Connections

Figure 8

PWM & RS485 CONNECTIONS AT

BENCHMARK BOILER WITH C-MORE CONTROL BOX

3-12

Figure 9

BMS RS485 & RS232 CONNECTOR LOCATIONS

3-13

Figure 10

BMS RS485 & RS232 CONNECTOR PIN ASSIGNMENTS

3-14

1/2 “ NPT

Figure 11

HEADER SENSOR INSTALLATION WITH WELL

3-15

Figure 12

OUTSIDE AIR SENSOR MOUNTING AND CONNECTIONS

3-16

Section 4 ______________________________

Familiarizing Yourself With the BMS_____

4.1 ABOUT BMS MODES

The BMS has three basic modes: Normal Mode, Field Adjust Mode and Configure System Mode. The Normal Mode is a “Read-Only” mode which only allows you to view system settings. The Field Adjust (FIELD ADJ) Mode and System Configuration (CONFIG SYS) Mode allow you to view or change BMS settings to customize and tune the system to the specific needs of your site. The BMS keypad normally displays the functions applicable to the Normal and Field Adjust Mode. However, the keys perform slightly different functions for Normal and Field Adjust Modes. When operating in the System Configuration Mode, you must install the SYSTEM CONFIGURATION OVERLAY sheet, supplied with the BMS, over the keypad. Figures 13 and 14 show the Normal/Field Adjust layout and the System Configuration keypad layouts respectively.

The following paragraphs describe the operation of the BMS keypad for each mode. In addition, tabular listings summarizing keypad operation for each mode are provided in Appendices C, D and E. Ensure that 120 Vac power is supplied to the BMS and the ON key LED is illuminated. If the LED is not illuminated, press the ON key.

4.1.1 Selecting and Viewing Functions

As previously mentioned, the Normal mode, is a read-only mode which allows functions to be viewed, but not changed. However, functions associated with the keypad keys can also be viewed in the FIELD ADJ and CONFIG SYS modes, provided the appropriate mode key (FIELD ADJ or CONFIG SYS) is first selected. For example, pressing the HDR TEMP key displays the supply water temperature. You can view all mode functions by simply pressing its associated key. You must be in the System Configuration mode (CONFIG SYS) to view the functions associated with the SYSTEM CONFIGURATION OVER-

LAY.

4.1.2 Changing Function Settings

To change, rather than simply display settings and functions, the BMS must be in the FIELD ADJ or CONFIG SYS mode. To change a function value, press the ▲ and ▼ arrow keys until the display shows the desired selection. Once you change the value, associated with one or more function keys they are automatically stored in nonvolatile memory. For example, if you change the values for three separate functions in the Field Adjust mode, you don’t need to exit and then re-enter the mode for each function change.

4-1 4-2

Figure 13

NORMAL & FIELD ADJUST MODE OVERLAY

Figure 14

SYSTEM CONFIGURATION MODE OVERLAY

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NOTE

Sample Normal Mode displays with their Factory Default values are provided in Appendix C.

4.2 NORMAL MODE DISPLAYS

AND FUNCTIONS

When power is applied to the BMS, it is automatically placed in the Normal Mode. It allows you to view the settings currently stored in memory for BMS parameters. In addition, you can enter the Field Adjust or System Configuration Mode by pressing the FIELD ADJ or CONFIG SYS key. The functions provided by the keypad keys are described in the following paragraphs.

4.2.1 HDR TEMP

Pressing and releasing this key displays the actual header sensor water temperature in °F. Pressing and holding this key displays the header setpoint temperature presently stored in memory.

4.2.2 AIR TEMP

Pressing and releasing this key displays the actual outside air temperature. Pressing and holding this key displays the actual inside air temperature, only if an indoor air temperature sensor is installed. If an indoor air sensor is not installed, INDOOR AIR TEMP NOT CONNECTED will be displayed.

4.2.3 % LOAD

Pressing and releasing this key displays the actual firing rate percentage (% Load) for the boiler plant. It also displays the number of boilers presently operating.

4.2.4 SYS START TEMP

Pressing and holding this key displays the System Start Relay temperature setting in °F presently stored in memory. The system will start whenever the outside air temperatures drops below this setting.

4.2.5 REF TEMP

Pressing and holding this key displays the Header Reference Temperature in °F presently stored in memory.

4.2.6 HDR TEMP LIMIT

Pressing and holding this key displays the header high limit temperature setting (°F) stored in memory.

4.2.7 FIELD ADJ

Pressing and releasing this key places the BMS in the Field Adjust Mode and lights the FIELD ADJ key LED. When this key is pressed, the display will read FLD ADJUSTMENT MAKE SELECTION. Refer to paragraph 4.3 for key functions when in this mode.

4.2.8 SET POINT

Pressing and holding this key displays the indoor setpoint temperature (°F) stored in memory.

4.2.9 PROP BAND

Pressing this key displays the indoor air proportional bandwidth. This bandwidth is a variable used in an equation that solves for the proper offset of supply water temperature based on an indoor air temperature. Normally the display will read INDOOR PROP BAND 00.0°F/°F. See paragraph 4.3.9 for additional information.

4.2.10 OFFSET

Pressing and holding this key displays the Header Temperature Offset (°F) for the present time and day-of-the-week. See paragraph 4.3.10 for additional information on setting up an offset schedule.

4.2.11 RESET RATIO

Pressing and holding this key will display the header reset ratio if a value is currently stored in memory. This function is only used in the Indoor/Outdoor Reset Mode. If this function is not set, or the Constant Setpoint or Remote (4-20 mA) mode is used, the display will show FUNCTION NOT VALID.

Also, ALARM CANCEL is printed directly above this key. Pressing and releasing this key will open the Alarm Relay contacts until the Alarm condition reappears.

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4.2.12 ▲ and ▼ Arrow Keys

The ▲ and ▼ arrow keys are not active in this mode, since no changes can be made to the displayed settings

4.2.13 ON and OFF Keys

Pressing and releasing the ON or OFF key enables or disables the BMS. In addition, the corresponding key LED will light when the key is pressed.

4.2.14 CONFIG SYS

Pressing and releasing this key places the BMS in the System Configuration Mode and lights the CONFIG SYS key LED. When this key is pressed, the display will read

CONFIG. SYSTEM MAKE SELECTION.

Refer to paragraph 4.4 for key functions when in this mode.

NOTE

Sample Field Adjust Mode displays with their Factory Default values and allowable entry ranges are provided in Appendix D.

4.3 FIELD ADJUST MODE

DISPLAYS AND FUNCTIONS

The Field Adjust Mode allows you to view or change settings currently stored in memory for BMS parameters. Many of the settings in this mode have been preset by AERCO to their Factory Defaults. However, you can reset many functions to suit the specific needs of your BMS installation.

The Field Adjust Mode is entered by simply pressing the FIELD ADJ key and verifying that the FIELD ADJ key LED lights. When this key is pressed, the display will read

FLD. ADJUSTMENTS MAKE SELECTION.

The following paragraphs describe the functions of the keys when in the Field Adjust Mode.

NOTE

When in the Field Adjust Mode, the HDR TEMP and AIR TEMP keys are used to set multiple functions required for Modbus Network operation. Refer to Modbus Communication Manual GF-114 for additional information on set-up and installation of Modbus (RS485) Networks.

4.3.1 HDR TEMP

The HDR TEMP key is used to set multiple Modbus functions when the BMS is configured as the Modbus Master and is directly controlling C-More Boiler Controller Slaves on the RS485 Network. This key is used to set functions as follows:

NOTE

Default values for each function are indicated below. Refer to Modbus Communication Manual GF-114 for required settings. Use the ▲ and ▼ arrow keys to increment or decrement the displayed value.

1. Press key once. RS485 BAUDRATE is displayed. Default = 9600.

2. Press key again. MIN SLAVE ADDR is displayed. Default = 0.

3. Press key again. MAX SLAVE ADDR is displayed. Default = 0.

4. Press key again. NUMBER OF NETW BLRS is displayed. Default=0. This key is used to set the maximum number of C-More Boilers that will be controlled on the Modbus Network.

5. Press key again. MODBUS CNTL TYPE is displayed. Default = Round Robin.

6. Press key again. NETW BOILER 1 ADDRESS=0 is displayed. Default = 0. This address must be the same as the Comm Address stored in the C-More Boiler Controller.

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7. Repeatedly pressing the HDR TEMP key allows the NETW BOILER ADDRESS to be set for each boiler being controlled on the Modbus Network.

4.3.2 AIR TEMP

The AIR TEMP key is used to set multiple Modbus functions when the BMS is configured as a Modbus Slave to an EMS (or BAS) Master. This key is used to set functions as follows:

NOTE

Default values for each function are indicated below. Refer to Modbus Communication Manual GF-114 for required settings. Use the ▲ and ▼ arrow keys to increment or decrement the displayed value.

1. Press key once. RS232 MODE is

displayed. This function can be set to NORMAL or MODBUS SLAVE. The

Default = MODBUS SLAVE.

2. Press key again. RS232 BAUDRATE is displayed. Default = 9600.

3. Press key again. MODBUS ADDRESS is displayed. Default = 128.

4. Press key again. NETWORK TIMEOUT is displayed. Default = 60 sec.

5. Press key again. REMOTE SIGNAL. is displayed. This function can be set to 420MA or MODBUS. Default = 4-20MA.

6. Press key again. MODBUS PASS THRU is displayed. This function can be set to ENABLED or DISABLED. Default = DISABLED.

4.3.3 % LOAD

The % LOAD key has two separate and distinct functions in the Field Adjust Mode. Pressing and holding this key displays the actual firing rate (load) percentage and the number of boilers presently operating. Releasing the % LOAD key changes its function to Setting the Internal Clock as described in the following paragraph.

4.3.4 Setting the Internal Clock With The % LOAD Key

Pressing and releasing the % LOAD key changes the first line of the display to SET TIME CLOCK. The second line of the display will show: MONTH, DATE, YEAR, DAY, HOURS, or MINS. Since these functions wrap around, it is strongly suggested that you repeatedly press the % LOAD key until the display shows MONTH: in the second line. This will make the following steps easier to follow:

NOTE

When performing the following steps, use the ▲ and ▼ arrow keys to increment or decrement the displayed value. Pressing and holding the ▲ or ▼ key will change the displayed value at a rapid rate.

1. Press key until MONTH: is displayed. Set the actual number of the month (1-

12).

2. Press key again to display DATE:. Set the actual day of the current month (1-31).

3. Press key again to display YEAR:. Set the last 2 digits of the year.

4. Press key again to display DAY:. Set the day that you want to be the first day of the week. AERCO normally sets Sunday as DAY 1, however any day of the week can be set as DAY 1.

For example, if the actual DATE (day of month) entered in step 2 is a Monday, and you want Monday to be the first day of the week, set DAY: to 1. Conversely, if you want to retain Sunday as the first day of the week, set DAY: to 2 to indicate you are currently in the second day of the week.

5. Press key again to display HOURS:. Set the hours using the 24-hour format (0 to

23).

6. Press key again to display MINS. Set the minutes (0 to 59).

7. This completes the Internal Clock settings.

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4.3.5 SYS START TEMP

When in the Field Adjust Mode, the SYS START TEMP key has two functions. First,

It lets you select the outdoor temperature at which the system starts. Second, it lets you select the system start option (TEMP ONLY or TEMP AND LOAD).

For example, with the system start temperature set at 70°F (SYS. START RELAY 70°F), the system start relay will close and enable the boilers when the outside air temperature falls to 69°F (or lower).

To always enable the boilers, regardless of the system start temperature, or if an outside air temperature sensor is not used, see paragraph 4.4.2 in the System Configuration Mode section.

• Pressing and releasing the SYS START TEMP key once displays the System

Start Relay temperature. (AERCO presets System Start to an outside air temperature of 70°F). To change the displayed start temperature, press the ▲ or ▼ arrow key.

• Pressing and releasing this key a second time displays the System Start Option which can be set to either outside air temperature only (TEMP ONLY) or outside air temperature and load (TEMP AND LOAD). To change Start Option, press ▲ or ▼ key to toggle the setting.

If TEMP ONLY is chosen, the BMS will close the system start relay contacts when the outdoor air temperature drops below the system start temperature setting, without regard to load.

The TEMP AND LOAD feature is used when the System Start Relay will control dampers. It keeps dampers closed until it is necessary to open them for combustion. This is designed to ensure that cold air is not always entering the boiler room.

If TEMP AND LOAD is chosen, two conditions are necessary for the system start relay contacts to close and enable the boilers. First, the firing rate (displayed as %

LOAD) must be above 11%. Second the outdoor air temperature must be below the system start temperature. The system start relay contacts will open when the load percentage falls below 7%.

4.3.6 REF TEMP

The REF TEMP key has two functions, depending on the operating mode used by the boilers connected to the BMS.

• In the Indoor/Outdoor Reset or Remote Setpoint Mode, pressing and releasing this key displays the Building Reference Temperature (BLDG REF TEMP).

• In the Constant Setpoint Mode, pressing this key displays the header supply water temperature setpoint (HEADER REF. TEMP).

To change the displayed Reference Temperature, press the ▲ or ▼ arrow key.

4.3.7 HDR TEMP LIMIT

This key allows you to view or change the low and high temperature limits for the header supply water temperature.

In addition, when in the 4-to-20 mA Remote Setpoint Mode, it automatically scales the 4to-20 mA signal. Accordingly, 4 mA will be equal to the header low limit setting and 20 mA will be equal to the header high limit setting.

• Pressing and releasing this key once displays the header high limit temperature (HDR HIGH LIMIT).

• Pressing and releasing this key a second time displays the header low limit temperature (HDR LOW LIMIT).

• Pressing and releasing this key a third time displays the header offset temperature (HEADER OFFSET).

To change the displayed header high, low or offset temperature limits, press the ▲ or ▼ arrow key.

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4.3.8 FIELD ADJ

The FIELD ADJ key LED should be lit to indicate that the BMS is already in the Field Adjust Mode. Pressing and releasing this key when already in the Field Adjust Mode will cause the BMS to exit the Field Adjust Mode and switch the BMS to the Normal (Read-Only) Mode.

4.3.9 SET POINT

Pressing and releasing this key allows you to view or change the indoor setpoint temperature. This function is only used when an indoor air temperature sensor is connected to the BMS. If used, the input can be provided by a resistive type sensor, or a 4-to-20 mA input.

4.3.10 PROP BAND

Pressing this key displays the indoor air proportional bandwidth. This bandwidth is a variable used in an equation that solves for the proper offset of supply water temperature based on an indoor air temperature. Normally, the display will read INDOOR PROP BAND 00.0°F/°F.

AERCO presets the proportional bandwidth to 00.00°F/°F. It should NOT be readjusted unless your system has an indoor air temperature sensor and is operating in the Indoor Setpoint mode. If the indoor temperature feature is not being used, PROP BAND MUST be set to 00.00°F/°F or the BMS will not run the boiler plant.

4.3.11 OFFSET

The OFFSET key is used to enable and set up an Offset Schedule for the header supply temperature. The schedule can be set up for a 7-day period.

Pressing and releasing this key once will display OFFSET ENABLE followed by OFF or ON (Default is OFF). If an Offset Schedule will be used, toggle the display to ON using the ▲ or ▼ arrow key.

Normally, if an Offset Schedule is used, it is controlled automatically using the set-up procedures described in paragraph 4.3.12. However, if desired, the header offset can

be controlled manually by connecting a switch across the SET BACK wiring terminals (see para. 3.8). If a manual offset is used, refer to paragraph 4.3.13

IMPORTANT

Prior to setting up an automatic Reset Schedule (para. 4.3.12) or manual Set Back (para. 4.3.13), refer to the paragraph 4.3.4 to determine which Day of the Week has been set as Day 1. AERCO presets Day 1 of the week as Sunday. However, any day of the week can be specified as Day 1 by performing the steps outlined in paragraph 4.3.4.

4.3.12 Setting Up A Reset Schedule

The basic steps for setting up an automatic Reset Schedule consist of first selecting the temperature offset and then entering the start and stop times for which the offset will be in effect. Keep in mind that the BMS uses a 24-hour clock (00:00 to 23:59).

In the following example, for Day 1, we want to offset the setpoint temperature by -15°F starting at 12:30 am (00:30) and return it to the normal setpoint at 8:15 am (08:15). Proceed as follows:

1. Press OFFSET key once and toggle the

display to OFFSET ENABLE ON.

2. Press key a second time. OFFSET

TEMP DAY 1

entry of the offset temperature. Set the offset temperature to -15 using the ▲ and ▼ arrow keys.

3. Press key a third time. OFFSET ON

TIME DAY 1

prompting Hours to be entered for the start time. Set the Hours to zero

(midnight) using the ▲ and ▼ arrow keys.

4. Press key a fourth time. OFFSET ON

TIME DAY 1: 0

prompting Minutes to be entered for the start time. Set the Minutes to 30 using the ▲ and ▼ arrow keys.

is displayed prompting

0: 0 is displayed

0 is displayed,

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5. Press key a fifth time. OFFSET OFF

TIME DAY 1

prompting Hours to be entered for off time. Since the BMS uses a 24-hour clock format, set the Hours to 8 using the ▲ and ▼ arrow keys.

6. Press key a sixth time. OFFSET OFF

TIME DAY 1: 8

prompting Minutes to be entered. Set the Minutes to 15 using the ▲ and ▼ arrow keys.

7. This completes the steps for setting the Offset Temperature, and Start/Stop Times for Day 1.

For a 7-Day Schedule, steps 2 through 7 would be repeated as needed. Offset Schedule entries stored in memory can be reviewed by repeatedly pressing the

OFFSET key as necessary.

4.3.13 Manual Set Back

If a switch is connected across the SET BACK terminals (para. 3.8), the header offset temperature can be controlled manually by setting all offset times to zero. Using the OFFSET key:

1. Toggle the display to OFFSET ENABLE ON.

2. Set the desired OFFSET TEMP. A different OFFSET TEMP can be entered for each day if desired.

3. Set the OFFSET ON TIME and OFFSET OFF TIME to zero for each day.

Once programmed as described above, closing the SET BACK switch will enable the programmed OFFSET TEMP for that day. Opening the SET BACK switch will disable the OFFSET.

0: 0 is displayed

0 is displayed

4.3.14 RESET RATIO

The Reset Ratio is only used in the Indoor/Outdoor Reset Mode of operation. This ratio the amount that the supply water temperature will rise for each degree drop in outside air temperature. A reset ratio of 2.0 means that the supply water temperature will increase 2°F for every 1°F decrease in

outdoor air temperature. For example, if the building reference temperature is set at 70°F, when outside air temperature drops to 69°F, and the reset ratio is 1.8, the water supply temperature will increase to 71.8°F. AERCO presets the Reset Ratio to

1.2°F/°F. See Appendix B for Reset Ratio Charts.

Pressing and releasing this key will display the Header Reset Ratio (°F/°F) if a value is currently stored in memory. When operating in the Constant Setpoint or Remote (4-20 mA) mode, the display will show FUNCTION NOT VALID.

4.3.15 ▲ and ▼ Arrow Keys

These keys are used to increment (▲) or decrement (▼) the displayed variable, or toggle the display through available options. When these keys are depressed and held the displayed value will increment or decrement at a rapid rate.

4.3.16 ON and OFF Keys

Pressing and releasing the ON or OFF key enables or disables the BMS. In addition, the corresponding LED will light when the corresponding key is pressed.

4.3.17 CONFIG SYS

When the BMS is in the Field Adjust Mode, this key has two functions. First, it allows you to select the types of faults which will cause an alarm. Second, it allows you to select how alarms are cleared.

• Pressing and releasing the CONFIG SYS key once displays the FAULT ALARM RELAY status and allows you to select the types of faults which will cause an alarm. The choices are: ALL FAULTS,

NO INTERLOCK, INTERLOCK 2 or INTERLOCK 1.

Selecting ALL FAULTS causes the BMS Fault Relay to close and generate an alarm when either Interlock 1 or 2 opens. It also closes the Fault Relay when any of the fault messages listed in Appendix H, Table H-1 are displayed.

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Selecting INTERLOCK 2 causes the Fault Relay to close and generate an alarm only when Interlock 2 opens. However, if INTERLOCK 1 opens, a fault message will be generated but the Fault Relay will not be closed.

Selecting INTERLOCK 1 causes the Fault Relay to close and generate an alarm only when Interlock 1 opens. However, if INTERLOCK 2 opens, a fault message will be generated but the Fault Relay will not be closed.

Selecting NO INTERLOCK causes the Fault Relay to remain open and not generate an alarm when either Interlock 1 or Interlock 2 opens.

It should be noted that the BMS will always Interlock 1 or 2 opens, regardless selected Fault Relay option.

• Select the desired option using the ▲ or ▼ arrow key.

• Pressing and releasing the CONFIG SYS key a second time displays FAULT ALARM CLEAR and allows you to select how faults are cleared. The available choices are MANUAL RESET or AUTOMATIC. Toggle to the desired option using the ▲ or ▼ arrow key.

Prior to placing the BMS in the System Configuration Mode, the FIELD ADJ key must be pressed to exit the Field Adjust Mode. Pressing and releasing the CONFIG SYS key places the BMS in the System Configuration Mode and lights the CONFIG SYS key LED. When this key is pressed, the display will read CONFIG. SYSTEM MAKE SELECTION. Refer to paragraph 4.4 for key functions when in this mode.

Sample System Configuration mode displays with their Factory Default values are provided in Appendix E.

shut down the boilers when

of the

NOTE

4.4 SYSTEM CONFIGURATION MODE DISPLAYS AND FUNCTIONS

The System Configuration Mode allows you to program and operate the BMS to effectively run and manage the performance of the boiler plant. In order to effectively use this mode, the SYSTEM CONFIGURATION OVERLAY provided with the BMS must be placed over the keypad for proper identification of key functions (Figure 12).

The System Configuration Mode is entered by simply pressing the CONFIG SYS key and verifying that the CONFIG SYS key LED lights.

The keys described in the following paragraphs allow you to view or change settings currently stored in memory. If the desired setting is not displayed for the selected BMS parameter, press the ▲ or ▼ arrow key to increase, decrease or toggle the displayed setting. All changes made will be stored in memory.

4.4.1 TEMP FAIL MODE

Pressing and holding this key displays the actual header sensor water temperature in °F. This is a “Read Only” display and cannot be changed.

Pressing and releasing this key allows you to display and select a Temperature Failure Mode (TEMP FAIL MODE) of either SHUTDOWN or SWITCH INPUTS.

If SHUTDOWN is selected, regardless of the operating mode, the BMS will shut down the boiler plant whenever a temperature sensor fails or either interlock opens. If the BMS is operating in the Remote Setpoint mode, the BMS will also shut down the boiler plant if the remote 4-to-20-mA input signal drops below 3 mA. If any of these failures occur, the fault relay will close and the BMS will display the appropriate failure message.

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If SWITCH INPUTS is selected, the BMS will automatically switch to Constant Setpoint mode if a sensor or remote input error occurs. Once the sensor or remote input error has been cleared, the BMS will automatically switch to the previous mode.

When selecting SWITCH INPUTS, the reference temperature for the Constant Setpoint mode must be preset. See Section 5 for programming steps.

Regardless of whether SHUTDOWN or SWITCH INPUTS is selected, the BMS will shut down and close the fault relay contacts if the header sensor circuit fails.

4.4.2 SYS ENABLE

Pressing and releasing this key allows you to select the INTERLOCK 1 enable setting of START ENABLED or ALWAYS ENABLED.

The START ENABLED feature will not enable the boiler plant until the outside air temperature falls below the system start temperature. If the boiler plant begins to operate and Interlock 1 is open, the BMS will wait 30 seconds before stopping the boilers and displaying a fault message.

This feature is intended for use with auxiliary equipment having limit switches. For instance, dampers with proving end switches, can be triggered by the BMS system start relay as the boilers start. If the dampers do not open, the end switch wired to Interlock 1 will not make (close) and the BMS will shut down the boilers.

The ALWAYS ENABLED feature allows the boilers to run, regardless of the system start and outside air temperature settings. This feature is used when there is a loss of an outside air sensor or one is not installed. It will also function if an outside air temperature sensor is present. It should be noted that if either Interlock 1 or 2 opens, the BMS will shut down the boilers.

The system start relay will close only after the outside air temperature falls below the system start temperature, whether START

ENABLED or ALWAYS ENABLED is selected. AERCO recommends that the system be equipped with a flow switch that is interlocked to the BMS. This is especially important if ALWAYS ENABLED is selected and the BMS is controlling the pumps based on outside air temperature, or the BMS is interfaced with an energy management system that is controlling the pumps.

4.4.3 MAX PWR INPUT

This key provides two distinct functions. First, it is used to establish the maximum firing rate percentage for the boilers being controlled by the BMS. Second, it permits adjustment of the pulse width modulation (PWM) signal supplied to the boilers.

• Pressing and releasing the MAX PWR INPUT key once displays the maximum

allowable firing rate percentage for the boilers (MAX POWER INPUT 100%). If desired, the maximum firing rate of the boilers can be limited to values below 100%. This is useful if there is a problem with gas supply pressure.

For example, if gas pressure is too low, the boilers can be run at a lower firing rate temporarily until proper gas pressure can be restored. If necessary, adjust the firing rate using the ▲ or ▼ arrow key.

• Pressing and releasing the MAX PWR INPUT key a second time displays a

PWM TIMEBASE CAL message. If necessary, the PWM pulse width ON time can be adjusted using the ▲ and ▼ arrow keys. Pressing the ▲ arrow key increases the pulse width ON time and pressing the ▼ key reduces the ON time. The PWM TIMEBASE CAL is adjustable from -30 to 30 (Default = 0).

The PWM TIMEBASE CAL should only be adjusted when all boilers are indicating a firing rate above or below the firing rate being supplied by the BMS PWM signal. If necessary, individual boilers can be adjusted via their respective C-More Control Systems.

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4.4.4 START LEVEL and STOP LEVEL Keys

These keys allow you to set the energy levels (firing rate percentages) at which additional boilers are staged-in or stagedout of the system during Sequential or Combination mode operation. While the start level can be set at any percentage up to 100%, it is best to keep it below 60%. This allows the system to operate at optimum efficiency under low loads. The BMS is preset with 45% start and 18% stop levels, which generally provide the best performance.

When changing the start or stop levels, it is important to remember that load-balancing affects bumpless transfer. A sufficiently wide gap between the start and stop levels must be maintained to prevent cycling between units. For example, in a two-boiler system with a start level of 60% and a stop level of 30%, when the first boiler reaches 60%, the BMS will distribute the load between the two boilers, so that each will have a firing rate of 30%. However, since the stop level is 30%, the BMS will automatically shut down one boiler and allow the firing rate of the second boiler to increase to 60%. The BMS will then repeat this undesirable cycling. To avoid this, the start level could be set to 65%, leaving the stop level at 30%. When the BMS distributes the load after the first boiler reaches a 65% firing rate, the individual load would be 32.5%, sufficiently above the stop level. Conversely, the stop level could be changed to 25%, leaving the start level at 60%. In this case, when the BMS distributes the load, there will be 5% margin between this load (30%) and the stop level (25%).

• Pressing the START LEVEL key displays firing rate percentage at which the boilers will start.

• Pressing the STOP LEVEL key displays firing rate percentage at which the boilers will stop.

4.4.5 BLR OP MODE

This key is used to select the Boiler Operating Mode. It allows you to make choices concerning the effective and efficient way to fire the boilers based on the building load. The mode choices include: Parallel, Sequential, or Combination Mode.

Pressing the BLR OP MODE key displays BOILER OP MODE followed by the currently selected mode (PARALLEL, SEQUENTIAL or COMBINATION). AERCO presets the mode to SEQUENTIAL. If necessary, use the ▲ and ▼ arrow keys to toggle between the 3 available modes. The following paragraphs describe the advantages of each mode selection.

4.4.5.1 Sequential Mode

The Sequential Mode provides a greater turn-down ratio than Parallel Mode. This is because the turn-down ratio in Sequential Mode is equal to the number of boilers multiplied by 14 for KC Series boilers and by 15 for Benchmark boilers. In Parallel Mode, the turn-down ratio is fixed at 14:1 for KC Series boilers and 15:1 for Benchmark boilers, and does not consider the number of boilers in the plant.

In Sequential Mode, each boiler is started one at a time based on the load and start/stop levels programmed in the BMS. The BMS will start a single boiler when there is a load demand. Once the first boiler reaches the start level, a second boiler will be started and the load will be distributed evenly between the two boilers.

For instance, if a start level of 50% is chosen, when the first boiler reaches 50% a second boiler will start (after a 30 second delay), and the BMS will distribute the load 25% for each boiler. If the firing rate of both boilers reach the start level, a third boiler is started by the BMS (after a 30 second delay), and the load will be distributed across all three boilers. This sequence will continue base on load demand and the number of boilers connected to the BMS.

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As the load drops off, the firing rates decrease. When all boilers reach the stop level, the first boiler turned on will be shut off by the BMS and its load will be evenly distributed to the remaining firing boilers. This off-sequencing continues until only one boiler is left firing. The last boiler will turn off when its stop level is reached.

4.4.5.2 Parallel Mode

When operating in Parallel Mode, the boilers are simultaneously started by the BMS. The start and stop levels have no effect when in Parallel Mode. The turn-down ratio in Parallel Mode is fixed at 14:1 for KC 1000 Series boilers and 15:1 for Benchmark boilers, regardless of the number of boilers in the plant.

4.4.5.3 Combination Mode

Combination mode is used only when the boiler plant will be used to satisfy both space heating and domestic hot water needs. This configuration, known as a Combination System, is used in conjunction with an AERCO Combination Control Panel (CCP). This system uses BMS-mode boilers dedicated to space heating and Combination boilers that are primarily used to satisfy the domestic hot water need. The domestic combination boilers are also available for the space heating load when the domestic hot water load is satisfied. This is accomplished using a motorized valve and storage tank equipped with a heat exchanger. For additional information on the Combination System, see AERCO’s CCP-1 literature.

4.4.5.4 Designating the Number of

Combination Boilers

A maximum of 4 combination boilers can be connected to the BMS. However, when using the Combination Mode, it is necessary to tell the BMS how many combination boilers there are. This is accomplished as follows:

IMPORTANT

When connecting combination boilers to the BMS, it is important that you start at the BLR 8 terminals on Terminal Strip JP2 and work towards BLR 5.

1. With the COMBINATION MODE selected, press the BLR OP MODE key. The display will read: COMBINATION MODE X OF CCP BOILERS, (where X is the number of combination boilers).

2. Enter the number of combination boilers connected to the BMS using the ▲ and ▼ arrow keys.

4.4.6 HDR SET MODE

This key has two functions. First, it is used to select the Indoor/Outdoor Reset, Constant Setpoint, or Remote Setpoint boiler mode operation. Second, it is used to select the type of indoor temperature sensor used with the BMS, if one is installed. The type of sensor can be either resistive (thermistor) or a constant voltage signal with current varying from 4 to 20 mA.

Pressing the HDR SET MODE key once selects the Header Set Mode function. If the desired mode is not displayed, toggle the display to the desired mode (IN/OUTDOOR

RESET, REMOTE SET TEMP or CONSTANT SETTEMP) using the ▲ or ▼

arrow key.

Pressing the HDR SET MODE key a second time toggles the display to indicate the type of indoor temperature sensor which will be used with the BMS (THERMISTOR or 4-20 mA). If necessary, toggle the display to the desired sensor type using the ▲ or ▼ arrow key.

If the REMOTE SET TEMP mode is selected and the Indoor Temperature Sensor feature is used, the Sensor input type must be THERMISTOR (resistive) since the BMS has only one 4-to-20 mA input.

4.4.7 INTGL RATE GAIN, TEMP

BANDWIDTH and DERIV GAIN Keys

These three keys provide PID (Proportional Integral Derivative) control functions which govern temperature control and response of the BMS to the boiler system. Since each system is different, these PID controls can tune the BMS to the characteristics of your

4-13

specific installation. The factory defaults preset by AERCO work well for most applications. In instances when there is a large error between the setpoint and the actual supply water temperature, the BMS may appear to require PID tuning. However, It is best to observe BMS operation over a period of time prior to making any PID changes. Contact AERCO or an AERCO representative prior to making any PID setting changes.

The functions provided by the PID function keys are described in the following paragraphs.

4.4.7.1 TEMP BANDWIDTH

Header Temperature Bandwidth (HDR TEMP B.W.) concerns the system’s

response to the setpoint error. Setpoint error is the difference between the supply water temperature setpoint and the actual supply water temperature. A constant setpoint error will yield a constant and proportionate correction factor for the duration of the error. If there is a deviation from the constant error, the correction factor will be changed in proportion to the deviation. For instance, a temperature bandwidth of 50°F is chosen. The header temperature setpoint is 180°F and the actual incoming supply water temperature is 130°F

. This is a 50° error and the following

is true:

Temp. Error_____

X 100 = Firing Rate in %

Prop Bandwidth

Therefore:

50 X 100% = Firing Rate 50

1 X 100 = 100 % Firing Rate

With an error of 30° and a bandwidth of 50, the following would be true:

30/50 X 100 = .6 X 100 = 60% Firing Rate.

4.4.7.2 INTGL RATE GAIN

Integral gain responds to the setpoint error over a period of time. Integral references the proportional bandwidth error signal and sums itself with respect to the period of time that an error exists. Based on the example in the previous paragraph (4.4.7.1), if the integral is 0.15 repeats per minute and the firing rate is 60%, and a temperature error exists for 1 minute, then the following is true:

(0.15 reps/min.) x (60% firing rate) = 9% actual firing rate

60% firing rate +9% firing rate = 69% firing rate

If the error continues and is present for another minute, another 9% correction factor will be added:

69% firing rate +9% firing rate = 78% firing rate

If, after a load change, the supply water temperature stabilizes at a temperature above or below the setpoint, the integral gain should be increased. If, after a load change, the supply water temperature overshoots and oscillates excessively, integral gain should be reduced.

4.4.7.3 DERIV GAIN

Derivative gain is a function of time. It senses and responds to the rate of change of the setpoint error. A slow rate of change will yield a small amount of derivative gain. Conversely, a fast rate of change will yield a large derivative gain. Too high a derivative gain setting will produce a large output for a short time. This can result in overshoot of the setpoint. Too low a derivative gain setting will have the opposite effect, producing a small output for a longer period, and may result in slow system response or the system undershooting the setpoint.

4-14

4.4.8 AUX RELAY

This key is used to display or change the firing rate at which the Auxiliary Relay opens and closes. The Auxiliary Relay is typically used with AERCO’s Combination Control Panel (CCP) system or to start an auxiliary boiler for use under peak load conditions. If this boiler is of the noncondensing type, the OFF firing rate percentage must be high enough to prevent the boiler from operation in condensing mode.

Pressing the AUX RELAY key once displays the firing rate percentage at which the relay opens (AUX RELAY OPEN). The default value of 45% is acceptable for a CCP system. However, to run another noncondensing boiler, this percentage may need to be changed to approximately 70%. The displayed percentage can be changed in 1% increments from 1 to 99%.

Pressing the AUX RELAY key again displays the firing rate percentage at which the relay closes (AUX RELAY CLOSE). Two options are available for this function: 100%

FIRING RATE, or 100% AND OFF

(default). Pressing the ▲ or ▼ arrow key will toggle the display. If 100% RATE is selected, the Auxiliary Relay contacts close when the BMS indicates that all boilers are at a 100% firing rate. If the default setting of 100% AND OFF is selected, the Auxiliary contacts close when the BMS indicates that all boilers are at a

100% firing rate determines that all boilers are off. The offstate is when each boiler has either faulted, or someone has pressed the off button on the boilers. This function allows a boiler that is wired to the Auxiliary Relay contacts to fire when all of the other boilers have faulted or have been turned off.

, or when the BMS

FIRING

When in Combination Control Panel (CCP) mode, care must be taken to ensure that the

AUX

RELAY OPEN percentage is set so

that the system does not oscillate turning boilers on and off. A maximum open percentage of 45% is recommended for Combination Control mode. If using the AUX contacts to fire an auxiliary boiler, the recommended open percentage is 70%.

4.4.9 ▲ and ▼ Arrow Keys

These keys are used to increment (▲) or decrement (▼) the displayed variable, or toggle the display through available options. Pressing and holding these keys will increment or decrement the displayed value at a rapid rate.

4.4.10 ON and OFF Keys

Pressing and releasing the ON or OFF key enables or disables the BMS. In addition, the corresponding LED will light when the corresponding key is pressed.

4.4.11 CONFIG SYS

When the CONFIG SYS key LED is lit, pressing this key will exit the System Configuration Mode and place the BMS in the Normal Mode. When this occurs, the display will show HEADER TEMP (°F) which is the default Normal Mode display. See paragraph 4.2 for key functions in Normal Mode.

4-15

Section 5 ______________________________

Programming the BMS Mode of Operation__

Prior to programming, the BMS must be mounted and all required wiring completed. In addition, all connections should be checked for accuracy. The BMS is now ready to be programmed for the desired mode of operation of the boiler plant. The steps for programming will vary somewhat, depending on whether the Indoor/Outdoor Reset, Remote Setpoint or Constant Setpoint operating mode is selected.

5.1 INDOOR/OUTDOOR RESET MODE

The Indoor/Outdoor Reset mode is based on outside air temperature. The header supply water temperature will vary up or down in accordance with outside air temperature. This mode requires that, as a minimum, a System Start Temperature (SYS.START RELAY), Building Reference Temperature (BLDG REF. TEMP) and Reset Ratio be programmed into the BMS. This data is based on the degree days for your geographic area. An outdoor air sensor MUST be installed when operating in this mode (refer to paragraph 3.3.2).

5.1.1 Selecting Indoor/Outdoor Reset Mode

To select Indoor/Outdoor Reset mode, perform the following steps:

1. Press the CONFIG SYS key to enter the System Configuration mode. The CONFIG SYS key LED will illuminate.

2. Place SYSTEM CONFIGURATION OVERLAY on the BMS front panel.

3. Press the HDR SET MODE key once. HEADER SET MODE is displayed with the present mode selection.

4. While observing the display, toggle the

HDR SET MODE using the ▲ or ▼ key to IN/OUTDOOR RESET.

5. Press the CONFIG SYS key to exit the System Configuration mode. The key LED will go off.

6. Remove the SYSTEM CONFIGURA-

TION OVERLAY from the front panel.

5.1.2 Entering System Start

Temperature

The system start temperature is the outside temperature at which the boiler plant begins to operate. AERCO presets the system start temperature at 70°F. However, temperatures from 32 to 120°F can be selected using the ▲ and ▼ arrow keys on the keypad. Proceed as follows to enter the system start temperature:

1. Press FIELD ADJ mode key. Verify that the FIELD ADJ key LED illuminates.

2. Press the SYS START TEMP key.

3. Using the ▲ and ▼arrow keys, select the desired Start Temperature for the boiler plant.

5.1.3 Determining Reset Schedule

There are two possible variables that must be considered when determining reset schedule; reset ratio and building reference temperature. There are two methods for determining reset ratio. The first method uses the charts in Appendix B. This method is suitable for most installations. However, if a special reset schedule is desired for reheat or other purposes, the calculation method must be used. In this method, both reset ratio and building reference temperature must be calculated. See Appendix B for further instructions concerning both of these methods.

5-1

5.1.4 Entering the Building Reference Temperature

To enter the Building Reference Temperature, perform the following steps:

1. Enter Field Adjust mode by pressing the FIELD ADJ key. Verify that the key LED illuminates.

2. Press the REF TEMP key. The display will show the present BLDG REF. TEMP.

3. Using the ▲ and ▼ arrow keys, select the desired Building Reference Temperature.

5.1.5 Entering the Reset Ratio

Enter the Reset Ratio as follows:

1. Ensure that the BMS is in the Field Adjust mode.

2. Press the RESET RATIO key. The display will show RESET RATIO

1.2°F/°F which is the default setting.

3. Using the ▲ and ▼ arrow keys, select the desired Reset Ratio.

4. Initialize the system as described in paragraph 5.5.

NOTE

For Remote Setpoint control utilizing a RS485 Modbus network, refer to Modbus Communication Manual GF-114.

5.2 SETUP FOR REMOTE

SETPOINT MODE

In order to set up the BMS to operate in this mode, a 4-to-20 mA communication line from an Energy Management System with a floating ground is required. In addition, a BMS header sensor is required. This mode may be used with or without an outdoor air temperature sensor installed. Entries in this mode are required for the following items:

• Header Set Mode

5.2.1 Entering Header Set Mode and Boiler Operating Mode

These selections are made with the BMS in the System Configuration mode. Proceed as follows:

1. Press the CONFIG SYS key to enter the System Configuration mode. The CONFIG SYS key LED will illuminate.

2. Place SYSTEM CONFIGURATION OVERLAY on the BMS front panel.

3. Press the HDR SET MODE key once. HDR SET MODE is displayed with the present mode selection.

4. While observing the display, toggle the

HDR SET MODE to REMOTE SET TEMP using the ▲ or ▼ arrow key.

5. Press the BLR OP MODE key. BOILER OP MODE is displayed with the present

mode selection.

6. Select either the PARALLEL MODE or SEQUENTIAL MODE using the ▲ or ▼ arrow key.

7. Press the CONFIG SYS key to exit the System Configuration mode. The CONFIG SYS LED will go off.

8. Remove the SYSTEM CONFIGUR- ATION overlay from the BMS front panel.

5.2.2 Entering Remote Signal Type and

Header Temperature Limits

These selections are made with the BMS in the Field Adjust mode. Proceed as follows:

1. Enter Field Adjust mode by pressing the FIELD ADJ key. Verify that the key LED illuminates.

2. Press the AIR TEMP key five times until the first line of the display reads REMOTE SIGNAL.

3. Using the ▲ or ▼arrow key, toggle the second line of the display to read 4-20MA.

• Boiler Operating Mode

• Remote Signal Type

• Header Temperature Limits.

4. Next, press and release the HDR TEMP

key once. HDR HIGH LIMIT is

LIMIT

displayed with the present high temperature limit setting.

5-2

NOTE

Steps 5, 6 and 7 scale the 20 mA Remote Signal to the selected HDR HIGH LIMIT and HDR LOW LIMIT settings.

5. Select the desired header high temperature limit setting using the ▲ and ▼ arrow keys. The selected temperature will be equal to a 20 mA Remote Signal.

6. Press and release the HDR TEMP LIMIT key again. HDR LOW LIMIT is displayed with the present low temperature limit setting.

7. Select the desired header low temperature limit setting using the ▲ and ▼ arrow keys. The selected temperature will be equal to a 4 mA Remote Signal.

5.3 S

ETUP FOR CONSTANT

SETPOINT MODE

In this mode of operation, only a header sensor is required. Entries in this mode are required for Header Set Mode, Boiler Operating Mode and Header Reference Temperature.

5.3.1 Entering Header Set and Boiler

Operating Modes

These selections are made with the BMS in the System Configuration mode. Proceed as follows:

1. Press the CONFIG SYS key to enter the System Configuration mode. The CONFIG SYS key LED will illuminate.

2. Place SYSTEM CONFIGURATION OVERLAY on the BMS front panel.

3. Press the HDR SET MODE key once. HEADER SET MODE is displayed with the presently stored mode selection.

4. While observing the display, toggle the

HDR SET MODE to CONSTANT SETTEMP using the ▲ or ▼ arrow key.

5. Press the BLR OP MODE key. BOILER OP MODE is displayed with the

presently stored mode selection.

6. Select the PARALLEL, SEQUENTIAL or

COMBINATION MODE using the ▲ or ▼ arrow key.

7. Press the CONFIG SYS key to exit the System Configuration mode. The CONFIG SYS LED will go off.

8. Remove the SYSTEM CONFIG- URATION overlay from the BMS front panel.

5.3.2 Entering Header Reference

Temperature (Setpoint)

The Header Reference Temperature (Setpoint) is entered as follows:

1. Enter Field Adjust mode by pressing the FIELD ADJ key. Verify that the key LED illuminates.

2. Press the REF TEMP key. The display will show the present HEADER REF. TEMP stored in memory.

3. Set the desired setpoint temperature using the ▲ and ▼arrow keys. The setpoint temperature can be adjusted from 40°F to 220°F.

4. Initialize the BMS using the procedures in paragraph 5.5.

5.4 CONFIGURING BOILERS

FOR PULSE WIDTH MODULATION (PWM)

Configuring each boiler for BMS control using Pulse Width Modulation (PWM) differs, depending on the Control System used by each AERCO boiler. Refer to the appropriate Operation and Maintenance Manuals provided with the boilers being used. If the KC1000 or Benchmark boilers are equipped with the newer C-More Control Systems, proceed to paragraph

5.4.1. However, if the boilers are equipped

with the older Modular Control Systems, proceed to paragraph 5.4.2.

5-3

5.4.1 C-More Control System PWM Setup

For PWM communication, each boiler’s CMore Control System must have the Configuration Menu items properly set up as follows:

1. Boiler Mode – This option must be set for Direct Drive.

2. Remote Signal – This option must be set for BMS (PWM Input).

Refer to Operation and Maintenance Manual GF-109 (KC1000 Boiler) or GF-110 (Benchmark Boiler) for instructions on changing menu items.

NOTE

AERCO Modular Control Systems are equipped with Honeywell (Blue) or Fire-Eye (Red) Temperature Controllers.

5.4.2 Modular Control System PWM

Setup

For proper PWM communication, each boiler’s Modular Control System Temperature Controller must be properly addressed and configured as follows:

5.4.2.1 Temperature Controller

Addressing

For proper PWM communication, each boiler’s Temperature Controller must be set to a comm. Address of 32. This is true whether the boilers are space heating or Combination (CCP) types.

If the individual boiler’s temperature controller is not correctly addressed, the secure menu of the temperature controller must be entered in order to change the address. Refer to Operation and Maintenance Manual GF-106 (KC1000 Boiler) or GF-107 (Benchmark Boiler) for detailed procedures.

5.4.2.2 Configuring the Temperature

Controller

Once addressing has been completed, it is necessary to perform two more configuration steps to each boiler’s temperature controller. Each temperature controller must be in the Remote and Auto/Off (Manual) modes for proper communication and operation with the BMS.

Refer to Operation and Maintenance Manual GF-106 (KC1000 Boiler) or GF-107 (Benchmark Boiler) for detailed procedures to set each boiler to the Remote and Auto/Off (Manual) modes.

5.5 SYSTEM INITIALIZATION

AND POLLING

In order for the BMS to recognize each boiler, a closed signal loop must exist between the BMS and the boiler. Initialization and polling is accomplished by performing the following simple steps:

1. Set the ON/OFF switch on each boiler control panel to ON.

2. Turn on the BMS by pressing the ON key. The BMS will automatically poll (recognize) each boiler at prescribed intervals.

3. Check the yellow REMOTE (REM) LED on each boiler control panel to ensure it is ON. This indicates that the boiler is now being controlled by the BMS.

4. If any of the boiler REMOTE LEDs are off, check to ensure that:

(a) Boiler AC power is not turned off.

(b) Boiler is not shut down due to a

fault.

broken.

The BMS will continuously poll the boilers at prescribed intervals. Therefore, if a boiler is placed off-line and then placed back on-line, it will again be recognized by the BMS during the next polling cycle.

5-4

5.6 TESTING THE SYSTEM

The following procedure places a load on the system and will begin firing the boilers. At this point it is very important to make sure the system pumps are running.

After system has been initialized as described in paragraph 5.5, proceed as follows:

IMPORTANT

Prior to performing these tests, view and record the PRESENT settings stored in the BMS for HDR SET MODE and REF TEMP. These settings MUST be restored to these values upon completion of the following tests.

1. Turn off the BMS by pressing the OFF key. The OFF LED will illuminate..

2. Place the SYSTEM CONFIGURATION OVERLAY on the BMS front panel.

3. Press the CONFIG SYS key. The CONFIG SYS LED will illuminate.

4. Press the HDR SET MODE key. HEADER SET MODE will be displayed, followed by the mode setting stored in memory (IN/OUTDOOR RESET,

REMOTE (4-20ma.), or CONSTANT SETTEMP).

10. Set the HEADER REF. TEMP (setpoint) to 220°F using the ▲ and ▼ arrow keys.

11. Press the FIELD ADJ key. The LED will turn off.

12. Press the %LOAD key and monitor the display for the firing rate (PERCENT OF LOAD) and the number of boilers firing (Units).

13. When all boilers have reached at least a 55% firing rate, any boilers that have not started have not been identified by the BMS.

14. Remember that in the Sequential or Combination modes, the BMS turns boilers on in 30-second intervals. Therefore, in a 6-boiler plant, with five boilers operating at 55% capacity, a boiler that has not started after 3 minutes has not been recognized. In parallel mode, all boilers will start at the same time.

15. This completes the System Test. Return the HDR SET MODE and REF TEMP settings to their previously stored values.

16. If the System Test is not completed successfully, contact AERCO at 1-800-526-0288.

5. Select CONSTANT SETTEMP using the ▲ or ▼ arrow key.

6. Press the CONFIG SYS key The LED will turn off.

7. Remove the SYSTEM CONFIGURATION OVERLAY.

8. Press the FIELD ADJ key. The LED will illuminate.

9. Press the REF TEMP key.

5-5

Appendix A ____________________________

SPECIFICATIONS

INPUTS

POWER

Input voltage 120 VAC, 60Hz, 1 phase, ± 10%, fused at 1 A

OUTSIDE AIR SENSOR (NTC thermistor)

Acceptable types AERCO GP-122662 (Sensor Only) or

Range -60°F to +80°F

Short sensor protection Invoked at +200°F

HEADER SENSOR (NTC thermistor)

Acceptable types AERCO 64038 (Sensor Only) or

Range 40°F to +220°F

GM-122781 (Sensor & Mounting Plate)

GM-122790 (Sensor and Thermowell)

Short sensor protection Invoked at +300°F

INDOOR TEMPERATURE SENSOR (NTC thermistor)

Acceptable types AERCO GP-122882 (Sensor Only)

Range 40°F to 140°F

Short sensor protection Invoked at 300°F

A-1

Appendix A (cont.) ________________________

CURRENT LOOP

Input resistance

Protection Isolated from AC line potential, fuse-protected at

Operational current range 4 mA to 20 mA

SET BACK

Input 12 VDC at 15 mA. External short activates circuit;

OUTPUTS

SYSTEM START RELAY

Contact Rating 120 VAC at 5 A, fuse protected at 5 A

Operation Relay closes when outside air temperature is less

FAULT ALARM RELAY

Contact Rating 120 VAC at 5 A, fuse protected at 5 A

250 Ohms

62 mA, open loop detected at <1 mA

Open deactivates it

than the system start temperature setting

Operation Relay closes when valid error condition occurs

AUXILIARY RELAY

Contact Rating 120 VAC at 5 A, fuse protected at 5 A

Operation

Relay closes when all available boilers are operating at maximum power input (fire rate). Relay can be programmed to close when all available boilers are at maximum power input or no boilers are available (all boilers faulted or turned off).

A-2

Appendix A (cont.) ________________________

BOILER DRIVE

Drive Type (PWM) Signal (with 12 msec time base)

Valve drive 100% fire rate at 95% pulse width, 0% fire rate at

Current Loop Determination Optically isolated detection

MEMORY

Non-Volatile Memory

ALARMS

Error Handling

Error Messages Refer to Appendix H for displayed error messages

Optically-isolated, pulse width modulated

5% pulse width

EPROM storage of system input. Variables changed in Field Adjust or Configure System mode. EPROM storage of on/off state. All other variables stored in volatile memory which is not retained after power interruption.

If a valid error condition occurs, the display will show the error condition for 2 seconds, then return to the previous display. If multiple error conditions are present, the display will show all error modes. The alarm relay contacts will close upon detection of the error. The alarm can be canceled by pressing the RESET RATIO key or correcting the error.

and troubleshooting information.

A-3

Appendix A (cont.) ________________________

DEFAULT VALUES

System State Halted (stop mode) Header Set Mode

Indoor Air Input

Boiler Op Mode

Start Level 45%

Stop Level 18%

Auxiliary Relay Open 45% Fire Rate

Auxiliary Relay Close 100% and Off

Header Temperature Bandwidth 70°F

Integral Gain .15 repeats/min.

Derivative Gain .15

Indoor/Outdoor Reset

Thermistor

Sequential

System Start Relay 70°F

Building Reference Temperature 70°F

Header Reference Temperature 160°F

Header High Limit 220°F

Header Low Limit 40°F

Reset Ratio 1.2

Indoor Setpoint 70°F

All Offset Temperatures 0

All Offset Times 0

Indoor Prop Band 0

Maximum Power Input 100%

Interlock 1 Start Enabled

Number of Combo Units 1

Real-Time Clock Set to Present Date and Time

A-4

Appendix B _____________________________

Methods for Determining Reset Schedule and Indoor/Outdoor Reset Ratio Charts

Using the Charts to Determine Reset Schedule

Each table in this appendix provides data for a specific building reference temperature. On the vertical axis of each table are degree day temperatures. These are the average lowest temperatures likely to be encountered. The engineer of your system should have this number for your area. The reset ratio is shown across the top. The data in the tables is header temperature. To determine the reset ratio for your installation, follow these steps:

• On the vertical axis, find the degree

day for your area.

• Select the temperature that should be

maintained in the header to maintain the building at the desired temperature. The system engineer should have this information.

• The proper reset ratio is the value

found above the two selected points. For example, for a degree day of 15°F and a header temperature of 125°F, the reset ratio is 1.4.

Determining Reset Schedule By Formula

There are two steps required to determine reset schedule with this method. The first is to determine the reset ratio by dividing the range of outside temperatures by the range of header temperatures:

header/Toutside

= Reset Ratio.

for example, If T

varies from -10 to

outside

+95°F (105° range), and

varies from 125 to 200°F (75°

header

range), then the reset ratio equals

75°/105° = 0.714.

Once the reset ratio is determined, this number and the lowest or highest header temperature and corresponding lowest or highest air temperature, are input to the following equation to yield the building reference temperature:

- RR (TR-TO)+TR, where:

header

RR is the reset ratio TR is the building reference temperature TO is the minimum outside temperature, and

is the maximum heating system

header

Temperature desired at the minimum outside air temperature.

So in this example:

header

= 200°F

200°F = 0.714 [TR-(-10°F)] +TR 200°F = 1.714TR + 7.14°F

Solving for TR:

TR = (200°F-7.14°F)/1.714 TR = 192.86°F/1.714 TR = 112.5°F

Therefore, use a reset ratio of 0.7 (closest to 0.714) and a building reference temperature of 113 (closest to

112.5).

B-1

Appendix B (cont.) _________________________

Header Temperature for a Building Reference

Temperature of 50°F

Reset Ratio

Air Temp (°F) 0.6

50 50

45 53

40 56

35 59

30 62

25 65

20 68

10 74

5 77

0 80

-5 83

-10 86

-15 89 102 116 128 141 154 167 180 193

71 78 85 92 99

0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

50 50 50 50 50 50 50 50 50

54 55 56 57 58 59 60 60 62

58 60 62 64 66 68 70 72 74

62 65 68 71 74 77 80 83 86

66 70 74 78 82 86 90 94 98

70 75 80 85 90 95 100 105 110

70 75 80 85 90 95

74 80 86 92 98 104

106 113 120 127

82 90 98

86 95 104

90 100 110

94 105 116

98 110 122

106 114 122 130 138

113 122 131 140 149

120 130 140 150 160

127 138 149 160 171

134 146 158 170 182

100 105

110

111

110

122

134

146

158

170

182

194

206

-20 92 106 120 134 148 162 176 190 204

B-2

218

Appendix B (cont.) _________________________

Header Temperature for a Building Reference

Temperature of 65°F

Air Temp (0F)

65 60 55 71 73 75 77 79 81 83 85 87 89 50 74 77 80 83 86 89 92 95 98 101 45 77 81 85 89 93 97 101 105 109 113 40 80 85 90 95 100 105 110 115 120 125 35 30 25 89 97 105 113 121 129 137 145 153 161 20 92 101 110 119 128 137 146 155 164 173 15 10

5 101 113 125 137 149 161 173 185 197 209 0 104 117 130 143 156 169 182 195 208

-5 107 121 135 149 163 177 191 205 219

-10 110 125 140 155 170 185 200 215

-15 113 129 145 161 177 193 209

-20 116 133 150 167 201 218

0.6 0.8

65 65 65 65 65 65 65 65 65 65 68 69 70 71 72 73

83 89 95 86 93

95 98

105 115 126 135 145 109 120 131 142 153

1.0 1.2 1.4 1.6

100 107 114 121

Reset Ratio

101 107 113

1.8 2.0 2.2

119 128

155 164

75 76

125 131 135 142

165 175 175 186

2.4

137 149

185 197

B-3

Appendix B (cont.) __________________________

Header Temperature for a Building Reference

Temperature of 70°F

Air Temp (0F) 0.6

70 70 65 73 60 76 55 79 50 82 45 40 35 30 94 102 110 118 126 134 142 150 158 166 25 97 106 115 124 133 142 151 160 169 178 20 100 110 120 130 140 150 160 170 180 190 15 103 114 125 136 147 158 169 180 191 202 10 106 118 130 142 154 166 178 190 202 214

5 109 122 135 148 161 174 187 200 213 0 112 126 140 154 168 182 196 210

-5 115 130 145 160 175 190 205

-10 118 134 150 166 182 198 214

-15 121 138 155 172 189 206

-20 124 142 160 178 196 214

85 90 88 94 91 98

0.8

70 74 78 82 86

1.0 1.2

70 70 75 76 80 82 85 88 90 94

95 100 105 110 115 120 125 130 100 106 112 118 124 130 136 142 105 112 119 126 133 140 147 154

Reset Ratio

1.4 1.6 1.8 2.0 2.2 2.4

70 70 70 70 70 70 77 78 79 80 81 82 64 86 88 90 92 94 91 94 97 98 102 106

100 103 106 110 114 118

B-4

Appendix B (cont.) __________________________

Header Temperature for a Building Reference

Temperature of 75°F

Air Temp (°F)

75 75 75 75 75 75 75 75 75 75 75 70 78 79 80 81 82 83 84 85 88 75 65 81 83 85 87 89 91 93 95 97 87 60

55 87 91 96 99 103 107 111 115 119 111 50 90 95 100 105 110 115 120 125 130 123 45 93 99 105 111 117 123 129 135 141 135 40 96 103 110 117 124 131 138 145 156 147 35 99 107 115 123 131 139 147 155 163 159 30 102 111 120 129 138 147 156 165 174 171

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

84 87 90 93 96 99

25 105 115 125 135 145 155 165 175 185 183 20 108 119 130 141 152 163 174 185 196 195

15 111 123 135 147 159 171 183 195 207 207 10 114 127 140 153 166 179 192 205 218 219

5 117 131 145 159 173 187 201 215 0 120 135 150 165 180 195 210

-5 123 139 155 171 187 203 219

-10 126 143 160 177 194 211

-15 129 147 165 183 201 219

Reset Ratio

102 105 108

B-5

Appendix B (cont.) _________________________

Header Temperature for a Building Reference

Temperature of 80°F

Air Temp (°F)

80 75 83 84 85 86 87 88 89 90 91 92 70 86 88 90 92 94 96 98 100 102 104 65 60 55 50 45 101 108 115 122 129 136 143 150 157 164 40 104 112 120 128 136 144 152 160 168 176 35 107 116 125 134 143 152 30 110 120 130 140 150 160 170 180 190 200 25 113 124 135 146 157 168 174 190 201 212 20 116 128 140 152 164 176 188 200 212 15 119 132 145 158 171 184 197 210 10 122 136 150 164 178 192 206

5 125 140 155 170 185 200 215 0 128 144 160 176 192 208

-5 131 148 165 187 199 216

-10 134 152 170 188 206

0.6

80 80 80 80 80 80 80 80 80 80

89 92 95 98 92 96 95 100

0.8

104 110 116 122 128 134 140 148 152

1.0 1.2

100 104 108 112 116 120 124 128 105 110 115 120 125 130 135 140

Reset Ratio

1.4 1.6 1.8 2.0 2.2 2.4

101 104 107 110 113 116

161

170 179 188

B-6

Appendix B (cont.) _________________________

Header Temperature for a Building Reference

Temperature of 90°F

Air Temp (°F)

90 85 80 75 70 102 106 65 105 110 60 108 114 55 111 118 50 114 122 45 117 126 40 120 130 35 123 134 30 126 138 150 162 174 186 198 210 25 129 142 155 168 181 194 207 20 132 146 160 174 188 202 218 15 135 150 10 138 154 170 186 202 218

5 141 158 0 144 162 180 198 216

0.6

0.8 1.0

90 90 90 90 90 90 90 90 90 90 93 94 95 96 97 98 99 96 98 100 99

102

105 110 115 120 125 130 135 140 145

165

175

102 104 106 108 110 112 114 108 111 114 117 120 123 126 114 118 122 126 130 134 138 120 125 130 135 140 145 150 126 132 138 144 150 156 162 132 139 146 153 160 167 174 138 146 154 162 170 178 186 144 153 162 171 180 189 198 150 160 170 180 190 200 210 156 174 186 198 210

180 195 210

192 209

Reset Ratio

1.2 1.4 1.6

1.8 2.0 2.2

100 101 102

2.4

B-7

Appendix C _____________________________

Normal (Read-Only) Mode

Display Messages and Defaults

Key Display Message Default Range

HDR

TEMP

(Press and Hold) HEADER SET TEMP

AIR

TEMP

(Press and Hold) INDOOR AIR TEMP

% LOAD

SYS

START TEMP

(Press and Hold)

REF

TEMP

(Press and Hold)

HEADER REF. TEMP

BLDG REF TEMP

HDR

TEMP

LIMIT

(Press and Hold)

SET

POINT

(Press and Hold)

PROP BAND

(Press and Hold)

RESET

RATIO

(Press and Hold)

OFF SET

(Press and Hold)

HEADER TEMP 160°F (Default Display)

160°F OUTSIDE AIR TEMP 70°F

70°F (If Connected) PERCENT OF LOAD 100% 8 Units SYS. START RELAY 70°F

BLDG REF TEMP (Indoor/Outdoor Reset Mode)

(Constant Setpoint Mode)

(Remote Setpoint Mode) HDR HIGH LIMIT 220°F

INDOOOR SET POINT 70°F

INDOOR PROP BAND

00.0°F/°F

RESET RATIO

1.2°F/°F (Indoor/Outdoor Reset Mode Only) FUNCTION NOT VALID (All Other Modes) OFFSET TEMP 0°F

160°F 40 to 220°F

100 % 0 to 100 %

0 to 40 Units

70°F 32 to 120°F

70°F 40 to 220°F

120°F 40 to 220°F

70°F 40 to 220°F

220°F 40 to 220°F

70°F 50 to 150°F

00.0°F/°F 0 to 20°F/°F in 0.5°F/°F

increments

1.2°F/°F 0.3 to 3.0°F/°F in 0.1 increments

0°F -50 to +50°F

C-1

D-1

Appendix D _____________________________

Field Adjust Mode

Display Messages and Defaults

Key Display Message Default Range

HDR

TEMP

(Press Once)

(Press 2nd Time) MIN SLAVE ADDR

(Press 3rd Time) MAX SLAVE ADDR

(Press 4th Time) NUMBER NETW BLRS

(Press 5th Time) MODBUS CNTL TYPE

(Press 6th Time) NETW BOILER 1

AIR

TEMP

(Press Once)

(Press 2nd Time) RS232 BAUDRATE

(Press 3rd Time) MODBUS ADDRESS

(Press 4th Time) NETWORK TIMEOUT

(Press 5th Time) REMOTE SIGNAL

(Press 6th Time) MODBUS PASS THRU

% LOAD

(Press & Hold)

% LOAD

(Press & Release)

(Press 2nd Time) SET TIME CLOCK

(Press 3rd Time) SET TIME CLOCK

(Press 4th Time) SET TIME CLOCK

(Press 5th Time) SET TIME CLOCK

(Press 6th Time) SET TIME CLOCK

RS485 BAUDRATE 9600

Round Robin

ADDRESS=0 (Repeat for Each Netw Boiler) RS232 MODE MODBUS SLAVE

9600

128

4-20MA

DISABLED PERCENTAGE OF LOAD 100% 8 Units SET TIME CLOCK MONTH: 06

DATE: 21

YEAR: 03

DAY: 1

HOURS: 14

MINS: 30

9600 2400, 4800, 9600,

14400, 19200

0 0 to 127

0 0 to 32

Round Robin Round Robin or

Broadcast

0 0 to 127

MODBUS SLAVE NORMAL or

MODBUS SLAVE

9600 2400, 4800, 9600,

14400, 19200

128 0, 128 to 247

60 sec. 5 to 240 sec.

4-20MA 4-20MA or

MODBUS

DISABLED ENABLED or

DISABLED

100 % 0 to 100 %

0 to 8 Units

Present month 01 to 12

Present day of

month

Present year 00 to 99

Day one is

Sunday

Present time 00 to 23

Present time 00 to 59

1 to 31

1 to 7

Appendix D (cont.)__________________________

Field Adjust Mode

Display Messages and Defaults (cont.)

Key Display Message Default Range

SYS

START

TEMP

(Press 2nd Time) SYS START OPTION

REF

TEMP

HEADER REF TEMP

HDR TEMP LIMIT

(Press 2nd Time) HDR LOW LIMIT

(Press 3rd Time) HEADER OFFSET

SET

POINT

PROP BAND

RESET

RATIO

OFFSET

CONFIG

SYS

(Press 2nd Time) FAULT ALARM CLEAR

SYS START RELAY 70°F

TEMP ONLY BLDG REF TEMP (When in Indoor/Outdoor Reset Mode or Remote Setpoint Mode)

(When in Constant Setpoint Mode) HDR HIGH LIMIT 220°F

40°F

0°F INDOOOR SET POINT 70°F INDOOR PROP BAND

00.0°F/°F

RESET RATIO

1.2°F/°F (Indoor/Outdoor Reset Mode Only) FUNCTION NOT VALID (All Other Modes) OFFSET ENABLE OFF OFFSET TEMP DAY 1: OFFSET ON TIME DAY 1 OFFSET OFF TIME DAY 1 FAULT ALARM RELAY ALL FAULTS

MANUAL RESET

70°F 32 to 120°F

TEMP ONLY TEMP ONLY, or

TEMP AND LOAD

70°F 40 to 220°F

120°F 40 to 220°F

220°F 40 to 220°F

40°F 40 to 220°F

0°F -5°F to 5°F

70°F 50 to 150°F

00.0°F/°F 0 to 20°F/°F in 0.5°F/°F

increments

1.2°F/°F 0.3 to 3.0°F/°F in 0.1 increments

OFF ON or OFF

0 -50 to +50°F

00:00 00 to 23 Hours

00 to 59 Mins.

00:00 00 to 23 Hours

00 to 59 Mins.

ALL FAULTS ALL FAULTS,

NO INTERLOCK,

INTERLOCK 2 INTERLOCK 1

MANUAL

RESET

MANUAL RESET

or AUTOMATIC

D-2

Appendix E _____________________________

Config Sys Mode

Display Messages and Defaults

Key

TEMP FAIL

MODE

SYS

ENABLE

MAX PWR INPUT

(Press 2nd Time)

START LEVEL

STOP

LEVEL

BLR OP

MODE

(Press 2nd Time)

If COMBINATION

MODE is selected

HDR SET

MODE

(Press 2nd Time)

INTGL RATE

GAIN

TEMP

BANDWIDTH

AUX

RELAY

(Press 2nd Time)

DERIV

GAIN

Display Message Defaults Range

TEMP FAIL MODE SHUTDOWN INTERLOCK 1 START ENABLED MAX POWER INPUT 100% PWM TIMEBASE CAL 0

BLR. START LEVEL 45% BLR STOP LEVEL 18% BOILER OP MODE

SEQUENTIAL MODE

COMBINATION MODE 1 OF CCP BOILERS

HEADER SET MODE IN/OUTDOOR RESET

INDOOR TEMP INP. THERMISTOR INPUT INTEGRAL GAIN

0.15 REP/MIN HDR TEMP B.W. 70°F AUX RELAY OPEN 45% AUX RELAY CLOSE 100% AND OFF DERIVATIVE GAIN

0.15 MIN.

SHUTDOWN SHUTDOWN or

SWITCH INPUTS

START ENABLED

100% 50 to 100%

0 -30 to 30

45%

18% 10 to 45%

SEQUENTIAL SEQUENTIAL,

1 1 to 4

IN/OUTDOOR RESET

THERMISTOR THERMISTOR or

0.15 REP/MIN 0.00 to 9.99

70°F 5 to 100°F

45% 0 to 99%

100% AND OFF 100% AND OFF or

0.15 MIN. -2.00 to 2.00 MIN.

START ENABLED or ALWAYS ENABLED

25 to 100%

PARALLEL or COMBINATION

IN/OUTDOOR RESET, CONSTANT SETTEMP, REMOTE SET TEMP

4-20 mA

REP/MIN

100% FIRE RATE

E-1

Appendix F _____________________________

Temperature Sensor Resistance Data

Temperature

(°F)

-40 239,571 180 1,362

-30 173,530 190 1,155

-20 127,088 200 984

-10 94,059 210 842

0 70,314 220 723

Resistance

(ohms)

Temperature

(°F)

Resistance

(ohms)

10 53,068 230 623

20 40,418 240 539

30 31,053 250 468

40 24,057 260 408

50 18,787 270 357

60 14,783 280 313

70 11,717 290 276

80 9,353 300 243

90 7,516 310

100 6,078 320

110 4,946 330

120 4,049 340

130 3,333 350 140 2,759 360

150 2,296 370

160 1,920 380 170 1,613 390

F-1

Appendix G _____________________________

Parts List

Part Number

GP-122783 Boiler Management System (BMS) Complete BMS

124376 Electronics

GP-6-217 #10-32 x 3/8 inch Mounting Screws GP-6-218 #10-32 x 1/2 inch Mounting Screw GP-161228 Mounting Plate GP-181108 Field Adjust Overlay GP-181109 System Configuration Overlay

18949 Machined Front Panel

122784 Control Panel

GP-123042

GP-123043

GP-122662 Outside Air Temperature Sensor

GM-122781 Outside Air Temperature Sensor Kit

64038 Header Temperature Sensor Sensor Only

GP-122758

GM-122790

GM-122791 Outdoor Reset Kit

GP-122882 Indoor Temperature Sensor 65020 Low Voltage Terminal Block (16 pin) 65021 High Voltage Terminal Block (9 pin)

120 VAC, 1A, 2AG subminiature, fastacting fuse (Littlefuse 225001) 12 VAC, 5A, 2AG Subminiature, FastActing Fuse (Littlefuse 225005)

Thermowell for Header Temperature Sensor

Header Temperature Sensor Kit

Description

BMS Controls per Spec. 5C5-380

Supplied with Control Panel (122784) Includes Machined Front Panel (18949)

For BMS Electronics

For System-Start, Fault Alarm, and Auxiliary Relays

Includes Sensor (122662) and Mounting Bracket

Thermowell Only

Includes 64038 and GP-122758 Includes GM-122781 and GM-122790

Comment

G-1

Appendix H _____________________________

TROUBLESHOOTING

When a fault occurs in the boiler plant, the BMS flashes error messages at 2-second intervals and the alarm contacts close. To cancel alarms (open contacts but message still displays), press the RESET RATIO key The fault messages shown in Table H1 can occur in any mode of operation, Constant Setpoint, Indoor/Outdoor Reset, or Remote Setpoint. Some of the most common problems encountered in BMS operation are contained in Table H2.

Table H1 Error Messages

Fault Message

Description & Possible cause

OUTSIDE AIR TEMP NOT CONNECTED

OUTSIDE AIR TEMP SENSOR ERROR

HEADER TEMP SENSOR ERROR

INDOOR AIR TEMP SENSOR ERROR

• Open outside air temp. sensor: resistance greater than 240K ohms (less than -40°F) Shorted outside air temp. sensor: resistance less than 1K ohms (greater than 200°F) No sensor connected

Note: Displays only in 4-to-20 mA and Constant

Setpoint modes. It does not display as an error message, and will display only after pressing the AIR TEMP key.

When in Indoor/Outdoor Reset Mode, the outside air temperature sensor is either open, shorted, or not connected.

• Open header sensor: resistance greater than 240K ohms (less than

-40°F) Shorted header sensor: resistance less than 240 ohms (over 300°F) Sensor not installed

• Open indoor air temp. sensor: resistance greater than 240K ohms (less than -40°F) . Shorted sensor: resistance less than 240 ohms (over 300°F) No sensor installed and Prop Band is adjusted to > 0°F/°F

SYSTEM ERROR, INTERLOCK 1

Interlock 1 is open

H-1

Appendix H _____________________________

Table H1 Error Messages - Continued

Fault Message

Description & Possible cause

SYSTEM ERROR, INTERLOCK 2 OPEN

(4-20 MA) INPUT OPEN LOOP ERROR

FAIL SAFE MODE ACTIVATED

NETWORK COMM FLT TIMEOUT ERROR

NETWORK DISABLED MODBUS LISTEN

Interlock 2 is open

The 4-to-20-mA remote input signal has dropped below 3 mA, or the signal is not present at the BMS.

This message can be displayed when the BMS is controlling the boilers via Modbus or PWM communication. It indicates that the BMS is operating in the Fail Safe (Constant Setpoint) mode.

Displayed during Modbus Remote Setpoint operation when the BMS is functioning as a Slave to an EMS Master. Error indicates that the Network Timeout has expired.

Displayed during Modbus operation when the “FORCE LISTEN ONLY” Modbus diagnostic command is sent to the BMS Slave by the controlling Master, thereby disabling normal Modbus Network communication. It indicates that the Master is listening for the “RESTART COMMUNICATIONS OPTIONS” diagnostic command required to restart normal Modbus communication. The BMS will operate in the Fail Safe mode during this period.

H-2

Appendix H ____________________________

Table H2 Common Problems

Problem

Possible Causes

Solution

Boiler plant not started by BMS

Boiler not being recognized by BMS with Modular Control Box

• Outside air temperature higher than system’s start temperature

• System must be initialized

• Wiring between boilers and

BMS not correct

• Temperature controller is

not in Manual/Remote mode

• Temperature controller’s secure menu is not locked

• Boilers are not correctly

addressed

• Wiring between the BMS

and boilers is incorrect Indoor sensor not installed but value has been entered under PROP BAND

• Check outside air temperature and system start temperature. System start temperature should be higher than outside air temperature for boilers to run. See para. 4.3.3 and

4.3.5. Initialize and test system (para. 5.5 and 5.6).

• Check wiring (Section 3)

• Check temperature controller. The

REM and MAN lights should be illuminated. If not, shut off AC power to the boiler, wait 30 sec., and reapply power. The boiler will automatically return to remote/manual mode.

• Go to Secure menu in temperature controller. It should display Secure

3. If the display shows Secure 4, relock to Secure 4.

• See para. 5.4

• See Section 3 for correct wiring

connections

• If value has been entered under PROP BAND, change value to 00/00° F

Boiler not being recognized by BMS with

C-More Control Box

• C-More Box not configured correctly.

• C-More Box not enabled. Front panel switch is off.

• Incorrect wiring between BMS and Boiler.

H-3

• Ensure that the C-More Boiler is configured for Direct Drive and PWM (see para. 5.5 of GF-109 (KC1000) or GF-110 (Benchmark) for required menu settings.

• Check ON/OFF switch.

• See Section 3 for correct wiring

connections

Appendix H _____________________________

Table H2 Common Problems - Continued

Problem

Possible Causes

Solution

Boilers overshooting setpoint or tripping aquastat

Modbus Network faults encountered. Boiler plant not operating

• Header sensor not installed correctly

• PID setting require adjustment

• Adjustable aquastat set too low

• System pumps are shut

down and not controlled by or interlocked with the BMS

• BMS is set to ALWAYS ENABLE

• BMS or boilers not properly configured for Modbus communication

• Check header sensor connections and installation.

• Adjust PID settings. See para. 4.4.7

• If aquastat is set lower than 200°F,

reset it to 220°F.

• If system pumps are shut down,

check start and stop temperatures on energy management system. They should correspond to those set in the BMS. In addition, interlock wiring can be run between the BMS and energy management system to disable the BMS pumps when pumps are not running.

• If BMS is set to ALWAYS

ENABLED, change it to START ENABLED

• Refer to Modbus Communication Manual GF-114. Check all wiring connections and software menu settings.

H-4

Appendix I _____________________________

GENERAL WIRING

I-1

Appendix J _____________________________

PROGRAMMING THE BMS USING RS-232 COMMUNICATION

Introduction

The RS-232 port on the left side of the BMS can be used to program the BMS using a laptop computer or other suitable terminal. Connection to a laptop or other terminal device is made using a 9-pin RS-232 adapter cable. Communication can be accomplished using any “Dumb Terminal” emulation, such as Hyper Terminal which is included with Microsoft Windows. The RS-232 communication feature allows the BMS to be easily programmed to your installation requirements using a listing of entry commands.

Set-Up

Regardless of the terminal emulation utilized, the following guidelines must be adhered to when interfacing the BMS to the Terminal device:

1. Connect a 9-pin serial cable to the RS-232 connector near the lower left corner of the BMS front panel.

2. Connect the free end of the cable to the COM 1 or COM 2 port on your laptop, or other suitable terminal device.

3. Set up the emulator communication link as follows:

(a) Set the baud rate to 9600.

(b) Set the data format to 8 bits, 1 stop bit, no parity and either Xon/Xoff or No Flow Control.

4. Turn on the BMS by pressing the ON key. Verify that the ON LED lights.

5. Press the FIELD ADJ key on the BMS to enter the Field Adjust Mode. Verify that the FIELD

ADJ LED lights.

IMPORTANT

The RS232 MODE setting MUST be set to NORMAL to permit the

6. Press the AIR TEMP key until RS232 MODE is shown in the top line of the display. If necessary, press the ▲ or ▼ arrow key until NORMAL appears in the second line of the display.

7. Press the FIELD ADJ key to exit the Field Adjust Mode. Verify that the FIELD ADJ LED goes off.

8. Start the emulator software program.

BMS functions to be programmed via the RS232 port.

9. At the command prompt, enter the password EXACTLY as follows (case-sensitive):

P=gobms

10. Press Return (<Rtn>) on your terminal.

11. The setup is now complete. You are ready to begin viewing or changing BMS functions.

-1

Appendix J (cont.) __________________________

Programming Procedure

BMS functions which can be viewed or changed are listed in Table J-1 along with their corresponding command numbers. Functions which can only be viewed (such as actual sensor readings) are marked “Read Only”. Viewing or changing function values is accomplished as follows:

1. Select the number of the desired command from Table J-1.

2. To view a parameter, type ?, followed by the command number and then press return (<Rtn>). For example, to view command no. 00 (HEADER TEMPERATURE), enter:

?00<Rtn>

The header temperature reading will be displayed. All temperature readings are in °F.

3. To program (set) a BMS parameter, type @, followed by the command number, an equal sign, the parameter value and a trailing zero. For example, to set command 05 (SYSTEM OUTSIDE AIR START TEMPERATURE) to 65°F, enter:

@05=650<Rtn>

Use the above steps to view and/or program the desired BMS functions listed in Table J-1.

-2

Appendix J (cont.) __________________________

Table J-1. BMS COMMANDS

No.

00 Header Temperature (°F) 40 to 220 Read Only

01 Outside Air Temperature (°F) -60 to 80 Read Only

02 Indoor Air Temperature (°F) 40 to 160 Read Only

03 Fire Rate (%) 0 to 100 Read Only

04 Header Set Temperature (°F) 40 to 220 Read Only

COMMAND

ENTRY RANGE

FACTORY DEFAULT

05 System Outside Air Start Temperature

(°F)

06 System Start Mode 0 = Temp Only

1 = Temp and Load

07 Manual Header Set Temperature (°F) 40 to 220 160

08 Reference Temperature (°F) 40 to 220 70°F

09 Indoor Prop Band 0.0 to 20.0

10 Setpoint Temperature(°F) 40 to 220 160

11 Reset Ratio 0.3 to 3.0

12 Maximum Header Temperature (°F) 40 to 220 220

13 Minimum Header Temperature (°F) 40 to 220 40

14 Boiler Start Percent 25 to 100 45

15 Boiler Stop Percent 10 to 45 18

16 Integral Gain (Rep./Min) 0.00 to 9.99

17 Header Set Mode 0 = Constant Settemp

1 = Indr/Outdr Reset

2 = Remote Settemp

32 to 120 70

0 = Temp Only

0.0

(0.1 increments)

1.2

(0.1 increments)

0.15

(0.01 increments)

1 = Indr/Outdr Reset

18 Derivative Gain -2.00 to 2.00

(0.01 increments)

19 Header Bandwidth (°F) 5 to 100 70

20 Aux Relay Off Level (%) 0 to 99 45

-3

0.15

Appendix J (cont.) __________________________

No.

Table J-1. BMS COMMANDS

COMMAND

ENTRY RANGE

FACTORY DEFAULT

21 Aux Relay Mode 0 = 100% Fire Rate

1 = 100% and OFF

22 Temperature Sensor Fail Mode 0 = Shutdown

1 = Switch Inputs

23 Fault Relay Mode 0 = All Faults

1 = No Interlock

2 = Interlock 2

3 = Interlock 1

24 Alarm Clear Method 0 = Automatic

1 = Manual

25 Boiler Operation Mode 0 = Parallel

1 = Sequential

2 = Combination

26 Number Of PWM Combo Units 0 to 4 1

27 28 29

30 Maximum PWM Percent Level 50 to 100 100

Reserved

1 = 100% AND OFF

0 = Shutdown

0 = All Faults

0 = Automatic

1 = Sequential

31 Interlock 1 Method Of Operation 0 = Always Enabled

1 = Start Enabled

32 Real Time Clock - Minutes 00 to 59 Present Time

33 Real Time Clock - Hours 00 to 23 Present Time

34 Real Time Clock - Day Of Week 1 to 7 Present Day

35 Real Time Clock - Year 00 to 99 Present Year

36 Real Time Clock - Day Of Month 00 to 31 Present Day

37 Real Time Clock - Month 00 to 12 Present Month

38 (Day 1)

Thru Offset Temperatures (Day 1-7) -50 to +50°F All Set To 0°F

44 (Day 7)

1 = Start Enabled

-4

Appendix J (cont.) __________________________

Table J-1. BMS COMMANDS – (Continued)

No.

45 (Day 1)

Thru Offset ON Time – Minutes (Day 1-7) 00 to 59 All Set to Zero

51 (Day 7)

52 (Day 1)

Thru Offset ON Time – Hours (Day 1-7) 00 to 23 All Set To Zero

58 (Day 7)

COMMAND

ENTRY RANGE

FACTORY DEFAULT

59 Offset Enable 0 = Disabled

1 = Enabled

60 Header Offset (°F) 0 to 5 0

61 System Start Relay Contact Operation

With Interlocks

70 (Day 1)

Thru Offset OFF Time – Minutes (Day 1-7) 00 to 59 All Set To Zero

76 (Day 7)

77 (Day 1)

Thru Offset OFF Time – Hours (Day 1-7) 0 to 23 All Set To Zero

83 (Day 7)

84 (Reserved)

85 Indoor Air Input 0 or 1

0 = No Action

1 = Either Intlk Opens Start Relay

2 = Intlk 1 Opens Start Relay

3 = Intlk 2 Opens Start Relay

0 = 4 - 20 mA

1 = Thermistor

0 = Disabled

0 = No Action

1 = Thermistor

Command Nos. 86 and Up Apply Only to BMS Units Equipped With Modbus Capability

86 Remote Signal 0 or 1

0 = 4 - 20 mA

1 = Modbus

0 = 4 - 20 mA

-5

Appendix J (cont.) __________________________

Table J-1. BMS COMMANDS – (Continued)

No.

COMMAND

ENTRY RANGE

FACTORY DEFAULT

87 RS232 Mode 0 or 1

0 = Normal

1 = Modbus

88 RS232 Baud Rate 2400, 4800, 9600,

14400, 19200

89 Number Of Network Boilers 0 to 32 0

90 Min Slave Address 0 to 127 0

91 Max Slave Address 0 to 127 0

92 Net Boiler 1 Address Address for Network

Boiler 1 (same as Boiler #9)

93 Net Boiler 2 Address Address for Network

Boiler 2 (same as Boiler #10)

94 Net Boiler 3 Address Address for Network

Boiler 3 (same as Boiler #11)

95 Net Boiler 4 Address Address for Network

Boiler 4 (same as Boiler #12)

1 = Modbus

9600

96 Net Boiler 5 Address Address for Network

Boiler 5 (same as Boiler #13)

97 Net Boiler 6 Address Address for Network

Boiler 6 (same as Boiler #14)

98 Net Boiler 7 Address Address for Network

Boiler 7 (same as Boiler #15)

99 Net Boiler 8 Address Address for Network

Boiler 8 (same as Boiler #16)

100 Net Boiler 9 Address Address for Network

Boiler 9 (same as Boiler #17)

-6

Appendix J (cont.) __________________________

Table J-1. BMS COMMANDS – (Continued)

No.

COMMAND

ENTRY RANGE

FACTORY DEFAULT

101 Net Boiler 10 Address Address for Network

Boiler 10 (same as Boiler #18)

102 Net Boiler 11address Address for Network

Boiler 11 (same as Boiler #19)

103 Net Boiler 12 Address Address for Network

Boiler 12 (same as Boiler #20)

104 Net Boiler 13 Address Address for Network

Boiler 13 (same as Boiler #21)

105 Net Boiler 14 Address Address for Network

Boiler 14 (same as Boiler #22)

106 Net Boiler 15 Address Address for Network

Boiler 15 (same as Boiler #23)

107 Net Boiler 16 Address Address for Network

Boiler 16 (same as Boiler #24)

108 Net Boiler 17 Address Address for Network

Boiler 17 (same as Boiler #25)

109 Net Boiler 18 Address Address for Network

Boiler 18 (same as Boiler #26)

110 Net Boiler 19 Address Address for Network

Boiler 19 (same as Boiler #27)

111 Net Boiler 20 Address Address for Network

Boiler 20 (same as Boiler #28)

112 Net Boiler 21 Address

Address for Network Boiler 21 (same as Boiler #29)

-7

Appendix J (cont.) __________________________

Table J-1. BMS COMMANDS – (Continued)

No.

COMMAND

ENTRY RANGE

FACTORY DEFAULT

113 Net Boiler 22 Address Address for Network

Boiler 22 same as Boiler #30)

114 Net Boiler 23 Address Address for Network

Boiler 23 (same as Boiler #31)

115 Net Boiler 24 Address Address for Network

Boiler 24 (same as Boiler #32)

116 Net Boiler 25 Address Address for Network

Boiler 25 (same as Boiler #33)

117 Net Boiler 26 Address Address for Network

Boiler 26 (same as Boiler #34)

118 Net Boiler 27 Address Address for Network

Boiler 27 (same as Boiler #35)

119 Net Boiler 28 Address Address for Network

Boiler 28 (same as Boiler #36)

120 Net Boiler 29 Address Address for Network

Boiler 29 (same as Boiler #37)

121 Net Boiler 30 Address Address for Network

Boiler 30 (same as Boiler #38)

122 Net Boiler 31 Address Address for Network

Boiler 31 (same as Boiler #39)

123 Net Boiler 32 Address

Address for Network Boiler 32 (same as Boiler #40)

-8

Appendix J (cont.) __________________________

Table J-1. BMS COMMANDS – (Continued)

No.

COMMAND

ENTRY RANGE

FACTORY DEFAULT

124 Network Baud 2400, 4800, 9600,

14400, 19200

125 Network Timeout 5 to 240 sec 60 sec.

126 Password Lo 0 to 255 0

127 Password Hi 0 to 255 0

128 Modbus Control Type 0 = Round-Robin

1 = Broadcast

129 Modbus Pass-Thru 0 = Disabled

1 = Enabled

130

(Reserved For Future Expansion) Undefined

9600

0 = Round Robin

0 = Disabled

-9

AERCO BMS 168 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents