AERCO BMS II BOILER User Manual

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GF-124

Instruction

AERCO INTERNATIONAL, Inc., Northvale, New Jersey, 07647 USA

Installation, Operation

& Maintenance Instructions

BMS II BOILER

MANAGEMENT

SYSTEM

JANUARY 19, 2011

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 mainte nance manual is s ubject to change without notice from AERCO International, Inc.

AERCO makes no warranty of any kind with respect to this material, inc luding but not limited to implied warranties of merchantability and fitness for a particular application. AERCO International is not liable for er rors appearing in this manual. Nor for incide ntal or consequential damages occurring in connection with the furnishing, perform ance, or use of this material.

FOREWORD

Phrase, Abbreviation or

A (Amp)

Ampere

ADDR

Address

ALRM

Alarm

AUX

Auxiliary

below)

Baud Rate

Symbol rate, or simply the number of distinct symbol changes (signaling each symbol is 1 bit long.

BCM

Boiler Control Module used with AERCO Modulex Series Boilers

BLR

Boiler

BMS II

AERCO Boiler Management System, Second Generation

BND

Band

Bias Resistors

A pair of resistors used to force the communication line to a definite logic state so that noise is not picked up as invalid data during communication.

BLDG (Bldg)

Building

C-More Controller (or Control Box)

A control system developed by AERCO and currently used in all Benchmark and KC1000 Series product lines.

CNTL

Control

DIP

Dual In-Line Package

DYN

Dynamic

EMS

Energy Management System; often used interchangeabl y with BAS

Ethernet

A computer networking technology for Local Area Networks (LANs)

FDX

Full-Duplex

FLT

Fault

GND

Ground

HDR

Header

HDX

Half-Duplex

Foreword

The Model 5R5-384 B oiler Management S ystem II (BMS II) is the l atest model of AERCO’s BMS lin e of flexible boiler plant contr ollers.. The system can control a boil er plant comprised of AERCO Benc hmark Series, Modulex Series or KC10 00 Boilers. The BMS II can stage an d coordinate the operation of up to 32 AERCO Boilers with maximized efficiency. With individual boilers with turn-down ratios as high as 20:1, a 5-boiler plant can deli ver a system turn-down ratio of 100: 1 when the bo il e r s ar e s taged to opera te sequentially.

The BMS II is fully compatible with a wide array of Building Automation Systems (BAS) or Energy Management System s (EMS) utilizing M odbus Pr otocol. T he BAS or EMS com municates with the BMS II utilizing a RS232 i nterfac e. If the BAS or EMS does not c ontain a RS23 2 port , the BMS II can be order ed with a RS485-to-RS232 Converter which can be easily installed within the BMS II’ wiring compartment.

PHRASES, ABBREVIATIONS & ACRONYMS

The phrases, abbreviations and acronyms used in this document are listed in the following table

Phrases, Abbreviations and Acronyms

Acronym

BAS Building Automation System, often used interchangeably with EMS (see

events) transmitted per second. It is not equal to bits per second, unless

Meaning

FOREWORD

Hex

Hexadecimal Number (0 - 9, A - F)

Hertz (Cycles Per Second)

INTLK

Interlock

I/O

Input/Output

I/O Box

Input/Output (I/O) Box currently used on all Benchmark and KC Series products

Internet Protocol

ISO

Isolated

LSB

Least Significant Byte

LSD

Least Significant Digit

MA (mA)

Milliampere

MAX (Max)

Maximum

MIN (Min)

Minimum

Modbus®

A serial, half-duplex data transmission protocol developed by AEG Modicon

MSB

Most Significant Byte

MSD

Most Significan t Digit

MS/TP

Master-Slave/Token-Passing (usually over RS485 networks)

OFFS

Offset

OUTD

Outdoor

PTP

Point-to-Point (usually over RS232 networks)

REF (Ref)

Reference

Response Time

The maximum amount of time allowed to receive a response to a request

(or EIA-232)

RS232 Standard

RS422 (or EIA-422)

A standard for serial, full-duplex (FDX) transmission of data based on the RS422 Standard

(or EIA-485)

RS485 Standard

RTN

Return

RTU

Remote Terminal Unit

SEN

Sensor

SETPT (Setpt)

Setpoint Temperature

SHLD (Shld)

Shield

SLTA

Serial LonTalk Adapter

SYS

System

TEMP (Temp)

Temperature

Terminating Resistor

A resistor placed at each end of a daisy-chain or multi-drop network in order to prevent reflections that may cause invalid data in the communication

VAC

Volts, Alternating Current

VDC

Volts, Direct Current

VFD

Vacuum Fluorescent Display

Phrases, Abbreviations and Acronyms - Continued

Phrase, Abbreviation or

Acronym

Meaning

RS232

RS485

A standard for serial, full-duplex (FDX) transmission of data based on the

A standard for serial, half-duplex (HDX) transmission of data based on the

CONTENTS

GF-124 – BMS II BOILER MANAGEMENT SYSTE M

Operating & Maintenance Instructions

TABLE OF CONTENTS

CHAPTER 1 - GENERAL INFORMATION .................................................................................................... 1-1

1.1 SAFETY PRECAUTIONS & WARNINGS ................................................................................................... 1-1

1.2 INTRODUCTION ........................................................................................................................................... 1-1

1.3 BMS II GENERAL description ....................................................................................................................... 1-1

1.4 BMS II FEATURES ........................................................................................................................................ 1-2

Simplified Installation and Set-Up .................................................................................................................... 1-2

User-Friendly Control System Interface ............................................................................................................ 1-2

Retention of Menu Option Settings ................................................................................................................... 1-3

Application Flexibility ....................................................................................................................................... 1-3

Sequential or Parallel Operation ........................................................................................................................ 1-3

Accuracy ............................................................................................................................................................ 1-3

Bumpless Transfer ............................................................................................................................................. 1-3

Fault Alarm Surveillance ................................................................................................................................... 1-3

BMS II Programming Via RS232 Port. ............................................................................................................. 1-3

CHAPTER 2 - INSTALLATION ...................................................................................................................... 2-1

2.1 INTRODUCTION ........................................................................................................................................... 2-1

2.2 SITE SELECTION AND MOUNTING .......................................................................................................... 2-1

Mounting the BMS ............................................................................................................................................ 2-1

2.3 GENERAL WIRING REQUIREMENTS ....................................................................................................... 2-2

2.4 POWER WIRING ........................................................................................................................................... 2-3

2.5 SENSOR INSTALLATION AND WIRING ................................................................................................... 2-5

Header Sensor .................................................................................................................................................... 2-5

Return Sensor .................................................................................................................................................... 2-5

Outdoor Air Sensor ............................................................................................................................................ 2-6

2.6 RS485 (MODBUS) WIRING AT THE BMS II .............................................................................................. 2-8

BMS II Bias Switches & Loop Te rmination Resistors ...................................................................................... 2-8

2.7 RS485 (MODBUS) WIRING, BIAS & TERMINATION AT AERCO BOILERS ........................................ 2-9

RS485 Wiring, Termination& Bias for Benchmark Series and KC1000 Boilers .............................................. 2-9

RS485 Wiring for Modulex Series Boilers ...................................................................................................... 2-15

2.8 SAMPLE RS485 (MODBUS) NETWORK DIAGRAMS ............................................................................ 2-15

2.9 RS232 WIRING AT THE BMS II ................................................................................................................ 2-17

2.10 INTERLOCK WIRING ............................................................................................................................... 2-18

Interlock 1 (INT 1) Wiring .............................................................................................................................. 2-18

Interlock 2 (INT 2) Wiring .............................................................................................................................. 2-18

2.11 SET BACK WIRING .................................................................................................................................. 2-18

2.12 RELAY WIRING ........................................................................................................................................ 2-18

System Start Relay ........................................................................................................................................... 2-19

Fault Alarm Relay ........................................................................................................................................... 2-19

Auxiliary Relay................................................................................................................................................ 2-19

2.13 4 – 20 mA WIRING .................................................................................................................................... 2-19

CHAPTER 3 - OPERATION ............................................................................................................................. 3-1

3.1 INTRODUCTION ........................................................................................................................................... 3-1

3.2 FRONT PANEL OPERATING CONTROLS AND DISPLAYS ................................................................... 3-1

3.3 BMS II MENU STRUCTURE ........................................................................................................................ 3-3

Menu Processing Procedure .............................................................................................................................. 3-3

3.4 OPERATING MENU ...................................................................................................................................... 3-5

HEADER TEMP and PERCENT OF LOAD .................................................................................................... 3-5

HEADER SETPOINT ....................................................................................................................................... 3-5

OUTSIDE AIR TEMP ....................................................................................................................................... 3-5

I/O STATUS ...................................................................................................................................................... 3-6

RETURN TEMP ................................................................................................................................................ 3-6

iii

CONTENTS

TABLE OF CONTENTS (cont.)

3.5 SETUP MENU ................................................................................................................................................ 3-6

ENTER PASSWORD ........................................................................................................................................ 3-6

Date and Time Menu Options ............................................................................................................................ 3-6

3.6 RS232 MENU .................................................................................................................................................. 3-7

RS232 MODE.................................................................................................................................................... 3-7

RS232 BAUD RATE ......................................................................................................................................... 3-7

MODBUS ADDRESS ....................................................................................................................................... 3-7

NETWORK TIMEOUT .................................................................................................................................... 3-7

MODBUS PASS THRU .................................................................................................................................... 3-7

3.7 RS485 MENU .................................................................................................................................................. 3-7

RS485 BAUD RATE ......................................................................................................................................... 3-8

MIN SLAVE ADDR ......................................................................................................................................... 3-8

MAX SLAV E AD D R ........................................................................................................................................ 3-8

NUMBER NETWK BLRS ................................................................................................................................ 3-8

MODBUS CNTL TYPE .................................................................................................................................... 3-8

NETW BOILER Xx ADDRE S S = Yyy (Where Xx = 01 – 32; Yyy = 001 – 127) ............................................ 3-8

3.8 FIELD ADJUST MENU. ................................................................................................................................ 3-8

HEADER SET MODE ...................................................................................................................................... 3-8

HDR HIGH LIMIT ............................................................................................................................................ 3-8

HDR LOW LIMIT ............................................................................................................................................. 3-9

INTERNAL SETPT .......................................................................................................................................... 3-9

RESET RATIO .................................................................................................................................................. 3-9

BLDG REF TEMP ............................................................................................................................................ 3-9

REMOTE SIGNAL ........................................................................................................................................... 3-9

OFFSET ENABLE ............................................................................................................................................ 3-9

Offset Menu Options ......................................................................................................................................... 3-9

Setting Up An Offset Schedule ........................................................................................................................ 3-10

Manual Offset .................................................................................................................................................. 3-10

3.9 CONFIGURATION MENU .......................................................................................................................... 3-10

BOILER OP MODE ........................................................................................................................................ 3-10

SYS INTLK CONFIG ..................................................................................................................................... 3-11

BLR START LEVEL ...................................................................................................................................... 3-11

BLR STOP LEVEL ......................................................................................................................................... 3-11

MAX POWER INPUT .................................................................................................................................... 3-11

FAIL SAFE MODE ......................................................................................................................................... 3-11

3.10 TUNING MENU ......................................................................................................................................... 3-12

PROPORTIONAL BND ................................................................................................................................. 3-12

INTEGRAL GAIN .......................................................................................................................................... 3-12

DERIVATIVE GAIN ...................................................................................................................................... 3-13

HDR TEMP DEADBND ................................................................................................................................. 3-13

3.11 RELAY MENU ........................................................................................................................................... 3-13

SYS START TEMP ......................................................................................................................................... 3-13

SYS START OPTIO N ..................................................................................................................................... 3-13

SYS START INTLK ....................................................................................................................................... 3-13

AUX RELAY OPEN ....................................................................................................................................... 3-13

AUX RE LAY CLOSE ..................................................................................................................................... 3-13

FAULT ALRM RELAY.................................................................................................................................. 3-14

FAULT ALARM BLRS .................................................................................................................................. 3-14

FAULT ALRM CLEAR .................................................................................................................................. 3-14

3.12 CALIBRATION MENU ............................................................................................................................. 3-14

HDR SENS OFFSET ....................................................................................................................................... 3-14

OUTD SENS OFFSET .................................................................................................................................... 3-14

4 - 20 MA OFFSET ......................................................................................................................................... 3-14

RETN SENS OFFSET ..................................................................................................................................... 3-14

RAMP UP %/MIN ........................................................................................................................................... 3-15

CONTENTS

TABLE OF CONTENTS (cont.)

RAMP DOWN %/MIN ................................................................................................................................... 3-15

LOAD START PCT ........................................................................................................................................ 3-15

LOAD STOP PCT ........................................................................................................................................... 3-15

RESET DEFAULTS ........................................................................................................................................ 3-15

3.13 BMS II QUICK-START GUIDE ................................................................................................................ 3-16

CONSTANT SETPT MODE (Default) ........................................................................................................... 3-16

REMOTE SETPT MODE ............................................................................................................................... 3-17

OUTDOOR RESET MODE ............................................................................................................................ 3-18

CHAPTER 4 - PROGRAMMING BMS II OPERATING MODEs .................................................................. 4-1

4.1 INTRODUCTION ........................................................................................................................................... 4-1

4.2 OUTDOOR RESET MODE ............................................................................................................................ 4-1

Selecting Outdoor Reset Mode .......................................................................................................................... 4-2

Determining Reset Schedule .............................................................................................................................. 4-2

Entering Reset Ratio and Building Reference Temperature .............................................................................. 4-2

Selecting Boiler Operating Mo de ...................................................................................................................... 4-3

Entering Boiler Start and Boiler Stop Levels .................................................................................................... 4-3

Entering Sys t em Start Temperature ................................................................................................................... 4-3

Entering Load Start Percent (Req uire d Only for Modulex Installations) .......................................................... 4-4

4.3 REMOTE SETPOINT MODE ........................................................................................................................ 4-4

Selecting Remote Setpoint Mode ...................................................................................................................... 4-5

Entering Header High Limit and Low Limit Temperatures............................................................................... 4-5

Selecting Remote Signal Type ........................................................................................................................... 4-5

Selecting Boiler Operating Mo de ...................................................................................................................... 4-6

Entering Boiler Start and Boile r Stop Levels .................................................................................................... 4-6

Entering Load Start Percent (Req uire d Only for Modulex Installations) .......................................................... 4-7

4.4 CONSTANT SETPOINT MODE ................................................................................................................... 4-7

Selecting Constant Setpoint Mode ..................................................................................................................... 4-7

Selecting Internal Setpoint Temperature ........................................................................................................... 4-8

Selecting Boiler Operating Mo de ...................................................................................................................... 4-8

Entering Boiler Start and Boiler Stop Levels .................................................................................................... 4-8

Entering Load Start Percent (Req uire d Only for Modulex Installations) .......................................................... 4-9

4.5 “TEMP AND LOAD” OPTION ...................................................................................................................... 4-9

4.6 “START ENABLED” OPTION ...................................................................................................................... 4-9

4.7 SYSTEM INITIALIZATION AND POLLING ............................................................................................ 4-10

4.8 TESTING THE SYSTEM ............................................................................................................................. 4-10

CHAPTER 5 - TROUBLESHOOTING ............................................................................................................. 5-1

5.1 FAULT MESSAGES & COMMON PROBLEMS ......................................................................................... 5-1

APPENDIX A - BMS MENUS A-1 APPENDIX B - STATUS AND FAU LT MESSAGES B-1 APPENDIX C - METHODS FOR DETERMINING RESET SCHEDULE C-1 APPENDIX D - NTC TEMPERATURE RESISTANCE CHART D-1 APPENDIX E - BMS II WIRING DIAGRAM E-1 APPENDIX F - BMS II PARTS AND ACCESSORIES F-1 APPENDIX G - PROGRAMMING THE BMS II USING RS232 COMMUNIC ATI ON G-1 APPENDIX H - BMS II MODBUS ADDRESS ASSIGNMENTS H-1 APPENDIX I - BOILER START AND BOILER STOP LEVELS I-1

GENERAL INFORMATION

CHAPTER 1 - GENERAL INFORMATION

1.1 SAFETY PRECAUTIONS & WARNINGS

The Warnings and Cautions appearing throughout this manual should be reviewed and thoroughly understood prior to attempting to install, operate, troubleshoot or repair the BMS II.

1.2 INTRODUCTION

This manual provides installation, operation and troubleshooting instructions for the AERCO Boiler Management System, Model 5R5-384. Since this Model is the second generation of AERCO’s Boiler Management System (BMS) line, this Model is referred to as the BMS II throughout this document.

1.3 BMS II GENERAL DESCRIPTION

The BMS II (Figure 1-1) is a rugged , flexible contro ller designed to stag e and coordinate the o peration of up to 32 AERCO Benchmark Series, Modulex Series or KC1000 Boilers while maximizing operational efficiency. Under norm al lo ad condit ions, t he BM S II can pr ecise ly regu late the header tem perat ure of the boiler plant within ±2°F.

Boiler plant control is accomplished via a RS485 network utili zing Mo dbus pr otoc ol. For facilities that have taken a building-wide appr oach to energy eff iciency, the BMS II can be easi ly integrated with an Ener gy Management System (EMS) or Building Automation System (BAS) utilizing Modbus protocol. Physical connection to the rem ote EMS or BAS is accom plished vi a an RS232 interface. EMS/BA S integratio n will also permit utilizat ion of the pass-thru function incorporated in the B MS II. The pa ss-thru f unction permits the remote system to monitor up to 35 operating parameters from each boiler in the plant.

The BMS II is housed in a NEMA 13 e nclosur e. A hin ged cle ar-plas tic c over ove r the unit ’s panel cont rols protects against inci den tal cont act of control settings a nd pro vi des a degree of protection a ga ins t a irbor n e debris and the spraying or splashing of water. The physical dimensions, weight and electrical power requirements for the BMS II are as follows:

Dimensions 9.50” W x 7.25” H x 4.00” D Weight 3 lbs. Power Requirements 85-to-265 VAC, Single-Phase, 50-60 Hz @ 1A

Each BMS II shipment includes a Header Sensor Kit, Part No. GM-122790 which is required for all modes of operation. Other available options which can be ordered with your shipment include:

Outdoor Air Sensor Kit, Part No. GM-122781

Required for Outdoor Reset Mode Operation

Return Sensor Kit, Part No. 122790 (Same as Header Sensor Kit)

RS485-to-RS232 Converter, Part No 124943

Used for external monitoring of boiler water return temperature

For use with EMS or BAS equipment that do not include a RS232 Port

1-1

GENERAL INFORMATION

WIRING

COMPARTMENT

COVER

CONTROL

PANEL

CLEAR

PLASTIC

COVER

1.4 BMS II FEATURES

The following paragraphs briefly describe some of the unique features incorporated in the BMS II.

Simplified Installation and Set-Up

The BMS II system operates on single-phase input power ranging from 85 to 265 VAC, 50-60 Hz. Connections to the boi ler plant are accom plished utilizing a 2-wire RS485 networ k connected in a d aisychain configuration. W hen an EMS or BAS is used with the B MS II, connec tions ar e made via the RS2 32 port terminals. In the event that the EMS or BAS is not equipped with a RS232 port, the BMS II can be ordered with a RS485 to RS23 2 Converter which can be easily insta lled withi n the wiring c ompartm ent of the BMS II. With the exception of AC power, interlock and setback inputs and relay outputs, BMS II connections are accomplished using twisted-shielded pair cable.

User-Friendly Control System Interface

The unit incorporates a menu-driven architecture which is comprised of 9 primary menus. The user interface to these m enus is ac c om plished v ia t he BM S I I contr ol pa nel and a V acuum Fluorescent Displ a y (VFD). The displa y is c a pa ble of dis p laying two lines w ith 16 char ac ters per line. V ir tua ll y al l of t he c o ntrol panel keys are identical to the C-More Contr ol System c urrently used on A ERCO Benchm ark Series and KC1000 Boilers. This commonality will help simplify the time required for system setup of the BMS II.

Figure 1-1. Boiler Management System II (BMS)

1-2

GENERAL INFORMATION

Retention of Menu Option Settings

By using non-volatile memory, the BMS II retains program and menu settings during shut-down or when input AC power is interrupted. Settings can be retained for more than 2 years.

Application Flexibility

Four different configuration options can be selected to match the needs of any closed-loop system. These configurations are: Outdoor Reset, Constant Setpoint, Remote Setpoint via a 4-20 Ma input and Remote Setpoint via Modbus.

Sequential or Parallel Operation

Boilers can be programmed for either sequential or parallel operation using the BMS II keypad controls. When set for sequential operation, the boilers are brought on-line one at a time as needed. When set for parallel operation, the boilers are all brought on-line together at the same firing rate.

Accuracy

Using PID (Proportional Integral Derivative) and Ramp-Up/Ramp-Down Modulation Control Algorithms, the BMS II provides dynamic responses to all changes in boiler plant operation. Header temperatures, as well as percentages of boiler input are precisely controlled with virtually no over-shoot or short-c ycling of boiler units. A header temperature accuracy of ±2°F is virtually assured during continuous plant operation.

Bumpless Transfer

When operated sequentially, The BMS II stages boilers on and off at selectable firing rate percentages. The result is a seamless transition with undetectable room temperature changes. In addition, when in sequential mode, the BMS II sequences boilers using a first-on, first-off basis, thereby equalizing the accumulated run time of all boilers in the plant. The BMS II also continuously monitors the number of Boilers that are available for operation. In the event of a boiler malfunction, or required servicing, the BMS II automatically compensates for a lack of response from any unit and brings on the next available boiler to satisfy the demand. This feature operates in both sequential and parallel modes.

Fault Alarm Surveillance

If an EMS or BAS is not used with the BMS II to monitor faults, a Fault Alarm Relay can be activated thereby notifying facility managers of faults associated with the BMS II.

BMS II Programming Via RS232 Port.

If desired, the BMS II can be programmed by connecting a Laptop Computer or other terminal emulation device to the RS232 Port terminals on the BMS II. Detailed set-up instructions and available command listings are provided in Ap p end ix G. Most settings are also programmable using Modbus.

1-3

INSTALLATION

CHAPTER 2 - INSTALLATION

2.1 INTRODUCTION

This Chapter provides the descriptions and procedures neces sary to mount the BMS II and connect all boiler plant units and applic able sensors. Guideli nes are also provided for connec tion of an EMS or BAS being used with the s ystem. Ref er to the wiring diagram provided in Appen dix E when mak ing all wiring connections to the BMS II.

2.2 SITE SELECTION AND MOUNTING

Ensure that the site selected for installation of the BMS II provides the following:

• Access to single-phase AC power from 110 to 240 VAC, 60 Hz nominal

• Sufficient clearances to permit maintenance and setup/operational tasks on the BMS II.

Mounting the BMS

AERCO recommends that the BMS II be wall-mounted using a sheet of plywood or other suitable material. For easy viewing, the BMS II controls and display should be at eye level. Mounting is accomplished using three screws (not provided). The s pacing for the three screws are indicate d on the rear of the BMS II in millim eters. Figure 2-1 shows th e rear of the panel enc losure and also in dicates the required spacing for the three mounting scr ews in inch es . Proceed as follows to mount the unit:

1. First install a screw o n the mounting sur face at the to p center locatio n shown in Figure 2-1. Lea ve a space of approximately 1/8 inch between the mounting surface and the head of the screw.

2. Remove the wiring compartment cover f rom the front of the BMS II (see Figure 1-1) to provid e acc es s to the slots for the two lower mounting screw locations.

3. Hang the BMS II on the installed top screw. Position the unit so it is level.

4. Mark the locations for the two lower screws.

5. Remove the BMS II and drill two pilot holes for the lower screws.

6. Replace the BMS II on the installed top-center screw.

7. Secure the BMS II to the wall by installing the two lower screws. DO NOT over-tighten the screws.

2-1

INSTALLATION

198 mm (7.8")

145 mm (5.7")

15 mm

(0.6")

REAR VIEW

Figure 2-1. BMS II Mounting Provisions

2.3 GENERAL WIRING REQUIREMENTS

All wiring connections to t he BMS II are made at th e terminals located behind the wiring compartment cover as shown in Fi gure 2-2. Run all wiring t hrough the knock-outs provided on the bottom sur face of the unit. Shielded, twisted-pair cable should be used for sensor and communication wiring. This wiring should be 18 to 24 AWG. Examples of s uitable sensor and comm unication wire are: Belden 9841, 87 61, 3105A or equivalent. AC power wiring should be 1 4 to 18 AWG. The BMS II wiring diagram is provided in Appendix E. Once mount ing is com plete and the BMS is secured in p lace, loose n the two ca ptive scr ews on the wiring compartment cover using a Phillips screwdriver. Feed all wiring through the knock-outs provided on the bottom of the panel.

NOTE

Refer to the wiring diagram provided in Appendix E when making all wiring connections to the BMS II.

2-2

INSTALLATION

WARNING

THE BMS II CAN BE POWERED BY SINGLE-PHASE AC VOLTAGES RANGING FROM 85 TO 265 VAC. THEREFORE, EXERCISE EXTREME CARE WHEN CONNECTING POWER WIRING TO THE UNIT. ENSURE THAT THE EXTERNAL CIRCUIT BREAKER SUPPLYING LINE VOLTAGE TO THE BMS II IS TURNED OFF TO AVOID SEVERE ELECTRICAL SHOCK.

2.4 POWER WIRING

Use 14 to 18 AWG wire for AC power connections and proceed as follows:

1. Feed the power wiring thr ough the right-m ost knock -out in the bottom of the panel enclosure (Figure 2-2).

2. Connect the Line (black ), Neutral (white) and Groun d (green) wire leads to the L, N an d terminals. The term inal blocks can be detac hed fr om the BMS II headers if necess ary to sim plify field wiring connections.

3. Following completion of power wiring, turn on the exter nal circuit breaker or switch and apply power to the unit. The BMS II display will momentarily show:

AERCO BMSII REV X.XX

(Where: X.XX represents the revision level of the installed BMS II software)

4. Next, since the Header Sensor is not yet installed, the display will then show:

HEADER TEMP SENSOR ERROR

The red FAULT LED indicator will also light and a fault message will alternately be displayed as follows:

HEADER SENSOR ERROR

5. Press the ON-OFF k ey on the keypad. The green ON LED indicator w ill light and the BMS II d isplay will continue to show the above message.

6. After verifying proper power connections, press the ON-OFF key. The ON LED will turn off.

(GND)

7. Turn off the external power switch and/or circuit breaker. The BMS II display will go blank.

8. DO NOT apply power to the BMS II until all of the required external connections described in paragraphs 2.5 through 2.11 have been completed.

2-3

INSTALLATION

SENSORS

& 4-20 mA

INTERLOCKS

& SETBACK

RS485

& RS232

AC POWER

RELAYS

2-4

Figure 2-2. BMS II With Wiring Compartment Cover Removed

INSTALLATION

2.5 SENSOR INSTALLATION AND WIRING

There are two types of sensors that can be installed : a Header Sensor and an Outside Air Sensor. If desired, an optional Return Sensor can also be installed. The Return Sensor is the same type and part number as the Header S ensor, however it is only used for `external m onitoring purposes. The Header Sensor is required for all Outdoor Reset Mode.

All Sensor wiring should be run separately from power wiring to avoid inducing electrical noise on the sensor wiring.

Header Sensor

A Header Sensor Kit, (part no. 12279 0) is provided with the BMS II. This Kit cont ains the Header Sensor (64038), a Thermowell (122758) and some heat conductive grease which MUST be use d with the Sens or. When installing the Sensor , use a 1/ 2 inch NPT tapped coupling or a 4 x 4 x 1/2 in ch T ee fitting. Shielded pair, 18 AWG c able (Belden # 8760 or equiv.) is recommended for Header S ensor wiring. The Header Sensor must be installed between 2 and 10 feet downstream of the LAST boiler in the boiler plant’s supply water header. Install the Header Sensor as follows:

The Header Sensor is a thermistor type sensor. The Resistance vs. Temperature Chart for this sensor is provided in Appendix D. The length of the Header Sensor wire leads should not exceed 600 feet.

modes of operation. The Outdoor Air Sensor is required for operation in the

NOTE

1. Refer to Figure 2-3 f or the Header ‘Sens or ins ta llat ion details.

2. Install the Header Sensor and Thermowell i nto the 1/2 inch NPT tapped c oupling or a 4 x 4 x 1/2 inch Tee fitting using heat-conductive grease provided. This will aid in its response.

3. For proper response , e ns ur e th at t he Hea der Sensor probe is inser ted at le ast 2 inc hes i nto the wat er flow.

4. Using shielded pair c able (Belden #8760 or equiv.) connect t he Header Sensor leads to HDR SE N terminals 4 and 5 on the BMS II. There is no polarity to observe when making these connections.

5. Terminate the cable shield at SHLD terminal 3 of the BMS II. DO NOT terminate the shield at the Sensor end of the cable.

Return Sensor

As mentioned in paragraph 2.5, the Return Sensor is identical to the Header Sensor. Therefore, if a Return Sensor is being ins talled, another Header Sensor K it (part no. 122790) is required. The Ret urn Sensor should be i nstal led in the boiler water r eturn lin e within 3 feet of the first boil er in t he bo iler p lant ’s return water line . The installation details sho wn in Figure 2-3 for the Header S ensor also apply to the Return Sensor. If used, install the Return Sensor as follows:

1. Refer to Figure 2-3 an d ins tall the Ret ur n S ens or a nd Thermowell into the 1/2 inc h t ap ped c oupling or or Tee fitting using heat conductive grease.

2. Using shielded pair ca ble (Belden #8760 or equiv.) connect the Retur n Sensor leads to term inals 6 and 5 on the BMS II. There is no polarity to observe when making these connections.

3. Terminate the cable shield at SHLD terminal 3 of the BMS II. DO NOT terminate the shield at the Sensor end of the cable.

2-5

INSTALLATION

PROBE DEPTH MUST EXTEND AT LEAST 2" INTO PIPE

WELDED 1/2" COUPLING OR 4"x4*x1/2" T - FITTING

HEADER SENSOR WITH THERMOWELL INSTALLED

Figure 2-3. Header Sensor Installation Details

Outdoor Air Sensor

The Outdoor Air T emperature Sensor (part n o. GP-122662) is r equired when operating in the BMS II in the Outdoor Reset Mode (paragraph 4.2). An Outdoor Air Sensor Kit (part no. GM-122781) is also available. This kit contains the Sensor (GP-122662) and a Mounting Bracket for wall mounting. The Outdoor Air Sensor should be mounted on the North side of the building, shielded from direct sunlight, and awa y from air intakes or outlets f rom the building. Shielded pair 18 AWG cable (Belden # 8760 or equiv.) is recomm ended for sensor wiring. The Outdoor Air Sensor can be m ounted up to 600 feet from the BMS II.

1. Refer to Figure 2-4 for a typical Outdoor Air Sensor installation.

2. Attach the sensor to the mounting br acket and secure the bracket in a suitable loc ation on the North side of the building.

3. Using shielded pair cable ( Belden #8760 or equiv.), connect t he two Sensor lea ds to terminals 1 and 2 on the BMS II. There is no polarity to observe when connecting the sensor.

NOTE

The Outdoor Air Sensor is a thermistor type sens or. The Resistance vs. Temperature Chart for this t ype of s ensor is provi ded i n Appendix E. T he length of the Header Sensor wire leads should not exceed 600 feet.

2-6

INSTALLATION

INSTALL SENSOR ON NORTH FACING WALL OUT OF DIRECT SUNLIGHT AND AWAY FROM ALL AIR INLETS/OUTLETS

4. Terminate the cable shield at SHLD terminal 3 of the BMS II. DO NOT terminate the shie ld at the Sensor end of the cable.

Figure 2-4. Outdoor Air Sensor Installation

2-7

INSTALLATION

MASTER

SLAVE

2.6 RS485 (MODBUS) WIRING AT THE BMS II

The BMS II comm unicates with the AERCO Boilers over a RS485 network using Modbus pr otocol. All Modbus networks are im plemented utilizing a Master/Slave scenario where onl y one device, the Master, can initiate a communication sequence. AERCO Boilers equipped with C-More or E8/BCM (Modulex) control systems can only function as Slaves on a Modbus network. However, the BMS II can function as a Master controlling C-M ore or E8/BCM Boiler Slaves, or as a Slave contro lled by an Energ y Managem ent System (EMS) developed by other manufacturers. Additional information on implementing Modbus networks is provided in AERCO Modbus Communication Manual GF-114.

RS485 (Modbus) networks are wired in a “daisy chain” configuration similar to the example shown in Figure 2-5. Shielded twisted-pair, 18 – 24 AWG cable (Belden #9841, #3105A, #8760 or equiv.) is recommended for RS485 wiring connections.

Figure 2-5. Typical Daisy-Chain Modbus/RS485 Network

At the BMS II, RS485 (M odbus) wiri ng connections a re made at the wiring terminals labe led 485 B+ and 485 A-. The cable shield is terminated at the SHLD terminal (3) of the BMS II.

BMS II Bias Switches & Loop Termination Resistors

Each BMS II conta ins a built-in 120 ohm loop term ination resistor and two bias DIP switches which are mounted on the lower portion of the motherboard (Figure 2-6). The 120 ohm termination resistor is always active and is designed to matc h the electr ical im pedanc e at the B MS II end of the RS485 loop. T herefore, only one additional termination resistor will be required at the boi ler end of the RS485 loop. The two bias switches are used to activa te or deactiva te bias voltage on the RS485 networ k and should be positioned as follows, depending on the type of AERCO boilers being used:

NOTE

Refer to paragraph 2.7 for detailed instructions and illustrations describing how to implem ent loop termination, bias and wiring connections on the RS485 loop.

1. When wiring to Boiler C ontrol Modules (BCMs) controlling Mo dulex Boi lers, the BMS II bi as switches must be activated b y placing them in the on (down) position. Loop term ination is accomplished by activating the termination resistor in the last BCM on the RS485 loop.

2. When wiring to C-More co ntrol systems (Benchmark & KC1000 Boilers), the positions of the BMS II bias switches will de pend on which one of the two available methods is used. Loop termination wil l also depend on the method employed. See par agr aph 2.7 for details.

2-8

INSTALLATION

BIAS DIP

SWITCHES

NOTE: THE BIAS DIP SWITCHES CAN BE ACCESSED FROM THE WIRING COMPARTMENT WITHOUT REMOVING THE FRONT PANEL FROM THE UNIT.

WIRING COMPARTMENT

Figure 2-6. Location of BMS II DIP Switches

2.7 RS485 (MODBUS) WIRING, BIAS & TERMINATION AT AERCO

BOILERS

The RS485 wiring connections at the AERCO Boilers will depend on the type of AERCO Boilers and Control Systems bei ng used on the Mo dbus Network. Benchmark Series and KC1000 Boilers cur rently utilize C-More Control S ystems. Modulex Series Boilers utilize Boiler Control Modu les (BCMs) with E8 Controllers.

RS485 Wiring, Termination& Bias for Benchmark Series and KC1000 Boilers

RS485 wiring connec tions are m ade at the RS 485 CO MM term inals of each boiler’s I/O Box (Figures 2-7 or 2-8). However, activating bias and loop termination can be performed using one of two available methods as described be lo w:

2-9

INSTALLATION

Method 1

For Method 1, the bias switches in the BMS II are left in the deactivated (up) position. ). Bias and termination are contr olled at the b oiler end of the RS485 loop by activatin g the bias and ter mination DIP switches on the PMC board of the last 2-7 (Benchmark), or Figure 2-8 (KC1000) and proceed as follows:

1. Using a daisy-chain wiring configuration, connect the RS485 pos itive lead to the RS485 COMM + terminal in the I/O Box for each boiler.

2. Connect the RS485 negative lead to the RS485 COMM - terminal in the I/O Box for each boiler.

3. DO NOT terminate the shields to the Ground (G) terminal at the boiler end of the RS485 loop. Connect the s hields of the incom ing and outgoing lea ds togeth er. The RS485 loop shield should onl y be terminated at terminal 3 of the BMS II.

4. At the last boiler in the daisy-chain, activate the BIAS1, BIAS2 and TERM switches on the PMC board in the C-More Control Box. Refer to G F-114, paragraph 4.3.2 for detailed instru ctions on accessing the PMC board.

5. DO NOT activate the bias switches on the B MS II. These switches m ust be in the up position when using Method 1.

The advantage of us ing Method 2 is that the bias and termination of the RS485 loop do not require any changes t o be made t o the DIP s witches on the PMC board in the last C-More Control Box.

C-More Control Box on the daisy-chain. Refer to sheet 1 of Figure

NOTE

Method 2

For Method 2, bias is controll ed at the BMS II by setting the two bias switches (Figure 2-6) to the active (down) position. Term ination at the boi ler end of RS48 5 loop is accomplished b y installin g a 120 ohm , 1/2 Watt termination resis t or in the I/O Box of the last (Benchmark), or Figure 2-8 (KC1000) and proceed as follows:

1. Using a daisy-chain wiring configuration, connect the RS485 pos itive lead to the RS485 COMM + terminal in the I/O Box for each boiler.

2. Connect the RS485 negative lead to the RS485 COMM - terminal in the I/O Box for each boiler.

3. DO NOT terminate the shields to the Ground (G) terminal at the boiler end of the RS485 loop. Connect the shields of the incom ing and outgoing lea ds togeth er. The RS485 loop shield s hould onl y be terminated at terminal 3 of the BMS II.

4. At the last boi ler in th e daisy-chain, install a 1 20 ohm , 1/2 W att term ination res isto r ac ross the RS485 COMM + and - terminals in the boiler’s I/O Box.

5. When using Method 2, activate the two bias switches in the BMS II (Figure 2-6) by placing them in the down position.

boiler on the daisy-chain. Refer to s he et 2 of Figure 2-7

2-10

INSTALLATION

METHOD 1 – BIAS & TERMINATION ACTIVATED AT C-MORE PMC BOARD

Figure 2-7. RS485 (Modbus) Wiring For Benchmark Series Boilers (Sheet 1 of 2)

2-11

INSTALLATION

METHOD 2 – TERMINATION ACTIVAT E D AT I/O BOX

Figure 2-7. RS485 (Modbus) Wiring For Benchmark Series Boilers (Sheet 2 of 2)

2-12

mA OUT

RS-485 COMM.

ANALOG IN

SENSOR COMMON

OUTDOOR SENSOR IN

REMOTE INTL'K IN

B.M.S. (PWM) IN

SHIELD

AUX SENSOR IN

NOT USED

EXHAUST SWITCH IN DELAYED INTL'K IN

FAULT RELAY 120 VAC, 5A, RES

AUX RELAY 120 VAC, 5A, RES

NOT USED

NC COM NO

NOT USED

NOTE

DO NOT TERMINATE THE SHIELDS OF THE RS485 COMM LEADS TO THE GROUND (G) TERMINAL. THE SHIELDS MUST BE TERMINATED AT THE SOURCE ENDS ONLY. CONNECT THE SHIELDS OF THE INCOMING AND OUTGOING RS485 LEADS TOGETHER.

C32

C41

C29

C20

C31

C35

C47

C44

R29

R30

C53

R74

CBS3

R69

C50

R67

R68

C52

C57

CR1

U17

R76

C51

R71

R73

R72

JP2

R70

U21

C56

C64

R75

U13

U20

C59

C49

C48

C61

CBS4

U14

R78

R79

DS5

DS4

RS232

C60

C62

C46

U19

U15

U18

C58

C55

C54

DS3

R77

U16

C63

R16

U11

R66

U10

R15

C45

R14

C19

C16

R32 R17

C18

R18

C34

R33

C27

R31

C26

R47

C39

R55

R53

C36

R81

R45

R44

C37

R48

R46

C38

R49

BIAS1

TERM

BIAS2

R50

C40

CBS1

RS485

C11

R51

BH1

R10

C12

C13

DS1

RS485

R52

DS2

R54

C10

R11

R65

R34

R12

R13

C14

C15

R36

C28

C25

R35

C23

R37

R38

C30

C43

C65

R58

R62

R80

OFF = VOLT

CURR/VOLT

ON = CURR

R57

C66

R64

R56

CBS2

R25

U12

R20

R19

C17

R27

R23

R21

R22

C21

R28

R26

C24

R60

R41

R40

R24

R39

C22

R42 R43

C33

R61

R63

C42

R59

CR2

PMC BOARD

ACTIVATE BIAS1, BIAS2 & TERM DIP SWITCHES ON PMC BOARD OF LAST

C-MORE CONTROL BOX

DO NOT USE THESE TERMINALS

KC1000

REMOVE SHEET METAL

COVER TO ACCESS I/O BOX

RS485 COMM CONNECTIONS (See NOTE)

I/O BOARD

INSTALLATION

METHOD 1 – BI AS & T E RMI NATI ON AC T IVATED AT C -M ORE PMC BOARD

Figure 2-8. RS485 (Modbus) Wiring For KC1000 Boilers (Sheet 1 of 2)

2-13

INSTALLATION

mA OUT

RS-485 COMM.

ANALOG IN

SENSOR COMMON

OUTDOOR SENSOR IN

REMOTE INTL'K IN

B.M.S. (PWM) IN

SHIELD

AUX SENSOR IN

NOT USED

EXHAUST SWITCH IN DELAYED INTL'K IN

FAULT RELAY 120 VAC, 5A, RES

AUX RELAY 120 VAC, 5A, RES

NOT USED

NC COM NO

NOT USED

NOTE

DO NOT USE THESE TERMINALS

CONNECT 120 OHM, 1/2 WATT RESISTOR BETWEEN + AND – RS485 COMM TERMINALS ON LAST

C-MORE CONTROL BOX

KC1000

REMOVE SHEET METAL

COVER TO ACCESS I/O BOX

I/O BOARD

METHOD 2 – TERMINATION ACTIVATED AT I/O BOX

Figure 2-8. RS485 (Modbus) Wiring For KC1000 Boilers (Sheet 2 of 2)

2-14

INSTALLATION

SW1

I 0

BCM FRONT VIEW

7 6 5 4 3 2 1

JP2

JP1

JUMPER

SHOWN IN “TERMINATED” (UP) POSITION

MODBUS B (+)

MODBUS A (-)

RS485 Wiring for Modulex Series Boilers

RS485 wiring connec ti ons ar e made at the MODBUS t erminals of each Boiler ’s BCM Module as shown in Figure 2-9. Connect the wiring as follows:

1. Connect the positive lead to terminal 1 (MO DBU S B + ) of connec tor Y2.

2. Connect the negative lead to terminal 2 (MODBUS A -) of connector Y2.

3. DO NOT terminate the shields at the Boiler end of the RS485 loop. Connect the shields of the incoming and outgoing leads together. T he RS485 loop shield should onl y be terminated at th e BMS II.

4. The last BCM in the daisy-chain must have the termination jumper engaged as shown in Figure 2-9.

5. The two BMS II bias switches (Figure 2-6) must be activated by placing them in the down position.

Figure 2-9. RS485 (Modbus) Wiring For Modulex Series Boilers

2.8 SAMPLE RS485 (MODBUS) NE TWORK DIAGRAMS

Figure 2-10 shows a sam ple RS485 ( Modbus) Net work diagram with the BMS I I connecte d to KC1000 or Benchmark Series Boilers equipped with C-More Control S ystems. Figure 2-11 sho ws a similar sample diagram with the BMS II connected to Modulex Series Boilers equipped with BCMs and E8 Controllers.

2-15

INSTALLATION

BMS II

RS232 PORT

485 B (+) 485 A (-)

SHLD

(TERM. 3)

RS485 COMM

P/O I/O BOX

C-MORE

SLAVE

NETWORK BOILER 1

RS485 COMM

P/O I/O BOX

C-MORE

SLAVE

NETWORK BOILER 2

TO OTHER NETWORK

BOILERS

(3 – 32)

RS485 PORT

NOTE

THE LAST C-MORE SLAVE ON THE RS485 LOOP MUST HAVE ITS TERMINATION RESISTOR (TERM) AND BIAS (BIAS1, BIAS2) DIP SWITCHES TURNED ON. REFER TO GF-114 MODBUS COMMUNICATION MANUAL FOR DETAILS.

THE BIAS SWITCHES IN THE BMS II SHOULD BOTH BE “OFF”

SET BOTH

SWITCHES

TO “OFF”

BIAS

SWITCHES

BMS II

RS232 PORT

485 B (+) 485 A (-)

SHLD

(TERM. 3)

TO OTHER NETWORK

BOILERS

(3 – 9)

RS485 PORT

NOTE

THE LAST BCM SLAVE ON THE RS485 LOOP MUST HAVE ITS TERMINATION RESISTOR (T) ACTIVATED. REFER TO GF-115-C FOR MORE INFORMATION.

THE BIAS SWITCHES IN THE BMS II SHOULD BOTH BE TURNED “ON”.

SET BOTH

SWITCHES

TO “ON”

BIAS

SWITCHES

B (+)

P/O BCM (Y2)

NETWORK BOILER 1

A (-)

MODBUS

B (+)

P/O BCM (Y2)

NETWORK BOILER 2

A (-)

MODBUS

Figure 2-10. Sample RS485 (Modbus) Network For Benchmark or KC1000 Boilers

Figure 2-11. Sample RS485 (Modbus) Network For Modulex Series Boilers

2-16

INSTALLATION

RS232

(50 FT. MAX.)

EMS

T+/R+

SHLD

RS485 PORT

T-/R-

SEE NOTE 1

TO BOILERS CONTROLLED VIA RS485 NETWORK (4000 FT. MAX.)

485

PORT

RXD

TXD

+(B)

-(A)

SHLD

BMS II

232

PORT

ISO GND

TXD

RXD

GND

RS485-TO-RS232

CONVERTER

RS485

(4000 FT. MAX.)

ISO 12V

SEE

NOTE 2

T+

R-

R+

T-

SHIELD

4-WIRE RS485 PORT

DETAIL “A”

NOTES:

1. IF THE EMS CONTAINS A 4-WIRE RS485 PORT, SEE DETAIL “A”.

2. THE BMS II PROVIDES A 12V OUTPUT IF NEEDED TO POWER THE RS485-TO-RS232 CONVERTER.

RXD

TXD

+(B)

-(A)

SHLD

TO BOILERS CONTROLLED VIA RS485 NETWORK (4000 FT. MAX.)

BMS II

485

PORT

RS232 (50 FT. MAX.)

EMS

TXD

GND

RS232 PORT

RXD

232

PORT

ISO GND

EMS WITH RS232 PORT

EMS WITH ONLY RS485 PORT

2.9 RS232 WIRING AT THE BMS II

The BMS II comm unicates with an external Energy Mana gement System (EMS) or Building Automation System (BAS) ut ilizing the wiring terminals labe led RXD (Receive D ata), TXD (T ransmit Data) and 232 ISO GND (Is olated Ground). If the EMS does not contain an RS232 port, a RS485-to-RS232 Converter (AERCO Part No. 124943) is r equired to communicate with t he BMS II. If a Converter is required, it can be installed inside the wiring compartment of the BMS II, or installed exter nally. The BMS II provides an isolated 12 VDC output terminal (ISO 12V) which can be used to power AERCO’s RS485-to-RS232 Converter if needed. Refer to Figure 2-12 for sample network layouts.

Figure 2-12. Sample Network Connections To EMS

2-17

INSTALLATION

2.10 INTERLOCK WIRING

The BMS II is equipped with two interlocks designated Interlock 1 (INT 1) and Interlock 2 (INT 2). Since both interlocks m us t be c lo sed f or the BM S t o o per ate the bo iler pl ant, the associated wiring terminals are jumpered, prior to shipm ent. If desired, proving device switches can be c onnected to either place of the jumper. If used, interlock wiring connections are made as described in the following paragraphs.

CAUTION

DO NOT remove the factory-installed jumpers for INT1 or INT2 unless the respective Interlock is being connected to an external proving device. The boiler plant WILL NOT operate if one or both Interlocks remain open.

NOTE

If necessary, Interlock 1, Interlock 2 or both can be programmed to operate the boilers only when the outdoor air temperature f alls below the system start temperature. The selection is made with “SYS START INTLK” in the Relay Menu. The default is set to Interlock 1. See paragraph 3.11 for detail s.

interl ock in

Interlock 1 (INT 1) Wiring

Interlock 1 is often us ed with auxiliary equipm ent, such as air dam pers or flow switches. It can also be used as a general purpose interlockIf used, connect the end proving switch to INT 1 terminals 9 and 10 as shown in the wiring diagram in Appendix E.

Interlock 2 (INT 2) Wiring

Similar to Interlock 1, 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 prov ing switch to INT 2 terminals 11 and 12 as shown in the wiring d iagram in Appendix E.

2.11 SET BACK WIRING

The SET BACK terminals, shown in the wiring di agram in Appe ndix E, are used only when im plem enting a manually-controlled header temperature offset. If used, connect a dry contact switch across SET BACK terminals 13 and 14. See the sub-section entitled Ma nual Offset included in par agraph 3.8 (Field Adjust Menu),

2.12 RELAY WIRING

The BMS contains a System Start (SYS START) Relay, a Fault Alarm (FLT ALARM) Relay and an Auxiliary (AUX) R elay which can be conn ected to external monitoring or c o ntrol d ev ic es. The contacts for each of these relays are rat ed at 120 V AC, 5A an d are fus ed internall y at 5A with replace able f uses . The contact terminals for these relays are shown in the wiring diagram in Appendix E.

2-18

INSTALLATION

NOTE

The state of the SYS START, FLT ALARM and AUX Relays are controlled by options contained in the Relay Menu described in Chapter 3, paragraph 3.11.

System Start Relay

The state of the System Start (SYS ST ART) relay contacts are controlled b y the value set for the S YS START TEMP and SYS START OPTION in the Relay Menu. The contacts ar e closed either when the outdoor air tem perature is less than the System Start Tem perature ( SYS STAR T TEMP) or when there is a load, or both. T he default value for this temperature setting is 70°F. See paragraph 4.5 f or additional information.

Fault Alarm Relay

The state of the Fault Alarm (FLT ALARM) relay contacts are controlled by the option select ed for the FAULT ALRM RELAY, FAULT ALARM BLR and FAULT ALRM CLEAR in the Relay Menu. Contact closure can be set to: AL L FAU LTS, NO INTERLOCK, INTERLOCK 2 or INTERLOCK 1. The default f or this option is ALL FAULTS.

Auxiliary Relay

The state of the Auxiliary (AUX) relay contacts are controlled by the AUX RELAY CLOSE and AUX RELAY OPEN options selected in the Relay Menu. Contact closure can be set to occ ur either when all available boilers are at the 100% Fire Rate or for either when all boilers are at 100% Fire Rate or no boilers are available (all boilers faulted or turned off).

2.13 4 – 20 MA WIRING

The BMS II can accept a remote 4 – 20 m A current signal representing a setpoint. T his input is fused internally at 0.63A. Connect the signal leads to the 4-20 + and 4–20 – terminals. Refer to Chapter 4, paragraph 4.3 for Remote Setpoint programming using a 4 -20 mA input.

2-19

OPERATION

CHAPTER 3 - OPERATION

3.1 INTRODUCTION

The information in this Chapter provides a guide to t he operation of the BMS II using the controls and display mounted on th e front panel of the unit. This Chapter describes the basic procedure to navigate through the extensive ar ray of menus and options incor porated in the B MS II design. Des criptions for a ll menus and options are also provided.

3.2 FRONT PANEL OPERATING CONTROLS AND DISPLAYS

The front panel of the BMS II cont ains an vacuum fluorescent displa y (VFD) and an 8-key touch-pad. T he display and controls are illustrated and described in Figure 3-1 and Table 3-1 respectively.

Figure 3-1. BMS II Front Panel Controls and Displays

3-1

OPERATION

FUNCTION

ON Indicator

Green ON LED lights when the BMS II is enabled.

Table 3-1. BMS II Front Panel Controls and Displays

ITEM NO.

CONTROL, INDICATOR

OR DISPLAY

1 VFD Display The Vacuum Fluorescent Display (VFD) display consists of 2

lines each capable of displaying up to 16 alphanumeric characters. The information displayed includes:

• Startup Messages

• Alarm Messages

• Operating Status Messages

• Menu Selections

FAULT Indicator Red FAULT LED indicator lights when a BMS II alarm

condition occurs. An alarm message will also appear in the VFD display.

CLEAR Key

MENU Keypad

Turns off the FAULT indicator and relay if FAULT ALRM CLEAR is set to Manual and the fault is still active or no longer active. If FAULT ALRM CLEAR is set to Automatic and the fault is still active, this will also turn off the fault relay and indicator. In both cases the alarm message will remain until the alarm is no longer valid.

Consists of 6 keys which provide the following functions for the BMS II menus:

BACK

▲ (Up) Arrow When in one of the main menu categories, pressing this key

▼ (Down) Arrow When in one of the main menu categories, pressing this key

CHANGE

ENTER

Steps through the main menu categories shown in Figure 2-1. The Menu categories wrap around in the order shown.

Allows you to go back to the previous menu level without changing any information. Cont inuous ly pressing this key will bring you back to the default status display in the Operating Menu. Also, this key allows you to go back to the top of a main menu category.

will move you forward through the displayed menu category. If the CHANGE key was pressed and the menu item is flashing, press the ▲ arrow key increment the setting.

will select the displayed menu category. If the CHANGE key was pressed and the menu item is flashing, pressing the ▼ (Down) arrow key will decrement the selected setting.

Permits a setting to be changed (edited). A valid password must be entered before changing most menu items. When the CHANGE key is pressed, the displayed menu item will alternate in color with the background (reverse video). Pressing the ▲ or ▼ arrow key when this occurs will increment or decrement the displayed setting.

Saves the modified menu information in memory. The display will return to the normal state.

ON/OFF Key

3-2

Enables and disables BMS II operation.

OPERATION

3.3 BMS II MENU STRUCTURE

The BMS II incorpora tes an extens ive m enu str ucture which perm its the op erator to set u p, and c onf igure the unit. The menu s tructure c onsists of nine maj or menu cat egories as s hown in Figure 3-2. Each of the menus shown, contain opt ions which permit oper ating parameters to be view ed or changed. The menus are protected by two different password levels to prevent unauthorized use. These passwords provide access as follows:

• Password Level 1 (159) allows viewing of all menu categories. In addition, this Password Level allows

all Menu options to be changed, except for Calibration Menu options.

• Password Level 2 (6817) allows viewing and changing of the options contained in the Calibration

Menu. In addition, it allows all Level 1 menu categories to be viewed or changed. The Calibration Menu should only be used by factory-trained personnel.

Prior to entering the corr ect password, the options contained in al l of the Menu categor ies (except the Calibration Menu) can be viewed. However, except for Internal Setpoint Temperature (Field Adjust Menu), none of the viewable menu options can be changed.

Once the valid Leve l 1 (159) or Level 2 (6817) password is entered, the opt ions listed in the available menus can be viewed and changed, if desired.

Menu Processing Procedure

Accessing each m enu and option is accom plished using th e Menu Ke ys shown in Figure 3-1. Therefore, it is imperative that you be thorou ghly familiar with th e following basic steps before attem pting to perform specific menu processing procedures.

1. The BMS Il will normall y be in the Operating Menu and the VFD will d isplay the current unit status. Pressing the ▲ or ▼ arrow key will display the other available data in the Operating Menu.

2. Press the MENU key. The display will show the Setu p Menu which is the nex t menu categor y shown in Figure 3-2. This m enu conta ins the Pas sword optio n which m ust be entered if other menu opt ions will be changed.

3. Continue pressing the MENU key until the desired menu is displayed.

4. With the desired m enu d isp layed, press the ▲ arr o w k e y. The f ir st option in the selected menu will be displayed.

5. Continue pressing the ▲or ▼ arrow key until the desi red menu option is displayed. Press ing the ▲ arrow key will displa y the available m enu options in the Top-Down sequence. Press ing the ▼ arrow key will display the options in the Bottom-Up sequence. The menu options will stop when the last option is reached, go ing forward, or the first option is reached, going back wards. They do not wraparound after the first or last available option.

6. To change the value or setting of a displayed menu option, press the CHANGE key. The displayed option will appear in revers e video. Press the ▲ or ▼ arrow k ey to scroll through the availab le menu option choices for the option to be changed. The menu option choices do not wrap around.

7. To select and store a changed menu option, press the ENTER key.

3-3

OPERATION

OPERATING

SETUP

RS232

RS485

FIELD ADJUST

CONFIGURATION

TUNING

RELAY

CALIBRATION

LEVEL 1 PWD

LEVEL 2 PWD

Figure 3-2. BMS II Menu Structure

3-4

OPERATION

NOTE

Paragraphs 3.4 through 3.12 provide detailed descriptions of the options contained in each of the menus shown in Figur e 3-2. The menu options appear in the first line of the VFD display and the corresponding value or setting for the displayed option will appear in the second line of the display.

Refer to Appendix A for tabular summaries of all menu options showing the allowable entry ranges and default values,

3.4 OPERATING MENU

The Operating Menu disp lays a number of key operating p arameters for the BMS II: These parameters include:

HEADER TEMP, HEADER SETPO INT, OUTSIDE AIR TEMP, PE RCENT OF LOAD, I/O STATUS and RETURN TEMP.

All of the item s in this menu ar e “Read-Only” and do not allow personnel to c hange or adjust an y of the displayed param eters. Since this menu is “Read O nly”, it can be viewed at any tim e without entering a password. The Operating Menu options are described in the paragraphs which follow.

HEADER TEMP and PERCENT OF LOAD

The H EADER TEMP m enu option displays the actual water tem perature (°F) m easured by the Header Sensor c onnected to HDR SEN terminals 4 and 5 of the BM S II. If the Header Sensor is not installed, HDR SENS ERROR will ap pear in the first line of the display. T he red FAULT indicator will a lso lig ht. The Header Sensor MUST be installed for the BMS II to operate properly.

The PERCENT OF LOAD option shows the percent level going from the BMS II to each boiler in the boiler plant. It also shows the number of boiler units that are operating.

HEADER SETPOINT

This menu option is the se tpoint temperature to wh ich the control is set when operat ing in the Constant Setpoint, Remote Setpoi nt or Outdoor Reset Mode. W hen in the Constant Setpoint Mode, this value is equal to the Internal Setpoint s etting in the Co nfigur ati on Menu. W hen in the Rem ote Setpoin t Mode, this value is the setpoint equiv alent to the remote analo g signal or Modbus valu e supplied to the unit . When in the Outdoor Reset Mode, this is the derived value from the charts in Appendix D.

OUTSIDE AIR TEMP

The O UTSIDE AIR TEMP option shows the outd oor air temperature (°F) measured b y the Outdoor Air Sensor. This sensor is connected to OUT AIR SENS t erm inals 1 and 2 of the BMS II. If the Sensor is not connected, the second line of the display will sho w NOT CONNECTED. The Outdoor Air Sensor MUST be connected when operating in the Outdoor Reset Mode.

3-5

OPERATION

I/O STATUS

I/O (Input/Output) STATUS is displayed as a hexadecimal number. The meaning of each bit is as indicated below. The h igher 4 bits, or most significant digit (MSD), indicate which inputs are activated. The lower 4 bits, or least significant digit (LSD), indicate which relay outputs are activated.

MSD: Bit 7 =(empty) Bit 6 = Interlock 1 Bit 5 = Interlock 2 Bit 4 = Setback LSD: Bit 3 = (empty) Bit 2 = Sys Sta rt Relay Bit 1 = Fault Relay Bit 0 = Aux Relay

RETURN TEMP

The RETURN TE MP (°F) option is displayed only if an option al Return Sensor is installed in the boiler water return line. When instal led, it is conn ected to ter m inals 5 and 6 on the BMS II. T his option al sensor is used for external monitoring purposes ONLY.

3.5 SETUP MENU

The SETUP MENU per mits the operator t o set the unit pass word which is requi red to change an y of the menu options. To prevent unauthorized use, a previously entered password entry will time-out after 1 hour. Therefore, the password must be reentered when required. In addition to permitting password entries, the Setup Menu is also used to ent er the date and time. Descriptions of the Setup Menu options follow.

ENTER PASSWORD

The ENTER PASSWORD option allows the Level 1 (159) or Level 2 (6817) to be entered. Once the valid Level 1 password (15 9) is entered , options in all Menus, exc ept the Calibr ation Menu, can

be changed. The Level 2 password (6817) must be entered to view or change options in the Calibration Menu. Onl y

factory trained personnel should use this Menu.

Date and Time Menu Options

The Setup Menu options associated with date and time are as follows:

• SET MONTH 01 -12

• SET DATE 01 – 31

• SET YEAR 00 – 99

• SET HOUR 00 -23

• SET MINUTE 00 – 59

• SET DAY OF WEEK SUNDAY TO SATURDAY

3-6

OPERATION

3.6 RS232 MENU

The RS232 MENU options permit the BMS II to communicate with an external Energy Management System (EMS) or Computer via the RS232 Port wiring terminals labeled RXD, TX D , ISOG ND on the BMS II. The RS232 Menu options ar e used to select the RS232 Mode, Baud Rate, Modbus Address, Net work Timeout period and Modbus Pass-Thru feature for the BMS II.

RS232 MODE

The RS232 MODE option allows the se lection of the type of comm unication desired at the RS232 p ort: NORMAL (dumb term inal) or MODB US SLAVE ( Modbus Protocol). W hen the BMS II is bei ng controlle d by an external Energy Management System (EMS), via Modbus Protocol, set this option to MODBUS SLAVE (default). If the EMS being used contains only a RS485 port, a RS485-to-RS232 Converter is required.

RS232 BAUD RATE

The RS232 BAUDRATE option sets the communication Baud Rate between the BMS II and the

EMS. Available settings include 2400, 4800, 9600 (default), or 19200. Both the BMS II and EMS MUST be set to the same baud rate to enable the communication link.

MODBUS ADDRESS

The MODBUS ADDRESS option sets the BMS II address when operating as a Slave on a Modbus Network. The address can be set from 128 (default) to 247.

NETWORK TIMEOUT

When the BMS II is operating in the R emote Setpt mode via Modbus, the NETWORK TIMEO UT option defines the maximum time (seconds) allowed before re-sending the setpoint information. If the information is not re-sent with in t his t im e perion, the BMS w ill def ault to its Failsafe m ode of operat ion set in the Configuration M enu. The network tim eout period is selec table from 005 to 240 seconds (Def ault =

060).

MODBUS PASS THRU

When enabled, the MO DBUS PASS T HRU option all ows an EMS or computer , communicating f rom the RS232 port, to access inform ation from the boilers connected on t he RS485 port of the BMS II. W hen enabled, it allows boiler monitoring and setup but not direct control of the boilers

3.7 RS485 MENU

The BMS II comm unicates with the conn ected AERCO network boilers via its RS485 ( Modbus) Port (485 B+ and 485 A-). Ther efore, the RS485 Menu contains the options necessary to enable communic ation between the BMS II and the connected network boiler slaves. Each network boiler on the Modbus network must be assigned a unique address to enable communication.

The RS485 Menu options are used to select the RS232 Baud Rate, Min./Max. Range of Slave Addresses, Total Number of Network ed Boiler s, T ype of Modbus C ontr ol and the U n iqu e Ad dres s for eac h Networked Boiler. Descriptions of these options follow.

The BMS II can autom atically detect bo ilers within the “”Min Slave Addr” and “Ma x Slave Addr” r ange, or you can program the boiler addresses in the order desired. AERCO recommends programming the addresses in the des ired order. W hen programming the boiler addres ses, set the “Min Slave Ad dr” and “Max Slave Addr” to zero.

3-7

OPERATION

RS485 BAUD RATE

The RS485 BAUDRATE option Sets the communication baud rate for the Modbus network

between the BMS II and the Boilers connected to the RS485 terminals [B(+), A(-)]. Available settings are 2400, 4800, 9600 (default), or 19200.

MIN SLAVE ADDR

The MIN SLAVE ADDR sets the M inimum Slave Address for the Boi lers being controlled on the RS485 (Modbus) Network when automatic boiler detection is desired; otherwise, leave set to zero. Allowable entry range is 000 to 127 (default = 000).

MAX SLAVE ADDR

The MAX SL AVE ADDR Sets the Maximum Slave Addr ess for the Boilers bein g control led on the R S485 (Modbus) Network when automatic boiler detection is desired; otherwise, leave set to zero. Allowable entry range is 000 to 127 (default = 000).

NUMBER NETWK BLRS

This menu option sets the Number of Network Boilers connected to the BMS II RS485 (Modbus) terminals. Up to 32 Boilers can be connected to the Network (default = 02).

MODBUS CNTL TYPE

This menu option sets the Modbus Control Type to ROUND ROBIN or BROADCAST. Only ROUND ROBIN can be used at this time. When set to ROUND ROBIN, each networked boiler is addressed individually in sequence. BROADCAST is currently not used for the BMS II.

NETW BOILER Xx ADDRESS= Yyy (Where Xx = 01 – 32; Yyy = 001 – 127)

Up to 32 Network Boilers c an be accomm odated on the Modbus Network. Eac h Boiler mus t be assigned a unique address on the net work ranging from 001 to127. No addresses should be ent ered if automatic boiler detection is desired. Simply set the MIN SLAVE ADDR and MAX SLAVE ADDR t o the minimum and maximum address range of the boilers. To program boiler addresses in the order you desire, en ter them here and set the MIN SLAVE ADDR and MAX SLAV E ADD R t o zero.

3.8 FIELD ADJUST MENU.

The FIELD ADJUST MENU contains the most extens ive list of options com pared to the other 8 Menu categories. The optio ns in t his menu allow you to adjust impor tant par ameters to suit the specif ic ne eds of your BMS II installation. Included are options to select the Header Mode and Temperature Limits, Internal Setpoint, Building Ref erence Temperatur e, Reset Ratio and Rem ote Signal. In addit ion, the Field A djust Menu conta ins a series of options which can be used to set up a H eader Setpo int Off set Schedule f or an entire week. Descriptions of the Field Adjust Menu options :

HEADER SET MODE

The HEADER S ET MODE option s ets the Header Setpoint selec tion method for the BMS II. Allo wable selections are: CONSTANT SETPT, OUTDOOR RESET or REMOTE SETPT. (Default = CONSTANT SETPT).

HDR HIGH LIMIT

The HDR HIGH LIMIT option sets the maximum temperature setting allowed for the Header Setpoint. This setting also defines the 20 mA temperature equivalent when operating in the Remote Setpoint Mode using a 4 – 20 mA signal. The allowable setting range is from the HDR LOW LIMIT to 220°F. (Default = 200°F).

3-8

OPERATION

HDR LOW LIMIT

The HDR LOW LIMIT menu option sets the minimum temperature s etting allowed for the Header S etpt. This setting also d efines the 4 m A temperature eq uivalent when op erating in the Remote Setpoint Mode using a 4 – 20 mA signal. The setting range is from 40°F to the HDR HIGH LIMIT. (Default = 40°F).

INTERNAL SETPT

The INTERNAL SETPT temperature is the HEADER SETPT used when CO NSTANT SET PT is selected for the HEADER SET MOD E or when the BMS II oper ates in the Fa ilsaf e Mode a nd CONST ANT SET PT is selected as the FAIL SAFE MODE setting in the Configuration Menu.

RESET RATIO

This menu option is displayed only if the HEADER SET MODE is set to OUTDOOR RESET. The RESET RATIO option setting def ines the rat io of the increase in H eader tem per ature w ith res pect t o each degre e

decrease in Outdoor temperature starting from the Building Reference Temperature (BLDG REF TEMP). The Reset Ratio is adjustable from 0.3 to 3.0. (Default = 1.2). The Reset Ratio Charts provided in

Appendix D are suitable for most applications. However, if a special reset schedule is desired, the calculation method described in Appendix D must be used.

BLDG REF TEMP

The BLDG REF TEMP menu option is only displayed when the HEADER SET MODE is set to OUTDOOR RESET. This option is used to set the Buildi ng Reference Temperature (BLDG REF TEMP)

to the desired value from 40°F to 220°F. (Default = 70°F).

REMOTE SIGNAL

The REMOTE SIGNAL menu opti on is onl y displa yed when the HEADER SET MODE is set t o REMOTE SETPT. When displayed, this option is used to select the controlling remote signal: to 4 – 20 mA or

MODBUS. (Default = 4-20 mA)

OFFSET ENABLE

The OFFSET ENABLE m enu option is used to turn ON, or turn OFF the Setpoint Tem perature Offset feature. (Default = OFF)

Offset Menu Options

The Field Adjust Menu cont ains a s eries of m enu options wh ich perm it an of fset sc hedu le to be s et up for a 7-day period (Sunday through Saturday). For each day

• OFFS TEMP [Setpoint Offset Temperature (-50°F to +50°F)]

• ON HOUR (00 to 23)

• ON MINUTE (00 to 59)

• OFF HOUR (00 to 23)

• OFF MINUTE (00 to 59)

Normally, if an Offset Schedule is used, it is controlled automatically using the set-up procedures described in the paragraph titled “Setting Up An O ffset Reset Sched ule” However, if desired, the header offset can be contro lled manually by conn ecting a switch acros s the SET BACK wir ing terminals 13 and 14 as shown in the wiring d iagram in App endix E. If a manual of fset is used, ref er to the paragraph titled “Manual Offset”.

(Sunday – Saturday), these options include:

3-9

OPERATION

Setting Up An Offset Schedule

The basic steps in volved in setting up an autom atic re set schedu le consist first selec ting the temperat ure offset and then entering the start and stop tim es for which the offs et will be in effec t. Keep in mind that the BMS II uses a 24-hour clock (00;00 to 23:59) The steps are outlined below. In this example, the setpoint temperature is being offset -15°F on Sunday from 12:01 AM (00:01) to 8:00 AM (08 hrs)

1. Scroll through the FIELD ADJUST MENU and select O FF SET ENA BL E. Set this option to ON.

2. Next, scroll to SUN OFFS TEMP and set the Offset Temperature to -15°F.

3. Press the ▲ arrow key. SUN ON HOUR will be displayed. Set the HOUR to 00.

4. Press the ▲ arrow key again. SUN ON MINUTE will be displayed. Set the MINUTE to 01.

5. Press the ▲ arrow key again. SUN OFF HOUR will be displayed. Set the HOUR to 08.

6. Press the ▲ arrow k e y again. SUN OFF MINUTE will be displayed. Set the MINUTE to 00.

7. Repeat steps 2 through 6 to s et offset schedules for the remaining days of the week . Different offset temperatures and ON/OFF times can be set for each day if desired.

Manual Offset

If a switch is connected across terminals 13 and 14 on the BMS II, the offset temperature can be controlled manually. To set up a manual offset schedule, proceed as follows:

1. Scroll through the FIELD ADJUST MENU and select O FF SET ENA BL E. Set this option to ON.

2. Next, scroll to SUN OFFS TEMP and set the desired Offset Temperature. A different Offset Temperature can be set for each day if desired.

3. Scroll through the remaining days of the week and set the desired offset temperature for each day.

Once programmed as des cribed above, closin g the SET BACK s witch will enab le the program med OFFS TEMP for that da y. Open ing the SET BA CK s witch will disab le the OFFSET and the Header Setp oint will return the selected I NT ER N AL SETPT temperature.

3.9 CONFIGURATION MENU

The Configuration Menu contains options which set the Boiler operating modes start/stop levels and maximum allowable p ower input. In a ddition, it con tains a Fai l Safe Mode feat ure which is used to sel ect the default mode when the controlling input source is lost.

BOILER OP MODE

The BOILER OP MODE menu option sets the control operation method for the BMS II. to either SEQUENTIAL or PARALLEL MODE.

Parallel Mode

When PARALLEL MODE is selected, all boilers are simultaneously started by the BMS II. The BLR START LEVEL and BLR STOP LEV EL set in the Configur ation Menu (s ee below) have no ef fect when in

this mode. Regardless of t he number of Boilers in t he plant, the turn-do wn ratio in the Parallel Mode is fixed at 20:1 for KC1000 S eries Boilers (except 11:1 f or KC Low NOx). For Benchmark Series Boilers, the turn-down ratio is fixed at 20:1 for BMK2.0, 2.0LN, and 1.5LN Boilers. However, for BMK3.0LN Boilers the turn-down ratio is fixed at 15:1.

3-10

OPERATION

Sequential

When SEQ UENTIAL MOD E is selected it provides a gr eater turn-down ratio than the PAR ALLEL MODE. This is due to the fact that the turn-down ratio in the Sequent ial Mode is equal to the num ber of Boilers multiplied by the 20 for KC1000 Series and Benchmark Series units.

In Sequential Mode, each boiler is started one at a time based on the load and start/stop levels programmed in the BMS. T he BMS will start a single Modulex boiler when there is a load dem and or a Benchmark or KC1000 boil er when the boiler start level is reac hed. Once the fir st boiler reac hes twicethe start level, a second boiler will be started and the load will be distributed evenly between the two boilers.

For instance, if a s tart level of 25% is c hosen, when t he firs t boiler reaches 50% a sec ond boiler will start (after a 30 second delay), and t he BMS w ill distribute the load 25% for eac h boiler. If the firing rate of both boilers reach a combined v alu e equa l to 3 times the start level, a thir d bo iler is s tar ted b y the BM S (af ter a 30 second delay), and t he load will be distributed across all three boilers. This sequence will cont inue based on load demand and the number of boilers connected to the BMS.

SYS INTLK CONFIG

This option selects when the System Start Interlock takes effect. The available choices are START ENABLED (default) and ALW AYS ENABLED. If STAR T ENABLED is selecte d, the BMS II will wait 30

seconds after the System Start Relay is acti vated before looking for a cl osure across the System Start Interlock selected. (See SYS START INTLK in the RELAY MENU). If no closure is seen after 30 seconds, the BMS II will stop the boilers and display a fault message and activate the fault relay. ALWAYS ENABLED will cause a fault whenever the interlocks are opened.

NOTE:

The BLR START LEVEL and BLR STOP LEVEL must be programmed in the BMS II by the user. Refer to Appendix I for additional information on START/STOP LEVELS.

BLR START LEVEL

The Boiler Start Level (BLR START LEVEL) sets the per centage level at which the Bo ilers connected t o the BMS II will start. The allowable entry range is from 1% to 100% (default = 20%).

BLR STOP LEVEL

The Boiler S top Level (BLR STO P LEVEL) menu option s et the percentage level below which th e Boilers connected to the BMS II will stop. The allowable entry range is from 1% to 40% (default = 16%).

MAX POWER INPUT

The Maximum Power Input ( MAX POWER INPUT ) sets the maximum Percent Le vel that the BMS II can ramp up the boil ers to. This may be useful in an o ver-sized boiler plant. The allowable entr y range is from 50 % to 100% (default = 100%).

FAIL SAFE MODE

Selects the desired op erating mode of the BMS II if it loses its Outdoor Air Sensor when operating in the Outdoor Reset mode, or loses its Remote Signal when operating in the Remote Setpoint mode. If CONSTANT SETPT is selec ted as the FAIL SAF E MODE, the BMS II will operat e the bo iler s to ac hie ve a Header Setpt equal to t he programmed Inter nal Setpt. If SHUTDOWN is selected, it will shut do wn a ll t he boilers.

NOTE:

If the Header Sensor is lost, the BMS II will shut down all the boilers.

3-11

OPERATION

3.10 TUNING MENU

The TUNING MENU options are used to select PID (Proportional Integral Derivative) control functions incorporated in the BMS II. These functions gover n temperature control and response of the ‘BMS II to the boiler system. Since each system is different, these PID controls can tune the BMS II to the characteristics of your specific installation. The factory defaults preset by AERCO work well for most applications. In instanc es when there is a large error between the setpoint and the actu al supply water temperature, the BMS II may appear to require PID tuning. However, it is best to observe BMS II 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 TUNING MENU optio ns include Proportional Bandwidth, Integral Gain, Derivative Gain an d Header Temperature Deadband.

PROPORTIONAL BND

The Proportional Band width (degrees) represen ts the imm ediate respons e to a setpo int error. T his value is the temperature dev iation from setpoint f or which a 100% output c hange is desired. This is a part of the PID output calculation in the BMS II.

For instance, prop ortional band of 50°F is chose n. The header temperature s etpoint 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_____ Prop Bandwidth

Therefore:

X 100% = Firing Rate

50 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.

X 100 = Firing Rate in %

INTEGRAL GAIN

The Integral Gain (repeats/min) responds to the setpoint error over time. Integral references the proportional band error s ig nal and s ums itself with respect to the per iod of time the error exists. Based on the previous example, if the i ntegr al ga in is 0.15 rep e ats/m inute at a f iring rate of 60% an d a t em perature error exists for one 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.

3-12

OPERATION

DERIVATIVE GAIN

Derivative Gain is a f unction of tim e. It senses and responds to th e rate of change of the setpoint error . A slow rate of change will yield a sm all amount of deriv ative gain. Conversel y, a fast rate of change wil l 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.

HDR TEMP DEADBND

This is the temperature deviation al lowed from setpoint with in which the Percent Leve l output will remain constant. The default value is 5°F.

3.11 RELAY MENU

As the name implies, the RELAY MEN U contains the options necessary to selec t the actions performed by the System Start (SYS START), Fault Alarm (FLT ALARM) and Auxiliary (AUX) Relays in the BMS II.

SYS START TEMP

If an Outdoor Air S ensor is installed, th is menu option is used to select the Outdoor Tem perature below which the System Start Relay is allowed to activate (close), provided that the SYS START OPTION conditions specified below are satisfied. The percent level will always remain at 0% until the System Start Relay is activated The System Start R e lay will open if the Ou tdo or temperature is abo ve th e va lue set f or this option.

SYS START OPTION

The SYS START OPTION can be set to TEMP ONLY or TEMP AND LOAD. Selecting TEMP ONLY means the System Start Relay wil l be active wh enever the Outdoor Temperature f alls below the S ystem Start Temperature (SYS START TEMP).

Selecting TEMP AND LOAD will cause t he System Start Relay to activate if the Outdoor Temperature falls below the S ystem Start Temperature and the Percent of Load (Operating Menu) is at or above the LOAD START PCT (Calibration Menu). It will deac tivate (open) the S ystem Start Rela y when the Percent of Load goes below

the LOAD START PCT .

SYS START INTLK

The SYS START INTLK selects the Interlock associated with the System Start Relay activation when SYS INTLK CONFIG is set for START ENABLED. Available settings include, INTERLOCK 1 (default), INTERLOCK 2, or INTERLOCK 1&2.

AUX RELAY OPEN

The AUX RELA Y OP EN se tting is the Perc ent Le vel o utput bel ow whic h the AUX Re lay will ope n if it was closed due to the conditions described by the AUX RELAY CLOSE setting.

AUX RELAY CLOSE

This determines the cond ition for which the AUX relay will close. If 100% FIR E RATE is selected, the AUX relay will close wh en all av ailable b oilers are f iring at 10 0%. If 100% AND OFF (default) is selected, it wil l close when all available boilers are f iring at 100 % as well as when no boil ers are availabl e and the boiler plant is below setpoint. This relay can trigger emergency heat in the latter case.

3-13

OPERATION

FAULT ALRM RELAY

This setting tells the BMS II which faults should activate the fault alarm relay. The default is ALL FAULTS. If NO INTERLO CK is s elected, the Fau lt Alarm Rela y will not activate when the interlocks ar e

opened, however t he BMS II will still shut do wn all boiler s. If INTERLOCK 2 is selected, the Fault Alarm Relay will only activate w hen Interlock 2 is opene d and not when Interlock 1 is opened. Sim ilarly, when INTERLOCK 1 is selected, the fault alarm relay will only activate when Interlock 1 is opened and not when Interlock 2 is opened.

FAULT ALARM BLRS

This selection tells the BMS II whether to activate the fault alarm relay if a boiler connected to it is faulted.

FAULT ALRM CLEAR

Selecting MANUAL will latch the fault al arm relay if a f ault conditi on occur s and goes away. T he CLEA R key must be pushed to dea c tivat e t he re lay. If set to AUT O MAT IC , the f ault rel a y wil l o pen when t he fault condition goes away.

3.12 CALIBRATION MENU

NOTE

The Level 2 Password (6817) must be entered in order to view or change options in the Calibration Menu.

The optio ns contained in this Menu should only be u sed by factory-trained personnel, si nce it contains options that could adversely affect system operation if incorrectly set.

HDR SENS OFFSET

This option sets the offset temperature value that is added to t he displayed Header Sensor temperature in the event that it is dif ferent from a trusted ref erence Header temperature r eading and needs cali bration. Be sure the Header Senso r is properly installed before range is ±10°F

adjusting this offset value. T he allowable offset

OUTD SENS OFFSET

This offset value is added to the Outdoor Sensor temperature displayed in case it is different from a trusted reference outdoor temperature reading and needs calibration. Be sure the Outdoor sensor is properly installed before adjusting this value. The allowable offset range is ±10°F.

4 - 20 MA OFFSET

This offset value is adde d to the 4 – 20 mA Rem ote signal input to t he BM S II in the event that calibra tion is needed. The allowable offset range is ±1.0 mA.

RETN SENS OFFSET

This offset value is add ed t o the R et urn S ens or temperature displ a yed in c as e it is dif f er ent f r om a trus ted reference return temperature reading and needs calibration. Be sure the Return Sensor is properly installed before adjusting this value. The allowable offset range is ±10°F

3-14

OPERATION

RAMP UP %/MIN

This sets the maximum Per cent Level ramp up rate for the B MS II. The Percent Level output will follow the PID output if i t is slower than this rate. The def ault setting is 20% per minut e. Refer to the fol lowing example:

RAMP UP %/MIN.

20 5 Minutes 40 2.5 Minutes 50 2 Minutes

Time Required To Go

From 0% To 100%

NOTE

To turn off the RAMP UP %/MIN function, set the value to zero (0).

RAMP DOWN %/MIN

This sets the maximum Percent Level ramp down rate for the BMS II. The Percent Level output will follow the PID output if it is slower than this rate. The defau lt setti ng is 200% p er m inute. Refer to the follo wing example:

RAMP DOWN %/MIN.

200 30 Seconds 300 20 Seconds 100 1 Minute

Time Required To Go

From 100% To 0%

NOTE

To turn off the RAMP DOWN %/MIN function, set the value to zero (0).

LOAD START PCT

When the SYS START O PTION is set to TEMP AND LOAD, this parameter determ ines the percent of load value at or above w hich the “load” portion of the param eter is true. This value cannot exceed the BLR START LEVEL set in the Configuration Menu The default setting is 1%.

LOAD STOP PCT

When the SYS START O PTION is set to TEMP AND LOAD, this parameter determ ines the percent of load value at or below which the “ load” portion of the parameter is false. T his value cannot exceed the BLR STOP LEVEL set in the Configuration Menu nor the LOAD START PCT. The default is 0%.

RESET DEFAULTS

This option is use d to set the BMS II to its factory default values. Make sure that you want to r eset all options before activating

3-15

OPERATION

1. SETUP MENU

ENTER PASSW O R D

Enter 159

2. RS485 MENU

Enter this menu if there are more than 2 boilers (default), otherwise go to step 3

NUMBER NETW BOILERS

This setting is preset to 2. If more than 2 Boilers (default), enter number (03, 04, etc)



NETW BOILER 01

ADDRESS= 001

Address 001 and 002 are preset. Enter other Network Addresses if required (003, 004, 005, etc.)

3. FIELD ADJUST MENU

If Setpt is other than 160°F (default), enter this menu; otherwise go to step 4



INTERNAL SET PT

Enter Setpoint temperature

4. CONFIGURATION MENU

If BLR START LEVEL=20% & BLR STOP LEVEL=16%, skip this menu.



BLR START LEVEL

Enter Boiler Start Level Percent (default = 20%). See Appendix I.



BLR STOP LEVEL

Enter Boiler Stop Level Percent (default = 16%). See Appendix I.

5. CALIBRATION MENU

Required Only For Modulex Installations



LOAD START PCT

Enter a Value 2% Below the BLR START LEVEL

3.13 BMS II QUICK-START GUIDE

NOTE

The “Quick Start” procedures in paragraph 3.13 assume that the user fully understands the BMS II menu structure and is able to navigate through these menus to display and change menu options. Refer to paragraph 3.3 for menus and menu processing procedures.

The following procedure as sumes that you are pro gramming a ne w BMS II that has the “Factor y Default” settings currently stored in memory.

If you wish to restore a “Field-Programmed” BMS II to the “Factory Default” values, go to the CALIBRATION MENU and select the RESET DEFAULTS option. ALL SET TINGS, EXCEPT TIME AND DATE, WILL RETURN TO THEIR FACTOR DEFAULTS.

This paragraph provides the instructions to quickl y start up and operate the BMS II in some of the most commonly used modes. The ranges and default values of the Menu Options used in the following instructions are summarized in Appendix A.

CONSTANT SETPT MODE (Default)

MENU & OPTION ACTION







3-16

OPERATION

1. FIELD ADJUST MENU

HEADER SET MODE

Set to REMOTE SETPT

HDR HIGH LIMIT

Enter the maximum temperature for the Remote Setpoint input = 200°F



40°F



REMOTE SIGNAL

Select 4-20 mA (default) or MODBUS



2. CONFIGURATION MENU



FAIL SAFE MODE

Set to CONSTANT SETPT if you want to maintain a Constant (Default = SHUTDOWN)

3. CALIBRATION MENU

Required Only For Modulex Installations



LOAD START PCT

Enter a Value 2% Below the BLR START LEVEL

REMOTE SETPT MODE

Perform the procedur e described for the CONSTANT SETPT MODE and t hen continue with the steps described below:

MENU & OPTION ACTION





HDR LOW LIMIT



(this will be the temperature equivalen t to a 20 m A inp ut) Default

Enter the minimum temperature for the Remote Setpoint input (this wi l l be the temperature equivalent to a 4 mA input) Default =

Setpoint temperature in the event that the Remote s ignal is lost.

3-17

OPERATION

1. FIELDADJUST MENU

HEADER SET MODE

Set to OUTDOOR RESET

RESET RATIO

Enter a different value, if required (default = 1.2). Refer to Appendix C.



BLDG REF TEMP

Enter the desired Building Reference Temperature. Default = 70°F (Refer to Appendix C).



2. CONFIGURATION MENU



FAIL SAFE MODE

Set to CONSTANT SETPT if you want to maintain a Constant 

3. RELAY MENU

SYS START TEMP

Enter the outdoor temperature below which the system will be activated.



4. CALIBRATION MENU

Required Only For Modulex Installations



LOAD START PCT

Enter a Value 2% Below the BLR START LEVEL

OUTDOOR RESET MODE

Perform the procedur e described for the CONSTANT SETPT MODE and t hen continue with the steps described below:

MENU & OPTION ACTION





Setpointt temperatur e in the event that the Outdoor Sensor s ignal is lost. (Default = SHUTDOWN)

After completing the “Quick Start” procedure for any of the modes des cribed above, check to ens ure that the “ON” LED is lit. If it is not, press the ON/OFF key to activate the BMS II.

For further programming details, refer to Chapter 4.

3-18

PROGRAMMING BMS II

CHAPTER 4 - PROGRAMMING BMS II OPERATING MODES

4.1 INTRODUCTION

Prior to programming, the BMS-II must be mounted and all required wiring completed. In addition, all connections should b e check ed for ac curac y. Once these it ems are completed , the BM S-II is ready to be programmed for the desire d mode of operation for the boiler plant. The steps for programming will vary somewhat, depending on whether the Outdoor Reset, Remote Setpoint or Constant Set point operating mode is selected.

NOTE

The Level 1 Password (159) must be entered prior to programming the BMS II for operation in any of the modes described in paragraphs 4.2 through 4.4. Refer to Chapter 3 for instructions on password entry and basic menu processing procedures.

4.2 OUTDOOR RESET MODE

The Outdoor Reset mode operates based on outs ide air temperatur e. In this mode, the header supply water temperature will vary up or do wn in accor dance with outside air t emperatur e. Ther efore, in ord er to set up and operate in this mode, an outdoor air sensor MU ST be installe d. This m ode requires entries to be made in the Field Adjust Menu, Conf iguration Menu and Relay Menu. For Modulex installations an entry will also be required in +the Calibration Menu. The required entries are as follows:

• FIELD ADJUST MENU

o HEADER SET MODE o RESET RATIO o BLDG REF TEMP

• CONFIGURATION MENU

o BOILER OPERATING MODE o BLR START LEVEL o BLR STOP LEVEL

• RELAY MENU

o SYSTEM START RELAY TEMP

• CALIBRATION MENU (Required Only For Modulex Installations)

o LOAD START PCT

The programming set-up instructions for the above menu options are provided in paragraphs which follow.

4-1

PROGRAMMING BMS II

Selecting Outdoor Reset Mode

The Outdoor Reset Mode is selected using the Header Set Mode option in the Field Adjust Menu as follows:

1. Using the keypad on the BMS II, press the MENU key, until FIE LD ADJUST MENU appears in the display.

2. Using the ▲ or ▼ arrow key on the keypad, scroll through th e menu until HEADER SET MOD E is displayed in the first line of the VFD display. The second line of the display will sho w the currently selected Header Set Mode (CONSTANT SETPOINT, OUTDOOR RESET or REMOTE SET PO IN T).

3. If OUTDOOR RESET is not displa yed in the s econd line of the d ispla y, press the CHANGE key. The VFD display will switch to a reverse video format indicating that a change is in process.

4. Using the ▲ or ▼ arrow key, select OUTDOOR RESET.

5. Press the ENTER key to store the change. The rever se video displa y will revert to the nor mal displa y format indicating that the change has been store in memory. While still in the Field Adjust Menu, proceed to the next paragraph and continue the set-up procedure.

Determining Reset Schedule

There are two variables that must be considered when determining Reset Schedule: Reset Ratio and Building Reference Temperature. There are two methods for determining the Reset Ratio. The first method utilizes the Reset Ratio Charts provided in Appendix C. This method is suitable for most installations. Ho wever, if a special R eset Sc hedu le is des ired for r eheat or ot her purposes , the c alculation method must be used. W hen using this method, both Reset Ratio and Buil ding reference Temperature must be calculated. Refer to Appendix C for further instructions concerning both of these methods.

Once the Reset Rati o and Building Reference Temperature have bee n determined, proceed to the next paragraph and enter these options.

Entering Reset Ratio and Building Reference Temperature

The Reset Ratio and Buildi ng Referenc e T emperatur e (BLD G REF T EMP) are also entered using options contained in the Field Adjust Menu. These parameters are entered as follows:

1. To enter the required Reset Ratio, scroll through the Field Adjust Menu and select RESET RATIO.

2. If the desired ratio is not displayed, press the CHANGE key. The disp lay will switch to a reverse video format indicating that a change is in process.

3. Select the required Reset Ratio using the ▲ or ▼ arrow key.

4. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory.

5. Next, scroll through the Field Adjust Menu and select BLDG REF TEMP.

6. If the desired BLDG R EF TEMP is not d is pla yed, pr es s the CHANGE key. Th e d i s p lay will switch t o a reverse video format.

7. Select the required BLDG REF TEMP using the ▲ or ▼ arrow key.

8. Press the ENTER key to store the change. The reverse video disp lay will revert to the normal VFD display format.

9. This completes the required entries in the Field Adjust Menu. Proceed to the next paragraph and select the Boiler Operating Mode.

4-2

PROGRAMMING BMS II

Selecting Boiler Operating Mode

The Boiler Plant can be set for either Parallel or Sequential Mode operation. The Boiler Operating Mode is selected in the Configuration Menu as follows:

1. Using the keypad on the B MS II, pr ess the MENU ke y, until CONFIGURATION MENU appears in the display.

2. On the keypad, press the ▲ arrow key once. BOILER OP MODE will be displa yed in the f irst line of the VFD display. The second line of the display will show the currently selected Boiler Operating Mode. (SEQUENT IAL MO D E or PARALLEL MODE). The default setting is SEQUENTI AL MO D E.

3. If the desired Operating Mode is not displayed in the second line of the display, press the CHANGE key. The VFD display will switch to a reverse video format indicating that a change is in process.

4. Using the ▲ or ▼ arrow key, toggle the display to the desired setting.

5. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been stored in memory.

Entering Boiler Start and Boiler Stop Levels

The Boiler (BLR) Start and Boiler Stop Levels are also entered in the Configuration Menu. Refer to Appendix I to determine the correct Start and Stop levels for your installation. Enter the appropriate values in the Configuration Menu as follows:

1. Using the ▲ or ▼ arrow key on the keypad, scroll thr ough the Configur ation Menu un til BLR ST ART LEVEL is displayed along with the current setting (default = 20%).

2. If the desired B oiler Start L evel is not displa yed, pres s the CHANGE key. T he d is pla y wil l s witch to t o a reverse video format.

3. Select the desired Boiler Start Level using the ▲ or ▼ arrow key.

4. Press the ENTER k ey to store the changed Start Level.. T he reverse video display will revert to th e normal VFD display format.

5. Next, scroll through the menu until the BLR STOP LEVEL is displayed along with the current setti ng (default = 16%).

6. If the desired Boiler Stop Leve l is not displayed, rep eat steps 2, 3 and 4 above a nd enter t he desired Stop Level.

Entering System Start Temperature

In order to set up the Outdoor Reset M ode, the Syste m Start T emperatur e mus t be entered. The System Start Temperature is the o utside air temperature at which the boiler plant b egins to operate. The fac tory default value for the System Start Temperature (SYS START TEMP) is 70°F. However, temperatures from 32°F to 120°F can be selected using the ▲ and ▼ arrow ke ys on the BMS II keypad. Proceed as follows:

1. Press the MENU key until RELAY MEN U appears in the display.

2. Press the ▲ arrow key once. SYS START TEMP will be d isplayed along with th e current setting for the System Start Temperature.

3. Press the CHANGE key to change the displayed tem perature. The display will switch to a reverse video format.

4. Select the desired System Start temperature using the ▲ or ▼ arrow key.

5. Press the ENTER k ey to store the cha nged temperatu re. The reverse vide o display will re vert to the normal VFD display format.

4-3

PROGRAMMING BMS II

6. If the boiler plant contains Modulex Boilers, proceed to the next paragraph (Entering Load Start Percent).

7. If the boiler plant Does Not contain Modulex Boilers, the BMS II is now fully programmed for operation in the Outdoor Reset Mode.

Entering Load Start Percent (Required Only for Modulex Installations)

If the boiler plant conta ins Modulex boilers, th e LOAD START PCT opt ion in the Calibration Me nu must be entered. This opt ion should be set 2% below the BLR START LE VEL set in the C onfiguration Menu. Proceed as follows:

1. Press the MENU key until CONFIGURATION MENU appears in the display.

2. Scroll through the menu using the ▲ or ▼ arrow key until LOAD START PCT appears in the display along with the current setting for this option (default = 1%).

3. Refer to Appendix I to determine the appropriate BLR START LE VE L for the Modulex Boiler .

4. Press the CHANGE ke y to change the displayed value. The display will switch to a reverse video format.

5. Using the ▲ and ▼ arrow keys, set the LOAD START PCT to 2% below the BLR START LEVEL.

6. Press the ENTER key t o store the changed percentage. The rever se video displa y will revert to the normal VFD display format.

7. The BMS II is now fully programmed for operation in the Outdoor Reset Mode with Modulex Boilers.

4.3 REMOTE SETPOINT MODE

In order to set up the BMS II to opera te in this m ode, a Modbus com m unication l ine or a 4-to-20 mA input line with a floating ground from an Ener gy Management System (EMS) is required. In addit ion, a BMS header sensor is re quired. This mode may be used with or without an outdoor air tem perature sensor installed. Entries in this mode are required for the following menu items:

• FIELD ADJUST MENU

o HEADER SET MODE o HEADER HIGH LIMIT o HEADER LOW LIMIT o REMOTE SIGNAL

• CONFIGURATION MENU

o BOILER OPERATING MODE o BLR START LEVEL o BLR STOP LEVEL

• CALIBRATION MENU (Required Only For Modulex Installations)

o LOAD START PCT

The programming set-up instructions for the above menu options are provided in paragraphs which follow.

4-4

PROGRAMMING BMS II

Selecting Remote Setpoint Mode

The Remote Setpoint Mod e is selected using the Header Set Mo de option in the Field Adjust Menu as follows:

1. Using the keypad on the BMS II, press the MENU key, until FIELD AD JUST MENU appear s in the display.

2. Using the ▲ or ▼ arrow key on the keypad, scroll through the menu until HEADER S ET MODE is displayed in the first line of the VFD display. The second line of the display will sho w the currently selected Header Set Mode (CO NST ANT SETPOINT, OUTDO OR RESET or RE MOTE SETPOINT).

3. If REMOT E SETPOINT is not displa yed in the second line of the display, pres s the CHANGE key. The VFD display will switch to a reverse video format indicating that a change is in process.

4. Using the ▲ or ▼ arrow key, select REMOTE SETPOINT.

5. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory. With the BMS II still in the FIELD ADJUST MENU, proceed to the next paragraph and continue the set-up procedure.

Entering Header High Limit and Low Limit Temperatures

The Header High Lim it and Header Low L im it are also s electe d using options in t he Fiel d Adjus t Menu as follows:

1. Using the ▲ or ▼ arrow key on the keypad, scroll through the menu until HDR HIGH LIMIT is displayed in the first line of the VFD display. The second line of the display will sho w the currently selected Header High Limit temperature (default = 200°F).

2. If the required HDR HIGH LIMIT is not displayed in the sec ond li ne of the displ a y, pr ess the CHANGE key. The VFD display will switch to a reverse video format indicating that a change is in process.

3. Using the ▲ or ▼ arrow key, select required HDR HIGH LIMIT temperature.

4. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory.

5. Next, scroll through the FIELD ADJUST MENU until HDR LOW LIMIT is displayed in th e first line of the VFD display. The seco nd line of the display will show the currently select ed Header Low Limit temperature (default = 040°F).

6. If the required HDR LOW LIMIT is not displayed, press the CHANGE key.

7. Using the ▲ or ▼ arrow key, select required HDR LOW LIMIT temperature. Press the ENTER k e y t o store the change.

8. With the BMS II st ill in the FIELD ADJ UST MENU, proc eed to the next paragraph a nd continue the set-up procedure.

NOTE

If the Remote Signal is set to 4 – 20 mA, the H DR HIGH LIMIT temperature defines the 20 mA value and the HDR LOW LIMIT temperature defines the 4 mA value.

Selecting Remote Signal Type

The boilers connected to the BMS II c an be controlled by either a 4-to-20 m A signal or a Modbus signal from an Energy Management System (EMS). The Remote Signal type is selected in the Field Adjust Menu as follows:

4-5

PROGRAMMING BMS II

1. Using the ▲ or ▼ arrow key on the keypad, scroll through the menu until REMOTE SIGNAL is displayed in the first line of the VFD display. The second line of the display will sho w the currently selected Remote Signal (4-20 mA or MODBUS). The default is 4-20 mA.

2. If the required REMOTE SIGNAL is not displayed in the second line of the display, press the CHANGE ke y. The VFD display will switch to a reverse video f ormat indicating that a change is in process.

3. Using the ▲ or ▼ arrow key, toggle the display to the required signal type.

4. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory.

5. This completes all required entries in the Field Adjust Menu. To complete Remote Setpoint Mode setup, select the Boiler Operating Mode option as described below.

Selecting Boiler Operating Mode

The Boiler Plant can be set for either Parallel or Sequential Mode operation. The Boiler Operating Mode is selected in the Configuration Menu as follows:

1. Using the keypad on the B MS II, pr ess the MENU ke y, until CONFIGURATION MENU appears in the display.

2. On the keypad, press the ▲ arrow key once. BOIL ER OP MODE wi ll be disp layed in th e first li ne of the VFD display. The second line of the display will show the currently selected Boiler Operating Mode. (SEQUENT IAL MO D E or PARALLEL MODE). The default setting is SEQUENTIAL MO D E.

3. If the desired Operating Mode is not disp layed in the second line of the dis play, press the CHANGE key. The VFD display will switch to a reverse video format indicating that a change is in process.

4. Using the ▲ or ▼ arrow key, toggle the display to the desired setting.

5. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory.

6. The BMS II is now programmed for operation in the Remote Setpoint Mode.

Entering Boiler Start and Boiler Stop Levels

1. Using the ▲ or ▼ arrow key on the keypad, scroll through the Configuration Menu until BL R START LEVEL is displayed along with the current setting (default = 20%).

2. If the desired Boiler Start Level is not displa yed, pres s the CHANGE key. T he dis p la y will s witc h to t o a reverse video format.

3. Select the desired Boiler Start Level using the ▲ or ▼ arrow key.

4. Press the ENTER k ey to store the changed Start Level.. The r everse video display will revert to th e normal VFD display format.

5. Next, scroll through the menu until the BLR STOP LEVEL is dis played along with the current setti ng (default = 16%).

6. If the desired Boiler Stop Level is not d isplayed, repeat s teps 2, 3 and 4 above for the desired Stop Level.

4-6

PROGRAMMING BMS II

Entering Load Start Percent (Required Only for Modulex Installations)

If the boiler plant conta ins Modulex boilers, th e LOAD START PC T option in the Cal ibration Menu must be entered. This opt ion should be set 2% below the BLR START LE VEL set in the C onfiguration Menu. Proceed as follows:

1. Press the MENU key until CONFIGURATION MEN U appears in the display.

2. Scroll through the menu using th e ▲ or ▼ arrow key until LOAD START PCT ap pears in the displa y along with the current setting for this option (default = 1%).

3. Refer to Appendix I to determine the appropriate BLR START LE VE L for the Modulex Boiler .

4. Press the CHANGE key to change the displa yed value. The display will switch to a reverse video format.

5. Using the ▲ and ▼ arrow keys, set the LOAD START PCT to 2% below the BLR START LEVEL.

6. Press the ENTER key to store the cha nged percentage. The r everse video displa y will revert to the normal VFD display format.

7. The BMS II is now fully programmed for operation in the Outdoor Reset Mode with Modulex Boilers.

4.4 CONSTANT SETPOINT MODE

In the Constant Setpo int Mode of operation, only a header sensor is required. Entries in this m ode are required for the following items:

• FIELD ADJUST MENU

o HEADER SET MODE o INTERNAL SETPOINT

• CONFIGURATION MENU

o BOILER OPERATING MODE o BLR START LEVEL o BLR STOP LEVEL

• CALIBRATION MENU (Required Only for Modulex Installations)

o LOAD START PCT

The set-up instructions for the above menu options are provided in paragraphs which follow.

Selecting Constant Setpoint Mode

The Constant Setpoi nt Mode is selected using the Header Set Mode option in the Field Adjus t Menu as follows:

1. Using the keypad on the BMS II, press the MENU key, until FIELD AD JUST MENU appear s in the display.

2. Using the ▲ or ▼ arrow key on the keypad, scroll through the menu until HEADER S ET MODE is displayed in the first line of the VFD display. The second line of the display will sho w the currently selected Header Set Mode (CONSTANT SETPOINT, OUTDOOR RESET or REMOTE SETPOINT).

3. If CON STANT SETPOI NT is not d isplayed in the sec ond lin e of the d isplay, pres s the CHANGE key. The VFD display will switch to a reverse video format indicating that a change is in process.

4. Using the ▲ or ▼ arrow key, select CONST ANT S ET POINT.

5. Press the ENTER key to store the change. T he reverse video dis pla y will revert to the norm al display format indicating that the change has been store in memory. With the BMS II still in the FIELD ADJUST MENU, proceed to next paragraph to select the Internal Setpoint Temperature.

4-7

PROGRAMMING BMS II

Selecting Internal Setpoint Temperature

The Internal Setpoint Temperature is selected using in the Field Adjust Menu as follows:

1. Using the ▲ or ▼ arrow key on th e keypad, scroll through the menu until INTERNAL SETPT is displayed in the first line of the VFD display. The second line of the display will sho w the currently selected Internal Setpoint temperature (default = 160°F). If the required INTERNAL SETPT is not displayed in the second line of the displa y, press the CHANGE key. The VFD displa y will switch to a reverse video format indicating that a change is in process.

2. Using the ▲ or ▼ arrow key, select required INTERNAL SETPT temperature.

3. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory.

4. This completes the required entries in the Field Adjust Menu. To complete the Constant Setpoint Mode set-up, select the Boiler Operating Mode as described below.

Selecting Boiler Operating Mode

The Boiler Plant can be set for either Parallel or Sequential Mode operation. The Boiler Operating Mode is selected in the Configuration Menu as follows:

1. Using the keypad on the B MS II, pr ess the MENU ke y, until CONFIGURATION MENU appears in the display.

2. On the keypad, press the ▲ arrow key once. BOIL ER OP MODE wi ll be disp layed in th e first li ne of the VFD display. The second line of the display will show the currently selected Boiler Operating Mode. (SEQUENT IAL MO D E or PARALLEL MODE). The default setting is SEQUENTI AL MO D E.

4. Using the ▲ or ▼ arrow key, toggle the display to the desired setting.

5. Press the ENTER key to store the change. T he reverse video disp lay will rever t to the norm al display format indicating that the change has been store in memory.

6. The BMS II is now programmed for operation in the Constant Setpoint Mode.

Entering Boiler Start and Boiler Stop Levels

1. Using the ▲ or ▼ arrow key on the keypad, scroll through the Configuration Menu until BLR ST ART LEVEL is displayed along with the current setting (default = 20%).

2. If the desired Boiler Start Level is not displayed, pres s the CHANGE key. The dis pla y will s witch to t o a reverse video format.

3. Select the desired Boiler Start Level using the ▲ or ▼ arrow key.

4. Press the ENTER k ey to store the changed Start Level.. The r everse video display will revert to th e normal VFD display format.

5. Next, scroll through the menu until the BLR STOP LEVEL is displa yed along with the cur rent setting (default = 16%).

6. If the desired Boiler Stop Level is not d isplayed, repeat steps 2, 3 and 4 abo ve for the desired Stop Level.

4-8

PROGRAMMING BMS II

Entering Load Start Percent (Required Only for Modulex Installations)

If the boiler plant conta ins Modulex boilers, th e LOAD START PC T option in the Cal ibration Menu must be entered. This opt ion should be set 2% below the BLR START LE VEL set in the C onfiguration Menu. Proceed as follows:

1. Press the MENU key until CONFIGURATION MENU appears in the display.

2. Scroll through the menu using th e ▲ or ▼ arrow key until LOAD START PCT ap pears in the displa y along with the current setting for this option (default = 1%).

3. Refer to Appendix I to determine the appropriate BLR START LE VE L for the Modulex Boiler .

4. Press the CHANGE key to change the displa yed value. The display will switch to a reverse video format.

5. Using the ▲ and ▼ arrow keys, set the LOAD START PCT to 2% below the BLR START LEVEL.

6. Press the ENTER key to store the cha nged percentage. The re verse video displa y will revert to the normal VFD display format.

7. The BMS II is now fully programmed for operation in the Outdoor Reset Mode with Modulex Boilers.

4.5 “TEMP AND LOAD” OPTION

The boiler plant, and the System Start Relay, can be programm ed to start based on either, or both, an outdoor temperature and/ or load dem and criteria. W hen the SYS START OPT ION is set to TEMP O NL Y, the outdoor temperatur e is the only criteria use d to activate the s ystem. In this case the system , and the System Start Relay, will activate when the outdoor temperature falls below the SYS START TEMP setting. If no outdoor sensor is installed, the system (and the System Start Relay) will always be activated in this case. The system will shut down and the System Start Relay deactivated when the outdoor temperature rises above the SYS START TEMP setting.

If the SYS START OPTION is set to TEMP AND LOAD, the system (and the System Start Relay) will start when the outdoor temperature is below the SYS START TEMP setting and the load demand (PERCENT OF LO AD) is at or above the LOAD START PC T (in Calibration Menu) . The PERCENT OF LOAD display in the Operating Menu will show 0% until both of these criteria are satisfied. The system will shut down and the System Start Rela y deactivated if either the outdoor temperat ure rises above the SYS START TEMP or the PER CENT OF LOAD fa lls below the LOAD STOP PCT. If no outdoor sensor is installed, the s ystem (and the System Start R elay) will activate when th e PERCENT OF LOAD is at or above the LOAD START PCT. The system will sh ut down when the PERCENT OF LOAD falls below the

LOAD STOP PCT.

4.6 “START ENABLED” OPTION

The BMS II can be used to turn on and prove a device such as a fresh air damper, gas booster or the flow of a local pump before ram ping up the output. With SYS INTLK C ONFIG (Configurat ion Menu) set to START ENABLED, the BMS II will allow 30 seconds after it activates the System Start Relay before proving the selected interlock (such as SYS START INTLK) and ramping up the output. The System Start Relay can activate t he de vic e and the dry-contact proving s w itch of th e device, or devices can be wired to one or both interlocks.

4-9

PROGRAMMING BMS II

4.7 SYSTEM INITIALIZATION AND POLLING

In order for the BMS II to recognize the boilers connect ed to the RS485 Net work, Initial ization an d polling must be accomplished b y performing the following steps:

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

2. Turn on the BMS II b y pressing the ON key. The BMS II will automaticall y poll (recogn ize) each boi ler at prescribed intervals.

3. Check the yellow REMOTE (REM) LED on each boiler control pane l t o ens ur e it i s O N. This indicates that the boiler is now being controlled by the BMS II.

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. (c) The RS485 Network connection is not broken.

The BMS II will cont inuousl y poll the boilers at prescribed in tervals. T herefore, if a boiler is placed of f-line and then placed back on-line, it will again be recognized by the BMS II during the next polling cycle.

4.8 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 4.5, proceed as follows:

IMPORTANT

Prior to performing these tests, view and record the PRESENT settings stored in the BMS II for HEADER SET MODE and INTERNAL SETPT. These settings are located in the Field Adjust Menu and MUST be restored to these values upon com pletion of the following tests.

1. Turn off the BMS II by pressing the ON/OFF key. The ON LED will turn off.

2. Using the MENU key, select the FIELD ADJUST MENU and scroll to the HEADER SET MODE option, T he second line of the displa y will show the current setting stor ed in memory (CONSTANT SETPT, OUTDOOR RESET,or REMOTE SETPT).

3. If CONSTANT SETPT is not currently selected, press the CHANGE key. Select the CONSTANT SETPT mode using the ▲ or ▼ arrow key. When selected, s tore the cha nge by pressing the ENTER key.

4. Next, scroll to the INTERNAL SETPT menu option. The second line of the display will show the current Internal Setpoint temperature (°F) stored in memory.

5. Press the CHANGE key. Set the INTER NAL S ETPT tem perature to 180°F using the ▲ and ▼ arrow keys. When set, store the change by pressing the ENTER key.

6. Turn on the BMS II by pres sing the ON/OFF key. The ON indicator will light and the boiler plant will start to operate.

4-10

PROGRAMMING BMS II

7. Using the MENU key on the BMS II, scr oll to the OPERATING MENU. T he f irs t li ne of the d is pla y wi l l show the Header Temper ature. The second line of the display will show the Firing Rate % and th e number of Units (boilers) firing.

8. When all boilers have reached at leas t a 55% firing rate, any boilers that have not started ha ve not been identified by the BMS II.

9. Remember that in the Sequ ential mode, the BMS II turns boiler s on in 30-second intervals. T her ef ore, in a 6-boiler plant, with fiv e boilers operating at 55% capacity, a bo iler that has not started after 3 minutes has not been recognized. In parallel mode, all boilers will start at the same time.

10. This completes the System Test. Return the HEADER SET MOD E and INTERNA L SETPT settings to their previously stored values .

11. If the System Test is not completed successfully, refer to the troubleshooting procedures in this manual (Chapter 5) and the applicable O & M Manuals for the boilers included in the boiler plant. If the problem can still not be resolved, contact AERCO at 1-800-526-0288.

CAUTION

Monitor the HDR TEMP reading to ensure it is not ramping up too high. If it is, press the ON/OFF key of t he BMS II to sh ut down the boilers. Remember that the boiler outlet temperature may be higher than the BMS II header temperature.

NOTE

When a Building Automation System (BAS) is connected to monitor the BMS II, ensure that the RS232 Menu is configured properly.

If the boilers connected to the BMS II are to be monitored by the BAS, ensur e that the MODBUS PASS THRU option in the RS232 Menu is enabled.

4-11

TROUBLESHOOTING

Fault Message Description & Possible cause

Interlock 1 is open

Interlock 2 is open

CHAPTER 5 - TROUBLESHOOTING

5.1 FAULT MESSAGES & COMMON PROBLEMS

When a fault occurs in t he boiler plant, the BMS II flashes fault m essages at 2-second inter vals and the Fault Alarm (FLT ALARM) r ela y contac ts are close d. T he red FAULT indicator on the fr ont pan el will als o light. To cancel the alarm (open relay contacts), pres s the CLEAR k ey on the BMS II keypad. The FAULT indicator will turn off, however the fault message will continue to be displayed.

The fault messages shown in T able 5-1 can appear when the BMS II is op erat ing i n an y of the three basic modes (Constant Setpoint, Outdoor Reset, or Remote Setpoint).

Table 5-2 lists some comm on problems that may occur during BMS II oper ation and provide Probable Causes and Corrective Action for each listed Probable Cause.

Table 5-1. Fault Messages

OUTSIDE AIR TEMP NOT CONNECTED

OUTSIDE AIR TEMP SENSOR ERROR

HEADER SENSOR ERROR

INTERLOCK 1 ERROR INTERLOCK 2 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 Remote Setpt and Constant

Setpoint modes. I

When in 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

5-1

TROUBLESHOOTING

Fault Message Description & Possible cause

Table 5-1. Fault Messages – Continued

CURRENT LOOP ERROR

FAIL SAFE MODE ACTIVATED

MODBUS TIMEOUT ERROR

NETWORK DISABLED MODBUS LISTEN

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

This message indicates that the BMS II is operating in the Fail Safe (Constant Setpoint) mode.due to sensor loss or signal loss.

Displayed during Modbus Remote Setpoint operation when the BMS II is functioning as a Slave to an EMS Master. Error indica tes that the Netw ork Timeout has expired.

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

5-2

TROUBLESHOOTING

Problem

Possible Causes

Solution

More Control Box.

Table 5-2 Common Problems

Boiler plant not started by BM S II

BMK or KC Boiler with C-More Control Box not being recognized by BMS II.

• BMS II not turned ON.

• Outside air temperature higher

than system’s start temperature

• Configuration not correct.

• System must be initialized

• Wiring between boilers and

BMS II not correct

• C-More Box not configured correctly.

• Press ON/OFF button and ensure that the LED lights

• Check outside air temperature and system start temperature. System start temperature should be higher than outside air temperature for boilers to run. Check SYS START TEMP setting in RELAY MENU (paragraph 3.11).

• Check SYS START OPTION in RELAY MENU. Load START PCT and STOP PCT in CALIBRATION MENU paragraphs 3.11, 3.12).

• Initialize and test system (para. 4.7 and

4.8).

• Check wiring. (See Chapter 2 & Appendix E)

• Ensure that the C-More Boiler is configured for Direct Drive (see Chapter 5 of correct BMK or KC1000 O & M Manual for required menu settings).

Modulex Boiler with BCM Control not being recognized by BMS II.

BMS II controlling boilers. EMS can see BMS II, but cannot see boilers.

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

• Incor r ect wiri ng bet ween BMS II and Boiler.

• Alarm condition present on C-

• BCM not configured correctly.

• 3-position switch on boiler not

in correct position.

• BCM Control is in alarm.

• Incor r ect wiri ng bet ween B MS

II and BCM Control.

• MODBUS PASS THRU not enabled in BMS II.

• EMS communication response time too short.

• Check ON/OFF switch.

• See Chapter 2 for correct wiring

connections

• Clear alarm condition.

• Ensure that last boiler has ter mination

activated (see GF-114, GF-115-C).

• Ensure that the 3-position switch is in the 0 (zero) position.

• Clear alarm condition.

• Refer to Chapter 2 for correct wiring

connections.

• See RS232 MENU (par agraph 3.6).

• Allow at least 2 seconds to receive

boiler information.

5-3

TROUBLESHOOTING

Problem

Possible Causes

Solution

and BMS II.

and connections.

PID requires adjustment.

Refer to TUNING MENU (para. 3.10).

3.12)

running.

Table 5-2 Common Problems - Continued

EMS cannot see BMSII

Boiler RAMP UP or

RAMP DOWN too slow or too fast

HEADER TEMPERATURE not reaching Setpoint

Need to restore Factory Default Settings.

Boilers over-shooting setpoint or tripping aquastat

• Incorrect address

• Incorrect Baud Rate

• Faulty wiring between EM S

• RAMP UP or RAMP DOWN

time needs adjustment.

•

• Deadband requires

adjustment

• PID requires adjustment

• Too many setting changes.

• Header sensor not installed

correctly

• PID setting require adjustment

• See RS232 MENU (paragraph 3.6).

• See RS232 MENU (paragr aph 3.6).

• See Chapter 2. Check wiring polarity

• Refer to CALIBRATION MENU

(paragraph 3.12) and check the RAMP UP %/MIN or RAMP DOWN %/MIN

•

• Check HDR TEMP DEADBND in

TUNING MENU (paragraph 3.10). Default = 5°.

• See TUNING MENU (paragraph 3.10).

• Go to RESET DEFAULTS option in

CALIBRATION MENU (paragraph

• Check header sensor connections and installation.

• Adjust PID settingsin TUNING MENU (paragraph 3.10).

Modbus Network faults encountered. Boiler plant not operating

• Adjustable aquastat set too low

• System pumps are shut down

and not controlled by or interlocked with the BMS II

• BMS II or boilers not properly configured for Modbus communication.

• Bias and/or terminati on not

activated.

• 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 II. In addition, interlock wiring can be run between the BMS II and energy management system to disable the BMS II pumps when pumps are not

• Refer to Modbus Communication Manual GF-114 for C-More control or GF-115-C for BCM control on Modulex boilers. Check all wiring connections and software menu settings.

• Activate terminati on in last boi ler. Activate bias on BMS II for BCM control or in last C-More control.

5-4

APPENDIX A

APPENDIX A _____________________________

BMS II MENUS

AVAILABLE CHOICES OR LIMITS

MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT

OPERATING MENU

HEADER TEMP 40 280 N/A HEADER SET TEMP 40 220 N/A OUTSIDE AIR TEMP -60 180 N/A PERCENT OF LOAD 0 100 N/A I/O STATUS Bit 0 = AUX Relay

RETURN TEMP 40 280 N/A

SETUP MENU

ENTER PASSW O R D (Level 1 = 159)

(Level 2 = 6817) SET MONTH 01 12

0 32000 0

Bit 1 = Fault Relay Bit 2 = Sys Start Relay Bit 3 = Empty Bit 4 = Setback Bit 5 = Interlock 2 Bit 6 = Interlock 1 Bit 7 = Empty

SET DATE 01 31 SET YEAR 00 99 SET HOUR 00 23 SET MINUTE 00 59 SET DAY OF WEEK SUNDAY TO SATURDAY

RS232 MENU

RS232 MODE MODBUS SLAVE,

RS232 BAUDRATE 2400, 4800,

MODBUS ADDRESS 128 247 128 NETWORK TIMEOUT (Seconds) 005 240 060 MODBUS PASS THRU DISABLED,

MODBUS SLAVE

NORMAL

9600

9600, 19200

DISABLED

ENABLED

A-1

APPENDIX A

APPENDIX A _____________________________

BMS II MENUS - Continued

AVAILABLE CHOICES OR LIMITS

MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT

RS485 MENU

RS485 BAUDRATE 2400, 4800,

9600, 19200 MIN SLAVE ADDR 000 127 000 MIN SLAVE ADDR 000 127 000 NUMBER NETW BLRS 00 32 02 MODBUS CNTL TYPE ROUND ROBIN,

BROADCAST

NETW BOILER 01 ADDRESS =

NETW BOILER 02 ADDRESS =

NETW BOILER 03 ADDRESS =

Etc., Up To: NETW BOILER 32

ADDRESS =

000 127 001

000 127 002

000 127 000

9600

ROUND ROBIN

FIELD ADJUST MENU

HEADER SET MODE CONSTANT SETPOINT,

OUTDOOR RESET,

REMOTE SETPOINT

CONSTANT

SETPOINT

HDR HIGH LIMIT 040°F 220°F 200°F HDR LOW LIMIT 040°F 220°F 040°F INTERNAL SETPT 040°F 220°F 160°F RESET RATIO

(Displayed Only if HDR SET MODE = OUTDOOR RESET)

BLDG REF TEMP (Displayed Only If

HDR SET MODE = OUTDOOR RESET)

REMOTE SIGNAL (Displayed Only If HDR SET MODE

= REMOTE SETPT

A-2

0.3 3.0 1.2

40°F 220°F 70°F

4 – 20 mA,

MODBUS

4 - 20 mA

APPENDIX A

APPENDIX A _____________________________

BMS II MENUS - Continued

AVAILABLE CHOICES OR LIMITS

MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT

FIELD ADJUST MENU – Cont.

OFFSET ENABLE OFF,

SUN OFFS TEMP

SUN ON HOUR 00 23 00 SUN ON MINUTE 00 59 00 SUN OFF HOUR 00 23 00 SUN OFF MINUTE 00 59 00 Etc., Up To: SAT OFF MINUTE 00 59 00

-50.0°F 50.0°F 00.0

OFF

CONFIGURATION MENU

BOILER OP MODE SEQUENTIAL MODE,

PARALLEL MODE

SYS INTLK CONFIG START ENABLED,

ALWAYS ENABLED BLR START LEVEL 001% 100% 020% BLR STOP LEVEL 001% 040% 016% MAX POWER INPUT 050% 100% 100%

SEQUENTIAL

MODE

START ENABLED

FAIL SAFE MODE SHUTDOWN,

CONSTANT SETPOINT

SHUTDOWN

TUNING MENU

PROPORTIONAL BND 005°F 120°F 070°F INTEGRAL GAIN 0.00 REP/MIN 9.99 REP/MIN 0.15 REP/MIN DERIVATIVE GAIN -2.00 MIN. 2.00 MIN. 0.15 MIN. HDR TEMP DEADBND 001°F 015°F 005°F

A-3

APPENDIX A

APPENDIX A _____________________________

BMS II MENUS - Continued

AVAILABLE CHOICES OR LIMITS

MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT

RELAY MENU

SYS START TEMP 032°F 120°F 070°F SYS START OPTION TEMP ONLY,

TEMP AND LOAD

SYS START INTLK DISABLED

INTERLOCK 1 INTERLOCK 2

INTERELOCK 1&2 AUX RELAY OPEN 000% 099% 045% AUX RELAY CLOSE 100% FIRE RATE,

100% AND OFF

FAULT ALRM RELAY ALL FAULTS,

NO INTERLOCK,

INTERLOCK 2,

INTERLOCK 1

FAULT ALARM BLRS NO BLR FAULTS,

ALL BLR FAULTS

FAULT ALRM CLEAR AUTOMATIC,

MANUAL RESET

TEMP ONLY

INTERLOCK 1

100% AND OFF

ALL FAULTS

NO BLR FAULTS

AUTOMATIC

CALIBRATION MENU

HDR SENS OFFSET -10.0° 10.0° 00.0° OUTD SENS OFFSET -10.0° 10.0° 00.0° 4 – 20 MA OFFSET -10.0 10.0 00.0 RET SENS OFFSET -10.0° 10.0° 00.0 RAMP UP %/MIN 000 300 020 RAMP DOWN %/MIN 000 300 200 LOAD START PCT 000 100 1 LOAD STOP PCT 000 100 0 RESET DEFAULTS NO,

YES (DONE If Selected)

A-4

APPENDIX B

APPENDIX B _____________________________

STATUS AND FAULT MESSAGES

DISPLAY MESSAGES DESCRIPTION

STATUS MESSAGES:

FAIL SAFE MODE ACTIVATED

NETWORK DISABLED MODBUS LISTEN

OUTSIDE AIR TEMP NOT CONNECTED

RETURN TEMP NOT INSTALLED

FAULT MESSAGES

OUTDOOR SENSOR ERROR

HEADER SENSOR ERROR

RETURN SENSOR ERROR

INTERLOCK 1 ERROR

INTERLOCK 2 ERROR

The system is running in the Constant Setpt mode due to loss of the Remote signal or Outdoor Air sensor input.

“Forced Listen Only Mode” has been activated. All Modbus commands except “restart Communications Options” will be ignored. The BMS II will operate in the Fail Safe Mode.

The Outdoor Air Temperature Sensor is not installed and connected.

The Boiler Return Temperature Sensor is not installed.

The Outdoor Air Temperature Sensor signal is out of range.

The Header Temperature Sensor signal is out of range or disconnected.

The Return Temperature Sensor signal is out of range.

Interlock 1 input is open.

Interlock 2 input is open.

4 – 20 mA INPUT ERROR

MODBUS TIMEOUT ERROR

The 4 – 20 mA Remote Input signal is lost.

The Modbus remote input information was not receive d withi n the network timeout period.

B-1

APPENDIX C

APPENDIX C _____________________________

METHODS FOR DETERMINING RESE T SCHEDUL E AND 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 dat a 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 requir ed to determine reset schedule with this method. The first is to determine the reset ratio b y dividing th e range of outside temperatures by the range of header temperatures:

header/Toutside

for example, (105° range), and

= Reset Ratio.

If T

varies from -10 to +95°F

outside

then the reset ratio equals

75°F/105°F = 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 t o the following equation to yield the building reference temperature:

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

Temperature desired at the m inimum outside air temperature.

So in this example:

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).

varies from 125 to 200°F (75° range),

header

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

header

is the maximum heating system

header

= 200°F

C-1

RESET RATIO

Air

Temp

50°F

45°F

53°F

54°F

55°F

56°F

57°F

58°F

59°F

60°F

62°F

40°F

56°F

58°F

60°F

62°F

64°F

66°F

68°F

70°F

72°F

74°F

35°F

59°F

62°F

65°F

68°F

71°F

74°F

77°F

80°F

83°F

86°F

30°F

62°F

66°F

70°F

74°F

78°F

82°F

86°F

90°F

94°F

98°F

25°F

65°F

70°F

75°F

80°F

85°F

90°F

95°F

100°F

105°F

110°F

20°F

68°F

74°F

80°F

86°F

92°F

98°F

104°F

110°F

116°F

122°F

15°F

71°F

78°F

85°F

92°F

99°F

106°F

113°F

120°F

127°F

134°F

10°F

74°F

82°F

90°F

98°F

106°F

114°F

122°F

130°F

138°F

146°F

5°F

77°F

86°F

95°F

104°F

113°F

122°F

131°F

140°F

149°F

158°F

0°F

80°F

90°F

100°F

110°F

120°F

130°F

140°F

150°F

160°F

170°F

-5°F

83°F

94°F

105°F

116°F

127°F

138°F

149°F

160°F

171°F

182°F

-10°F

86°F

98°F

110°F

122°F

134°F

146°F

158°F

170°F

182°F

194°F

-15°F

89°F

102°F

115°F

128°F

141°F

154°F

167°F

180°F

193°F

206°F

-20°F

92°F

106°F

120°F

134°F

148°F

162°F

176°F

190°F

204°F

218°F

RESET RATIO

Air

Temp

60°F

55°F

63°F

64°F

65°F

66°F

67°F

68°F

69°F

70°F

71°F

72°F

50°F

66°F

68°F

70°F

72°F

74°F

76°F

78°F

80°F

82°F

84°F

45°F

69°F

72°F

75°F

78°F

81°F

84°F

87°F

90°F

93°F

96°F

40°F

72°F

76°F

80°F

84°F

88°F

92°F

96°F

100°F

104°F

108°F

35°F

75°F

80°F

85°F

90°F

95°F

100°F

105°F

110°F

115°F

120°F

30°F

78°F

84°F

90°F

96°F

102°F

108°F

114°F

120°F

126°F

132°F

25°F

81°F

88°F

95°F

102°F

109°F

116°F

123°F

130°F

137°F

144°F

20°F

84°F

92°F

100°F

108°F

116°F

124°F

132°F

140°F

148°F

156°F

15°F

87°F

96°F

105°F

114°F

123°F

132°F

141°F

150°F

159°F

168°F

10°F

90°F

100°F

110°F

120°F

130°F

140°F

150°F

160°F

170°F

180°F

5°F

93°F

104°F

115°F

126°F

137°F

148°F

159°F

170°F

181°F

192°F

0°F

96°F

108°F

120°F

132°F

144°F

156°F

168°F

180°F

192°F

204°F

-5°F

99°F

112°F

125°F

138°F

151°F

164°F

177°F

190°F

203°F

216°F

-10°F

102°F

116°F

130°F

144°F

158°F

172°F

186°F

200°F

214°F

-15°F

105°F

120°F

135°F

150°F

165°F

180°F

195°F

210°F

-20°F

108°F

124°F

140°F

156°F

172°F

188°F

204°F

APPENDIX C _____________________________

Table C-1. Header Temperature for a Building Reference Temperature of 50°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Table C-2. Header Temperature for a Building Reference Temperatrure of 60°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

C-2

APPENDIX C

RESET RATIO

Air

Temp

65°F

60°F

68°F

69°F

70°F

71°F

72°F

73°F

74°F

75°F

76°F

77°F

55°F

71°F

73°F

75°F

77°F

79°F

81°F

83°F

85°F

87°F

89°F

50°F

74°F

77°F

80°F

83°F

86°F

89°F

92°F

95°F

98°F

101°F

45°F

77°F

81°F

85°F

89°F

93°F

97°F

101°F

105°F

109°F

113°F

40°F

80°F

85°F

90°F

95°F

100°F

105°F

110°F

115°F

120°F

125°F

35°F

83°F

89°F

95°F

101°F

107°F

113°F

119°F

125°F

131°F

137°F

30°F

86°F

93°F

100°F

107°F

114°F

121°F

128°F

135°F

142°F

149°F

25°F

89°F

97°F

105°F

113°F

121°F

129°F

137°F

145°F

153°F

161°F

20°F

92°F

101°F

110°F

119°F

128°F

137°F

146°F

155°F

164°F

173°F

15°F

95°F

105°F

115°F

125°F

135°F

145°F

155°F

165°F

175°F

185°F

10°F

98°F

109°F

120°F

131°F

142°F

153°F

164°F

175°F

186°F

197°F

5°F

101°F

113°F

125°F

137°F

149°F

161°F

173°F

185°F

197°F

209°F

0°F

104°F

117°F

130°F

143°F

156°F

169°F

182°F

195°F

208°F

-5°F

107°F

121°F

135°F

149°F

163°F

177°F

191°F

205°F

219°F

-10°F

110°F

125°F

140°F

155°F

170°F

185°F

200°F°

215°F

-15°F

113°F

129°F

145°F

161°F

177°F

193°F

209°F

-20°F

116°F

133°F

150°F

167°F

201°F

218°F

RESET R ATI O

Air

Temp

70°F

65°F

73°F

74°F

75°F

76°F

77°F

78°F

79°F

80°F

81°F

82°F

60°F

76°F

78°F

80°F

82°F

84°F

86°F

88°F

90°F

92°F

94°F

55°F

79°F

82°F

85°F

88°F

91°F

94°F

97°F

100°F

103°F

106°F

50°F

82°F

86°F

90°F

94°F

98°F

102°F

106°F

110°F

114°F

118°F

45°F

85°F

90°F

95°F

100°F

105°F

110°F

115°F

120°F

125°F

130°F

40°F

88°F

94°F

100°F

106°F

112°F

118°F

124°F

130°F

136°F

142°F

35°F

91°F

98°F

105°F

112°F

119°F

126°F

133°F

140°F

147°F

154°F

30°F

94°F

102°F

110°F

118°F

126°F

134°F

142°F

150°F

158°F

166°F

25°F

97°F

106°F

115°F

124°F

133°F

142°F

151°F

160°F

169°F

178°F

20°F

100°F

110°F

120°F

130°F

140°F

150°F

160°F

170°F

180°F

190°F

15°F

103°F

114°F

125°F

136°F

147°F

158°F

169°F

180°F

191°F

202°F

10°F

106°F

118°F

130°F

142°F

154°F

166°F

178°F

190°F

202°F

214°F

5°F

109°F

122°F

135°F

148°F

161°F

174°F

187°F

200°F

213°F

0°F

112°F

126°F

140°F

154°F

168°F

182°F

196°F

210°F

-5°F

115°F

130°F

145°F

160°F

175°F

190°F

205°F

-10°F

118°F

134°F

150°F

166°F

182°F

198°F

214°F

-15°F

121°F

138°F

155°F

172°F

189°F

206°F

-20°F

124°F

142°F

160°F

178°F

196°F

214°F

APPENDIX C _____________________________

Table C-3. Header Temperature for a Building Reference Temperature of 65°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Table C-4. Header Temperature for a Building Reference Temperature of 70°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

C-3

RESET RATIO

Air

Temp

75°F

70°F

78°F

79°F

80°F

81°F

82°F

83°F

84°F

85°F

86°F

87°F

65°F

81°F

83°F

85°F

87°F

89°F

91°F

93°F

95°F

97°F

99°F

60°F

84°F

87°F

90°F

93°F

96°F

99°F

102°F

105°F

108°F

111°F

55°F

87°F

91°F

95°F

99°F

103°F

107°F

111°F

115°F

119°F

123°F

50°F

90°F

95°F

100°F

105°F

110°F

115°F

120°F

125°F

130°F

135°F

45°F

93°F

99°F

105°F

111°F

117°F

123°F

129°F

135°F

141°F

17°F

40°F

96°F

103°F

110°F

117°F

124°F

131°F

138°F

145°F

152°F

159°F

35°F

99°F

107°F

115°F

123°F

131°F

139°F

147°F

155°F

163°F

171°F

30°F

102°F

111°F

120°F

129°F

138°F

147°F

156°F

165°F

174°F

183°F

25°F

105°F

115°F

125°F

135°F

145°F

155°F

165°F

175°F

185°F

195°F

20°F

108°F

119°F

130°F

141°F

152°F

163°F

174°F

185°F

196°F

207°F

15°F

111°F

123°F

135°F

147°F

159°F

171°F

183°F

195°F

207°F

219°F

10°F

114°F

127°F

140°F

153°F

166°F

179°F

192°F

205°F

218°F

5°F

117°F

131°F

145°F

159°F

173°F

187°F

201°F

215°F

0°F

120°F

135°F

150°F

165°F

180°F

195°F

210°F

-5°F

123°F

139°F

155°F

171°F

187°F

203°F

219°F

-10°F

126°F

143°F

160°F

177°F

194°F

211°F

-15°F

129°F

147°F

165°F

183°F

201°F

219°F

RESET RATIO

Air

Temp

80°F

75°F

83°F

84°F

85°F

86°F

87°F

88°F

89°F

90°F

91°F

92°F

70°F

86°F

88°F

90°F

92°F

94°F

96°F

98°F

100°F

102°F

104°F

65°F

89°F

92°F

95°F

98°F

101°F

104°F

107°F

110°F

113°F

116°F

60°F

92°F

96°F

100°F

104°F

108°F

112°F

116°F

120°F

124°F

128°F

55°F

95°F

100°F

105°F

110°F

115°F

120°F

125°F

130°F

135°F

140°F

50°F

98°F

104°F

110°F

116°F

122°F

128°F

134°F

140°F

146°F

152°F

45°F

101°F

108°F

115°F

122°F

129°F

136°F

143°F

150°F

157°F

164°F

40°F

104°F

112°F

120°F

128°F

136°F

144°F

152°F

160°F

168°F

176°F

35°F

107°F

116°F

125°F

134°F

143°F

152°F

161°F

170°F

179°F

188°F

30°F

110°F

120°F

130°F

140°F

150°F

160°F

170°F

180°F

190°F

200°F

25°F

113°F

124°F

135°F

146°F

157°F

168°F

174°F

190°F

201°F

212°F

20°F

116°F

128°F

140°F

152°F

164°F

176°F

188°F

200°F

212°F

15°F

119°F

132°F

145°F

158°F

171°F

184°F

197°F

210°F

10°F

122°F

136°F

150°F

164°F

178°F

192°F

206°F

5°F

125°F

140°F

155°F

170°F

185°F

200°F

215°F

0°F

128°F

144°F

160°F

176°F

192°F

208°F

-5°F

131°F

148°F

165°F

182°F

199°F

216°F

-10°F

134°F

152°F

170°F

188°F

206°F

APPENDIX C _____________________________

Table C-5. Header Temperature for a Building Reference Temperature of 75°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

Table C-6. Header Temperature for a Building Reference Temperature of 80°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

C-4

APPENDIX C

RESET RATIO

Air

Temp

90°F

85°F

93°F

94°F

95°F

96°F

97°F

98°F

99°F

100°F

101°F

102°F

80°F

96°F

98°F

100°F

102°F

104°F

106°F

108°F

110°F

112°F

114°F

75°F

99°F

102°F

105°F

108°F

111°F

114°F

117°F

120°F

123°F

126°F

70°F

102°F

106°F

110°F

114°F

118°F

122°F

126°F

130°F

134°F

138°F

65°F

105°F

110°F

115°F

120°F

125°F

130°F

135°F

140°F

145°F

150°F

60°F

108°F

114°F

120°F

126°F

132°F

138°F

144°F

150°F

156°F

162°F

55°F

111°F

118°F

125°F

132°F

139°F

146°F

153°F

160°F

167°F

174°F

50°F

114°F

122°F

130°F

138°F

146°F

154°F

162°F

170°F

178°F

186°F

45°F

117°F

126°F

135°F

144°F

153°F

162°F

171°F

180°F

189°F

198°F

40°F

120°F

130°F

140°F

150°F

160°F

170°F

180°F

190°F

200°F

210°F

35°F

123°F

134°F

145°F

156°F

167°F

178°F

189°F

200°F

30°F

126°F

138°F

150°F

162°F

174°F

186°F

198°F

210°F

25°F

129°F

142°F

155°F

168°F

181°F

194°F

207°F

20°F

132°F

146°F

160°F

174°F

188°F

202°F

216°F

15°F

135°F

150°F

165°F

180°F

195°F

210°F

10°F

138°F

154°F

170°F

186°F

202°F

218°F

5°F

141°F

158°F

175°F

192°F

209°F

0°F

144°F

162°F

180°F

198°F

216°F

APPENDIX C _____________________________

Table C-7. Header Temperature for a Building Reference Temperature of 90°F

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4

C-5

APPENDIX D

APPENDIX D _____________________________

NTC Temperature Sensor Resistance Chart

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

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

Resistance (ohms) Temperature (°F) Resistance (ohms)

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

NOTE

This Temperature Chart is applicable to He ader Sensor (and R eturn Sensor), Part No. 64038 and

Outside Air Sensor, Part No. GP-

122662.

D-1

APPENDIX E

2 3

-8 9

OUT

AIR

SENS

HDR

SEN

4-20

INT1

INT2

SET

BACK

485 ISO GND

485 B+

485 A-

RXD

TXD

ISO 12V

FLT

ALARM

AUX

SYS

START

SHLD

RTN

85–265 VAC

TERMINALS

PROVIDE 12 VDC

@ 15 mA

RELAYS RATED AT 120

VAC, 5A & FUSED

INTERNALLY AT 5A

232 ISO GND

OUTSIDE AIR SENSOR

HEADER TEMP SENSOR

RETURN TEMP SENSOR

4 – 20 mA WHEN UTILIZED

CONTACT CLOSES ON

OUTSIDE AIR TEMP

CONTACT CLOSES ON

BMS FAULT CONDITION

CONTACT CLOSES WHEN

HEATING PLANT IS AT

MAX. POWER INPUT

POWER INPUT, 16 AWG

120 VAC, 60 Hz, 1A

FUSED INTERNALLY

AT 1A

SENSOR WIRING

(NOTE 1)

INTERLOCKS &

SETBACK WIRING

(NOTE 2)

NOTES

1. AERCO RECOMMENDS USING TWO-CONDUCTOR, TWISTED,

SHIELDED PAIR , 22 AWG CABLE (BELDEN 9841 OR EQUIV.)

- TERMINATE SHIELDS AT BMS SHIELD (SHLD) TERMINAL ONLY.

- DO NOT CONNECT SHIELDS AT SENSOR ENDS.

- DO NOT RUN SENSOR WIRING WITH POWER WIRING.

2. CONTACTS PROVIDED BY OTHERS. USE CONTACTS RATED FOR

LOW SIGNAL LEVELS.

JUMPER INTERLOCKS (INT1, INT2) IF EXTERNAL CONTACTS ARE NOT USED.

3. IF THE EMS BEING USED CONTAINS ONLY A RS485 PORT, A RS485-TO-RS232

CONVERTER IS REQUIRED. IF NECESSARY, A 12 VDC OUTPUT IS PROVIDED

BY THE BMS II TO POWER THE RS485-TO-RS232 CONVERTER,

RS485

BOILERS

RS232

FROM EMS

(NOTE 3)

TO SHLD

(TERM. 3)

IF NEEDED (NOTE 3)

APPENDIX E _____________________________

BMS II WIRING DIAGRAM

E-1

APPENDIX F

PART NUMBER

DESCRIPTION

COMMENTS

64053

Boiler Management System II (BMS II)

Complete BMS II

12 VAC, 5A, 2AG Subminiature, FastActing Fuse (Littlefuse 225005)

For System-Start, Fault Alarm, and Auxiliary Relays

63 microamp fuse for current loop

GP-122662

Outside Air Temperature Sensor

Sensor Only

Includes Sensor (GP-122662) and Mounting Bracket

Thermowell for Header Temperature Sensor

Includes 64038 and GP-122758

Includes GM-122781 and GM-122790

62017

Low Voltage Terminal Block (14 pin)

APPENDIX F _____________________________

BMS II PARTS AND ACCESSORIES

GP-123043 69091 4 – 20 mA Fuse

GM-122781 Outside Air Temperature Sensor Kit 64038 Header Temperature Sensor Sensor Only GP-122758

GM-122790 GM-122791 Outdoor Reset Kit

62018 High Voltage Terminal Block ( 9 pin) 62019 RS485 Terminal Block (3 pin) 62020 RS232 Terminal Block (4 pin)

Header Temperature Sensor Kit

Thermowell Only

F-1

APPENDIX G

APPENDIX G _____________________________

PROGRAMMING THE BMS II USING RS-232 COMMUNICATION

Introduction

The RS-232 port located in the wiring compartment area of the BMS II can be used to program the BMS II using a laptop computer or other suitable terminal. Connect ion to a laptop or other terminal device is made by wiring to the RXD, TXD and GND connections ( see paragraph 2.9 and Figure 2-12 for pinout information when wiring from a DB9 connector).. 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 cable leads to the RS-232 connector in the wiring area of the BMS II.

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: (d) Set the baud rate to 9600. (e) 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 II by pressing the ON/OFF k e y. Verify that the ON LED lights .

5. Press the MENU key. Go to the SETUP MENU and enter a valid PASSWORD.

6. Press the MENU key and go to the RS232 MENU.

7. Press the ▲ arrow key to display the RS232 MODE option.

8. Press the ▲ or ▼ arrow key to display NORMAL. Press the ENTER key to store the NORMAL selection

9. Start the emulator software program.

10. At the command prompt, enter the password EXACTLY as follows (case-sensitive): P=gobms

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

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

G-1

APPENDIX G

APPENDIX G (cont.) __________________________

Programming Procedure

BMS II 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 p arameter, type @, followed by the comm and 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 II functions listed in Table G-1.

G-2

APPENDIX G

No.

COMMAND

ENTRY RANGE

FACTORY

DEFAULT

Header Temperature (°F)

40 to 220

Read Only

Outside Air Temperature (°F)

-60 to 80

Read Only

Return Sensor (°F)

40 to 160

Read Only

Percent of Load (%)

0 to 100

Read Only

Header Set Temperature (°F)

40 to 220

Read Only

System Start Temp erature (°F)

32 to 120

System Start Mode

0 = Temp Only 1 = Temp and Load

0 = Temp Only

Internal Setpt (°F)

40 to 220

160

Bldg Reference Temperature (°F)

40 to 220

70°F

Not Used

Reset Ratio

0.3 to 3.0

(0.1 increments)

1.2

Maximum Header Temperature (°F)

40 to 220

220

Minimum Header Temperature (°F)

40 to 220

Boiler Start Percent

25 to 100

Boiler Stop Percent

10 to 45

(0.01 increments)

Header Set Mode

0 = Constant Setpt 2 = Remote Settemp

0 = Constant Setpt

Derivative Gain

-2.00 to 2.00

(0.01 increments)

0.15

Proportional Band (°F)

5 to 100

Aux Relay Open

0 to 99

Aux Relay Close

0 = 100% Fire Rate 1 = 100% and OFF

1 = 100% AND OFF

1 = Switch Inputs

Fault Relay Mode

0 = All Faults

3 = Interlock 1

0 = All Faults

1 = Manual

Boiler Operation Mode

0 = Parallel 2 = Combination

1 = Sequential

APPENDIX G (cont.) __________________________

Table G-1. BMS II COMMANDS

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

1 = Indr/Outdr Reset

22 Failsafe Mode 0 = Shutdown

1 = No Interlock 2 = Interlock 2

24 Alarm Clear Method 0 = Automatic

1 = Sequential

0.15

0 = Shutdown

0 = Automatic

G-3

APPENDIX G

No.

COMMAND

ENTRY RANGE

FACTORY

DEFAULT

Not Used

27 29

Maximum Power Input

50 to 100

100

System Interlock Configuration

0 = Always Enabled 1 = Start Enabled

1 = Start Enabled

Real Time Clock - Minutes

00 to 59

Present Time

Real Time Clock - Hours

00 to 23

Present Time

Real Time Clock - Day Of Week

1 to 7

Present Day

Real Time Clock - Year

00 to 99

Present Year

Real Time Clock - Day Of Month

00 to 31

Present Day

Real Time Clock - Month

00 to 12

Present Month

(Day 1 – Sun.)

Thru

Offset Temperatures (Day 1-7)

-50 to +50°F

All Set To 0°F

(Day 7 – Sat.)

(Sun.)

Thru

Offset ON Time – Minutes (Sun.-Sat.)

00 to 59

All Set to Zero

(Sat.)

(Sun.)

Thru

Offset ON Time – Hours (Sun.-Sat.)

00 to 23

All Set To Zero

(Sat.)

Offset Enable

0 = Disabled 1 = Enabled

0 = Disabled

Header Temp Offset (°F)

-10°F to 10°F

System Start Interlock

1 = Intlk 1 Opens

Start Relay

1 = Intlk 1

(Sun.)

Thru

Offset OFF Time – Minutes (Sun.-Sat.)

00 to 59

All Set To Zero

Sat.)

(Day 1)

Thru

Offset OFF Time – Hours (Day 1-7)

0 to 23

All Set To Zero

(Day 7)

(Reserved)

Not Used

0 or 1

APPENDIX G (cont.) __________________________

Table G-1. BMS II COMMANDS

Reserved

G-4

Start Relay 2 = Intlk 2 Opens Start Relay 3 = Either Intlk Opens

APPENDIX G

No.

COMMAND

ENTRY RANGE

FACTORY

DEFAULT

Remote Signal

0 or 1 1 = Modbus

0 = 4 - 20 mA

RS232 Mode

0 or 1 1 = Modbus

1 = Modbus

RS232 Baud Rate

0=2400, 1=4800, 4=19200

2 = 9600

Number Of Network Boilers

0 to 32

Min Slave Address

0 to 127

Max Slave Address

0 to 127

Net Boiler 1 Address

Address for Network Boiler 1

001

Net Boiler 2 Address

Address for Network Boiler 2

002

Net Boiler 3 Address

Address for Network Boiler 3

000

Boiler 4

Net Boiler 5 Address

Address for Network Boiler 5

000

Net Boiler 6 Address

Address for Network Boiler 6

000

Net Boiler 7 Address

Address for Network Boiler 7

000

Net Boiler 8 Address

Address for Network Boiler 8

000

Boiler 9

101

Net Boiler 10 Address

Address for Network Boiler 10

000

102

Net Boiler 11 Address

Address for Network Boiler 11

000

103

Net Boiler 12 Address

Address for Network Boiler 12

000

104

Net Boiler 13 Address

Address for Network Boiler 13

000

Boiler 14

106

Net Boiler 15 Address

Address for Network Boiler 15

000

APPENDIX G (cont.) __________________________

Table G-1. BMS COMMANDS – (Continued)

0 = 4 - 20 mA

0 = Normal

2=9600, 3=14400,

95 Net Boiler 4 Address Address for Network

100 Net Boiler 9 Address Address for Network

105 Net Boiler 14 Address Address for Network

000

G-5

No.

COMMAND

ENTRY RANGE

FACTORY

DEFAULT

107

Net Boiler 16 Address

Address for Network Boiler 16

000

108

Net Boiler 17 Address

Address for Network Boiler 17

000

109

Net Boiler 18 Address

Address for Network Boiler 18

000

110

Net Boiler 19 Address

Address for Network Boiler 19

000

Boiler 20

112

Net Boiler 21 Address

Address for Network Boiler 21

000

113

Net Boiler 22 Address

Address for Network Boiler 22

000

114

Net Boiler 23 Address

Address for Network Boiler 23

000

115

Net Boiler 24 Address

Address for Network Boiler 24

000

Boiler 25

117

Net Boiler 26 Address

Address for Network Boiler 26

000

118

Net Boiler 27 Address

Address for Network Boiler 27

000

119

Net Boiler 28 Address

Address for Network Boiler 28

000

120

Net Boiler 29 Address

Address for Network Boiler 29

000

Boiler 30

122

Net Boiler 31 Address

Address for Network Boiler 31

000

123

Net Boiler 32 Address

Address for Network Boiler 32

000

124

Network Baud

0=2400, 1=4800, 4=19200

2 = 9600

125

Network Timeout

5 to 240 sec

60 sec.

126

Password Lo

0 to 255

127

Password Hi

0 to 255

128

Modbus Control Type

0 = Round-Robin 1 = Broadcast

0 = Round Robin

APPENDIX G (cont.) __________________________

Table G-1. BMS II COMMANDS – (Continued)

111 Net Boiler 20 Address Address for Network

116 Net Boiler 25 Address Address for Network

121 Net Boiler 30 Address Address for Network

000

2=9600, 3=14400,

APPENDIX G

No.

COMMAND

ENTRY RANGE

FACTORY DEFAULT

129

Modbus Pass-Thru

0 = Disabled 1 = Enabled

0 = Disabled

130

Header Temp Deadband

01 to 15°F

05°F

131

Outside Temp Sensor Offset

-10.0°F to 10.0°F

0.0°F

132

Ramp Up %/Min

000 to 300

133

Ramp Down %/Min

000 to 300

200

134

Fault Alarm Boilers

No Blr Faults All Blr faults

No Blr Faults

135

4-20 mA Offset

-1.00 to 1.00 mA

0.0 mA

136

Return Sensor Offset

-10.0 to 10.0°F

0.0°F

137

Load Start Pct

000 to 100

138

Load Stop Pct

000 to 100

Bit 7 = Empty

151

(Reserved For Future Expansion)

Undefined

APPENDIX G (cont.) __________________________

Table G-1. BMS II COMMANDS – (Continued)

150 I/O Status 00 to 255

Bit 0 = AUX Relay Bit 1 = Fault Relay Bit 2 = Sys Start Relay Bit 3 = Empty Bit 4 = Setback Bit 5 = Interlock 2 Bit 6 = Interlock 1

G-7

APPENDIX H

APPENDIX H __________________________

BMS II MODBUS ADDRESS ASSIGNMENTS

IMPORTANT

All Modbus addresses specified in this manual are written generically in hexadecimal format. However, many Building Automation Systems utilize another form of addressing where:

40001 is added to the generic address for a Holding Register address.

And

30001 is added to the generic address for an Input Register address.

Be sure to check the addressing scheme being used by the BAS that is being interfaced to the BMS II.

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Default/Comments

0x0000

0x0001

40 to 220°F

0x0002

-60 to 120°F

0x0003

Indoor Air/Return Temperature

40 to 220°F

0x0004

Fire Rate Out

0 to 100% (out to boilers)

0x0005

40 to 220°F

0x0006

Network Address

128 to 247

Default = 128

0x0007

Total Boilers Fired

0 to 32 (for BMS II)

0x0008

Total Boilers On Line

0 to 32 0x0009

0x000A

Fault/Message Code

0 to 65535

5 = 4-20mA Input Error

0x000B

0x000F

(Reserved)

0x0010

Lead Boiler Number

1 to 32

H-1 BMS II STANDARD INPUT REGISTER ASSIGNMENMTS

The Read Only Input Register assignments for the BMS II are listed in Table H-1 which follows:

Table H-1. BMS II Standard Input Register Address Mapping

(Reserved) Header Temperature Outside Air Temperature

Header Set Temperature

(Reserved)

thru

Bit: 0 = Outside Air Sensor 1 = Header Sensor Error 2 = Interlock 1 Error 3 = Interlock 2 Error 4 = Indoor Air Sensor Error/ Return Sensor Error

H-2

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Comments

0x0011 0x0018

Not Applicable

Used for 8 BMS Legacy

0x0019

Boiler 1 Status

119 = Not On-Line

122 = On-Line But Faulted

BMS II has only Network

0x001A

Boiler 2 Status (Net Boiler 2)

Same As Above

0x001B

Boiler 3 Status

Same As Above

0x001C

Boiler 4 Status (Net Boiler 4)

Same As Above

0x001D

Boiler 5 Status (Net Boiler 5)

Same As Above

0x001E

Boiler 6 Status (Net Boiler 6)

Same As Above

(Net Boiler 7)

(Net Boiler 8)

0x0021

Boiler 9 Status (Net Boiler 9)

Same As Above

0x0022

Boiler 10 Status

(Net Boiler 10)

Same As Above

0x0023

Boiler 11 Status

(Net Boiler 11)

Same As Above

0x0024

Boiler 12 Status (Net Boiler 12)

Same As Above

0x0025

Boiler 13 Status

(Net Boiler 13)

Same As Above

0x0026

Boiler 14 Status

(Net Boiler 14)

Same As Above

APPENDIX H (cont.) __________________________

Table H-1. BMS II Standard Input Register Address Mapping-Cont.

Thru

(Net Boiler 1)

(Net Boiler 3)

0x001F Boiler 7 Status

0x0020 Boiler 8 Status

120 = On-Line But Not Fired 1–40 = Fired & Sequence 121 = On-Line But Disabled

Same As Above

(PWM) Boilers Only

Boilers so Net Boiler 1 = Boiler 1, etc.

H-3

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Comments

122 = On-Line But Faulted

0x0028

Boiler 16 Status

(Net Boiler 16)

Same As Above

(Net Boiler 17)

0x002A

Boiler 18 Status

(Net Boiler 18)

Same As Above

0x002B

Boiler 19 Status

(Net Boiler 19)

Same As Above

0x002C

Boiler 20 Status

(Net Boiler 20)

Same As Above

0x002D

Boiler 21 Status

(Net Boiler 21)

Same As Above

(Net Boiler 22)

0x002F

Boiler 23 Status

Same As Above

0x0030

Boiler 24 Status

(Net Boiler 24)

Same As Above

0x0031

Boiler 25 Status

(Net Boiler 25)

Same As Above

0x0032

Boiler 26 Status

(Net Boiler 26)

Same As Above

(Net Boiler 27)

0x0034

Boiler 28 Status

(Net Boiler 28)

Same As Above

0x0035

Boiler 29 Status

(Net Boiler 29)

Same As Above

0x0036

Boiler 30 Status

(Net Boiler 30)

Same As Above

APPENDIX H (cont.) __________________________

Table H-1. BMS II Standard Input Register Address Mapping-Cont.

0x0027 Boiler 15 Status

(Net Boiler 15)

0x0029 Boiler 17 Status

0x002E Boiler 22 Status

119 = Not On-Line 120 = On-Line But Not Fired 1–40 = Fired & Sequence 121 = On-Line But Disabled

Same As Above

(Net Boiler 23)

0x0033 Boiler 27 Status

H-4

Same As Above

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Comments

0x0037

Boiler 31 Status

119 = Not On-Line

122 = On-Line But Faulted

0x0038

Boiler 32 Status

(Net Boiler 32)

Same As Above

0x0039

I/O Status

00 to 255

Bit map of Input/Output

Bit 7 = Empty

0x003A

Return Sensor Temp

40°F to 220°F

0x003B 0xFFFF

APPENDIX H (cont.) __________________________

Table H-1. BMS II Standard Input Register Address Mapping-Cont.

(Net Boiler 31)

Thru

120 = On-Line But Not Fired 1–40 = Fired & Sequence 121 = On-Line But Disabled

Status: Bit 0 = AUX Relay Bit 1 = Fault Relay Bit 2 = Sys Start Relay Bit 3 = Empty Bit 4 = Setback Bt 5 = Interlock 2 Bit 6 = Interlock 1

H-5

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Default/Comments

0x0000 0x0003

(Reserved)

0x0004

Net Header Set

40 to 220°F

Valid when Hdr Set

Network

0x0005

System Start Temp

32 to 120°F

Default = 70°F

0x0006

System Start Option

0 or 1 1 = Temp and Load

Default = 0

0x0008

Bldg Ref Temp

40 to 220°F

Default = 70°F

0x0009

Not Applicable

0x000A

Not Applicable

0x000B

Reset Ratio

0.3 to 3.0 (0.1 increments),

Default = 1.2 (Value x 10)

0x000C

40 to 220°F

Default = 200°F

0x000D

Min Header Temp

40 to 220°F

Default = 40°F

0x000E

Start Percent

25 to 100%

Default = 20%

0x000F

Stop Percent

10 to 45%

Default = 16%

0x0010

Integral Gain

0.00 to 9.99 Rep/Min (in 0.01 increments

Default = 0.15 Rep/Min (Value x 100)

0x0011

0, 1, or 2

2 = Remote Setpt

Default = 0

APPENDIX H (cont.) __________________________

H-2. BMS II Controller Standard Holding Re gister Assignments

The Holding Register addr ess assignments for the BMS II are listed in Table H -2 which follows. Un less otherwise specified, all Holding Register Menu items are Read/Write (R/W).

Table H-2. BMS II Standard Holding Register Address Mapping

thru

Temp

0x0007 Manual Hdr Set

Temp/Internal Setpt

Max Header Temp

0 = Temp Only,

40 to 220°F Default = 160°F

Mode=Remote Setpt and Remote Signal =

H-6

Header Set Mode

0 = Constant Setpt 1 = In/Outdoor Reset

(Constant Setpt))

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Default/Comments

0x0013

Bandwidth

5 to 120°F

Default = 70°F

0x0014

0 to 99%

Default = 45%

0x0015

0 or 1 1 = 100% Fire Rate and Off

Default = 1

0x0016

0 or 1 1 = Constant Setpt

Default = 0

0x0017

Fault Alarm Relay

0, 1, 2, 3

3 = Interlock 2

Default = 0

1 = Manual

0x0019

0, 1 or 2

2 = Combination

Default = 1

0x001A

0x001B

0x001C

0x001D

0x001E

50 to 100%

Default = 100%

0x001F

0 or 1 1 = Start Enabled

Default = 1

0x0020

Minutes

00 to 59

Present Time

APPENDIX H (cont.) __________________________

Table H-2. BMS II Standard Holding Register Address Mapping

0x0012

0x0018

Derivative Gain

Header Temp

Aux Relay Open Aux Relay Mode

Failsafe Mode

Mode

Fault Alarm Clear

Method

Boiler Operation

Mode

-2.00 to 2.00 (0.00 increments)

0 = 100% Fire Rate

0 = Shutdown

0 = All Faults, 1 = No Interlock 2 = Interlock 1

0 or 1 0 = Automatic

0 = Parallel 1 = Sequential

Default = 0.15 (Value x 100)

(100% Fire Rate & Off)

(Shutdown)

(All Faults)

Default = 0 (Automatic)

(Sequential)

Not Applicable

(Reserved) (Reserved) (Reserved) Max Power Input

Sys Intlk Config

Real Time Clock

0 = Always Enabled

(Fire Rate)

(Start Enabled)

H-7

APPENDIX H

Modbus Data

Address (Hex)

Menu Item

Units and Range

Default/Comments

Minutes

0x0021

Real Time Clock Hours

00 to 23 Hours

Present Time

0x0022

Day of Week

1 to 7

Present Day

0x0023

Year

00 to 99

Present Year

0x0024

Day of Month

01 to 31

Present Day of Month Month

0x0026

Offset Temp Sun.

-50 to 50°F

Default = 0°F

0x0027

Offset Temp Mon.

-50 to 50°F

Default = 0°F

0x0028

Offset Temp Tue.

-50 to 50°F

Default = 0°F

0x002D

Day 1 – Minutes

00 to 59 Minutes

Default = o Day 2 – Minutes

0x002F

Offset On Time Day 3 – Minutes

00 to 59 Minutes

Default = 0

0x0030

Day 4 – Minutes

00 to 59 Minutes

Default = 0

0x0031

Day 5 – Minutes

00 to 59 Minutes

Default = 0

0x0032

Day 6 – Minutes

00 to 59 Minutes

Default = 0 Day 7 – Minutes

APPENDIX H (cont.) __________________________

Table H-2. BMS II Standard Holding Register Address Mapping

0x0020

0x0025

0x0029 0x002A 0x002B

Real Time Clock

Offset Temp Wed. Offset Temp Thu. Offset Temp Fri.

00 to 59 Present Time

01 to 12 Present Month

-50 to 50°F Default = 0°F

H-8

0x002C

0x002E

0x0033

Offset Temp Sat. Offset On Time

Offset On Time

-50 to 50°F Default = 0°F

00 to 59 Minutes Default = 0

AERCO BMS II BOILER User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

GENERAL INFORMATION

Simplified Installation and Set-Up

User-Friendly Control System Interface

Retention of Menu Option Settings

Application Flexibility

Sequential or Parallel Operation

Accuracy

Bumpless Transfer

Fault Alarm Surveillance

BMS II Programming Via RS232 Port.

INSTALLATION

Mounting the BMS

Header Sensor

Return Sensor

Outdoor Air Sensor

BMS II Bias Switches & Loop Termination Resistors

RS485 Wiring, Termination& Bias for Benchmark Series and KC1000 Boilers

Method 1

Method 2

RS485 Wiring for Modulex Series Boilers

Interlock 1 (INT 1) Wiring

Interlock 2 (INT 2) Wiring

System Start Relay

Fault Alarm Relay

Auxiliary Relay

OPERATION

Menu Processing Procedure

HEADER TEMP and PERCENT OF LOAD

HEADER SETPOINT

OUTSIDE AIR TEMP

I/O STATUS

RETURN TEMP

ENTER PASSWORD

Date and Time Menu Options

RS232 MODE

RS232 BAUD RATE

MODBUS ADDRESS

NETWORK TIMEOUT

MODBUS PASS THRU

RS485 BAUD RATE

MIN SLAVE ADDR

MAX SLAVE ADDR

NUMBER NETWK BLRS

MODBUS CNTL TYPE

NETW BOILER Xx ADDRESS= Yyy (Where Xx = 01 – 32; Yyy = 001 – 127)

HEADER SET MODE

HDR HIGH LIMIT

HDR LOW LIMIT

INTERNAL SETPT

RESET RATIO

BLDG REF TEMP

REMOTE SIGNAL

OFFSET ENABLE

Offset Menu Options

Setting Up An Offset Schedule

Manual Offset

BOILER OP MODE

Parallel Mode

Sequential

SYS INTLK CONFIG

BLR START LEVEL

BLR STOP LEVEL

MAX POWER INPUT

FAIL SAFE MODE

PROPORTIONAL BND

INTEGRAL GAIN

DERIVATIVE GAIN

HDR TEMP DEADBND

SYS START TEMP

SYS START OPTION

SYS START INTLK

AUX RELAY OPEN

AUX RELAY CLOSE

FAULT ALRM RELAY

FAULT ALARM BLRS

FAULT ALRM CLEAR