AERCO C-More Controls User Manual

structio In n

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

No.

GF-112

C-MORE CONTROL PANEL

OPERATION

For

Benchmark Series

&

KC Series

Systems

Printed in U.S.A. REVISED JANUARY, 2009

C-MORE CONTROL PANEL OPERATION

TABLE OF CONTENTS

PARA. PAGE

SECTION 1 – GENERAL INFORMATION 1

1.1 INTRODUCTION 1

1.2 SAFETY PRECAUTIONS AND WARNINGS 1

1.3 FEATURES AND BENEFITS 1

1.4 CONTROL PANEL DESCRIPTION 2

SECTION 2 – CONTROL PANEL MENU STRUCTURE 6

2.1 CONTROL PANEL MENUS 6

2.2 MENU PROCESSING PROCEDURES 6

2.3 OPERATING MENU 7

2.4 SETUP MENU 7

2.5 CONFIGURATION MENU 8

2.6 TUNING MENU 10

2.7 CALIBRATION MENU 11

2.8 DIAGNOSTICS MENU 11

SECTION 3 – CONTROL PANEL MENU DESCRIPTIONS 13

3.1 MENU ITEM DESCRIPTIONS 13

3.2 FACTORY DEFAULTS 13

SECTION 4 – CONTROL PANEL DISPLAY MESSAGES 21

4.1 STARTUP AND STATUS MESSAGES 21

4.2 FAULT MESSAGES 21

SECTION 5 –INPUT/OUTPUT INTERFACES & OPERATING MODES 24

5.1 INTRODUCTION 24

5.2 I/O INTERFACES 24

5.3 MODES OF OPERATION 26

5.4 START SEQUENCE 31

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C-MORE CONTROL PANEL OPERATION

TABLE OF CONTENTS - Continued

SECTION 6 – CALIBRATION AND DIAGNOSTIC MENUS 33

6.1 INTRODUCTION 33

6.2 CALIBRATION PROCEDURES 33

6.3 DIAGNOSTICS PROCEDURES 35

SECTION 7 – RS232 COMMUNICATION 38

7.1 INTRODUCTION 38

7.2 RS232 COMMUNICATION SETUP 38

7.3 MENU PROCESSING UTILIZING RS232
COMMUNICATION

7.4 DATA LOGGING 39

APPENDIX A - C-MORE CONTROL PANEL VIEWS A-1

APPENDIX B - TROUBLESHOOTING GUIDE B-1

APPENDIX C - INDOOR/OUTDOOR RESET RATIO CHARTS C-1

APPENDIX D - TEMPERATURE SENSOR RESISTANCE CHART D-1

APPENDIX E - WIRING DIAGRAMS E-1

APPENDIX F - C-MORE CONTROL PANEL DIP SWITCH
SETTINGS

38

F-1

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C-MORE CONTROL PANEL OPERATION

SECTION 1 - GENERAL INFORMATION

1.1 INTRODUCTION

The information in this Section provides a guide
to the operation of KC and Benchmark Series

units using the C-More Control Panel. In

addition, it provides information describing the
numerous types of external sensors and control
devices which can be interfaced to the unit using
terminals provided in the Input/Output (I/O) Box
utilized with the Control Panel. Information
regarding the set up of all Water Heater and
Boiler Operating Modes is also included herein.

1.2 SAFETY PRECAUTIONS AND WARNINGS

It is imperative that the initial startup of KC and
Benchmark Series units be performed by factory
trained personnel. Operation prior to initial
startup by factory trained personnel will void the
equipment warranty. In addition, the following
WARNINGS and CAUTIONS must be observed
at all times.

CAUTION:

All initial installation procedures must be
satisfied before attempting to start the unit.

WARNING:

ELECTRICAL VOLTAGES IN KC SERIES
UNITS INCLUDE 120 AND 24 VOLTS AC.
VOLTAGES IN BENCHMARK SERIES UNITS
MAY ALSO INCLUDE 460 AND 220 VOLTS
AC. THEREFORE, THESE UNITS MUST BE
SERVICED ONLY BY FACTORY CERTIFIED

SERVICE TECHNICIANS.

WARNING:

DO NOT ATTEMPT TO DRY FIRE THE
UNIT. STARTING THE UNIT WITHOUT A
FULL WATER LEVEL CAN SERIOUSLY
DAMAGE THE UNIT AND MAY RESULT IN
PERSONNEL INJURY OR PROPERTY
DAMAGE. THIS SITUATION WILL VOID ANY
WARRANTY.

FEATURES AND BENEFITS

KC and Benchmark Series units equipped
the new C-More Control Panel include a number
of additional features and benefits. These
include:

1.3.1 System Start Temperature

The Sy tem Start Temperature feature s allows a
boiler to be enabled or disabled based on the
outside air temperature. When the outside air
temperature goes below the System Start
Temperature, the boiler is enabled. When the
outside air temperature is above the System
Start Temperature, the boiler is disabled. This
feature may be used in any boiler mode of
operation. It requires that an outdoor air
temperature sensor be connected to the boiler.

1.3.2 Setpoint Low Limit

This option allows the user to
unit’s setpoint can be set. The allowable range is
40°F to 240°F. The factory default is set at 60°F.

limit how low the

1.3.3 Setpoint High Limit

This option has two functions. In the
Indoor/Outdoor Reset, Constant Setpoint and 4
to 20 mA Remote Setpoint Modes, the Setpoint
High Limit option limits how high the unit’s
setpoint can be set. The allowable range is 40°F
to 240°F.

In the 4 to 20 mA Direct Drive, Combination or
BMS Mode of operation, the Setpoint High Limit
acts as a temperature limiting governor. Should
the unit’s outlet temperature equal the Setpoint
High Limit Setting, a PID function will intervene
and maintain the outlet temperature at the
Setpoint High Limit minus the Setpoint Limit
Band.

To use the Setpoint High Limit feature, the
Setpoint Limiting option must be enabled and a
Setpoint Limit Band selected. This Band is
preset at 5°F, however it is adjustable from 0°F
to 10°F.

1.3.4

with

1.3

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C-MORE CONTROL PANEL OPERATION

Temp Hi Limit

The Temp Hi Limit is a te e The F
that will shut down the unit and generate an
alarm if the if the outlet temperature exceeds its
setting. It is preset at 210°F, however it is
adjustable from 40°F to 240°F.

mperature limit featur

1.3.5 Max Fire Rate

This feature allows the
firing rate. This feature can be useful if site or
equipment limitations require that less BTU’s be
input into the system. This feature is meant to be
used only on a temporary basis until the system
or equipment limitations are resolved.

user to limit the unit’s

1.3.6 Pump Delay Timer

The C-More control system a
turn a pump on and off as the boiler cycles on
and off on demand. The Pump Delay Timer
feature allows the user to keep the pump
running up to 30 minutes after the unit has shut
down and the demand satisfied.

llows the user to

1.3.7 Aux Start On Delay

The AUX START ON DELAY
conjunction with the Auxiliary Relay. When a call
for heat is produced, the Aux Relay will energize
and can be used to start a system or gas
booster pump, open a louver or valve, or start
some other necessary system process. The Aux
Start On Delay is a timer that can be set from 0
to 120 seconds. It tells the combustion control
system to wait a specified period of time for the
device started by the Aux Relay to come up to
speed, open or make a proving switch. Once the
waiting period expires, the start sequence will
resume. Should the device not prove within the
preset time interval, the unit will shut down and
generate an alarm.

feature works in

1.3.8

Failsafe Mode

whether the unit shuts down or switches to the
Constant Setpoint mode of operation in the
event that a loss of signal causes the unit to
become inoperable. For example, if a 4 to 20
mA Remote Setpoint signal is being sent, but is
not seen by the unit, the unit will shut down or
automatically switch to the Constant Setpoint
mode and work off the unit’s internal setpoint.
The default setting for this option is Shutdown.

1.3.9 RS232 Monitoring

This feature allows a laptop co
suitable device to be connected to the RS232
port on the Control Panel front panel. This
permits the unit to be monitored either locally or
remotely via a Modem.

1.3.10 Aux Temp

This feature permits a
connected to the Aux Sensor In terminals in the
I/O Box. The sensor must be within the
resistance range used with the C-More Control
system. It can be used to monitor the user’s
parameter of choice. This feature is always
enabled. This is strictly a monitoring function
and plays no role in control of the unit.

1.4 CONTROL PANEL DESCRIPTION

The C-More Control Panel is available in t
models. One model has a horizontal panel
control layout as shown in Figure 1-1A and is
used on KC Series units. The other model has a
vertical panel control layout as shown in Figure
1-1B and is used on Benchmark Series units.
These models contain identical controls,
indicators and displays and are functionally
identical. These controls, indicators and displays
are listed and described in Table 1-1.

ailsafe mode allows

temperature sensor to be

the user to select

mputer or other

wo

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C-MORE CONTROL PANEL OPERATION

Figure 1-1A. C-More Control Panel For KC Series Units

12

10

7

11

3

1

2

4

8

9

5

6

Figure 1-1B. C-More Control Panel For Benchmark Series Units

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C-MORE CONTROL PANEL OPERATION

Table 1-1. Operating Controls, Indicators and Displays

ITEM

NO.

CONTROL, INDICATOR

OR DISPLAY

1 LED Status Indicators Four Status LEDs indicate the current operating status as

follows:

COMM

MANUAL

REMOTE

DEMAND

2 VFD Display Vacuum Fluorescent Display (VFD) consists of 2 lines each

OUTLET

3

TEMPERATURE

Display

RS232 Port

4

READY Indicator

5

ON/OFF Switch

6

LOW WATER LEVEL

7

TEST/RESET Switches

FAULT Indicator Red FAULT LED indicator lights when a boiler alarm

8

CLEAR Key

9

10 MENU Keypad Consists of 6 keys which provide the following functions for

MENU

BACK

Lights when RS232 communication is occurring
Lights when the unit is being controlled using the front panel

keypad.
Lights when the unit is being controlled by an external signal

from an Energy Management System
Lights when there is a demand for heat.

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

Startup Messages
Alarm Messages
Operating Status Messages
Menu Selections

3–Digit, 7–Segment LED display continuously displays the
outlet water temperature. The °F or °C LED next to the
display lights to indicate whether the displayed temperature is
in degrees Fahrenheit or degrees Celsius.

Port permits a Laptop Computer or External Modem to be
connected to the unit’s Control Panel.

Lights when ON/OFF switch is set to ON and all Pre-Purge
conditions have been satisified.

Enables and disables boiler operation.

Allow the operator to test the operation of the water level
monitor.

Pressing TEST opens the water level probe circuit and
simulates a Low Water Level alarm.

Pressing RESET resets the water level monitor circuit.
Pressing CLEAR resets the display.

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

Turns off the FAULT indicator and clears the alarm message
if the alarm is no longer valid. Lockout type alarms will be
latched and cannot be cleared by simply pressing this key.
Troubleshooting may be required to clear these types of
alarms

the Control Panel Menus:
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. Continuously pressing this key will
bring you back to the default status display in the VFD. Also,
this key allows you to go back to the top of a main menu
category.

FUNCTION

4

ITEM

NO.

10

(Cont.)

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Table 1-1. Operating Controls, Indicators and Displays - Continued

CONTROL, INDICATOR

OR DISPLAY

▲ (Up) Arrow When in one of the main menu categories (Figure 1-2),

pressing this key will select the displayed menu category. If
the CHANGE key was pressed and the menu item is flashing,
pressing the ▲ arrow key will increment the selected setting.

▼ (Down) Arrow When in one of the main menu categories (Figure 1-2),

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

FUNCTION

CHANGE

ENTER

11

12

AUTO/MAN Switch

FIRE RATE Bargraph

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
begin to flash. Pressing the ▲ or ▼ arrow key when the item
is flashing will increment or decrement the displayed setting.

Saves the modified menu information in memory. The
display will stop flashing.

This switch toggles the boiler between the Automatic and
Manual modes of operation. When in the Manual (MAN)
mode, the front panel controls are enabled and the MANUAL
status LED lights.

When in the Automatic (AUTO) mode, the MANUAL status
LED will be off and the front panel controls disabled.

20 segment red LED bargraph continuously shows the Fire
Rate in 5% increments from 0 to 100%

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C-MORE CONTROL PANEL OPERATION

SECTION 2 - CONTROL PANEL MENU STRUCTURE

2.1 CONTROL PANEL MENUS

The Control Panel incorporates an extensive
menu structure which permits the operator to set
up, and configure the unit. The menu structure
consists of six major menu categories as shown
in Figure 2-1. Each of the menus shown, contain
options which permit operating parameters to be
viewed or changed. The menus are protected by
two different password levels to prevent
unauthorized use.

Password Level 1 allows viewing of all menu
categories and also allows the Setup,
Configuration and Tuning Menu options to be
changed.

Password Level 2 allows viewing and changing
of all Level 1 menu categories and also allows
access to the Calibration and Diagnostic Menus.
These two additional menu categories should
only be used by factory trained personnel to
calibrate and troubleshoot the unit.

A third Password Level called the Factory
Password also exists. However, access to this
menu is restricted to Factory Authorized
personnel only.

Prior to entering the correct password, the
options contained in the Operating, Setup,
Configuration and Tuning Menu categories can
be viewed. However, except for Internal Setpoint
Temperature (Configuration Menu), none of the
viewable menu options can be changed.

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

2. Press the MENU key. The display will show
the Setup Menu which is the next menu
category shown in Figure 2-1. This menu
contains the Password option which must be
entered if other menu options will be
changed.

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

4. With the desired menu displayed, press the
▲ or ▼ arrow key. The first option in the
selected menu will be displayed.

OPERATING

LEVEL 1 PWD

SETUP

CONFIGURATION

TUNING

LEVEL 2 PWD

CALIBRATION

2.2 MENU PROCESSING PROCEDURE

Accessing each menu and option is
accomplished using the Menu Keys shown in
Figure 1-1. Therefore, it is imperative that you
be thoroughly familiar with the following basic
steps before attempting to perform specific
menu processing procedures.

1. The Control Panel will normally be in the
Operating Menu and the VFD will display the
current unit status. Pressing the ▲ or ▼
arrow key will display the other available data
in the Operating Menu.

6

DIAGNOSTICS

Figure 2-1. Menu Structure

C-MORE CONTROL PANEL OPERATION

5. Continue pressing the ▲or ▼ arrow key until
the desired menu option is displayed.
Pressing the ▲ arrow key will display the
available menu options in the Top-Down
sequence. Pressing the ▼ arrow key will
display the options in the Bottom-Up
sequence. The menu options will 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 begin to flash. Press the
▲ or ▼ arrow key to scroll through the
available 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.

NOTE:

Paragraphs 2.3 through 2.8 provide brief
descriptions of the options contained in
each menu. Refer to Section 3 for detailed
descriptions of each menu option.

2.3 OPERATING MENU

The Operating Menu displays the unit status and
a number of key operating parameters for the
unit as listed in Table 2-1. This menu is “Read­Only” and does not allow personnel to change or
adjust any of the displayed items. Since this

menu is “Read-Only”, it can be viewed at any
time without entering a password. Press the ▲
arrow key to display the menu item in the order
listed (Top-Down). Pressing the ▼ arrow key
will display the menu items in reverse order
(Bottom-Up).

2.4 SETUP MENU

The Setup Menu (Table 2-2) permits the
operator to set the unit password which is
required to change any 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 enter date and time, language to be used for
display messages, units of temperature
measurements and entries required for external
communication and control of the unit via the
RS232 port. A view-only software version
display is also provided to indicate the current
Control Box software version,

NOTE

The Outdoor Temp display item shown with an asterisk in Table
2-1 will not be displayed unless the Outdoor Sensor function has
been enabled in the Configuration Menu (Table 2-3).

Table 2-1. Operating Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Status Message
Active Setpoint 40°F 240°F
Aux Temp 30°F 245°F
Outdoor Temp* -70°F 130°F
Fire Rate In 0% Max Fire Rate
Flame Strength 0% 100%
Run Cycles 0 999,999
Run Hours 0 999,999
Fault Log 0 9 0

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Table 2-2. Setup Menu

Available Choices or Limits
Menu Item Display Minimum Maximum Default

Passsword
Level 1 = 159
Level 2 = 6817
Language English English
Time 12:00 am 11:59 pm
Date 01/01/00 12/31/99
Unit of Temp Fahrenheit

Comm Address 0 127 0
Baud Rate 2400

Software Ver 0.0 Ver 9.9

2.5 CONFIGURATION MENU

The Configuration Menu shown in Table 2-3
permits adjustment of the Internal Setpoint
(Setpt) temperature regardless of whether the
valid password has been entered. Setpt is
required for operation in the Constant Setpoint
mode. The remaining options in this menu
require the valid password to be entered, prior to
changing existing entries. This menu contains a
number of other configuration settings which
may or may not be displayed, depending on the
current operating mode setting.

0 9999 0

Celsius

4800
9600

19.2K

The Configuration Menu settings shown in
Table 2-3 are Factory-Set in accordance
with the requirements specified for each
individual order. Therefore, under normal
operating conditions, no changes will be
required.

Fahrenheit

9600

NOTE:

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C-MORE CONTROL PANEL OPERATION

Table 2-3. Configuration Menu

Available Choices or Limits
Menu Item Display Minimum Maximum Default

Internal Setpt Lo Temp Limit Hi Temp Limit 130°F
Unit Type Boiler

Unit Size 0.5 MBTU

Boiler Mode
(If Unit Type = Boiler)

Heater Mode
(If Unit Type = Water Heater)
Remote Signal
(If Mode = Remote Setpoint,
Direct Drive or Combination)

Bldg Ref Temp
(If Boiler Mode = Outdoor
Reset)
Reset Ratio
(If Boiler Mode = Outdoor
Reset)
Outdoor Sensor Enabled or Disabled Disabled
System Start Tmp
(If Outdoor Sensor =
Enabled)
Setpt Lo Limit 40°F Setpt Hi Limit 60°F
Setpt Hi Limit Setpt Lo Limit 240°F 200°F
Temp Hi Limit 40°F 240°F 210°F
Max Fire Rate 40% 100% 100%
Pump Delay Timer
(If Unit Type = Boiler)
Aux Start On Dly 0 sec 120 sec 0 sec
Failsafe Mode Shutdown or Constant Setpt Shutdown
mA Output Setpoint

Low Fire Timer 2 sec 120 sec 2 sec
Setpt Limiting Enabled or Disabled Disabled
Setpt Limit Band 0°F 10°F 5°F

Boiler

Water Heater

1.0 MBTU

1.0 MBTU

1.5 MBTU

2.0 MBTU

2.5 MBTU

3.0 MBTU

Constant Setpoint

Remote Setpoint

Direct Drive

Combination

Outdoor Reset

Constant Setpoint

Remote Setpoint

4 – 20 mA/1 – 5V

0 -20 mA/0 – 5V

PWM Input (BMS)

Network

40°F 230°F 70°F

0.1 9.9 1.2

30°F 100°F 60°F

0 min 30 min 0 min

Outlet Temp

Fire Rate Out

Off

Constant
Setpoint

Constant
Setpoint
4 to 20 mA/
1-5V

Off

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C-MORE CONTROL PANEL OPERATION

2.6 TUNING MENU

The Tuning Menu items in Table 2-4 are Factory
set for each individual unit. Do not change
these menu entries unless specifically requested
to do so by Factory-Trained personnel.

The Breakpoint Menu items shown in the following
Table with an asterisk are displayed only if Unit
Type = Water Heater and the Heatr Bkpt Dsp
option in the Calibration Menu (Table 2-5) is
Enabled. These Breakpoint values correspond to a
130°F default setpoint

Table 2-4. Tuning Menu

Available Choices or Limits
Menu Item Display Minimum Maximum Default

Prop Band 1°F 120°F 70°F (Boiler)

Integral Gain 0.00 2.00 1.00 (Boiler)

Derivative Time
(If Unit Type = Boiler)
Min Load Adj
(If Unit Type = Water Heater)
Max Load Adj
(If Unit Type = Water Heater)
FFWD Temp
(If Unit Type = Water Heater)
Outlet Feedback
(If Unit Type = Water Heater)
Feedback Gain
(If Unit Type = Water Heater
& Heatr Tuning Dsp is
Enabled)
Breakpt at 100%* 30°F 240°F 77°F
Breakpt at 90%* 30°F 240°F 81°F
Breakpt at 80%* 30°F 240°F 85°F
Breakpt at 70%* 30°F 240°F 91°F
Breakpt at 60%* 30°F 240°F 95F
Breakpt at 50%* 30°F 240°F 102F
Breakpt at 40%* 30°F 240°F 110°F
Breakpt at 30%* 30°F 240°F 112°F
Breakpt at 20%* 30°F 240°F 114°F
Breakpt at 10%* 30°F 240°F 130°F
Breakpt at 0%* 30°F 240°F 135°F
Reset Defaults? Yes

0.00 min 2.00 min 0.00 min (Boiler)

-50°F 50°F 0°F

-50°F 50°F 0°F

30°F 245°F

.01 1.00 0.05

Are You Sure?

NOTE

On (Yes)

Off (No)

No

8°F (Water Heater)

1.60 (Water Heater)

0.10 min (Water Heater)

On (Yes)

No

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C-MORE CONTROL PANEL OPERATION

2.7 CALIBRATION MENU

The Calibration Menu is used by Factory
Trained Service personnel to adjust or reset the
parameters listed in Table 2-5.

Table 2-5. Calibration Menu

Available Choices or Limits

Menu Item Display Minimum Maximum Default

Stepper Fbk
(Not adjustable via
RS232 serial
communication)
PWM In Adj -5.0% 5.0% 0.0%
Analog In Adj -5.0% 5.0% 0.0%
Flow In Adj -5.0% 5.0% 0.0%
CO In Adj -5.0% 5.0% 0.0%
O2 In Adj -5.0% 5.0% 0.0%
mA Out Adj -1.0 mA 1.0 mA 0.0 mA
A/F Sensitivity 1% 5% 2%
Power Reset Automatic

Water Temp Reset Automatic

Gas Press Reset Automatic

Min Off Time 0 Min 15 Min 1 Min (Boiler)

Heatr Tuning Dsp
(If Unit Type = Water
Heater)
Heatr Bkpt Dsp
(If Unit Type = Water
Heater)
Stop Level 0% Start Level 16
Start Level Stop Level 40% 20

Cal 100%

Verify 50%

Enabled or Disabled Disabled

Enabled or Disabled Disabled

Cal 0%

Manual

Manual

Manual

Cal 0%

Automatic

Automatic

Manual

0 Min (Water Heater)

2.8 DIAGNOSTICS MENU

The Diagnostics Menu shown in Table 2-6 is
used by Factory-Trained Service personnel to
troubleshoot the unit. This menu category
contains a number of Built In Test (BIT) test
routines to be used to check the operational
status of the Control Panel displays and keypad
keys. It also allows the operator to activate
relays, view switch status and increment the
stepper motor contained in the Air/Fuel Valve.

NOTE

With the exception of the Sensor Log Interval
(Int) setting, none of the following Diagnostic
Menu items can be initiated via a remote serial
communications link.

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C-MORE CONTROL PANEL OPERATION

Table 2-6. Diagnostics Menu

Available Choices or Limits
Menu Item Display Minimum Maximum Default

Display Test Off

LEDs

7-Seg

Bar-graph

Keypad Test Off

Manual, Menu

Up, Down

Change, Enter

Clear

(Back Key exits test mode)
Relay Test
(Allows user to force
outputs ON or OFF)

Switch Test
(Allows user to view
the status of all
switch inputs)

Stepper Test
(Allows user to
adjust the stepper
motor position using

the ▲ and ▼ keys)
Sensor Log Int

(Allows user to set
the time interval for
logging Sensor
inputs in Database)

Igniter ON/Igniter OFF

Blower ON/Blower OFF

Pump ON/Pump OFF

Aux ON/Aux OFF

Fault ON/Fault OFF

Exhaust sw ON/Exhaust sw OFF

SSOV sw ON/SSOV sw OFF

Blower Proof ON/Blower Proof OFF

Ignition sw ON/Ignition sw OFF

Over Temp sw ON/Over Temp sw OFF

Low Gas Pres ON/Low Gas Pres OFF

Hi Gas Pres ON/Hi Gas Pres OFF

Water Lev sw ON/Water Lev sw OFF

Rem Int sw ON/Rem Int sw OFF

Front Pnl sw ON/Front Pnl sw OFF

Delayed Int ON/Delayed Int OFF

Purge sw ON/Purge sw OFF

0% 100% 0%

12 Hrs, or 24 Hrs

Off

Off

Off

1 Min, 5 Min

15 Min, 30 Min

1 Hr, 6 Hrs

Off

Off

Off

Off

30 Min.

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C-MORE CONTROL PANEL OPERATION

SECTION 3 - CONTROL PANEL MENU DESCRIPTIONS

3.1 MENU ITEM DESCRIPTIONS

Descriptions of the menu items and options
contained in each of the six major menu
categories are listed and described in Table 3-1.
Factory Default values for each of these items
are summarized in Table 3-2.

3.2 FACTORY DEFAULTS

The factory default values for each menu item
are summarized in Table 3-2.

Table 3-1. Menu Item Descriptions

MENU LEVEL & OPTION DESCRIPTION

OPERATING MENU
Active Setpoint This is the setpoint temperature to which the control

is operating when operating in the Constant Setpoint,
Remote Setpoint or Outdoor Reset (Boiler Only)
Mode. When in the Constant Setpoint Mode, this
value is equal to the Internal Setpoint setting in the
Configuration Menu. When in the Remote Setpoint
Mode, this value is the setpoint equivalent to the
remote analog signal supplied to the unit. When
operating a Boiler in the Outdoor Reset Mode, this is

the derived value from the charts in Appendix C.
Aux Temp For monitoring purposes only
Outdoor Temp Displayed only if outdoor sensor is installed and

enabled.
Fire Rate In Desired input fire rate. This would normally be the

same as the fire rate shown on the bar-graph (fire

rate out) when the boiler is operating.
Flame Strength Displays flame strength from 0 to 100%.
Run Cycles Displays the total number of run cycles from 0 to

999,999.
Run Hours Displays total run time of unit in hours from 0 to

999,999.
Fault Log Displays information on the last 10 faults (numbered

0 through 9).

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Table 3-1. Menu Item Descriptions - Continued

MENU LEVEL & OPTION DESCRIPTION

SETUP MENU

Password

Level 1

Level 2

Language English is the ONLY language available
Time Displays time from 12:00am to 11:59pm.
Date Displays dates from 01/01/00 to 12/31/99
Unit of Temp Permits selection of temperature displays in degrees

Comm Address For RS485 MODBUS communications (0 to 127).

Baud Rate Allows the RS232 communication Baud Rate to be

Software Version Identifies the current software version of the control

Allows Level 1 or 2 password to be entered.

Entering the Level 1 Password (159) allows options in

the Setup, Configuration and Tuning Menus to be

modified.

Entering the Level 2 Password (6817) allows options

in the Calibration and Diagnostics Menus to be

changed/activated, in addition to all Level 1 Menu

options.

Fahrenheit (°F) or degrees Celsius (°C). Default is

°F.

Default address is 0.

set (2400 to 19.2K). Default is 9600.

box (Ver 0.0 to Ver 9.9).

CONFIGURATION MENU
Internal Setpoint Allows internal setpoint to be set (40°F to 240°F).

Unit Type Allows selection of Boiler or Water Heater. Default is

Unit Size Sets unit size from 0.5 to 3.0 MBTUs. Default is 1.0

Boiler Mode
(If Unit Type = Boiler)

Heater Mode
(If Unit Type = Water Heater)
Remote Signal
(If Mode = Remote Setpoint,

Direct Drive or Combination)

Bldg Ref Temp
(If Boiler Mode = Outdoor

Reset)

Default is 130°F.

Boiler.

MBTU.

Allows selection of: Constant Setpoint, Remote

Setpoint, Direct Drive, Combination, or Outdoor Reset

Mode. Default is Constant Setpoint Mode.

Allows selection of Constant Setpoint or Remote

Setpoint Mode. Default is Constant Setpoint Mode.

Used to set the type of external signal which will be

used when operating in the Remote Setpoint, Direct

Drive or Combination Mode. Default is 4 to 20 mA /

1 to 5V.

Allows the building reference temperature to be set

when operating a Boiler in the Outdoor Reset Mode.

Default is 70°F

14

C-MORE CONTROL PANEL OPERATION

Table 3-1. Menu Item Descriptions - Continued

MENU LEVEL & OPTION DESCRIPTION

CONFIGURATION MENU

(Continued)
Reset Ratio
(If Boiler Mode = Outdoor

Reset)
Outdoor Sensor Allows outdoor sensor function to be enabled or

System Start Tmp
(If Outdoor Sensor is Enabled)

Setpoint Lo Limit Used to set the minimum allowable setpoint (40°F to

Setpoint Hi Limit Used to set the maximum allowable setpoint (Setpoint

Temp Hi Limit This is the maximum allowable outlet temperature

Max Fire Rate Sets the maximum allowable fire rate for the unit

Pump Delay Timer
(If Unit Type = Boiler)

Aux Start On Dly Specifies the amount of time to wait (0 to 120 sec.)

Failsafe Mode Allows the Failsafe Mode to be set to either Constant

mA Output Can be set to allow this output to monitor Setpoint,

Low Fire Timer Specifies how long (2 to 120 sec.) to remain in the

Setpt Limiting Allows Setpt Limiting to be enabled or disabled.

Setpt Limit Band When Setpt Limiting is enabled, this menu item

Permits setting of Reset Ratio when operating Boiler

in the Outdoor Reset Mode. Reset Ratio is

adjustable from 0.1 to 9.9. Default is 1.2.

disabled. Default is Disabled.

If outdoor sensor is enabled, this menu item allows

the system start temperature to be set from 30°F to

100°F. Default is 60°F.

Setpoint Hi Limit). Default is 60°F

Lo Limit to 240°F). Default is 200°F.

(40°F to 240°F). Any temperature above this setting

will turn off the unit. The temperature must then drop

5°F below this setting to allow the unit to run. Default

Hi Limit is 210°F.

(40% to 100%). Default is 100%.

Specifies the amount of time (0 to 30 min.) to keep

the pump running after the unit turns off. Default is

zero.

between activating the Aux Relay (due to a demand)

and checking the pre-purge string to start the unit.

Default is 0 sec.

Setpoint or Shutdown. Default is Shutdown.

Outlet Temperature, Fire Rate Out, or be set to OFF.

Default is OFF.

low fire position after ignition, before going to the

desired output. Default is 2 sec.

Default is disabled.

allows the Setpt Limit Band to be set from 0°F to

10°F. Default is 5°F.

15

C-MORE CONTROL PANEL OPERATION

MENU LEVEL & OPTION DESCRIPTION

`Table 3-1. Menu Item Descriptions - Continued

TUNING MENU

Prop Band Generates a fire rate based on the error that exists

Integral Gain This sets the fraction of the output, due to setpoint

Derivative Time This value (0.00 to 2.00 min.) responds to the rate of

Min Load Adj
(If Unit Type = Water Heater)

Max Load Adj
(If Unit Type = Water Heater)

FFWD Temp
(If Unit Type = Water Heater)
Outlet Feedback Used to Enable or Disable feedback. Disable this

Feedback Gain
(If Unit Type = Water Heater)
Breakpoint at 100%
Thru
Breakpoint at 0%
(If Unit Type = Water Heater)

Reset Defaults? Resets Tuning Menu options to Factory Defaults

between the setpoint temperature and the actual
outlet temperature. If the actual error is less than the
proportional band setting (1 to 120°F), the fire rate
will be less than 100%. If the error is equal to or
greater than the proportional band setting, the fire
rate will be 100%. Defaults are 70°F (Boiler), 8°F
(Water Heater)

error, to add or subtract from the output each minute
to move towards the setpoint. Gain is adjustable
from 0.00 to 2.00 (Defaults are 1.00 for Boilers, 1.60
for Water Heaters).

change of the setpoint error. This is the time that
this action advances the output. (Defaults are 0.0
min. for Boilers, 0.10 min. for Water Heaters)

Setting is adjustable from -50°F to +50°F (Default is
zero). It adjusts the output by adding an offset to the
breakpoint chart at minimum flow. This is used to
fine tune Feed-Forward (FFWD) output at low flow
levels.

Setting is adjustable from -50°F to +50°F (Default is
zero). It adjusts the output by changing the scaling
of the breakpoint chart at maximum flow.

Displays the Feed-Forward temperature.

function for Feed-Forward control only.
Adjustable from 0.01 to 1.00 (Default is 0.05).

Allows breakpoint temperature settings to be entered
for 100% to 0% in 10% increments. The Bkpt Dsp
options in the Calibration Menu must be enabled to
view breakpoint temperatures. See Table 2-4 for
breakpoint default values.

16

C-MORE CONTROL PANEL OPERATION

Table 3-1. Menu Item Descriptions – Continued

MENU LEVEL & OPTION DESCRIPTION

CALIBRATION MENU

Stepper Fbk
(Not adjustable via RS232

serial communication)

PWM In Adj Allows the Pulse Width Modulation (PWM) duty cycle

Analog In Adj Allows adjustment of the analog input from -5.0% to

Flow In Adj Allows adjustment of the water Flow Rate Input from

CO In Adj Allows adjustment of the Carbon Monoxide level from

O2 In Adj Allows adjustment of the Oxygen level from -5.0% to

mA Out Adj Allows adjustment of the milliamp output from -5.0

A/F Sensitivity Allows adjustment of the Air/Fuel (A/F) Valve stepper

Power Reset Allows the Power Reset Option to be set to Auto or

Water Temp Reset Allows the Water Temperature Reset function to be

Gas Press Reset Allows the Gas Pressure Reset function to be set to

Min Off Time Allows the minimum Off time to be set from 0 to 10

Heatr Tuning Dsp
(Water Heater Only)

Heatr Bkpt Dsp Allows Heater Breakpoint Display to be Enabled or

Stop Level Allows the Stop Level to be set to a firing rate ranging

Start Level Allows the Start Level to be set to a firing rate ranging

Allows the Air/Fuel Valve stepper motor feedback

current to be calibrated at the 0% (fully closed) and

100% (fully open) positions. Verification can also be

accomplished at the 50% position.

to be adjusted from -5.0% to +5.0% in 0.1%

increments. Default = 0.0%.

+5.0%. Default = 0.0%.

-5.0% to +5.0%. Default = 0.0%.

-5.0% to +5.0% in 0.1 % increments. Default = 0.0%.

+5.0% in 0.1% increments. Default = 0.0%

mA to +5.0 mA. Default = 0.0 mA

motor sensitivity to be adjusted from 1% to 5% in 1%

increments. Default is 2%.

Manual. Default is Auto.

set to Auto or Manual. Default is Auto.

Auto or Manual. Default is Manual.

minutes. Default = 1 min.(Boiler), 0 min. (Water

Heater).

Allows Heater Tuning Display to be Enabled or

Disabled. Default is Disabled.

Disabled. When Enabled, Breakpoints can be viewed

and/or changed. Default is Disabled.

from 0% to the presently set Start Level. Default is

16%.

from the presently set Stop Level to a maximum of

40%. Default is 20%.

17

C-MORE CONTROL PANEL OPERATION

Table 3-1. Menu Item Descriptions – Continued

MENU LEVEL & OPTION DESCRIPTION

DIAGNOSTICS MENU

Display Test*

Keypad Test*

Relay Test*

Switch Test*

Stepper Test*

Sensor Log Int Allows the Sensor Log Interval to be set to: 1 Min, 5

* Not adjustable via RS232 serial communication

Allows testing of the front panel LED indicators, 3­character, 7-segment LED display and 20-segment
LED Bargraph.

Allows testing of the operational status of each front
panel key. The VFD will display the name of each
key as it is pressed.

Allows user to force relay outputs ON or OFF. The
relays tested include: Igniter, Blower, Pump, Aux and
Fault relay.

Allows the ON/OFF status of all switch inputs to be
viewed. These switches include: Exhaust, SSOV,
Blower Proof, Ignition, Over-Temp, Low Gas Pres, Hi
Gas Pres, Water Lev, Rem Int, Front Pnl, Delayed
Int and Purge switches.

Allows adjustment of the Air/Fuel Valve stepper
motor position using the ▲ and ▼ keys. The Bargraph

display will light to indicate the current stepper motor
position.

Min, 15 Min, 30 Min, 1 Hr, 6 Hrs, 12 Hrs or 24 Hrs.
Default setting is 30 Min.

18

Table 3-2. Default Settings

MENU & OPTION

Setup Menu

Password
Language
Unit of Temp
Comm Address
Baud Rate

Configuration Menu

Internal Setpt
Unit Type
Unit Size
Boiler Mode

(If Unit Type = Boiler)
Heater Mode

(If Unit Type = Water Heater)
Remote Signal

(If Mode = Remote Setpoint, Direct Drive or

Combination)

Bldg Ref Temp
(If Boiler Mode = Outdoor Reset)

Reset Ratio
(If Boiler Mode = Outdoor Reset)

Outdoor Sensor
System Start Tmp

(If Outdoor Sensor = Enabled)
Temp Hi Limit
Max Fire Rate
Pump Delay Timer (If Unit Type = Boiler)
Aux Start On Dly
Failsafe Mode
mA Output
Low Fire Timer
Setpt Limiting
Setpt Limit Band

Tuning Menu

Prop Band
Integral Gain
Derivative Time
Min Load Adj (If Unit Type = Water Heater)
Max Load Adj (If Unit Type = Water Heater)
FFWD Temp Adj (If Unit Type = Water Heater)
Outlet Feedback (If Unit Type = Water Heater)
Feedback Gain (If Unit Type = Water Heater)

C-MORE CONTROL PANEL OPERATION

FACTORY DEFAULT

0

English

Fahrenheit

0

9600

130°F
Boiler

1.0 MBTU

Constant Setpoint

Constant Setpoint

4 – 20 mA / 1-5V

70°F

1.2

Disabled

60°F

210°F
100%

0 min
0 sec

Shutdown

Off

2 sec

Disabled

5°F

70°F (Boiler), 8°F (Water Heater)

1.00 (Boiler), 1.60 (Water Heater)

0.00 min (Boiler), 0.10 min (Water Heater)
0°F
0°F

N/A

On

0.05

19

C-MORE CONTROL PANEL OPERATION

Table 3-2. Default Settings – Continued

MENU & OPTION

Breakpoint At 100% (If Unit Type = Water Heater)
Breakpoint At 90% (If Unit Type = Water Heater)
Breakpoint At 80% (If Unit Type = Water Heater)
Breakpoint At 70% (If Unit Type = Water Heater)
Breakpoint At 60% (If Unit Type = Water Heater)
Breakpoint At 50% (If Unit Type = Water Heater)
Breakpoint At 40% (If Unit Type = Water Heater)
Breakpoint At 30% (If Unit Type = Water Heater)
Breakpoint At 20% (If Unit Type = Water Heater)
Breakpoint At 10% (If Unit Type = Water Heater)
Breakpoint At 0% (If Unit Type = Water Heater)
Reset Defaults?

Calibration Menu

Stepper Fbk
PWM Adj
Analog In Adj
Flow In Adj
CO In Adj
O2 In Adj
mA Out Adj
A/F Sensitivity
Power Reset
Water Temp Reset
Gas Press Reset
Min Off Time
Heatr Tuning Dsp (If Unit Type = Water Heater)
Heatr Bkpt Dsp (If Unit Type = Water Heater)
Stop Level
Start Level

Diagnostics Menu

Display Test
Keypad Test
Relay Test
Switch Test
Stepper Test
Sensor Log Int

FACTORY DEFAULT

77°F
81°F
85°F
91°F

95°F
102°F
110°F
112°F
114°F
130°F
135°F

No

Cal 0%

0.0%

0.0%

0.0%

0.0%

0.0%

0.0 mA
2%

Auto
Auto

Manual

1 Min (Boiler), 0 Min (Water Heater)

Disabled
Disabled

16
20

Off
Off
Off
Off

0%

30 min.

20

C-MORE CONTROL PANEL OPERATION

SECTION 4 - CONTROL PANEL DISPLAY MESSAGES

4.1 STARTUP & STATUS MESSAGES.

Startup and status messages are displayed on
the VFD display on the front panel of the C-More
Control Panel. This display is comprised of two
lines with 16 characters per line. The startup and
status messages which may appear in the
display are listed in Tables 4-1.

.2

4

Table 4-1. Startup and Status Messages

MESSAGE DESCRIPTION

DISABLED

HH:M D/YY

M pm MM/D

STANDBY

DEM AY AND DEL

XX sec

P

URGING Displayed during the purge cycle during startup. The

XX sec

IGNI IAL

TION TR Displayed during ignition trial of startup sequence. The

XX sec

FLAME PROVEN

W he initial warm-up only. ARMUP

XX sec

WAIT Prompts the oper tor to wait. a

Displayed if ON/OFF switch is set to OFF. The displ
shows the time and date that the unit was disabled.
Displayed when ON/OFF switch is in the ON position, but
there is no demand for heat. The time
displayed.
Displayed if Demand Delay is active.

duration of the purge cycle counts up in seconds.

duration of cycle counts up in seconds.
Displayed after flame has been detected for a period of 2
seconds. Initially, the flame strength is shown in %. After 5
seconds has elaps
of flame strength.
Displayed for 2 minutes during t

FAULT MESSAGES.

Fault messages which may appear in the VFD
display are listed in Table 4-2.

ay also

and date are also

ed, the time and date are shown in place

21

C-MORE CONTROL PANEL OPERATION

Table 4-2. Fault Messages

FAULT MESSAGE FAULT DESCRIPTION

HIGH WATER TEMP

SWITCH OPEN

LOW WATER

LEVEL

LOW GAS

PRESSURE

HIGH GAS

PRESSURE

INTERLOCK

OPEN

DELAYED

INTERLOCK OPEN

AIRFLOW FAULT

DURING PURGE

PRG SWTCH OPEN

DURING PURGE

IGN SWTCH OPEN

DURING IGNITION

IGN SWTCH CLOSED

DURING PURGE

PRG SWTCH CLOSED

DURING IGNITION

AIRFLOW FAULT

DURING IGN

AIRFLOW FAULT

DURING RUN

SSOV

SWITCH OPEN

SSOV FAULT

DURING PURGE

SSOV FAULT

DURING IGN

SSOV FAULT
DURING RUN
SSOV RELAY

FAILURE

FLAME LOSS

DURING IGN
FLAME LOSS
DURING RUN

HIGH EXHAUST
TEMPERATURE

The High Water Temperature Limit Switch is open.

The Water Level Control board is indicating low water level.

The Low Gas Pressure Limit Switch is open.

The High Gas Pressure Limit Switch is open.

The Remote Interlock is open.

The Delayed Interlock is open.

The Blower Proof Switch opened during purge.

The Purge Position Limit switch on the air/fuel valve opened
during purge.
The Ignition Position Limit switch on the air/fuel valve opened
during ignition.
The Ignition Position Limit switch on the air/fuel valve closed
during purge.
The Purge Position Limit switch on the air/fuel valve closed
during ignition.
The Blower Proof Switch opened during ignition.

The Blower Proof Switch opened during run.

The SSOV switch opened during standby.

The SSOV switch opened during purge.

The SSOV switch closed or failed to open during ignition.

The SSOV switch closed for more than 15 seconds during
run.
A failure has been detected in one of the relays that control
the SSOV.
The Flame signal was not seen during ignition or lost within 5
seconds after ignition.
The Flame signal was lost during run.

The High Exhaust Temperature Limit Switch is closed.

22

C-MORE CONTROL PANEL OPERATION

Table 4-2. Fault Messages - Continued

FAULT MESSAGE

RESIDUAL

FLAME

HEAT DEMAND

FAILURE

IGN BOARD

COMM FAULT

DIRECT DRIVE
SIGNAL FAULT

REMOTE SETPT

SIGNAL FAULT

OUTDOOR TEMP

SENSOR FAULT

OUTLET TEMP

SENSOR FAULT

FFWD TEMP

SENSOR FAULT

HIGH WATER

TEMPERATURE

LINE VOLTAGE

OUT OF PHASE

STEPPER MOTOR

FAILURE

MODBUS COMM

FAULT

The Flame signal was seen for more than 30 seconds during
standby.
The Heat Demand Relay on the Ignition/Stepper (IGST)
board failed to activate when commanded.
A communication fault has occurred between the Primary
Micro-Controller (PMC) board and Ignition/Stepper (IGST)
board.
The direct drive signal is not present or is out of range.

The remote setpoint signal is not present or is out of range.

The temperature measured by the Outdoor Air Sensor is out
of range.
The temperature measured by the Outlet Sensor is out of
range.
The temperature measured by the Feed-Forward (FFWD)
Sensor is out of range.
The temperature measured by the Outlet Sensor exceeded
the Temp Hi Limit setting.
The High AC voltage is out of phase from the low AC voltage.

The stepper motor failed to move the valve to the desired
position.
The RS485 (MODBUS) network information is not present or
is corrupted.

FAULT DESCRIPTION

23

C-MORE CONTROL PANEL OPERATION

SECTION 5 - INPUT/OUTPUT INTERFACES & OPERATING MODES

5.1 INTRODUCTION

This Section provides descriptions of the
Input/Output (I/O) wiring connections which can
be made at the Input/Output (I/O) Box included
with the C-More Control Panel. For KC Series
units, the I/O Box is located on the left side of
the unit. For Benchmark Series units, the I/O
Box is located on the front of the unit behind the
door.

Also included in this Section are descriptions of
the available operating modes which can be set
up for Water Heaters and Boilers utilizing the C­More menus.

5.2 I/O INTERFACES

All wiring connections are made at the terminal
strips contained in the I/O Box. The I/O Box
cover contains a connection diagram as shown
in Figure 5-1. Refer to this diagram when
making all field wiring connections to the I/O
Box. The connections shown in Figure 5-1 are
described in the following paragraphs.

CAUTION!

DO NOT make any connections to the I/O
Box terminals labeled “NOT USED”.
Attempting to do so may cause equipment
damage.

5.2.1 OUTDOOR SENSOR IN

An outdoor air temperature sensor (AERCO Part
No. 122790) will be required mainly for the
Indoor/Outdoor Reset Mode of operation for
boilers. It can also be used with another mode if
it is desired to use the outdoor sensor
enable/disable feature. This feature allows the
boiler to be enabled or disabled based on the
outdoor air temperature. The factory default for
the outdoor sensor is DISABLED. To enable the
sensor or choose a system start temperature,
see the Configuration Menu in Table 2-3.

The outdoor sensor may be wired up to 200 feet
from the boiler. It is connected to the OUTDOOR
SENSOR IN and SENSOR COMMON terminals
in the I/O Box (see Figure. 5-1). Wire the sensor
using a twisted shielded pair cable of 18-22
AWG wire. There is no polarity to observe when

terminating the wires. The shield is to be
connected only to the terminals labeled SHEILD
in the I/O Box. The sensor end of the shield
must be left free and ungrounded.

When mounting the sensor, it must be located
on the North side of the building where an
average outside air temperature is expected.
The sensor must be shielded from direct sunlight
as well as impingement by the elements.
If a shield is used, it must allow for free air

circulation

.

5.2.2 AUX SENSOR IN

The AUX SENSOR IN terminals can be used to
add an additional temperature sensor for
monitoring purposes. This input is always
enabled and is a view only input that can be
seen in the operating menu. The sensor must be
wired to the AUX SENSOR IN and SENSOR
COMMON terminals. It must be similar to
AERCO BALCO wire sensor P/N 123449. A
resistance chart for this sensor is provided in
Appendix D.

5.2.3 ANALOG IN

The ANALOG IN + and – terminals are used
when an external signal is used to drive the
firing rate (Direct Drive Mode- Boiler Only) or
change the setpoint (Remote Setpoint Mode) of
the unit.

Either a 4 to 20 mA / 1 to 5 VDC or a 0 to 20
mA/ 0 to 5 VDC signal may be used to vary the
setpoint or firing rate. The factory default setting
is for 4 to 20 mA / 1 to 5 VDC, however this may
be changed to 0 to 20 mA / 0 to 5 VDC using the
Configuration Menu described in Sections 2 and

3. If voltage rather than current is selected as
the drive signal, a DIP switch must be set on the
PMC Board located inside the Control Box.
Refer to Appendix F for information on setting
DIP switches.

All supplied signals must be floating (unground­ed) signals. Connections between the source
and the unit’s I/O Box must be made using
twisted shielded pair wire of 18 – 22 AWG, such
as Belden 9841(see Fig. 5-1). Polarity must be
maintained and the shield must be connected

24

C-MORE CONTROL PANEL OPERATION

only at the source end and must be left floating
(not connected) at the unit’s I/O Box.

Whether using voltage or current for the drive
signal, they are linearly mapped to a 40°F to 240°F
setpoint or a 0% to 100% firing rate. No scaling for

these signals is provided.

5.2.4 B.M.S. (PWM) IN

interlocks which are labeled REMOTE INTL’K IN
and DELAYED INTL’K IN. Both interlocks,
described below, are factory wired in the closed
position.

NOTE:

Both the Delayed Interlock and the Remote
Interlock must be in the closed position to allow
the unit to fire.

NOTE

Only BMS Model 168 can utilize pulse width

modulation, not

These terminals are used to connect the AERCO
Boiler Management System (BMS Model 168) to
the unit. The BMS Model 168 utilizes a 12
millisecond, ON/OFF duty cycle. This duty cycle is
Pulse Width Modulated (PWM) to control firing
rate. A 0% firing rate = a 5% ON pulse and a
100% firing rate = a 95% ON pulse.

the BMS II Model 5R5-384.

5.2.5 SHIELD

The SHIELD terminals are used to terminate any
shields used on sensor wires connected to the
unit. Shields must only be connected to these
terminals.

5.2.6 mA OUT

These terminals provide a 4 to 20 mA output that
can be used to monitor setpoint ( 40°F to 240°F),
outlet temperature (30°F to 245°F), or fire rate (0%
to 100%). This function is enabled in the
Configuration Menu (Table 2-3).

5.2.9.1 REMOTE INTERLOCK IN

The remote interlock circuit (REMOTE INTL’K IN)
is provided to remotely start (enable) and stop
(disable) the Boiler if desired. The circuit is 24 VAC
and comes factory pre-wired closed (jumpered).

5.2.9.2 DELAYED INTERLOCK IN

The delayed interlock circuit (DELAYED INTL’K IN)
is typically used in conjunction with the auxiliary relay
described in paragraph 5.2.11. This interlock circuit
is located in the purge section of the start string. It
can be connected to the proving device (end switch,
flow switch etc.) of an auxiliary piece of equipment
started by the unit’s auxiliary relay. The delayed
interlock must be closed for the unit to fire. If the
delayed interlock is connected to a proving device
that requires time to close (make), a time delay (Aux
Start On Dly) that holds the start sequence of the unit
long enough for a proving switch to make can be
programmed. Should the proving switch not prove
within the programmed time frame, the unit will shut
down. The Aux Start On Dly can be programmed
from 0 to 120 seconds. This option is locate in the
Configuration Menu.

5.2.7 RS485 COMM

These terminals are used for RS485 MODBUS
serial communication between the unit and an
external “Master”, such as a Boiler Management
System or other suitable device.

5.2.8 EXHAUST SWITCH IN

These terminals permit an external exhaust switch
to be connected to the exhaust manifold of the
unit. The exhaust sensor should be a normally
open type switch (such as AERCO Part No.

123463) that closes (trips) at 500°F.

5.2.9 INTERLOCKS

The unit offers two interlock circuits for interfacing
with Energy Management Systems and auxiliary
equipment such as pumps or louvers. These
interlocks are called the Remote Interlock and
Delayed Interlock. The wiring terminals for these
interlocks are located inside the I/O Box. The I/O
Box cover contains a wiring diagram (Figure 5-1)
which shows the terminal strip locations for these

5.2.10 FAULT RELAY

The fault relay is a single pole double throw
(SPDT) relay having a normally open and normally
closed set of relay contacts that are rated for 5
amps at 120 VAC and 5 amps at 30 VDC,
resistive. The relay energizes when any fault
condition occurs and remains energized until the
fault is cleared and the CLEAR button is
depressed.

5.2.11 AUXILIARY RELAY CONTACTS

Each unit is equipped with a single pole double
throw (SPDT) relay that is energized when there is
a demand for heat and de-energized after the
demand for heat is satisfied. The relay is provided
for the control of auxiliary equipment, such as
pumps and louvers, or can be used as a unit
status indictor (firing or not firing). Its contacts are
rated for 120 VAC @ 5 amps resistive. Refer to
Figure 5-1 to locate the AUX RELAY terminals for
wiring connections.

25

C-MORE CONTROL PANEL OPERATION

Figure 5-1. I/O Box Terminal Strip Connections

5.3 MODES OF OPERATION

KC Series Water Heaters are capable of being
operated in either the Constant Setpoint Mode
or Remote Setpoint Mode. In addition to the
Constant and Remote Setpoint Modes, KC and
Benchmark Series Boilers can also be operated
in the Direct Drive Mode, Boiler Management
System (BMS) Mode, Indoor/Outdoor Reset
Mode or Combination Mode.

The following paragraphs briefly describe the
required connections and menu settings to place
the unit in each of these modes.

5.3.1 Constant Setpoint Mode

The Constant Setpoint mode is used when a
fixed header temperature is desired. Common
uses of this mode of operation include water
source heat pump loops, and indirect heat
exchangers for potable hot water systems or
processes.

There are no external sensors necessary to
operate in this mode. While it is necessary to set
the desired setpoint temperature, it is not
necessary to change any other temperature­related functions. The unit is factory preset with
settings that work well in most applications.
Prior to changing any temperature-related
parameters, other than the setpoint, it is
suggested that an AERCO representative be

contacted. See Sections 2 and 3 for complete
listings of temperature related menu functions
and factory defaults.

5.3.1.1 Setting The Setpoint

The setpoint temperature of the unit is
adjustable from 40°F to 240°F.. To set the unit
for operation in the Constant Setpoint Mode, the
following menu settings must be made in the
Configuration Menu:

MENU OPTION SETTING

Boiler (or Heater)

Constant Setpoint
Mode
Internal Setpt Select desired setpoint

using ▲ and ▼ arrow

keys (40° to 240°F)

Refer to paragraph 2.2 for detailed instructions
on changing menu options.

5.3.2 Remote Setpoint Modes

The unit’s setpoint can be remotely controlled by
an Energy Management System utilizing either a
current or voltage signal level.

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