Aerco E8 User Manual

GF-115-C

OMM-0084_0D

E8 Controller and BCM

Modulex MLX & EXT Boilers

For Modulating, Condensing,

Hot Water Boiler Models:

• MLX-303

E8 Controller for MLX & EXT Series Boilers

Boiler Communications Module (BCM)

for MLX and EXT Series Boilers

• MLX-454

• MLX-606

• MLX-757

• MLX-909

• MLX-1060

• EXT 321

• EXT 481

• EXT 641

• EXT 802

• EXT 962

• EXT 1123

• EXT 1530

• EXT 1912

• EXT 2295

• EXT 2677

• EXT 3060

For

USER MANUAL

Installation, Operation, and Maintenance

.

Revised: 06/05/2013

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GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

Technical Support:

1-800-526-0288

www.aerco.com

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: [phone]

(Mon–Fri, 8am-5pm EST)

Disclaimer

The information containe d in this manual is subject to c hange without notice from AERCO International,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantability and fitness f or a particular application. A ERCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.

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Table of Contents

Table of Contents .......................................................................................... 3

1. INTRODUCTION ................................................................................ 7

1.1 Safety and Warnings ........................................................................................ 7

2. E8 CONTROLLER AND BCM DESCRIPTION ..................................... 9

2.1 E8 Controller Features And Functions ........................................................... 9

2.2 BCM Features And Functions ....................................................................... 10

3. E8 CONTROLLER OPERATION ....................................................... 11

3.1 NORMAL Mode Operation (Door Closed)..................................................... 11

3.1.1 NORMAL Mode Display Functions ................................................................... 11

3.1.2 HEATING Mode Selection (in NORMAL Mode) ............................................. 12

3.1.3 MENU Mode Operation (Door Open) ................................................................ 12

3.2 Software Menus .............................................................................................. 13

3.2.1 Basic Menu/Sub-Menu Navigation and Selection .............................................. 15

3.2.2 Basic Parameter Navigation, Selection, and Revision ........................................ 16

4. E8 CONTROLLER MENUS AND SUB-MENUS ................................. 17

4.1 DISPLAY Menu ............................................................................................... 18

4.2 USER Menu ..................................................................................................... 21

4.3 TIME PROGRAM Menu and Sun-Menus ....................................................... 24

4.4 EXPERT Menu and Sub-Menus ..................................................................... 25

4.4.1 Available V-Curve Preset Voltage Curves for 0 – 10 Volt Input ....................... 31

4.5 EXPERT HS Menu (Not Used) ...................................................................... 31

4.6 GENERAL Menu ............................................................................................. 32

4.6.1 DATE / TIME Menu ........................................................................................... 32

4.6.2 SERVICE Menu .................................................................................................. 34

4.7 E8 Controller Initial Startup ........................................................................... 37

4.7.1 CAP/MODULE Function (Maximum Kilowatts per Burner) ............................ 39

4.7.1 Available Settings for Relay Functions 1 – 4 ...................................................... 40

5. E8 OPERATING MODE: Set-up and Programming ............................. 42

5.1 Indoor/Outdoor Reset Mode .......................................................................... 42

5.1.1 Wiring Connections............................................................................................. 42

5.1.2 Indoor/Outdoor Reset Operation Configuration ................................................. 42

5.1.3 Viewing the Boiler Setpoint ................................................................................ 44

5.2 Constant Set Point Mode ............................................................................... 44

5.2.1 Wiring Connections............................................................................................. 45

5.2.2 Constant Setpoint Mode Configuration............................................................... 45

5.2.3 Viewing Constant Set Point ................................................................................ 45

5.2.4 Configuring Set Point High and Low Limits Per Outside Temperature Sensor . 45

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Operations and Maintenance Manual

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5.3 0 to 10 Volt Remote Set Point Mode ............................................................. 48

5.3.1 Remote Signal Source Wiring Connections ........................................................ 48

5.3.2 Configuring Remote Signal Source..................................................................... 49

5.3.3 Setting the Voltage and Set Point Limits for U1/U2 and T1/T2 ......................... 50

5.3.4 Setting the Curve 11-UO Voltage ....................................................................... 51

5.3.5 Viewing the Set Point .......................................................................................... 52

5.4 Domestic Hot Water Operation Using A Tank Sensor ................................ 52

5.4.1 Sensor Wiring Connections ................................................................................. 52

5.4.2 Configuring the Controller for DHW With a Tank Sensor ................................. 53

5.4.3 Setting the DHW Set Point ................................................................................. 54

5.4.4 Displaying Temperatures Associated With DHW .............................................. 55

5.5 DHW Operation Using an Aquastat .............................................................. 56

5.5.1 Sensor Wiring Connections ................................................................................. 56

5.5.2 Configuring the Controller for DHW With an Aquastat ..................................... 56

5.5.3 Setting the DHW Set Point ................................................................................. 56

5.5.4 Displaying Temperatures Associated With DHW .............................................. 56

5.6 Boiler & Pump Enable/Disable ...................................................................... 56

6. CONNECTION DIAGRAMS .............................................................. 58

6.1 Power Terminal Assignments ....................................................................... 59

6.2 Sensor Terminal Assignments ...................................................................... 60

7. BOILER COMMUNICATIONS MODULE (BCM) ................................ 62

7.1 Boiler Communications Module (BCM) Description ................................... 62

7.2 BCM Fault Relay ............................................................................................. 64

7.2.1 BCM Fault Relay Wiring .................................................................................... 64

7.2.2 Clearing Faults .................................................................................................... 64

7.3 BCM Configured as Back-Up Controller ...................................................... 65

7.3.1 BCM Back-Up Controller Wiring ....................................................................... 65

7.4 BCM Configured as Primary Controller Utilizing Modbus .......................... 66

7.4.1 Operating Scenario .............................................................................................. 66

7.4.2 Physical Modbus RS485 Wiring ......................................................................... 67

7.4.3 Disconnecting the E8 from the E-Bus on the BCM Board. ................................ 68

7.4.4 AERCO BMS II/ACS Master to BCM Slave Wiring Connections. ................... 69

7.4.5 EMS or BAS Master to BCM Slave Wiring Connections .................................. 69

7.5 RS485 Loop Termination Resistors and Bias .............................................. 69

7.5.1 Master AERCO BMS II/ACS or EMS/BAS Terminating Resistor and Bias ..... 69

7.5.2 BCM Controller Terminating Resistor and Bias ................................................. 70

7.6 Modbus Network Wiring Diagram ................................................................. 70

7.7 Modbus Software Set-Up ............................................................................... 74

7.7.1 BCM Set-Up for Modbus Operation ................................................................... 74

7.7.2 Monitoring and Configuration Only ................................................................... 75

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7.7.3 AERCO BMS II/ACS Modbus Control and Monitoring .................................... 75

7.7.4 Modbus Remote Setpoint Control and Monitoring ............................................. 75

7.7.5 EMS or BAS Set-Up As Master to BCM Controller Slaves ............................... 75

7.8 Multiple Modulex Boiler Heating Mode – Utilizing a BMS II or ACS ........... 75

7.8.1 Sequence of Operation (Example: Four-Modulex boiler installation) ................ 76

8. E8 CONTROLLER MENU LISTINGS ................................................ 78

8.1 DISPLAY Menu ............................................................................................... 78

8.2 USER Menu ..................................................................................................... 80

8.3 TIME PROGRAM Menu .................................................................................. 82

8.4 EXPERT Menu ................................................................................................ 85

8.5 GENERAL Menu ............................................................................................. 89

8.5.1 DATE / TIME Sub-Menu ................................................................................... 90

8.5.2 SERVICE Sub-Menu .......................................................................................... 90

9. BCM MODBUS AND ADDRESS ASSIGNMENTS .............................. 94

9.1 BCM Modbus Communication & Support Requirements ........................... 94

9.1.1 Function Codes .................................................................................................... 94

9.1.2 Modbus Support Requirements ........................................................................... 94

9.2 BCM Controller Standard Holding Register Assignments ......................... 95

9.2.1 BCM Controller Standard Input Register Assignments ...................................... 95

9.2.2 BCM Controller Standard Holding Register Assignments ................................. 95

10. E8, BCM, AND BMM FAULT CODES ............................................. 102

10.1 Processing and Clearing Fault Codes ........................................................ 103

10.2 Fault Codes and Descriptions ..................................................................... 104

10.2.1 E8 Controller Fault Codes ............................................................................. 105

10.2.2 BCM (Boiler Communications Module) Fault Codes ................................... 106

10.2.3 BMM (Burner Management Module) Fault Codes ....................................... 108

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1. INTRODUCTION

The information in this manual provides a guide to the operation of the Modulex Boiler using
the E8 Controller and the Boiler Communications Module (BCM) mounted on the front of the
unit. Sections 3, 4, 5, 6, and 8 provide descriptions and procedures for the E8 Controller.
Sections 7, 9, and 10 provide similar inf ormation for the BCM.

It is imperative that the initial startup procedures be performed by factory trained personnel.
Operation by untrained personnel, prior to the initial startup, will void the equipment warranty.
In addition, CAUTIONS and WARNINGS in this manual must be observed at all times.

1.1 Safety and Warnings

The following defined symbols are used throughout this manual to notif y the reader of potential
hazards of varying risk levels.

Indicates an imminently hazardous situation, which if not avoided,

!

DANGER

!

WILL result in death or serious injury.
Indicates a potentially hazardous situation, which if not avoided,

!

WARNING

!

DANGER

Note that all hazard notifications and notes are presented enclosed in a rectangle with filleted
(round) corners, as shown below, in order to differentiate them from the main text.

It is of utmost importance to observe all CAUTIONS and
WARNINGS presented in this manual to avoid injury, death, and
damage to the equipment. Failure to properly heed safety
warnings and cautions may result in the voiding of applicable
warranties.

!

MAY result in death or serious injury.
Indicates a potential hazardous situation, which if not avoided,

COULD result in minor or moderate injury. Also may caution

!

against unsafe practices.

!

CAUTION

!

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Operations and Maintenance Manual

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Rotary Knob

LCD Display

Hinged Cover

2. E8 CONTROLLER AND BCM DESCRIPTION

Modulex boilers contain advanced and reliable electronic controls, which includes the E8
Controller and the BCM (Boiler Communications Module), providing comprehensive
programming and monitoring of the Modulex boiler and its functions. Features and functions of
the E8 Controller are described in the following sections.

2.1 E8 Controller Featur e s And Functions

A standard component included in Modulex units, the E8 Controller is responsible for the
staging and modulation of individual thermal heating modules in a Modulex boiler and also
monitors supply and return water temperatures and domestic hot water zones.

The E8 Controller is housed in a compact enclosure measuring 5.7” (145 mm) x 3.9” (100 mm).
The Controller is mounted on the front of the Modulex Boiler and contains all of the controls,
indicators and displays necessary to adjust, operate and troubleshoot the Modulex Boiler. T he
E8 features the following functions for Modulex boilers:

• Shares the heating load among as many of the boiler's thermal heating modules as
possible. maximizing the overall operating efficiency of the boiler.

• Provides access t o all testing/programming parameters of each individual heating module:
operation test, operation time, boiler freeze protection and pump's anti seize program.

• Drives lead-lag burner operation based on operating hours. The boiler module with the least
burner operating hours is the first to start and the burner with the most operating hours is the
first to stop.

• Supports DHW (Domestic Hot Water) production using a dedicated sensor to control a
dedicated pump or 3-way diverting valve for storage tank temperature control.

• Supports a manual operation service mode to control individual modules during
troubleshooting or combustion calibration procedures.

• Drives diagnostics such as relay and senor testing.

• Supports Modbus integration with AERCO BMS

Building Automation Systems. AERCO also offers a Communication Gateway to support
BACnet, Lonworks and N2 system integration.

II and AERCO Control System (ACS) or

Window

(in closed

position)

Figure 2-1: Modulex E8 Controller Front Panel

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2.2 BCM Features And Functions

The BCM (Boiler Communications Module) is an electronic module in Modulex boilers (one per
burner), which supports full interoperability to BAS (Building Automation Systems) via Modbus
protocol to make remote communications and control possible. In addition, it provides
customers with a remote alarm contact to notify customers of faults detected within any of
boiler's multiple thermal modules. Finally, in the event the boiler's master controller stops
working, the BCM also takes over operations of the boiler.

As a back-up controller, the BCM further increases the reliability of a product line already known
for its uniquely redundant design. Each Modulex boiler combines between two and seven
independent, 151,500 BTU/hr., pre-assembled thermal modules housed in a common
enclosure. Each module has its own dedicated controller with a com bustion safeguard, variable­speed fan, modulating gas valve, electronic ignition, modulating burner, flow temperature
sensor, thermostat and heat exchanger. The independent operation of these thermal modules
increases each boiler's overall reliability. If a single module requires maintenance or repair, the
other module(s) in the boiler can maintain the system load requirements -- thereby providing a
level of redundancy that was previously only realized in multi-boiler installations.

A photo of the module is shown in Figure 2-2 below. Additional information for the BCM
component can be found in Section 7, 9, and 10.

Figure 2-2: Modulex BCM (Boiler Communications Module)

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Heating Mode display symbol. The display symbols apply to all internal heating
circuits for which a separate heating mode has been selected. Note that each

H B E D I G F C A

3. E8 CONTROLLER OPERATION

The E8 Controller operates in NORMAL Mode when the controller door is closed, which allows
for monitoring the boiler status through the display window and setting the HEATING Mode.
When the door is opened, the unit enters MENU Mode, and in this mode the boiler may be
initialized, configured, and adjusted. The controls and display for the E8 controller are described
in the following sub-sections.

3.1 NORMAL Mode Operation ( Door Clos e d)

When the hinged door is closed on the E8, the unit is in NORMAL Mode.

3.1.1 NORMAL Mode Display Functions

Figure 3-1 des cribes the types of information provided on the LCD display when in NORMAL

Mode (door closed). Note that the display in the illustration is only an example, and that an E8
Controller in service will show information a ppropri ate for its configuration.

Figure 3-1: E8 LCD Display in NORMAL Mode (Door Closed)

E8 Controller Display in NORMAL Mode

Item Functions

A

Current time (24 hour format)

B

DCF reception OK (only if receiver is connected via eBUS)
Display of the active heating program for the first heating circuit (here: 6:00 to 08:00

C

a.m. and 4:00 to 10:00 p.m.)
Bus icon (if this icon does not appear, check data line to connected CAN controllers

D

=> check eBUS via DISPLAY level)

E

Status display: Shows symbols for Internal Burner 1 Relay ON; Heating Mode; Hot Water Preparation.

F

symbol occupies a different space across the display bottom. See Figure 3-2.

G

Display of current temperature of HS 1 or header temperature when cascading.

H

Display of number of active burners (only applies when cascading).
Selectable display and Error Codes (refer to "DISPLAY SEL" parameter in the USER

I

menu).

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E8 Controller HEATING Modes

Turn the Rotary Knob to select the heating mode

heating mode is indicated by a symbol at

is not changed for 5 seconds.

HEATING Mode Symbols:

3.1.2 HEATING Mode Selection (in NORMAL Mode)

Heating modes may be selected using the Rotary Knob on the controller when the hinged door
is in the closed position (NORMAL Mode). As the Rotary Knob is turned, each appropriate
heating mode symbol is displayed, in turn, along the lower edge of the display.

Mode changes take effect when the setting is not changed for 5 seconds. The symbols and
description for the available heating modes are shown in Figure 3-2.

Only currently selected
mode will be displayed.

Figure 3-2: Heating Mode Display Symbols and Description

SYMBOL MODE NAME DESCRIPTION

Heating Mode

Selection

Standby / OFF

Automatic Mode 1

Automatic Mode 2

Summer Mode

Day

Mode
Night

Mode

Service Mode

requir ed. The
the bottom of the display. It takes effect when the setting

(Heat OFF and hot water (HW) preparation OFF, only
frost protection mode)

(Heat a c c or di ng to t im er pr og r a m 1; HW acc or d ing to
HW prog ram)

(Heat a ccordi ng to timer program 2; HW accord ing to
HW prog ram)

(Heating OFF, HW according to HW program)

(24 Hour heating with comfort temperature 1; HW
according to HW program)

(24 Hour heating with reduced temperature; HW
according to program)

(Automatic reset after 15 minutes. Boiler regulated at
max bo iler tem peratur e)

3.1.3 MENU Mode Operation (Door Open)

Opening the E8 controller hinged door reveals the E8 controls (Figure 3-3) and initiates the

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Insert narrow screwdriver deep into holes and lift up

When lit, this LED indicates that the value shown in the display can be

D

position (10/2 o’clock) screwdriver adjustable switch.

FLOW (in EXPERT/HEAT

F

E D C B A

G

MENU Mode, which enables access to an extensive set of software menus.

INSTALLATI
ON

Figure 3-3: E8 Controller Controls (cover open in MENU Mode)

E8 Controller Controls and Indicators

ITEM FUNCTION

A
B
C

E

LCD display: Selected Menu/Sub-menus, parameter names/values, and selected

busses are indicated in the LCD display when in MENU Mode.
Mounting Key Access Holes:

controller to remove.
Change LED:

changed using the Rotary Knob (G).

Optical Adaptor: For PC connection
Program Key: Used to select a sub-menu level, select a parameter value to change, or

save a new parameter value.
Manual/Automatic Switch: A 2-

Normally, this switch is set to the Automatic (2 o’clock) position to allow program control
of the boiler. When set to the Manual (10 o’clock) position, a flashing “EMERG –
MODE” message is displayed. Heating Circuit 1 (HC1) pump and the first burner stage
are switched on. Pumps for Heating Circuit 2 (HC2) and Domestic Hot Water (DHW) will

F

also be switched on if sensors are installed and enabled. The pump(s) will turn off when
the flow temperature reaches the value set for MAX T­CIRCUIT 1 menu). The first burner stage will cut off when the boiler temperature
reaches the value set for MAX T-MODUL (in EXPERT/INSTALLATION menu).

G Rotary Knob: Used to navigate through menus and parameters or adjust parameters.

3.2 Software Menus

Software menus are divided into five main menus, each with a set of sub-menus (Table 3-1).

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INSTALLATION

HOT WATER

HEAT CIRCUIT I

HEAT CIRCUIT II

SOLAR/MF

INSTALLATION

HOT WATER

HEAT CIRCUIT I

HEAT CIRCUIT II

SOLAR/MF

CIRCL TIME

HOTW-PROG

HTG-PROG 1

HTG-PROG 2

INSTALLATION

HOT WATER

HEAT CIRCUIT I

HEAT CIRCUIT II

SOLAR/MF

SERVICE

DATE/TIME

HOLIDAY

CLOCK CHANGE

Sub-MENU Name

The rotary knob on the front of the E8 Controller is used to sequentially cycle through the
menus and the sub-menus. Two small arrows at the bottom of the display point to the selected
menu and sub-menu name, respectively. Note that some menus and sub-menus are read-only
or not available, according to the boiler used and the initial startup configuration.

NOTE

The menu processing steps presented in this manual assume that all required
(one-time) INSTALLATION menu items have already been entered at setup. It
should be noted that whenever the unit is powered down and then powered up
again, the INSTALLATION menu will reappear. When this occurs, the
INSTALLATION menu items DO NOT need to be reentered. Normally, after entry
of the required initial INSTALLATION menu entries, turning the Rotary Knob
clockwise will automatically advance the Controller to t he DISPLAY menu group.
All items in this group are “Read Only” and cannot be changed.

See Sub-section 4.7, E8 Contr oller Initial Startup f or more information about
initial setup and configuration of the E8 Controller.

Table 3-1: Main Menus and Sub-Menus

MAIN MENUS SUB-MENUS

DISPLAY

USER

TIME

PROGRAMS

EXPERT

EXPERT HS

GENERAL

INSTALLATION

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INSTALLATI

Points down to
Points right to

Points left to

Points down to

Sub-MENU

MENU

Selected
Buss(es)

Selected Bus(es)

Selected

Selected

MENU Name

Names

Sub-MENU
Name

Names

Figure 3-4: E8 Display in MENU Mode (after first opening hinged door)

3.2.1 Basic Menu/Sub-Menu Navigation and Selection

Selected Menu and Sub-menu are indicated by two black arrows at display bottom pointing to
the Menu and Sub-menu names s ilk-screened below the display (see Figure 3-4).

Following initial startup and one-time entry of the required INSTALLATION menu items (see
E8 Controller Initial Startup, sub-section 4.7), to access, view and/or change menu items
follow these instructions:

Menu/Sub-Menu Navigation and S election

1. When the ON/OFF switch on the front of the boiler is turned O N and the swing-down hing ed
panel is opened, the controller will enter MENU Mode and INSTALLATION will be displayed
(Figure 3-4) in the LCD. This is the initial INSTALLAT ION menu and it is assumed that all
entries have already been made. See sub-section 4.8 for INSTALLATION menu initial entry
information.

2. Turn the Rotary Knob clockwise until the display advances to the DISPLAY menu. The dial
on the clock face will rotate one revolution counter clockwise and t hen go off. The display will
then show INSTALLATION, which is the first sub-menu in the DISPLAY menu group (Figure
3-4). The two small black arrows at bottom of the display will point down to the menu and
submenu names, in this case DISPLAY and INSTALLATION, respectively.

3. To view functions included in the INSTALLATION sub-menu, press the Program Key (Item
E, Figure 3-3). If desired, turn the Rotary Knob to scroll through the functions in the
INSTALLATION sub-menu. As previously mentioned, these display functions are read-only
and cannot be changed. Once you reach the end of the sub-menu, RETURN will appear in
the display.

4. To exit this sub-menu and advance to the next sub-menu in the DISPLAY menu, press the
Program Key. INSTALLATION will again be displayed. Turn the Rotary Knob clockwise until
the next sub-menu is displayed.

5. Repeat steps 2, 3 and 4 to view the remaining main menus and their associated sub-menus.
The remaining main menus are: USER, TIME PROGRAM, EXPERT, EXPERT HS (Not
Applicable to Modulex), and GENERAL.

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Parameter Change Pro cedu re

Use Rotary Knob to navigate to desired Menu/Sub-

Press Program Key to access parameters in the
selected (displayed) sub-menu.

Turn Rotary Knob to sequence through the available
parameters.

To change a parameter value, press the Program Key
To change the displayed parameter value, turn Rotary

To save the displayed parameter value to the controller
will turn off indicating the new value has been saved.

HOT-WATER

T-DHW

T-DHW

141.0

142.0

HOT-WATER

T-DHW

displayed

sub-menu

displayed

values

accessed

displayed

value

Displayed

Example: User Menu & Hot Water Sub-menu

parameters

Cycle thru

cycle thru

push!

push!

push!

142.0

Display Detail

Description

Examples

140.0

Displayed

Sub-menu

3.2.2 Basic Parameter Navig at io n, Select io n, and Revision

When in the USER, TIME PROGRAM, EXPERT, or GENERAL Main Menu, virtually all sub-
menu items can be changed if the desired. Perform the following steps to access, view, and/or
change menu item parameters:

menu. Menu and sub-menu are indicated by two small
black arrows at bottom of LCD display pointing down to
menu/sub-menu names below display (see Figure 3-

when desired parameter is displayed. The Change LED
will light up indicating the displayed parameter may now
be changed.

Knob; clockwise to increase value and counter­clockwise to decrease the value.

memory, press the Program Key. The Change LED

accessed

parameters

parameter

values

Value Saved!

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4. E8 CONTROLLER MENUS AND SUB-MENUS

This section provides flow-chart illustrations and tabular listings of all Menu and Sub-Menu functions.
Overall menu hierarchy is shown below:

1. DISPLAY

a. INSTALLATION
b. HOT WATER
c. HEAT CIRCUIT I
d. HEAT CIRCUIT II
e. SOLAR/MF

2. USER

a. INSTALLATION
b. HOT WATER
c. HEAT CIRCUIT I
d. HEAT CIRCUIT II

e. SOLAR/MF

3. TIME PROGRAMS

a. CIRCL TIME
b. HOTW-PROG
c. HTG-PROG 1
d. HTG-PROG 2

4. EXPERT

a. INSTALLATION
b. HOT WATER
c. HEAT CIRCUIT I
d. HEAT CIRCUIT II
e. SOLAR/MF

5. EXPERT HS

a. INSTALLATION

6. GENERAL

a. SERVICE
b. DATE/TIME
c. HOLIDAY
d. CLOCK CHANGE

IMPORTANT!

In the following flow-chart illustrations and t abular listings, descriptions, entry
ranges, and default values are provided for only the commonly used functions
which are referenced in Section 5, titled E8 Operating Mode: Set-Up &
Programming. These commonly used functions are shown in Bold Italics in
the illustrations and tables which follow. Refer to Section 8 for additional
information on functions marked “Not Applicable” in the illustrations and tables
provided.

PR1: 02/23/12 Page 17 of 112

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

DISPLAY

INSTALLATION

T-OUTSIDE
T-EXT DES
T-COLL DES
T-COLLECTOR
T-BOIL
T-SOLID FUEL
T-RETURN 1
T-RETURN 2
T-BUFFER T
T-BUFFER M
T-BUFFER L
T-STORAGE 3
MODGRAD
RETURN

HOT WATER

T-DHW RATED
T-DHW
T-DHW L

RETURN

HTG CIRCUIT 2

T-ROOM DES A
T-ROOM
HUMIDITY
T-FLOW RATED
T-FLOW
N-OPT-TIME
RETURN

SOLAR M/F

T-MF1
T-MF2
T-MF3
T-MF4
T-COLLECTOR
T-DHW
T-DHW L
RETURN

HTG CIRCUIT 1

T-ROOM DES A
T-ROOM
HUMIDITY
T-FLOW RATED
T-FLOW
N-OPT-TIME
RETURN

4.1 DISPLAY Menu

The DISPLAY Menu contains an INSTALLATION, HOT WATER, HEATING (HTG) CIRCUIT 1
& 2 and a SOLA R M/ F Su b-Menu as shown in Figure 4-1 and in Table 4-1.

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Figure 4-1: DISPLAY Menu Flow Chart

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

Reset and Constant Set Point modes.

T-COLLECTOR

Header Set Point temperature (cascade)

sequence between Heat Modules.

T-SOLID FUEL

Not Applicable

T-RETURN 1

Not Applicable

T-RETURN 2

Not Applicable

T-BUFFER T

Not Applicable

T-BUFFER M

Not Applicable

T-BUFFER L

Not Applicable

T-STORAGE 3

Not Applicable

Knob to sequence between Heat Modules.

Sub-Menu.

Based on heating prog and

USER/HOT WATER menu.

WATER Sub-Menu.

All DISPLAY Menu & Sub-Menu functions are READ ONLY and
cannot be changed. Temperature readings shown are in °F.

FUNCTION DESCRIPTION REMARKS

INSTALLATION Sub-Menu

NOTE

Table 4-1: DISPLAY Menu Listing

T-OUTSIDE Outside air temperature

T-EXT DES

T-COLL DES

T-BOIL

Boiler Set Point setting in 0 to 10 volt input
mode

Boiler Set Point temperature in Indoor/ Outdoor

Press Program Key to display temperature
and ON/OFF status of individual Heat
Modules (HS) which range from 2 (EXT

321) to 8 (EXT 3060). Turn Rotary Knob to

Displayed only if outside
air sensor is installed.

A 0 to 10 volt external input
signal can be used to change the
Boiler set point.

The Burner symbol ( )
is displayed when the
respective Heat Module is
ON.

Press Prog Key to display Modulation % for

MODGRAD

RETURN

individual Heat Modules (HS). Turn Rotary

Press Program Key to exit INSTALLATION

HOT WATER Sub-Menu

T-DHW RATED

T-DHW Actual hot water temperature
T-DHW L Not Applicable

T-CIRCL Not Applicable

RETURN

DHW set point temperature

Press Program Key to exit the HOT

Table 4-1: DISPLAY Menu Listing (Continued)

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operating mode. Actual
DHW set point as set in

Only if tank sensor is
installed

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

T-DHW

Current hot water temperature

FLOW

N-OPT-TIME

Not Applicable

CIRCUIT 1 Sub-Menu.

T-MF1

Not Applicable

T-MF2

Not Applicable

Currently not used

1

T-DHW L

Not Applicable

M/F Sub-Menu.

FUNCTION DESCRIPTION REMARKS

HTG CIRCUIT 1 Sub-Menu

T-ROOM DES A Not Applicable

T-ROOM Current room air temperature.

HUMIDITY Room humidity (%).

T-DHW RATED Hot water set point temperature

T-FLOW RATED Current flow set point temperature

Current flow temperature

RETURN

HTG CIRCUIT 2 Sub-Menu

Functions for HTG (Heating) Circuit 2 are identical to HTG Circuit 1 Functions
above.

Press Program Key to exit HTG

Only if indoor sensor is

connected

Only if humidity sensor

is installed and

parameters set for

heating circuit.

Appears only if heating

circuit is programmed

as hot water circuit

Same as above

Not applicable

SOLAR M/F Sub-Menu

T-MF3
T-MF4
T-COLLECTOR

T-DHW

RETURN

Not Applicable
Not Applicable

Not Applicable
Not Applicable

Press Program Key to exit SOLAR

Currently not used

Currently not used
Currently not used

Currently not used
Currently not used

Currently not used

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GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

USER

INSTALLATION

LANGUAGE
CONTRAST
DISPLAY SEL
RETURN

HOT WATER

1X DHW

T-DHW 1

T-DHW 2
T-DHW 3
BOB VALUE
CIRCL-P-DHW
ANTILEGION

RETURN

SOLAR M/F

RETURN

HTG CIRCUIT 1

MODE

T-ROOM DES 1
T-ROOM DES 2
T-ROOM DES 3
T-REDUCED
T-ABSENCE

T-LIMIT DAY
T-LIMIT N
HEATSLOPE

OPTIM HEAT
MAX OPT-TIME
ECONO OPTI
PC ENABLE

RETURN

HTG CIRCUIT 1

MODE

T-ROOM DES 1
T-ROOM DES 2
T-ROOM DES 3
T-REDUCED
T-ABSENCE

T-LIMIT DAY
T-LIMIT N
HEATSLOPE

OPTIM HEAT
MAX OPT-TIME
ECONO OPTI
PC ENABLE

RETURN

4.2 USER Menu

The USER Menu (Figure 4-2) contains the same Sub-Menus as the DISPLAY Menu.
However, the USER Menu items are not “Read Only” and therefore can be changed. The Sub­Menu functions in the USER Menu also differ from those contained in the DISPLAY Menu.
Tabular listings for the USER Menu items are provided in Table 4-2.

Figure 4-2: USER Menu Flow Chart

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GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

CONTRAST

00

Domestic Hot Water

connected).

Menu.

1X DHW

Not Applicable

T-DHW 1

Hot Water set point

50°F - 158°F

140°F

T-DHW 2

Not Applicable

BOB-VALUE

Not Applicable

DHW

Menu.

Table 4-2: USER Menu Listing

FUNCTION

INSTALLATION Sub-Menu

LANGUAGE Selects display language.

Adjusts display contrast
Sets the day of the week or the sensor

temperature (°F) to appear in the display when
the swing-down panel is closed.

DESCRIPTION

Day: SUN – SAT

T-OUTSIDE: Outside Temperature

FLOW TEMP (1/2): Flow Temp. For Heating

Circuit 1 or 2 supply

DISPLAY
SEL

water temperature. (Only
if sensor is installed)

T-DHW:
Temperature.

T-BOILER; Boiler Outlet Temperature.

T-ROOM (1 / 2): Room Temp, Heating

Circuit 1 or 2 (ONLY if
Remote Control is

ENTRY RANGE DEFAULT

12 languages are

available.

-20 to 20

ENGLISH

See

DESCRIPTION

Column

- - - -

RETURN

HOT WATER Sub-Menu

T-DHW 3

CIRCL-P-

RETURN

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Press Program Key to exit INSTALLATION Sub-

Not Applicable

Not Applicable
Press Program Key exit HOT WATER Sub-

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

Night

T-ROOM DES 2

Not Applicable

T-ROOM DES 3

Not Applicable

-23.0°F–104.0°F

periods.

-23.0°F–104.0°F

1°F.

MAX OPT-TIME

Not Applicable

ECONO OPTI

Not Applicable

CIRCUIT 1 (or 2) sub-menu.

display to the TIME PROGRAM Menu.

Table 4-2: USER Menu Listing (Continued)

FUNCTION

HTG CIRCUIT 1 Sub-Menu

MODE Displays Timer Mode for Boiler

T-ROOM DES 1

T-REDUCED
T-ABSENCE

T-LIMIT DAY Applies during day-time heating periods

T-LIMIT N

HEATSLOPE

Not Applicable

Not Applicable
Not Applicable

Applies during reduced night-time

Indicate number of degrees that the flow
temperature changes if the outside
temperature increases or decreases by

DESCRIPTION

ENTRY RANGE

- - - -, Standby,

Auto 1, Auto 2, Day,

- - - -,

- - - -,

0.00 – 3.00 1.20

DEFAULT

- - - -

66.0°F

50.0°F

OPTIM HEAT

PC-ENABLE

RETURN

HTG CIRCUIT 2 Sub-Menu

Functions for HTG Circuit 2 are identical to HTG Circuit 1 Functions listed above.

SOLAR M / F Sub-Menu (No Functions Currently In This Sub-Menu)

RETURN

Not Applicable

Not Applicable
Press Program Key to exit HTG

Pressing the Program Key with SOLAR
M/F displayed will change display to
RETURN . Press Progr am Key again to
redisplay SOLAR M/F. Turning the
Rotary Knob clockwise will advance thd

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GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

TIME PROGRAM

CIRCL TIME

MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
SUNDAY
MO-FR
SA-SU
MO-SU
RETURN

HOTW-PROG

MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
SUNDAY
MO-FR
SA-SU
MO-SU
RETURN

HTG-PROG 1

MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
SUNDAY
MO-FR
SA-SU
MO-SU
RETURN

HTG-PROG 2

MONDAY
TUESDAY
WEDNESDAY
THURSDAY
FRIDAY
SATURDAY
SUNDAY
MO-FR
SA-SU
MO-SU
RETURN

4.3 TIME PROGRAM Menu and Sun-Menus

Day and Time-related functions can be set using the TIME PROGRAM Menu and its
associated Sub-Menus. However, at the present time, none of the Sub-Menus and functions
in the TIME PROGRAM Menu are being utilized. This menu is shown in Figure 4-3.

Refer to Secti on 8 for additional information on these Menu and Sub-Menu functions.

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Figure 4-3: TIME PROGRAM Menu Flow Chart

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

EXPERT

INSTALLATION

CODE-NO
BUS ID HS
BUS ID 1
BUS ID 2
AF SUPPLY
BUS TERM
EBUS SUPPLY
TIME MASTER
MAX T COLL
MIN T COLL
MAX T-HS2
MIN T-HS2
V-CURVE
CURVE 11-U1
CURVE 11-U2
CURVE 11-T1
CURVE 11-T2
CURVE 11-UA
HYSTERESIS
FOUND MODULS
CAP/MODULE
NEW CONFIG
MIN MOD CASC
HW-BOILER
CONTR DEVIAT
DES OUTPUT
BLOCK TIME
MAX T-MODUL
DYN UPWARD
DYN DOWNWARD
RESET TIME
MODULAT MAX
MODULAT MIN
MIN MOD HS
SEQUENCE 1
SEQUENCE 2
SEQU CHANGE
SEQ SW TIME
LOCK TIME
HYST BURNER 2
HS COOL FUNC
T-HS COOL
HEATSOURCE 1
HS1 BUS
HEATSOURCE 2
STORAGE HS 2
BUFFER
RETURN

CONTINUED ON SHEET

2

4.4 EXPERT Menu and Sub-Menus

The EXPERT Menu contains the following Sub-Menus: INSTALLATION, HOT WATER, HEAT
CIRCUIT 1, HEAT CIRCUIT 2 and SOLAR M/F as shown in Figure 4-4. As this figure shows,
the EXPERT Menu includes an extensive list of Sub-Menu functions, particularly in the
INSTALLATION Sub-Menu. Tabular listings for the EXPERT Menu and Sub-Menu items are
provided in Table 4-3.

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Figure 4-4: EXPERT Menu Flow Chart (Sheet 1 of 2)

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

EXPERT

HTG CIRCUIT 1

HC FUNCTION
PUMP MODE

MIXER OPEN
MIXER CLOSE

MAX T-FLOW
MIN T-FLOW
T-FROST PROT

OUT-TEMP-DEL
SLOPE OFFSET
B-HEAT SINK

RETURN

HOT-WATER

DHW RELIEF

PARALLEL
T-BOILER DHW

HYST DHW
DHW FOLLOWUP

THERM INPUT

WALL HUNG
LOAD THROUGH

RETURN

HTG CIRCUIT 2

HC FUNCTION
PUMP MODE
MAX T-FLOW
MIN T-FLOW
T-FROST PROT

OUT-TEMP-DEL
B-HEAT SINK
RETURN

SOLAR M/F

RELAY FUNC 1
T-MF 1 SETP
MF1 HYST
RELAY FUNC 2
T-MF 2 SETP
MF2 HYST
RELAY FUNC 3
T-MF 3 SETP
MF3 HYST
RELAY FUNC 4
T-MF 4 SETP
MF4 HYST

F15 FUNCTION
RETURN

CONTINUED FROM SHEET 1

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Figure 4-4: EXPERT Menu Flow Chart (Sheet 2 of 2)

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

INSTALLATION Sub-Menu

CODE-NO

Permits entry of valid Code No.(0000)

0000 - 9999

0000

the boiler

CHANGE

numbers must not be assigned twice.

AF SUPPLY

Outdoor sensor power supply

00, 01 (OFF/ON)

01 (ON)

BUS TERM

Bus terminating resistor (Must be set to 01)

00, 01 (OFF/ON)

01 (ON)

SUPPLY

MASTER

point temperature.

temperature.

MAX T-HS2

Not Applicable

MIN T -HS2

Not Applicable

0 to 10 Volt input Voltage curves. Choose
customize a curve.

CURVE 11-U1

Low voltage setting

0.00V – 10.00V

0.000

CURVE 11-U2

High voltage setting

0.00V – 10.00V

10.00

CURVE 11-T1

Minimum set point temperature

32.0°F – 248.0°F

59.0°F

CURVE 11-T2

Maximum set point temperature

32.0°F – 248.0°F

185.0°F

this setting will stop/ s tart the Boiler.

NOTE

Whenever “CODE NO.” is displayed, it indicates that the valid
password must be entered. This is accomplished by entering code

0000 (four zeros) by pressing the Program Key four (4) times.

Table 4-3: EXPERT Menu Listing

FUNCTION DESCRIPTION ENTRY RANGE DEFAULT

BUS ID HS

BUS ID 1

BUS ID 2

EBUS

TIME

MAX T-COLL

MIN T-COLL

BUS ID HS MUST be set to - - - - to operate

The heating circuits are sequentially
numbered starting with “01“, heating circuit

Heating circuits are sequentially numbered
starting with “01“, heating circuit numbers
must not be assigned twice.

Switches the Ebus supply ON/OFF 00, 01 (OFF/ON) 01 (ON)

Not Applicable
Sets the maximum allowable header set

Sets the minimum allowable header set point

01 - 08

(00), 01 – 15 01

(00), 01 – 15 - - - -

86.0°F – 230.0°F 185.0°F

50.0°F – 176.0°F 50.0°F

DO NOT

V-CURVE

CURVE 11-UO

from preset curves (see Section 4.4.1) or

Stop/Start voltage level. Going below/above

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00 – 11 11

0.00V – 10.00V 1.00

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Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

INSTALLATION Sub-Menu (Continued)

MODULS

for service.

module.

321-1123

110 Kw: 1530-3060

CASC

HW-BOILER

Not Applicable

00 – 08

00

actual water temperature.

DES OUPUT

Required system output [in %]

0 – 100%

00

SWITCH TIME

Not Applicable

(N/A)

(N/A)

BLOCK TIME

Not Applicable

(N/A)

(N/A)

MODUL

230.0°F

UPWARD

DOWNWARD

RESET TIME

Not Applicable

5 – 500

50

after the delay time elapses.

off

MIN MOD HS

Not Applicable

0% - 60%

35%

HW

SEQUENCE 1

SEQUENCE 2

Boiler sequence 2

87654321

Table 4-3: EXPERT Menu Listing (Continued)

FUNCTION DESCRIPTION ENTRY RANGE DEFAULT

HYSTERESIS Not Applicable

FOUND

CAP/MODULE

NEW CONFIG Not Applicable
MIN MOD

CONTR
DEVIAT

MAX T-

DYN

Displays the number of heat modules available

Displays the maximum Kw output of each heat

Not Applicable 01 – 08 01

Control Deviation indicates the temperature
difference between the Boiler set point and the

Maximum temperature of Heat Module

Not Applicable (N/A) (N/A)

–

Display

00 – 1000 Kw

Display °F

122.0°F to

50 Kw:

194.0°F

DYN

MODULAT
MAX

MODULAT
MIN

MOD LEVEL

Not Applicable (N/A) (N/A)

Start Level. If this modulation percentage is
exceeded, the next heat module is connected

Stop Level. If value drops below this
modulation percentage, the last heat generator
(module) of the current sequence is switched

Not Applicable
Boiler sequence 1

50% - 100% 30%

10% - 60% 35%

12345678

Table 4-3: EXPERT Menu Listing (Continued)

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GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

ENTRY

RANGE

SEQU CHANGE

Sequence change mode

01 – 06

06

SEQ SW TIME

Time to sequence change (hours)

10 – 800

200

LOCK TIME

Not Applicable

00 min – 30 min

00

HYST BURNER2

Not Applicable

–

T-HS COOL

Not Applicable

Identification of Boiler Type being used:

06 = Multi-Stage, modulating (cascade via BUS)

Heat Source

HEATSOURCE 2

Not Applicable

N/A

N/A

STORAGE HS2

Not Applicable

N/A

N/A

BUFFER

Not Applicable

N/A

N/A

SCREED

Not Applicable

N/A

N/A

SCREED PROGR

Not Applicable

N/A

N/A

RETURN

Press Program Key to exit INSTALLATION Sub-Menu.

HOT WATER Sub-Menu

DHW RELIEF

Not Applicable

N/A

N/A

02 = Pump Parallel Running

DHW)

HYST DHW

Hot Water Hysteresis

48°F – 129°F

48°F

min.

Storage Tank With Thermostat = 01

WALL HUNG

Not Applicable

LOAD THROUGH

Not Applicable

RETURN

Press Program Key to exit HOT WATER Sub-Menu.

FUNCTION DESCRIPTION

DEFAULT

INSTALLATION Sub-Menu (Continued)

HS COOL-FCT Not Applicable

00 = No Boiler

HEATSOURCE 1

HS 1 BUS

01 = Single-Stage, switching
02 = Single-Stage, modulating
03 = 2-Stage, switching
04 = 2 individual, switching
05 = Multi-Stage, switching

Communication connection between Controller and

See

DESCRIPTION

00 – 04 02

06

(Multi-Stage

Modulating)

Parallel pump operation.

PARALLEL

T-BOILER DHW

DHW FOLLOWUP Pump Run-Down Time

THERM INPUT

00 = Hot Water Priority
01 = Hot Water Partial Priority

Boiler temperature increase during Hot Water
operation.

Boiler Temp = (DHW Temp Setting) + (T-BOILER

Storage Tank With Sensor = 00

Table 4-3: EXPERT Menu Listing (Continued)

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00, 01, 02

32°F – 194°F 97°F

00 min. – 30

00, 01

01

00 min.

00

GF-115-C

Modulex E8 Controller a nd BCM

Operations and Maintenance Manual

OMM-0084_0D

ENTRY

RANGE

valve.

Circulation pump mode control for ON/OFF

03 = Continuous pump operation

MIXER OPEN

Not Applicable

MIXER CLOSE

Not Applicable

Maximum allowable water temperature setting
for the heating circuit.

68°F –

230°F

Minimum allowable water temperature setting
for the heat circuit.

50°F –

230°F

Specifies the minimum allowable outside air

INSTALLATION Mode)

DEL

OFFSET

B-HEAT SINK

Press Program Key to exit HEAT CI RCUIT 1
(or 2) Sub-Menu.

FUNCTION DESCRIPTION

HEAT CIRCUIT 1 & 2 Sub-Menus

The Sub-Menu Functions for HEAT CIRCUIT 1 & HEAT CIRCUIT 2 are identical, except for
the MIXER OPEN & MIXER CLOSE Functions which apply only to HEAT CIRCUIT 1. The
Function values in this Sub-Menu level will change, depending on the Heat Circuit Function
(HC FUNCTION) selected.

Heat Circuit Function defines type of circuit:
00 = Standard Heat Circuit (indoor / outdoor reset)

01 = Control to fixed flow temperature (constant setpoint)

HC FUNCTION

PUMP MODE

02 = Swimming pool control (HC 2 ONLY)
03 = Hot Water Circuit
04 = Return flow temp. Increase via mixing

switching of pumps.
00 = Standard pump control

01 = Pump switching per heating limits
02 = Pump switching per heating program

00 – 04

00 – 03 00

DEFAULT

00

(Standard

Heat

Circuit)

MAX T-FLOW
MIN T-FLOW

temperature setting for the Frost Protection
Mode. If temperature drops below this value,

T-FROST PROT

OUT-TEMP-

SLOPE

RETURN

the system switches to the Frost Protect Mode
and the pumps are switched ON.
(This Function should be set to 0°F in the

Not Applicable N/A N/A

Not Applicable N/A N/A
Not Applicable

Table 4-3: EXPERT Menu Listing (Continued)

FUNCTION DESCRIPTION ENTRY DEFAULT

176°F

50°F

-5°F –
41°F

N/A

32°F

N/A

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