AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
Modbus® is a registered
Released: 05/18/2012
MODBUS
USER MANUAL
Installation, Operation, and Maintenance
MODBUS Communication For:
• C-More Boiler Controllers
• Boiler Management System
(BMS/BMS II)
• AERCO Control System
(ACS)
Communication
®
trademark of AEG Modicon
GF-114
Technical Support:
www.aerco.com
OMM-0035_0BUSER MANUAL
MODBUS
(Mon–Fri, 8am-5pm EST)
Communication
1-800-526-0288
Disclaimer
The information contained in this manual is subject to change
without notice from AERCO International, Inc. AERCO makes no
warranty of any kind with respect to this material, including but not
limited to implied warranties of merchantability and fitness for a
particular application. AERCO International is not liable for errors
appearing in this manual. Nor for incidental or consequential
damages occurring in connection with the furnishing,
performance, or use of this material.
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Contents USER MANUAL
MODBUS
CommunicationGF-114
OMM-0035_0C
TABLE OF CONTENTS
TABLE OF CONTENTS ............................................................................................................... 3
CHAPTER 1: INTRODUCTION AND GENERAL DESCRIPTION ....................... 7
6.2 C-MORE BOILER CONTROLLER SETUP FOR MODBUS OPERATION ........................ 81
6.2.1 Monitoring and Configuration Control .......................................................................... 81
6.2.2 Modbus Direct Drive Control and Monitoring .............................................................. 82
6.2.3 Modbus Remote Setpoint Control ............................................................................... 82
6.3 BMS II/ACS SETUP FOR OPERATION AS A SLAVE TO AN EMS MASTER ................. 83
6.3.1 BMS II/ACS Monitoring and Configuration By An EMS Master ................................... 83
6.3.2 BMS II/ACS Modbus Remote Setpoint Control By An EMS Master ............................ 83
6.4 BMS II/ACS SETUP AS MASTER TO C-MORE BOILER CONTROLLERS ..................... 84
APPENDIX A: C-MORE BOILER CONTROLLER STATUS & FAULT MESSAGES,
CONVERSION EQUATIONS, BCM FAULT CODES, BMM FAULT CODES, AND I/O
STATUS
TABLES……………………………………………………………………………………………….87
MODBUS
CommunicationGF-114
OMM-0035_0C
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OMM-0035_0CUSER MANUALContents
MODBUS
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Communication
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Chapter 1
Introduction & Description USER MANUAL
MODBUS
CommunicationGF-114
OMM-0035_0C
CHAPTER 1.INTRODUCTION AND GENERAL
DESCRIPTION
1.1 INTRODUCTION
The information contained in this manual provides general guidelines for implementing a
Modbus® communications network utilizing AERCO’s Boiler Management System (BMS) Model
168, Boiler Management System II (BMS II) Model 5R5-384, or AERCO Control System (ACS)
and C-More Boiler Controllers.
Throughout this document, the following terminology shall be used when referring to BMS
Model 168 and BMS II Model 5R5-384:
• BMS: Applies to BMS Model 168 Only
• BMS II: Applies to BMS II Model 5R5-384 Only
• BMS/BMS II: Applies to Both Models (BMS and BMS II)
• BMS II/ACS: Applies to Both Models (BMS II and ACS)
• ACS: Applies to ACS Only
All Modbus networks are implemented utilizing a Master-Slave technique where only one
device, the Master, can initiate a communication sequence. AERCO C-More Controllers can
only function as Slave devices in a Modbus network. However, the AERCO BMS can function
both as a Master controlling C-More Slaves, or as a Slave controlled by an Energy Management
System (EMS) or Building Automation System (BAS) developed by other manufacturers.
1.2 AERCO BMS AND C-MORE CONTROLLER MODELS COVERED
To easily determine if your AERCO BMS or C-More Boiler Controller is equipped with Modbus
capabilities, check the current software version as follows:
For BMS:
• Apply power to the BMS
• The BMS will display: INITIALIZING followed by EPROM REV K
• If REV K or higher is displayed, the BMS Controller can support Modbus
• If the REV level is lower than K, the BMS Controller cannot support Modbus
For BMS II/ACS:
• All BMS II Controllers support Modbus
For C-More:
• Apply external power to the C-More Controller
• Scroll through the Setup Menu and observe the displayed Software Version
• If 2.00 or higher is displayed, the C-More Controller can support Modbus
• If a Software Version lower than 2.00 is displayed, the C-More Controller cannot support
Modbus
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Communication Medium:
Allowable Cable Lengths:
PWM:
1,000 Feet, Maximum
Address Support From Master:
1 to 127 (From Master BMS/BMS II/ACS or
0 is Reserved for Broadcast
Messages
Transmission Mode Support
RTU (Remote Terminal Unit)
Timing Specifications:
last character of
Seconds
OMM-0035_0CUSER MANUALIntroduction & Description
MODBUS
Communication Chapter 1
1.3 MIMIMUM MODBUS SUPPORT REQUIREMENTS
Implementation of a Modbus communication network utilizing the AERCO C-More Controller
and BMS/BMS II will be limited to the minimum support requirements listed in Table 1-1 which
follows. The remaining paragraphs in this Section provide more detailed descriptions for each
of the items listed.
Table 1-1: Modbus Communication and Support Requirements
Silent period of at least 3.5 character times
Before first character and After
message
No more than 1.5 character times of silence
between received and transmitted characters
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Fixed at 10 seconds For C-More
Adjustable For BMS/BMS II/ACS: 5 to 240
Chapter 1
Introduction & Description USER MANUAL
MODBUS
CommunicationGF-114
OMM-0035_0C
1.3.1 Communication Medium
The communication medium for each of the possible Modbus network configurations may vary
depending on the Master/Slave scenario being implemented. Detailed installation procedures
and wiring diagrams for the configurations described in the following paragraphs are provided in
Section 4 of this manual.
1.3.1.1 EMS Master To BMS/BMS II/ACS Slave
The Modbus network connections between the EMS and BMS/BMS II/ACS will depend on the
type of port provide on the EMS Master. If the EMS contains a RS232 port, a direct connection
can be made directly to the BMS/BMS II/ACS RS232 port. For optimum results the wire length
between the EMS and BMS/BMS II/ACS RS232 connection should not exceed 50 feet. If the
EMS Master contains a RS485 port, a RS485-to-RS232 converter will be required to implement
the Modbus network.
1.3.1.2 BMS/BMS II/ACS Master To C-More Boiler Controller Slaves
Up to a total of 32 C-More Boiler Controllers can be connected to a BMS/BMS II/ACS Master on
the Modbus Network. Multi-point drop network connections are made using shielded, twistedpair wire. In addition to the Modbus Network Boilers, up to 8 additional Legacy Boilers can be
connected to the BMS Pulse Width Modulation (PWM) wiring connection. The BMS II and ACS
do not support PWM. It should be noted that the BMS, BMS II, and ACS include a Modbus
Pass-Thru feature which, when enabled, permits an EMS to monitor and configure (but not
directly control) the boilers.
1.3.1.3 EMS Master To C-More Boiler Controller Slaves
The number of C-More Boiler Controllers which can be connected to a Modbus Network which
utilizes a third party EMS Master will depend on the EMS’s limitations. Theoretically, the
maximum number of Slave devices is limited to 127. If the EMS contains a RS232 port, a
RS232-to-RS485 converter will be required to provide the necessary RS485 interfaces and
signal levels for the C-More Boiler Controllers. Multi-drop network connections are made using
shielded, twisted-pair wire.
1.3.2 Address Support
Address support is assigned as follows:
• BMS/BMS II/ACS Address Support From EMS Master: 128 – 247 (80 – F7 hex)
• C-More Address Support From BMS/BMS II/ACS or EMS Master: 1 – 127 (01 – 7F hex)
• Broadcast Messages: Address 0 is reserved for all Broadcast messages
1.3.3 Modbus Transmission Modes
Many Modbus Controllers can be set up to transmit using either the ASCII (American Standard
Code for Information Interchange) transmission mode, or the RTU (Remote Terminal Unit)
transmission mode. However, since RTU messages can be formatted using far fewer binary
bits than the corresponding ASCII message, it is far more efficient. Therefore, all Modbus
messages for the AERCO BMS/BMS II/ACS and C-More Boiler Controllers use RTU
transmission ONLY. If a third-party EMS Master is being used in the Modbus network, ensure
that it is set for RTU transmission.
1.3.4 Timing Specifications
As Table 1-1 shows, Baud Rate and Heartbeat Timeout will vary depending on the
Configurations of the AERCO BMS/BMS II/ACS and C-More Boiler Controllers being used in the
Modbus Network. Ensure that the Baud Rate used by the controlling Master (BMS/BMS II/ACS
05/18/12 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526-0288 Page 9 of 200
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Function Code
Function Name
Read Holding Register (Read Multiple
Registers)
04
Read Input Registers
06
Preset (Write) Single Register
Diagnostics
Codes)
17
Report Slave ID
Sub-
Code
00
Return Query Data
Loop-Back
01
Restart Communications Options
Resets the Slave. Cancels Listen Only Mode.
02
Return Diagnostic Register
Not Used
04
Force Listen Only Mode
Reset by Restart Communications Option
Also cleared at power up. Clears only the
counters
12
Return Bus Communication Error Count
Slave CRC errors only.
13
Return Bus Exception Error Count
Slave Exception Response count.
Number of messages addressed to the slave
broadcast messages.
Number of messages addressed to the slave
for which no response was returned.
18
Return Bus Character Overrun Count
Number of overrun and framing errors.
OMM-0035_0CUSER MANUALIntroduction & Description
MODBUS
Communication Chapter 1
or EMS) matches the appropriate Baud Rate supported by the Network Slaves (BMS/BMS
II/ACS or C-More Controllers). Also, ensure that the Modbus Master can refresh the control
information to all C-More Slaves before the Heartbeat Timeout period expires.
1.4 MODBUS FUNCTION SET SUPPORT
The complete Modbus protocol includes a total of 24 Function Codes. However, for AERCO
BMS/BMS II/ACS and C-More Boiler Controllers, only the Codes listed in Table 1-2 are
supported. The supported Diagnostic Sub-Function Codes associated with Diagnostic Function
Code 08 are listed in Table 1-3.
Table 1-2: Required Function Code Set
03
08
(See Table 1-3 for supported Sub-Function
Table 1-3: Minimum Diagnostic (Function Code 08) Sub-Function Set
Function
10 Clear Counters and Diagnostic Register
Sub-Function Name Comments
14 Return Slave Message Count
15 Return Slave No Response Count
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and successfully processed. Includes
Chapter 1
Exception Code
Description
Comments
The function code received is not valid or
is not supported.
The data address received is invalid or is
not accessible due to security setting.
03
Illegal Data Value
The data value received is not valid
Phrase, Abbreviation
or Acronym
ACS
AERCO Control System
ASCII
American Standard Code for Information Interchange
BAS
Building Automation System
Baud
Bits per Second (bps)
BMS (BMS II)
Boiler Management System (Boiler Management System II)
(or Control Box)
used in all Benchmark and KC Series product lines
EMS
Energy Management System
FDX
Full-Duplex
HDX
Half-Duplex
Hex
Hexadecimal Number (0 - 9, A - F)
Input/Output (I/O) Box currently used on all Benchmark and KC
Series products
LSB
Least Significant Byte
A serial, half-duplex data transmission protocol developed by AEG
Modicon
MSB
Most Significant Byte
A standard for serial, full-duplex (FDX) transmission of data based
on the RS232 Standard
A standard for serial, full-duplex (FDX) transmission of data based
on the RS422 Standard
based on the RS485 Standard
RTU
Remote Terminal Unit
Introduction & Description USER MANUAL
MODBUS
CommunicationGF-114
OMM-0035_0C
1.5 EXCEPTION RESPONSES
With the exception of Broadcast Messages, queries transmitted by the Master expect a normal
response from the addressed Slave on the network. However, if the addressed Slave cannot
process or interpret the message, it will respond with one of the Exception Codes listed in Table
1-4.
Table 1-4: Minimum Exception Code Set
01 Illegal Function
02 Illegal Data Address
1.6 PHRASES, ABBREVIATIONS & ACRONYMS
The phrases, abbreviations and acronyms used in this manual are listed in Table 1-5.
Table 1-5: Phrases, Abbreviations and Acronyms
C-More Controller
I/O Box
Modbus®
RS232
Meaning
A control system developed by AERCO International and currently
RS422
RS485
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A standard for serial, half-duplex (HDX) transmission of data
GF-114
OMM-0035_0CUSER MANUALIntroduction & Description
MODBUS
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Communication Chapter 1
Page 12 of 200 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph.: 800-526-0288 05/18/12
Chapter 2
Standard Register Assignments USER MANUAL
MODBUS
CommunicationGF-114
OMM-0035_0C
CHAPTER 2.STANDARD REGISTER ASSIGMENTS
2.1 INTRODUCTION
This Section provides the standard data register addresses assigned to the AERCO and CMore Boiler Controllers, the AERCO Boiler Management System (BMS/BMS II), and AERCO
Control System (ACS). These data registers consist of Input Registers and Holding Registers.
All register addresses provided throughout this manual are expressed as hexadecimal numbers.
2.1.1 Input Registers
The Input Registers for the AERCO C-More Boiler Controllers and AERCO BMS/BMS II/ACS
are intended for information and functions that cannot or should not be controlled remotely.
Therefore, unless otherwise specified, ALL Input Register data are READ ONLY.
IMPORTANT
All Modbus addresses specified in this manual are written
generically in decimal/hexadecimal format. However, many
Building Automation Systems utilize another form of addressing
where:
40001 is added to the generic address for a Holding Register
address.
And
30001 is added to the generic address for an Input Register
address. Be sure to check the addressing scheme being used by
the BAS that is being interfaced to the XPC Gateway.
2.1.2 Holding Registers
The Holding Registers for the AERCO C-More Boiler Controllers and AERCO BMS/BMS II/ACS
are intended for information and functions that can be read or written (R/W). Therefore unless
otherwise specified, all Holding Register data are R/W.
CAUTION
DO NOT write in any Register Addresses marked as “Reserved” in
the Input Register and Holding Register Tables which follow.
Failure to observe this precaution may result in unstable
operation.
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Table 2-1: C-More Boiler Controller Standard Input Register Address Mapping
(Continued)
Address
29 (0x001D)
30 (0x001E)
31 (0x001F)
32 (0x0020)
33 (0x0021)
34 (0x0022)
Menu Item Units and Range
Sensor Log
Outlet Temp
Sensor Log
Inlet Temp
Sensor Log
FFWD Temp
Sensor Log
Exhaust Temp
Sensor Log
Outdoor Temp
Sensor Log
Aux Temp
DEGREES_1 (0 to 1000)
DEGREES_1 (0 to 1000)
DEGREES_1 (0 to 1000)
DEGREES_3 (0 to 1000)
DEGREES_2 (0 to 1000)
DEGREES_1 (0 to 1000)
Default/
Comments
Tables A-2 and A-3 for
Tables A-2 and A-3 for
Tables A-2 and A-3 for
Tables A-2 and A-3 for
Tables A-2 and A-3 for
Tables A-2 and A-3 for
35 (0x0023)
36 (0x0024)
37 (0x0025)
38 (0x0026)
39 (0x0027)
40 (0x0028)
41 (0x0029)
42 (0x002A)
43 (0x002B)
Time Log
Status
PPM_UNITS
% (0 to 100)
GPM_UNITS
74 (“O”) = Off
80 (“P”) = Power Up
% (0 to 100)
% (0 to 100)
Int (0 to 65535)
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Chapter 2
Modbus Data
Decimal (Hex)
See Appendix A,
Remote Set Point Mode
Normally Read Only. R/W
ONLY in Direct Drive Mode.
2 (0x0002)
Modbus Password
int (0 to 65535)
Default = 0
3 (0x0003)
Password
int (0 to 65535)
Default = 0
See Appendix A,
Default = 130°F
5 (0x0005)
(Reserved)
Int (0 to 1439)
1count/min
Date count starts with Jan.
counts
bool (0, 1)
1=Degrees Celsius (°C)
enum (0, 1, 2, 3, 4)
3 = 19.2k
bool (0, 1)
1 = Water Heater
enum (0, 1, 2, 3, 4, 5)
5 = 3 MBTU
Standard Register Assignments USER MANUAL
MODBUS
CommunicationGF-114
OMM-0035_0C
2.2.2 C-More Boiler Controller Standard Holding Register Assignments
The Read/Write Input Register address assignments are listed in Table 2-2 which follows.
Unless otherwise specified, all Holding Register menu items are Read/Write (R/W)
Table 2-2: C-More Controller Standard Holding Register Address Mapping
Address
0 (0x0000)
1 (0x0001) Net Direct Drive % (0 to 100)
4 (0x0004) Internal Set Point DEGREES_1 (0 to 1000)
6 (0x0006) Time
7 (0x0007) Date
Menu Item Units and Range Comments
Net Remote Set
Point
DEGREES_1 (0 to 1000)
int (0 to 65535)
1count/day
Tables A-2 and A-3 for
Conversions. R/W ONLY in
Tables A-2 and A-3 for
Conversions
1, 2000. For Example: Jan.
1 2001 would equal 365
8 (0x0008) Unit of Temp
9 (0x0009) Baud Rate
10 (0x000A) Unit Type
11 (0x000B) Unit Size
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Table 2-3: BMS/BMS II Standard Input Register Address Mapping (Continued)
Modbus Data
Address
47 (0x002F)
Boiler 31 Status (Net Boiler 23)
Boiler 23 Status (BMS II)
Menu Item Units and Range Comments
120 = On-Line But Not
Fired
1–40 = Fired & Sequence
121 = On-Line But
Disabled
122 = On-Line But
48 (0x0030)
49 (0x0031)
50 (0x0032)
51 (0x0033)
52 (0x0034)
53 (0x0035)
54 (0x0036)
55 (0x0037)
56 (0x0038)
57 (0x0039) I/O Status 0 to 255
Same As Above
Same As Above
Same As Above
Same As Above
Same As Above
Same As Above
Same As Above
Same As Above
status (BMS II Only)
Bit 0 = AUX Relay
Bit 1 = Fault Relay
Bit 2 = Sys Start Relay
Bit 3 = Empty
Bit 4 = Setback
Bit 5 = Interlock 2
Bit 6 = Interlock 1
Page 24 of 200 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph.: 800-526-0288 05/18/12
Chapter 2
Decimal (Hex)
59 (0x003B)
Net Blr 1 Outlet Temp
40°F to 220°F
When Blr Cntl Type = 1 or 2
60 (0x003C)
Net Blr 2 Outlet Temp
40°F to 220°F
61 (0x003D)
Net Blr 3 Outlet Temp
40°F to 220°F
62 (0x003E)
Net Blr 4 Outlet Temp
40°F to 220°F
63 (0x003F)
Net Blr 5 Outlet Temp
40°F to 220°F
64 (0x0040)
Net Blr 6 Outlet Temp
40°F to 220°F
65 (0x0041)
Net Blr 7 Outlet Temp
40°F to 220°F
66 (0x0042)
Net Blr 8 Outlet Temp
40°F to 220°F
67 (0x0043)
Net Blr 9 Outlet Temp
40°F to 220°F
68 (0x0044)
Net Blr 10 Outlet Temp
40°F to 220°F
69 (0x0045)
Net Blr 11 Outlet Temp
40°F to 220°F
70 (0x0046)
Net Blr 12 Outlet Temp
40°F to 220°F
71 (0x0047)
Net Blr 13 Outlet Temp
40°F to 220°F
72 (0x0048)
Net Blr 14 Outlet Temp
40°F to 220°F
73 (0x0049)
Net Blr 15 Outlet Temp
40°F to 220°F
74 (0x004A)
Net Blr 16 Outlet Temp
40°F to 220°F
75 (0x004B)
Net Blr 17 Outlet Temp
40°F to 220°F
76 (0x004C)
Net Blr 18 Outlet Temp
40°F to 220°F
77 (0x004D)
Net Blr 19 Outlet Temp
40°F to 220°F
78 (0x004E)
Net Blr 20 Outlet Temp
40°F to 220°F
79 (0x004F)
Net Blr 21 Outlet Temp
40°F to 220°F
80 (0x0050)
Net Blr 22 Outlet Temp
40°F to 220°F
81 (0x0051)
Net Blr 23 Outlet Temp
40°F to 220°F
82 (0x0052)
Net Blr 24 Outlet Temp
40°F to 220°F
83 (0x0053)
Net Blr 25 Outlet Temp
40°F to 220°F
84 (0x0054)
Net Blr 26 Outlet Temp
40°F to 220°F
85 (0x0055)
Net Blr 27 Outlet Temp
40°F to 220°F
Standard Register Assignments USER MANUAL
MODBUS
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OMM-0035_0C
Table 2-3: BMS/BMS II Standard Input Register Address Mapping (Continued)
Modbus Data
Address
Menu Item
Units and
Comments
Range
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2.3.2 BMS/BMS II Controller Standard Holding Register Assignments
The Holding Register address assignments for the BMS/BMS II/ACS are listed in Table 2-4
which follows. Unless otherwise specified, all Holding Register Menu items are Read/Write
(R/W).
Table 2-4: BMS/BMS II Standard Holding Register Address Mapping
Address
4 (0x0004)
6 (0x0006) System Start Option
7 (0x0007)
9 (0x0009) Indoor Prop Band
Menu Item Units and Range
Net Header Set
Temp
Default/
Comments
40 to 220°F
40 to 220°F Default = 160°F
Remote Setpt and Remote
Default = 0
10 (0x000A)
11 (0x000B) Reset Ratio
14 (0x000E) Start Percent 25 to 100%
15 (0x000F) Stop Percent 10 to 45%
16 (0x0010) Integral Gain
17 (0x0011) Header Set Mode
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50 to 150°F
0 = Constant Setpt
1 = In/Outdoor Reset
Default = 0
(Constant Setpt))
Chapter 2
Decimal (Hex)
-2.00 to 2.00
19 0x0013)
Header Temp Bandwidth
5 to 120°F
Default = 70°F
20 (0x0014)
Aux Relay Open
0 to 99%
Default = 45%
0 or 1
1 = 100% Fire Rate and Off
0 or 1
Setpt
0, 1, 2, 3
3 = Interlock 2
0 or 1
1 = Manual
0, 1 or 2
2 = Combination
Default = 0 (BMS Only)
assign Combo Boilers)
27 (0x001B)
(Reserved)
28 (0x001C)
(Reserved)
29 (0x001D)
(Reserved)
Max Power Input
Default = 100%
(Fire Rate)
Interlock 1 Method
(BMS II)
0 or 1
1 = Start Enabled
MODBUS
CommunicationGF-114
Standard Register Assignments USER MANUAL
Table 2-4: BMS/BMS II Standard Holding Register Address Mapping (Cont.)
OMM-0035_0C
Modbus Data
Address
18 (0x0012) Derivative Gain
21 (0x0015) Aux Relay Mode
22 (0x0016)
23 (0x0017)
Menu Item Units and Range
Temp Sensor Fail
Mode/Failsafe Mode
Fault Alarm Relay Mode
(0.00 increments)
0 = 100% Fire Rate
0 = Shutdown
1 = Switch Inputs/Constant
0 = All Faults,
1 = No Interlock
2 = Interlock 1
Default/
Comments
Default = 0.15
(Value x 100)
Default = 1
(100% Fire Rate & Off)
Default = 0
(Shutdown)
Default = 0
(All Faults)
24 (0x0018) Fault Alarm Clear Method
25 (0x0019) Boiler Operation Mode
Number Of
26 (0x001A)
30 (0x001E)
31 (0x001F)
Combination Mode
Boilers
(BMS)/Sys Intlk Config
0 = Automatic
0 = Parallel
1 = Sequential
0 to 4
50 to 100%
0 = Always Enabled
Default = 0
(Automatic)
Default = 1
(Sequential)
(Start at Boiler 8 and
work back to Boiler 5 to
Default = 1
(Start Enabled)
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