AERCO Modulex E8 Controls Guide

GF-115-C

OMM-0084_0D

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

USER MANUAL

Other manuals for this product include:

Gas Fired Boiler Systems

Modulex E8 Controller

• MLX-303

E8 Controller for MLX Series Boilers

Boiler Communications Module (BCM)

for MLX Series Boilers

Installation, Operation, and Maintenance

Modulating, Condensing, Hot Water Boiler Models:

• MLX-454

• MLX-606

• MLX-757

• MLX-909

• MLX-1060

And BC Module (BCM)

.

• GF-115-H MLX Series Boiler Manual

• GF-115-G MLX Gas Design Guide

• GF-115-P-H MLX Piping Guide

• GF-115-V MLX Venting Guide

• GF-115-E MLX Electrical Power Guide

Revised: 11/30/2012

PR1: 11/30/12 Page 1 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Technical Support:

1-800-526-0288

www.aerco.com

(Mon–Fri, 8am-5pm EST)

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 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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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

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 information 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 notify the reader of potential hazards of varying risk levels.

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

Indicates a potentially hazardous situation, which if not avoided, 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.

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.

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Operations and Maintenance Manual

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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

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 Features 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. The 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 to 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 II and AERCO Control System (ACS) or

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

Window

(in closed

position)

Figure 2-1: Modulex E8 Controller Front Panel

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GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

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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 combustion 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 Closed)

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 describes 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 appropriate 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 heat generators (only applies when cascading).

Selectable display and Error Codes (refer to "DISPLAY SEL" parameter in the USER

I

menu).

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GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

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SYMBOL

MODE NAME

DESCRIPTION

Turn the Rotary Knob to select the heating mode

heating mode is indicated by a symbol at the bottom of the display. It takes effect when the setting 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

E8 Controller HEATING Modes

Heating Mode

Selection

Standby / OFF

Automatic Mode 1

Automatic Mode 2

Summer Mode

Day

Mode

Night Mode

required. The

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

(Heat according to timer program 1; HW according to HW program)

(Heat according to timer program 2; HW according to HW program)

(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)

Service Mode

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(Automatic reset after 15 minutes. Boiler regulated at max boiler temperature)

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

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

3.1.3 MENU Mode Operation (Door Open)

Opening the E8 controller hinged door reveals the E8 controls (Figure 3-3) and initiates the MENU Mode, which enables access to an extensive set of software menus.

INSTALLATION

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

E8 Controller Controls and Indicators

ITEM FUNCTION

A

B

C

E

F

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 (A).

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 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.

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GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

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AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

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

3.2 Software Menus

Software menus are divided into five main menus, each with a set of sub-menus (Table 3-1). 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 the DISPLAY menu group. All items in this group are “Read Only” and cannot be changed.

See Sub-section 4.7, E8 Controller Initial Startup for 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

INSTALLATION

GENERAL

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GF-115-C

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Operations and Maintenance Manual

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Points down to Points right to

Points left to

Points down to

Sub-MENU

MENU

Sub-MENU Name

Selected Buss(es)

Selected Bus(es)

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 silk-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 Selection

1. When the ON/OFF switch on the front of the boiler is turned ON and the swing-down hinged panel is opened, the controller will enter MENU Mode and INSTALLATION will be displayed (Figure 3-4) in the LCD. This is the initial INSTALLATION 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 counterclockwise and then 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 Procedure

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.

-

T-DHW

displayed

sub-menu

displayed

values

accessed

displayed

value

Displayed

Example: User Menu & Hot Water Sub-menu

parameters

accessed

Cycle thru

cycle thru

push!

Display Detail

Description

Examples

Displayed

Sub-menu

3.2.2 Basic Parameter Navigation, Selection, 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-

HOT

WATER

HOT-WATER

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

parameters

T-DHW

parameter

values

142.0

DHW

T

140.0

141.0

142.0

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 tabular 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.

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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 SOLAR M/F Sub-Menu as shown in Figure 4-1 and in Table 4-1.

Figure 4-1: DISPLAY Menu Flow Chart

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Modulex E8 Controller and BCM

Operations and Maintenance Manual

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Boiler Set Point temperature in Indoor/ Outdoor

T-COLLECTOR

sequence between Heat Modules.

Knob to sequence between Heat Modules.

Sub-Menu.

Based on heating prog and

USER/HOT WATER menu.

T-DHW L

Not Applicable

T-CIRCL

Not Applicable

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

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

MODGRAD

Boiler Set Point setting in 0 to 10 volt input mode

Reset and Constant Set Point modes.

Header Set Point temperature (cascade)

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

303) to 7 (MLX-1060). Turn Rotary Knob to

Press Prog Key to display Modulation % for individual Heat Modules (HS). Turn Rotary

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.

RETURN

Press Program Key to exit INSTALLATION

HOT WATER Sub-Menu

T-DHW RATED

T-DHW Actual hot water temperature

RETURN

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DHW set point temperature

Press Program Key to exit the HOT

operating mode. Actual DHW set point as set in

Only if tank sensor is installed

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Modulex E8 Controller and BCM

Operations and Maintenance Manual

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FUNCTION

DESCRIPTION

REMARKS

T-DHW

T-FLOW RATED

FLOW

N-OPT-TIME

Not Applicable

CIRCUIT 1 Sub-Menu.

T-MF3

Not Applicable

T-MF4

Not Applicable

1

T-DHW

Not Applicable

T-DHW L

Not Applicable

M/F Sub-Menu.

Table 4-1: DISPLAY Menu Listing (Continued)

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

Current hot water temperature

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-MF1

T-MF2

T-COLLECTOR

RETURN

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Not Applicable

Press Program Key to exit SOLAR

Currently not used

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Modulex E8 Controller and BCM

Operations and Maintenance Manual

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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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CONTRAST

00

Domestic Hot Water

connected).

Menu.

T-DHW 1

Hot Water set point

50°F - 158°F

140°F

T-DHW 2

Not Applicable

T-DHW 3

Not Applicable

DHW

Menu.

Table 4-2: USER Menu Listing

FUNCTION DESCRIPTION ENTRY RANGE DEFAULT

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.

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

12 languages are

available.

-20 to 20

ENGLISH

See

DESCRIPTION

Column

- - - -

RETURN

HOT WATER Sub-Menu

1X DHW Not Applicable

BOB-VALUE Not Applicable

CIRCL-P-

RETURN

PR1: 11/30/12 Page 22 of 112

Press Program Key to exit INSTALLATION Sub-

Not Applicable

Press Program Key exit HOT WATER Sub-

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Night

T-ROOM DES 1

Not Applicable

T-ROOM DES 2

Not Applicable

T-REDUCED

Not Applicable

T-ABSENCE

Not Applicable

-23.0°F–104.0°F

periods.

-23.0°F–104.0°F

1°F.

OPTIM HEAT

Not Applicable

ECONO OPTI

Not Applicable

PC-ENABLE

Not Applicable

CIRCUIT 1 (or 2) sub-menu.

display to the TIME PROGRAM Menu.

Table 4-2: USER Menu Listing (Continued)

FUNCTION DESCRIPTION ENTRY RANGE DEFAULT

HTG CIRCUIT 1 Sub-Menu

- - - -, Standby,

MODE Displays Timer Mode for Boiler

Auto 1, Auto 2, Day,

- - - -

T-ROOM DES 3

T-LIMIT DAY Applies during day-time heating periods

T-LIMIT N

HEATSLOPE

MAX OPT-TIME

RETURN

HTG CIRCUIT 2 Sub-Menu

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

Not Applicable

Applies during reduced night-time

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

Not Applicable

Press Program Key to exit HTG

- - - -,

0.00 – 3.00 1.20

66.0°F

50.0°F

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

Pressing the Program Key with SOLAR M/F displayed will change display to

RETURN

PR1: 11/30/12 Page 23 of 112

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RETURN. Press Program Key again to redisplay SOLAR M/F. Turning the Rotary Knob clockwise will advance thd

GF-115-C

Modulex E8 Controller and 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 Section 8 for additional information on these Menu and Sub-Menu functions.

Figure 4-3: TIME PROGRAM Menu Flow Chart

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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.

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.

PR1: 11/30/12 Page 25 of 112

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

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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

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

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Modulex E8 Controller and 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.

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.

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/start 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

MAX T-HS2

MIN T-HS2

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

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

Not Applicable

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 para. 3.5.1) 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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Operations and Maintenance Manual

OMM-0084_0D

(Continued)

HYSTERESIS

Not Applicable

–

MODULS

for service.

module.

NEW CONFIG

Not Applicable

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)

MODUL

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

INSTALLATION Sub-Menu

FOUND

CAP/MODULE

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 122.0°F to 230.0°F 194.0°F

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

Display

00 – 1000 Kw 40 Kw

Display °F

MODULAT MAX

MODULAT MIN

MOD LEVEL

PR1: 11/30/12 Page 28 of 112

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 12345678

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50% - 100% 30%

10% - 60% 35%

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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

SCREED

Not Applicable

N/A

SCREED PROGR

Not Applicable

N/A

RETURN

Press Program Key to exit INSTALLATION Sub-Menu.

HOT WATER Sub-Menu

DHW RELIEF

Not Applicable

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.

Table 4-3: EXPERT Menu Listing (Continued)

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

PR1: 11/30/12 Page 29 of 112

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

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00, 01, 02

32°F – 194°F 97°F

00 min. – 30

00, 01

01

00 min.

00

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Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

ENTRY

RANGE

mixing valve.

Circulation pump mode control for

03 = Continuous pump operation

MIXER CLOSE

Maximum allowable water temperature setting for the heating circuit.

Minimum allowable water temperature setting for the heat circuit.

Specifies the minimum allowable outside

INSTALLATION Mode)

DEL

OFFSET

B-HEAT SINK

Not Applicable

N/A

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

Table 4-3: EXPERT Menu Listing (Continued)

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 01 = Control to fixed flow temperature

HC FUNCTION

PUMP MODE

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

ON/OFF 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)

MIXER OPEN

MAX T-FLOW

MIN T-FLOW

T-FROST PROT

OUT-TEMP-

SLOPE

RETURN

Not Applicable

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

68°F – 230°F 176°F

50°F – 230°F 50°F

-5°F – 41°F 32°F

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ENTRY

RANGE

SOLAR M/F Sub-Menu

FUNCTION

SET TEMP

HYST (1-4)

02 = Light sensor

Sub-Menu.

Table 4-3: EXPERT Menu Listing (Continued)

FUNCTION DESCRIPTION

MF (1-4)

F15 FUNCTION

RETURN

Not Applicable

F15 Function 00 = Room Sensor for Heating Circuit 2 01 = 0 – 10V iInput

Press Program Key to exit SOLAR M/F

00 -02 00

DEFAULT

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

The following listing (Table 4-4) shows the available preset V-Curve settings for operation in the 0 to 10 Volt Mode:

Table 4-4: V-Curve Preset Voltage Curves for 0 – 10 Volt Input

CURVE NO. U1 U2 T1 T2 UO

0 2.0 V 10.0 V 32°F 194°F 2.0 V

1 2.5 V 0.3 V 100°F 176°F 5.0 V

2 2.5 V 0.3 V 100°F 167°F 5.0 V

3 2.5 V 0.3 V 100°F 113°F 5.0 V

4 4.0 V 0.1 V 68°F 185°F 5.0 V

5 4.0 V 0.1 V 68°F 167°F 5.0 V

6 4.0 V 0.1 V 68°F 131°F 5.0 V

7 4.0 V 0.1 V 68°F 189°F 5.0 V

8 4.0 V 0.1 V 68°F 189°F 5.0 V

9 4.0 V 0.1 V 68°F 163°F 5.0 V

10 4.0 V 0.1 V 68°F 127°F 5.0 V

11 4.0 V 0.1 V 68°F 194°F 5.0 V

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DATE/TIME

HOLIDAY

YEAR START MONTH START DAY START YEAR STOP MONTH STOP DAY STOP

TIME-DATE

TIME (MIN) TIME (HOUR) YEAR MONTH

DAY

RETURN

CLOCK CHANGE

MONTH START DAY START MONTH STOP DAY STOP

4.5 EXPERT HS Menu (Not Used)

(Not applicable to Modulex boilers)

4.6 GENERAL Menu

The GENERAL Menu contains a DATE/TIME Menu and a SERVICE Menu.

4.6.1 DATE / TIME Menu

This Sub-Menu is used to set the time, date, holiday (vacation) schedule and, where necessary, enter clock change settings (daylight savings time, etc). The DATE/TIME menu functions are illustrated and described in Figure 4-5 and Table 4-5.

PR1: 11/30/12 Page 32 of 112

Figure 4-5: DATE/TIME Menu Flow Chart

NOTE

All items in the following DATE/TIME Menu must be entered in sequence. Press the Program Key to step through the menu functions. Use the Rotary Knob to adjust/change entries. Press the Program Key to store entries and sequence to the next function

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TIME

Set current time (min., hours)

00:00 – 24:00

YEAR

Set current year

XXXX

MONTH

Set current month

01 – 12

DAY

Set currrent day

01 – 31

YEAR

Set current holiday start year

XXXX

START

DAY START

Set current holiday start day

01 – 31

YEAR STOP

Set current holiday end year

XXXX

STOP

DAY STOP

Set current holiday end day

01 – 31

START

DAY START

Set clock change start day

01 – 31

MONTH END

Set clock change end month

01 – 12

DAY END

Set clock change end day

01 – 31

Key.

Table 4-5: DATE / TIME Menu Listing

FUNCTION DESCRIPTION ENTRY RANGE

TIME – DATE Sub-Menu

This Sub-Menu is used to set the time, date, holiday schedule and, where necessary, enter clock change settings (daylight savings time, etc).

HOLIDAY Sub-Menu

This Sub-Menu sets the start and end dates for Holiday (Vacation) periods where no heat or hot water is required.

MONTH

CLOCK CHANGE Sub-Menu

This Sub-Menu is used in areas where seasonal time changes are required for “Daylight Savings“, etc.

MONTH

RETURN

Set current holiday start month 01 – 12

Set current holiday end month 01 – 12

Set clock change start month 01 -12

When CLOCK CHANGE reappears, press Program

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SERVICE

SENSOR TEST

F1 F2 F3 F5 F6 F8 F9 F11 F12 F13 F14

RELAY TEST

CODE NO 01 - 11

SW NO 259-04

BURNER TIME BURNER START LIMITER TEST SERVICE RESET USER RESET EXPERT RESET PRG RETURN

RETURN

CASCADE MANU

BOILER 01 – 00% BOILER 02 – 00% BOILER 03 – 00% BOILER 04 – 00% BOILER 05 – 00% BOILER 06 – 00% BOILER 07 – 00% BOILER 08 – 00% BOILER INT – 00% RETURN

4.6.2 SERVICE Menu

The SERVICE Menu contains all the test and diagnostic functions/values required for Customer Service Engineers to troubleshoot the equipment in a timely manner. The SERVICE Menu items are illustrated and described in Figure 4-6 and Table 4-6 respectively.

Some of the functions in this Sub-Menu require a valid Code No. (password) to be entered, prior to accessing/changing Function values. When prompted by a “CODE NO.” display, enter

0000 (four zeros) by pressing the Program Key four (4) times. This will allow function access.

Figure 4-6: SERVICE Menu Flow Chart

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RELAY TEST Sub-Menu

No relay

A1: Pump, Heating Circuit 1

A3: Hot Water Charging Pump

A4: Mixer OPEN, Heating Circuit 2

A7: HS2 ON [2-stage:HS 1+2 (after 10s) ON]

Multifunction 1

Multifunction 2

A10: Multifunction 3

A11: Collector Pump / Multifunction 4

SENSOR

temperature heating circuit 1

Flow temperature, heating circuit 2

Heat generator /header temperature

Outside temperature

Table 4-6: SERVICE Menu Listing

FUNCTION DESCRIPTION REMARKS

This Sub-Menu is used to check the status of the relays contained in the Controlller. These relays are numbered 00 through 11 and are defined as shown below. CODE NO. Entry is required to access these relays.

RELAY NO.

00

01

02

03

04

05

06

07

08

09

10

11

SENSOR TEST Sub-Menu

This Sub-Menu is used to check and display the temperature readings of the sensors connected to the Controller.

F1

A2: Pump, Heating Circuit 2

A5: Mixer CLOSED, Heating Circuit 2

A6: HS 1 ON

A8: Mixer OPEN Heating Circuit 1 /

A9: Mixer CLOSED Heating Circuit 1 /

Buffer storage temperature Lower

F2

F3

F5

F6

F8

F9

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Buffer storage temperature middle or room

Upper buffer storage temperature

Upper hot water temperature

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FUNCTION

DESCRIPTION

REMARKS

SENSOR TEST Sub-Menu

multifunction 1

multifunction 2

temperature multifunction 3

multifunction 4

input

currently installed in the Controller

menu functions.

8)

(1-8)

Start with Program Key (hold down)!

DO NOT USE

00

DO NOT USE

RETURN

Exit level using Program Key

Table 4-6: SERVICE Menu Listing (Continued)

F11

F12

F13

F14

F15; Light; 0-10V I

OTHER ENTRIES

Additional items and functions in the SERVICE Sub-Menu include the following:

SW NO XXX-XX

CASCADE MANU (1-8)

BURNER TIME (1-

Flow temperature heating circuit 1 or temperature

Hot water temperature lower or temperature

Solid fuel boiler temperature or collector 2 or

Collector 1 temperature or temperature

Room temperature heating circuit 2 or measured value of the light sensor or voltage value 0-10V

Specifies the Software Version and Index number

Starting different burner stages of the cascade See GF-115-H, Section 7, Sub-section 7.5 for

additional startup instructions using these sub-

Program Key – Burner time for all stages

BURNER START

LIMITER TEST (1-8)

SERVICE

Program Key – Burner start for all stages

Safety temperature limiter test with heat generator temperature display

Input of date or operating hours for service messages

WARNING: NEVER ATTEMPT TO USE THE FOLLOWING RESET FUNCTIONS.

RESET USER 00

RESET EXPERT

RESET T-PRG 00

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4.7 E8 Controller Initial Startup

Initial startup of the Modulex Controller requires a number of one-time entries to be made in the initial INSTALLATION Menu that appears in the display when the E8 controller door is first opened. Table 4-7 on the next page lists the description, entry range, and default entry for all parameter. Instructions for entry into this menu is shown below.

NOTE

All items in the INSTALLATION Menu must be entered in sequence. Press the Program Key to step through the menu

functions. Use Rotary Knob to adjust/change entries. Press the Program Key to store entries and sequence to the next menu item.

Initial Startup INSTALLATION Entry

1. Set the POWER rocker switch, located to the right of the Controller, to the ON (1) position.

2. Open the panel cover on the Controller. The LCD display will read INSTALLATION. All values in this level must be entered, in sequence, without interruption. The initial entries required include: LANGUAGE, TIME and DATE as shown in the INSTALLATION Table at right.

3. The first function that appears is LANGUAGE. By default, the display should show ENGLISH. If ENGLISH is not displayed, turn the Rotary Knob until ENGLISH appears.

4. Press the Program Key to store setting.

5. Next, TIME will be displayed. Enter the current time (minutes, hours) using the Rotary Knob. Press the Program Key to store each value.

6. The next items displayed are the YEAR, MONTH and DAY. Enter each item using the Rotary Knob and press the Program Key as previously described to store the entry.

7. Following entry of all LANGUAGE, TIME and DATE entries, continue entering the remaining items shown in Figure 4-7 and Table 4-7 until all required items have been entered. Use the Program Key and Rotary Knob to select, adjust and store all entries as previously described.

8. Continue step 7 until RETURN appears in the display, indicating that you are at the end of the INSTALLATION menu.

9. Press the Program Key to exit the INSTALLATION menu.

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PARAMETERS

DESCRIPTION

DEFAULT

LANGUAGE

Set Language

ENGLISH

TIME

Set current time (min., hrs)

00:00 – 24:00

YEAR

Set current year

XXXX (4 digits)

MONTH

Set current month

00-12

DAY

Set current day of month

00-31

CONF DEVICE

Confirm Device

- - - -, 01 – 06

- - - -

HEATSOURCE 1

Heat Source 1

00 – 06

06

HS1 BUS

Heat Source 1 Bus

00 – 04

02

HEATSOURCE 2

Heat Source 2

00 – 05

00

STORAGE HS2

Storage Heat Source 2

00 – 03

00

BUFFER

Buffer

00, 01, 02

00

HC FUNCTION 1

Heating Circuit Function 1

00, 01, 03

00

HC FUNCTION 2

Heating Circuit Function 2

00 – 04

00

CAP/MODULE

See Paragraph 4.8.1 for instructions.

00 – 1000 Kw

40 Kw

4.8.2)

Setpoint

MF1 HYST

Multifunction Relay 1 Hysteresis

4°F – 18°F

9°F

4.8.2)

Setpoint

MF2 HYST

Multifunction Relay 2 Hysteresis

4°Ra – 18°Ra

9°F

RELAY FUNC 3

Relay Function 3

00 – 26

01

Setpoint

MF3 HYST

Multifunction Relay 3 Hysteresis

4°F – 18°F

9°F

RELAY FUNC 4

Relay Function 4

00 – 26

02

Setpoint

MF4 HYST

Multifunction Relay 4 Hysteresis

4°F – 18°F

9°F

BUS ID 1

Bus Identification No. 1

00 – 15

01

BUS ID 2

Bus Identification 2

00 – 15

02

5K SENSOR

5,000 Ohm Sensor

00=5K, 01=1K

00 = 5 K

Table 4-7: INSTALLATION Menu Listing

INSTALLATION Sub-Menu

ENTRY RANGE

RELAY FUNC 1

T-MF1 SETP Temperature – Multifunction Relay 1

RELAY FUNC 2

T-MF2 SETP Temperature – Multifunction Relay 2

T-MF3 SETP Temperature – Multifunction Relay 3

T-MF4 SETP Temperature – Multifunction Relay 4

Relay Function 1 (See Paragraph

Relay Function 2 (See Paragraph

00 – 26 00

86°F – 194°F 86°F

00 – 26 00

86°F – 194°F 86°F

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4.7.1 CAP/MODULE Function (Maximum Kilowatts per Burner)

When the Program Key is pressed with CAP/MODULE displayed, the display may show “SCAN”, indicating that the Controller is searching for related MODULE (BOILER) functions. Once the scan is complete, follow instructions below.

CAP/MODULE Function (Setting Max. Kw per Burner)

1. Press the Program Key. The display will show CODE NO., requesting the valid code to be entered.

2. Enter code 0000 (four zeros) by pressing the Program Key four times. The red LED will remain lit while the four code digits are entered.

3. Press the Program Key

4. The display will show BOILER 1 (meaning Heat Module 1), along with kilowatt (Kw) setting for the first Module. The default setting for each Boiler Module is 40 Kw.

NOTE

The 40 Kw setting is only a control parameter. It does not represent the maximum input of each module.

5. If the desired Kw setting is not displayed, press the Program Key and change the setting using the Rotary Knob. Once the desired setting is displayed, press the Program Key to store the value.

6. Continue scrolling through each BOILER (Heat Module) and observe the Kw setting for each one. Change as needed by repeating step 5.

7. Once all BOILER modules have been set, RETURN will be displayed.

8. Press the Program Key to continue with the next menu function (RELAY FUNC 1) in the INSTALLATION Menu Table.

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FUNCTION

DESCRIPTION

01

Header Pump

03

Booster Pump

06

Pump HS2

21

Pulsed Circulation Pump

23

Solar Integration

25

Return Flow Temperature Increase HS2

4.7.1 Available Settings for Relay Functions 1 – 4

Table 4-8 lists the available Function selections for Multi-Function (MF) Relays 1 thru 4:

Table 4-8: Relay 1-4 Functions

00 No MF Relay Function

02 Circulation (Time)

05 Pump HS1

20 Temperature-Controlled Circulation Pump

22 Solid Fuel Boiler Integration (Not Applicable)

24 Return Flow Temperature Increase HS1

26 Return Flow Temperature Increase Via Buffer Storage

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5. E8 OPERATING MODE: Set-up and Programming

The following paragraphs provide the detailed set-up and programming procedures necessary to configure the Modulex Boiler for service operation.

NOTE

When performing the following operating mode set-up procedures, refer to Section 3 of this document for illustrations and descriptions of the Controller operating controls and displays. Refer to Section 6 for Controller wiring connections.

5.1 Indoor/Outdoor Reset Mode

This mode is used to adjust the boiler set point based on the outdoor air temperature and a programmed heating curve. The heating curve can be customized using functions provided in the USER menu. The outdoor air sensor provided with the Modulex boiler must be installed to enable this mode of operation. The following paragraphs provide the procedures necessary to wire and configure the controller for operation in the Indoor/Outdoor Reset mode.

5.1.1 Wiring Connections

The outdoor air sensor provided with the boiler should be mounted on the outer North or North-East side of the building away from windows, doors and vents. Never mount the outdoor air sensor in a location where it is exposed to direct sunlight.

Wire the sensor using shielded 2-conductor, 18 AWG wire (Belden #8760, or equiv.). Connect the outdoor air sensor wire leads to terminals 9 (F9) and 10 (GND) of Connector 1 on the rear of the Controller. There is no polarity to observe when connecting the wire leads. Refer to the wiring diagrams in Section 6 for the locations of sensor connections. This sensor must be connected prior to configuring the Controller (Paragraph 5.1.2).\

5.1.2 Indoor/Outdoor Reset Operation Configuration

The Indoor/Outdoor Reset Mode is configured using the USER menu as shown in instructions on the next page.

IMPORTANT

The outdoor air sensor MUST be connected as described in paragraph 5.1.1 above, prior to configuring the Controller for Indoor/Outdoor Reset Mode operation.

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60

70

80

90

100

110

120

130

140

150

160

170

180

190

200

210

220

0510152025303540455055606570

Outside Temperature ( F )

Flow Temperature ( F )

Indoor/Outdoor Reset Configuration in USER Menu

1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position.

2. Open controller front panel.

3. Turn the Rotary Knob clockwise to the USER menu. The first sub-menu displayed will be

INSTALLATION.

4. Continue scrolling clockwise through the USER menu until the HTG CIRCUIT 1 sub-menu

is displayed.

5. With HTG CIRCUIT 1 displayed, press Program Key to enter sub-menu.

6. Use Rotary Knob to scroll to the HEATSLOPE sub-menu item. The display will show

“HEATSLOPE” and the current value stored in memory (0.00 to 3.00).

7. To change the HEATSLOPE value, press the Program Key. The red LED will light.

8. Refer to Heat Slope Diagram (Figure 5-1) to determine the required value for the

HEATSLOPE function based on the boiler installation design set point. The value entered must be between 0 and 3.00.

9. Turn Rotary Knob until the desired HEATSLOPE value is displayed.

10. Press the Program Key to store the HEATSLOPE value.

11. Continue scrolling through the HTG CIRCUIT 1 sub-menu until RETURN is displayed.

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Press the Program Key to exit the HTG CIRCUIT 1 sub-menu.

Figure 5-1: Heat Slope Diagram

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5.1.3 Viewing the Boiler Setpoint

The setpoint temperature setting is viewed in the E8 controller display as shown below.

Viewing the Boiler Setpoint

1. Turn the Rotary Knob to the DISPLAY menu. The first sub-menu displayed will be

INSTALLATION.

2. Press the Program Key to enter the INSTALLATION sub-menu.

3. Turn Rotary Knob clockwise until T-COLL DES is displayed along with corresponding

temperature reading. This T-COLL DES reading equals the boiler set point.

5.2 Constant Set Point Mode

When a fixed header temperature is desired, configure the the Constant Set Point Mode as shown in the instructions below.

Constant Setpoint Mode Configuration

1. Set the ON/OFF switch on the front of the Modulex boiler to the ON position.

2. Open the Controller front panel.

3. Turn the Rotary Knob clockwise to the EXPERT menu. The first item (sub-menu) displayed

will be INSTALLATION.

4. Continue turning the Rotary Knob clockwise until HEAT CIRCUIT 1 is displayed.

5. Press the Program Key to enter the HEAT CIRCUIT 1 sub-menu.

6. Scroll to HC FUNCTION. The currently stored setting (00 or 01) will be displayed. Normally,

00 will be displayed since this is the Factory Default. However, for the Constant Set Point Mode, the HC FUNCTION setting must be changed to 01. If the HC FUNCTION is currently set to 00, proceed to step 7. However, if it is set to 01, skip to step 11.

7. If the HC FUNCTION is set to 00, press the Program Key. CODE NO. will be displayed

requesting the valid code to be entered.

8. Enter code 0000 (four zeros) by pressing the Program Key four times. The red LED will

remain lit while the digits are entered.

9. With HC FUNCTION again displayed, press the Program Key. The red LED will light. Turn

the Rotary Knob to change the HC FUNCTION to 01.

10. Press the Program Key to store the 01 setting for the HC FUNCTION. Red LED will go off.

RESET will be momentarily displayed, followed by display of the current Controller software version (e.g. SW 259-04). Following RESET, the Controller display will then switch to the initial INSTALLATION menu.

11. Use Rotary Knob to scroll to the USER menu and access HTG CIRCUIT 1 sub-menu. Press

Program Key to enter the sub-menu.

12. Using Rotary Knob, scroll to T – FLOW DAY. The currently stored value for T – FLOW DAY

will be displayed. This represents the current Constant Set Point temperature in °F.

13. To change Constant Set Point value, press the Program Key and turn the Rotary Knob to

select the desired Constant Set Point. Press the Program Key again to store the Set Point.

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MAX T-FLOW

MIN T-FLOW

The minimum allowable outlet water temperature

5.2.1 Wiring Connections

There are NO wiring connections required for this mode.

5.2.2 Constant Setpoint Mode Configuration

The Constant Setpoint Mode is enabled using functions contained in the EXPERT menu and USER menu as shown on previous page.

5.2.3 Viewing Constant Set Point

The set point is viewed in the DISPLAY menu as shown below.

Viewing the Constant Setpoint

1. Use Rotary Knob to navigate to the DISPLAY menu. First sub-menu displayed will be

INSTALLATION.

2. Press the Program Key to enter the INSTALLATION sub-menu.

Turn Rotary Knob clockwise until T-COLL DES is displayed along with corresponding temperature reading. This T-COLL DES reading equals the boiler set point in °F.

5.2.4 Configuring Set Point High and Low Limits Per Outside Temperature

Sensor

It is often desirable to control the maximum and minimum outlet water temperature based on outside air temperature. For instance it might be desirable to set the outlet water temperature to be 180º F whenever the outside temperature is 15º F or below, and 120º F whenever the outside temperature is 60º F or higher. Four parameters must be set in the E8 Controller to accomplish this. They are: HEATSLOPE, MAX T-FLOW, MIN T-FLOW, and MAX T-COLL. Descriptions are provided in Table 5-1.

Table 5-1: E8 Controller Outside Temperature Sensor Parameters

Parameter Description

HEATSLOPE

MAX T-COLL

To select the best HEATSLOPE value to enter into the E8 Controller, consider the set of heat slope curves shown in Figure 5-1. Locate the two points given by the coordinate pairs (Outside Temperature, Flow Temperature); One for the low temperature range and one for the high temperature range. Now find the curve that best fits these two points. Do not expect any single curve to go through either point, let alone both points. Simply pick the best fit.

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A curve that relates a boiler’s outflow temperature with the outside air temperature monitored with a temperature sensor

The maximum allowable outlet water temperature

The maximum allowable outflow water collection manifold surface temperature

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5.2.4.1 Configuring HEATSLOPE Parameter

The HEATSLOPE value is configured as shown in the instructions below.

Configuring HEATSLOPE Parameter

1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position.

2. Open controller front panel.

3. Turn the Rotary Knob clockwise to the USER menu.

4. Press Program Key to select the User submenu. The first item (sub-menu) displayed will

be INSTALLATION.

5. Continue scrolling clockwise through the USER menu until the HTG CIRCUIT 1 sub-menu

is displayed.

6. With HTG CIRCUIT 1 displayed, press the Program Key to enter this sub-menu.

7. Using the Rotary Knob, scroll to the HEATSLOPE variable. The display will show

“HEATSLOPE” and the current value stored in memory (0.00 to 3.00).

8. If the desired value for HEATSLOPE is not displayed, press the Program Key once. The

red LED will light.

9. Determine the required value for the HEATSLOPE function as explained above. The

value to be entered must be between 0 and 3.00 inclusively.

10. Turn the Rotary Knob until the desired HEATSLOPE value is displayed.

11. Press the Program Key to store the HEATSLOPE value. The value will flash indicating it was entered.

Continue scrolling through the HTG CIRCUIT 1 sub-menu until RETURN is displayed. Press the Program Key to exit the HTG CIRCUIT 1 sub-menu.

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5.2.4.2 Configuring MAX T-FLOW and MIN T-FLOW Parameters

To enter the MAX T-FLOW and MIN T-FLOW values, see instructions below.

Configuring MAX T-FLOW and MIN T-FLOW Parameters

1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position.

2. Open controller front panel.

3. Turn the Rotary Knob clockwise to the EXPERT menu. The first item (sub-menu) displayed will be INSTALLATION.

4. Continue scrolling clockwise through the EXPERT menu until the HTG CIRCUIT 1 submenu is displayed.

5. With HTG CIRCUIT 1 displayed, press the Program key to enter the sub-menu.

6. Use Rotary Knob to scroll to MAX T-FLOW sub-menu. The display will show “MAX T- FLOW” and the current value stored in memory (68 to 230).

7. To change MAX T-FLOW value, press the Program Key 6 times to sequence through the 4 digits and back to the current value for MAX T-FLOW.

8. Press the Program Key one more time. The red LED will light.

9. Rotate the Rotary Knob until the desired value for MAX T-FLOW is displayed.

10. Press the Program Key once. The new value for MAX T-FLOW will flash indicating it was entered.

11. Turn the Rotary Knob to the next parameter displayed, MIN T-FLOW.

12. Press the Program Key once. The red LED will light.

13. Now turn Rotary Knob until desired MIN T-FLOW (50 – 230) value is displayed.

14. Press the Program Key once. The new value for MIN T-FLOW will flash indicating it was entered.

Continue scrolling through the HTG CIRCUIT 1 sub-menu until RETURN is displayed. Press the Program Key to exit the HTG CIRCUIT 1 sub-menu.

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5.2.4.3 Configuring MAX T-COL Parameter

To enter the MAX T-COL value, see instructions below.

Configuring MAX T-COLL Parameter

1. Set the ON/OFF switch on the front of the Modulex boiler to the ON position.

2. Open the swing-down hinged panel of the Controller.

3. Turn the Rotary Knob clockwise to the EXPERT menu. The first item (sub-menu) displayed will be INSTALLATION.

4. The first sub-menu to be displayed will be INSTALLATION.

5. Press the Program key once to enter this sub-menu.

6. Using the Rotary Knob, scroll to MAX T-COLL. The display will show “MAX T-COLL” and the current value stored in memory (86 to 230).

7. If the desired value for MAX T-FLOW is not displayed, press the Program Key 6 times to go through the digit sequence.

8. Now press the Program key one more time. The red LED will light.

9. Rotate the Rotary Knob until the desired value for MAX T-COLL is displayed.

10. Press the Program Key once. The new value for MAX T-COLL will flash indicating it was entered.

11. Continue scrolling through the INSTALLATION sub-menu until RETURN is displayed. Press the Program Key to exit the INSTALLATION sub-menu.

5.3 0 to 10 Volt Remote Set Point Mode

This mode allows the boiler set point to be controlled by an external control signal. The following paragraphs provide the procedures necessary to wire, configure and set the required functions necessary to operate in the 0 to 10 volt remote set point mode.

5.3.1 Remote Signal Source Wiring Connections

When setting up to operate in the 0 to 10 volt remote set-point mode, the remote signal source must be wired to terminals 1 (F-15) and 2 (GND) of connector number 3 (III) on the rear of the Controller. See Section 6 for illustrations and pin-outs of the connectors located on the rear of the Controller.

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5.3.2 Configuring Remote Signal Source

Configure the Remote Signal Source as shown in the instructions below.

Configuring Remote Signal Source

1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position.

2. Open Controller front panel.

3. Turn Rotary Knob clockwise to EXPERT menu. The first sub-menu displayed will be

INSTALLATION (sub-menu items scroll in this sequence: INSTALLATION, HOT WATER, HEAT CIRCUIT 1, HEAT CIRCUIT 2, SOLAR / MF). Continue scrolling

(clockwise) through the EXPERT menu until SOLAR / MF is displayed.

4. With SOLAR / MF displayed, press the Program Key to enter the SOLAR / MF sub-menu.

5. Scroll through the SOLAR / MF sub-menu by turning Rotary Knob clockwise until the F-15

FUNCTION is displayed along with it’s presently stored value (default is 00).

6. Press Program Key to change the F-15 FUNCTION. Display will show CODE NO.,

requesting valid code to be entered.

7. Enter code 0000 (four zeros) by pressing the Program Key four times. The red LED will

remain lit while the four code digits are entered.

8. With F-15 FUNCTION displayed again and red LED lit, turn Rotary Knob to change the F-

15 FUNCTION to 01.

9. Press the Program Key to store the 01 setting for the F-15 FUNCTION. The red LED will

go off.

10. Continue scrolling through the sub-menu until RETURN is displayed.

11. Press the Program Key to exit the SOLAR / MF sub-menu.

12. With SOLAR / MF displayed, turn Rotary Knob counter-clockwise until the

INSTALLATION sub-menu is displayed in the LCD.

13. With INSTALLATION displayed in the LCD, proceed directly to paragraph 5.3.3.

NOTE

When navigating the menus during configuration and you scroll past the SOLAR / MF item, the EXPERT HS menu will be displayed. If this occurs, slowly turn the Rotary Knob counterclockwise until SOLAR / MF is again displayed.

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

NOTE

Ensure that steps 1 through 13 in Paragraph 5.3.2 were completed prior to performing the following steps.

NOTE

When scrolling through sub-menus and functions, enter required Code 0000 only when prompted to do so. Normally, Code 0000 only needs to be entered once, unless you exit and re-enter EXPERT menu.

U1 and U2 settings: To set the voltage limits corresponding to the minimum and maximum allowable set point limits, follow the instructions below.

Voltage & Set Point Limits: U1 & U2

1. Press the Program Key to enter the EXPERT menu – INSTALLATION sub-menu. The display will show CODE NO. requesting the valid code to be entered.

2. Enter code 0000 (4 zeros) by pressing the Program Key four times. The red LED will remain lit while the four code digits are entered. A dashed line will appear in the display following code entry.

3. Next, turn the Rotary Knob clockwise until CURVE 11-U1 is displayed.

4. Press the Program Key. The red LED will light.

5. Enter the desired low voltage limit for U1 by turning the Rotary Knob. The voltage will increment in 0.10 volt increments.

6. With the desired low voltage limit displayed, press the Program Key to set the U1 voltage. The red LED will go off.

7. Turn the Rotary Knob clockwise and scroll to CURVE 11-U2.

8. Press the Program Key. The red LED will light.

9. Enter the desired high voltage limit for U2 by turning the Rotary Knob.

10. With the desired high voltage limit displayed, press the Program Key to set the U2 voltage. The red LED will go off.

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T1 and T2 Settings: The previous steps set the U1 and U2 voltages which will be used to scale the minimum and maximum set point levels. To set the minimum (T1) and maximum (T2) set point temperatures which correspond to the U1 and U2 voltage levels, follow instructions below.

Voltage & Set Point Limits: T1 & T2

1. Turn the Rotary Knob clockwise and scroll to CURVE 11-T1. This will be the minimum set point temperature.

2. Press the Program Key. The red LED will light.

3. Enter the desired low set point temperature limit for T1 by turning the Rotary Knob. The selected T1 value will correspond to U1.

4. With the desired low set point temperature limit displayed, press the Program Key to set the T1 temperature (low set point limit). The red LED will go off.

5. Finally, turn the Rotary Knob clockwise and scroll to CURVE 11-T2. This will be the maximum set point temperature.

6. Press the Program Key. The red LED will light.

7. Enter the desired high set point temperature limit for T2 by turning the Rotary Knob. The selected T2 value will correspond to U2.

8. With the desired high set point temperature limit displayed, press the Program Key to set the T2 temperature (high set point limit). The red LED will go off.

This completes the required steps for setting the low and high limits corresponding to the set point voltage and temperature functions. Proceed immediately to paragraph 5.3.4 to set the

CURVE 11-UO voltage.

5.3.4 Setting the Curve 11-UO Voltage

UO is a voltage level that will turn off the boiler. Therefore, the UO voltage level must be set below the limit set for the U1 voltage. For example; if U1 is set for 1 Volt, UO should be set to

0.9 Volt (or lower). After setting the low and high set point limits as described in paragraph

5.3.3, set the UO voltage per instructions below.

Setting Curve 11-UO Voltage

1. Turn the Rotary Knob clockwise and scroll to CURVE 11-UO.

2. Press the Program Key. The red LED will light.

3. Using the Rotary Knob, adjust the UO voltage to below the voltage set for U1.

4. With UO set to the desired value, press the Program Key to store the setting. The red LED will go off.

5. This completes all of the required entries for operation in the 0 to 10 Volt Remote Set Point Mode.

6. To exit the EXPERT menu – INSTALLATION sub-menu, continue scrolling using the Rotary Knob until RETURN is displayed.

7. Press the Program Key to return to exit the INSTALLATION sub-menu.

To view the remote set point temperature, proceed to paragraph 5.3.5.

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5.3.5 Viewing the Set Point

The set point is displayed as shown in instructions below.

NOTE

When viewing the set point temperature using the steps in paragraph 5.3.5, you will note that the when the voltage source is equal to 0.9 Volt, the set point temperature will drop to 41°F (9°C), thereby shutting down the boiler.

Example:

U1 = 1 Volt and the set point = 80°F U2 = 8 Volts and the set point = 180°F UO should be set to 0.9 Volt

Viewing the Setpoint

1. Turn the Rotary Knob to the DISPLAY menu – INSTALLATION sub-menu.

2. Press the Program Key to enter the INSTALLATION sub-menu.

3. Using the Rotary Knob, scroll to T-EXT DES to view the set point temperature.

5.4 Domestic Hot Water Operation Using A Tank Sensor

With the controller hinged panel closed, turn the Rotary Knob until the Faucet symbol ( ) appears in the lower part of the display window. When there is a demand for domestic hot water (DHW), a second Faucet symbol will be displayed. This second Faucet symbol indicates that the boiler is currently in the DHW mode and is raising the temperature of the domestic water to the DHW set point. Once the DHW demand has been satisfied, the boiler will switch back to the space heating mode. The second Faucet symbol will change to a heating circuit symbol, indicating that the boiler is back in the space heating mode.

The following procedures describe the wiring connection and Controller configuration setting needed to provide domestic hot water (DHW) using a tank sensor installed in a thermowell.

5.4.1 Sensor Wiring Connections

To monitor the DHW temperature, connect the tank sensor wire leads to Connector 1, Terminals 6 (F6) and 7 (GND) on the rear of the Controller. After the sensor is connected, turn the ON/OFF switch to the OFF position, then back to the ON position. This is necessary to ensure that the Controller recognizes the added sensor.

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5.4.2 Configuring the Controller for DHW With a Tank Sensor

Both EXPERT and USER Menus will be used to configure the Controller for DHW production. The DISPLAY Menu will be used to display the set point. Follow instructions below to configure the controller for DHW with a tank sensor.

IMPORTANT

The tank sensor MUST be connected (Section 5.4.1), prior to configuring Controller for DHW operation. If sensor is not connected, many required functions will not display.

Configure the Controller for DHW with a Tank Sensor

1. With Controller front cover closed, turn Rotary Knob until Faucet symbol ( ) appears in the lower part of the of the display window.

2. Next, open Controller front panel.

3. Turn Rotary Knob clockwise to EXPERT, HOT WATER sub-menu.

4. With HOT WATER displayed, press the Program Key to enter sub-menu.

5. Scroll through HOT WATER sub-menu turning Rotary Knob clockwise until THERM INPUT is displayed with the current setting (00 or 01). If 00 is displayed (sensor), skip to step 6.

6. If the THERM INPUT is currently set to 01 (Aquastat), press Program Key to change the THERM INPUT. The display will show “CODE NO.”, requesting entry of a valid code.

7. Enter code 0000 (four zeros) by pressing the Program Key four times. The red LED will remain lit while the four code digits are entered.

8. With THERM INPUT again displayed and the red LED lit, turn Rotary Knob to change to 00 for sensor operation.

9. Press Program Key to store 00 setting for THERM INPUT. Red LED is off.

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5.4.3 Setting the DHW Set Point

The set point temperature is set in the USER menu as shown in instructions below.

NOTE

Typically, a higher water temp is needed to heat domestic hot water to its setpoint. Do this by using EXPERT / HOT WATER / T BOILER DHW. Degrees entered are added to DHW Setpoint in USER MENU. See paragraph 5.2.3.

Setting the DHW Set Point

1. Use Rotary Knob to scroll to USER menu and INSTALLATION sub-menu.

2. Continue scrolling clockwise until the HOT WATER sub-menu is displayed.

3. Press the Program Key to enter the HOT WATER sub-menu.

4. Scroll to T-DHW 1, displayed along with the current DHW set point temperature.

5. To change DHW set point, press the Program Key. Red LED will light.

6. Using the Rotary Knob, enter the desired set point temperature.

7. With desired DHW set point displayed, press Program Key to save. The red LED will go off.

8. Continue scrolling until RETURN is displayed. Press Program Key to exit.

9. Scroll clockwise to the EXPERT menu, HOT WATER sub-menu.

10. Press Program Key and scroll to the T BOILER DHW in HOT WATER sub-menu. Current

value is displayed in °F.

11. To change temp, press Program Key to enter value that will be added to the DHW set point.

Red LED lights.

12. Adjust the T BOILER DHW temperature to desired value using the Rotary Knob.

13. Press Program Key to store the temp setting. The red LED will go off.

14. Continue scrolling through the HOT WATER sub-menu until RETURN is displayed. Press

the Program Key to exit the sub-menu.

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5.4.4 Displaying Temperatures Associated With DHW

Functions in the DISPLAY menu are used to display the actual DHW temperature measured by the tank sensor. The swing-down hinged panel must be open to access and display these functions.

5.4.4.1 Viewing DHW Set Point and Actual DHW Temperature

The DHW set point and the actual DHW temperature measured by the tank sensor are displayed as shown in the instructions below.

Viewing DHW Setpoint and Actual DHW Temperature

1. Turn the Rotary Knob to the DISPLAY menu. The first sub-menu displayed will be INSTALLATION.

2. Continue turning the Rotary Knob clockwise until the HOT WATER sub-menu is displayed.

3. Press the Program Key to enter the HOT WATER sub-menu.

4. Turn Rotary Knob to display T-DHW RATED. The temperature value shown is the DHW set point temperature.

5. Next, scroll to T-DHW. The temperature value shown is the actual DHW temperature measured by the tank sensor.

6. Continue scrolling until RETURN is displayed. Press the Program Key to exit the HOT WATER sub-menu.

5.4.4.2 Viewing DHW Set Point With T-BOILER DHW Function

The setting for T-BOILER DHW, in the EXPERT/HOT WATER Menu, adds to the Domestic Hot Water setpoint (T-DHW RATED), becoming the final supply water temperature to the domestic hot water tank. The T-COLL DES reading equals the DHW setpoint plus the value of the TBOILER DHW function or T-DHW RATED + T-BOILER DHW = T-COLL DES.

EXAMPLE: If T-DHW RATED is set at 140° and T-BOILER DHW is set at 45°, then the T-COLL DES (Boiler Outlet Temperature) will be 185°.

To view DHW set point with the T-BOILER DHW setting already added to it, refer to the instruction below.

Viewing DHW Setpoint with T-BOILER DHW Function

1. Turn the Rotary Knob to the DISPLAY menu. The first sub-menu displayed will be

INSTALLATION.

2. Press the Program Key to enter the INSTALLATION sub-menu.

3. Turn the Rotary Knob clockwise until T-COLL DES is displayed along with corresponding temperature reading.

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5.5 DHW Operation Using an Aquastat

Operation, wiring connections and Controller configuration settings for DHW heating using an aquastat are virtually identical to the procedures previously described in paragraph 5.4 for the tank sensor. Therefore, the following paragraphs describe only the differences between these two types of applications.

5.5.1 Sensor Wiring Connections

To monitor the DHW temperature, connect the aquastat wire leads to Connector KF/SPF, Terminals 6 (F6) and 7 (GND). After the sensor is connected, turn the ON/OFF switch to the OFF position, then back to the ON position. This is necessary to ensure that the Controller recognizes the added sensor.

IMPORTANT

The aquastat MUST be connected as described above, prior to configuring the Controller for DHW operation. Also, the aquastat must be closed (shorted) for the Controller to display the required sub-menu functions.

5.5.2 Configuring the Controller for DHW With an Aquastat

The procedures for configuring the Controller for DHW with an Aquastat are virtually identical to those specified in paragraph 5.4.2. The only difference is that the THERM INPUT in the EXPERT menu/HOT WATER sub-menu must be set to 01 (Aquastat) instead of 00 (Sensor).

5.5.3 Setting the DHW Set Point

Same as paragraph 5.4.3.

5.5.4 Displaying Temperatures Associated With DHW

Same as paragraphs 5.4.4 through 5.4.4.2.

5.6 Boiler & Pump Enable/Disable

The Enable/Disable feature found between terminals 3 and 4 of connector “I” can be used to start/stop the boiler only in Indoor/Outdoor Reset and Constant Set Point modes of operation. The Enable/Disable does not start/stop the boiler in 0 to 10 Volt Remote Set Point mode. To start/stop the boiler in 0 to 10 Volt Remote Set Point mode, see paragraph 5.3.4.

To use the Enable/Disable feature, wire a dry set of contacts between terminals 3 and 4 of Connector “I” and then set the boiler to Standby mode ( ). To set the boiler to Standby mode, close the swing-down front panel door of the E8 and turn the wheel counterclockwise until the Standby symbol ( ) is displayed. With terminals 3 and 4 closed, the Standby symbol, and others in the display, will be blinking. This indicates that the boiler is enabled. When the connection is broken between terminals 3 and 4, the Standby symbol, and others in the display, will stop blinking indicating that the boiler is disabled.

The Enable/Disable feature not only start/stops the boiler but also start/stops the pumps.

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∼

Sensor Terminal Assignments

Term

Pin#

Function

VII

(1+2)

Ebus (FA) or 0-10V output

I

(1,2,3+M)

F1/F2/F3 = buffer storage tank low/middle/top

I

(2+3+M)

FBR2 (FBR1) for heating circuit 1

I

(2+M)

F2 = Room sensor for heating circuit 1

I

(4+5)

F5 = Flow sensor heating circuit 2

I

(6+7)

F6 = Storage tank sensor

I

(7+8)

F8 = Boiler sensor/header sensor

I

(9+10)

F9 = Outdoor sensor

V

(1+M)

F11 = Flow sensor heating circuit 1/Multifunction relay sensor 1

V

(2+M)

F12 = Hot-water tank low/Multifunction relay sensor 2

VIII

(1+M)

F13 = PT1000 => HS2/collector 2/Multifunction relay sensor 3

VIII

(2+M)

F14 = PT1000 => Collector 1/Multifunction relay sensor 4

III

(1-3)

FBR2 (FBR1) for heating circuit 2

III

(1+2)

F15 = 0-10V input/light sensor/Room sensor for heating circuit 2

III

(2+3)

F17 = Pulse counter for output measurement

IX

(1+2)

Data line CAN bus

IX

(3+4)

Power supply CAN bus

6. CONNECTION DIAGRAMS

120V∼; Relay switching capacity 2(2)A, 250V

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Term

Pin#

Function

II

(1)

Neutral conductor, mains

II

(2)

Power supply, unit

II

(3)

Power supply, relay

II

(4)

A1 = Secondary Pump, heating circuit 1

II

(5)

A2 = Secondary Pump, heating circuit 2

II

(6)

A3 = Cylinder charging pump

II

(7)

A4 = Mixer motor heating circuit 2 on

II

(8)

A5 = Mixer motor heating circuit 2 to

II

(9+10)

A6 = Burner stage 1/HS 1

VI

(1+2)

A7 = Burner stage 2/HS 2/Solid fuel

IV

(1)

A8 = Mixer motor heating circuit 1 on/Multifunction relay 1

IV

(2)

A9 = Mixer motor heating circuit 1 to/Multifunction relay 2

A10 = Primary Pump, Collector pump 2/Switching valve to solar tank 2/Multifunction relay 3

IV

(4)

A11 = Collector pump 1 (speed controlled) multifunction relay 4

Mains Terminal Assignments

IV (3)

6.1 Power Terminal Assignments

Plug 2 [II]

Plug 6 [VI]

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6.1 Power Terminal Assignments (Continued)

Plug 4 [IV]

IMPORTANT

THE PRIMARY PUMP (COLLECTOR PUMP 2) MUST

BE WIRED TO RELAY A10.

6.2 Sensor Terminal Assignments

Connector 7 [VII]

Connector 1 [I]

Connector 5 [V]

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6.2 Sensor Terminal Assignments (Continued)

Connector 8 [VIII] => PT 1000 Sensor

Connector 3 [III]

Connector 9 [IX]

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7. BOILER COMMUNICATIONS MODULE (BCM)

When installed and enabled, the BCM enhances the range of control functions offered by the Modulex Boilers. These additional control functions include the following:

• BCM provides a fault relay which energizes when any fault condition occurs in the Modulex Boiler.

• BCM serves as a Back-up Controller in the event that the primary E8 Controller fails.

• BCM can be selected as the Primary Controller instead of the E8.

• BCM can function as a “Slave” to a “Master” Energy Management System (EMS), Building

Automation System (BAS) or AERCO’s Boiler Manage

• ment System II (BMS II/AERCO Control System (ACS) on a Modbus Network.

Paragraphs 7.1 through 7.7, which follow, provide detailed descriptions of the BCM and each of the additional control functions listed above.

7.1 Boiler Communications Module (BCM) Description

The BCM shown in Figure 7-1 is housed in a compact enclosure measuring 4.13” (105 mm) x

3.50” (89 mm). The BCM is installed on the front of the Modulex Boiler, behind the removable front panel.

Figure 7-1: Boiler Communications Module (BCM)

Input/Output (I/O) connections to the BCM are made via four connectors mounted on the Printed Circuit Board (PCB) of the BCM. Two Control Switches are mounted on the clear plastic cover on the front of the BCM. Three LED Status Indicators are mounted directly on the BCM PCB and can be viewed through the clear plastic cover. In addition, the PCB contains an on-board, screwdriver-adjustable 10-position address switch. The control and indicator functions are illustrated and described in Figure 7-2.

If the Modulex Boiler was shipped with the BCM factory-installed, a third Control Switch is mounted above the BCM. This switch is used to enable/disable the e-Bus connection between the E8 and BCM Controllers. Refer to paragraph 7.4.3 for details.

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Communication Status Indicator functions as follows:

STATUS

DESCRIPTION

No devices detected by either communication

Only one communication device detected at one

Both communication interfaces

Input

(Modbus/Ebus)

Output

Reset

Switch

DL1

(Yellow)

DL2

(Red)

DL3

(Green)

Enable/Disable

Switch (I/O)

SW1

Switch

Communications

(Ebus)

Boiler Communications Module (BCM) Features and Functions

Feature Function

Enable/Disable

Switch (I/0)

Reset Switch

Figure 7-2: Boiler Communications Module (BCM) Features

Two-position rocker switch enables the BCM to act as a BackUp Controller when placed in the ON (I) position.

Momentary two-position rocker switch resets (clears) fault relay and LED when activated.

DL1 LED

OFF

(Yellow)

BLINKING

ON

DL2 LED

(Red)

DL3 LED

(Green)

SW1

10-Pos. Rotary

Switch

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Alarm Status LED lights when a fault is detected by the BCM. Activating the Reset Switch will clear the faults.

Pump Status Indicator lights when Pump is running.

Screwdriver-adjustable rotary switch labeled 0 – 9. This switch is used to set the corresponding address of the Modulex Boiler on the input Modbus or Ebus Network.

interface.

communication interface (input or output).

(input & output) are active.

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BCM

SWITCHES

4 3 2 1

3 2 1

Y4

FAULT RELAY

ALARM SIGNAL

COLLECTOR CKT.

PUMP CONTROL

RESET

ENABLE/

DISABLE

BROWN

RED

BLACK

{

Y2

Y3

Y4

Y1

SW1

A1

I

0

Y3

{

7.2 BCM Fault Relay

The BCM Fault Relay is activated (energized) when a fault condition occurs in the Modulex Boiler. When activated, the Fault Relay provides contact closure across pins 3 and 4 of connector Y4 on the BCM board. In addition, the red LED on the BCM board will light continuously.

7.2.1 BCM Fault Relay Wiring

If desired, pins 3 and 4 of connector Y4 (Figure 7-3) can be wired to an external source to provide a remote alarm indication when the BCM Fault Relay is activated.

7.2.2 Clearing Faults

A fault can be cleared by pressing and releasing the black Reset Switch on the front cover of the BCM. However, if the cause of the fault has not been corrected, the Fault Relay will again be activated.

Figure 7-3: BCM Fault Relay & Reset Switch Wiring

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7.3 BCM Configured as Back-Up Controller

When the BCM is configured as the Back-Up Controller for the E8, it will assume control of the Modulex Boiler if the E8 fails. In the event of an E8 Controller failure, the BCM will operate the Modulex Boiler in the Constant Setpoint Mode (default setpoint = 180°F [82°C]). The primary Boiler Pump must also be wired to the BCM so it will run when the BCM assumes control in the Back-Up Mode.

If a setpoint temperature lower than 180°F is desired, the setpoint can be changed prior to boiler start-up. Refer to paragraph 7.3.1 for details.

7.3.1 BCM Back-Up Controller Wiring

The Primary Boiler Pump must be wired to BCM Connector Y4 as shown in Figure 7-4. Also, if a Constant Setpoint temperature lower than the default setting of 180°F (82°C) is desired in the event of an E8 failure, the appropriate resistor must be connected across terminals 6 and 7 of BCM Connector Y2 as shown in Figure 7-5.

Figure 7-4: BCM Back-Up Controller Wiring

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Y2

Y3

Y4

Y1

SW1

A1

I

0

7 6 5 4 3 2 1

Y2

SEE CHART

RESISTOR SETPOINT

160°F

120°F

100°F

140°F

100K OHMS

47K OHMS

22K OHMS

10K OHMS

180°F

OPEN

SHORT

80°F

Figure 7-5: Installing Resistor to Change Default Setpoint

7.4 BCM Configured as Primary Controller Utilizing Modbus

NOTE: When the BCM is configured as the primary controller, the E8 will display the

fault code “E200”.

The BCM can be configured as the Primary Controller, instead of the E8, when it is connected to a Modbus Network. However, the E8 must be disconnected from the e-Bus connection on the BCM Board (see Paragraph 7.4.3). All Modbus Networks are implemented utilizing a “Master – Slave” scenario where only one device, the “Master”, can initiate a communication sequence. However, BCMs can only function as “Slave” devices on a Modbus Network. Therefore, the BCM must be interfaced to an external controlling “Master”. The “Master” can be AERCO’s Boiler Management System II (BMS II), AERCO Control System (ACS), or an Energy Management System (EMS)/Building Automation System (BAS) developed by other manufacturers.

The following subordinate paragraphs provide descriptions of Modbus Network operation and required wiring connections between the BCM “Slaves and the controlling “Master” (EMS, BAS).

Detailed information on the Modbus Function Codes, Input/Holding Register Assignments and other Modbus requirements supported by the BCM are provided in Section 9 of this document.

7.4.1 Operating Scenario

Each Modulex Boiler must be equipped with its own BCM to allow Modbus Network monitoring and control. An EMS or BAS Master can control the Networked Modulex Boilers utilizing Remote Setpoint. An AERCO BMS II Master can control the networked Modulex boilers utilizing a Modbus signal.

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Y2

Y3

Y4

Y1

SW1

A1

I

0

MODBUS B (+)

BCM FRONT VIEW

7 6 5 4 3 2 1

Y2

MODBUS A (-)

MASTER

SLAVE

#1

SLAVE

#2

SLAVE#3SLAVE#4SLAVE

#5

In the event that the external control signal from the Master BMS II or ACS, EMS, or BAS is lost, the BCM will assume control of the Modulex Boilers, if enabled. When this occurs, the BCM will maintain the boiler at a constant setpoint based on the resistor installed between terminals 6 and 7 of connector Y2 (see Figure 7-5). In addition, the BCM Fault Relay will be activated and the red Fault LED (DL2) will light.

7.4.2 Physical Modbus RS485 Wiring

Modbus RS485 devices should be wired in a “Daisy-Chain” configuration similar to the example shown Figure 7-6. DO NOT wire the units in a “Star” configuration where all devices are connected to a central point (node).

Figure 7-6. Typical Daisy-Chain Modbus/RS485 Network

The physical wiring connections for a Modbus Network should be made using shielded twistedpair wire, from 18 to 24 AWG. Examples of suitable wire are: Belden # 9841, #8761, #3105A, or equivalent.

Modbus wiring connections are made at terminals 1 and 2 of BCM connector Y2 as shown in

Figure 7-7.

Figure 7-7: BCM Modbus (RS485) Connections

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BCM 3-Pos Switch

(Equivalent Terminal in Modulex Wiring Diagram)

Position I

(NOTE 1)

Position O (0)

Position II (1a)

The BCM is the Gate-way

fails.

The E8 is the primary

The BCM is the Gate-way

continuously run the pump.

The E8 is the primary

the pump.

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

NOTE

When the BCM is configured as the primary controller, the E8 will display the fault code “E200”.

If the BCM was retrofitted in the field utilizing Technical Service Bulletin 2007-07, refer to this bulletin and disconnect CBL 24 from Connector VII on the E8 Controller. However, if the Modulex Boiler was shipped with the BCM factory-installed, it will contain a 3-position switch mounted above the BCM (Figure 7-8). Refer to the switch matrix in Table 7-1 for descriptions of how the factory-installed 3-position switch functions with respect to the 2-position ON/OFF (Enable/Disable) switch on the BCM.

Table 7-1: 3-Position BCM Switch Functions

BCM 2-Pos Switch

(Enable/Disable)

(1b)

(see NOTE 2)

(See NOTE 3)

O (OFF)

(Disable)

I (ON)

(Enable)

NOTES:

1. DO NOT set the 3-Position Switch to Position I.

2. Set the 3-Position Switch to Position O ONLY when controlling Boilers from an external Controller via Modbus Communication. See Paragraph 3.1.2 for setting HEAT Modes.

3. Position II is the Default position for the 3-Position Switch. Ensure it is set to this position when it arrives from the Factory. See Paragraph 3.1.2 for setting HEAT Modes.

for Modbus and external

DO NOT

USE

DO NOT

USE

control. The E8 does not control the boiler and the BCM will not take over the boiler if the Modbus signal

for Modbus and external control. The E8 does not control the boiler and the BCM will take over the boiler if the Modbus signal fails. If E8 is in Standby Mode, BCM will cycle the pump with the boiler. If E8 is in Day Mode, the E8 will

controller and the BCM allows monitoring through Modbus, but will not take over boiler if the E8 fails.

controller and the BCM allows monitoring, and the BCM will take over the boiler if E8 fails. If E8 is in Standby Mode, E8 will cycle the pump (must use Enable/Disable). If E8 is in Day Mode, the E8 will continuously run

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Figure 7-8: Location of 2-Position and 3-Position Switches

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

The AERCO BMS II/ACS contains a RS232 port for connection to an EMS/BAS or personal computer. In addition, the BMS II/ACS contains a RS485 port for connection to the BCM’s Modbus input.

7.4.5 EMS or BAS Master to BCM Slave Wiring Connections

When a third-party EMS or BAS Master is used, the Modbus Network connections will depend on the available communication port(s) on the EMS/BAS. Many EMS/BAS Models contain only a RS232 (DB9) port, while others contain either a 2-Wire or 4-Wire RS485 port. In addition, some EMS/BAS models contain both a RS232 and a RS485 port. If the EMS or BAS is equipped with only a RS232 port, a RS232-to-RS485 converter will be required (such as a B&B Electronics, Model 485SD9TD or AERCO Part No. 124943).

7.5 RS485 Loop Termination Resistors and Bias

A terminating resistor (120 ohms) on each end of the RS485 loop is designed to match the electrical impedance characteristic of the twisted-pair loop and prevent echoes or cross-talk from corrupting data on the line. Short or medium length Modbus/RS485 loops (less than 1000 feet) can usually operate satisfactorily without the terminating resistor. However, longer loop runs (over 1000 feet), may require terminating resistors.

Bias may be necessary on the RS485 loop to minimize noise on the circuit. Loop bias is accomplished by activating pull-up/pull-down resistors on the last Boiler Communications Module (BCM) in the chain. AERCO recommends that both terminating resistors and bias be implemented on the RS485 circuit as described in paragraphs 7.5.1 and 7.5.2 which follow.

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

All AERCO BMS II/ACS units are equipped with a built-in terminating resistor. Therefore, when the BMS II or ACS is the controlling Master, no terminating resistor needs to be added. In addition, the BMS II/ACS contains two Bias DIP switches which must be activated when the BMS II/ACS is the controlling Master. Refer to BMS II Manual GF-124/ACS Manual GF-131, paragraph 2.6 and Figure 2-6 for additional information on these switches.

When a third-party EMS or BAS is used as the controlling Master, consult the manufacturer’s Technical Manual for termination resistor recommendations. If the EMS/BAS being used does not provide a bias and one is needed, pull-down bias can be implemented by installing a 1K ohm resistor (not provided) across terminals 2 and 4 on BCM connector Y2 (Figure 7-9).

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Y2

Y3

Y4

Y1

SW1

A1

I

0

BCM FRONT VIEW

7 6 5 4 3 2 1

Y2

JP2

JP1

T

C

V

JUMPER

SHOWN IN

“TERMINATED”

POSITION

1K OHMS

PULL-DOWN

BIAS

RESISTOR

DO NOT INSTALL BIAS RESISTOR WHEN BMS II IS “MASTER”

7.5.2 BCM Controller Terminating Resistor and Bias

BCMs can function only as Slave devices on a Modbus Network. Since the Slaves are connected in a “Daisy-Chain” configuration, the terminating resistor must be enabled only in the last BCM Controller in the chain. Enabling the terminating resistor is accomplished by positioning jumper JP1 as shown in Figure 7-9 only on the BCM Board contained in the last BCM Controller.

As mentioned in paragraph 7.5.1, when the controlling Master is an EMS or BAS, pull-down bias may be implemented by connecting a 1K ohm resistor as shown in Figure 7-9. DO NOT install this bias resistor if the controlling Master is an AERCO BMS II or ACS. Bias will be provided by the BMS II/ACS DIP switches. The last unit in the chain must be energized (even if disabled) to enable bias.

Figure 7-9: BCM Loop Termination and Bias

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7.6 Modbus Network Wiring Diagram

A “Sample” Modbus Network wiring diagram for an AERCO BMS II/ACS Master controlling BCM Slaves is shown in Figure 7-10. Activate the terminating resistor in the last BCM on the daisychain loop. DO NOT install the 1K bias resistor. Instead, activate the two bias DIP switches in the BMS II/ACS. Refer to GF-124, Figure 2-6 for the location of these switches.

Figure 7-11 shows a Sample Modbus Network wiring diagram for a Master EMS/BAS controlling BCM Controller Slaves. This Figure shows an EMS or BAS Master equipped with a RS485 port. If the EMS or BAS contains a 4-Wire RS485 port, refer to Detail “A” for wiring details. If the controlling Master EMS/BAS contains only a RS232 port, a RS232-to-RS485 converter will be required to interface with connector Y2 at each BCM Controller. It should be noted that this diagram is only intended as a guide and does not include all possible scenarios. Refer to the EMS/BAS manufacturer’s manual prior to attempting any network wiring connections.

CAUTION!

It is imperative that polarity be maintained between all Modbus Network connections. The Network will not operate if the proper polarity is not maintained. Also, twisted-pair wiring shields should only be terminated at the controlling Master for the Modbus Network.

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TO OTHER NETWORK

BOILER SLAVES (3 - 9)

AERCO BMS II

MASTER

485 B +

485 A -

RS485 PORT

SHLD

(TERM 3)

+

Y2-2 – MODBUS “A” (-)

(PART OF BCM CONN. Y2)

MODULEX BOILER SLAVE #1

NOTES:

THE LAST BCM SLAVE ON THE RS485 LOOP

MUST HAVE ITS TERMINATION RESISTOR

ENABLED.

ALSO, THE 2 BIAS DIP SWITCHES IN THE BMS II

SHOULD BE TURNED ON,

Y2-1 – MODBUS “B” (+)

BCM

+

Y2-2 – MODBUS “A” (-)

(PART OF BCM CONN. Y2)

MODULEX BOILER SLAVE #2

Y2-1 – MODBUS “B” (+)

BCM

RS232 PORT

BIAS DIP

SWITCHES (2)

SET BOTH

SWITCHES TO “ON”

Figure 7-10. AERCO BMS II Master Controlling Modulex Boiler Slaves

Figure 7-10:

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OMM-0084_0D

Figure 7-11. EMS/BAS Master Controlling Modulex Boiler Slaves

TO OTHER NETWORK

BOILER SLAVES (3 - 9)

(SEE NOTE 3)

EMS MASTER

T+/R+

T-/R-

RS485 PORT

SHIELD

+

Y2-2 – MODBUS “A” (-)

(PART OF BCM CONN. Y2)

MODULEX BOILER SLAVE #1

NOTES:

1. IF EMS MASTER CONTAINS A 4-WIRE RS485 PORT,

TIE THE TWO POSITIVE (+) AND NEGATIVE (-)

LEADS TOGETHER AS SHOWN IN DETAIL “A”

2. IF EMS MASTER CONTAINS ONLY A RS232

PORT, A RS232-TO-RS485 CONVERTER WILL BE

REQUIRED.

3. THE LAST BCM SLAVE ON THE RS485 LOOP

MUST HAVE ITS TERMINATION RESISTOR

ENABLED. ALSO, A 1K OHM BIAS RESISTOR

MAY BE REQUIRED. CHECK WITH THE EMS

MANUFACTURER.

SEE NOTES 1 & 2

DETAIL “A”

(SEE NOTE 1)

T+

T-

4-WIRE RS485 PORT

SHIELD

R+

R-

T+/R+

T-/R-

Y2-1 – MODBUS “B” (+)

BCM

+

Y2-2 – MODBUS “A” (-)

(PART OF BCM CONN. Y2)

MODULEX BOILER SLAVE #2

Y2-1 – MODBUS “B” (+)

BCM

Figure 7-11:

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Y2

Y3

Y4

Y1

SW1

A1

I

0

2

1

4

3

5

6

7

8

9

SW1

7.7 Modbus Software Set-Up

The following paragraphs provide the information and procedures necessary to configure the Boiler Communications Modules (BCMs) to operate on a Modbus Network.

NOTE

The following paragraphs assume that between 1 and 9 Modulex Boilers are being controlled on the Modbus Network.

7.7.1 BCM Set-Up for Modbus Operation

The BCM Controller can be set up for the following types of Modbus operating modes:

• Monitoring and Configuration Only

• AERCO BMS II/ACS Modbus Control and Monitoring

• Modbus Remote Setpoint Control and Monitoring

In order for the BCM Controller to be recognized by the Modbus Master, a valid address must be set at each BCM on the Modbus Network. Address selection on each BCM is accomplished by setting rotary DIP switch SW1. This switch is located in the lower right portion of each BCM as shown in Figure 7-12.

As Figure 7-12 shows, SW1 is a 10-position switch labeled 0 – 9. SW1 is set to the desired position using a small flat-tip screwdriver. Figure 7-12 shows SW1 set to address 0 (zero) which disables the BCM on the Modbus Network. Only Modbus addresses 1 through 9 will be recognized by the Modbus Master. SW1 must be set to a different position for each Modulex Boiler being controlled on the Modbus Network.

Once the desired address has been set on each BCM, the Modulex Boiler is configured for Modbus Network control by the controlling Master EMS/BAS or AERCO BMS II/ACS. In order for the BCM to act as the Back-Up Controller if the Modbus Master signal is lost, the ENABLE/DISABLE switch must be set to ENABLE (1).

See Section 9 of this document and Section 2 of GF-124 for Modbus points for the BCM and BMS II/ACS.

Figure 7-12: Location of BCM Address Selection Switch SW1

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7.7.2 Monitoring and Configuration Only

For monitoring and configuration only, set the 3-position switch to position II when the E8 is controlling the boiler. The boiler operation can be monitored via the Modbus terminals.

7.7.3 AERCO BMS II/ACS Modbus Control and Monitoring

The BCM’s modulation output can be controlled by writing to its requested modulation level register (Standard Holding Register or Control Register #1). It will ramp up the boiler based on the settings in the Standard Holding Register or Setting Register 3000 to 3015. The default maximum setpoint temperature limit is 180°F as shown in register 3015. This value should not be increased, if possible. The default timeout interval is 30 seconds as shown in register 3011.

7.7.4 Modbus Remote Setpoint Control and Monitoring

To send a setpoint temperature to the BCM and have it control the boiler based on its internal settings, 3 registers need to be adjusted:

• the desired setpoint should be written to the Requested Setpoint (Address 1004) in the

Standard holding Registers or Control Registers. This value should be written at least 3 times within the Communication Timeout time (Address 3011).

• The Heat Request Command (Control Register Address 1021) should be set to 0xEE

(238) to request heat.

• If the modulation level should be allowed to go above 50%, adjust the Maximum

Modulation Level setting (Address 1017).

NOTE

If power is lost, all Control Register settings return to their default values. Be sure to read them regularly and refresh if necessary. The changes to the Settings Registers are stored during powerdown.

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

Refer to the set-up instructions in the manufacturer’s equipment manual for the Energy Management System (EMS) or Building Automation System (BAS) being used as the controlling Master.

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

Multiple Modulex boiler plants are the ultimate energy conversion for building space heating. By modulating input at extremely high combustion efficiency, there is no wasted energy from overshoot. A multiple Modulex boiler plant offers inherent standby protection and ease of installation along with longevity.

In a multiple boiler plant of over two boilers, the use of an AERCO Boiler Management System II (BMS II) Model 5R5-384/AERCO Control System (ACS) is recommended for maximum efficiency and flexibility of operator control. The BMS II/ACS has the capability of controlling up to 32 boilers as well as auxiliary equipment. The BMS II/ACS system has an Internal Plant Start adjustment that can be set from 32°F to 100°F outdoor air temperature. When the boiler plant is activated, the system pump should be started simultaneously. This can be controlled from

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outside the BMS II/ACS, but boilers that fire with no flow will trip out on internal high temperature limit controls.

The following example briefly explains the operational sequence for a boiler plant consisting of multiple Modulex Boilers controlled by a BMS II or ACS:

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

When there is a need for heat, the BMS II will send a fire rate signal to the first boiler to begin firing. The Boiler Communications Module (BCM) of the first boiler will turn on one of its modules. When the BMS II/ACS fire rate signal to this boiler reaches a value twice that of the start level percentage (programmed by the user into the BMS II/ACS), the BMS II/ACS will call on the second boiler to begin firing one module, and the BMS II/ACS will then split the fire rate signal between the two boilers and send each a signal equal to the start level percentage. When the combined BMS II/ACS fire rate signal to the two boilers reaches a value three times that of the start level percentage, the BMS II/ACS will call on the third boiler to begin firing one module, and the BMS II/ACS will then split the fire rate signal between the three boilers and send each a signal equal to the start level percentage. As the demand increases, in a similar method as above, the BMS II/ACS will call on the BCM of the fourth boiler to turn on one module. At this point, the BMS II will modulate the fire rate signal to the boilers in a parallel manner, while the BCM of each boiler sequences the individual modules.

Boiler inputs will modulate down and come off line in response to the BMS II/ACS in a reverse manner. Whether the BMS II/ACS is set in a Constant Temperature or Modulating Temperature mode, it will use the modulating ability to prevent header temperature fluctuation and maximize efficiency. As well, the BMS II/ACS can stage auxiliary equipment such as combustion air dampers and fans. Refer to BMS II Operations and Maintenance Manual GF-124/ACS Manual GF-131, and Product Spec BMS-II for details.

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INSTALLATION Sub-Menu

installed.

Constant Set Point modes.

(cascade)

sequence between Heat Modules.

T-SOLID FUEL

For HS2 = Solid fuel boiler (A7)

T-RETURN 1

Return flow temperature of HS 1

T-RETURN 2

Return flow temperature of HS 2

T-BUFFER T

Buffer storage tank temperature – top

Only if buffer storage installed

charging zone HS

T-BUFFER L

Buffer storage tank - low

pool-heating)

MODGRAD

Modulation degree of HS (BUS)

INSTALLATION Sub-Menu.

8. E8 CONTROLLER MENU LISTINGS

8.1 DISPLAY Menu

The DISPLAY Menu contains an INSTALLATION, HOT WATER, HEATING (HTG) CIRCUIT 1 & 2 and a SOLAR HEATING Sub-Menu. The sub-menu functions associated with each of these items are listed in Table 8-1.

NOTE

All DISPLAY area menus are READ ONLY and cannot be changed. Temperature readings are in °F.

Table 8-1: DISPLAY Menu Sub-Menus and Parameters

FUNCTION DESCRIPTION REMARKS

T-OUTSIDE Outside air temperature

External Set Point value specification (0-

T-EXT DES

T-COLL DES

T-COLLECTOR

T-BOIL

10V) Boiler Set Point setting in 0 to 10 volt input mode

Heat Source (HS) / Header Set Point value (cascade). Boiler Set Point temperature in Indoor/Outdoor Reset and

HS / Header Set Point temperature

Press Program Key to display temperature and ON/OFF status of individual Heat Modules (HS) which range from 2 (MLX-303) to 7 (MLX-1060). Turn Rotary Knob to

Only if outside air sensor is

A 0 to 10 volt external input signal can be used to preset a Set Point value for the control system.

Not Applicable

T-BUFFER M

T-STORAGE 3

RETURN

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Buffer storage tank temperature - mid

Temperature of storage tank 3 (e.g. solar

Press Program Key to exit

Only if buffer storage installed

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FUNCTION

DESCRIPTION

REMARKS

Based on heating program and

WATER menu.

T-DHW

Actual hot water temperature

(inflow)

Menu.

program and operating (timer) mode

T-ROOM

Current room air temperature.

with heat-up optimization activated

Sub-Menu.

Table 8-1: DISPLAY Menu Sub-Menus and Parameters (Continued)

HOT WATER Sub-Menu

T-DHW RATED

T-DHW L

T-CIRCL Return flow temperature of recirculation

RETURN

DHW set point temperature

Temperature of HW tank in the lower section

Press Program Key to exit HOT WATER Sub-

HTG CIRCUIT 1 Sub-Menu

Programmed room temperature setting

T-ROOM DES A

HUMIDITY Room humidity (%).

T-DHW RATED Hot water set point temperature

specified in currently selected heating

operating mode. Actual DHW set point as set in the USER/HOT

Only if tank sensor is installed

Not applicable

Only if indoor sensor is connected

Only if humidity sensor installed & parameters set for heating circuit.

Appear only if heating circuit is programmed as hot water circuit.

T-DHW Current hot water temperature

T-FLOW RATED Current flow set point temperature

FLOW Current flow temperature

N-OPT-TIME

RETURN

Previous time required to heat up

Press Program Key to exit HTG CIRCUIT 1

Same as above

Not applicable

HTG CIRCUIT 2 Sub-Menu

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

SOLAR M/F Sub-Menu

T-MF1 Temperature Multi-Function Sensor 1 (=F11)

T-MF2 Temperature Multi-Function Sensor 2 (=F12)

T-MF3 Temperature Multi-Function Sensor 3 (=F13)

T-MF4 Temperature Multi-Function Sensor 4 (=F14)

T-COLLECTOR 1 Temperature Collector 1 (set point temp)

T-DHW Upper hot water temperature

T-DHW L Hot water temperature in-feed

RETURN

Press Program Key to exit SOLAR M/F Sub-Menu.

Currently not used

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FUNCTION

DESCRIPTION

DEFAULT

CONTRAST

Adjusts display contrast

00

Heating Circuit 1 or 2

connected)

Sub-Menu.

1X DHW

Enables storage tank for heating

00, 01 (OFF/ON)

00 = OFF

or 3

BOB-VALUE

Currently Not Applicable

(N/A)

Water

Sub-Menu.

8.2 USER Menu

The USER Menu contains exactly the same sub-menus as the DISPLAY Menu. However, the USER Menu items are not “Read Only” and therefore can be changed if desired.

Table 8-2: USER Menu Sub-Menus and Parameters

ENTRY RANGE

INSTALLATION Sub-Menu

LANGUAGE Selects display language.

Sets the day of the week or the sensor temperature (°F) to appear in the display

DISPLAY SEL

when the swing-down panel is closed.

Day: SUN – SAT

T-OUTSIDE: Outside Temperature

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

supply water temperature. (Only if sensor is installed)

T-DHW: Domestic Hot Water Temp

T-BOILER; Heat Generator Temp.

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

Circuit 1 or 2 (ONLY if Remote Control is

12 languages are available.

-20 to 20

See

DESCRIPTION

Column

ENGLISH

- - - -

RETURN

HOT WATER Sub-Menu

T-DHW 1, 2 or 3 Hot Water set point for enable time 1, 2,

CIRCL-P-DHW

RETURN

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Press Program Key to exit INSTALLATION

Circulation Pump for Domestic Hot

Press Program Key exit HOT WATER

50°F – 158°F 140°F

00, 01 (OFF/ON) 00 = OFF

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FUNCTION

DESCRIPTION

ENTRY RANGE

DEFAULT

Day, Night

enable tiime.

setting.

holidays (vacations).

-23.0°F–104.0°F

periods.

-23.0°F–104.0°F

temperature increases or decreases by 1°F.

OPTIM HEAT

Heating optimization

00, 01, 02

00

02.

ECONO OPTI

Reduction optimization

0:00 – 2:00 [h]

0:00 [h]

Computer.

(or 2) sub-menu.

TIME PROGRAM Menu.

Table 8-2: USER Menu Sub-Menus and Parameters (Continued)

HTG CIRCUIT 1 Sub-Menu

MODE Displays Timer Mode for Boiler

- - - -, Standby, Auto 1, Auto 2,

- - - -

T-ROOM DES 1

T-ROOM DES 2

T-ROOM DES 3

T-REDUCED

T-ABSENCE

Room temperature setting for first

Room temperature setting for second

Room temperature setting for third

Reduced night-time room temperature

Required room temperatures during

T-LIMIT DAY Applies during day-time heating periods

T-LIMIT N

HEATSLOPE

MAX OPT-TIME

Applies during reduced night-time

Indicate number of degrees that that the flow temperature changes if the outside

Only active if OPTIM HEAT is set to 01 or

41.0°F – 104.0°F 68.0° F

41.0°F – 104.0°F 50.0° F

41.0°F – 104.0°F 59.0° F

- - - -,

0.00 – 3.00 1.20

0:00 – 3:00 [h] 2:00 [h]

66.0°F

50.0°F

Code Number for enabling access to

PC-ENABLE

RETURN

heating circuit data from a Personal

Press Program Key to exit HTG CIRCUIT 1

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)

Pressing the Program Key with SOLAR M/F displayed will change display to RETURN.

RETURN

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Press Program Key again to redisplay SOLAR M/F. Turning the Rotary Knob clockwise will advance thd display to the

0000 – 9999 0000

N/A

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individually for each day of the week or they can be set in groups as listed in the options which follows:

function.

TUESDAY

Same as previous except for Tuesday.

See prev.

WEDNESDAY

Same as previous for Wednesday

See prev.

THURSDAY

Same as previous for Thursday

See prev.

FRIDAY

Same as previous for Friday

See prev.

SATURDAY

Same as previous for Saturday

See prev.

SUNDAY

Same as previous for Sunday

See prev.

MO – FRI

Same as above for Monday – Friday

See prev.

22:00h

RETURN

Press Program Key to exit CIRCL sub-menu

8.3 TIME PROGRAM Menu

All time-related functions can be set using the TIME PROGRAM Menu and its associated submenus. The sub-menus and functions in this menu contain programs which set the ON and OFF times for the following devices using a 24-Hour clock format:

• Circulation (CIRCL) Pump

• Hot Water (HOTW) Charging Pump

• Heating (HTG) Circuits 1 & 2

The time programs for each device can be set for a single day, weekdays (Monday – Friday). Weekends (Saturday, Sunday) or for an entire week (Monday – Sunday). The available options are listed in the following Table.

Table 8-3: TIME PROGRAM Menu Sub-Menus and Parameters

FUNCTION DESCRIPTION

ENTRY RANGE

DEFAULT

CIRCL TIME Sub-Menu

The CIRCL (Circulation) Time Sub-Menu is used to set the ON-OFF times for Circulation Pump. Press the Program Key to enter this Sub-Menu and view or change ON-OFF times. The times can be set

View or change the pump ON – OFF times for

MONDAY

Monday. Press the Program Key to view current settings. Turn Rotary Knob to change displayed ON or

OFF time if required. Press Program Key to store displayed ON or

OFF time and sequence the display to the next

All ON and OFF times can be set in 15 minute increments from 00:00 – 24:00

ON: 5:00h

OFF: 21:00h

SA – SU Same as previous for Saturday and Sunday See prev.

MO – SU Same as previous for Monday – Sunday See prev.

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Sub-Menu.

display to the next function.

TUESDAY

Same as previous except for Tuesday.

See prev.

WEDNESDAY

Same as previous for Wednesday

See prev.

THURSDAY

Same as previous for Thursday

See prev.

FRIDAY

Same as previous for Friday

See prev.

SATURDAY

Same as previous for Saturday

See prev.

SUNDAY

Same as previous for Sunday

See prev.

MO – FRI

Same as above for Monday – Friday

See prev.

22:00h

PROG sub-menu.

Table 8-3: TIME PROGRAM Menu Sub-Menus and Parameters (Continued)

FUNCTION DESCRIPTION ENTRY RANGE DEFAULT

HOTW – PROG Sub-Menu

MONDAY

The HOTW – PROG (Hot Water Program) Sub-Menu is used to set the ON-OFF times for the Hot Water Charging Pump.

The procedures for viewing/changing ON-OFF times are identical to those previously described for the CIRCL TIME Sub-Menu, except they apply to the Hot Water Charging Pump.

The days/day groups are also identical to the those shown in the CIRCL TIME

View or change the pump ON – OFF times for Monday.

Press the Program Key to view current settings.

Turn Rotary Knob to change displayed ON or OFF time if required.

Press Program Key to store displayed ON or OFF time and sequence the

All ON and OFF times can be set in 15 minute increments from 00:00 – 24:00

ON: 5:00h OFF:

21:00h

SA – SU

MO – SU Same as previous for Monday – Sunday See prev.

RETURN

Same as previous for Saturday and Sunday

Press Program Key to exit HOTW –

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ENTRY

RANGE

24:00

TUESDAY

Same as previous except for Tuesday.

See prev.

WEDNESDAY

Same as previous for Wednesday

See prev.

THURSDAY

Same as previous for Thursday

See prev.

FRIDAY

Same as previous for Friday

See prev.

SATURDAY

Same as previous for Saturday

See prev.

SUNDAY

Same as previous for Sunday

See prev.

MO – FRI

Same as above for Monday – Friday

See prev.

SA – SU

Same as previous for Saturday and Sunday

See prev.

MO – SU

Same as previous for Monday – Sunday

See prev.

menu.

above.

menu.

Table 8-3: TIME PROGRAM Menu Sub-Menus and Parameters (Continued)

FUNCTION DESCRIPTION

HTG – PROG 1 Sub-Menu

The HTG-PROG 1 (Heating Program 1) SubMenu is used to set the ON-OFF times for Heating Circuit 1

The procedures for viewing/changing ON-OFF times are identical to those previously described for the CIRCL TIME Sub-Menu, except they

MONDAY

apply to the HTG PROGRAM 1.

The days/day groups are also identical to the those shown in the CIRCL TIME Sub-Menu.

The associated ON / OFF times are as shown In the DEFAULT column

View or change the pump ON – OFF times for Monday.

Press the Program Key to view current settings. Turn Rotary Knob to change displayed ON or

OFF time if required. Press Program Key to store displayed ON or

OFF time and sequence the display to the next function.

All ON and OFF times can be set in 15 minute increments from 00:00 –

DEFAULT

ON: 6:00h

OFF: 22:00h

RETURN

HTG – PROG 2 Sub-Menu

RETURN

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Press Program Key to exit HTG – PROG 1 sub-

Sub-Menu Functions, processing procedures, ranges and defaults are same as HTG PROG 1

Press Program Key to exit HTG – PROG 2 sub-

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INSTALLATION Sub-Menu

CODE-NO

Permits entry of valid Code No.(0000)

0000 – 9999

0000

BUS ID HS

BUS ID HS MUST be set to - - - - (Default)

01 - 08

- - - -

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)

EBUS SUPPLY

Switches the eBUS supply ON/OFF

00, 01 (OFF/ON)

01 (ON)

time master. LEAVE SET TO 00.

temperature.

Source 2) set point temperature (Not Applicable)

(N/A)

temperature.

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

temperature)

this setting will stop/start the Boiler.

8.4 EXPERT Menu

The EXPERT Menu includes the same sub-menus as the USER Menu described in subsection A.2. However, in order to change any settings, the valid Code No. (password) must

be entered. Whenever “CODE NO.” is displayed, it indicates that the valid password must be entered. This is accomplished by entering code 0000 (4 zeros) by pressing the Program Key 4 times.

As the following Table shows, the EXPERT Menu contains a large number of functions, particularly in the INSTALLATION Sub-Menu.

Table 8-4: EXPERT Menu Sub-Menus and Parameters

FUNCTION

BUS ID 1

BUS ID 2

DESCRIPTION

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

ENTRY RANGE

(00), 01 - 15 01

(00), 01 - 15 - - - -

DEFAULT

TIME MASTER

MAX T-COLL

MIN T-COLL

MAX T-HS2

MIN T-HS2

V-CURVE

CURVE 11-T1

CURVE 11-T2

CURVE 11-UO

When set to 00, it indicates there is no time master. When set to 01 the Controller is the

Sets the maximum allowable header set point

Sets the minimum allowable header set point

Sets the maximum allowable HS2 (Heat

Sets the minimum allowable HS2 set point

from preset curves (see para. 3.5.1) or

Low temperature level setting (Min. set point

High temperature level setting (Max. set point

Stop/Start voltage level. Going below/above

00, 01

86.0°F – 230.0°F 185.0°F

50.0°F – 176.0°F 50.0°F

86.0°F – 230.0°F

50.0°F – 176.0°F 104.0°F

00 - 11 11

32.0°F – 248.0°F 59.0°F

32.0°F – 248.0°F 185.0°F

0.00V – 10.00V 1.00

00

(N/A)

185.0°F

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ENTRY

RANGE

(Not Applicable)

number of heat modules available for service.

maximum kW output of each heat module.

(Currently Not Applicable)

simultaineously.

actual temperature.

DES OUPUT

Required system output [in %]

0 - 100%

00

(N/A)

BLOCK TIME

Not Applicable

(N/A)

230.0°F

(Not Applicable)

DOWNWARD

(Not Applicable)

RESET TIME

Resetting time for Controller (seconds)

5 - 500

50

SEQ SW TIME (see below) elapses.

the current sequence is switched off

MIN MOD HS

Connection of the next heat generator

0% - 60%

35%

(Currently Not Applicable)

SEQUENCE 1

Boiler sequence 1

12345678

SEQUENCE 2

Boiler sequence 2

87654321

Table 8-4: EXPERT Menu Sub-Menus and Parameters (Continued)

FUNCTION DESCRIPTION

DEFAULT

INSTALLATION Sub-Menu (Continued)

HYSTERESIS

FOUND MODULS

CAP/MODULE

NEW CONFIG

MIN MOD CASC

HW-BOILER Number of stages for HW operation 00 - 08 00

CONTR DEVIAT

Dynamic Switching hysteresis stage 1.

Display of heat generators automatically reported via BUS with BUS ID. Displays the

After restarting, the Controller, searches the bus systems for available new heat modules and the

If the BUS configuration was modified, the automatic search for generators on the BUS may be activated here.

Specifies the number of heat modules started

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

5K - 20K

(N/A)

display

00 - 1000 kW 40 kW

00, 01

(OFF/ON)

(N/A)

01 - 08 01

display F

5.0K

(N/A)

00

(N/A)

SWITCH TIME Internal control value: only for switching cascade (-99) - 0 - (99)

MAX T-MODUL Maximum temperature of Heat Module

DYN UPWARD

DYN

MODULAT MAX

MODULAT MIN

MOD LEVEL HW

Dynamic heat generator connection

Dynamic heat generator deactivation

Start Level. If this modulation percentage is exceeded, the next heat generator (module) is connected after the delay time specified by the

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

Entry of the set modulation percentage for the heat generators in hot water operation

122.0°F –

(N/A) (N/A)

50% - 100% 30%

10% - 60% 35%

40% - 100%

(N/A)

Display

194.0°F

80%

(N/A)

PR1: 11/30/12 Page 85 of 112

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GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

FUNCTION

DESCRIPTION

DEFAULT

SEQU CHANGE

Sequence change mode

01 - 06

06

SEQ SW TIME

Time to sequence change (seconds)

10 - 800

200

switching HS

HYST BURNER2

Solid fuel integration: hysteresiys for charging pump

2K - 20K

2.0

HS COOL-FCT

T-HS COOL

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

HS 1 BUS

Connections for HS 1

00 - 04

02

HEATSOURCE 2

Secondary heat generator type

00 - 05

00

STORAGE HS2

Not Applicable

00 - 03

00

BUFFER

Not Applicable

00, 01, 02

00

SCREED

Not Applicable

N/A

SCREED PROGR

Not Applicable

N/A

Menu.

HOT WATER Sub-Menu

01 = ON

02 = Pump Parallel Running

HYST DHW

Hot Water Hysteresis

48°F – 129°F

48°F

DHW FOLLOWUP

Pump Run-Down Time

00 min. – 30 min.

00 min.

01 = ON

00 = OFF

01 = ON

00 = OFF

01 = ON

Table 8-4: EXPERT Menu Sub-Menus and Parameters (Continued)

INSTALLATION Sub-Menu (Continued)

ENTRY RANGE

LOCK TIME

HEATSOURCE 1

RETURN

Min. delay time after switching ON or with

Identification of Boiler Type being used: 00 = No Boiler 01 = Single-Stage, switching 02 = Single-Stage, modulating

03 = 2-Stage, switching 04 = 2 individual, switching 05 = Multi-Stage, switching

Press Program Key to exit INSTALLATION Sub-

00 min - 30 min 00

06

(Multi-

Stage

Modulating)

DHW RELIEF Charge pump blocking.

Parallel pump operation.

PARALLEL

T-BOILER DHW

THERM INPUT Storage Tank With Thermostat

WALL HUNG For Modulating Heat Source (HS)

LOAD THROUGH

PR1: 11/30/12 Page 86 of 112

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00 = Hot Water Priority 01 = Hot Water Partial Priority

Boiler temperature increase during Hot Water operation.

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

00 = OFF

00, 01, 02

32°F – 194°F 97°F

00 = OFF

01 (ON)

01

00 (OFF)

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

FUNCTION

DESCRIPTION

DEFAULT

Function (HC FUNCTION) selected.

valve.

03 = Continuous pump operation

to oscillate

Specifies speed setting at which mixing valve

may cause the mixing valve to oscillate

Maximum allowable water temperature setting for the heating circuit.

Minimum allowable water temperature setting for the heat circuit.

Specifies the minimum allowable outside air

Mode and the pumps are switched ON.

Outside Temperature Delay. Specifies the

insulated structures, set time to 0 hours)

48°F

(N/A)

Table 8-4: EXPERT Menu Sub-Menus and Parameters (Continued)

HEAT CIRCUIT 1 & 2 Sub-Menus

ENTRY RANGE

HC FUNCTION

PUMP MODE

MIXER OPEN (NOT for HW

circuit)

The Sub-Menu Functions for HEAT CIRCUIT 1 & HEAT CIRCUIT 2 are identical. The Function values in this Sub-Menu level will change, depending on the Heat Circuit

Heat Circuit Function defines type of circuit: 00 = Standard Heat Circuit 01 = Control to fixed flow temperature 02 = Swimming pool control (HC 2 ONLY) 03 = Hot Water Circuit 04 = Return flow temp. increase via mixing

Circulation pump mode control for ON/OFF switching of pumps. 00 = Standard pump control

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

Specifies speed setting at which mixer motor opens when there is a control temperature difference.Entering small temperature difference values may cause the mixing valve

00 – 04

00 - 03 00

5°F -25°F 18°F

00

(Standard

Heat

Circuit)

MIXER CLOSE (NOT for HW

circuit)

MAX T-FLOW

MIN T-FLOW

FROST PROT

OUT-TEMP-DEL

SLOPE OFFSET

PR1: 11/30/12 Page 87 of 112

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closes when there is a control temperature difference. Entering small temperature difference values

temperature setting for the Frost Protection Mode. If temperature drops below this value, the system switches to the Frost Protect

elapsed time before a decrease in the outside temperature will affect the indoor room temperature. The time entered must be consistent with the type of building construction (i.e., thick well-insulated walls can use a long time delay. For light, poorly

Heating slope distance. 32°F – 194°F

5°F -25°F 12°F

68°F – 230°F 176°F

50°F – 230°F 50°F

-5°F – 41°F 32°F

0:00 – 24:00

0:0

(N/A)

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

FUNCTION

DESCRIPTION

ENTRY RANGE

DEFAULT

00 = OFF

01 = ON

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

SOLAR M/F Sub-Menu

indicates switching temperature for relay

HYST (1-4)

02 = Light sensor

Sub-Menu.

Table 8-4: EXPERT Menu Sub-Menus and Parameters (Continued)

HEAT CIRCUIT 1 & 2 Sub-Menus (Continued)

B-HEAT SINK

RETURN

MF (1-4) FUNCTION

Circuit Enable

Multi-Function (MF) Relay Functions. 00 = No Function 01 = Header Pump 02 = Circulation (Time) 03 = Booster Pump 05 = Pump HS1 06 = Pump HS2 20 = Temp-Controlled Circulation Pump 21 = Pulsed Circulation Pump 22 = Solid Fuel Boiler Integration 23 = Solar Integration 24 = Return Flow Temperature Increase

HS1 25 = Return Flow Temperature Increase

HS2 26 = Return Flow Temperature Increase

HS Via Buffer Storage

00, 01, 02, 03,

05, 06 & 20-26

01 (ON)

00

(No

Function)

MF (1-4) SET TEMP

MF (1-4)

Multi-Function Relay Set Point Temperature

Multi-Function Relay Hysteresis 39°F – 64°F 48°F

F15 Function

F15 FUNCTION

RETURN

PR1: 11/30/12 Page 88 of 112

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00 = Room Sensor for Heating Circuit 2 01 = 0 – 10V iInput

Press Program Key to exit SOLAR M/F

86F – 194F 86°F

00 -02 00

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

FUNCTION

DESCRIPTION

ENTRY RANGE

TIME - DATE Sub-Menu

etc).

TIME

Set current time (min., hours)

00:00 – 24:00

YEAR

Set current year

XXXX

MONTH

Set current month

01 - 12

DAY

Set currrent day

01 - 31

HOLIDAY Sub-Menu

or hot water is required.

YEAR

Set current holiday start year

XXXX

MONTH START

Set current holiday start month

01 - 12

DAY START

Set current holiday start day

01 – 31

YEAR STOP

Set current holiday end year

XXXX

MONTH STOP

Set current holiday end month

01 – 12

DAY STOP

Set current holiday end day

01 - 31

CLOCK CHANGE Sub-Menu

“Daylight Savings“, etc.

MONTH START

Set clock change start month

01 -12

DAY START

Set clock change start day

01 – 31

MONTH END

Set clock change end month

01 – 12

DAY END

Set clock change end day

01 – 31

Program Key.

8.5 GENERAL Menu

The GENERAL Menu contains a DATE/TIME Sub-Menu and a SERVICE Sub-Menu.

8.5.1 DATE / TIME Sub-Menu

This Sub-Menu is used to set the time, date, holiday schedule and, where necessary, enter clock change settings (daylight savings time, etc.).

NOTE

All items in the following DATE/TIME Menu must be entered in sequence. Press the Program Key to step through the menu functions. Use the Rotary Knob to adjust/change entries. Press the Program Key to store entries and sequence to the next function.

Table 8-5: GENERAL Menu / TIME/DATE Sub-Menu and Parameters

This Sub-Menu is used to set the time, date, holiday schedule and, where necessary, enter clock change settings (daylight savings time,

This Sub-Menu sets the start and end dates for Holiday (Vacation) periods where no heat

This Sub-Menu is used in areas where seasonal time changes are required for

RETURN

PR1: 11/30/12 Page 89 of 112

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When CLOCK CHANGE reappears, press

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

FUNCTION

DESCRIPTION

REMARKS

RELAY TEST Sub-Menu

Menu is used to check the status of

relays are numbered 00 through 11 and are

required to access these relays.

00

No relay 01

A1: Pump, Heating Circuit 1

02

A2: Pump, Heating Circuit 2

03

A3: Hot Water Charging Pump

04

A4: Mixer OPEN, Heating Circuit 2

05

A5: Mixer CLOSED, Heating Circuit 2

06

A6: HS 1 ON

07

A7: HS2 ON [2-stage:HS 1+2 (after 10s) ON]

08

A8: Mixer OPEN Heating Circuit 1 / Multifunction 1

2

10

A10: Multifunction 3

11

A11: Collector Pump / Multifunction 4

SENSOR

the Controller.

F1

Buffer storage temperature Lower

room temperature heating circuit 1

F3

Upper buffer storage temperature

F5

Flow temperature, heating circuit 2

F5

Flow temperature, heating circuit 2

F6

Upper hot water temperature

F8

Heat generator /header temperature

F9

Outside temperature

8.5.2 SERVICE Sub-Menu

The SERVICE Menu contains all the test and diagnostic functions/values required for Customer Service Engineers to troubleshoot the equipment in a timely manner.

Some of the functions in this sub-menu require a valid Code No. (password) to be entered, prior to accessing/changing Function values. When prompted by a “CODE NO.” display, enter

0000 (four zeros) by pressing the Program Key four times. This will allow function access.

Table 8-6: GENERAL Menu / SERVICE Sub-Menus and Parameters

RELAY NO.

09

This Subthe relays contained in the Controlller. These

defined as shown below. CODE NO. Entry is

A9: Mixer CLOSED Heating Circuit 1 / Multifunction

SENSOR TEST Sub-Menu

F2

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This Sub-Menu is used to check and display the temperature readings of the sensors connected to

Buffer storage temperature middle or

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

FUNCTION

DESCRIPTION

REMARKS

SENSOR TEST Sub-Menu

or temperature multifunction 1

multifunction 2

or temperature multifunction 3

temperature multifunction 4

0-10V I

voltage value 0-10V input

OTHER ENTRIES (General -> Service level)

Controller

these sub-menu functions.

(1-8)

START (1-8)

Start with Program Key (hold down)!

RESET USER 00

DO NOT USE

00

RESET T-PRG 00

DO NOT USE

RETURN

Exit level using Program Key

Table 8-6: GENERAL Menu / SERVICE Sub-Menus and Parameters (Continued)

F11

F12

F13

F14

F15;

Light;

Flow temperature heating circuit 1

Hot water temperature lower or temperature

Solid fuel boiler temperature or collector 2

Collector 1 temperature or

Room temperature heating circuit 2 or measured value of the light sensor or

Additional items and functions in the SERVICE Sub-Menu include the following:

SW NO XXXXX

CASCADE MANU (1-8)

Specifies the Software Version and Index number currently installed in the

Starting different burner stages of the cascade.

See GF-115-H, Section 6, Paragraph 6.5 for additional startup instructions using

BURNER TIME

BURNER

LIMITER TEST (1-8)

Program Key - Burner time for all stages

Program Key - Burner start for all stages

Safety temperature limiter test with heat generator temperature display

SERVICE (only with code

no.)

WARNING: NEVER ATTEMPT TO USE THE FOLLOWING RESET

RESET EXPERT

PR1: 11/30/12 Page 91 of 112

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Input of date or operating hours for service messages

FUNCTIONS:

DO NOT USE

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

(This page left intentionally blank)

PR1: 11/30/12 Page 92 of 112

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GF-115-C

OMM-0084_0D

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9. BCM MODBUS AND ADDRESS ASSIGNMENTS

9.1 BCM Modbus Communication & Support Requirements

The Modbus communication support requirements incorporated in the BCM are as follows:

9.1.1 Function Codes

The BCM supports the Modbus Function Codes SHOWN IN Table 9-1.

Table 9-1: Supported Modbus Function Codes

FUNCTION CODE DESCRIPTION

03 Read up to 8 contiguous Holding Registers

04 Read up to 8 contiguous Address Registers

06 Write a single 16 bit Register

9.1.2 Modbus Support Requirements

The Modbus Network must conform to the support requirements listed in Table 9-2.

Table 9-2: Modbus Support Requirements

CHARACTERISTIC DESCRIPTION

Communication Medium

BMS II/ACS or EMS Master to BCM Slave

RS485 Allowable Cable Length 4000 Feet Maximum

Address Support From Master EMS

Transmission Mode Support RTU (Remote Terminal Unit)

Timing Specifications:

Baud Rate:

Data Framing:

Message Framing:

Character Framing:

RS485 2-Wire Differential Bus With Shield

1 to 9 via Address Select Switch (SW1). (Addresses from 10 to 127 can be implemented via

software)

Fixed at 9600

8 data bits, no parity, 1 stop bit

Silent period of at least 3.5 character times Before first character and After last character

No more than 1.5 character times of silence between received and transmitted characters.

Heartbeat Timeout:

Adjustable (0 or 1 – 240 seconds)

PR1: 02/23/12 Page 93 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus

Address

Menu Item

Units and Range

enum (2,8,10,18,23,32,42,38)

2 =

Standby

8 =

High temperature switch open

10 =

Low gas pressure switch open

18 =

Air flow switch open during ignition

23 =

Flame loss during run

32 =

Residual flame

42 =

Outlet temperature sensor fault

38 =

Other conditions not listed above

enum (1, 3, 5)

1 =

Standby (ready to run but not fired)

3 =

Remote (fired)

5 =

Fault (failure detected)

9.2 BCM Controller Standard Holding Register Assignments

9.2.1 BCM Controller Standard Input Register Assignments

The BCM Controller has only two Read Only Input Register addresses as shown in Table 9-3.

Table 9-3: BCM Controller Standard Input Register Address Mapping

Data

0

Status & Error Code

1

Unit Status

9.2.2 BCM Controller Standard Holding Register Assignments

The BCM Controller Holding Registers contain functions that are Read Only, Write Only or both Read & Write. The address assignments for these functions are listed in Table 9-4 and are grouped into the following major categories: Control Registers, Operating Data Registers, System Data Settings and Test Registers. Functions within each group are not necessarily in hex address order.

The Read Only, Write Only or Read/Write status for each function in Table 9-4 is shown in the Default/Comments column.

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GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus Data

Address

CONTROL REGISTERS

(Read/Write)

Level (address 0x03F9)

Maximum Modulation Level

% (0 to 100)

(Value x 2)

(Read/Write) 100° (50%)

32°F – 212°F (0°C – 100°C)

(Value x 10)

(Read/Write) 180°F

(Read/Write)

identification procedure

enum

0x01:

No action

0x33:

Space Heating mode enabled

0x44:

Space Heating & DHW modes enabled

0x55:

DHW mode enabled

0xBB:

Space Heating requested & DHW enabled

0xCC:

Check request

0xEE:

Space Heating request

Standby is selected.

Requested DHW Setpoint

32°F – 212°F (0°C – 100°C) (Value x 10)

enum (0, 1, 2)

2 = Switch ON

1030

Error/Reset

enum (0x5A)

(Read/Write)

Table 9-4: BCM Standard Holding Register Address Mapping

Menu Item Units and Range Default/(Comments)

AERCO BMS

1

1017

1004 Requested Setpoint

1001 System Command enum (0xAA)

1021

II/ACS Requested Modulation Level

Heat Request Command

% (0 to 100)

(0x01, 0x33, 0x44, 0x55, 0xBB, 0xCC, 0xEE)

A value other than 0 requests Run mode and supersedes the value set for Max Modulation

0xAA: Restart Slave

(Read/Write)

0x01

PR1: 11/30/12 Page 95 of 112

If enum is none of the above,

1022

1023 Pump Control

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0 = No action 1 = Switch OFF

(Read/Write)

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus Data

Address

CONTROL REGISTERS (Continued)

Flags

Bit 7: BMM #7

(Read/Write)

Check

Mode start

OPERATING DATA REGISTERS

0 – 0xFFFF

LSB:

Error Code

MSB:

Identification code

255: BCM

enum (0, 1, 2, 4)

0:

Stop

1:

Slave identification procedure

2:

Normal operation

4:

Monitor mode

14°F to 212°F

(Value x 10)

32°F to 212°F (0°C to

(Value x 10)

-31°F/-22°F to 86°F

(Value x 10)

(Read Only)

connected

Global Actual

Modulation Level

0 – 100%

(Read Only)

32°F to 212°F (0°C to

boiler heats up

32°F to 212°F (0°C to 100°C) (Value x 10)

(Read Only)

DHW Maximum

Setpoint

32°F to 212°F (0°C to 100°C) (Value x 10)

(Read Only)

Table 9-4: BCM Standard Holding Register Address Mapping (Continued)

Menu Item Units and Range Default/(Comments)

1041

Check Mode, Inserted burner control

0 Error Code

1000

1002

Cascade Control

Status

Flow Sensor

Temperature

(0 – 0xFF) Bit 0: BMM #0 to

of fault device: 0: BMM #0 to 7: BMM #7

(-10°C to 100°C)

Bit 0 (BMM #0) is automatically set at

(Read Only)

1003

1005

1008

1016

1018 Target Setpoint

1019

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Return Flow

Temperature

External Sensor

Temperature

Actual Target

Setpoint

100°C)

(-35°C/-30°C to 30°C)

100°C) (Value x 10) Should increase up to “Target Setpoint” temp as

(Read Only)

-31°F (-35°C) if not

(Read Only)

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus

Address

OPERATING DATA REGISTERS (Continued)

enum (0, 1, 2, 3, 6)

6: Test

Flags (0 -255)

Bit 7: BMM #7

Flags (0 -255)

Bit 7: BMM #7

Flags (0 -255)

Bit 7: BMM #7

Flags (0 – 255)

Bit 7: BMM #7

Flags (0 – 255)

Bit 7: BMM #7

0 – 100% (Value x 10)

0 – 10V

(Read Only)

0 – 100%

(Read Only) Global modulation level

from Cascade Manager

BMM #n Error Code

(n = 0 – 7)

0 – 0xFFFF

BMM #n Outlet Temperature

(n = 0 – 7)

14°F to 212°F (-10°C to 100°C) (Value x 10)

BMM #n Actual Modulation

Level (n = 0 – 7)

0 – 100%

Table 9-4: BCM Standard Holding Register Address Mapping (Continued)

Data

1020 Operating Mode

1100 Linked BMM

1101 Inserted BMM

1102 BMM in Check Mode

Menu Item Units and Range Default/(Comments)

0: Standby 1: Space Heating 2: DHW 3: Check

Bit 0: BMM #0 to

(Read Only)

1103 BMM Flame Status

1104 BMM Alarm Status

1108

1109 Pump Modulation Output

1200 Monitor Only

2n00

2n02

2n08

PR1: 11/30/12 Page 97 of 112

BMM Maximum Modulation Level

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Bit 0: BMM #0 to

(Read Only)

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus

Address

OPERATING DATA REGISTERS (Continued)

BMM #0 Capacity (n = 0 – 7)

0 – 255 kW

(Read Only)

Flag (0, 1)

1: Space Heating and DHW

Flags (0-255)

Bit 7: Alarm

SYSTEM DATA

0x3400 – 0x34FF

Low byte: Firmware Revision

0 – FFFF kW

(Read Only)

Boiler Mode = AERCO BMS II/ACS

2

(Read Only)

3

(Read Only)

SETTINGS

19

Modbus Address

1 - 127

(Read/Write)

9°F to 36°F (5°C to 20°C) (Value x 10)

(Read/Write)

9°F

3001

Minimum Inserted Burner

1 - 8

(Read/Write) 1

2°F to 54°F/minute (1°C to 30°C/minute)

Temp. Control: Proportional Band

0°F to 90°F (0°C to 50°C)

3004

Temp. Control: Integral Gain

0 - 50

(Read/Write) 12

Temp. Control: Derivative Gain

0 - 50

3006

Pump Over-run Time

1 – 10 minutes

(Read/Write) 5 min.

Table 9-4: BCM Standard Holding Register Address Mapping (Continued)

Data

2n10

2n11

2n20

1550

1011 Boiler Global Capacity

BMM #n Configuration (n = 0 – 7)

BMM #n Operating Flags (n = 0 – 7)

Firmware Code & Firmware Revision

Menu Item Units and Range

0: Space Heating Only

Bit 3: Flame detected Bit 4: Check mode Bit 6: Pump status

High byte: Firmware Code

Default/(Comm

ents)

(Read Only)

12

13 Remote Signal = Network

3000 Burner OFF Hysteresis

3002 Temp. Control: Slope Limit

3003

3005

(Read/Write) 9°F

(Read/Write) 45°F

(Read/Write) 12

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GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus Data

Address

SETTINGS (Continued)

Pump Modulation

Level

Pump Modulation

Level

Burner Minimum Modulation Level

(Read/Write)

35%

Water Δ Temp.

Protection

0°F/2°F – 90°F

(0°C/1°C-50°C)

(Read/Write)

36°F

0/10 – 240 sec. (in 10 sec.

0 = Disable

Temperature Limits

Analog Input Function

0/1; 0 = Setpoint Adjust,

1 = Outdoor Temp Sensor

(Read/Write)

0

3014

(Not Used)

Maximum Target Temperature

113°F to 185°F

(45°C to 85°C

(Read/Write)

180°F

TEST REGISTERS

(Write Only)

only in Test mode.

Table 9-4: BCM Standard Holding Register Address Mapping (Continued)

Menu Item Units and Range Default/Comments

3007

3008

3009

3010

3011

3012

3013

Output @ Minimum Burner

Output @ Maximum Burner

Communication Timeout Time

0 – 10V

(Value x 10)

0 – 10V

(Value x 10)

0 – 100%

intervals)

0/1; 0 =°C, 1 = °F 1 = °F

(Read/Write)

3V

(Read/Write)

10V

(Read/Write)

30 sec.

3015

1040 Test Mode Control

PR1: 11/30/12 Page 99 of 112

enum (0xA5/0x5A)

0xA5: Test mode release 0x5A: Test mode request

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This command is only executed in Standby mode. The other Write messages are executed

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Modbus Data

Address

TEST REGISTER (Continued)

Flags (0 - 0x1F80)

bit 0:

eBUS RX

bit 1:

eBUS-1 RX

bit 2:

eBUS -1 detect (true, false)

bit 7:

Room Stat (open, close)

bit 8:

0, not used

bit 9:

RESET by Low Voltage Detector

bit 10:

RESET by clock monitor

bit 11:

RESET by Watchdog timer

bit 12:

RESET (open, close)

bit 13:

SW1-1

bit 14:

SW1-2

bit 15:

SW1-4

Flags (0 - 0x0F)

bit 0:

Burner [OFF, ON]

bit 1:

Pump [OFF, ON]

bit 2:

Not used

Bit 3;

Alarm [OFF, ON]

bit 4:

DL1 [OFF, ON]

bit 5:

eBUS TX

bit 6:

eBUS-1 TX

bit 7:

eBUS Supply [OFF, ON]

Flags (0 - 0x0F)

bit 0:

Not used

bit 1:

Pump [OFF, ON]

bit 2:

MPump-PWM [100%, 0%]

bit 3;

Alarm [OFF, ON]

bit 4:

DL1 [OFF, ON]

bit 5:

eBUS TX

bit 6:

eBUS-1 TX

bit 7:

eBUS Supply [OFF, ON]

Table 9-4: BCM Standard Holding Register Address Mapping (Continued)

Menu Item Units and Range Default/(Comments)

3100

3101

Digital Inputs Status [0, 1]

Digital Outputs Status [0, 1]

(Read Only)

3102

PR1: 11/30/12 Page 100 of 112

AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 • Ph: 800-526- 0288

Digital Output Control in Test Mode [0, 1]

(Read/Write)

AERCO Modulex E8 Controls Guide

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

1. INTRODUCTION

1.1 Safety and Warnings

2. E8 CONTROLLER AND BCM DESCRIPTION

2.1 E8 Controller Features And Functions

2.2 BCM Features And Functions

3. E8 CONTROLLER OPERATION

3.1 NORMAL Mode Operation (Door Closed)

3.1.1 NORMAL Mode Display Functions

3.1.2 HEATING Mode Selection (in NORMAL Mode)

3.1.3 MENU Mode Operation (Door Open)

3.2 Software Menus

3.2.1 Basic Menu/Sub-Menu Navigation and Selection

3.2.2 Basic Parameter Navigation, Selection, and Revision

4. E8 CONTROLLER MENUS AND SUB-MENUS

4.1 DISPLAY Menu

4.2 USER Menu

4.3 TIME PROGRAM Menu and Sun-Menus

4.4 EXPERT Menu and Sub-Menus

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

4.5 EXPERT HS Menu (Not Used)

4.6 GENERAL Menu

4.6.1 DATE / TIME Menu

4.6.2 SERVICE Menu

4.7 E8 Controller Initial Startup

4.7.1 CAP/MODULE Function (Maximum Kilowatts per Burner)

4.7.1 Available Settings for Relay Functions 1 – 4

5. E8 OPERATING MODE: Set-up and Programming

5.1 Indoor/Outdoor Reset Mode

5.1.1 Wiring Connections

5.1.2 Indoor/Outdoor Reset Operation Configuration

5.1.3 Viewing the Boiler Setpoint

5.2 Constant Set Point Mode

5.2.1 Wiring Connections

5.2.2 Constant Setpoint Mode Configuration

5.2.3 Viewing Constant Set Point

5.2.4.1 Configuring HEATSLOPE Parameter

5.2.4.2 Configuring MAX T-FLOW and MIN T-FLOW Parameters

Continue scrolling through the HTG CIRCUIT 1 sub-menu until RETURN is displayed. Press the Program Key to exit the HTG CIRCUIT 1 sub-menu.

5.2.4.3 Configuring MAX T-COL Parameter

5.3 0 to 10 Volt Remote Set Point Mode

5.3.1 Remote Signal Source Wiring Connections

5.3.2 Configuring Remote Signal Source

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

5.3.4 Setting the Curve 11-UO Voltage

5.3.5 Viewing the Set Point

5.4 Domestic Hot Water Operation Using A Tank Sensor

5.4.1 Sensor Wiring Connections

5.4.2 Configuring the Controller for DHW With a Tank Sensor

5.4.3 Setting the DHW Set Point

5.4.4 Displaying Temperatures Associated With DHW

5.4.4.1 Viewing DHW Set Point and Actual DHW Temperature

5.4.4.2 Viewing DHW Set Point With T-BOILER DHW Function

5.5 DHW Operation Using an Aquastat

5.5.1 Sensor Wiring Connections

5.5.2 Configuring the Controller for DHW With an Aquastat

5.5.3 Setting the DHW Set Point

5.5.4 Displaying Temperatures Associated With DHW

5.6 Boiler & Pump Enable/Disable

6. CONNECTION DIAGRAMS

6.1 Power Terminal Assignments

6.2 Sensor Terminal Assignments

6.2 Sensor Terminal Assignments (Continued)

7. BOILER COMMUNICATIONS MODULE (BCM)

7.1 Boiler Communications Module (BCM) Description

7.2 BCM Fault Relay

7.2.1 BCM Fault Relay Wiring

7.2.2 Clearing Faults

7.3 BCM Configured as Back-Up Controller

7.3.1 BCM Back-Up Controller Wiring

7.4 BCM Configured as Primary Controller Utilizing Modbus

7.4.1 Operating Scenario

7.4.2 Physical Modbus RS485 Wiring

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

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

7.4.5 EMS or BAS Master to BCM Slave Wiring Connections