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.

PR1: 11/30/12 Page 2 of 112

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

GF-115-C

OMM-0084_0D

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.

PR1: 11/30/12 Page 7 of 112

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 8 of 112

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

GF-115-C

OMM-0084_0D

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

PR1: 02/23/12 Page 9 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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)

PR1: 11/30/12 Page 10 of 112

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

GF-115-C

OMM-0084_0D

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

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).

PR1: 02/23/12 Page 11 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

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

PR1: 11/30/12 Page 12 of 112

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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.

PR1: 11/30/12 Page 13 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

PR1: 11/30/12 Page 14 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

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.

PR1: 11/30/12 Page 15 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

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!

PR1: 11/30/12 Page 16 of 112

GF-115-C

OMM-0084_0D

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

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.

PR1: 02/23/12 Page 17 of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

DISPLAY

INSTALLATION

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

HOT WATER

T-DHW RATED T-DHW T-DHW L

RETURN

HTG CIRCUIT 2

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

SOLAR M/F

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

HTG CIRCUIT 1

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

4.1 DISPLAY Menu

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

Figure 4-1: DISPLAY Menu Flow Chart

PR1: 11/30/12 Page 18 of 112

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

PR1: 11/30/12 Page 19 of 112

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

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

PR1: 11/30/12 Page 20 of 112

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

Not Applicable

Press Program Key to exit SOLAR

Currently not used

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

USER

INSTALLATION

LANGUAGE CONTRAST DISPLAY SEL RETURN

HOT WATER

1X DHW

T-DHW 1

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

RETURN

SOLAR M/F

RETURN

HTG CIRCUIT 1

MODE

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

T-LIMIT DAY T-LIMIT N HEATSLOPE

OPTIM HEAT MAX OPT-TIME ECONO OPTI PC ENABLE

RETURN

HTG CIRCUIT 1

MODE

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

T-LIMIT DAY T-LIMIT N HEATSLOPE

OPTIM HEAT MAX OPT-TIME ECONO OPTI PC ENABLE

RETURN

4.2 USER Menu

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

Figure 4-2: USER Menu Flow Chart

PR1: 11/30/12 Page 21 of 112

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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-

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

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

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

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

PR1: 11/30/12 Page 24 of 112

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

EXPERT

INSTALLATION

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

CONTINUED ON SHEET 2

4.4 EXPERT Menu and Sub-Menus

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

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)

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

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

EXPERT

HTG CIRCUIT 1

HC FUNCTION PUMP MODE

MIXER OPEN MIXER CLOSE

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

OUT-TEMP-DEL SLOPE OFFSET B-HEAT SINK

RETURN

HOT-WATER

DHW RELIEF

PARALLEL T-BOILER DHW

HYST DHW DHW FOLLOWUP

THERM INPUT

WALL HUNG LOAD THROUGH

RETURN

HTG CIRCUIT 2

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

OUT-TEMP-DEL B-HEAT SINK RETURN

SOLAR M/F

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

F15 FUNCTION RETURN

CONTINUED FROM SHEET 1

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

PR1: 11/30/12 Page 26 of 112

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

GF-115-C

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

PR1: 11/30/12 Page 27 of 112

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

00 – 11 11

0.00V – 10.00V 1.00

GF-115-C

Modulex E8 Controller and BCM

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

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

50% - 100% 30%

10% - 60% 35%

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

ENTRY

RANGE

SEQU CHANGE

Sequence change mode

01 – 06

06

SEQ SW TIME

Time to sequence change (hours)

10 – 800

200

LOCK TIME

Not Applicable

00 min – 30 min

00

HYST BURNER2

Not Applicable

–

T-HS COOL

Not Applicable

Identification of Boiler Type being used:

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

Heat Source

HEATSOURCE 2

Not Applicable

N/A–

N/A

STORAGE HS2

Not Applicable

N/A–

N/A

BUFFER

Not Applicable

N/A

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

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

00, 01, 02

32°F – 194°F 97°F

00 min. – 30

00, 01

01

00 min.

00

GF-115-C

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

PR1: 11/30/12 Page 30 of 112

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

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