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Modulex E8
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AERCO Modulex E8 Maintenance Manual

E8 Controller and BCM for Modulex EXT
E8 Controller
For Modulex EXT Boilers
USER MANUAL
E8 Controller
• EXT 321
Installation, Operation & Maintenance Manual
Applies to Modulex EXT Natural Gas Modulating & Condensing Hot Water Boilers, including Models:
• EXT 481
• EXT 641
• EXT 802
• EXT 962
• EXT 1123
• EXT 1530
• EXT 1912
• EXT 2295
• EXT 2677
• EXT 3060
GF-136-C
Installation, Operation and Maintenance
Latest Update: 06/24/2013
OMM-0093_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 1 of 108 GF-136-C Ph.: 800-526-0288 PRI: 06/24/2013
Boiler Communications Module (BCM)
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
Technical Support
(Mon-Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com
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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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
GF-136-C
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION ................................................................................................................ 7
CHAPTER 2: E8 CONTROLLER AND BCM DESCRIPTION .................................................................. 9
2.1 E8 Controller Features and Functions................................................................................................. 9
2.2 BCM Features and Functions ............................................................................................................ 10
CHAPTER 3: E8 CONTROLLER OPERATION ..................................................................................... 11
3.1 NORMAL Mode Operation (Door Closed) ......................................................................................... 11
3.1.1 NORMAL Mode Display Functions ............................................................................................. 11
3.1.2 HEATING Mode Selection (in NORMAL Mode) ......................................................................... 12
3.1.3 MENU Mode Operation (Door Open) ......................................................................................... 13
3.2 Software Menus ................................................................................................................................. 14
3.2.1 Basic Menu/Sub-Menu Navigation and Selection ...................................................................... 15
3.2.2 Basic Parameter Navigation, Selection, and Revision ............................................................... 16
CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE .......................................................... 17
4.1 Initializing the E8 in the Installation Menu ......................................................................................... 17
4.2 QUICK START INSTRUCTIONS ...................................................................................................... 20
4.2.1 Setting Maximum and Minimum Flow Temperature ................................................................... 20
4.2.2 Setting Room Temperature and Outdoor Compensation ........................................................... 21
4.2.3 Setting Heating Programs and Pumps ....................................................................................... 22
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS .............................................................. 23
5.1 DISPLAY Menu ................................................................................................................................. 24
5.2 USER Menu ....................................................................................................................................... 28
5.3 TIME PROGRAM Menu and Sun-Menus .......................................................................................... 32
5.4 EXPERT Menu and Sub-Menus ........................................................................................................ 37
5.4.1 Available V-Curve Preset Voltage Curves for 0 – 10 Volt Input ................................................. 45
5.5 EXPERT HS Menu ............................................................................................................................ 46
5.6 GENERAL Menu ............................................................................................................................... 46
5.6.1 DATE / TIME Menu ..................................................................................................................... 46
5.6.2 SERVICE Menu .......................................................................................................................... 49
5.7 Installation Menu & E8 Controller Initial Startup ................................................................................ 53
5.7.1 CAP/MODULE Function (Maximum Kilowatts per Burner) ........................................................ 54
5.7.2 Available Settings for Relay Functions 1 – 4 .............................................................................. 55
CHAPTER 6: E8 SETUP AND PROGRAMMING .................................................................................. 57
6.1 Indoor/Outdoor Reset Mode .............................................................................................................. 57
6.1.1 Wiring Connections ..................................................................................................................... 57
6.1.2 Indoor/Outdoor Reset Operation Configuration .......................................................................... 57
6.1.3 Viewing the Boiler Setpoint ......................................................................................................... 59
6.2 Constant Set Point Mode................................................................................................................... 59
6.2.1 Wiring Connections ..................................................................................................................... 60
6.2.2 Constant Setpoint Mode Configuration ....................................................................................... 60
6.2.3 Viewing Constant Set Point ........................................................................................................ 60
6.2.4 Configuring Set Point High and Low Limits Per Outside Temperature Sensor .......................... 60
6.2.4.1 Configuring HEATSLOPE Parameter ............................................................................. 61
6.2.4.2 Configuring MAX T-FLOW and MIN T-FLOW Parameters ............................................. 62
6.2.4.3 Configuring MAX T-COLL Parameter ............................................................................. 63
6.3 0 to 10 Volt Remote Set Point Mode ................................................................................................. 63
6.3.1 Remote Signal Source Wiring Connections ............................................................................... 63
6.3.2 Configuring Remote Signal Source ............................................................................................ 64
6.3.3 Setting the Voltage and Set Point Limits for U1/U2 and T1/T2 .................................................. 65
6.3.4 Setting the Curve 11-UO Voltage ............................................................................................... 66
6.3.5 Viewing the Set Point .................................................................................................................. 67
6.4 Domestic Hot Water Operation Using A Tank Sensor ...................................................................... 67
6.4.1 Sensor Wiring Connections ........................................................................................................ 67
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
6.4.2 Configuring the Controller for DHW With a Tank Sensor ........................................................... 68
6.4.3 Setting the DHW Set Point ......................................................................................................... 69
6.4.4 Displaying Temperatures Associated With DHW ....................................................................... 70
6.4.4.1 Viewing DHW Set Point and Actual DHW Temperature ..................................70
6.4.4.2 Viewing DHW Set Point With T-BOILER DHW Function .................................70
6.5 DHW Operation Using an Aquastat ................................................................................................... 71
6.5.1 Sensor Wiring Connections ........................................................................................................ 71
6.5.2 Configuring the Controller for DHW With an Aquastat ............................................................... 71
6.5.3 Setting the DHW Set Point ......................................................................................................... 71
6.5.4 Displaying Temperatures Associated With DHW ....................................................................... 71
6.6 Boiler & Pump Enable/Disable .......................................................................................................... 71
CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS .............................................................. 73
7.1 SENSOR Terminal Assignments ...................................................................................................... 73
7.1.1 Connector 7 ................................................................................................................................ 74
7.1.2 Connector 1 ................................................................................................................................ 74
7.1.3 Connector 5 ................................................................................................................................ 74
7.1.4 Connector 8 => PT 1000 Sensor ................................................................................................ 74
7.1.5 Connector 3 ................................................................................................................................ 74
7.1.6 Connector 9 ................................................................................................................................ 74
7.2 MAINS Power Terminal Assignments ............................................................................................... 75
7.2.1 Connector 2 ............................................................................................................................... 75
7.2.2 Connector 6 ............................................................................................................................... 75
7.2.3 Connector 4 ............................................................................................................................... 75
CHAPTER 8: BOILER COMMUNICATIONS MODULE (BCM) ............................................................. 77
8.1 BCM Description ................................................................................................................................ 77
8.2 BCM Fault Relay ............................................................................................................................... 79
8.2.1 BCM Fault Relay Wiring ............................................................................................................. 80
8.2.2 Clearing Faults ............................................................................................................................ 80
8.3 BCM Configured as Back-Up Controller ............................................................................................ 80
8.3.1 BCM Back-Up Controller Wiring ................................................................................................. 80
8.4 BCM Configured as Primary Controller Utilizing Modbus ................................................................. 82
8.4.1 Operating Scenario ..................................................................................................................... 82
8.4.2 Physical Modbus RS485 Wiring ................................................................................................. 83
8.4.3 Disconnecting the E8 from the E-Bus on the BCM Board .......................................................... 83
8.4.4 AERCO BMS II/ACS Master to BCM Slave Wiring Connections. .............................................. 84
8.4.5 EMS or BAS Master to BCM Slave Wiring Connections ............................................................ 84
8.5 BCM Control of VFD Primary Pump .................................................................................................. 84
8.5.1 Pump Control Wiring ................................................................................................................... 84
8.5.2 Pump Control Operation ............................................................................................................. 84
8.6 RS485 Loop Termination Resistors and Bias ................................................................................... 84
8.6.1 Master BMS II/ACS or EMS/BAS Terminating Resistor and Bias .............................................. 85
8.6.2 BCM Controller Terminating Resistor and Bias .......................................................................... 85
8.7 Modbus Network Wiring Diagram ...................................................................................................... 86
8.8 Modbus Software Set-Up .................................................................................................................. 88
8.8.1 BCM Set-Up For Modbus Operation .......................................................................................... 88
8.8.2 Monitoring and Configuration Only ............................................................................................. 88
8.8.3 AERCO BMS II/ACS Modbus Control and Monitoring ............................................................... 89
8.8.4 Modbus Remote Setpoint Control and Monitoring...................................................................... 89
8.8.5 EMS or BAS Set-Up As Master to BCM Controller Slaves......................................................... 89
8.9 Multiple Modulex Boiler Heating Mode – Using A BMS II or ACS .................................................... 89
8.9.1 Sequence of Operation (Example: Four-Modulex boiler installation) ......................................... 89
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS.......................................................... 91
9.1 BCM Modbus Comm. & Support Requirements ............................................................................... 91
9.1.1 Function Codes ........................................................................................................................... 91
9.1.2 Modbus Support Requirements .................................................................................................. 91
9.2 BCM Controller Standard Holding Register Assignments ................................................................. 92
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
GF-136-C
9.2.1 BCM Controller Standard Input Register Assignments .............................................................. 92
9.2.2 BCM Controller Standard Holding Register Assignments .......................................................... 92
CHAPTER 10: E8, BCM, AND BMM FAULT CODES ........................................................................... 99
10.1 Processing and Clearing Fault Codes ........................................................................................... 100
10.2 Fault Codes and Descriptions ....................................................................................................... 100
10.2.1 E8 Controller Fault Code Table .............................................................................................. 101
10.2.2 BCM and BMM Fault Code Conversion Table ....................................................................... 103
10.2.3 BCM Fault Code Table ........................................................................................................... 104
10.2.4 BMM Fault Code Table ........................................................................................................... 105
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
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E8 Controller and BCM for Modulex EXT
CAUTION
!
!
Installation, Operation & Maintenance Manual

CHAPTER 1: INTRODUCTION

CHAPTER 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.
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.
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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E8 Controller and BCM for Modulex EXT Installation, Operation &
Maintenance Manual
CHAPTER 1: INTRODUCTION
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E8 Controller and BCM for Modulex EXT
Rotary Knob
LCD Display
Hinged Cover
Installation, Operation & Maintenance Manual

CHAPTER 2: E8 CONTROLLER AND BCM DESCRIPTION

CHAPTER 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 the 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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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 2: E8 CONTROLLER AND BCM DESCRIPTION

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 the 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, pre-assembled thermal modules housed in a common enclosure. Each module has its own dedicated controller with a combustion safeguard, variable-speed 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 Chapter 7, 9, and 10.
Figure 2-2: BCM (Boiler Control Module)
NOTE
Before operating any menus and functions in the E8, one MUST perform a one-time entry of items into the initial INSTALLATION menu. See Section 4.1 for more information about initial setup and configuration of the E8 Controller.
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E8 Controller and BCM for Modulex EXT
display symbols apply to all internal heating
circuits for which a separate heating mode has been selected. Note that each
A B C D E I H
G
F
Installation, Operation & Maintenance Manual

CHAPTER 3: E8 CONTROLLER OPERATION

CHAPTER 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 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 Display (NORMAL Mode)
ITEM FUNCTIONS
A
B
C
D
E
Current time (24 hour format)
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 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 => check eBUS via DISPLAY level)
Status display: Shows symbols for Internal Burner 1 Relay ON; Heating Mode; Hot Water Preparation.
Heating Mode display symbol. The
F
symbol occupies a different space across the display bottom. See Figure 3-2.
G
H
Display of current temperature of HS 1 or header temperature when cascading.
Display of number of active burners (only applies when cascading).
Selectable display and Error Codes ("DISPLAY SEL" parameter in USER menu).
I
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E8 Controller and BCM for Modulex EXT
Turn the Rotary Knob to select the heating mode
symbol at the bottom of the display. It takes effect when the setting is not changed for 5 seconds.
HEATING Mode
Installation, Operation & Maintenance Manual
CHAPTER 3: E8 CONTROLLER OPERATION

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.
Figure 3-2: E8 Display (HEATING Modes)
Symbols: Only the
currently selected mode will be displayed.
SYMBOL MODE NAME DESCRIPTION
Heating Mode
Selection
Standby / OFF
Automatic
Mode 1
Automatic
Mode 2
Summer
Mode
Day
Mode
required. The heating mode is indicated by a
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.
Night
Mode
Service
Mode
24 Hour heating with reduced temperature; HW according to program.
Automatic reset after 15 minutes. Boiler regulated at max boiler temperature.
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E8 Controller and BCM for Modulex EXT
Insert narrow screwdriver deep into holes and lift up
When lit, this LED indicates that the value shown in the display can be
are switched on. Pumps for Heating Circuit 2 (HC2) and Domestic Hot Water (DHW)
CIRCUIT 1 menu). The first burner stage will cut off when the boiler temperature
d to navigate through menus and parameters or adjust
A
B C D
E
G
F
Installation, Operation & Maintenance Manual
CHAPTER 3: E8 CONTROLLER OPERATION

3.1.3 MENU Mode Operation (Door Open)

Opening the E8 controller hinged door reveals the E8 controls (below) and initiates MENU Mode, which enables access to an extensive set of software menus.
E8 FRONT PANEL: Controls and Indicators
INSTALLATION
Figure 3-3: E8 Display Controls and Indicators
ITEM FUNCTION
A
B
C
D
E
LCD display: Selected Menu/Sub-menus, parameter names/values, and selected busses are indicated in the LCD display when in MENU Mode.
Mounting Key Access Holes: controller to remove.
Change LED: changed using the Rotary Knob (G).
Optical Adaptor: For PC connection
Program Key: Used to select a sub-menu level, select a parameter value to change, or save a new parameter value.
Manual/Automatic Switch: A 2-position (10/2 o’clock) screwdriver adjustable switch.
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
F
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 T-FLOW (in EXPERT/HEAT
reaches the value set for MAX T-MODUL (in EXPERT/INSTALLATION menu).
G
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Rotary Knob: Use parameters.
E8 Controller and BCM for Modulex EXT
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
Installation, Operation & Maintenance Manual
CHAPTER 3: E8 CONTROLLER OPERATION

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
Before operating any menus and functions in the E8, one MUST perform a one-time entry of items into the initial INSTALLATION menu. See Section 4.1, E8 Controller Initial Startup for more information about initial setup and configuration of the E8 Controller.
Note 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.
Table 3-1: Main Menus and Sub-Menus
MAIN MENUS SUB-MENUS
DISPLAY
USER
TIME PROGRAMS
EXPERT
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EXPERT HS
GENERAL
INSTALLATION
Points down to Points right to
Points left to
Selected Bus(es)
Points down to
Sub-MENU
MENU
Sub-MENU Name
Selected
MENU Name
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 3: E8 CONTROLLER OPERATION
Selected Buss(es)
Selected Sub-MENU Name
Names
Names
Figure 3-4: E8 Display in MENU Mode

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, Section 4.1), 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 Section 4.1 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, and GENERAL.
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E8 Controller and BCM for Modulex EXT
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 the Rotary Knob to sequence through the available parameters.
To change a parameter value, press the Program Key To change the displayed parameter value, turn the
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
displayed
value
Displayed
Example: User Menu & Hot Water Sub-menu
parameters
Cycle thru
cycle thru
push!
push!
push!
Display Detail
DESCRIPTION
EXAMPLES
Displayed
Sub-menu
Installation, Operation & Maintenance Manual
CHAPTER 3: E8 CONTROLLER OPERATION

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 3-4).
HOT
WATER
HOT-WATER
accessed
when the desired parameter is displayed. The Change LED will light up indicating the displayed parameter may now be changed.
Rotary 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
T-DHW
140.0
accessed
141.0
142.0
Value Saved!
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual

CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE

CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE

4.1 Initializing the E8 in the Installation Menu

When power is first applied to the boiler and then the E8 controller cover is opened, the
INSTALLATION
These values MUST be entered in order to initialize the boiler for operation. Once the
LANGUAGE, TIME
controller is initiated and operatable and may be configured for your boiler installation. To re­enter the
To initialize the E8 Controller, follow the instructions below and refer to Figure 4-1 and Table 4-1 on the following pages:
1. Set the POWER rocker switch, located to the left of the Controller, to the ON (I) position.
2. Open the panel cover on the Controller. The LCD display will read INSTALLATION. All
INSTALLATION
values in this level must be entered, in sequence, without interruption.
Menu is displayed once (only). See Figure 4-1 for a diagram of this menu.
and
values grouped here have been entered and accepted, the
DATE
menu, cycle the boiler power and open the cover again.
Initial Startup INSTALLATION Entry
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 this 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 4-1 and Table 4-1 until all required items have been entered. Use the Program Key and Rotary Knob to select, adjust and store all entries as previously described.
NOTE
Leave the BUS – ID HS parameter blank. Remaining parameters are already set and do not require any entry.
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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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE
WARNING
Menu selections shown
are the factory default
settings.
Figure 4-1: INSTALLATION Menu
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E8 Controller and BCM for Modulex EXT
ENTRY RANGE
LANGUAGE
Set Language
ENGLISH
TIME
Set current time (min., hrs)
00:00 – 24:00
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 Section 5.7.1 for instructions.
00 – 1000 Kw
40 Kw
RELAY FUNC 1
Relay Function 1 (See Section 5.7.2)
00 – 26
00
T-MF1 SETP
Temperature – Multifunction Relay 1 Setpoint
86°F – 194°F
86°F
MF1 HYST
Multifunction Relay 1 Hysteresis
4°F – 18°F
9°F
RELAY FUNC 2
Relay Function 2 (See Section 5.7.2)
00 – 26
00
T-MF2 SETP
Temperature – Multifunction Relay 2 Setpoint
86°F – 194°F
86°F
MF2 HYST
Multifunction Relay 2 Hysteresis
4°Ra – 18°Ra
9°F
RELAY FUNC 3
Relay Function 3
00 – 26
01
T-MF3 SETP
Temperature – Multifunction Relay 3 Setpoint
86°F – 194°F
86°F
MF3 HYST
Multifunction Relay 3 Hysteresis
4°F – 18°F
9°F
RELAY FUNC 4
Relay Function 4
00 – 26
02
T-MF4 SETP
Temperature – Multifunction Relay 4 Setpoint
86°F – 194°F
86°F
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
01=1K
Installation, Operation & Maintenance Manual
CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE
Table 4-1: INSTALLATION Menu Listing
PARAMETERS DESCRIPTION
INSTALLATION Sub-Menu
YEAR
Set current year
XXXX (4
DEFAULT
5K SENSOR 5,000 Ohm Sensor
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00=5K,
00 = 5 K
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE

4.2 QUICK START INSTRUCTIONS

Below are instructions for setting the most basic settings in the E8 controller, including maximum and minimum flow temperature, room temperature settings, heat slope, and initiation of heating programs.
IMPORTANT NOTE!
Before the boiler may be used, the E8 controller MUST be first intitialized by entering language, year, month, day, and hour in the Installation Menu as described in Section 4.1.

4.2.1 Setting Maximum and Minimum Flow Temperature

Figure 4-2: E8 Quick Start, Max. & Min. Flow Temperature Settings
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE

4.2.2 Setting Room Temperature and Outdoor Compensation

Figure 4-3: E8 Quick Start, Room Temperature and Outdoor Compensation
Settings with Outdoor Temperature (Slope) Chart
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE

4.2.3 Setting Heating Programs and Pumps

Figure 4-4: E8 Quick Start, Heating and Pump Program Settings
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E8 Controller and BCM for Modulex EXT
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
Installation, Operation & Maintenance Manual

CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS

CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
This chapter provides flow-chart illustrations and tabular listings of all Menu and Sub-Menu functions. Overall menu hierarchy is shown below:
MAIN MENUS SUB-MENUS
DISPLAY
USER
TIME PROGRAMS
EXPERT
EXPERT HS
INSTALLATION
GENERAL
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 Chapter 6, titled E8 Set-Up & Programming. These commonly used functions are shown in Bold Italics in the illustrations and tables which follow.
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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
DISPLAY
E8 Controller and BCM for Modulex EXT
DISPLAY
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS

5.1 DISPLAY Menu

The DISPLAY Menu contains the INSTALLATION, HOT WATER, HEATING (HTG) CIRCUIT 1 & 2 and a SOLAR M/F Sub-Menu as shown in Figures 5-1 & 5.2, and in Table 5-1.
Figure 5-1: DISPLAY Menu Flow Chart
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E8 Controller and BCM for Modulex EXT
DISPLAY
DISPLAY
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-2: DISPLAY Menu
NOTE
Some menus are visible only if the relevant sensor is wired (e.g. HOT WATER is displayed only if the DHW storage sensor is wired).
NOTE
All DISPLAY Menu and Sub-Menu functions are READ ONLY and cannot be changed. Temperature readings shown are in °F.
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E8 Controller and BCM for Modulex EXT
A 0 to 10 volt external input
Reset and Constant Set Point modes.
T-COLLECTOR
sequence between Heat Modules.
T-RETURN 1
Not Applicable
T-BUFFER T
Not Applicable
T-BUFFER L
Not Applicable
Knob to sequence between Heat Modules.
Sub-Menu.
Based on heating prog and
USER/HOT WATER menu.
T-DHW L
Not Applicable
WATER Sub-Menu.
DISPLAY
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
FUNCTION DESCRIPTION REMARKS
INSTALLATION Sub-Menu
DISPLAY
Table 5-1: DISPLAY Menu Listing46
T-EXT DES
T-COLL DES
T-BOIL
T-SOLID FUEL Not Applicable
T-RETURN 2 Not Applicable
T-BUFFER M Not Applicable
T-STORAGE 3 Not Applicable
MODGRAD
Boiler Set Point setting in 0 to 10 volt input mode
Boiler Set Point temperature in Indoor/ Outdoor
Header Set Point temperature (cascade)
Press Program Key to display temperature and ON/OFF status of individual Heat Modules (HS) which range from 2 (EXT
321) to 8 (EXT 3060). Turn Rotary Knob to
Press Prog Key to display Modulation % for individual Heat Modules (HS). Turn Rotary
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
T-CIRCL Not Applicable
RETURN
DHW set point temperature
Press Program Key to exit the HOT
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operating mode. Actual DHW set point as set in
Only if tank sensor is installed
E8 Controller and BCM for Modulex EXT
T-ROOM DES A
Not Applicable
heating circuit.
as hot water circuit
T-DHW
Current hot water temperature
T-FLOW RATED
FLOW
Current flow temperature
N-OPT-TIME
Not Applicable
CIRCUIT 1 Sub-Menu.
T-MF1
Not Applicable
T-MF2
Not Applicable
T-MF3
Not Applicable
Currently not used
T-MF4
Not Applicable
1
T-DHW
Not Applicable
M/F Sub-Menu.
DISPLAY
DISPLAY
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-1: DISPLAY Menu Listing (Continued)
FUNCTION DESCRIPTION REMARKS
HTG CIRCUIT 1 Sub-Menu
T-ROOM Current room air temperature.
HUMIDITY Room humidity (%).
T-DHW RATED Hot water set point temperature
Current flow set point temperature
RETURN
HTG CIRCUIT 2 Sub-Menu
Functions for HTG (Heating) Circuit 2 are identical to HTG Circuit 1 Functions above.
SOLAR M/F Sub-Menu
Press Program Key to exit HTG
Only if indoor sensor is
connected
Only if humidity sensor
is installed and
parameters set for
Appears only if heating
circuit is programmed
Same as above
Not applicable
T-COLLECTOR
T-DHW L Not Applicable
RETURN
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Not Applicable
Press Program Key to exit SOLAR
Currently not used
Currently not used
Currently not used
Currently not used
Currently not used
Currently not used
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
USER
USER
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS

5.2 USER Menu

The USER Menu (Figures 5-3 & 5-4) 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 5-2.
Figure 5-3: USER Menu Flow Chart
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E8 Controller and BCM for Modulex EXT
USER
USER
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-4: USER Menu Diagram
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E8 Controller and BCM for Modulex EXT
CONTRAST
Domestic Hot Water
connected).
Sub-Menu.
1X DHW
Not Applicable
T-DHW 1
Hot Water set point
50°F - 158°F
140°F
T-DHW 2
Not Applicable
T-DHW 3
Not Applicable
BOB-VALUE
Not Applicable
DHW
Menu.
USER
USER
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-2: 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
See
DESCRIPTION
Column
ENGLISH
00
- - - -
RETURN
HOT WATER Sub-Menu
CIRCL-P-
RETURN
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Press Program Key to exit INSTALLATION
Not Applicable
Press Program Key exit HOT WATER Sub-
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