Page 1
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
(and BCM)
Installation, Operation and Maintenance
Latest Update: 06/24/2013
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Boiler Communications Module (BCM)
Page 2
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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Page 3
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
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.
Page 14
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
Page 15
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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Page 17
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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Page 19
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
Page 20
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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Page 21
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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Page 22
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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Page 23
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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Page 24
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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Page 25
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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Page 26
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
Page 27
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
Page 28
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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Page 29
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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Page 30
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-
Page 31
E8 Controller and BCM for Modulex EXT
Night
T-ROOM DES 1
Not Applicable
T-ROOM DES 2
Not Applicable
T-ROOM DES 3
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
MAX OPT-TIME
Not Applicable
ECONO OPTI
Not Applicable
PC-ENABLE
Not Applicable
CIRCUIT 1 (or 2) sub-menu.
display to the TIME PROGRAM Menu.
USER USER
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-2: 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-LIMIT DAY Applies during day-time heating periods
T-LIMIT N
HEATSLOPE
RETURN
HTG CIRCUIT 2 Sub-Menu
Functions for HTG Circuit 2 are identical to HTG Circuit 1 Functions listed above.
SOLAR M / F Sub-Menu (No Functions Currently In This Sub-Menu)
RETURN
Applies during reduced night-time
Indicate number of degrees that the flow
temperature changes if the outside
temperature increases or decreases by
Press Program Key to exit HTG
Pressing the Program Key with SOLAR
M/F displayed will change display to
RETURN. Press Program Key again to
redisplay SOLAR M/F. Turning the
Rotary Knob clockwise will advance thd
- - - -,
- - - -,
0.00 – 3.00 1.20
66.0°F
50.0°F
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Page 32
5.3 TIME PROGRAM Menu and Sun-Menus
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
TIME
TIME
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 Figures 5-5 & 5-6.
Refer to Chapter 9 for additional information on these Menu and Sub-Menu functions.
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-5: TIME PROGRAM Menu Flow Chart
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Page 33
E8 Controller and BCM for Modulex EXT
TIME
TIME
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-6: TIME PROGRAM Menu Diagram
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Page 34
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.
See prev.
WEDNESDAY
Same as previous for Wednesday
See prev.
See prev.
THURSDAY
Same as previous for Thursday
See prev.
See prev.
FRIDAY
Same as previous for Friday
See prev.
See prev.
SATURDAY
Same as previous for Saturday
See prev.
See prev.
SUNDAY
Same as previous for Sunday
See prev.
See prev.
MO – FRI
Same as above for Monday – Friday
See prev.
See prev.
OFF: 22:00h
OFF: 22:00h
RETURN
Press Program Key to exit CIRCL sub-menu
Sub-Menu.
TIME TIME
Table 5-3: TIME PROGRAM Menu Sub-Menus and Parameters
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
E8 Controller and BCM for Modulex EXT
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.
HOTW – PROG Sub-Menu
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
ON: 6:00h
ON: 6:00h
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Page 35
E8 Controller and BCM for Modulex EXT
ENTRY
RANGE
display to the next function.
TUESDAY
Same as previous except for Tuesday.
See prev.
See prev.
WEDNESDAY
Same as previous for Wednesday
See prev.
See prev.
THURSDAY
Same as previous for Thursday
See prev.
See prev.
FRIDAY
Same as previous for Friday
See prev.
See prev.
SATURDAY
Same as previous for Saturday
See prev.
See prev.
SUNDAY
Same as previous for Sunday
See prev.
See prev.
MO – FRI
Same as above for Monday – Friday
See prev.
See prev.
22:00h
22:00h
PROG sub-menu.
TIME
TIME
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-3: TIME PROGRAM Menu Sub-Menus and Parameters (Continued)
FUNCTION DESCRIPTION
View or change the pump ON – OFF
times for Monday.
Press the Program Key to view current
settings.
MONDAY
SA – SU
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
Same as previous for Saturday and
Sunday
All ON and OFF
times can be set
in 15 minute
increments from
00:00 – 24:00
See prev.
DEFAULT
ON: 5:00h
OFF:
21:00h
ON: 6:00h
OFF:
MO – SU Same as previous for Monday – Sunday See prev.
RETURN
HTG – PROG 1 Sub-Menu
Press Program Key to exit HOTW –
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 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
ON: 6:00h
OFF:
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Page 36
ENTRY
RANGE
function.
TUESDAY
Same as previous except for Tuesday.
See prev.
See prev.
WEDNESDAY
Same as previous for Wednesday
See prev.
See prev.
THURSDAY
Same as previous for Thursday
See prev.
See prev.
FRIDAY
Same as previous for Friday
See prev.
See prev.
SATURDAY
Same as previous for Saturday
See prev.
See prev.
SUNDAY
Same as previous for Sunday
See prev.
See prev.
MO – FRI
Same as above for Monday – Friday
See prev.
See prev.
SA – SU
Same as previous for Saturday and Sunday
See prev.
See prev.
MO – SU
Same as previous for Monday – Sunday
See prev.
See prev.
sub-menu.
1 above.
sub-menu.
TIME
TIME
Table 5-3: TIME PROGRAM Menu Sub-Menus and Parameters (Continued)
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
E8 Controller and BCM for Modulex EXT
FUNCTION DESCRIPTION
View or change the pump ON – OFF times for
Monday.
Press the Program Key to view current
settings.
MONDAY
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
DEFAULT
ON: 6:00h
OFF:
22:00h
RETURN
HTG – PROG 2 Sub-Menu
RETURN
Press Program Key to exit HTG – PROG 1
Sub-Menu Functions, processing procedures,
ranges and defaults are same as HTG PROG
Press Program Key to exit HTG – PROG 2
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Page 37
5.4 EXPERT Menu and Sub-Menus
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
EXPERT
EXPERT
The EXPERT Menu contains the following Sub-Menus: INSTALLATION, HOT WATER, HEAT
CIRCUIT 1, HEAT CIRCUIT 2 and SOLAR M/F as shown in Figures 5-7 & 5-8. 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 5-4.
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-7: EXPERT Menu Flow Chart (Sheet 1 of 2)
Page 38
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
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
EXPERT EXPERT
Page 38 of 108 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0093_0A
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Figure 5-7: EXPERT Menu Flow Chart (Sheet 2 of 2)
Page 39
E8 Controller and BCM for Modulex EXT
EXPERT
EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-8: EXPERT Menu – 1 of 2
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Page 40
E8 Controller and BCM for Modulex EXT
EXPERT
EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-8: EXPERT Menu – 2 of 2
NOTE
The shaded items in the following table indicate those parameters
that change according to the boiler type and whether used singly
or in a cascaded configuration.
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Page 41
E8 Controller and BCM for Modulex EXT
INSTALLATION Sub-Menu
CODE-NO
Permits entry of valid Code No.(0000)
0000 - 9999
0000
the boiler
CHANGE
numbers must not be assigned twice.
AF SUPPLY
Outdoor sensor power supply
00, 01 (OFF/ON)
01 (ON)
BUS TERM
Bus terminating resistor (Must be set to 01)
00, 01 (OFF/ON)
01 (ON)
SUPPLY
MASTER
point temperature.
temperature.
MAX T-HS2
Not Applicable
----
----
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.
EXPERT
EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
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 5-4: EXPERT Menu Listing
FUNCTION DESCRIPTION ENTRY RANGE DEFAULT
BUS ID HS
BUS ID 1
BUS ID 2
EBUS
TIME
MAX T-COLL
MIN T-COLL
BUS ID HS MUST be set to - - - - to operate
The heating circuits are sequentially
numbered starting with “01“, heating circuit
Heating circuits are sequentially numbered
starting with “01“, heating circuit numbers
must not be assigned twice.
Switches the Ebus supply ON/OFF 00, 01 (OFF/ON) 01 (ON)
Not Applicable
Sets the maximum allowable header set
Sets the minimum allowable header set point
01 - 08
01 – 15 01
01 – 15 - - - -
86.0°F – 230.0°F 185.0°F
50.0°F – 176.0°F 50.0°F
DO NOT
MIN T-HS2
V-CURVE
CURVE 11-UO
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Sets minimum allowable HS2 set point
from preset curves (see Section 5.4.1) or
Stop/Start voltage level. Going below/above
50.0°F – 176.0°F 104.0F°
00 – 11 11
0.00V – 10.00V 1.00
Page 42
E8 Controller and BCM for Modulex EXT
ENTRY
RANGE
HYSTERESIS
Not Applicable
----
----
MODULS
for service.
321-1123
110 Kw: 1530-3060
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)
(N/A)
MODUL
230.0°F
UPWARD
DOWNWARD
RESET TIME
Not Applicable
5 – 500
50
after the delay time elapses.
off
MIN MOD HS
Not Applicable
0% - 60%
35%
HW
SEQUENCE 1
Boiler sequence 1
12345678
SEQUENCE 2
Boiler sequence 2
87654321
EXPERT
EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-4: EXPERT Menu Listing (Continued)
FUNCTION DESCRIPTION
INSTALLATION Sub-Menu (Continued)
FOUND
CAP/MODULE
MIN MOD
CONTR
DEVIAT
MAX T-
Displays the number of heat modules available
Displays the maximum Kw output of each heat
module.
Not Applicable 01 – 08 01
Control Deviation indicates the temperature
difference between the Boiler set point and the
Maximum temperature of Heat Module
DEFAULT
Display
00 – 1000 Kw
Display ----
122.0°F to
50 Kw:
194.0°F
DYN
DYN
MODULAT
MAX
MODULAT
MIN
MOD LEVEL
Not Applicable (N/A) (N/A)
Not Applicable (N/A) (N/A)
Start Level. If this modulation percentage is
exceeded, the next heat module is connected
Stop Level. If value drops below this
modulation percentage, the last heat generator
(module) of the current sequence is switched
Not Applicable ---- ----
50% - 100% 30%
10% - 60% 35%
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Page 43
E8 Controller and BCM for Modulex EXT
ENTRY
RANGE
SEQU CHANGE
Sequence change mode
01 – 06
06
SEQ SW TIME
Time to sequence change (hours)
10 – 800
200
LOCK TIME
Not Applicable
00 min – 30 min
00
HYST BURNER2
Not Applicable
----
----
T-HS COOL
Not Applicable
----
----
Identification of Boiler Type being used:
06 = Multi-Stage, modulating (cascade via BUS)
Heat Source
HEATSOURCE 2
Not Applicable
N/A
N/A
STORAGE HS2
Not Applicable
N/A
N/A
BUFFER
Not Applicable
N/A
N/A
SCREED
Not Applicable
N/A
N/A
SCREED PROGR
Not Applicable
N/A
N/A
RETURN
Press Program Key to exit INSTALLATION Sub-Menu.
HOT WATER Sub-Menu
DHW RELIEF
Not Applicable
N/A
N/A
02 = Pump Parallel Running
DHW)
HYST DHW
Hot Water Hysteresis
48°F – 129°F
48°F
min.
Storage Tank With Thermostat = 01
WALL HUNG
Not Applicable
00 (Off)
LOAD THROUGH
Not Applicable
00 (Off)
RETURN
Press Program Key to exit HOT WATER Sub-Menu.
EXPERT EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-4: 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
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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
Storage Tank With Sensor = 00
00, 01, 02
32°F – 194°F 97°F
00 min. – 30
00, 01
01
00 min.
00 (Off)
Page 44
E8 Controller and BCM for Modulex EXT
ENTRY
RANGE
valve.
Circulation pump mode control for ON/OFF
03 = Continuous pump operation
MIXER OPEN
Not Applicable
MIXER CLOSE
Maximum allowable water temperature setting
for the heating circuit.
68°F –
230°F
Minimum allowable water temperature setting
for the heat circuit.
50°F –
230°F
Specifies the minimum allowable outside air
INSTALLATION Mode)
DEL
OFFSET
B-HEAT SINK
Not Applicable
N/A
N/A
Press Program Key to exit HEAT CIRCUIT 1
(or 2) Sub-Menu.
EXPERT
EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-4: 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 (indoor / outdoor reset)
HC FUNCTION
PUMP MODE
01 = Control to fixed flow temperature (constant setpoint)
02 = Swimming pool control (HC 2 ONLY)
03 = Hot Water Circuit
04 = Return flow temp. Increase via mixing
switching of pumps.
00 = Standard pump control
01 = Pump switching per heating limits
02 = Pump switching per heating program
Not Applicable
00 – 04
00 – 03 00
DEFAULT
00
(Standard
Heat
Circuit)
MAX T-FLOW
MIN T-FLOW
temperature setting for the Frost Protection
Mode. If temperature drops below this value,
T-FROST PROT
OUT-TEMP-
SLOPE
RETURN
the system switches to the Frost Protect Mode
and the pumps are switched ON.
(This Function should be set to 0°F in the
Not Applicable N/A N/A
Not Applicable N/A N/A
-5°F –
41°F
176°F
50°F
32°F
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Page 45
E8 Controller and BCM for Modulex EXT
ENTRY
RANGE
SOLAR M/F Sub-Menu
FUNCTION
SET TEMP
HYST (1-4)
02 = Light sensor
Sub-Menu.
EXPERT
EXPERT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-4: EXPERT Menu Listing (Continued)
FUNCTION DESCRIPTION
MF (1-4)
MF (1-4)
MF (1-4)
F15 FUNCTION
RETURN
Not Applicable
Not Applicable
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
5.4.1 Available V-Curve Preset Voltage Curves for 0 – 10 Volt Input
The following listing (Table 5-4) shows the available preset V-Curve settings for operation in
the 0 to 10 Volt Mode:
Table 5-5: 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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Page 46
E8 Controller and BCM for Modulex EXT
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
GENERAL
DATE/TIME
GENERAL
DATE/TIME
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
5.5 EXPERT HS Menu
The EXPERT HS menu is a submenu of the EXPERT menu and is used for initialization of the
E8 controller. See Section 4.1 for how to use this menu to initialize the E8 controller.
5.6 GENERAL Menu
The GENERAL Menu contains a DATE/TIME Menu and a SERVICE Menu.
5.6.1 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 Figures 5-9 & 5-10 and Table 5-6.
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Figure 5-9: DATE/TIME Menu Flow Chart
Page 47
E8 Controller and BCM for Modulex EXT
GENERAL
DATE/TIME
DATE/TIME
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
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.
GENERAL
Figure 5-10: GENERAL Menu Diagram
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Page 48
E8 Controller and BCM for Modulex EXT
TIME – DATE Sub-Menu
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.
GENERAL
DATE/TIME
GENERAL
DATE/TIME
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-6: DATE / TIME Menu Listing
FUNCTION DESCRIPTION ENTRY RANGE
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
MONTH
Set current holiday start month 01 – 12
Set current holiday end month 01 – 12
CLOCK CHANGE Sub-Menu
This Sub-Menu is used in areas where seasonal time changes are required for “Daylight
Savings“, etc.
MONTH
RETURN
Set clock change start month 01 -12
When CLOCK CHANGE reappears, press Program
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Page 49
5.6.2 SERVICE Menu
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
SERVICE
SERVICE
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 Figures 5-11 & 5-12 and Table 5-7 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.
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-11: SERVICE Menu Flow Chart
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Page 50
SERVICE
SERVICE
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Figure 5-12: SERVICE Menu
Page 50 of 108 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0093_0A
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Page 51
RELAY NO.
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]
Multifunction 1
Multifunction 2
10
A10: Multifunction 3
11
A11: Collector Pump / Multifunction 4
SENSOR
F1
Lower buffer storage temperature
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
SERVICE
SERVICE
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-7: SERVICE Menu Listing
FUNCTION DESCRIPTION REMARKS
RELAY TEST Sub-Menu
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.
08 A8: Mixer OPEN Heating Circuit 1 /
09 A9: Mixer CLOSED Heating Circuit 1 /
SENSOR TEST Sub-Menu
This Sub-Menu is used to check and display the temperature readings of the
sensors connected to the Controller.
F2 Middle buffer storage temperature or room
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Page 52
E8 Controller and BCM for Modulex EXT
SENSOR TEST Sub-Menu
multifunction 1
multifunction 2
temperature multifunction 3
multifunction 4
input
OTHER ENTRIES
Additional items and functions in the SERVICE Sub-Menu include the following:
currently installed in the Controller
instructions using these sub-menu functions.
8)
(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
SERVICE
SERVICE
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
Table 5-7: SERVICE Menu Listing (Continued)
FUNCTION DESCRIPTION REMARKS
F11
F12
F13
F14
F15; Light; 0-10V I
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-136, Section 3.31 for additional calibration
Program Key – Burner time for all stages
BURNER START
LIMITER TEST
(1-8)
SERVICE
WARNING: NEVER ATTEMPT TO USE THE FOLLOWING RESET FUNCTIONS.
RESET EXPERT
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
DO NOT USE
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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
INSTALL
INSTALL
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
5.7 Installation Menu & E8 Controller Initial Startup
See Section 4.1 for instructions for initial startup of the E8 Controller, which requires a number
of one-time entries to be made in the initial INSTALLATION Menu that appear in the E8
display when the controller door is first opened. Table 5-8 lists the description, entry range,
and default entry for all INSTALLATION MENU parameters.
Table 5-8: 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
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Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
5.7.1 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 or 110 Kw setting, depending on model size, 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.
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E8 Controller and BCM for Modulex EXT
FUNCTION
DESCRIPTION
01
Header Pump
03
Booster Pump
06
Pump HS2
21
Pulsed Circulation Pump
23
Solar Integration
25
Return Flow Temperature Increase HS2
Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
5.7.2 Available Settings for Relay Functions 1 – 4
Table 5-9 lists the available Function selections for Multi-Function (MF) Relays 1 thru 4:
Table 5-9: 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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Installation, Operation & Maintenance Manual
CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS
(This Page Is Intentionally Blank)
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E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 6: E8 SETUP & PROGRAMMING
CHAPTER 6: E8 SETUP AND PROGRAMMING
The following sections 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 Chapter 3 of this document for illustrations and
descriptions of the Controller operating controls and displays.
Refer to Chapter 6 for Controller wiring connections.
6.1 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 sections provide the procedures necessary to
wire and configure the controller for operation in the Indoor/Outdoor Reset mode.
6.1.1 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 Chapter 7 for the locations of sensor connections. This sensor must be
connected (Section 7.1.2) prior to configuring the Controller.
6.1.2 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
Section 5.1.1 above, prior to configuring the Controller for
Indoor/Outdoor Reset Mode operation.
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E8 Controller and BCM for Modulex EXT
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
0510152025303540455055606570
Outside Temperature ( F )
Flow Temperature ( F )
Installation, Operation & Maintenance Manual
CHAPTER 6: E8 SETUP & PROGRAMMING
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.
NOTE
Before continuing, check to ensure that HC FUNCTION in the
EXPERT>HEATING CIRCUIT 1 menu is set to the default “00”.
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 6-1) 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.
Press the Program Key to exit the HTG CIRCUIT 1 sub-menu.
Figure 6-1: Heat Slope Diagram
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CHAPTER 6: E8 SETUP & PROGRAMMING
6.1.3 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.
6.2 Constant Set Point Mode
When a fixed header temperature is desired, configure 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 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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MIN T-FLOW
The minimum allowable outlet water temperature
Installation, Operation & Maintenance Manual
CHAPTER 6: E8 SETUP & PROGRAMMING
6.2.1 Wiring Connections
There are NO wiring connections required for this mode.
6.2.2 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.
6.2.3 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.
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 in °F.
6.2.4 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 6-1.
Table 6-1: E8 Controller Outside Temperature Sensor Parameters
Parameter Description
HEATSLOPE
MAX T-FLOW
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 6-1. 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.
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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Installation, Operation & Maintenance Manual
CHAPTER 6: E8 SETUP & PROGRAMMING
6.2.4.1 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.
12. 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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.2.4.2 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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.2.4.3 Configuring MAX T-COLL Parameter
To enter the MAX T-COLL 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.
6.3 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
sections 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.
6.3.1 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 Chapter 7 for illustrations and pin-outs of the connectors located on the rear of
the Controller.
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CHAPTER 6: E8 SETUP & PROGRAMMING
6.3.2 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 Section 6.3.3.
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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.3.3 Setting the Voltage and Set Point Limits for U1/U2 and T1/T2
NOTE
Ensure that all steps in Section 6.3.2 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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CHAPTER 6: E8 SETUP & PROGRAMMING
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 Section 6.3.4 to set the
CURVE 11-UO voltage.
6.3.4 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 Section 6.3.3,
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 Section 6.3.5.
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CHAPTER 6: E8 SETUP & PROGRAMMING
6.3.5 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 Section
6.3.5, 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.
6.4 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.
6.4.1 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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.4.2 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 6.4.1), prior to
configuring the Controller for DHW operation. If the 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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.4.3 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 / TBOILER DHW. Degrees entered are added to DHW Setpoint in
USER MENU. See Section 6.2.3.
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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.4.4 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.
6.4.4.1 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.
6.4.4.2 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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CHAPTER 6: E8 SETUP & PROGRAMMING
6.5 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 Section 6.4 for the
tank sensor. Therefore, the following sections describe only the differences between these
two types of applications.
6.5.1 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.
6.5.2 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 Section 6.4.2. 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).
6.5.3 Setting the DHW Set Point
Same as Section 6.4.3.
6.5.4 Displaying Temperatures Associated With DHW
Same as Section 6.4.4 through 6.4.4.2.
6.6 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 Section 6.3.4.
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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E8 Controller and BCM for Modulex EXT
Term
Pin#
Function
7
(1+2)
Ebus (FA) or 0-10V output
1
(1,2,3+M)
F1/F2/F3 = buffer storage tank low/middle/top
1
(2+3+M)
FBR2 (FBR1) for heating circuit 1
1
(2+M)
F2 = Room sensor for heating circuit 1
1
(4+5)
F5 = Flow sensor heating circuit 2
1
(6+7)
F6 = Storage tank sensor
1
(7+8)
F8 = Boiler sensor/header sensor
1
(9+10)
F9 = Outdoor sensor
5
(1+M)
F11 = Flow sensor heating circuit 1/Multifunction relay sensor 1
5
(2+M)
F12 = Hot-water tank low/Multifunction relay sensor 2
8
(1+M)
F13 = PT1000 => HS2/collector 2/Multifunction relay sensor 3
8
(2+M)
F14 = PT1000 => Collector 1/Multifunction relay sensor 4
3
(1-3)
FBR2 (FBR1) for heating circuit 2
3
(1+2)
F15 = 0-10V input/light sensor/Room sensor for heating circuit 2
3
(2+3)
F17 = Pulse counter for output measurement
9
(1+2)
Data line CAN bus
9
(3+4)
Power supply CAN bus
6
2 9 3
8 5 1
Installation, Operation & Maintenance Manual
CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS
CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS
120V~; Relay switching
capacity 2(2)A, 250V~
Figure 7-1: E8 Controller Rear Panel Terminals
7.1 SENSOR Terminal Assignments
Table 7-1: Sensor Terminal Assignments
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5 8 3
9
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CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS
Sensor Terminal Assignments (Continued)
7.1.1 Connector 7
7.1.2 Connector 1
7.1.3 Connector 5
7.1.4 Connector 8 => PT 1000 Sensor
7.1.5 Connector 3
7.1.6 Connector 9
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E8 Controller and BCM for Modulex EXT
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
IMPORTANT
2 6 4
Installation, Operation & Maintenance Manual
CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS
7.2 MAINS Power Terminal Assignments
Table 7-2: Mains Power Terminal Assignments
IV (3)
7.2.1 Connector 2
7.2.2 Connector 6
7.2.3 Connector 4
THE PRIMARY PUMP (COLLECTOR PUMP 2) MUST BE WIRED
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
CHAPTER 8: 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 provides a 0-10V output for controlling a VFD primary pump.
• BCM can function as a “Slave” to a “Master” Energy Management System (EMS), Building
Automation System (BAS) or AERCO’s Boiler Management System II (BMS II/AERCO
Control System (ACS) on a Modbus Network.
Following are detailed descriptions of the BCM and each of the additional control functions listed
above.
8.1 BCM Description
The BCM shown in Figure 8-1 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 lift-up front
panel.
Figure 8-1: 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. Three 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 8-2.
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Item
Feature
Function
Change-Over
3-Position Switch
Two-position rocker switch enables the BCM to act as a Back-
for description of settings related to Item B switch.
Momentary two-position rocker switch resets (clears) fault relay
and LED when activated.
SW1,
10-Position Rotary Switch
Rotary switch labeled 0 – 9. Sets the corresponding address of
Boiler on the input Modbus or EBUS Network.
Communication Status Indicator functions as follows:
Status
Description
No devices detected by either
communication interface.
Only one communication device detected
output).
Both communication interfaces
(input & output) are active.
Alarm Status LED lights when a fault is detected by the BCM.
Activating the Reset Switch will clear the faults.
G
Input
(Modbus/Ebus)
Output
DL2 (RED)
DL3 (GREEN)
Enable/Disable
SW1
Change-Over
Reset Switch
B
C A
E F G
Communications
Connector
3-Pos. Switch
E8 Controller and BCM for Modulex EXT
Installation, Operation & Maintenance Manual
CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
Communications
Connector (Ebus)
D
Figure 8-2: BCM Features and Controls
Series/Parallel,
A
Enable/Disable (I/0),
B
2-Position Switch
Reset Switch
C
Three-position rocker switch for setting internal/external boiler
control.
Up Controller when placed in the ON (I) position. See Table 8-1
D
OFF
DL1 LED: (YELLOW)
E
BLINKING
at one communication interface (input or
ON
DL2 LED: (RED)
F
DL3 LED: (GREEN)
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Pump Status Indicator lights when Pump is running.
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
The BCM Change-Over Series/Parallel 3-Position Switch and the Enable/Disable (I/0) 2Position Switch function as described in Table 8-1.
Table 8-1: Two and Three Position Switch functions
2-POSITION
SWITCH
(BCM Backup)
O
(OFF / DISABLED)
(To NOT use BCM
as backup)
I
(ON \ ENABLED)
(To use BCM as
backup)
I
(NOTE 1)
DO
NOT
USE
DO
NOT
USE
3-POSITION
SWITCH
(Internal/External Boiler Control)
O
(NOTE 2)
The BCM is the Gate-way
for Modbus and external
control. The E8 does not
control the boiler and the
BCM will NOT take over the
boiler if the Modbus signal
fails.
The BCM is the Gate-way
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
continuously run the pump.
The E8 is the primary
controller and the BCM
allows monitoring through
Modbus, but will NOT take
over boiler if the E8 fails.
The E8 is the primary
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 the pump.
II
(NOTE 3)
DO NOT set the 3-Position Switch to Position I.
NOTE 1
NOTE 2
Set the 3-Position Switch to Position O ONLY when controlling
Boilers from an external Controller via Modbus Communication.
See Section 3.1.2 for setting HEAT Modes.
NOTE 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
Section 3.1.2 for setting HEAT Modes.
8.2 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.
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
8.2.1 BCM Fault Relay Wiring
If desired, pins 3 and 4 of connector Y4 (Figure 8-3) can be wired to an external source to
provide a remote alarm indication when the BCM Fault Relay is activated.
8.2.2 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 8-3: BCM Fault Relay & Reset Switch Wiring
8.3 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 Section 8.3.1 for details.
8.3.1 BCM Back-Up Controller Wiring
The Primary Boiler Pump must be wired to BCM Connector Y4 as shown in Figure 8-4. 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 8-5.
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
Figure 8-4: BCM Back-Up Controller Wiring
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
Figure 8-5: Installing Resistor to Change Default Setpoint
8.4 BCM Configured as Primary Controller Utilizing Modbus
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 Section 8.4.3). 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 sections 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 Chapter 9 of this document.
8.4.1 Operating Scenario
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.
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
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E8 Controller and BCM for Modulex EXT
MASTER
SLAVE
#1
SLAVE
#2
SLAVE
#3
SLAVE
#4
SLAVE
#5
Installation, Operation & Maintenance Manual
CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
and 7 of connector Y2 (see Figure 8-5). In addition, the BCM Fault Relay will be activated and
the red Fault LED (DL2) will light.
8.4.2 Physical Modbus RS485 Wiring
Modbus RS485 devices should be wired in a “Daisy-Chain” configuration similar to the example
shown Figure 8-6. DO NOT wire the units in a “Star” configuration where all devices are
connected to a central point (node).
Figure 8-6. 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 8-7.
Figure 8-7: BCM Modbus (RS485) Connections
8.4.3 Disconnecting the E8 from the E-Bus on the BCM Board
See Table 8-1 for how to set the three position switch on the BCM to allow disconnection of the
E8 from the BCM.
NOTE
When the BCM is configured as the primary controller, the E8 will
display the fault code “E200”.
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
8.4.4 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.
8.4.5 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).
8.5 BCM Control of VFD Primary Pump
The BCM has a 0-10 V output that can be used to control a VFD primary pump. There is no
connection on the Modulex controller for pump mains power. Pump mains power must be
supplied externally, as directed by pump manufacturer’s instructions.
8.5.1 Pump Control Wiring
The 0-10 V signal wire must be wired to terminals 5 and 6 of terminal block Y2. See Figure 8-8.
The positive wire connects to terminal 5 and the negative to terminal 6.
8.5.2 Pump Control Operation
Adjustment of the 0-10 V signal is done through 3 Modbus registers. For setup and operation of
Modbus controls see Sections 8.7, 8.8, and 8.9. Data address 3006 is the “Pump Over-run
Time” and it controls the amount of time, in minutes, that the pump will continue to run after the
unit is shut down. Addresses 3007 and 3008 control the output voltage at minimum and
maximum fire, respectively. For further information see Table 9-4.
Figure 8-8: Primary Pump Control Wiring to BCM
8.6 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
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
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 Sections 8.6.1 and 8.6.2, which follow.
8.6.1 Master 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,
Section 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 8-9).
8.6.2 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 8-9 only on the BCM Board contained in the last
BCM Controller.
As mentioned in Section 8.6.1, 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 8-9. 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 8-9: BCM Loop Termination and Bias
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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
Installation, Operation & Maintenance Manual
CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
8.7 Modbus Network Wiring Diagram
A “Sample” Modbus Network wiring diagram for an AERCO BMS II/ACS Master controlling BCM
Slaves is shown in Figure 8-10. 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 for the location of these switches.
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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Figure 8-10: AERCO BMS II Master Controlling Modulex Boiler Slaves
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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
Installation, Operation & Maintenance Manual
CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
Figure 8-11 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.
Figure 8-11: EMS/BAS Master Controlling Modulex Boiler Slaves
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
8.8 Modbus Software Set-Up
The following sections provide the information and procedures necessary to configure the Boiler
Communications Modules (BCMs) to operate on a Modbus Network.
8.8.1 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 8-12.
SW1 is a 10-position switch labeled 0 – 9 (Figure 8-12). SW1 is set to the desired position using
a small flat-tip screwdriver. Figure 8-12 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 Chapter 9 of this document and Chapter 2 of GF-124 for Modbus points for the BCM and
BMS II/ACS.
Figure 8-12: Location of BCM Address Selection Switch SW1
8.8.2 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.
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
8.8.3 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.
8.8.4 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.
8.8.5 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.
8.9 Multiple Modulex Boiler Heating Mode – Using 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
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.
8.9.1 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
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CHAPTER 8: BOILER COMMUNICATION MODULE (BCM)
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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CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
CHAPTER 9: BCM MODBUS AND ADDRESS
ASSIGNMENTS
9.1 BCM Modbus Comm. & 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:
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
Data Framing:
Message Framing:
Character Framing:
Heartbeat Timeout:
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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.
Adjustable (0 or 1 – 240 seconds)
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Modbus
Address
0 – 0xFFFF
LSB:
Error Code
MSB:
Identification code
255: BCM
enum (1, 3, 5)
1 =
Standby (ready to run but not
fired)
3 =
Remote (fired)
5 =
Fault (failure detected)
2
Flow Sensor Temp
14° to 212° F(-10° to 100° C) (Valve X10)
3
Return Flow Temp
32° to 212° F(0° to 100° C) (Valve X10)
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
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
Menu Item Units and Range
Status & Error Code
of fault device:
0: BMM #0 to
7: BMM #7
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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Address
CONTROL REGISTERS
(Read/Write)
(address 0x03F9)
Maximum
Modulation Level
% (0 to 100)
(Value x 2)
(Read/Write)
100° (50%)
Requested
Setpoint
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)
Run Counters
Clear
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
Table 9-4: BCM Standard Holding Register Address Mapping
Modbus Data
1
1017
1004
1001 System Command enum (0xAA)
Menu Item Units and Range Default/(Comments)
AERCO BMS
II/ACS Requested
Modulation Level
(0x01, 0x33, 0x44, 0x55,
0xBB, 0xCC, 0xEE)
% (0 to 100)
A value other than 0
requests Run mode and
supersedes the value set for
Max Modulation Level
0xAA: Restart Slave
1021
1022
1023 Pump Control
1031
Heat Request
Command
(Read/Write)
0x01
If enum is none of the above,
(Read/Write)
0 = No action
1 = Switch OFF
enum (0x5A) (Read/Write)
(Read/Write)
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Modbus Data
Address
(Comments)
CONTROL REGISTERS (Continued)
Flags
Bit 7: BMM #7
(Read/Write)
Bit 0 (BMM #0) is
matically set at
Check Mode start
OPERATING DATA REGISTERS
0 – 0xFFFF
LSB:
Error Code
MSB:
Identification code
255: BCM
10
Run Hours
0-50000
----
11
Run Counts
0-50000
----
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)
Return Flow
Temperature
32°F to 212°F (0°C to 100°C)
(Value x 10)
(Read Only)
-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 100°C)
Setpoint” temp as 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)
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
Table 9-4: BCM Standard Holding Register Address Mapping (Continued)
1041
Menu Item Units and Range
Check Mode,
Inserted burner
control
0 Error Code
1000
Cascade Control
Status
(0 – 0xFF)
Bit 0: BMM #0 to
of fault device:
0: BMM #0 to
7: BMM #7
Default
auto-
(Read Only)
(Read Only)
1002
1003
1005
1008
1016
1018 Target Setpoint
1019
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Flow Sensor
Temperature
External Sensor
Temperature
Actual Target
Setpoint
(-10°C to 100°C)
(-35°C/-30°C to 30°C)
(Value x 10)
Should increase up to “Target
(Read Only)
-31°F (-35°C) if not
(Read Only)
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E8 Controller and BCM for Modulex EXT
Address
(Comments)
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%
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
Table 9-4: BCM Standard Holding Register Address Mapping (Continued)
Modbus Data
1020 Operating Mode
1100 Linked BMM
1101 Inserted BMM
1102 BMM in Check Mode
Menu Item Units and Range
0: Standby
1: Space Heating
2: DHW
3: Check
Bit 0: BMM #0
to
Bit 0: BMM #0
to
Bit 0: BMM #0
to
Default
(Read Only)
(Read Only)
(Read Only)
(Read Only)
1103 BMM Flame Status
1104 BMM Alarm Status
1108
1109 Pump Modulation Output
1200 Monitor Only
2n00
2n02
2n08
BMM Maximum Modulation Level
Bit 0: BMM #0
to
Bit 0: BMM #0
to
(Read Only)
(Read Only)
(Read Only)
(Read Only)
(Read Only)
(Read Only)
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Address
(Comments)
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.
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
Table 9-4: BCM Standard Holding Register Address Mapping (Continued)
Modbus 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
(Read Only)
(Read Only)
(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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Page 97
E8 Controller and BCM for Modulex EXT
Address
(Comments)
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
0 = Burners Array
1 = Standalone Burners
0 = None
3 = CH & Frost Protect
TEST REGISTERS
(Write Only)
only in Test mode.
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
Modbus Data
Table 9-4: BCM Standard Holding Register Address Mapping (Continued)
3007
3008
3009
3010
3011
Menu Item Units and Range
Output @
Minimum Burner
Output @
Maximum Burner
Communication
Timeout Time
0 – 10V
(Value x 10)
0 – 10V
(Value x 10)
0 – 100%
intervals)
Default
(Read/Write)
3V
(Read/Write)
10V
(Read/Write)
30 sec.
3012
3013
3015
3050 Application Code 0/1
3051 Services Enable 0-255
1040 Test Mode Control
0/1; 0 =°C, 1 = °F 1 = °F
enum (0xA5/0x5A)
0xA5: Test mode release
0x5A: Test mode request
1 = CH
2 = Frost Protection
This command is only
executed in Standby
mode. The other Write
messages are executed
OMM-0093_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 97 of 108
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Page 98
E8 Controller and BCM for Modulex EXT
Address
(Comments)
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]
Installation, Operation & Maintenance Manual
CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS
Table 9-4: BCM Standard Holding Register Address Mapping (Continued)
Modbus Data
3100
Menu Item Units and Range
Digital Inputs Status
[0, 1]
Default
(Read Only)
3101
3102
Digital Outputs
Status [0, 1]
Digital Output
Control in Test
Mode [0, 1]
(Read Only)
(Read/Write)
Page 98 of 108 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 OMM-0093_0A
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Page 99
E8 Controller and BCM for Modulex EXT
Fault Codes are
Installation, Operation & Maintenance Manual
CHAPTER 10: E8, BCM, AND BMM FAULT CODES
CHAPTER 10: E8, BCM, AND BMM FAULT CODES
This section provides tables for identifying faults (with fault troubleshooting tips) and describes
the procedures required to clear a displayed fault code after the cause of the fault has been
corrected. Fault codes are displayed in the upper right area of the LCD display on the E8
Controller as shown in Figure 10-1.
NOTE
See the Trouble-Shooting Guide in Chapter 6 of the Modulex EXT
manual (GF-136) for more detailed Fault Code descriptions and
trouble-shooting procedures.
Displayed Here
(i.e. E 70)
Figure 10-1: E8 Controller Fault Code Location
OMM-0093_0A AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Page 99 of 108
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Page 100
E8 Controller and BCM for Modulex EXT
Processing and Clearing a Fault Code
Flashing Fault Triangle
Fault Code
Installation, Operation & Maintenance Manual
CHAPTER 10: E8, BCM, AND BMM FAULT CODES
10.1 Processing and Clearing Fault Codes
When a fault occurs, the appropriate fault code will be displayed along with a “Flashing Triangle”
(Figure 10-2).
Figure 10-2: E8 Controller Fault Code and Flashing Triangle Location
To process and clear the fault, proceed as follows:
NOTE
If the cause of the fault has not been corrected, the displayed Fault
Code will reappear after performing the following steps.
1. Open the hinged cover on the controller.
2. Press the Program Key. The red LED will light. Also the display will show the fault code and
the number of the suspect module.
3. Correct the cause of the fault.
4. Press the Program Key again. The red LED will go off and the Fault Code will clear.
5. If more than one fault (or more than 1 failed module) exists, repeat the above steps until all
fault codes are cleared.
6. Close the hinged cover on the Controller.
7. Monitor the display to ensure no other Fault Codes appear.
8. Resume normal operation after all faults have been cleared.
10.2 Fault Codes and Descriptions
All fault codes are displayed in the E8 Controller display. There are fault codes for three
different devices as follows:
• E8 Controller: These are divided into four basic categories: PCB Element Faults,
System Manager Faults, Communication Faults, and Internal Faults. These fault codes
are shown in Table 10-1.
• BCM (Boiler Control Module): Use Table 10-2 to determine the meaning of the
• BMM (Burner Management Module): Use Table 10-2 to determine the meaning of the
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displayed BCM fault code, then look up BCM fault codes in Table 10-3.
displayed BMM fault code, then look up BMM fault codes in Table 10-4.
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