Aerco 5R5-384 User Manual Download

Page: 84 / 139

AERCO Control System (ACS)

CHAPTER 5

: Troubleshooting

Page 84 of 139

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, New York 10913

11/22/2017

GF-131

Phone: 800-526-0288

OMM-0081_0F

TABLE 5-2: Common Problems

Problem

Possible Causes

Solution

HEADER TEMPERA-

TURE not reaching

Setpoint

•

Deadband requires

adjustment

•

PID requires adjustment

•

Check

HDR TEMP DEADBND

TUNING MENU (paragraph 3.10).
Default = 5°.

•

See TUNING MENU (paragraph 3.10).

Need to restore Factory

Default Settings.

•

Too many setting changes.

•

Go to

RESET DEFAULTS

option in

CALIBRATION MENU (paragraph
3.12)

Boilers over-shooting

setpoint or tripping

aquastat

•

Header sensor not installed

correctly

•

PID setting require adjustment

•

Adjustable aquastat set too

low

•

System pumps are shut down

and not controlled by or
interlocked with the ACS

•

Check header sensor connections and

installation.

•

Adjust PID settingsin TUNING MENU

(paragraph 3.10).

•

If aquastat is set lower than 200°F,

reset it to 220°F.

•

If system pumps are shut down, check

start and stop temperatures on energy
management system. They should
correspond to those set in the ACS. In
addition, interlock wiring can be run
between the ACS and energy
management system to disable the
ACS pumps when pumps are not
running.

Modbus Network faults

encountered. Boiler

plant not operating

•

ACS or boilers not properly

configured for Modbus
communication.

•

Bias and/or termination not

activated.

•

Refer to Modbus Communication

Manual GF-114 for C-More control or
GF-115-C for BCM control on Modulex
boilers. Check all wiring connections
and software menu settings.

•

Activate termination in last boiler.

Activate bias on ACS for BCM control
or in last C-More control.

Percent of Load starts

to rise and suddenly

drops to zero.

•

Bias Switch and/or termination

resister not activated at either
the boiler or the ACS.

•

Refer to section 2.6 to 2.9 in this

manual.

Summary of Contents for 5R5-384

Page 1: ...w York 10913 Page 1 of 139 OMM 0081_0F Phone 800 526 0288 GF 131 Installation Operation Maintenance AERCO Control System ACS Front Panel Latest Update 11 22 2017 USER MANUAL For Control of Up to Thirty two 32 AERCO Boilers including Benchmark Series Modulex MLX Series Modulex EXT Series KC 1000 ...

Page 2: ...4 9 ACS Programming Via RS232 Port 13 CHAPTER 2 ACS INSTALLATION 15 2 1 INTRODUCTION 15 2 2 SITE SELECTION AND MOUNTING 15 2 2 1 Mounting the ACS 15 2 3 SITE SELECTION AND MOUNTING 16 2 4 POWER WIRING 17 2 5 SENSOR INSTALLATION AND WIRING 18 2 5 1 Header Sensor Installation 19 2 5 2 Return Sensor Installation 19 2 5 3 Outdoor Air Sensor Installation 20 2 6 RS485 MODBUS WIRING AT THE ACS 22 2 6 1 A...

Page 3: ...2 17 41 2 18 1 RS485 Menu Settings for Relay Panel Programming 41 2 18 2 Configuration Menu Relay Panel Settings 41 CHAPTER 3 OPERATION 43 3 1 INTRODUCTION 43 3 2 FRONT PANEL OPERATING CONTROLS AND DISPLAYS 43 3 3 1 Menu Processing Procedure 45 3 3 OPERATING MENU 47 3 4 1 Header Temp and Percent of Load 47 3 4 2 HEADER SETPOINT 47 3 4 3 OUTSIDE AIR TEMP 48 3 4 4 I O STATUS 48 3 4 5 RETURN TEMP 48 ...

Page 4: ... SELECT 53 3 9 2 BOILER OP MODE 53 3 9 3 PARALLEL MODE 54 3 9 4 SEQUENTIAL 54 3 9 5 SYS INTLK CONFIG 54 3 9 6 BLR START LEVEL 54 3 9 7 BLR STOP LEVEL 54 3 9 8 MAX POWER INPUT 55 3 9 9 FAIL SAFE MODE 55 3 9 10 LEAD BLR SELECT Lead Boiler Selection 55 3 9 11 LAST BLR SELECT Last Boiler Selection 55 3 9 12 ROTATE TIME 55 3 9 13 RET SENSOR MODE Return Sensor Mode 55 3 9 14 PLANT DT LIMIT Plant Delta T...

Page 5: ...ARM BLRS 61 3 12 8 FAULT ALRM CLEAR 61 3 12 CALIBRATION MENU 61 3 13 1 HDR SENS OFFSET 61 3 13 2 OUTD SENS OFFSET 61 3 13 3 4 20 MA OFFSET 62 3 13 4 RETN SENS OFFSET 62 3 13 5 RAMP UP MIN 62 3 13 6 RAMP DOWN MIN 62 3 13 7 RESET DEFAULTS 62 3 13 8 PASSTHRU WRITE 63 3 13 9 VALVE WAIT TIME 63 3 13 10 SYSTEM OVERRIDE Modbus Enable Disable 63 3 13 ACS QUICK START GUIDE MENU 63 3 14 1 CONSTANT SETPT MOD...

Page 6: ...STEM USING THE C MORE CONTROLS 78 CHAPTER 5 TROUBLESHOOTING 81 5 1 FAULT MESSAGES AND COMMON PROBLEMS 81 APPENDIX A ACS MENUS 85 APPENDIX B STATUS AND FAULT MESSAGES 91 B 1 ACS STATUS AND FAULT MESSAGES 91 B 2 C MORE STATUS AND FAULT MESSAGES 92 B 3 CONVERSION EQUATIONS FOR TEMPERATURE VARIABLES 96 B 4 INTERPRETING BCM FAULT CODES MODULEX 97 B 5 BCM BOILER COMMUNICATION MODULE FAULT CODES 98 B 6 B...

Page 7: ... 0288 GF 131 G 2 2 Running a Command on a Remote Machine Using PuTTY 114 G 3 RS232 COMMUNICATION SET UP 115 G 4 PROGRAMMING PROCEDURE 115 APPENDIX H ACS MODBUS ADDRESS ASSIGNMENTS 121 H 1 ACS CONTROLLER STANDARD INPUT REGISTER ASSIGNMENTS 121 H 2 ACS CONTROLLER STANDARD HOLDING REGISTER ASSIGNMENTS 128 APPENDIX I START AND STOP LEVELS 137 ...

Page 8: ...AERCO Control System ACS Page 8 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F This page intentionally blank ...

Page 9: ...ilizing Modbus Protocol The BAS or EMS communicates with the ACS utilizing a RS232 interface If the BAS or EMS uses a RS485 port the ACS can be ordered with a RS485 to RS232 Converter which can be easily installed within the ACS wiring compartment Technical Terms and Acronyms The phrases abbreviations and acronyms used in this document are listed in the following table Technical Terms and Acronyms...

Page 10: ... usually over RS485 networks OFFS Offset OUTD Outdoor PTP Point to Point usually over RS232 networks REF Ref Reference Response Time The maximum amount of time allowed to receive a response to a request RS232 or EIA 232 A standard for serial full duplex FDX transmission of data based on the RS232 Standard RS422 or EIA 422 A standard for serial full duplex FDX transmission of data based on the RS42...

Page 11: ...ment System EMS or Building Automation System BAS utilizing Modbus protocol Physical connection to the remote EMS or BAS is accomplished via an RS232 interface EMS BAS integration will also permit utilization of the pass thru function incorporated in the ACS The pass thru function permits the remote system to monitor up to 35 operating parameters from each boiler in the plant The ACS is housed in ...

Page 12: ...r BAS is not equipped with a RS232 port the ACS can be ordered with a RS485 to RS232 Converter which can be easily installed within the wiring compartment of the ACS With the exception of AC power interlock and setback inputs and relay outputs ACS connections are accomplished using shielded twisted pair cable 1 4 2 Control System Interface The unit incorporates a menu driven architecture which is ...

Page 13: ...changes in boiler plant operation Header temperatures as well as percentages of boiler input are precisely controlled with virtually no over shoot or short cycling of boiler units A header temperature accuracy of 2 F is virtually assured during continuous plant operation 1 4 7 Sequential Operation When operated sequentially The ACS stages boilers on and off at selectable firing rate percentages Th...

Page 14: ...ontrol System ACS CHAPTER 1 ACS General Information Page 14 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F This page intentionally blank ...

Page 15: ...other suitable material For easy viewing the ACS controls and display should be at eye level Mounting is accomplished using three screws not provided The spacing for the three screws are indicated on the rear of the ACS in millimeters Figure 2 1 shows the rear of the panel enclosure and also indicates the required spacing for the three mounting screws in inches Proceed as shown below to mount the ...

Page 16: ... of the unit Shielded twisted pair cable should be used for sensor and communication wiring This wiring should be 18 to 24 AWG Examples of suitable sensor and communication wire are Belden 9841 8761 3105A or equivalent AC power wiring should be 14 to 18 AWG The ACS wiring diagram is provided in Appendix E Once mounting is complete and the ACS is secured in place loosen the two captive screws on th...

Page 17: ...be detached from the ACS headers if necessary to simplify field wiring connections 3 Following completion of power wiring turn on the external circuit breaker or switch and apply power to the unit The ACS display will momentarily show AERCO ACS REV X XX Where X XX represents the revision level of the installed ACS software 4 Next since the Header Sensor is not yet installed the display will then s...

Page 18: ... an Outside Air Sensor The Header Sensor is required for all modes of operation The Outdoor Air Sensor is required for operation in the Outdoor Reset Mode All Sensor wiring should be run separately from power wiring to avoid inducing electrical noise on the sensor wiring If desired an optional Return Sensor may also be installed which is the same type and part number as the Header Sensor however i...

Page 19: ... the Header Sensor probe is inserted at least 2 inches into the water flow 4 Using shielded pair cable Belden 8760 or equiv connect the Header Sensor leads to HDR SEN terminals 4 and 5 on the ACS There is no polarity to observe when making these connections 5 Terminate the cable shield at SHLD terminal 3 of the ACS DO NOT terminate the shield at the Sensor end of the cable 2 5 2 Return Sensor Inst...

Page 20: ...irect sunlight and away from air intakes or outlets from the building Shielded pair 18 AWG cable Belden 8760 or equiv is recommended for sensor wiring The Outdoor Air Sensor can be mounted up to 600 feet from the ACS See instructions below NOTE The Outdoor Air Sensor is a thermistor type sensor The Resistance vs Temperature Chart for this sensor is provided in Appendix E Length of Header Sensor wi...

Page 21: ...2017 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Page 21 of 139 OMM 0081_0F Phone 800 526 0288 GF 131 Figure 2 4 Outdoor Air Sensor Installation INSTALL SENSOR ON NORTH FACING WALL OUT OF DIRECT SUNLIGHT AND AWAY FROM ALL AIR INLETS OUTLETS ...

Page 22: ... B and 485 A The cable shield is terminated at the SHLD terminal 3 of the ACS 2 6 1 ACS Bias Switches Loop Termination Resistors Each ACS contains a built in 120 ohm loop termination resistor and two bias DIP switches which are mounted on the lower portion of the motherboard Figure 2 6 The 120 ohm termination resistor is always active and is designed to match the electrical impedance at the ACS en...

Page 23: ...s RS485 wiring connections are made at the RS485 terminals of each boiler s I O Box Figures 2 7 or 2 8 However activating bias and loop termination can be performed using one of two available methods as described below in Method A and on the following page in Method B Where possible Method B is the preferred method Method A For Method A the bias switches in the ACS are left in the deactivated up p...

Page 24: ...nd termination of the RS485 loop do not require any changes to be made to the DIP switches on the PMC board in the last C More Control Box The bus is independent of any C More control box Method B For Method B bias is controlled at the ACS by setting the two bias switches Figure 2 6 to the active down position Termination at the boiler end of RS485 loop is accomplished by activating the MODBUS R6 ...

Page 25: ...RS485 Modbus Wiring For Benchmark Series Boilers Sheet 1 of 2 NOTE Do not terminate the shields of the RS485 leads to the ground GND terminal The shields must be terminated at the source ends only Connect the shields of the incoming and outgoing RS485 leads together I O Board ACTIVATE BIAS1 BIAS2 TERM DIP SWITCHES ON PCM BOARD OF LAST C MORE CONTROL BOX OPEN DOOR TO ACCESS I O BOX BENCHMARK DO NOT...

Page 26: ...dbus Wiring For Benchmark Series Boilers Sheet 2 of 2 NOTE Do not terminate the shields of the RS485 leads to the ground GND terminal The shields must be terminated at the source ends only Connect the shields of the incoming and outgoing RS485 leads together Connect 120 OHM Watt resister between and RS485 terminals on the LAST C More Box I O Board OPEN DOOR TO ACCESS I O BOX BENCHMARK DO NOT USE T...

Page 27: ...Modbus Wiring For KC1000 Boilers Sheet 1 of 2 NOTE Do not terminate the shields of the RS485 leads to the ground GND terminal The shields must be terminated at the source ends only Connect the shields of the incoming and outgoing RS485 leads together I O Board DO NOT USE THESE TERMINALS RS485 CONNECTIONS SEE NOTE PMC BOARD ACTIVATE BIAS1 BIAS2 TERM DIP SWITCHES ON PCM BOARD OF LAST C MORE CONTROL ...

Page 28: ... Modbus Wiring For KC1000 Boilers Sheet 2 of 2 NOTE Do not terminate the shields of the RS485 leads to the ground GND terminal The shields must be terminated at the source ends only Connect the shields of the incoming and outgoing RS485 leads together Connect 120 OHM Watt resister between and RS485 terminals on the LAST C More Box I O Board DO NOT USE THESE TERMINALS RS485 CONNECTIONS SEE NOTE REM...

Page 29: ... MODBUS B of connector Y2 2 Connect the negative lead to terminal 2 MODBUS A of connector Y2 3 DO NOT terminate the shields at the Boiler end of the RS485 loop Connect the shields of the incoming and outgoing leads together The RS485 loop shield should only be terminated at the ACS 4 The last BCM in the daisy chain must have the termination jumper engaged as shown in Figure 2 9 5 The two ACS bias ...

Page 30: ...ith the ACS connected to Modulex Series Boilers equipped with BCMs and E8 Controllers Figure 2 10 Sample RS485 Modbus Network For Benchmark or KC1000 Boilers Figure 2 11 Sample RS485 Modbus Network For Modulex Series Boilers NOTE The last C More slave on the RS485 loop must have its termination resister TERM and bias BIAS1 BIAS2 DIP Switches turned on Refer to Section 2 7 of this manual for detail...

Page 31: ...s labeled RXD Receive Data TXD Transmit Data and 232 ISO GND Isolated Ground If the EMS does not contain an RS232 port a RS485 to RS232 Converter AERCO P N 124943 is required to communicate with the ACS If a Converter is required it can be installed inside the wiring compartment of the ACS or installed externally The ACS provides an isolated 12 VDC output terminal ISO 12V which can be used to powe...

Page 32: ...d SETBK terminals Only a dry contact may be applied 2 10 1 Interlock 1 INT 1 Wiring Interlock 1 is often used with auxiliary equipment such as air dampers or flow switches It can also be used as a general purpose interlock If used connect the end proving switch to INT 1 terminals 9 and 10 as shown in wiring diagram in Appendix E 2 10 2 Interlock 2 INT 2 Wiring Similar to Interlock 1 Interlock 2 is...

Page 33: ...u Contact closure can be set to ALL FAULTS NO INTERLOCK INTERLOCK 2 or INTERLOCK 1 The default for this option is ALL FAULTS 2 12 3 Auxiliary Relay The state of the Auxiliary AUX relay contacts are controlled by the AUX RELAY CLOSE and AUX RELAY OPEN options selected in the Relay Menu Contact closure can be set to occur either when all available boilers are at the 100 Fire Rate or for either when ...

Page 34: ...LLATION AND WIRING 2 15 The ACS Relay Panel should be installed on a wall next to or as near as possible to the ACS The enclosure is the same as the ACS and so similar hardware can be used See Section 2 2 Site Selection and Mounting for further installation information Figure 2 14 AERCO Control System ACS Relay Box with Wiring Cover Removed and Breakout Illustration of Connection Silk Screening ...

Page 35: ...MM 0081_0F Phone 800 526 0288 GF 131 Figure 2 14a shows sample wiring diagram of the relay box wiring and Figure 2 14b shows the wiring to the ACS unit for a two valve combination system Your actual wiring may vary depending on the type of valves being used Figure 2 14a Wiring of the Relay Box to the AERCO Control System ACS Relay Box for ACS ...

Page 36: ...ER 2 ACS Installation Page 36 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F Figure 2 14b ACS Wiring DHW Option 1 DHW Pump Enabled Disabled by Building Controls ...

Page 37: ...S CHAPTER 2 ACS Installation 11 22 2017 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Page 37 of 139 OMM 0081_0F Phone 800 526 0288 GF 131 Figure 2 14c ACS Wiring DHW Option 2 DHW Pump Enabled Disabled by ACS ...

Page 38: ...ontrol System ACS CHAPTER 2 ACS Installation Page 38 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F Figure 2 14d ACS Wiring DHW Option 3 ...

Page 39: ...or 240 VAC The switch outputs connect directly to the ACS and are all dry contacts The specifics are below DHW Pump Relay This SPST relay is used to activate a DHW pump when the DHW Aquastat is calling for heat When the Aquastat stops calling the relay will remain activated for 1 minute before turning off Valve I Relay This SPDT relay controls the valve between the Building Priority boilers and th...

Page 40: ...t is not already closed Once closed the ACS will allow the DHW Priority boilers to run to provide heat to the tank If all the DHW Priority boilers are running at 100 for more than 2 minutes the ACS will open Valve 1 and close Valve 2 and activate the Building Priority boilers to help with DHW heating When the Aquastat Input opens the DHW Pump will turn off after some time delay currently 60 second...

Page 41: ...boilers would be programmed at NETW BOILER 1 ADDRESS NETW BOILER 2 ADDRESS NETW BOILER 3 ADDRESS and NETW BOILER 4 ADDRESS Building Priority boilers would be programmed at NETW BOILER 29 ADDRESS and NETW BOILER 30 ADDRESS DHW Priority boilers would be programmed at NETW BOILER 31 ADDRESS and NETW BOILER 32 ADDRESS 2 18 2 Configuration Menu Relay Panel Settings Configuration Menu Settings for Relay...

Page 42: ...APTER 2 ACS Installation Page 42 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F the number of boilers to your particular system This page intentionally blank ...

Page 43: ...ed on the front panel of the unit This Chapter describes the basic procedure to navigate through the extensive array of menus and options incorporated in the ACS design Descriptions for all menus and options are also provided FRONT PANEL OPERATING CONTROLS AND DISPLAYS 3 2 The front panel of the ACS contains an vacuum fluorescent display VFD and an 8 key touch pad The display and controls are illu...

Page 44: ... in Figure 2 1 The Menu categories wrap around in the order shown BACK Allows you to go back to the previous menu level without changing any information Continuously pressing this key will bring you back to the default status display in the Operating Menu Also this key allows you to go back to the top of a main menu category Up Arrow When in one of the main menu categories pressing this key will m...

Page 45: ...g each menu and option is accomplished using the Menu Keys shown in Figure 3 1 Therefore it is imperative that you be thoroughly familiar with the following basic steps shown in Instruction 3 1 1 before attempting to perform specific menu processing procedures Menu Processing Procedure 1 The ACS will normally be in the Operating Menu and the VFD will display the current unit status Pressing the or...

Page 46: ... of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F OPERATING SETUP RS232 RS485 FIELD ADJUST CONFIGURATION TUNING RELAY CALIBRATION LEVEL 1 PWD LEVEL 2 PWD Figure 3 2 ACS Menu Structure ...

Page 47: ...erature F measured by the Header Sensor connected to HDR SEN terminals 4 and 5 of the ACS If the Header Sensor is not installed HDR SENS ERROR will appear in the first line of the display The red FAULT indicator will also light The Header Sensor MUST be installed for the ACS to operate properly The PERCENT OF LOAD option shows the percent level going from the ACS to each boiler in the boiler plant...

Page 48: ...his optional sensor is used for monitoring purposes as well as for Plant DT limit operation 3 4 6 NETWORK BOILER OUTLET TEMPERATURE When BLR CNTL SELECT is set to C More or BCM the outlet temperature of the boilers connected may be viewed here Press the Change Key to view the other temperatures Press Enter to stop at a particular boiler temperature 3 4 7 NETWORK BOILER ERROR CODE When BLR CNTL SEL...

Page 49: ...to advance to the next digit Press Enter when the desired password is displayed 3 5 2 DATE AND TIME MENU OPTIONS The Setup Menu options associated with date and time are as follows SET MONTH 01 12 SET DATE 01 31 SET YEAR 00 99 SET HOUR 00 23 SET MINUTE 00 59 SET DAY OF WEEK SUNDAY TO SATURDAY RS232 MENU 3 5 The RS232 MENU options permit the ACS to communicate with an external Energy Management Sys...

Page 50: ...enable communication between the ACS and the connected network boiler slaves Each network boiler on the Modbus network must be assigned a unique address to enable communication The RS485 Menu options are used to select the RS232 Baud Rate Min Max Range of Slave Addresses Total Number of Networked Boilers Type of Modbus Control and the Unique Address for each Networked Boiler Descriptions of these ...

Page 51: ... your ACS installation Included are options to select the Header Mode and Temperature Limits Internal Setpoint Building Reference Temperature Reset Ratio and Remote Signal In addition the Field Adjust Menu contains a series of options which can be used to set up a Header Setpoint Offset Schedule for an entire week Descriptions of the Field Adjust Menu options 3 8 1 HEADER SET MODE The HEADER SET M...

Page 52: ...gnal to 4 20 mA or MODBUS Default 4 20 mA 3 8 8 OFFSET ENABLE The OFFSET ENABLE menu option is used to turn ON or turn OFF the Setpoint Temperature Offset feature Default OFF 3 8 9 OFFSET MENU OPTIONS The Field Adjust Menu contains a series of menu options which permit an offset schedule to be set up for a 7 day period Sunday through Saturday For each day Sunday Saturday these options include OFFS...

Page 53: ...p a MANUAL Offset Schedule 1 Scroll through the FIELD ADJUST MENU and select OFFSET ENABLE Set this option to ON 2 Next scroll to SUN OFFS TEMP and set the desired Offset Temperature A different Offset Temperature can be set for each day if desired 3 Scroll through the remaining days of the week and set desired offset temperature for each day Once programmed as described above closing the SET BACK...

Page 54: ...level of 25 is chosen when the first boiler reaches 50 a second boiler will start after a 30 second delay and the ACS will distribute the load 25 for each boiler If the firing rate of both boilers reach a combined value equal to 3 times the start level a third boiler is started by the ACS after a 30 second delay and the load will be distributed across all three boilers This sequence will continue ...

Page 55: ...the only lead boiler This boiler will be the first one fired and the last one shut down on the boiler plant This boiler will not be included in the rotation scheme Be sure that the address of the boiler being selected is programmed as NETW BOILER 1 The default selection for this option is NONE 3 9 11 LAST BLR SELECT Last Boiler Selection The LAST BLR SELECT option selects the boiler that is to be ...

Page 56: ... OPTION These will be defined later OPTION 2 This option is selected when the ACS is to control a boiler plant containing up to 8 combination boilers that are divided up into Building Priority BLDG PRIORITY boilers and Domestic Hot Water Priority DHW PRIORITY boilers along with building heat BLDG HEAT boilers and using two hydronic isolation valves in the main header one between the BLDG HEAT and ...

Page 57: ...ACS will be acting as the DHW valve close contact or will be operating normally as the contact to indicate when the boiler plant system is enabled The default is DHW VALVE CLOSE in which case the ACS will use the SYS RELAY as the valve closure contact and the AUX RELAY output as the valve open contact If the hydronic valve being controlled has a spring return closure or other non powered closure o...

Page 58: ...he characteristics of your specific installation The factory defaults preset by AERCO work well for most applications In instances when there is a large error between the setpoint and the actual supply water temperature the ACS may appear to require PID tuning However it is best to observe ACS operation over a period of time prior to making any PID changes Contact AERCO or an AERCO representative ...

Page 59: ...ain setting will produce a large output for a short time This can result in overshoot of the setpoint Too low a derivative gain setting will have the opposite effect producing a small output for a longer period and may result in slow system response or the system undershooting the setpoint 3 11 4 Decreasing Boiler Cycles The five settings below HI_DB_SETPT_EN DEADBAND HIGH DEADBAND LOW SETPT DOWN ...

Page 60: ...der temperature is below Setpoint DEMAND OFFSET RELAY MENU 3 11 As the name implies the RELAY MENU contains the options necessary to select the actions performed by the System Start SYS START Fault Alarm FLT ALARM and Auxiliary AUX Relays in the ACS 3 12 1 SYS START TEMP If an Outdoor Air Sensor is installed this menu option is used to select the Outdoor Temperature below which the System Start Re...

Page 61: ...t alarm relay will only activate when Interlock 1 is opened and not when Interlock 2 is opened 3 12 7 FAULT ALARM BLRS This selection tells the ACS whether to activate the fault alarm relay if a boiler connected to it is faulted 3 12 8 FAULT ALRM CLEAR Selecting MANUAL will latch the fault alarm relay if a fault condition occurs and goes away The CLEAR key must be pushed to deactivate the relay If...

Page 62: ... Percent Level ramp up rate for the ACS The Percent Level output will follow the PID output if it is slower than this rate The default setting is 20 per minute Refer to the following example Ramp Up Min Time Required To Go From 0 To 100 20 5 Minutes 40 2 5 Minutes 50 2 Minutes NOTE TO TURN OFF THE RAMP UP MIN FUNCTION SET THE VALUE TO ZERO 0 3 13 6 RAMP DOWN MIN This sets the maximum Percent Level...

Page 63: ... On you must write 51 to that address Writing any other number will be ignored The front panel switch would have top priority so that if it is switched Off by the front panel button it cannot be switched On by the modbus command But if it is switched On by the front panel button it can be switched On and Off by the modbus command Reading the status would show 1 for On 2 for Modbus Off and 0 for Fr...

Page 64: ...step 3 NUMBER NETW BOILERS This setting is preset to 2 If more than 2 Boilers default enter number 03 04 etc NETW BOILER 01 ADDRESS 001 Address 001 and 002 are preset Enter other Network Addresses if required 003 004 005 etc FIELD ADJUST MENU If Setpt is other than 160 F default enter this menu otherwise go to step 4 INTERNAL SETPT Enter Setpoint temperature CONFIGURATION MENU If BLR START LEVEL 2...

Page 65: ...IELD ADJUST MENU HEADER SET MODE Set to REMOTE SETPT HDR HIGH LIMIT Enter the maximum temperature for the Remote Setpoint input this will be the temperature equivalent to a 20 mA input Default 200 F HDR LOW LIMIT Enter the minimum temperature for the Remote Setpoint input this will be the temperature equivalent to a 4 mA input Default 40 F REMOTE SIGNAL Select 4 20 mA default or MODBUS CONFIGURATI...

Page 66: ...ue if required default 1 2 Refer to Appendix C BLDG REF TEMP Enter the desired Building Reference Temperature Default 70 F Refer to Appendix C CONFIGURATION MENU FAIL SAFE MODE Set to CONSTANT SETPT if you want to maintain a Constant Setpointt temperature in the event that the Outdoor Sensor signal is lost Default SHUTDOWN RELAY MENU SYS START TEMP Enter the outdoor temperature below which the sys...

Page 67: ...aragraphs 4 2 through 4 4 Refer to Chapter 3 for instructions on password entry and basic menu processing procedures OUTDOOR RESET MODE 4 2 The Outdoor Reset mode operates based on outside air temperature In this mode the header supply water temperature will vary up or down in accordance with outside air temperature Therefore in order to set up and operate in this mode an outdoor air sensor MUST b...

Page 68: ...t a change is in process 4 Using the or arrow key select OUTDOOR RESET 5 Press the ENTER key to store the change The reverse video display will revert to the normal display format indicating that the change has been store in memory While still in the Field Adjust Menu proceed to the next paragraph and continue the set up procedure 4 2 2 Determining Reset Schedule There are two variables that must ...

Page 69: ...eo format 7 Select the required BLDG REF TEMP using the or arrow key 8 Press the ENTER key to store the change The reverse video display will revert to the normal VFD display format 9 This completes the required entries in the Field Adjust Menu Proceed to the next paragraph and select the Boiler Operating Mode 4 2 4 SELECTING BOILER OPERATING MODE The Boiler Plant can be set for either Parallel or...

Page 70: ...e or arrow key 4 Press the ENTER key to store the changed Start Level The reverse video display will revert to the normal VFD display format 5 Next scroll through the menu until the BLR STOP LEVEL is displayed along with the current setting default 16 6 If the desired Boiler Stop Level is not displayed repeat steps 2 3 and 4 above and enter the desired Stop Level 4 2 6 Entering Boiler Start and Bo...

Page 71: ... follow 4 3 1 Selecting Remote Setpoint Mode The Remote Setpoint Mode is selected using the Header Set Mode option in the Field Adjust Menu as shown below Selecting Remote Setpoint Mode 1 Using the keypad on the ACS press the MENU key until FIELD ADJUST MENU appears in the display 2 Using the or arrow key on the keypad scroll through the menu until HEADER SET MODE is displayed in the first line of...

Page 72: ... display will switch to a reverse video format indicating that a change is in process 3 Using the or arrow key select required HDR HIGH LIMIT temperature 4 Press the ENTER key to store the change The reverse video display will revert to the normal display format indicating that the change has been store in memory 5 Next scroll through the FIELD ADJUST MENU until HDR LOW LIMIT is displayed in the f...

Page 73: ... indicating that the change has been store in memory 5 This completes all required entries in the Field Adjust Menu To complete Remote Setpoint Mode setup select the Boiler Operating Mode option as shown at right 4 3 4 Selecting Boiler Operating Mode The Boiler Plant can be set for either Parallel or Sequential Mode operation The Boiler Operating Mode is selected in the Configuration Menu as shown...

Page 74: ...Start Level is not displayed press the CHANGE key The display will switch to a reverse video format 3 Select the desired Boiler Start Level using the or arrow key 4 Press the ENTER key to store the changed Start Level The reverse video display will revert to the normal VFD display format 5 Next scroll through the menu until the BLR STOP LEVEL is displayed along with the current setting default 16 ...

Page 75: ...reverse video display will revert to the normal display format indicating that the change has been store in memory With the ACS still in the FIELD ADJUST MENU proceed to next paragraph to select the Internal Setpoint Temperature 4 4 2 Selecting Internal Setpoint Temperature The Internal Setpoint Temperature is selected using in the Field Adjust Menu below Selecting Internal Setpoint Temperature 1 ...

Page 76: ...ss the ENTER key to store the change The reverse video display will revert to the normal display format indicating that the change has been store in memory 6 The ACS is now programmed for operation in the Constant Setpoint Mode 4 4 4 Entering Boiler Start and Boiler Stop Levels The Boiler BLR Start and Boiler Stop Levels are also entered in the Configuration Menu Refer to Appendix I to determine t...

Page 77: ...e System Start Relay will activate when the PERCENT OF LOAD is at or above the LOAD START PCT The system will shut down when the PERCENT OF LOAD falls below the LOAD STOP PCT START ENABLED OPTION 4 6 The ACS can be used to turn on and prove a device such as a fresh air damper gas booster or the flow of a local pump before ramping up the output With SYS INTLK CONFIG Configuration Menu set to START ...

Page 78: ...arm and shut down the plant In this case you can set the Return Sensor Mode to OFF to temporarily disable the Plant Delta T function and then set it to NORMAL after the return water has warmed up Testing the System Using the C More Controls 1 Turn off the ACS by pressing the ON OFF key The ON LED will turn off 2 Using the MENU key select the FIELD ADJUST MENU and scroll to the HEADER SET MODE opti...

Page 79: ...T settings to their previously stored values 11 If the System Test is not completed successfully refer to the troubleshooting procedures in this manual Chapter 5 and the applicable O M Manuals for the boilers included in the boiler plant If the problem can still not be resolved contact AERCO at 1 800 526 0288 CAUTION Monitor the HDR TEMP reading to ensure it is not ramping up too high If it is pre...

Page 80: ...rol System ACS CHAPTER 4 Programing ACS Operating Modes Page 80 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F This page intentionally blank ...

Page 81: ...e Description Possible Cause OUTSIDE AIR TEMP NOT CONNECTED Open outside air temp sensor resistance greater than 240K ohms less than 40 F Shorted outside air temp sensor resistance less than 1K ohms greater than 200 F No sensor connected Note Displays only in Remote Setpt and Constant Setpoint modes I OUTSIDE AIR TEMP SENSOR ERROR When in Outdoor Reset Mode the outside air temperature sensor is ei...

Page 82: ...t operation when the ACS is functioning as a Slave to an EMS Master Error indicates that the Network Timeout has expired NETWORK DISABLED MODBUS LISTEN Displayed during Modbus operation when the FORCE LISTEN ONLY Modbus diagnostic command is sent to the ACS Slave by the controlling Master thereby disabling normal Modbus Network communication It indicates that the ACS is listening for the RESTART C...

Page 83: ...More Box not enabled Front panel switch is off Incorrect wiring between ACS and Boiler Alarm condition present on C More Control Box Ensure that the C More Boiler is configured for Direct Drive see Chapter 5 of correct BMK or KC1000 O M Manual for required menu settings Check ON OFF switch See Chapter 2 for correct wiring connections Clear alarm condition Modulex Boiler with BCM Control not being ...

Page 84: ...ons and installation Adjust PID settingsin TUNING MENU paragraph 3 10 If aquastat is set lower than 200 F reset it to 220 F If system pumps are shut down check start and stop temperatures on energy management system They should correspond to those set in the ACS In addition interlock wiring can be run between the ACS and energy management system to disable the ACS pumps when pumps are not running ...

Page 85: ... I O STATUS See Appendix B RETURN TEMP Displayed Only If RETURN SENSOR MODE NORMAL or DHW TANK TEMP 40 280 N A OUTLET TEMP Displayed Only If BOILER CONTROL SELECT CMORE or BCM 40 280 N A ERROR STATUS CODE Displayed Only If BOILER CONTROL SELECT CMORE or BCM See App B See App B N A SETUP MENU ENTER PASSWORD Level 1 159 Level 2 6817 0 32000 0 SET MONTH 01 12 SET DATE 01 31 SET YEAR 00 99 SET HOUR 00...

Page 86: ...0 9600 MIN SLAVE ADDR 000 127 000 MIN SLAVE ADDR 000 127 000 NUMBER NETW BLRS 00 32 02 MODBUS CNTL TYPE ROUND ROBIN BROADCAST ROUND ROBIN NETW BOILER 01 ADDRESS 000 127 001 NETW BOILER 02 ADDRESS 000 127 002 NETW BOILER 03 ADDRESS 000 127 000 Etc Up To FIELD ADJUST MENU HEADER SET MODE CONSTANT SETPOINT OUTDOOR RESET REMOTE SETPOINT CONSTANT SETPOINT HDR HIGH LIMIT 040 F 220 F 200 F HDR LOW LIMIT ...

Page 87: ... ON HOUR 00 23 00 SUN ON MINUTE 00 59 00 SUN OFF HOUR 00 23 00 SUN OFF MINUTE 00 59 00 Etc Up To SAT OFF MINUTE 00 59 00 CONFIGURATION MENU BOILER CONTROL SELECT OFF CMORE BCM OFF BOILER OP MODE SEQUENTIAL MODE PARALLEL MODE SEQUENTIAL MODE SYS INTLK CONFIG START ENABLED ALWAYS ENABLED START ENABLED BLR START LEVEL 001 100 020 BLR STOP LEVEL 001 040 016 MAX POWER INPUT 050 100 100 FAIL SAFE MODE S...

Page 88: ... DHW OPTION 1 NORMAL DHW VALVE 1 DHW VALVE 1 NUMBER OF DHW PRIORITY BLRS Displayed Only if DHW OPTION 2 0 TO NUM DHW BLRS 1 0 BOOST TEMP Displayed Only if DHW OPTION 3 40 F TO 200 F 140 F RETURN TEMP BOOST DISABLE 10 F TO 10 F 0 F TUNING MENU PROPORTIONAL BND 005 F 120 F 070 F INTEGRAL GAIN 0 00 REP MIN 9 99 REP MIN 0 15 REP MIN DERIVATIVE GAIN 2 00 MIN 2 00 MIN 0 15 MIN HIGH DB SETPT ENABLE BLR S...

Page 89: ... ALL FAULTS NO INTERLOCK INTERLOCK 2 INTERLOCK 1 ALL FAULTS FAULT ALARM BLRS NO BLR FAULTS ALL BLR FAULTS NO BLR FAULTS FAULT ALRM CLEAR AUTOMATIC MANUAL RESET AUTOMATIC CALIBRATION MENU HDR SENS OFFSET 10 0 10 0 00 0 OUTD SENS OFFSET 10 0 10 0 00 0 4 20 MA OFFSET 10 0 10 0 00 0 RET SENS OFFSET 10 0 10 0 00 0 RAMP UP MIN 000 300 020 RAMP DOWN MIN 000 300 200 RESET DEFAULTS NO YES DONE If Selected ...

Page 90: ...AERCO Control System ACS APPENDIX A ACS Menus Page 90 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F This page intentionally blank ...

Page 91: ...t restart Communications Options will be ignored The ACS will operate in the Fail Safe Mode OUTSIDE AIR TEMP NOT CONNECTED The Outdoor Air Temperature Sensor is not installed and connected RETURN TEMP NOT INSTALLED The Boiler Return Temperature Sensor is not installed FAULT MESSAGES OUTDOOR SENSOR ERROR The Outdoor Air Temperature Sensor signal is out of range HEADER SENSOR ERROR The Header Temper...

Page 92: ...in seconds 5 IGNITION TRIAL XX sec Displayed during ignition trial of startup sequence The duration of cycle counts up in seconds 6 FLAME PROVEN Displayed after flame has been detected for a period of 2 seconds Initially the flame strength is shown in After 5 seconds has elapsed the time and date are shown in place of flame strength 7 WARMUP XX sec Displayed for 2 minutes during the initial warm u...

Page 93: ... seen during ignition or lost within 5 seconds after ignition 23 FLAME LOSS DURING RUN The Flame signal was lost during run 24 HIGH EXHAUST TEMPERATURE The High Exhaust Temperature Limit Switch is closed 25 LOSS OF POWER A power loss occurred The time and date when power was restored is displayed 26 LOSS OF SENSOR Not Currently Used 27 LOSS OF SIGNAL Not Currently Used 28 HIGH O2 LEVEL Not Current...

Page 94: ...asured by the Outlet Sensor is out of range 43 FFWD TEMP SENSOR FAULT The temperature measured by the FFWD Sensor is out of range 44 HIGH WATER TEMPERATURE The temperature measured by the Outlet Sensor exceeded the Temp Hi Limit setting 45 LINE VOLTAGE OUT OF PHASE The High AC voltage is out of phase from the low AC voltage 46 STEPPER MOTOR FAILURE The stepper motor failed to move the valve to the...

Page 95: ...GF 131 TABLE B 2 C More Status and Fault Messages Code Message Description 57 INLET_TEMP_SENSOR_ OPEN_MESSAGE 58 INLET_TEMP_HIGH_ WARNING_MESSAGE 59 INLET_TEMP_LOW_ WARNING_MESSAGE 60 INLET_GAS_PRESSURE_ SENSOR_OPEN_MESSAGE 61 GAS_PLATE_DP_SENSOR_ OPEN_MESSAGE 62 INLET_WATER_FLOW_ SENSOR_OPEN_MESSAGE 63 INLET_WATER_FLOW_ LOW_WARNING_MESSAGE 64 INLET_WATER_FLOW_ HIGH_WARNING_MESSAGE ...

Page 96: ...C DEGREES_2 80 1000 500 220 RegVar Temp F 62 1000 500 183 RegVar Temp C DEGREES_3 40 1000 500 520 RegVar Temp F 4 1000 500 289 RegVar Temp C ABS_DEG_1 For RegVar 0 1000 500 230 RegVar Temp F For RegVar 0 1000 500 230 RegVar Temp F For RegVar 0 1000 500 128 RegVar Temp C For RegVar 0 1000 500 128 RegVar Temp C TABLE B 3 Conversion Equations for Temp Variables Temp to Variable Counts Register Variab...

Page 97: ...ault None 1 and 255 BMM 0 Fault Displayed Number BMM Fault Code in Table B 6 256 and 511 BMM 1 Fault Subtract 256 from Displayed Number BMM Fault Code in Table B 6 512 and 767 BMM 2 Fault Subtract 512 from Displayed Number BMM Fault Code in Table B 6 768 and 1023 BMM 3 Fault Subtract 768 from Displayed Number BMM Fault Code in Table B 6 1024 and 1279 BMM 4 Fault Subtract 1024 from Displayed Number...

Page 98: ... Check the system installation AUTOMATIC when Δ temperature Water Δ Temp Protection 19 High outlet temperature FlowSensor temperature 203 F All burners turned OFF and Pump ON at maximum speed Check Flow Sensor or system pump AUTOMATIC when FlowSensor 176 F 38 Settings Corrupted Ignition is inhibited Pump runs for 5 min at max speed Re program the settings Contact Factory MANUAL push reset switch o...

Page 99: ... during run Ignition retry Check combustion and wiring MANUAL push reset switch or cycle power 6 High outlet temperature FlowSensor temperature 203 F All burners turned OFF and Pump ON at maximum speed Check Flow Sensor or system pump AUTOMATIC when FlowSensor 176 F 10 Internal Failure Ignition is inhibited Contact Factory for new BCM MANUAL cycle the power 11 Flame signal detected before ignition...

Page 100: ...on retry after 60 second delay and failure remains until we have a successful burner operation If fan is stopped check supply voltage and fan wiring If OK try another fan If still not working change the BMM If fan is not stopped check the exhaust gas outlet for blockage If OK then check the air pressure switch wiring If still not working try another air pressure switch If still not working change ...

Page 101: ...rge timer The failure remains until we have a successful burner operation Check fan and wiring Check air proving switch and wiring AUTOMATIC 30 Settings Corrupted Ignition is inhibited Pump runs for 5 min at max speed Re program the settings Contact Factory MANUAL cycle the power or send reset message 32 Line voltage too low 96 VAC Wait for proper line voltage 102 VAC Check input voltage else try ...

Page 102: ... OFF ON 06 N A OFF OFF OFF N A ON ON OFF 07 N A OFF OFF OFF N A ON ON ON 08 09 N A N A N A N A N A N A N A N A 10 N A OFF OFF ON N A OFF OFF OFF 11 N A OFF OFF ON N A OFF OFF ON 12 N A OFF OFF ON N A OFF ON OFF 13 N A OFF OFF ON N A OFF ON ON 14 N A OFF OFF ON N A ON OFF OFF 15 N A OFF OFF ON N A ON OFF ON 16 N A OFF OFF ON N A ON ON OFF 17 N A OFF OFF ON N A ON ON ON 18 19 N A N A N A N A N A N A...

Page 103: ...A ON OFF OFF N A OFF ON ON 44 N A ON OFF OFF N A ON OFF OFF 45 N A ON OFF OFF N A ON OFF ON 46 N A ON OFF OFF N A ON ON OFF 47 N A ON OFF OFF N A ON ON ON 48 49 N A N A N A N A N A N A N A N A 50 N A ON OFF ON N A OFF OFF OFF 51 N A ON OFF ON N A OFF OFF ON 52 N A ON OFF ON N A OFF ON OFF 53 N A ON OFF ON N A OFF ON ON 54 N A ON OFF ON N A ON OFF OFF 55 N A ON OFF ON N A ON OFF ON 56 N A ON OFF ON...

Page 104: ...Status MSD Most Significant Digit LSD Least Significant Digit I O Status MSD Bit 3 Inter Lock MSD Bit 2 Inter Lock 2 MSD Bit 1 Setback MSD Bit 0 Lsd Bit 3 Sys Strt Relay LSD Bit 2 Fault Relay LSD Bit 1 Aux Relay LSD Bit 0 73 N A ON ON ON N A OFF ON ON 74 N A ON ON ON N A ON OFF OFF 75 N A ON ON ON N A ON OFF ON 76 N A ON ON ON N A ON ON OFF 77 N A ON ON ON N A ON ON ON 78 79 N A N A N A N A N A N ...

Page 105: ...elected points For example for a degree day of 15 F and a header temperature of 125 F the reset ratio is 1 4 C 2 DETERMINING RESET SCHEDULE BY FORMULA There are two steps required to determine reset schedule with this method The first is to determine the reset ratio by dividing the range of outside temperatures by the range of header temperatures Theader Toutside Reset Ratio for example If Toutsid...

Page 106: ...158 F 170 F 182 F 194 F 15 F 89 F 102 F 115 F 128 F 141 F 154 F 167 F 180 F 193 F 206 F 20 F 92 F 106 F 120 F 134 F 148 F 162 F 176 F 190 F 204 F 218 F TABLE C 2 Header Temperature for a Building Reference Temperature of 60 F Air Temp RESET RATIO 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 60 F 60 F 60 F 60 F 60 F 60 F 60 F 60 F 60 F 60 F 60 F 55 F 63 F 64 F 65 F 66 F 67 F 68 F 69 F 70 F 71 F 72 F 50 ...

Page 107: ...5 F 208 F 5 F 107 F 121 F 135 F 149 F 163 F 177 F 191 F 205 F 219 F 10 F 110 F 125 F 140 F 155 F 170 F 185 F 200 F 215 F 15 F 113 F 129 F 145 F 161 F 177 F 193 F 209 F TABLE C 4 Header Temperature for a Building Reference Temperature of 70 F Air Temp RESET RATIO 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 70 F 70 F 70 F 70 F 70 F 70 F 70 F 70 F 70 F 70 F 70 F 65 F 73 F 74 F 75 F 76 F 77 F 78 F 79 F 80...

Page 108: ...131 F 145 F 159 F 173 F 187 F 201 F 215 F 0 F 120 F 135 F 150 F 165 F 180 F 195 F 210 F 5 F 123 F 139 F 155 F 171 F 187 F 203 F 219 F 10 F 126 F 143 F 160 F 177 F 194 F 211 F 15 F 129 F 147 F 165 F 183 F 201 F 219 F TABLE C 6 Header Temperature for a Building Reference Temperature of 80 F Air Temp RESET RATIO 0 6 0 8 1 0 1 2 1 4 1 6 1 8 2 0 2 2 2 4 80 F 80 F 80 F 80 F 80 F 80 F 80 F 80 F 80 F 80 F...

Page 109: ... F 106 F 110 F 114 F 118 F 122 F 126 F 130 F 134 F 138 F 65 F 105 F 110 F 115 F 120 F 125 F 130 F 135 F 140 F 145 F 150 F 60 F 108 F 114 F 120 F 126 F 132 F 138 F 144 F 150 F 156 F 162 F 55 F 111 F 118 F 125 F 132 F 139 F 146 F 153 F 160 F 167 F 174 F 50 F 114 F 122 F 130 F 138 F 146 F 154 F 162 F 170 F 178 F 186 F 45 F 117 F 126 F 135 F 144 F 153 F 162 F 171 F 180 F 189 F 198 F 40 F 120 F 130 F 1...

Page 110: ...emperature F Resistance ohms 40 239 571 180 1 362 30 173 530 190 1 155 20 127 088 200 984 10 94 059 210 842 0 70 314 220 723 10 53 068 230 623 20 40 418 240 539 30 31 053 250 468 40 24 057 260 408 50 18 787 270 357 60 14 783 280 313 70 11 717 290 276 80 9 353 300 243 90 7 516 310 100 6 078 320 110 4 946 330 120 4 049 340 130 3 333 350 140 2 759 360 150 2 296 370 160 1 920 380 170 1 613 390 NOTE Th...

Page 111: ... Control System ACS APPENDIX E ACS Wiring Diagram 11 22 2017 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 Page 111 of 139 OMM 0081_0F Phone 800 526 0288 GF 131 APPENDIX E ACS WIRING DIAGRAM ...

Page 112: ...lt Alarm and Auxiliary Relays 69091 4 20 mA Fuse 63 microamp fuse for current loop GP 122662 Outside Air Temperature Sensor Sensor Only GM 122781 Outside Air Temperature Sensor Kit Includes Sensor GP 122662 and Mounting Bracket 64038 Header Temperature Sensor Sensor Only GP 122758 Thermowell for Header Temperature Sensor Thermowell Only GM 122790 Header Temperature Sensor Kit Includes 64038 and GP...

Page 113: ...e G 2 AQUIRING THE PuTTY APPLICATION Download the putty exe program to your desktop from www chiark greenend org uk sgtatham putty download html You can use PuTTY to logon to remote computers as well as run a single command on a remote server PuTTY does not need to be installed so just clicking the downloaded executable will start it G 2 1 Logging on to a Remote Machine Using PuTTY To use PuTTY to...

Page 114: ...g on the remote server After specifying the command line you want to run you will be asked for your account name and password and then the command you specified will execute When it completes your session will terminate and your window will either close or remain open depending on how you configure the session Here are the steps Running a Command on a Remote Machine Using PuTTY 1 Bring up the PuTT...

Page 115: ... the RS232 MODE option 8 Press the or arrow key to display NORMAL Press the ENTER key to store the NORMAL selection 9 Start the emulator software program 10 At the command prompt enter the password EXACTLY as follows case sensitive P gobms 11 Press Return Rtn on your terminal 12 The setup is now complete You are ready to begin viewing or changing ACS functions G 4 PROGRAMMING PROCEDURE ACS functio...

Page 116: ...12 Maximum Header Temperature F 40 to 220 220 13 Minimum Header Temperature F 40 to 220 40 14 Boiler Start Percent 25 to 100 20 15 Boiler Stop Percent 10 to 45 16 16 Integral Gain Rep Min 0 00 to 9 99 0 01 increments 0 15 17 Header Set Mode 0 Constant Setpt 1 Indr Outdr Reset 2 Remote Settemp 0 Constant Setpt 18 Derivative Gain 2 00 to 2 00 0 01 increments 0 15 19 Proportional Band F 5 to 100 70 2...

Page 117: ...utdr Reset 2 Remote Settemp 0 Constant Setpt 18 Derivative Gain 2 00 to 2 00 0 01 increments 0 15 19 Proportional Band F 5 to 100 70 20 Aux Relay Open 0 to 99 45 21 Aux Relay Close 0 100 Fire Rate 1 100 and OFF 1 100 AND OFF 22 Failsafe Mode 0 Shutdown 1 Switch Inputs 0 Shutdown 23 Fault Relay Mode 0 All Faults 1 No Interlock 2 Interlock 2 3 Interlock 1 0 All Faults 24 Alarm Clear Method 0 Automat...

Page 118: ...et F 10 F to 10 F 0 61 System Start Interlock 1 Intlk 1 Opens Start Relay 2 Intlk 2 Opens Start Relay 3 Either Intlk Opens Start Relay 1 Intlk 1 70 Sun Thru Offset OFF Time Minutes Sun Sat 00 to 59 All Set To Zero 76 Sat 77 Day 1 Thru Offset OFF Time Hours Day 1 7 0 to 23 All Set To Zero 83 Day 7 84 Reserved 85 Not Used 0 or 1 86 Remote Signal 0 or 1 0 4 20 mA 1 Modbus 0 4 20 mA 87 RS232 Mode 0 or...

Page 119: ... Boiler 11 000 103 Net Boiler 12 Address Address for Network Boiler 12 000 104 Net Boiler 13 Address Address for Network Boiler 13 000 105 Net Boiler 14 Address Address for Network Boiler 14 000 106 Net Boiler 15 Address Address for Network Boiler 15 000 107 Net Boiler 16 Address Address for Network Boiler 16 000 108 Net Boiler 17 Address Address for Network Boiler 17 000 109 Net Boiler 18 Address...

Page 120: ...Baud 0 2400 1 4800 2 9600 3 14400 4 19200 2 9600 125 Network Timeout 5 to 240 sec 60 sec 126 Password Lo 0 to 255 0 127 Password Hi 0 to 255 0 128 Modbus Control Type 0 Round Robin 1 Broadcast 0 Round Robin 129 Modbus Pass Thru 0 Disabled 1 Enabled 0 Disabled 130 Header Temp Deadband 01 to 15 F 05 F 131 Outside Temp Sensor Offset 10 0 F to 10 0 F 0 0 F 132 Ramp Up Min 000 to 300 20 133 Ramp Down M...

Page 121: ... 1 ACS CONTROLLER STANDARD INPUT REGISTER ASSIGNMENTS The Read Only Input Register assignments for the ACS are listed in Table H 1 which follows TABLE H 1 ACS Standard Input Register Address Mapping Modbus Data Address Decimal Hex Menu Item Units and Range Default Comments 0 0x0000 Reserved 1 0x0001 Header Temperature 40 to 220 F 2 0x0002 Outside Air Temperature 60 to 120 F 3 0x0003 Indoor Air Ret...

Page 122: ...red Sequence 121 On Line But Disabled 122 On Line But Faulted ACS has only Network Boilers so Net Boiler 1 Boiler 1 etc 26 0x001A Boiler 2 Status Net Boiler 2 Same As Above 27 0x001B Boiler 3 Status Net Boiler 3 Same As Above 28 0x001C Boiler 4 Status Net Boiler 4 Same As Above 29 0x001D Boiler 5 Status Net Boiler 5 Same As Above 30 0x001E Boiler 6 Status Net Boiler 6 Same As Above 31 0x001F Boile...

Page 123: ...6 Status Net Boiler 16 Same As Above 41 0x0029 Boiler 17 Status Net Boiler 17 Same As Above 42 0x002A Boiler 18 Status Net Boiler 18 Same As Above 43 0x002B Boiler 19 Status Net Boiler 19 Same As Above 44 0x002C Boiler 20 Status Net Boiler 20 Same As Above 45 0x002D Boiler 21 Status Net Boiler 21 Same As Above 46 0x002E Boiler 22 Status Net Boiler 22 Same As Above 47 0x002F Boiler 23 Status Net Bo...

Page 124: ...0038 Boiler 32 Status Net Boiler 32 Same As Above 57 0x0039 I O Status 00 to 255 Bit map of Input Output Status LSD Bit 0 AUX Relay Bit 1 Fault Relay Bit 2 Sys Start Relay Bit 3 Empty MSD Bit 4 Setback Bt 5 Interlock 2 Bit 6 Interlock 1 Bit 7 Empty See Appendix A Table A 7 58 0x003A Return Sensor Temp 40 F to 220 F When Ret Sensor Mode Normal 59 0x003B Net Blr 1 Outlet Temp 40 F to 220 F When Blr ...

Page 125: ...40 F to 220 F 76 0x004C Net Blr 18 Outlet Temp 40 F to 220 F 77 0x004D Net Blr 19 Outlet Temp 40 F to 220 F 78 0x004E Net Blr 20 Outlet Temp 40 F to 220 F 79 0x004F Net Blr 21 Outlet Temp 40 F to 220 F 80 0x0050 Net Blr 22 Outlet Temp 40 F to 220 F 81 0x0051 Net Blr 23 Outlet Temp 40 F to 220 F 82 0x0052 Net Blr 24 Outlet Temp 40 F to 220 F 83 0x0053 Net Blr 25 Outlet Temp 40 F to 220 F 84 0x0054 ...

Page 126: ...e as Above 102 0x0066 Net Blr 11 Code Same as Above 103 0x0067 Net Blr 12 Code Same as Above 104 0x0068 Net Blr 13 Code Same as Above 105 0x0069 Net Blr 14 Code Same as Above 106 0x006A Net Blr 15 Code Same as Above 107 0x006B Net Blr 16 Code Same as Above 108 0x006C Net Blr 17 Code Same as Above 109 0x006D Net Blr 18 Code Same as Above 110 0x006E Net Blr 19 Code Same as Above 111 0x006F Net Blr 2...

Page 127: ...913 Page 127 of 139 OMM 0081_0F Phone 800 526 0288 GF 131 TABLE H 1 ACS Standard Input Register Address Mapping Modbus Data Address Decimal Hex Menu Item Units and Range Default Comments 122 0x007A Net Blr 31 Code Same as Above 123 0x007B Net Blr 32 Code Same as Above 124 0x007C Thru 65535 0xFFFF Reserved for future expansion Not defined ...

Page 128: ...005 System Start Temp 32 to 120 F Default 70 F 6 0x0006 System Start Option 0 or 1 0 Temp Only 1 Temp and Load Default 0 7 0x0007 Manual Hdr Set Temp Internal Setpt 40 to 220 F Default 160 F 8 0x0008 Bldg Ref Temp 40 to 220 F Default 70 F 9 0x0009 Not Applicable 10 0x000A Not Applicable 11 0x000B Reset Ratio 0 3 to 3 0 0 1 increments Default 1 2 Value x 10 12 0x000C Max Header Temp 40 to 220 F Def...

Page 129: ...x0017 Fault Alarm Relay Mode 0 1 2 3 0 All Faults 1 No Interlock 2 Interlock 1 3 Interlock 2 Default 0 All Faults 24 0x0018 Fault Alarm Clear Method 0 or 1 0 Automatic 1 Manual Default 0 Automatic 25 0x0019 Boiler Operation Mode 0 1 or 2 0 Parallel 1 Sequential 2 Combination Default 1 Sequential 26 0x001A Not Applicable 27 0x001B Reserved 28 0x001C Reserved 29 0x001D Reserved 30 0x001E Max Power I...

Page 130: ...44 0x002C Offset Temp Sat 50 to 50 F Default 0 F 45 0x002D Offset On Time Day 1 Minutes 00 to 59 Minutes Default o 46 0x002E Offset On Time Day 2 Minutes 00 to 59 Minutes Default 0 47 0x002F Offset On Time Day 3 Minutes 00 to 59 Minutes Default 0 48 0x0030 Offset On Time Day 4 Minutes 00 to 59 Minutes Default 0 49 0x0031 Offset On Time Day 5 Minutes 00 to 59 Minutes Default 0 50 0x0032 Offset On T...

Page 131: ...n Minutes 0 to 59 Minutes Default 0 71 0x0047 Offset Off Time Mon Minutes 0 to 59 Minutes Default 0 72 0x0048 Offset Off Time Tue Minutes 0 to 59 Minutes Default 0 73 0x0049 Offset Off Time Wed Minutes 0 to 59 Minutes Default 0 74 0x004A Offset Off Time Thu Minutes 0 to 59 Minutes Default 0 75 0x004B Offset Off Time Fri Minutes 0 to 59 Minutes Default 0 76 0x004C Offset Off Time Sat Minutes 0 to 5...

Page 132: ...iler 3 Address Address for Network Boiler 3 Default 0 95 0x005F Net Boiler 4 Address Address for Network Boiler 4 Default 0 96 0x0060 Net Boiler 5 Address Address for Network Boiler 5 Default 0 97 0x0061 Net Boiler 6 Address Address for Network Boiler 6 Default 0 98 0x0062 Net Boiler 7 Address Address for Network Boiler 7 Default 0 99 0x0063 Net Boiler 8 Address Address for Network Boiler 8 Defaul...

Page 133: ...for Network Boiler 26 Default 0 118 0x0076 Net Boiler 27 Address Address for Network Boiler 27 Default 0 119 0x0077 Net Boiler 28 Address Address for Network Boiler 28 Default 0 120 0x0078 Net Boiler 29 Address Address for Network Boiler 29 Default 0 121 0x0079 Net Boiler 30 Address Address for Network Boiler 30 Default 0 122 0x007A Net Boiler 31 Address Address for Network Boiler 31 Default 0 123...

Page 134: ...142 0x008E ROTATE TIME 0 to 999 hrs Default 168 hrs 143 0x008F NUMBER OF DHW BOILERS 0 to 8 Default 1 144 0x0090 DHW OPTION 0 to 3 3 No Option 0 Option 1 1 Valve 1 Option 2 2 Valve 2 Option 3 Boost Default 3 145 0x0091 SYSTEM RELAY OPTION 0 or 1 0 Normal 1 DHW Valve 1 Close Default 0 146 0x0092 NUMBER DHW PRIORITY O to Num DHW Boilers 1 Default 1 147 0x0093 DHW SIGNAL 0 or 1 0 No Signal 1 Special ...

Page 135: ...09C VALVE WAIT STATE 0 Off 1 Current State If Option 1 or 2 Default 0 157 0x009D BOOST TEMP Hdr Low Limit to Hdr High Limit Default 140 158 0x009E VALVE WAIT TIME 0 to 500 Sec Default 120 159 0x009F RETURN TEMP BOOST DISABLE Off 80 to 80 Default Off 64726 160 0x00A0 MODBUS ON OFF 0 to 2 0 Front Panel Off 1 On 2 Modbus Off Default 0 161 0x00A1 BOILER CONTROL SELECT 0 to 2 0 None 1 C more 2 MLX BCM ...

Page 136: ...ol System ACS APPENDIX H ACS Modbus Address Assignments Page 136 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F This page intentionally blank ...

Page 137: ...e Calibration Menu in the C More Boiler Controllers For Modulex Boilers the corresponding Start and Stop Levels for each Boiler Model are listed in the following Table Modulex Series Start Stop Levels Model Modules Start Level Stop Level MLX 303 EXT 321 2 17 15 MLX 454 EXT 481 EXT 450 3 12 10 MLX 606 EXT 641 EXT 600 4 9 7 MLX 757 EXT 802 EXT 800 5 7 5 MLX 909 EXT 962 6 6 4 MLX 1060 EXT 1123 EXT 11...

Page 138: ...AERCO Control System ACS Page 138 of 139 AERCO International Inc 100 Oritani Dr Blauvelt New York 10913 11 22 2017 GF 131 Phone 800 526 0288 OMM 0081_0F NOTES ...

Page 139: ...CO International Inc 2017 Change Log Date Description Changed By 12 30 2015 Rev F Corrected labels to V1 and V2 Pumps in Figure 2 14a renumbered section in Appendix B B1 is now correctly labeled ACS Status Fault messages Chris Blair 11 22 2017 Rev G DIR 17 008 Added new Modulex model numbers to Appendix I updated formatting per current standard Chris Blair ...

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