Aerco E8 User Manual Download

Page: 1 / 112

06/05/13

AERCO International, Inc.

•

100 Oritani Dr.

•

Blauvelt, NY 10913

•

Ph: 800-526- 0288

Page

112

GF-115-C

OMM-0084_0D

Revised: 06/05/2013

E8 Controller and BCM

For

Modulex MLX & EXT Boilers

For Modulating, Condensing,
Hot Water Boiler Models:

•

MLX-303

•

MLX-454

•

MLX-606

•

MLX-757

•

MLX-909

•

MLX-1060

•

EXT 321

•

EXT 481

•

EXT 641

•

EXT 802

•

EXT 962

•

EXT 1123

•

EXT 1530

•

EXT 1912

•

EXT 2295

•

EXT 2677

•

EXT 3060

E8 Controller for MLX & EXT Series Boilers

Boiler Communications Module (BCM)

for MLX and EXT Series Boilers

USER MANUAL

Installation, Operation, and Maintenance

Summary of Contents for E8

Page 1: ...lex MLX EXT Boilers For Modulating Condensing Hot Water Boiler Models MLX 303 MLX 454 MLX 606 MLX 757 MLX 909 MLX 1060 EXT 321 EXT 481 EXT 641 EXT 802 EXT 962 EXT 1123 EXT 1530 EXT 1912 EXT 2295 EXT 2677 EXT 3060 E8 Controller for MLX EXT Series Boilers Boiler Communications Module BCM for MLX and EXT Series Boilers USER MANUAL Installation Operation and Maintenance ...

Page 2: ...kes 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 Technical Support Mon Fri 8am 5pm EST 1 ...

Page 3: ...NUS AND SUB MENUS 17 4 1 DISPLAY Menu 18 4 2 USER Menu 21 4 3 TIME PROGRAM Menu and Sun Menus 24 4 4 EXPERT Menu and Sub Menus 25 4 4 1 Available V Curve Preset Voltage Curves for 0 10 Volt Input 31 4 5 EXPERT HS Menu Not Used 31 4 6 GENERAL Menu 32 4 6 1 DATE TIME Menu 32 4 6 2 SERVICE Menu 34 4 7 E8 Controller Initial Startup 37 4 7 1 CAP MODULE Function Maximum Kilowatts per Burner 39 4 7 1 Ava...

Page 4: ...5 4 Displaying Temperatures Associated With DHW 56 5 6 Boiler Pump Enable Disable 56 6 CONNECTION DIAGRAMS 58 6 1 Power Terminal Assignments 59 6 2 Sensor Terminal Assignments 60 7 BOILER COMMUNICATIONS MODULE BCM 62 7 1 Boiler Communications Module BCM Description 62 7 2 BCM Fault Relay 64 7 2 1 BCM Fault Relay Wiring 64 7 2 2 Clearing Faults 64 7 3 BCM Configured as Back Up Controller 65 7 3 1 B...

Page 5: ... Menu 78 8 2 USER Menu 80 8 3 TIME PROGRAM Menu 82 8 4 EXPERT Menu 85 8 5 GENERAL Menu 89 8 5 1 DATE TIME Sub Menu 90 8 5 2 SERVICE Sub Menu 90 9 BCM MODBUS AND ADDRESS ASSIGNMENTS 94 9 1 BCM Modbus Communication Support Requirements 94 9 1 1 Function Codes 94 9 1 2 Modbus Support Requirements 94 9 2 BCM Controller Standard Holding Register Assignments 95 9 2 1 BCM Controller Standard Input Regist...

Page 6: ...3 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 6 of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D This page left intentionally blank ...

Page 7: ...nd Warnings The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels Indicates an imminently hazardous situation which if not avoided WILL result in death or serious injury Indicates a potentially hazardous situation which if not avoided MAY result in death or serious injury Indicates a potential hazardous situation which if not...

Page 8: ...3 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 8 of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D This page left intentionally blank ...

Page 9: ...r The E8 features the following functions for Modulex boilers Shares the heating load among as many of the boiler s thermal heating modules as possible maximizing the overall operating efficiency of the boiler Provides access to all testing programming parameters of each individual heating module operation test operation time boiler freeze protection and pump s anti seize program Drives lead lag b...

Page 10: ...further increases the reliability of a product line already known for its uniquely redundant design Each Modulex boiler combines between two and seven independent 151 500 BTU hr pre assembled thermal modules housed in a common enclosure Each module has its own dedicated controller with a combustion safeguard variable speed fan modulating gas valve electronic ignition modulating burner flow tempera...

Page 11: ...oller in service will show information appropriate for its configuration Figure 3 1 E8 LCD Display in NORMAL Mode Door Closed E8 Controller Display in NORMAL Mode Item Functions A Current time 24 hour format B DCF reception OK only if receiver is connected via eBUS C 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 D Bus icon if this ...

Page 12: ...ION Heating Mode Selection Turn the Rotary Knob to select the heating mode required The heating mode is indicated by a symbol at the bottom of the display It takes effect when the setting is not changed for 5 seconds Standby OFF Heat OFF and hot water HW preparation OFF only frost protection mode Automatic Mode 1 Heat according to timer program 1 HW according to HW program Automatic Mode 2 Heat ac...

Page 13: ...el select a parameter value to change or save a new parameter value F 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 are swi...

Page 14: ...nit is powered down and then powered up again the INSTALLATION menu will reappear When this occurs the INSTALLATION menu items DO NOT need to be reentered Normally after entry of the required initial INSTALLATION menu entries turning the Rotary Knob clockwise will automatically advance the Controller to the DISPLAY menu group All items in this group are Read Only and cannot be changed See Sub sect...

Page 15: ... 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 f...

Page 16: ...cess parameters in the selected displayed sub menu Turn Rotary Knob to sequence through the available parameters To change a parameter value press the Program Key when desired parameter is displayed The Change LED will light up indicating the displayed parameter may now be changed To change the displayed parameter value turn Rotary Knob clockwise to increase value and counter clockwise to decrease...

Page 17: ...IRCL TIME b HOTW PROG c HTG PROG 1 d HTG PROG 2 4 EXPERT a INSTALLATION b HOT WATER c HEAT CIRCUIT I d HEAT CIRCUIT II e SOLAR MF 5 EXPERT HS a INSTALLATION 6 GENERAL a SERVICE b DATE TIME c HOLIDAY d CLOCK CHANGE IMPORTANT In the following flow chart illustrations and tabular listings descriptions entry ranges and default values are provided for only the commonly used functions which are referenc...

Page 18: ...own in Figure 4 1 and in Table 4 1 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 CIRC...

Page 19: ...ram 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 sequence between Heat Modules The Burner symbol is displayed when the respective Heat Module is ON T SOLID FUEL Not Applicable T RETURN 1 Not Applicable T RETURN 2 Not Applicable T BUFFER T Not Applicable T BUFFER M Not Applicable T BUFFER L Not Applicable T S...

Page 20: ...ammed as hot water circuit T DHW Current hot water temperature Same as above T FLOW RATED Current flow set point temperature FLOW Current flow temperature N OPT TIME Not Applicable Not applicable RETURN Press Program Key to exit HTG CIRCUIT 1 Sub Menu HTG CIRCUIT 2 Sub Menu Functions for HTG Heating Circuit 2 are identical to HTG Circuit 1 Functions above SOLAR M F Sub Menu T MF1 Not Applicable Cu...

Page 21: ...e contained in the DISPLAY Menu Tabular listings for the USER Menu items are provided in Table 4 2 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 ...

Page 22: ...ar 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 water temperature Only if sensor is installed T DHW Domestic Hot Water Temperature T BOILER Boiler Outlet Temperature T ROOM 1 2 Room Temp Heating Circuit 1 or 2 ONLY if Remote Control is connected See DESCRIPTION Column RETURN Press Program Key ...

Page 23: ... LIMIT N Applies during reduced night time periods 23 0 F 104 0 F 50 0 F HEATSLOPE Indicate number of degrees that the flow temperature changes if the outside temperature increases or decreases by 1 F 0 00 3 00 1 20 OPTIM HEAT Not Applicable MAX OPT TIME Not Applicable ECONO OPTI Not Applicable PC ENABLE Not Applicable RETURN Press Program Key to exit HTG CIRCUIT 1 or 2 sub menu HTG CIRCUIT 2 Sub ...

Page 24: ...in the TIME PROGRAM Menu are being utilized This menu is shown in Figure 4 3 Refer to Section 8 for additional information on these Menu and Sub Menu functions 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 THURSD...

Page 25: ...istings for the EXPERT Menu and Sub Menu items are provided in Table 4 3 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 DY...

Page 26: ... 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 F1...

Page 27: ...starting with 01 heating circuit numbers must not be assigned twice 00 01 15 AF SUPPLY Outdoor sensor power supply 00 01 OFF ON 01 ON BUS TERM Bus terminating resistor Must be set to 01 00 01 OFF ON 01 ON EBUS SUPPLY Switches the Ebus supply ON OFF 00 01 OFF ON 01 ON TIME MASTER Not Applicable MAX T COLL Sets the maximum allowable header set point temperature 86 0 F 230 0 F 185 0 F MIN T COLL Sets...

Page 28: ...perature difference between the Boiler set point and the actual water temperature Display F 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 MAX T MODUL Maximum temperature of Heat Module 122 0 F to 230 0 F 194 0 F DYN UPWARD Not Applicable N A N A DYN DOWNWARD Not Applicable N A N A RESET TIME Not Applicable 5 500 50 MODULAT MAX Sta...

Page 29: ... Modulating HS 1 BUS Communication connection between Controller and Heat Source 00 04 02 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 PARALLEL Parallel pump operation 00...

Page 30: ...Heat Circuit PUMP MODE Circulation pump mode control for ON OFF switching of pumps 00 Standard pump control 01 Pump switching per heating limits 02 Pump switching per heating program 03 Continuous pump operation 00 03 00 MIXER OPEN Not Applicable MIXER CLOSE Not Applicable MAX T FLOW Maximum allowable water temperature setting for the heating circuit 68 F 230 F 176 F MIN T FLOW Minimum allowable w...

Page 31: ... Preset Voltage Curves for 0 10 Volt Input The following listing Table 4 4 shows the available preset V Curve settings for operation in the 0 to 10 Volt Mode Table 4 4 V Curve Preset Voltage Curves for 0 10 Volt Input CURVE NO U1 U2 T1 T2 UO 0 2 0 V 10 0 V 32 F 194 F 2 0 V 1 2 5 V 0 3 V 100 F 176 F 5 0 V 2 2 5 V 0 3 V 100 F 167 F 5 0 V 3 2 5 V 0 3 V 100 F 113 F 5 0 V 4 4 0 V 0 1 V 68 F 185 F 5 0 V...

Page 32: ...88 Page 32 of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D 4 6 GENERAL Menu The GENERAL Menu contains a DATE TIME Menu and a SERVICE Menu 4 6 1 DATE TIME Menu This Sub Menu is used to set the time date holiday vacation schedule and where ...

Page 33: ...RN CLOCK CHANGE MONTH START DAY START MONTH STOP DAY STOP Figure 4 5 DATE TIME Menu Flow Chart NOTE All items in the following DATE TIME Menu must be entered in sequence Press the Program Key to step through the menu functions Use the Rotary Knob to adjust change entries Press the Program Key to store entries and sequence to the next function Table 4 5 DATE TIME Menu Listing FUNCTION DESCRIPTION E...

Page 34: ...nu is used in areas where seasonal time changes are required for Daylight Savings etc MONTH START Set clock change start month 01 12 DAY START Set clock change start day 01 31 MONTH END Set clock change end month 01 12 DAY END Set clock change end day 01 31 RETURN When CLOCK CHANGE reappears press Program Key 4 6 2 SERVICE Menu The SERVICE Menu contains all the test and diagnostic functions values...

Page 35: ...T 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 Figure 4 6 SERVICE Menu Flow Chart Table 4 6 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 Thes...

Page 36: ...ircuit 1 Multifunction 2 10 A10 Multifunction 3 11 A11 Collector Pump Multifunction 4 SENSOR TEST Sub Menu This Sub Menu is used to check and display the temperature readings of the sensors connected to the Controller SENSOR F1 Lower buffer storage temperature F2 Middle buffer storage temperature or room temperature heating circuit 1 F3 Upper buffer storage temperature F5 Flow temperature heating ...

Page 37: ...de See GF 115 H Section 7 Sub section 7 5 for additional startup instructions using these sub menu functions BURNER TIME 1 8 Program Key Burner time for all stages BURNER START 1 8 Program Key Burner start for all stages LIMITER TEST 1 8 Safety temperature limiter test with heat generator temperature display Start with Program Key hold down SERVICE Input of date or operating hours for service mess...

Page 38: ...y should show ENGLISH If ENGLISH is not displayed turn the Rotary Knob until ENGLISH appears 4 Press the Program Key to store setting 5 Next TIME will be displayed Enter the current time minutes hours using the Rotary Knob Press the Program Key to store each value 6 The next items displayed are the YEAR MONTH and DAY Enter each item using the Rotary Knob and press the Program Key as previously des...

Page 39: ...y Function 2 See Paragraph 4 8 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 Multi...

Page 40: ... 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 ...

Page 41: ...nance Manual OMM 0084_0D 02 Circulation Time 03 Booster Pump 05 Pump HS1 06 Pump HS2 20 Temperature Controlled Circulation Pump 21 Pulsed Circulation Pump 22 Solid Fuel Boiler Integration Not Applicable 23 Solar Integration 24 Return Flow Temperature Increase HS1 25 Return Flow Temperature Increase HS2 26 Return Flow Temperature Increase Via Buffer Storage ...

Page 42: ... the procedures necessary to wire and configure the controller for operation in the Indoor Outdoor Reset mode 5 1 1 Wiring Connections The outdoor air sensor provided with the boiler should be mounted on the outer North or North East side of the building away from windows doors and vents Never mount the outdoor air sensor in a location where it is exposed to direct sunlight Wire the sensor using s...

Page 43: ...l to the HEATSLOPE sub menu item The display will show HEATSLOPE and the current value stored in memory 0 00 to 3 00 7 To change the HEATSLOPE value press the Program Key The red LED will light 8 Refer to Heat Slope Diagram Figure 5 1 to determine the required value for the HEATSLOPE function based on the boiler installation design set point The value entered must be between 0 and 3 00 9 Turn Rota...

Page 44: ...red setting 00 or 01 will be displayed Normally 00 will be displayed since this is the Factory Default However for the Constant Set Point Mode the HC FUNCTION setting must be changed to 01 If the HC FUNCTION is currently set to 00 proceed to step 7 However if it is set to 01 skip to step 11 7 If the HC FUNCTION is set to 00 press the Program Key CODE NO will be displayed requesting the valid code ...

Page 45: ...de air temperature For instance it might be desirable to set the outlet water temperature to be 180º F whenever the outside temperature is 15º F or below and 120º F whenever the outside temperature is 60º F or higher Four parameters must be set in the E8 Controller to accomplish this They are HEATSLOPE MAX T FLOW MIN T FLOW and MAX T COLL Descriptions are provided in Table 5 1 Table 5 1 E8 Control...

Page 46: ...ER 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 ...

Page 47: ... 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...

Page 48: ... 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 ...

Page 49: ... 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 c...

Page 50: ...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...

Page 51: ...nd to U2 8 With the desired high set point temperature limit displayed press the Program Key to set the T2 temperature high set point limit The red LED will go off This completes the required steps for setting the low and high limits corresponding to the set point voltage and temperature functions Proceed immediately to paragraph 5 3 4 to set the CURVE 11 UO voltage 5 3 4 Setting the Curve 11 UO V...

Page 52: ...nged 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 ...

Page 53: ...ont 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 ...

Page 54: ...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 ...

Page 55: ...wn is the DHW set point temperature 5 Next scroll to T DHW The temperature value shown is the actual DHW temperature measured by the tank sensor 6 Continue scrolling until RETURN is displayed Press the Program Key to exit the HOT WATER sub menu 5 4 4 2 Viewing DHW Set Point With T BOILER DHW Function The setting for T BOILER DHW in the EXPERT HOT WATER Menu adds to the Domestic Hot Water setpoint ...

Page 56: ...tually identical to those specified in paragraph 5 4 2 The only difference is that the THERM INPUT in the EXPERT menu HOT WATER sub menu must be set to 01 Aquastat instead of 00 Sensor 5 5 3 Setting the DHW Set Point Same as paragraph 5 4 3 5 5 4 Displaying Temperatures Associated With DHW Same as paragraphs 5 4 4 through 5 4 4 2 5 6 Boiler Pump Enable Disable The Enable Disable feature found betw...

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Page 58: ... 1 I 4 5 F5 Flow sensor heating circuit 2 I 6 7 F6 Storage tank sensor I 7 8 F8 Boiler sensor header sensor I 9 10 F9 Outdoor sensor V 1 M F11 Flow sensor heating circuit 1 Multifunction relay sensor 1 V 2 M F12 Hot water tank low Multifunction relay sensor 2 VIII 1 M F13 PT1000 HS2 collector 2 Multifunction relay sensor 3 VIII 2 M F14 PT1000 Collector 1 Multifunction relay sensor 4 III 1 3 FBR2 F...

Page 59: ... 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 IV 3 A10 Primary Pump Collector pump 2 Switching valve ...

Page 60: ... of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D 6 1 Power Terminal Assignments Continued Plug 4 IV IMPORTANT THE PRIMARY PUMP COLLECTOR PUMP 2 MUST BE WIRED TO RELAY A10 6 2 Sensor Terminal Assignments Connector 7 VII Connector 1 I Connector 5 V ...

Page 61: ...ni Dr Blauvelt NY 10913 Ph 800 526 0288 Page 61 of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D 6 2 Sensor Terminal Assignments Continued Connector 8 VIII PT 1000 Sensor Connector 3 III Connector 9 IX ...

Page 62: ...ptions of the BCM and each of the additional control functions listed above 7 1 Boiler Communications Module BCM Description The BCM shown in Figure 7 1 is housed in a compact enclosure measuring 4 13 105 mm x 3 50 89 mm The BCM is installed on the front of the Modulex Boiler behind the removable front panel Figure 7 1 Boiler Communications Module BCM Input Output I O connections to the BCM are ma...

Page 63: ...DL1 LED Yellow Communication Status Indicator functions as follows STATUS DESCRIPTION OFF No devices detected by either communication interface BLINKING Only one communication device detected at one communication interface input or output ON Both communication interfaces input output are active DL2 LED Red Alarm Status LED lights when a fault is detected by the BCM Activating the Reset Switch will...

Page 64: ... BCM board will light continuously 7 2 1 BCM Fault Relay Wiring If desired pins 3 and 4 of connector Y4 Figure 7 3 can be wired to an external source to provide a remote alarm indication when the BCM Fault Relay is activated 7 2 2 Clearing Faults A fault can be cleared by pressing and releasing the black Reset Switch on the front cover of the BCM However if the cause of the fault has not been corr...

Page 65: ...oint 180 F 82 C The primary Boiler Pump must also be wired to the BCM so it will run when the BCM assumes control in the Back Up Mode If a setpoint temperature lower than 180 F is desired the setpoint can be changed prior to boiler start up Refer to paragraph 7 3 1 for details 7 3 1 BCM Back Up Controller Wiring The Primary Boiler Pump must be wired to BCM Connector Y4 as shown in Figure 7 4 Also ...

Page 66: ...e 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 subo...

Page 67: ...ault LED DL2 will light 7 4 2 Physical Modbus RS485 Wiring Modbus RS485 devices should be wired in a Daisy Chain configuration similar to the example shown Figure 7 6 DO NOT wire the units in a Star configuration where all devices are connected to a central point node Figure 7 6 Typical Daisy Chain Modbus RS485 Network The physical wiring connections for a Modbus Network should be made using shiel...

Page 68: ...FF Disable DO NOT USE 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 E8 is the primary controller and the BCM allows monitoring through Modbus but will not take over boiler if the E8 fails I ON Enable DO NOT USE The BCM is the Gate way for Modbus and external control The E8 does not...

Page 69: ...s talk from corrupting data on the line Short or medium length Modbus RS485 loops less than 1000 feet can usually operate satisfactorily without the terminating resistor However longer loop runs over 1000 feet may require terminating resistors Bias may be necessary on the RS485 loop to minimize noise on the circuit Loop bias is accomplished by activating pull up pull down resistors on the last Boi...

Page 70: ... in paragraph 7 5 1 when the controlling Master is an EMS or BAS pull down bias may be implemented by connecting a 1K ohm resistor as shown in Figure 7 9 DO NOT install this bias resistor if the controlling Master is an AERCO BMS II or ACS Bias will be provided by the BMS II ACS DIP switches The last unit in the chain must be energized even if disabled to enable bias Y2 Y3 Y4 Y1 SW1 A1 I 0 BCM FRO...

Page 71: ...85 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 manu...

Page 72: ...485 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 ...

Page 73: ...ULEX 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 ...

Page 74: ...dress selection on each BCM is accomplished by setting rotary DIP switch SW1 This switch is located in the lower right portion of each BCM as shown in Figure 7 12 As Figure 7 12 shows SW1 is a 10 position switch labeled 0 9 SW1 is set to the desired position using a small flat tip screwdriver Figure 7 12 shows SW1 set to address 0 zero which disables the BCM on the Modbus Network Only Modbus addre...

Page 75: ...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 power down 7 7 5 EMS or BAS Set Up As Master to BCM Controller Slaves R...

Page 76: ...rt 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 me...

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Page 78: ...used to preset a Set Point value for the control system T COLL DES Heat Source HS Header Set Point value cascade Boiler Set Point temperature in Indoor Outdoor Reset and Constant Set Point modes T COLLECTOR HS Header Set Point temperature cascade T BOIL Press Program Key to display temperature and ON OFF status of individual Heat Modules HS which range from 2 MLX 303 to 7 MLX 1060 Turn Rotary Knob...

Page 79: ...HUMIDITY Room humidity Only if humidity sensor installed parameters set for heating circuit T DHW RATED Hot water set point temperature Appear only if heating circuit is programmed as hot water circuit T DHW Current hot water temperature Same as above T FLOW RATED Current flow set point temperature FLOW Current flow temperature N OPT TIME Previous time required to heat up with heat up optimization...

Page 80: ... 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 water temperature Only if sensor is installed T DHW Domestic Hot Water Temp T BOILER Heat Generator Temp T ROOM 1 2 Room Temp Heating Circuit 1 or 2 ONLY if Remote Control is connected See D...

Page 81: ...during day time heating periods 23 0 F 104 0 F 66 0 F T LIMIT N Applies during reduced night time periods 23 0 F 104 0 F 50 0 F HEATSLOPE Indicate number of degrees that that the flow temperature changes if the outside temperature increases or decreases by 1 F 0 00 3 00 1 20 OPTIM HEAT Heating optimization 00 01 02 00 MAX OPT TIME Only active if OPTIM HEAT is set to 01 or 02 0 00 3 00 h 2 00 h ECO...

Page 82: ... and view or change ON OFF times The times can be set individually for each day of the week or they can be set in groups as listed in the options which follows MONDAY View or change the pump ON OFF times for Monday Press the Program Key to view current settings Turn Rotary Knob to change displayed ON or OFF time if required Press Program Key to store displayed ON or OFF time and sequence the displ...

Page 83: ... Rotary Knob to change displayed ON or OFF time if required Press Program Key to store displayed ON or OFF time and sequence the display to the next function All ON and OFF times can be set in 15 minute increments from 00 00 24 00 ON 5 00h OFF 21 00h 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 fo...

Page 84: ...hange displayed ON or OFF time if required Press Program Key to store displayed ON or OFF time and sequence the display to the next function All ON and OFF times can be set in 15 minute increments from 00 00 24 00 ON 6 00h OFF 22 00h 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 pr...

Page 85: ...t not be assigned twice 00 01 15 AF SUPPLY Outdoor sensor power supply 00 01 OFF ON 01 ON BUS TERM Bus terminating resistor Must be set to 01 00 01 OFF ON 01 ON EBUS SUPPLY Switches the eBUS supply ON OFF 00 01 OFF ON 01 ON TIME MASTER When set to 00 it indicates there is no time master When set to 01 the Controller is the time master LEAVE SET TO 00 00 01 00 N A MAX T COLL Sets the maximum allowa...

Page 86: ... the temperature difference between the header set point and the actual temperature display F DES OUPUT Required system output in 0 100 00 SWITCH TIME Internal control value only for switching cascade 99 0 99 Display N A BLOCK TIME Not Applicable N A N A MAX T MODUL Maximum temperature of Heat Module 122 0 F 230 0 F 194 0 F DYN UPWARD Dynamic heat generator connection Not Applicable N A N A DYN DO...

Page 87: ... cascade via BUS 06 Multi Stage Modulating HS 1 BUS Connections for HS 1 00 04 02 HEATSOURCE 2 Secondary heat generator type 00 05 00 STORAGE HS2 Not Applicable 00 03 00 BUFFER Not Applicable 00 01 02 00 SCREED Not Applicable N A 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 Charge pump blocking 00 OFF 01 ON 01 ON PARAL...

Page 88: ...e Entering small temperature difference values may cause the mixing valve to oscillate 5 F 25 F 18 F MIXER CLOSE NOT for HW circuit Specifies speed setting at which mixing valve closes when there is a control temperature difference Entering small temperature difference values may cause the mixing valve to oscillate 5 F 25 F 12 F MAX T FLOW Maximum allowable water temperature setting for the heatin...

Page 89: ...mp HS2 20 Temp Controlled Circulation Pump 21 Pulsed Circulation Pump 22 Solid Fuel Boiler Integration 23 Solar Integration 24 Return Flow Temperature Increase HS1 25 Return Flow Temperature Increase HS2 26 Return Flow Temperature Increase HS Via Buffer Storage 00 01 02 03 05 06 20 26 00 No Function MF 1 4 SET TEMP Multi Function Relay Set Point Temperature indicates switching temperature for rela...

Page 90: ...current time min hours 00 00 24 00 YEAR Set current year XXXX MONTH Set current month 01 12 DAY Set currrent day 01 31 HOLIDAY Sub Menu This Sub Menu sets the start and end dates for Holiday Vacation periods where no heat or hot water is required YEAR Set current holiday start year XXXX MONTH START Set current holiday start month 01 12 DAY START Set current holiday start day 01 31 YEAR STOP Set cu...

Page 91: ...00 No relay 01 A1 Pump Heating Circuit 1 02 A2 Pump Heating Circuit 2 03 A3 Hot Water Charging Pump 04 A4 Mixer OPEN Heating Circuit 2 05 A5 Mixer CLOSED Heating Circuit 2 06 A6 HS 1 ON 07 A7 HS2 ON 2 stage HS 1 2 after 10s ON 08 A8 Mixer OPEN Heating Circuit 1 Multifunction 1 09 A9 Mixer CLOSED Heating Circuit 1 Multifunction 2 10 A10 Multifunction 3 11 A11 Collector Pump Multifunction 4 SENSOR T...

Page 92: ... items and functions in the SERVICE Sub Menu include the following SW NO XXX XX Specifies the Software Version and Index number currently installed in the Controller CASCADE MANU 1 8 Starting different burner stages of the cascade See GF 115 H Section 6 Paragraph 6 5 for additional startup instructions using these sub menu functions BURNER TIME 1 8 Program Key Burner time for all stages BURNER STA...

Page 93: ...3 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 93 of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D This page left intentionally blank ...

Page 94: ... 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 2 Wire Differential Bus With Shield RS485 Allowable Cable Length 4000 Feet Maximum Address Support From Master EMS 1 to 9 via Address Select Switch SW1 Addresses from 10 to 127 can be implemented via ...

Page 95: ...open 18 Air flow switch open during ignition 23 Flame loss during run 32 Residual flame 42 Outlet temperature sensor fault 38 Other conditions not listed above 1 Unit Status enum 1 3 5 1 Standby ready to run but not fired 3 Remote fired 5 Fault failure detected 9 2 2 BCM Controller Standard Holding Register Assignments The BCM Controller Holding Registers contain functions that are Read Only Write...

Page 96: ...ion Level 0 to 100 Value x 2 Read Write 100 50 1004 Requested Setpoint 32 F 212 F 0 C 100 C Value x 10 Read Write 180 F 1001 System Command enum 0xAA Read Write 0xAA Restart Slave identification procedure 1021 Heat Request Command enum 0x01 0x33 0x44 0x55 0xBB 0xCC 0xEE 0x01 No action 0x33 Space Heating mode enabled 0x44 Space Heating DHW modes enabled 0x55 DHW mode enabled 0xBB Space Heating requ...

Page 97: ...ult device 0 BMM 0 to 7 BMM 7 255 BCM Read Only 1000 Cascade Control Status enum 0 1 2 4 0 Stop 1 Slave identification procedure 2 Normal operation 4 Monitor mode Read Only 1002 Flow Sensor Temperature 14 F to 212 F 10 C to 100 C Value x 10 Read Only 1003 Return Flow Temperature 32 F to 212 F 0 C to 100 C Value x 10 Read Only 1005 External Sensor Temperature 31 F 22 F to 86 F 35 C 30 C to 30 C Val...

Page 98: ... to Bit 7 BMM 7 Read Only 1101 Inserted BMM Flags 0 255 Bit 0 BMM 0 to Bit 7 BMM 7 Read Only 1102 BMM in Check Mode Flags 0 255 Bit 0 BMM 0 to Bit 7 BMM 7 Read Only 1103 BMM Flame Status Flags 0 255 Bit 0 BMM 0 to Bit 7 BMM 7 Read Only 1104 BMM Alarm Status Flags 0 255 Bit 0 BMM 0 to Bit 7 BMM 7 Read Only 1108 BMM Maximum Modulation Level 0 100 Value x 10 Read Only 1109 Pump Modulation Output 0 10...

Page 99: ...Only SYSTEM DATA 1550 Firmware Code Firmware Revision 0x3400 0x34FF High byte Firmware Code Low byte Firmware Revision Read Only 1011 Boiler Global Capacity 0 FFFF kW Read Only 12 Boiler Mode AERCO BMS II ACS 2 Read Only 13 Remote Signal Network 3 Read Only SETTINGS 19 Modbus Address 1 127 Read Write 3000 Burner OFF Hysteresis 9 F to 36 F 5 C to 20 C Value x 10 Read Write 9 F 3001 Minimum Inserted...

Page 100: ...Read Write 35 3010 Water Δ Temp Protection 0 F 2 F 90 F 0 C 1 C 50 C Read Write 36 F 3011 Communication Timeout Time 0 10 240 sec in 10 sec intervals 0 Disable Read Write 30 sec 3012 Temperature Limits 0 1 0 C 1 F 1 F 3013 Analog Input Function 0 1 0 Setpoint Adjust 1 Outdoor Temp Sensor Read Write 0 3014 Not Used 3015 Maximum Target Temperature 113 F to 185 F 45 C to 85 C Read Write 180 F TEST RE...

Page 101: ...se 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 Read Only 3101 Digital Outputs Status 0 1 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 Read Only 3102 Digita...

Page 102: ...bes 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 Section 9 of Manual GF 115 H for more detailed Fault Code descriptions and trouble shooting procedures Figure 10 1 E8 Controller Fault Code...

Page 103: ...ll reappear after performing the following steps Processing and Clearing a Fault Code 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 m...

Page 104: ...he affected module from the second column apply the formula from the third column and identify the Error Table to reference from the fourth column Table 10 1 Determining the Error Code Reading from the E8 Controller Display Observed Code Observed Code Code to Look Up in Table Code 0 N A No Fault Code between 1 and 255 BMM 0 Fault Look up code 10 4 Code between 256 and 511 BMM 1 Fault Subtract 256 ...

Page 105: ...witch does not commute within 30 sec in the ignition cycle E 23 Air pressure switch always active E 24 Fan out of control doesn t achieve correct speed within 30 sec of ignition cycle start E 26 Fan out of control do not stop within 30 s ec from the stop of the burner E 27 Air pressure switch detect a technical fault during the ignition time E 30 Parameters setting alteration E 32 Electrical suppl...

Page 106: ...nal failure E 200 Communication Error HS1 E 201 Communication Error HS1 E 202 Communication Error HS1 E 203 Communication Error HS1 E 204 Communication Error HS1 E 205 Communication Error HS1 E 206 Communication Error HS1 E 207 Communication Error HS1 Internal Fault E 81 E8 EEPROM error The invalid value has been replaced with default value Check parameter values 10 2 2 BCM Boiler Communications M...

Page 107: ...act 256 from Displayed Number BMM Fault Code in Table 10 3 Between 512 and 767 BMM 2 Fault Subtract 512 from Displayed Number BMM Fault Code in Table 10 3 Between 768 and 1023 BMM 3 Fault Subtract 768 from Displayed Number BMM Fault Code in Table 10 3 Between 1024 and 1279 BMM 4 Fault Subtract 1024 from Displayed Number BMM Fault Code in Table 10 3 Between 1280 and 1535 BMM 5 Fault Subtract 1280 f...

Page 108: ...urned 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 or cycle power 50 Internal Failure Ignition is inhibited Contact Factory for new BCM MANUAL cycle the power 58 FlowSensor fault All burners turned OFF Che...

Page 109: ...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 Ignition is inhibite...

Page 110: ... wire from BMM If failure goes away check wiring or change BMM If failure remains check or change gas valve MANUAL push reset switch or cycle power 22 No air flow at burner after fan started for 30 seconds Ignition 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 work...

Page 111: ...ds after turned OFF Ignition is inhibited Check fan wiring AUTOMATIC 27 Air flow failure during ignition Restart pre purge 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 ...

Page 112: ... 13 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Ph 800 526 0288 Page 112 of 112 GF 115 C Modulex E8 Controller and BCM Operations and Maintenance Manual OMM 0084_0D AERCO International Inc 2012 ...

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