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Watts AERCO EXT Installation, Operation & Maintenance Manual Download Page 9

Ufly Controller and BCM for Modulex EXT

 

 

CHAPTER  2: Ufly CONTROLLER & BCM MODULES  

 

 

OMM-0159_A_A   

•  6/28/2022                Technical Support • (800) 526-0288  •  Mon-Fri, 8 am - 5 pm EST                Page 

9

  of 

83

 

2.1.3 Display Modes 

 

6  Display Mode 

 

7  Display Mode 

 

8  Display Mode 

 

Screen Off 

 

 

Home Screen 

 

 

Menu Screen 

 

 

 

 

 

 

 

NOTE: 

Menu icons do not indicate operating status. 

 

 

Summary of Contents for AERCO EXT

Page 1: ...EXT 600 2S EXT 800 2S EXT 1100 2S EXT 1500 2S EXT 2300 2S EXT 2600 2S EXT 3000 2S Disclaimer The information contained in this manual is subject to change without notice from AERCO International Inc...

Page 2: ...ions 21 4 1 2 Indoor Outdoor Reset Operation Configuration 22 4 1 3 Viewing the Boiler Setpoint 28 4 2 CONSTANT SET POINT MODE 28 4 3 0 TO 10 VOLT REMOTE SET POINT MODE 29 4 3 1 Wiring Connections 29...

Page 3: ...ller Slaves 56 6 9 MULTIPLE MODULEX BOILER HEATING MODE USING ACS 56 6 9 1 Sequence of Operation Example Four Modulex boiler installation 57 CHAPTER 7 BCM MODBUS AND ADDRESS ASSIGNMENTS 59 7 1 BCM MOD...

Page 4: ......

Page 5: ...he front of the unit It is imperative that the initial startup procedures be performed by factory trained personnel Operation by untrained personnel prior to the initial startup will void the equipmen...

Page 6: ...Ufly Controller and BCM for Modulex EXT CHAPTER 1 INTRODUCTION OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 6 of 83 This page intentionally blank...

Page 7: ...Ufly Controller Features and Functions The Ufly features the following functions for MODULEX boilers Shares the heating load among as many of the boiler s thermal heating modules as possible maximizin...

Page 8: ...ot Water Access domestic hot water parameters including setpoint timed programming and legionella protection function Solar This menu is currently not available Burner Access calibration manual operat...

Page 9: ...TROLLER BCM MODULES OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 9 of 83 2 1 3 Display Modes 6 Display Mode 7 Display Mode 8 Display Mode Screen Off Home Screen Men...

Page 10: ...over operation of the boiler Additional control functions include the following A fault relay which energizes when any fault condition occurs BCM serves as a Back up Controller if the primary Ufly Con...

Page 11: ...Fri 8 am 5 pm EST Page 11 of 83 CHAPTER 3 OPERATION MENU PARAMETERS This chapter introduces the Ufly controller basic menu contents needed to set up the MODULEX EXT boiler For more detailed informati...

Page 12: ...program Building Reference temperatures and domestic hot water setpoint change display and language settings and change the password for the Devices 3 1 1 Setting Time and Date 3 1 2 Setting Comfort a...

Page 13: ...ammed in the Setup Menu For details on Domestic Hot Water Operation see Section 4 4 The Ufly screen automatically turns off after 20 seconds default of inactivity If the Always on is toggled on like i...

Page 14: ...ble to Authorized AERCO Service technicians To Change the password 1 Enter the current password and click OK 2 Delete the current password using the backspace button 3 Enter new password and click OK...

Page 15: ...TERS OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 15 of 83 Outdoor Reset Parameter and Space Heating Setpoint are accessed via the Settings button Building Referenc...

Page 16: ...Page 16 of 83 3 3 Domestic Hot Water Menu The Domestic Hot Water Menu provides access to parameters to provide domestic hot water DHW using a tank sensor For DHW programming details see section 4 4 T...

Page 17: ...urner Management Module parameters BCM parameters for functions including 0 10V operation and domestic hot water operation and error history These parameters are for use by Authorized AERCO service te...

Page 18: ...n manual operation and troubleshooting settings This menu is password protected and is only for authorized AERCO technicians 3 5 1 Service Mode Manual Firing Rate Function 1 Click on the Service Mode...

Page 19: ...xt screen shown is for the selected Burner c Toggling the Activate button enables the selected burner to run during manual firing rate d The Current Fire Rate of activated burners will equal the manua...

Page 20: ...26 0288 Mon Fri 8 am 5 pm EST Page 20 of 83 3 Click on the Request buttons to set the manual setpoint desired 4 To disable the Manual Setpoint Function select the Home button 3 5 3 Reset Burner Workin...

Page 21: ...ating Menu The outdoor air sensor provided with the Modulex boiler must be installed to enable this mode of operation The following sections provide the procedures necessary to wire and configure the...

Page 22: ...on 4 1 1 above prior to configuring the Controller for Indoor Outdoor Reset Mode operation 1 Access the Heating menu from the Home Screen or from Main Menu Home Screen Main Menu 2 If there is more tha...

Page 23: ...temperature and OAR Min Out setting 6 Set Warm Weather Shutdown parameter to the threshold outside temperature above which the unit shuts down For example if set to 70 F when the outside temperature...

Page 24: ...o Choose this to set a Building Ref Temp that will be used 24 7 Use this to set a lower Building Ref Temp resulting to lower setpoint 3 Weekly Schedule 3 schedules available Choose this to setup Build...

Page 25: ...mp schedules to choose from Each day of the week can be selected from 5 choices of type of day and each type of day can be programmed with up to 3 time slots Creating Types of Day 1 Access the Heating...

Page 26: ...Creating Weekly Building Ref Temp schedules 1 Rename week type as desired e g School Week Spring Break Week etc Mon Fri can be combined to have a common type of Day if desired Sat Sun can be combined...

Page 27: ...s more than one heating circuit in the system select the one to be setup for outdoor reset 3 Select Comfort Eco Week 1 Week 2 or Week 3 Building Ref Temp 4 For weekly Building Ref Temp details of the...

Page 28: ...enu Home Screen Main Menu If there is more than one heating circuit in the system 4 2 Constant Set Point Mode When a fixed header temperature is desired configure the Constant Set Point Mode as shown...

Page 29: ...nt can also be set on this screen 4 3 0 To 10 Volt Remote Set Point Mode This mode allows the boiler set point to be controlled by an external control signal The following sections provide the procedu...

Page 30: ...0 to 10 volt Remote Setpoint Mode is configured as follows 1 Access Device Management from Main Menu select hcm Parameter Settings 2 Scroll to Parameter 799 Set Parameter 799 2 Parameter 799 defines t...

Page 31: ...te setpoint Unit will resume operation when voltage signal reaches 5 37V 90 F hcm 19 803 Enabled services 483 Max differential temperature 34 Burner Hysteresis 31 CH 1 Minimum setpoint 39 CH 1 Maximum...

Page 32: ...To monitor the DHW temperature connect the tank sensor wire leads to the Input Output box connector Y2 terminals 6 and 8 After the sensor is connected turn the ON OFF switch to the OFF position then b...

Page 33: ...ules available Choose this to setup DHW Setpoint on a 24 hr clock schedule Comfort and Eco DHW Setpoints can be set by tapping the settings icon Set Comfort DHW Setpoint to desired setting Set Eco DHW...

Page 34: ...ts for each day type Time slots are programmed in a 24 hr clock Creating Weekly DHW Setpoint schedules 1 Rename week type as desired e g School Week Spring Break Week etc Mon Fri can be combined to ha...

Page 35: ...8 Mon Fri 8 am 5 pm EST Page 35 of 83 Choosing the DHW Setpoint to use 1 Select Comfort Eco Week 1 Week 2 or Week 3 DHW Setpoint 2 For weekly DHW Setpoint details of the program can be viewed as follo...

Page 36: ...pm EST Page 36 of 83 Viewing the DHW Setpoint The setpoint temperature setting is viewed in the Heating Menu 4 5 Boiler Pump Enable Disable The boiler and pump can be enable disabled via terminals TA...

Page 37: ...tic boiler water pump are all disabled When Y2 TA 9 is closed the Modulex boiler boiler loop pump secondary loop pump and domestic boiler water pump are all enabled NOTE Terminals Y2 TA 9 can be used...

Page 38: ...fly Controller and BCM for Modulex EXT CHAPTER 4 UFLY SETUP AND PROGRAMMING OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 38 of 83 This page intentionally left blank...

Page 39: ...T CHAPTER 5 INPUT OUTPUT BOX BCM TERMINAL ASSIGNMENTS OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 39 of 83 CHAPTER 5 INPUT OUTPUT BOX BCM TERMINAL ASSIGNMENTS Figu...

Page 40: ...y Controller and BCM for Modulex EXT CHAPTER 5 INPUT OUTPUT BOX BCM TERMINAL ASSIGNMENTS OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 40 of 83 5 1 terminal Assignme...

Page 41: ...er s master controller stops working the BCM also takes over operations of the boiler The BCM enhances the range of control functions offered by the Modulex Boilers These additional control functions...

Page 42: ...Controller and BCM for Modulex EXT CHAPTER 6 BOILER COMMUNICATIONS MODULE BCM OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 42 of 83 Figure 6 2 BCM Key and LEDs Leg...

Page 43: ...Output box In addition the red LED on the BCM board will light continuously 6 2 1 BCM Fault Relay Wiring If desired pins 3 and 4 of connector Y4 Figure 6 4 can be wired to an external source to provi...

Page 44: ...Page 44 of 83 Figure 6 4 Alarm Signal location Figure 6 5 BCM Fault Relay Reset Switch Wiring 6 3 BCM Backup Controller Function 6 3 1 Backup Controller Setpoint The BCM is a backup controller and wi...

Page 45: ...t 0 NOTE A resistor can be installed on terminals Y2 6 7 and Parameter 799 can be changed to zero only if the normal operating mode is either Constant Setpoint or via Modbus AERCO ACS BAS EMS A resist...

Page 46: ...perated as a backup controller automatically in lieu of pressing the MANUAL button This is particularly useful if the normal mode of operation is via Modbus so that if the Modbus signal is lost the BC...

Page 47: ...o Parameter 376 This parameter defines the functionality of terminals Y2 TA 9 Set Parameter 376 3 to automatically activate the BCM as a backup controller NOTE Terminals Y2 TA 9 can be used for automa...

Page 48: ...troller for pump mains power Pump mains power must be supplied externally as directed by pump manufacturer s instructions 6 4 1 Pump Control Wiring The 0 10 V signal wire must be wired to terminals 4...

Page 49: ...to 2V and Parameter 313 is set to 10V the variable speed pump control will send 0VDC at 5 boiler firing rate and 10VDC at 100 boiler firing rate varying linearly between the two voltages NOTE Consult...

Page 50: ...ked Modulex Boilers utilizing Remote Setpoint An AERCO ACS Master can control the networked Modulex boilers utilizing a Modbus signal If the external control signal from the Master ACS EMS or BAS is l...

Page 51: ...re or 4 Wire RS485 port In addition some EMS BAS models contain both a RS232 and a RS485 port If the EMS or BAS is equipped with only a RS232 port a RS232 to RS485 converter will be required such as a...

Page 52: ...rolling Master See ACS Manual GF 131 Section 2 6 for additional information on these switches When a third party EMS or BAS is used as the controlling Master consult the manufacturer s Technical Manua...

Page 53: ...inating resistor in the last BCM on the daisy chain loop DO NOT install the 1K bias resistor Instead activate the two bias DIP switches in the ACS Refer to GF 124 for the location of these switches CA...

Page 54: ...the EMS BAS manufacturer s manual prior to attempting any network wiring connections Figure 6 15 EMS BAS Master Controlling Modulex Boiler Slaves 6 8 Modbus Software Set Up The following sections pro...

Page 55: ...BAS or AERCO ACS For the BCM to automatically act as the Back Up Controller if the Modbus Master signal is lost Parameter 376 of the BCM must be set to 3 and a jumper must be installed on terminals T...

Page 56: ...l Control Register settings return to default Be sure to read regularly and refresh if necessary The changes to the Settings Registers are stored during power down 6 8 4 EMS or BAS Set Up as Master to...

Page 57: ...ire rate signal to the two boilers reaches a value three times that of the start level percentage the ACS will call on the third boiler to begin firing one module and the ACS will then split the fire...

Page 58: ...fly Controller and BCM for Modulex EXT CHAPTER 6 BOILER COMMUNICATIONS MODULE BCM OMM 0159_A_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 58 of 83 This page intentionally blan...

Page 59: ...Requirements The Modbus Network must conform to the support requirements listed below TABLE 7 2 Modbus Support Requirements CHARACTERISTIC DESCRIPTION Communication Medium BMS II ACS or EMS Master to...

Page 60: ...to 7 BMM 7 255 BCM 1 Unit Status enum 1 3 5 1 Standby ready to run but not fired 3 Remote fired 5 Fault failure detected 2 Flow Sensor Temp 14 to 248 F 10 to 120 C Valve X10 3 Return Flow Temp 32 to 2...

Page 61: ...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 1021 Heat Request Command enum 0x01 0x33 0x44 0x55 0xBB 0xCC 0xEE 0x01 No action...

Page 62: ...e 2 Normal operation 4 Monitor mode Read Only 1002 Flow Sensor Temperature 14 F to 248 F 10 C to 120 C Value x 10 Read Only 1003 Return Flow Temperature 32 F to 248 F 0 C to 120 C Value x 10 Read Only...

Page 63: ...Only 1408 DHW actual temperature 14 F 212 F 10 C 100 C Value x 10 Read Only 1020 Operating Mode enum 0 1 2 3 6 0 Standby 1 Space Heating 2 DHW 3 Check 4 CH frost protection 6 Test Read Only 1100 Linke...

Page 64: ...y 2n08 BMM n Actual Modulation Level n 0 7 0 100 Read Only 2n10 BMM 0 Capacity n 0 7 0 255 kW Read Only 2n11 BMM n Configuration n 0 7 Flag 0 1 0 Space Heating Only 1 Space Heating and DHW Read Only 2...

Page 65: ...Read Write 12 3005 Temp Control Derivative Gain 0 50 Read Write 0 3006 Pump Over run Time 1 10 minutes Read Write 3 min 3018 Burner insertion delay time 30 900 sec in 10 sec intervals Read Write 120 s...

Page 66: ...d Write 95 F 9201 DHW maximum target temperature 122 F to 149 F 50 C to 65 C Read Write 149 F 9202 DHW request tank to target temperature differential 36 F to 36 F 20 C to 20 C Read Write 7 F 9203 DHW...

Page 67: ...rite 36 F 3011 Communication Timeout Time 0 10 240 sec in 10 sec intervals 0 Disable Read Write 30 sec 3012 Temperature Units 0 1 0 C 1 F 1 F 3013 Analog Input Function 0 1 0 Setpoint Adjust 1 Outdoor...

Page 68: ...s only executed in Standby mode The other Write messages are executed only in Test mode 1109 Pump Modulation Output 0 10V Value x 10 Read Write 3100 Digital inputs status 0 1 Flags 0 0xFFFF bit 0 Inpu...

Page 69: ...g Register Address Mapping Modbus Data Address Menu Item Units and Range Default Comments 3102 Digital outputs control in TEST mode 0 1 Flags 0 0xFFFF bit 0 Relay1 OFF ON bit 1 Relay2 OFF ON bit 2 Rel...

Page 70: ...Controller and BCM for Modulex EXT CHAPTER 7 BCM MODBUS AND ADDRESS ASSIGNMENTS OMM 0159_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 70 of 83 This page intentionally left bl...

Page 71: ...NG 8 1 Ufly Controller Error Codes Fault codes are displayed in the right hand section of the Ufly Controller display see Figure 8 1 There are codes for the following two different devices BCM Boiler...

Page 72: ...rost boiler AUTOMATIC when Flow sensor is greater than 41 F HCM 18 Global differential temperature Maximum temperature protection Fault is detected if Global FlowSensor Return Sensor Param 483 50 F No...

Page 73: ...C HCM 56 Heat control lack BCM No remote control detected It is possible to activate burner ignition from the BCM manual request button HCM 57 Burners lack BCM No BMM detected Burners turned OFF Check...

Page 74: ...when Flow sensor 176 F BMM 10 Internal failure Internal failure Ignition is inhibited Contact factory for new BMM MANUAL cycle the power BMM 11 Unexpected flame Flame signal detected before ignition...

Page 75: ...check the wiring If wiring is OK change BMM AUTOMATIC BMM 24 Low fan speed Modulating fan speed failure failed to reach the correct speed within 30 seconds from starting of burner ignition cycle Ignit...

Page 76: ...483 Maximum Differential Temperature Water T protection 0 F 2 F 90 F 0 C 1 C 50 C 0 Disabled Units may be expressed in R or K MLX EXT 450 2S 1100 2S 45 F 25 C MLX EXT 1500 2S 3000 2S 54 F 30 C 34 Burn...

Page 77: ...inimum Setpoint DHW setpoint must be set higher than the value of Parameter 650 77 F to 113 F 25 C to 45 C 95 F 35 C 385 DHW Maximum Setpoint 122 F to 149 F 50 C to 65 C 149 F 65C 360 DHW tank adjustm...

Page 78: ...urners minimum inserted 1 8 1 616 Cascade insert lock time Burner insertion delay time 30 900 sec 120 sec 613 Cascade remove lock time Burner removal delay time 30 900 sec MLX EXT 450 2S 1100 2S 120 s...

Page 79: ...n of the requested number of burner s 1 Contact closes with each failure of the boiler See Description 1 771 Water Pressure Sensor NOT APPLICABLE Note Leave at default value of 0 0 768 Min Gas Pressur...

Page 80: ...Communication Timeout 0 240 sec 30 sec 896 Temperature unit 0 C 1 F See Description 0 799 Analogue input function 0 10 V NOT APPLICABLE Note Leave at default value of 0 0 376 Programmable Input 1 fun...

Page 81: ...X EXT 1500 2S 3000 2S 91Hz 319 Maximum Modulation 1 100 100 346 Minimum modulation Burner Minimum modulation level 1 100 MLX EXT 450 2S 1100 2S 34 MLX EXT 1500 2S 3000 2S 31 314 Standby modulation 0 1...

Page 82: ...54 F 30 C 380 Programmable Sensor 1 function NOT APPLICABLE Note Leave at default value of 1 1 777 APS check NOT APPLICABLE Note Leave at default value of 0 0 623 Temperature sensors 0 10K 25 C B 3977...

Page 83: ...odulex EXT 0 APPENDIX B BMM PARAMETERS OMM 0159_A 6 28 2022 Technical Support 800 526 0288 Mon Fri 8 am 5 pm EST Page 83 of 83 Change Log Date Description Changed By 6 28 2022 Initial Release DBarron...

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