MODULEX EXT 321, 481, 641, 802, 962, 1123 BOILERS
Installation, Operation & Maintenance Manual
OMM-0087_0F
AERCO International, Inc.
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100 Oritani Dr.
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Blauvelt, NY 10913
Page
87
of
146
GF-143
Phone: 800-526-0288
07/13/15
4.2 BCM (Boiler Communication Module)
NOTE
Only the basic features and functions of the BCM are described in
the following sections. Refer to the E8 Controller User Manual (GF-
115-C) for detailed information and diagrams for wiring and using
the BCM in its various capacities.
The BCM (Boiler Communication Module) is an electronic module in MODULEX boilers, which
supports full interoperability to BAS (Building Automation Systems) via Modbus protocol to
make remote communications and control possible. In addition, it provides customers with a
remote alarm contact to notify customers of faults detected within any of the boiler's multiple
thermal modules. Finally, in the event the boiler's master controller stops working, the BCM also
takes over operations of the boiler.
As a back-up controller, the BCM further increases the reliability of a product line already known
for its uniquely redundant design. Each MODULEX boiler combines between two and seven
independent, 160,500 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 temperature
sensor, thermostat and heat exchanger. The independent operation of these thermal modules
increases each boiler's overall reliability. If a single module requires maintenance or repair, the
other module(s) in the boiler can maintain the system load requirements -- thereby providing a
level of redundancy that was previously only realized in multi-boiler installations.
A photo of the module is shown in Figure 4-6. Additional information for the BCM component
can be found in Section 7, 9, and 10 of the E8 Controller User Manual (GF-115-C).
BCM Features and Functions
4.2.1
When installed and enabled, the BCM enhances the range of control functions offered by the
Modulex Boilers. These additional control functions include the following:
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Providing a fault relay which energizes when any fault condition occurs in the Modulex
Boiler.
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Serving as a Back-up Controller in the event that the primary E8 Controller fails.
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Providing a 0-10V output to control a variable speed primary pump.
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May be selected as the Primary Controller instead of the E8.
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Functioning as a “Slave” to a “Master” Energy Management System (EMS), Building
Automation System (BAS) or AERCO’s Boiler Management System II (BMS II/AERCO
Control System [ACS]) on a Modbus Network.
BCM Description
4.2.2
The BCM shown in Figure 4-6 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 control panel.
Input/Output (I/O) connections to the BCM are made via four connectors mounted on the
Printed Circuit Board (PCB) of the BCM. Three Control Switches are mounted on the clear
plastic cover on the front of the BCM. Three LED Status Indicators are mounted directly on the
BCM PCB and can be viewed through the clear plastic cover. In addition, the PCB contains an
on-board, screwdriver-adjustable 10-position address switch, which is used to set the
corresponding address of the boiler on the input Modbus or EBUS Network.
Refer to Tables 4-5 and 4-6 for details on the features and functions of the BCM.
