AER E8 Manuale utente

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 1of 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

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 2of 112

GF-115-C

Modulex E8 Controller and BCM

Operations and Maintenance Manual

OMM-0084_0D

Disclaimer

The information contained in this manual is subject to change without notice from AERCO International,

Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to

implied warranties of merchantability and fitness for a particular application. AERCO International is not

liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in

connection with the furnishing, performance, or use of this material.

Technical Support:

(Mon–Fri, 8am-5pm EST)

1-800-526-0288

www.aerco.com

AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: 800-526-0288

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 3of 112

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Table of Contents

Table of Contents..........................................................................................3

1. INTRODUCTION................................................................................7

1.1 Safety and Warnings........................................................................................7

2. E8 CONTROLLER AND BCM DESCRIPTION.....................................9

2.1 E8 Controller Features And Functions...........................................................9

2.2 BCM Features And Functions.......................................................................10

3. E8 CONTROLLER OPERATION.......................................................11

3.1 NORMAL Mode Operation (Door Closed).....................................................11

3.1.1 NORMAL Mode Display Functions................................................................... 11

3.1.2 HEATING Mode Selection (in NORMAL Mode) ............................................. 12

3.1.3 MENU Mode Operation (Door Open)................................................................ 12

3.2 Software Menus..............................................................................................13

3.2.1 Basic Menu/Sub-Menu Navigation and Selection.............................................. 15

3.2.2 Basic Parameter Navigation, Selection, and Revision........................................ 16

4. E8 CONTROLLER MENUS 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 Available Settings for Relay Functions 1 – 4...................................................... 40

5. E8 OPERATING MODE: Set-up and Programming.............................42

5.1 Indoor/Outdoor Reset Mode..........................................................................42

5.1.1 Wiring Connections............................................................................................. 42

5.1.2 Indoor/Outdoor Reset Operation Configuration ................................................. 42

5.1.3 Viewing the Boiler Setpoint................................................................................ 44

5.2 Constant Set Point Mode...............................................................................44

5.2.1 Wiring Connections............................................................................................. 45

5.2.2 Constant Setpoint Mode Configuration............................................................... 45

5.2.3 Viewing Constant Set Point ................................................................................ 45

5.2.4 Configuring Set Point High and Low Limits Per Outside Temperature Sensor. 45

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 4of 112

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Operations and Maintenance Manual

OMM-0084_0D

5.3 0 to 10 Volt Remote Set Point Mode.............................................................48

5.3.1 Remote Signal Source Wiring Connections........................................................ 48

5.3.2 Configuring Remote Signal Source..................................................................... 49

5.3.3 Setting the Voltage and Set Point Limits for U1/U2 and T1/T2......................... 50

5.3.4 Setting the Curve 11-UO Voltage....................................................................... 51

5.3.5 Viewing the Set Point.......................................................................................... 52

5.4 Domestic Hot Water Operation Using A Tank Sensor ................................52

5.4.1 Sensor Wiring Connections................................................................................. 52

5.4.2 Configuring the Controller for DHW With a Tank Sensor................................. 53

5.4.3 Setting the DHW Set Point ................................................................................. 54

5.4.4 Displaying Temperatures Associated With DHW .............................................. 55

5.5 DHW Operation Using an Aquastat ..............................................................56

5.5.1 Sensor Wiring Connections................................................................................. 56

5.5.2 Configuring the Controller for DHW With an Aquastat..................................... 56

5.5.3 Setting the DHW Set Point ................................................................................. 56

5.5.4 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 BCM Back-Up Controller Wiring....................................................................... 65

7.4 BCM Configured as Primary Controller Utilizing Modbus..........................66

7.4.1 Operating Scenario.............................................................................................. 66

7.4.2 Physical Modbus RS485 Wiring......................................................................... 67

7.4.3 Disconnecting the E8 from the E-Bus on the BCM Board................................. 68

7.4.4 AERCO BMS II/ACS Master to BCM Slave Wiring Connections.................... 69

7.4.5 EMS or BAS Master to BCM Slave Wiring Connections.................................. 69

7.5 RS485 Loop Termination Resistors and Bias..............................................69

7.5.1 Master AERCO BMS II/ACS or EMS/BAS Terminating Resistor and Bias..... 69

7.5.2 BCM Controller Terminating Resistor and Bias................................................. 70

7.6 Modbus Network Wiring Diagram.................................................................70

7.7 Modbus Software Set-Up...............................................................................74

7.7.1 BCM Set-Up for Modbus Operation................................................................... 74

7.7.2 Monitoring and Configuration Only ................................................................... 75

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 5of 112

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Operations and Maintenance Manual

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7.7.3 AERCO BMS II/ACS Modbus Control and Monitoring.................................... 75

7.7.4 Modbus Remote Setpoint Control and Monitoring............................................. 75

7.7.5 EMS or BAS Set-Up As Master to BCM Controller Slaves............................... 75

7.8 Multiple Modulex Boiler Heating Mode – Utilizing a BMS II or ACS...........75

7.8.1 Sequence of Operation (Example: Four-Modulex boiler installation)................ 76

8. E8 CONTROLLER MENU LISTINGS................................................78

8.1 DISPLAY 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 Register Assignments...................................... 95

9.2.2 BCM Controller Standard Holding Register Assignments................................. 95

10. E8, BCM, AND BMM FAULT CODES .............................................102

10.1 Processing and Clearing Fault Codes........................................................103

10.2 Fault Codes and Descriptions.....................................................................104

10.2.1 E8 Controller Fault Codes............................................................................. 105

10.2.2 BCM (Boiler Communications Module) Fault Codes................................... 106

10.2.3 BMM (Burner Management Module) Fault Codes....................................... 108

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 6of 112

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Operations and Maintenance Manual

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1. INTRODUCTION

The information in this manual provides a guide to the operation of the Modulex Boiler using

the E8 Controller and the Boiler Communications Module (BCM) mounted on the front of the

unit. Sections 3, 4, 5, 6, and 8 provide descriptions and procedures for the E8 Controller.

Sections 7,9, and 10 provide similar information for the BCM.

It is imperative that the initial startup procedures be performed by factory trained personnel.

Operation by untrained personnel, prior to the initial startup, will void the equipment warranty.

In addition, CAUTIONS and WARNINGS in this manual must be observed at all times.

1.1 Safety and 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 avoided,

COULD result in minor or moderate injury. Also may caution

against unsafe practices.

Note that all hazard notifications and notes are presented enclosed in a rectangle with filleted

(round) corners, as shown below, in order to differentiate them from the main text.

It is of utmost importance to observe all CAUTIONS and

WARNINGS presented in this manual to avoid injury, death, and

damage to the equipment. Failure to properly heed safety

warnings and cautions may result in the voiding of applicable

warranties.

WARNING

CAUTION

DANGER

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 8of 112

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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288

2. E8 CONTROLLER AND BCM DESCRIPTION

Modulex boilers contain advanced and reliable electronic controls, which includes the E8

Controller and the BCM (Boiler Communications Module), providing comprehensive

programming and monitoring of the Modulex boiler and its functions. Features and functions of

the E8 Controller are described in the following sections.

2.1 E8 Controller Features And Functions

A standard component included in Modulex units, the E8 Controller is responsible for the

staging and modulation of individual thermal heating modules in a Modulex boiler and also

monitors supply and return water temperatures and domestic hot water zones.

The E8 Controller is housed in a compact enclosure measuring 5.7” (145 mm) x 3.9” (100 mm).

The Controller is mounted on the front of the Modulex Boiler and contains all of the controls,

indicators and displays necessary to adjust, operate and troubleshoot the Modulex Boiler. The

E8 features the following functions for Modulex boilers:

•Shares the heating load among as many of the boiler's thermal heating modules as

possible. maximizing the overall operating efficiency of the boiler.

•Provides access to all testing/programming parameters of each individual heating module:

operation test, operation time, boiler freeze protection and pump's anti seize program.

•Drives lead-lag burner operation based on operating hours. The boiler module with the least

burner operating hours is the first to start and the burner with the most operating hours is the

first to stop.

•Supports DHW (Domestic Hot Water) production using a dedicated sensor to control a

dedicated pump or 3-way diverting valve for storage tank temperature control.

•Supports a manual operation service mode to control individual modules during

troubleshooting or combustion calibration procedures.

•Drives diagnostics such as relay and senor testing.

•Supports Modbus integration with AERCO BMS II and AERCO Control System (ACS) or

Building Automation Systems. AERCO also offers a Communication Gateway to support

BACnet, Lonworks and N2 system integration.

Figure 2-1: Modulex E8 Controller Front Panel

Rotary Knob

LCD Display

Window

Hinged Cover

(in closed

position)

06/05/13 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 •Ph: 800-526- 0288 Page 10 of 112

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Modulex E8 Controller and BCM

Operations and Maintenance Manual

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2.2 BCM Features And Functions

The BCM (Boiler Communications Module) is an electronic module in Modulex boilers (one per

burner), which supports full interoperability to BAS (Building Automation Systems) via Modbus

protocol to make remote communications and control possible. In addition, it provides

customers with a remote alarm contact to notify customers of faults detected within any of

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, 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 temperature

sensor, thermostat and heat exchanger. The independent operation of these thermal modules

increases each boiler's overall reliability. If a single module requires maintenance or repair, the

other module(s) in the boiler can maintain the system load requirements -- thereby providing a

level of redundancy that was previously only realized in multi-boiler installations.

A photo of the module is shown in Figure 2-2 below. Additional information for the BCM

component can be found in Section 7, 9, and 10.

Figure 2-2: Modulex BCM (Boiler Communications Module)

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