AERCO Control System (ACS) Installation, Operation, and Maintenance Manual Used for up to Thirty-two (32) AERCO Boilers including: • Benchmark Series Boilers • AERCO Modulex Series Boilers • AERCO KC-1000 Series Boilers GF-131 OMM-0081_0D USER MANUAL Installation, Operation, and Maintenance AERCO Control System (ACS) AERCO Control System (ACS) Front Panel High Efficiency Innovation Revised: 04/23/2013 MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Technical Support: (Mon–Fri, 8am-5pm EST) 1-800-526-0288 www.aerco.com 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 Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table of Contents FOREWARD ................................................................................................................... 9 PHRASES, ABBREVIATIONS & ACRONYMS .......................................................... 9 1. 2. ACS GENERAL INFORMATION ........................................................................... 11 1.1 SAFETY PRECAUTIONS AND WARNINGS .........................
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 2.10 INTERLOCK WIRING ...................................................................................... 32 2.10.1 Interlock 1 (INT 1) Wiring ....................................................................... 32 2.10.2 Interlock 2 (INT 2) Wiring ....................................................................... 32 2.11 SETBACK WIRING ................................................................
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.7 RS232 MODE......................................................................................... 49 RS232 BAUD RATE ............................................................................... 49 MODBUS ADDRESS ............................................................................. 49 NETWORK TIMEOUT ............................................................................
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 3.9.16 3.9.17 3.9.18 3.9.19 3.9.20 3.9.21 GF-131 OMM-0081_0D DHW OPTION (Domestic Hot Water Option) ......................................... 56 NUMBER DHW BLRS (Number of Domestic Hot Water Boilers) ........... 56 DHW SIGNAL (Domestic Hot Water Signal) .......................................... 57 NUM DHW PRIORITY (Number of DHW Priority Boilers) ...................... 57 VALVE WAIT STATES ......................................
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 3.14 ACS QUICK-START GUIDE MENU ................................................................ 63 4. 3.14.1 CONSTANT SETPT MODE (Default):.................................................... 64 3.14.2 REMOTE SETPT MODE: ....................................................................... 65 3.14.3 OUTDOOR RESET MODE ....................................................................
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D B.5 BCM (BURNER MANAGEMENT MODULE) FAULT CODES .......................... 99 B.6 ACS (AERCO CONTROL SYSTEM) I/O STATUS .......................................... 102 APPENDIX C: RESET SCHEDULE AND OUTDOOR RESET RATIO CHARTS ..... 105 C.1 USING THE CHARTS TO DETERMINE RESET SCHEDULE ........................ 105 C.2 DETERMINING RESET SCHEDULE BY FORMULA......................................
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D FOREWARD The AERCO Control System (ACS) is AERCO’s solution for a flexible boiler plant controller. The system can control a boiler plant comprised of AERCO Benchmark Series, Modulex Series or KC1000 Boilers. The ACS can stage and coordinate the operation of up to thirty-two (32) AERCO Boilers with maximized efficiency.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Phrases, Abbreviations and Acronyms (Continued) Phrase, Abbreviation or Acronym FDX FLT GND HDR HDX Hex Hz INTLK I/O I/O Box IP ISO LSB LSD MA (mA) MAX (Max) MIN (Min) Modbus® MSB MSD MS/TP OFFS OUTD PTP REF (Ref) Response Time RS232 (or EIA-232) RS422 (or EIA-422) RS485 (or EIA-485) RTN RTU SEN SETPT (Setpt) SHLD (Shld) SLTA SYS TEMP (Temp) Terminating Resistor VAC VDC VFD MC2: 04/23/13 Meaning Full-Duplex Fa
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 1. ACS GENERAL INFORMATION 1.1 SAFETY PRECAUTIONS AND WARNINGS 1.2 INTRODUCTION The warnings and cautions appearing throughout this manual should be reviewed and thoroughly understood prior to attempting to install, operate, troubleshoot or repair the ACS Controller. This manual provides installation, operation and troubleshooting instructions for the AERCO Control System, Model 5R5-384. 1.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Clear Plastic Cover Front Panel Wiring Compartment Cover Figure 1-1: AERCO Control System (ACS) 1.4 ACS FEATURES The following paragraphs briefly describe some of the unique features incorporated in the ACS. 1.4.1 Simplified Installation and Set-Up The ACS system operates on single-phase input power ranging from 85 to 265 VAC, 50-60 Hz.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 1.4.3 Retention of Menu Option Settings By using non-volatile memory, the ACS retains program and menu settings during shut-down or when input AC power is interrupted. Settings can be retained for more than 2 years. 1.4.4 Application Flexibility Four different configuration options can be selected to match the needs of any closed-loop system.
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual 2. OMM-0081_0D ACS INSTALLATION 2.1 INTRODUCTION 2.2 SITE SELECTION AND MOUNTING This Chapter provides the descriptions and procedures necessary to mount the ACS and connect all boiler plant units and applicable sensors. Guidelines are also provided for connection of an EMS or BAS being used with the system. Refer to the wiring diagram provided in Appendix E when making all wiring connections to the ACS.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 145 mm (5.7") 15 mm (0.6") 198 mm (7.8") REAR VIEW Figure 2-1: ACS Mounting Provisions 2.3 SITE SELECTION AND MOUNTING All wiring connections to the ACS are made at the terminals located behind the wiring compartment cover as shown in Figure 2-2. Run all wiring through the knock-outs provided on the bottom surface of the unit.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual ! WARNING OMM-0081_0D ! THE ACS CAN BE POWERED BY SINGLE-PHASE AC VOLTAGES RANGING FROM 85 TO 265 VAC. THEREFORE, EXERCISE EXTREME CARE WHEN CONNECTING POWER WIRING TO THE UNIT. ENSURE THAT THE EXTERNAL CIRCUIT BREAKER SUPPLYING LINE VOLTAGE TO THE ACS IS TURNED OFF TO AVOID SEVERE ELECTRICAL SHOCK. 2.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Figure 2-2: ACS with Wiring Compartment Cover Removed 2.5 SENSOR INSTALLATION AND WIRING Two types of sensors may be installed, including a Header Sensor and 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.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 2.5.1 Header Sensor Installation A Header Sensor Kit, (part no. 122790) is provided with the ACS. This Kit contains the Header Sensor (64038), a Thermowell (122758) and some heat conductive grease which MUST be used with the Sensor. When installing the Sensor, use a 1/2 inch NPT tapped coupling or a 4 x 4 x 1/2 inch Tee fitting. Shielded pair, 18 AWG cable (Belden # 8760 or equiv.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D HEADER SENSOR WITH THERMOWELL INSTALLED PROBE DEPTH MUST EXTEND AT LEAST 2" INTO PIPE WELDED 1/2" COUPLING OR 4"x4*x1/2" T - FITTING Figure 2-3: Header Sensor Installation Details 2.5.3 Outdoor Air Sensor Installation The Outdoor Air Temperature Sensor (part no. GP-122662) is required when operating in the ACS in the Outdoor Reset Mode (paragraph 4.2). An Outdoor Air Sensor Kit (part no.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D INSTALL SENSOR ON NORTH FACING WALL OUT OF DIRECT SUNLIGHT AND AWAY FROM ALL AIR INLETS/OUTLETS Figure 2-4: Outdoor Air Sensor Installation MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual 2.6 OMM-0081_0D RS485 (MODBUS) WIRING AT THE ACS The ACS communicates with the AERCO Boilers over a RS485 network using Modbus protocol. All Modbus networks are implemented utilizing a Master/Slave scenario where only one device, the Master, can initiate a communication sequence. AERCO Boilers equipped with C-More or E8/BCM (Modulex) control systems can only function as Slaves on a Modbus network.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D BIAS DIP SWITCHES WIRING COMPARTMENT NOTE: THE BIAS DIP SWITCHES CAN BE ACCESSED FROM THE WIRING COMPARTMENT WITHOUT REMOVING THE FRONT PANEL FROM THE UNIT. Figure 2-6: Location of ACS DIP Switches 2.7 RS485 (MODBUS) WIRING, BIAS, AND TERMINATION AT AERCO BOILERS The RS485 wiring connections at the AERCO Boilers will depend on the type of AERCO Boilers and Control Systems being used on the Modbus Network.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D BIAS/Loop Term: METHOD A 1. Using a daisy-chain wiring configuration, connect the RS485 positive lead to the RS485 + terminal in the I/O Box for each boiler. 2. Connect the RS485 negative lead to the RS485 - terminal in the I/O Box for each boiler. 3. DO NOT terminate the shields to the Ground (GND) terminal at the boiler end of the RS485 loop. Connect the shields of the incoming and outgoing leads together.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D I/O Board 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. METHOD A – BIAS & TERMINATION ACTIVATED AT C-MORE PMC BOARD Figure 2-7: RS485 (Modbus) Wiring For Benchmark Series Boilers (Sheet 1 of 2) MC2: 04/23/13 AERCO International, Inc.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D I/O Board Connect 120 OHM, ½ Watt resister between + and – RS485 terminals on the LAST C-More Box. 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.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D I/O Board 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. METHOD A – BIAS & TERMINATION ACTIVATED AT C-MORE PMC BOARD Figure 2-8: RS485 (Modbus) Wiring For KC1000 Boilers (Sheet 1 of 2) MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D I/O Board Connect 120 OHM, ½ Watt resister between + and – RS485 terminals on the LAST C-More Box. 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.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 2.7.2 RS485 Wiring for Modulex Series Boilers RS485 wiring connections are made at the MODBUS terminals of each Boiler’s BCM Module as shown in Figure 2-9. Connect the wiring as shown below: RS485 Wiring at Boiler BCM of Modulex Boiler(s) 1. Connect the positive lead to terminal 1 (MODBUS B +) of connector Y2. 2. Connect the negative lead to terminal 2 (MODBUS A -) of connector Y2. 3.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 2.8 GF-131 OMM-0081_0D SAMPLE RS485 (MODBUS) NETWORK DIAGRAMS Figure 2-10 shows a sample RS485 (Modbus) Network diagram with the ACS connected to KC1000 or Benchmark Series Boilers equipped with C-More Control Systems. Figure 2-11 shows a similar sample diagram with the ACS connected to Modulex Series Boilers equipped with BCMs and E8 Controllers.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 2.9 GF-131 OMM-0081_0D RS485 WIRING AT THE ACS The ACS communicates with an external Energy Management System (EMS) or Building Automation System (BAS) utilizing the wiring terminals 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 Part No. 124943) is required to communicate with the ACS.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 2.10 INTERLOCK WIRING The ACS is equipped with two interlocks designated Interlock 1 (INT 1) and Interlock 2 (INT 2). Since both interlocks must be closed for the ACS to operate the boiler plant, the associated wiring terminals are jumpered, prior to shipment. If desired, proving device switches can be connected to either interlock in place of the jumper.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D NOTE The state of the SYS START, FLT ALARM and AUX Relays are controlled by options contained in the Relay Menu described in Chapter 3, paragraph 3.11. 2.12.1 System Start Relay The state of the System Start (SYS START) relay contacts are controlled by the value set for the SYS START TEMP and SYS START OPTION in the Relay Menu.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 2.15 RELAY PANEL INSTALLATION AND WIRING 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.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 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) MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Figure 2-14b: ACS Wiring: DHW Option 1 DHW Pump Enabled/Disabled by Building Controls MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Figure 2-14c: ACS Wiring: DHW Option 2 DHW Pump Enabled/Disabled by ACS MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Figure 2-14d: ACS Wiring: DHW Option 3 MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 2.16 RELAY PANEL COMPONENTS 2.16.1 Power The power connector is located at the left side of the wiring panel. It uses single phase AC power from 110 to 240 VAC, 60 Hertz. 2.16.2 Inputs The inputs are all dry switch (digital) inputs.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 2.17 RELAY PANEL OPERATION Front Panel Clear Plastic Cover Wiring Compartment Cover Figure 2-15: ACS Relay Panel Front Panel The board operates basically as follows: a) In the normal idle state, all the inputs, except one of the Valve End Switch In inputs, would be open. As a result, the Aquastat Out would be open and the Valve End Switch Out would be closed.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 2.18 ACS PROGRAMMING FOR USE WITH THE ACS RELAY PANEL The AERCO CONTROL SYSTEM (ACS) can be programmed for 3 different types of DHW options. For “Option 1” and “Option 3” operation, the ACS Relay Panel is not needed. It is needed for Option 2 operation. Below we will illustrate programming the ACS for a total of 8 boilers with 2 DHW Priority boilers, 2 Building Priority boilers, and the rest Building boilers.
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual 3. OMM-0081_0D OPERATION 3.1 INTRODUCTION 3.2 FRONT PANEL OPERATING CONTROLS AND DISPLAYS The information in this Chapter provides a guide to the operation of the ACS using the controls and display mounted 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.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table 3-1: ACS Front Panel Controls and Display 1 CONTROL, INDICATOR OR DISPLAY VFD Display 2 FAULT Indicator 3 CLEAR Key ITEM NO. 4 FUNCTION The Vacuum Fluorescent Display (VFD) display consists of 2 lines each capable of displaying up to 16 alphanumeric characters.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 3.3 GF-131 OMM-0081_0D ACS MENU STRUCTURE The ACS incorporates an extensive menu structure which permits the operator to set up, and configure the unit. The menu structure consists of nine major menu categories as shown in Figure 3-2. Each of the menus shown, contain options which permit operating parameters to be viewed or changed. The menus are protected by two different password levels to prevent unauthorized use.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D OPERATING LEVEL 1 PWD SETUP RS232 RS485 FIELD ADJUST CONFIGURATION TUNING RELAY LEVEL 2 PWD CALIBRATION Figure 3-2: ACS Menu Structure MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D NOTE Paragraphs 3.4 through 3.12 provide detailed descriptions of the options contained in each of the menus shown in Figure 3-2. The menu options appear in the first line of the VFD display and the corresponding value or setting for the displayed option will appear in the second line of the display.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D If the Sensor is not connected, the second line of the display will show NOT CONNECTED. The Outdoor Air Sensor MUST be connected when operating in the Outdoor Reset Mode. 3.4.4 I/O STATUS I/O (Input/Output) STATUS is displayed as a hexadecimal number. The meaning of each bit is as indicated below. The higher 4 bits, or most significant digit (MSD), indicate which inputs are activated.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D permitting password entries, the SETUP MENU is also used to enter the date and time. Descriptions of the SETUP MENU options follow. 3.5.1 ENTER PASSWORD The ENTER PASSWORD option allows the Level 1 (159) or Level 2 (6817) to be entered. Once the valid Level 1 password (159) is entered, options in all Menus, except the Calibration Menu, can be changed.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 3.6.4 NETWORK TIMEOUT When the ACS is operating in the Remote Setpt mode via Modbus, the NETWORK TIMEOUT option defines the maximum time (seconds) allowed before re-sending the setpoint information. If the information is nozt re-sent within this time period, the ACS will default to its Failsafe mode of operation set in the Configuration Menu and display “MODBUS TIMEOUT ERROR”.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D ROUND ROBIN can be used at this time. When set to ROUND ROBIN, each networked boiler is addressed individually in sequence. BROADCAST is currently not used for the ACS. 3.7.6 NETW BOILER Xx ADDRESS=Yyy Up to 32 Network Boilers can be accommodated on the Modbus Network (Where Xx = 01 – 32 and Yyy = 001 – 127). Each Boiler must be assigned a unique address on the network ranging from 001 to127.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D the calculation method described in Appendix D must be used. 3.8.6 BLDG REF TEMP The BLDG REF TEMP menu option is only displayed when the HEADER SET MODE is set to OUTDOOR RESET. This option is used to set the Building Reference Temperature (BLDG REF TEMP) to the desired value from 40°F to 220°F. (Default = 70°F). 3.8.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Setting Up an 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 Offset Temperature to -15°F. 3. Press the ▲ arrow key. SUN ON HOUR will be displayed. Set the HOUR to 00. 4. Press the ▲ arrow key again. SUN ON MINUTE will be displayed. Set the MINUTE to 01. 5. Press the ▲ arrow key again.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 3.9.3 PARALLEL MODE When PARALLEL MODE is selected, all boilers are simultaneously started by the ACS. The BLR START LEVEL and BLR STOP LEVEL set in the Configuration Menu (see below) have no effect when in this mode. Regardless of the number of Boilers in the plant, the turn-down ratio in the Parallel Mode is fixed at 20:1 for KC1000 Series Boilers (except 11:1 for KC Low NOx).
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D NOTE For best efficiency, the Boiler Start Level (BLR START LEVEL) and Boiler Stop Level (BLR STOP LEVEL) of the ACS must be the same values as all of the C-More Controls in the heating plant, i.e. if the boilers are set to 20%/16% (Start/Stop levels), then the ACS must be set to 20%/16%. These values must NEVER be set lower than the values at the boilers. 3.9.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D maximum temperature difference allowed between the Header temperature and the Return temperature. If we exceed this value by 18°, the ACS will shut down the boiler plant. When the temperature difference gets below the PLANT DT LIMIT, the boiler plant will be activated again. The Return TC must be installed for this function to operate. 3.9.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D These boilers begin from NETW BOILER 32 and backward. If 3 is entered, then NETW BOILER 30, NETW BOILER 31, and NETW BOILER 32 would be combination boilers. 3.9.18 DHW SIGNAL (Domestic Hot Water Signal) NOTE This function apples only to the C-More Controller, although it is not currently implemented at this time.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 3.10.2 BOOST MAX TIMER This setting is the maximum amount of time that the boost input should be continually activated. It should be assumed that the switch is broken if the boost input remains activated longer than the time entered in this setting.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D If the error continues and is present for another minute, another 9% correction factor will be added: 69% firing rate +9% firing rate = 78% firing rate If, after a load change, the supply water temperature stabilizes at a temperature above or below the setpoint, the integral gain should be increased.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D NOTE In the Revision C firmware and later, the BMSII will shut down the last boiler firing when the Percent Output Level goes below the BLR STOP LEVEL. The shutdown will be indicated by the second line of the default display flashing.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D FAULTS. If NO INTERLOCK is selected, the Fault Alarm Relay will not activate when the interlocks are opened, however the ACS will still shut down all boilers. If INTERLOCK 2 is selected, the Fault Alarm Relay will only activate when Interlock 2 is opened and not when Interlock 1 is opened.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual RAMP UP %/MIN. Time Required To Go From 0% To 100% 20 5 Minutes 40 2.5 Minutes 50 2 Minutes GF-131 OMM-0081_0D 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 ramp down rate for the ACS. The Percent Level output will follow the PID output if it is slower than this rate. The default setting is 200% per minute.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 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 Front Panel Off. 3.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 3.14.1 CONSTANT SETPT MODE (Default): MENU & OPTION ACTION 1. SETUP MENU ENTER PASSWORD Enter 159 2. RS485 MENU Enter this menu if there are more than 2 boilers (default), otherwise go to 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 3. FIELD ADJUST MENU Address 001 and 002 are preset.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 3.14.2 REMOTE SETPT MODE: Perform the procedure described for the CONSTANT SETPT MODE and then continue with the steps described below: ACTION MENU & OPTION 1.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 3.14.3 OUTDOOR RESET MODE Perform the procedure described for the CONSTANT SETPT MODE and then continue with the steps described below: MENU & OPTION ACTION 1. FIELDADJUST MENU HEADER SET MODE Set to OUTDOOR RESET RESET RATIO Enter a different value, if required (default = 1.2). Refer to Appendix C. BLDG REF TEMP Enter the desired Building Reference Temperature.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual 4. 4.1 OMM-0081_0D PROGRAMMING ACS OPERATING MODES INTRODUCTION Prior to programming, the ACS must be mounted and all required wiring completed. In addition, all connections should be checked for accuracy. Once these items are completed, the ACS is ready to be programmed for the desired mode of operation for the boiler plant.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.2.1 Selecting Outdoor Reset Mode The Outdoor Reset Mode is selected using the Header Set Mode option in the Field Adjust Menu as shown below: Selecting Outdoor Reset 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 first line of the VFD display.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.2.3 Entering Reset Ratio and Building Reference Temperature The Reset Ratio and Building Reference Temperature (BLDG REF TEMP) are also entered using options contained in the Field Adjust Menu. These parameters are entered as shown below: Entering Reset Ratio and Building Reference Temperature 1. To enter the required Reset Ratio, scroll through the Field Adjust Menu and select RESET RATIO. 2.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.2.5 Entering System Start Temperature In order to set up the Outdoor Reset Mode, the System Start Temperature must be entered. The System Start Temperature is the outside air temperature at which the boiler plant begins to operate. The factory default value for the System Start Temperature (SYS START TEMP) is 70°F.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 4.3 GF-131 OMM-0081_0D REMOTE SETPOINT MODE In order to set up the ACS to operate in this mode, a Modbus communication line or a 4-to-20 mA input line with a floating ground from an Energy Management System (EMS) is required. In addition, a ACS header sensor is required. This mode may be used with or without an outdoor air temperature sensor installed.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.3.2 Entering Header High Limit and Low Limit Temperatures The Header High Limit and Header Low Limit are also selected using options in the Field Adjust Menu as shown below: Entering Header High Limit and Low Limit Temperatures 1. Using the ▲ or ▼ arrow key on the keypad, scroll through the menu until HDR HIGH LIMIT is displayed in the first line of the VFD display.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.3.3 Selecting Remote Signal Type The boilers connected to the ACS can be controlled by either a 4-to-20 mA signal or a Modbus signal from an Energy Management System (EMS). Remote Signal type is selected in the Field Adjust Menu as shown below: Selecting Remote Signal Type 1.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.3.5 Entering Boiler Start & Stop Levels The Boiler (BLR) Start and Boiler Stop Levels are also entered in the Configuration Menu. Refer to Appendix I to determine the correct Start and Stop levels for your installation. Enter the appropriate values in the Configuration Menu as shown below: Entering Boiler Start & Stop Levels 1.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 4.4.1 Selecting Constant Setpoint Mode The Constant Setpoint Mode is selected using the Header Set Mode option in the Field Adjust Menu as shown below: Selecting Constant Setpoint Mode 1. Using the keypad on the ACS, press the MENU key, until FIELD ADJUST MENU appears in the display. 2.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D 4.4.3 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 below: Selecting Boiler Operating Mode 1. Using the keypad on the ACS, press the MENU key, until CONFIGURATION MENU appears in the display. 2. On the keypad, press the ▲ arrow key once.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D set to TEMP ONLY, the outdoor temperature is the only criteria used to activate the system. In this case the system, and the System Start Relay, will activate when the outdoor temperature falls below the SYS START TEMP setting. If no outdoor sensor is installed, the system (and the System Start Relay) will always be activated in this case.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual 4.8 OMM-0081_0D Testing the System The following procedure places a load on the system and will begin firing the boilers. At this point it is very important to make sure the system pumps are running. After system has been initialized as described in paragraph 4.5, proceed as shown in Instruction 4.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual ! CAUTION GF-131 OMM-0081_0D ! Monitor the HDR TEMP reading to ensure it is not ramping up too high. If it is, press the ON/OFF key of the ACS to shut down the boilers. Remember that the boiler outlet temperature may be higher than the ACS header temperature. NOTE When a Building Automation System (BAS) is connected to monitor the ACS, ensure that the RS232 Menu is configured properly.
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AERCO Control System (ACS) Installation, Operation, and Maintenance Manual 5. 5.1 GF-131 OMM-0081_0D TROUBLESHOOTING Fault Messages And Common Problems When a fault occurs in the boiler plant, the ACS flashes fault messages at 2-second intervals and the Fault Alarm (FLT ALARM) relay contacts are closed. The red FAULT indicator on the front panel will also light. To cancel the alarm (open relay contacts), press the CLEAR key on the ACS keypad.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table 5-1: Fault Messages (Cont.) Fault Message CURRENT LOOP ERROR FAIL SAFE MODE ACTIVATED MODBUS TIMEOUT ERROR Description & Possible cause The 4-to-20-mA remote input signal has dropped below 3 mA, or the signal is not present at the ACS. This message indicates that the ACS is operating in the Fail Safe (Constant Setpoint) mode.due to sensor loss or signal loss.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table 5-2: Common Problems Problem Possible Causes • ACS not turned ON. • Outside air temperature higher than system’s start temperature Boiler plant not started by ACS • Configuration not correct. • System must be initialized • Wiring between boilers and ACS not correct • C-More Box not configured correctly. BMK or KC Boiler with C-More Control Box not being recognized by ACS. • C-More Box not enabled.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table 5-2: Common Problems (Cont.) Problem EMS cannot see ACS Boiler RAMP UP or RAMP DOWN too slow or too fast Possible Causes • Incorrect address • Incorrect Baud Rate • Faulty wiring between EMS and ACS. • See RS232 MENU (paragraph 3.6). • See RS232 MENU (paragraph 3.6). • See Chapter 2. Check wiring polarity and connections. • RAMP UP or RAMP DOWN time needs adjustment.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D APPENDIX A: ACS MENUS Table A-1: ACS Menus MENU LEVEL & OPTION AVAILABLE CHOICES OR LIMITS MINIMUM MAXIMUM DEFAULT OPERATING MENU HEADER TEMP 40 280 N/A HEADER SET TEMP 40 220 N/A OUTSIDE AIR TEMP -60 180 N/A PERCENT OF LOAD 0 100 N/A I/O STATUS LSD: MSD: Bit 0 = AUX Relay Bit 0 = Setback Bit 1 = Fault Relay Bit 1 = Interlock 2 Bit 2 = Sys Start Relay Bit 2 = Interlock 1 Bit 3 = Empty Bit 3
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table A-1: ACS Menus - Continued MENU LEVEL & OPTION AVAILABLE CHOICES OR LIMITS MINIMUM DEFAULT MAXIMUM RS232 MENU RS232 MODE MODBUS SLAVE, NORMAL MODBUS SLAVE RS232 BAUDRATE 2400, 4800, 9600, 19200 9600 MODBUS ADDRESS 128 247 128 NETWORK TIMEOUT (Seconds) 005 240 060 MODBUS PASS THRU DISABLED, ENABLED DISABLED RS485 MENU 2400, 4800, 9600, 19200 RS485 BAUDRATE 9600 MIN SLAVE ADDR 000
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table A-1: ACS Menus - Continued MENU LEVEL & OPTION AVAILABLE CHOICES OR LIMITS MINIMUM DEFAULT MAXIMUM 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 040°F 220°F 040°F INTERNAL SETPT 040°F 220°F 160°F RESET RATIO (Displayed Only if HDR SET MODE = OUTDOOR RESET) 0.3 3.0 1.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table A-1: ACS Menus - Continued MENU LEVEL & OPTION AVAILABLE CHOICES OR LIMITS MINIMUM DEFAULT MAXIMUM 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 SAF
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table A-1: ACS Menus - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT 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.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table A-1: ACS Menus - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAXIMUM DEFAULT 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.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX B: STATUS AND FAULT MESSAGES B.1 C-MORE STATUS AND FAULT MESSAGES Table B-1: C-More Status And Fault Messages DISPLAY MESSAGES DESCRIPTION STATUS MESSAGES: FAIL SAFE MODE ACTIVATED The system is running in the Constant Setpt mode due to loss of the Remote signal or Outdoor Air sensor input. NETWORK DISABLED MODBUS LISTEN “Forced Listen Only Mode” has been activated.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table B-2: C-More Status and Fault Messages CODE MESSAGE DESCRIPTION DISABLED HH:MM pm MM/DD/YY Displayed if ON/OFF switch is set to OFF. The display also shows the time and date that the unit was disabled. 2 STANDBY Displayed when ON/OFF switch is in the ON position, but there is no demand for heat. The time and date are also displayed. 3 DEMAND DELAY XX sec Displayed if Demand Delay is active.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table B-2: C-More Status and Fault Messages - Continued CODE MESSAGE DESCRIPTION 17 IGN SWTCH OPEN DURING IGNITION The Ignition Position Limit switch on the Air/Fuel valve opened during ignition. 18 AIRFLOW FAULT DURING IGN The Blower Proof Switch opened during ignition. 19 AIRFLOW FAULT DURING RUN The Blower Proof Switch opened during run.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table B-2: C-More Status and Fault Messages - Continued CODE MESSAGE DESCRIPTION 39 DIRECT DRIVE SIGNAL FAULT The direct drive signal is not present or is out of range. 40 REMOTE SETPT SIGNAL FAULT The remote setpoint signal is not present or is out of range. 41 OUTDOOR TEMP SENSOR FAULT The temperature measured by the Outdoor Air Sensor is out of range.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table B-2: C-More Status and Fault Messages - Continued CODE MESSAGE 58 INLET_TEMP_HIGH_WARN ING_MESSAGE, 59 INLET_TEMP_LOW_WARNI NG_MESSAGE, 60 INLET_GAS_PRESSURE_S ENSOR_OPEN_MESSAGE, 61 GAS_PLATE_DP_SENSOR _OPEN_MESSAGE, 62 INLET_WATER_FLOW_SE NSOR_OPEN_MESSAGE, 63 INLET_WATER_FLOW_LO W_WARNING_MESSAGE, 64 INLET_WATER_FLOW_HIG H_WARNING_MESSAGE, MC2: 04/23/13 DESCRIPTION AERCO International
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D B.2 CONVERSION EQUATIONS FOR TEMPERATURE VARIABLES Table B-3: Conversion Equations for Temp.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D For (degF>0): For (degC> 0): (degF) ∗ (1000) + 115 RegVar = 230 (degC) ∗ (1000) − 115 RegVar = 128 For (degF<0): For (degC<0): (degF) ∗ (1000) − 115 RegVar = 230 (degC) ∗ (1000) − 64 RegVar = 128 ABS_DEG_1 B.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Example: A displayed number of “261” means the fault occurred on BMM #1, and after subtracting 256 from 261 (261 – 256 = 5), the actual Fault Code is 5, which, according to Table A-6 means “Flame Loss During Run”. B.4 BCM (BOILER COMMUNICATION MODULE) FAULT CODES Table B-5: BCM (Boiler Control Module) Fault Codes CODE EFFECT CORRECTION RESET Boiler Pipe is frozen. FlowSensor temp. is 36°F or less.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D B.5 BCM (BURNER MANAGEMENT MODULE) FAULT CODES Table B-6: BMM (Burner Management Module) Fault Codes CODE DESCRIPTION EFFECT 1 High Limit (STB) Thermostat activated All burners turned OFF and Pump ON at maximum speed. Check FlowSensor thermal connection to boiler. MANUAL - push reset switch when temperature goes below limit. Low Gas Pressure All burners turned OFF .
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table B-6: BMM (Burner Management Module) Fault Codes - Continued CODE DESCRIPTION EFFECT CORRECTION RESET 14 Return Sensor fault All burners turned OFF. Check return sensor or wiring. AUTOMATIC All burners turned OFF and Pump ON at maximum speed. Check the system installation. 15 Maximum Δtemperature protection.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table B-6: BMM (Burner Management Module) Fault Codes - Continued CODE DESCRIPTION 24 26 32 40 CORRECTION RESET Fan speed out of control: It doesn't reach pre-purge speed within 30 seconds. Ignition retry after 60 second delay and failure remains until we have a successful burner operation. Check fan wiring.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D B.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table B-7: ACS I/O Status - Continued (NOTE: MSD = Most Significant Digit; LSD = Least Significant Digit) I/O STATUS (MSD Bit 3) INTERLOCK (MSD Bit 2) 46 47 48 - 49 50 51 52 53 54 55 56 57 58 - 59 60 61 62 63 64 65 66 67 68 - 69 70 71 72 73 74 75 76 77 78 - 79 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A ON ON N/A ON ON ON ON ON ON
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX C: RESET SCHEDULE AND OUTDOOR RESET RATIO CHARTS C.1 USING THE CHARTS TO DETERMINE RESET SCHEDULE Each table in this appendix provides data for a specific building reference temperature. On the vertical axis of each table are degree day temperatures. These are the average lowest temperatures likely to be encountered. The engineer of your system should have this number for your area.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Therefore, use a reset ratio of 0.7 (closest to 0.714) and a building reference temperature of 113 (closest to 112.5). Table C-1: Header Temperature for a Building Reference Temperature of 50°F Air Temp 50°F 45°F 40°F 35°F 30°F 25°F 20°F 15°F 10°F 5°F 0°F -5°F -10°F -15°F -20°F RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table C-3: Header Temperature for a Building Reference Temperature of 65°F Air Temp 65°F 60°F 55°F 50°F 45°F 40°F 35°F 30°F 25°F 20°F 15°F 10°F 5°F 0°F -5°F -10°F -15°F -20°F RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table C-5. Header Temperature for a Building Reference Temperature of 75°F Air Temp 75°F 70°F 65°F 60°F 55°F 50°F 45°F 40°F 35°F 30°F 25°F 20°F 15°F 10°F 5°F 0°F -5°F -10°F -15°F RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table C-7: Header Temperature for a Building Reference Temperature of 90°F Air Temp 90°F 85°F 80°F 75°F 70°F 65°F 60°F 55°F 50°F 45°F 40°F 35°F 30°F 25°F 20°F 15°F 10°F 5°F 0°F RESET RATIO 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX D: NTC TEMPERATURE SENSOR RESISTANCE Table D-1: NTC Temperature Sensor Resistance Chart Temperature (°F) Resistance (ohms) Temperature (°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 2
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX E: ACS WIRING DIAGRAM MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX F: ACS PARTS AND ACCESSORIES Table F-1: ACS Parts and Accessories List PART NUMBER 64053 GP-123043 DESCRIPTION ACS II (ACS) 12 VAC, 5A, 2AG Subminiature, FastActing Fuse (Littlefuse 225005) 69091 4 – 20 mA Fuse GP-122662 Outside Air Temperature Sensor GM-122781 Outside Air Temperature Sensor Kit 64038 Header Temperature Sensor Thermowell for Header Temperature Sensor GP-122758 GM-122790 Head
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AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D APPENDIX G: PROGRAMMING USING RS232 COMMUNICATION G.1 INTRODUCTION The RS-232 communication feature allows the ACS to be easily programmed to your installation requirements using a listing of entry commands. The RS-232 port located in the wiring compartment area of the ACS can be used to program the ACS using a laptop computer or other suitable terminal.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D serial port, and data received through that port will be displayed in the PuTTY window. To create a Serial connection, click the radio button labeled Serial. The Serial line and Speed fields will then be automatically filled in as shown in left image of Figure 9-1, but will allow you to specify the serial line to use (if your computer has more than one) and what speed (baud rate) to use when transferring data.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D 5. You are now ready to execute this command on the remote machine, simply click the Open button at the bottom of the dialog. 6. You will have to provide an account name and password in the terminal window to complete the process. G.3 RS232 COMMUNICATION SET-UP Regardless of the terminal emulation utilized, the following guidelines must be adhered to when interfacing the ACS to the Terminal device: 1.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table G-4: ACS Commands No.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table G-4: ACS Commands - Continued No.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table G-4: ACS Commands - Continued No. COMMAND 26 27 28 29 30 Not Used 31 System Interlock Configuration 32 33 34 35 36 37 38 Thru 44 45 Thru 51 52 Thru 58 Reserved Maximum Power Input Real Time Clock - Minutes Real Time Clock - Hours Real Time Clock - Day Of Week Real Time Clock - Year Real Time Clock - Day Of Month Real Time Clock - Month (Day 1 – Sun.) Offset Temperatures (Day 1-7) (Day 7 – Sat.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table G-4: ACS Commands - Continued No.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table G-4: ACS Commands - Continued No.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table G-4: ACS Commands - Continued No. COMMAND ENTRY RANGE 129 Modbus Pass-Thru 130 131 132 133 Header Temp Deadband Outside Temp Sensor Offset Ramp Up %/Min Ramp Down %/Min 134 Fault Alarm Boilers 135 136 137 138 4-20 mA Offset Return Sensor Offset Load Start Pct Load Stop Pct 0 = Disabled 1 = Enabled 01 to 15°F -10.0°F to 10.0°F 000 to 300 000 to 300 No Blr Faults All Blr faults -1.00 to 1.
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AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX H: ACS MODBUS ADDRESS ASSIGNMENTS IMPORTANT! All Modbus addresses specified in this manual are written generically in hexadecimal format. However, many Building Automation Systems utilize another form of addressing where: 40001 is added to the generic address for a Holding Register address. And 30001 is added to the generic address for an Input Register address.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table H-1: ACS Standard Input Register Address Mapping - Continued Modbus Data Address Decimal (Hex) 17 (0x0011) Thru 24 (0x0018) 25 (0x0019) Menu Item Units and Range Used for 8 ACS Legacy (PWM) Boilers Only Not Applicable Boiler 1 Status (Net Boiler 1) 119 = Not On-Line 120 = On-Line But Not Fired 1–40 = Fired & Sequence 121 = On-Line But Disabled 122 = On-Line But Faulted 26 (0x001A) Boiler 2 Statu
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-1: ACS Standard Input Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range 39 (0x0027) Boiler 15 Status (Net Boiler 15) 119 = Not On-Line 120 = On-Line But Not Fired 1–40 = Fired & Sequence 121 = On-Line But Disabled 122 = On-Line But Faulted 40 (0x0028) Boiler 16 Status (Net Boiler 16) Same As Above 41 (0x0029) Boiler 17 Status (Net Boiler 17) Same
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-1: ACS Standard Input Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range 55 (0x0037) Boiler 31 Status (Net Boiler 31) 119 = Not On-Line 120 = On-Line But Not Fired 1–40 = Fired & Sequence 121 = On-Line But Disabled 122 = On-Line But Faulted 56 (0x0038) Boiler 32 Status (Net Boiler 32) Same As Above 57 (0x0039) I/O Status 00 to 255 Default/ Commen
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-1: ACS Standard Input Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 69 (0x0045) Net Blr 11 Outlet Temp 40°F to 220°F 70 (0x0046) Net Blr 12 Outlet Temp 40°F to 220°F 71 (0x0047) Net Blr 13 Outlet Temp 40°F to 220°F 72 (0x0048) Net Blr 14 Outlet Temp 40°F to 220°F 73 (0x0049) Net Blr 15 Outlet Temp 40°F to 220°F 74 (0
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-1: ACS Standard Input Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item 93 (0x005D) Net Blr 2 Code Same as Above 94 (0x005E) Net Blr 3 Code Same as Above 95 (0x005F) Net Blr 4 Code Same as Above 96 (0x0060) Net Blr 5 Code Same as Above 97 (0x0061) Net Blr 6 Code Same as Above 98 (0x0062) Net Blr 7 Code Same as Above 99 (0x0063) Net Blr 8 Code Same as
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table H-1: ACS Standard Input Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range 120 (0x0078) Net Blr 29 Code Same as Above 121 (0x0079) Net Blr 30 Code Same as Above 122 (0x007A) Net Blr 31 Code Same as Above 123 (0x007B) Net Blr 32 Code Same as Above (Reserved for future expansion) (Not defined) 124 (0x007C) Thru 65535 (0xFFFF) MC2: 04/23/13 AER
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D H.2 ACS CONTROLLER STANDARD HOLDING REGISTER ASSIGNMENTS The Holding Register address assignments for the ACS are listed in Table H-2 which follows. Unless otherwise specified, all Holding Register Menu items are Read/Write (R/W).
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range -2.00 to 2.00 (0.00 increments) Default/ Comments Default = 0.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 32 (0x0020) Real Time Clock Minutes 00 to 59 Present Time 33 (0x0021) Real Time Clock Hours 00 to 23 Hours Present Time 34 (0x0022) Real Time Clock Day of Week 1 to 7 Present Day 35 (0x0023) Real Time Clock Year 00 to 99 Present Year 36 (0x0024)
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 52 (0x0034) Offset On Time Day 1 – Hours 00 to 23 Hours Default = 0 53 (0x0035) Offset On Time Day 2 – Hours 00 to 23 Hours Default = 0 54 (0x0036) Offset On Time Day 3 – Hours 00 to 23 Hours Default = 0 55 (0x0037) Offset On Time Day 4 – Hours 00 to 23
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 76 (0x004C) Offset Off Time Sat. – Minutes 0 to 59 Minutes Default = 0 77 (0x004D) Offset Off Time Sun. – Hours 0 to 23 Hours Default = 0 78 (0x004E) Offset Off Time Mon. – Hours 0 to 23 Hours Default = 0 79 (0x004F) Offset Off Time Tue.
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 94 (0x005E) Net Boiler 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 Addres
AERCO Control System (ACS) Installation, Operation, and Maintenance Manual GF-131 OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 112 (0x0070) Net Boiler 21 Address Address for Network Boiler 21 Default = 0 113 (0x0071) Net Boiler 22 Address Address for Network Boiler 22 Default = 0 114 (0x0072) Net Boiler 23 Address Address for Network Boiler 23 Default = 0 115 (0x0073) Net Bo
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Default/ Comments Units and Range 131 (0x0083) Outside Temp Sensor Offset -50 to +50°F Default = 0 132 (0x0084) Dyn Up 0 to 300%/Min Default = 20 133 (0x0085) Dyn Down 0 to 300%/Min Default = 200 134 (0x0086) Fault Alarm Boilers 0 = No Blr Faults 1 = All Blr Faults Default = 0 135
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Table H-2: ACS Standard Holding Register Address Mapping - Continued Modbus Data Address Decimal (Hex) Menu Item Units and Range Default/ Comments 150 (0x0096) DEADBAND HIGH 0 to 25° Default = 1° 151 (0x0097) DEADBAND LOW 0 to 25° Default = 1° 152 (0x0098) SETPOINT DOWN RATE 0 to 100°/Min Default = 100° 153 (0x0099) DEMAND OFSET 0 to 100° Default = 0° 154 (0x009A) PLANT DT LIMIT 10 to 100°
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D APPENDIX I: BOILER START AND STOP LEVELS The ACS Configuration Menu contains options for the Boiler (BLR) Start and Boiler Stop Levels.
AERCO Control System (ACS) GF-131 Installation, Operation, and Maintenance Manual OMM-0081_0D Change Log Date Description Changed By 01/09/2013 Rev C: 04/23/2013 Rev D: corrected formatting and numbering errors – Chris Blair content is unchanged © AERCO International, Inc., 2013 MC2: 04/23/13 AERCO International, Inc. • 100 Oritani Dr.
