E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual GF-136-C E8 Controller (and BCM) For Modulex EXT Boilers Applies to Modulex EXT Natural Gas Modulating & Condensing Hot Water Boilers, including Models: • EXT 321 • EXT 481 • EXT 641 • EXT 802 • EXT 962 • EXT 1123 • EXT 1530 • EXT 1912 • EXT 2295 • EXT 2677 • EXT 3060 USER MANUAL Installation, Operation and Maintenance E8 Controller Boiler Communications Module (BCM) Latest Update: 06/24/2013 OMM-0
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual 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.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual GF-136-C TABLE OF CONTENTS CHAPTER 1: INTRODUCTION ................................................................................................................ 7 CHAPTER 2: E8 CONTROLLER AND BCM DESCRIPTION.................................................................. 9 2.1 E8 Controller Features and Functions................................................................................................. 9 2.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual 6.4.2 Configuring the Controller for DHW With a Tank Sensor ........................................................... 68 6.4.3 Setting the DHW Set Point ......................................................................................................... 69 6.4.4 Displaying Temperatures Associated With DHW ....................................................................... 70 6.4.4.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual GF-136-C 9.2.1 BCM Controller Standard Input Register Assignments .............................................................. 92 9.2.2 BCM Controller Standard Holding Register Assignments .......................................................... 92 CHAPTER 10: E8, BCM, AND BMM FAULT CODES ........................................................................... 99 10.1 Processing and Clearing Fault Codes .............
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E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 1: INTRODUCTION CHAPTER 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. It is imperative that the initial startup procedures be performed by factory trained personnel.
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E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 2: E8 CONTROLLER AND BCM DESCRIPTION CHAPTER 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.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 2: E8 CONTROLLER AND BCM DESCRIPTION 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.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 3: E8 CONTROLLER OPERATION CHAPTER 3: E8 CONTROLLER OPERATION The E8 Controller operates in NORMAL Mode when the controller door is closed, which allows for monitoring the boiler status through the display window and setting the HEATING Mode. When the door is opened, the unit enters MENU Mode, and in this mode the boiler may be initialized, configured, and adjusted.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 3: E8 CONTROLLER OPERATION 3.1.2 HEATING Mode Selection (in NORMAL Mode) Heating modes may be selected using the Rotary Knob on the controller when the hinged door is in the closed position (NORMAL Mode). As the Rotary Knob is turned, each appropriate heating mode symbol is displayed, in turn, along the lower edge of the display. Mode changes take effect when the setting is not changed for 5 seconds.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 3: E8 CONTROLLER OPERATION 3.1.3 MENU Mode Operation (Door Open) Opening the E8 controller hinged door reveals the E8 controls (below) and initiates MENU Mode, which enables access to an extensive set of software menus.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 3: E8 CONTROLLER OPERATION 3.2 Software Menus Software menus are divided into five main menus, each with a set of sub-menus (Table 3-1). The rotary knob on the front of the E8 Controller is used to sequentially cycle through the menus and the sub-menus. Two small arrows at the bottom of the display point to the selected menu and sub-menu name, respectively.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 3: E8 CONTROLLER OPERATION Sub-MENU Name Points left to Selected Bus(es) INSTALLATION Points right to Selected Buss(es) Points down to Selected Sub-MENU Name Points down to Selected MENU Name MENU Names Sub-MENU Names Figure 3-4: E8 Display in MENU Mode 3.2.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 3: E8 CONTROLLER OPERATION 3.2.2 Basic Parameter Navigation, Selection, and Revision When in the USER, TIME PROGRAM, EXPERT, or GENERAL Main Menu, virtually all submenu items can be changed if the desired. Perform the following steps to access, view, and/or change menu item parameters: PARAMETER CHANGE PROCEDURE DESCRIPTION Use Rotary Knob to navigate to desired Menu/Submenu.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE 4.1 Initializing the E8 in the Installation Menu When power is first applied to the boiler and then the E8 controller cover is opened, the INSTALLATION Menu is displayed once (only). See Figure 4-1 for a diagram of this menu. These values MUST be entered in order to initialize the boiler for operation.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE WARNING Menu selections shown are the factory default settings. Figure 4-1: INSTALLATION Menu Page 18 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE Table 4-1: INSTALLATION Menu Listing PARAMETERS DESCRIPTION ENTRY RANGE DEFAULT INSTALLATION Sub-Menu LANGUAGE Set Language TIME Set current time (min.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE 4.2 QUICK START INSTRUCTIONS Below are instructions for setting the most basic settings in the E8 controller, including maximum and minimum flow temperature, room temperature settings, heat slope, and initiation of heating programs.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE 4.2.2 Setting Room Temperature and Outdoor Compensation Figure 4-3: E8 Quick Start, Room Temperature and Outdoor Compensation Settings with Outdoor Temperature (Slope) Chart OMM-0093_0A GF-136-C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 4: E8 INITIALIZATION AND QUICK START GUIDE 4.2.3 Setting Heating Programs and Pumps Figure 4-4: E8 Quick Start, Heating and Pump Program Settings Page 22 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS This chapter provides flow-chart illustrations and tabular listings of all Menu and Sub-Menu functions.
DISPLAY E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual DISPLAY CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.1 DISPLAY Menu The DISPLAY Menu contains the INSTALLATION, HOT WATER, HEATING (HTG) CIRCUIT 1 & 2 and a SOLAR M/F Sub-Menu as shown in Figures 5-1 & 5.2, and in Table 5-1.
DISPLAY E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual DISPLAY CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Figure 5-2: DISPLAY Menu NOTE Some menus are visible only if the relevant sensor is wired (e.g. HOT WATER is displayed only if the DHW storage sensor is wired). NOTE All DISPLAY Menu and Sub-Menu functions are READ ONLY and cannot be changed. Temperature readings shown are in °F. OMM-0093_0A GF-136-C AERCO International, Inc. • 100 Oritani Dr.
E8 Controller and BCM for Modulex EXT DISPLAY Installation, Operation & Maintenance Manual DISPLAY CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-1: DISPLAY Menu Listing46 FUNCTION DESCRIPTION REMARKS INSTALLATION Sub-Menu T-EXT DES Boiler Set Point setting in 0 to 10 volt input mode T-COLL DES Boiler Set Point temperature in Indoor/ Outdoor Reset and Constant Set Point modes.
E8 Controller and BCM for Modulex EXT DISPLAY Installation, Operation & Maintenance Manual DISPLAY CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-1: DISPLAY Menu Listing (Continued) FUNCTION DESCRIPTION REMARKS HTG CIRCUIT 1 Sub-Menu T-ROOM DES A Not Applicable T-ROOM Current room air temperature. Only if indoor sensor is connected HUMIDITY Room humidity (%). Only if humidity sensor is installed and parameters set for heating circuit.
USER E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual USER CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.2 USER Menu The USER Menu (Figures 5-3 & 5-4) contains the same Sub-Menus as the DISPLAY Menu. However, the USER Menu items are not “Read Only” and therefore can be changed. The SubMenu functions in the USER Menu also differ from those contained in the DISPLAY Menu. Tabular listings for the USER Menu items are provided in Table 5-2.
USER E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual USER CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Figure 5-4: USER Menu Diagram OMM-0093_0A GF-136-C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
E8 Controller and BCM for Modulex EXT USER USER Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-2: USER Menu Listing FUNCTION DESCRIPTION ENTRY RANGE DEFAULT 12 languages are available. ENGLISH -20 to 20 00 See DESCRIPTION Column ---- 50°F - 158°F 140°F INSTALLATION Sub-Menu LANGUAGE Selects display language.
USER E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual USER CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-2: USER Menu Listing (Continued) FUNCTION DESCRIPTION ENTRY RANGE DEFAULT - - - -, Standby, Auto 1, Auto 2, Day, Night ---- HTG CIRCUIT 1 Sub-Menu MODE Displays Timer Mode for Boiler T-ROOM DES 1 Not Applicable T-ROOM DES 2 Not Applicable T-ROOM DES 3 T-REDUCED Not Applicable Not Applicable T-ABSENCE Not Applicable T-LIMIT DAY Applies during d
TIME E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.3 TIME PROGRAM Menu and Sun-Menus Day and Time-related functions can be set using the TIME PROGRAM Menu and its associated Sub-Menus. However, at the present time, none of the Sub-Menus and functions in the TIME PROGRAM Menu are being utilized. This menu is shown in Figures 5-5 & 5-6.
TIME E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Figure 5-6: TIME PROGRAM Menu Diagram OMM-0093_0A GF-136-C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
E8 Controller and BCM for Modulex EXT TIME TIME Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-3: TIME PROGRAM Menu Sub-Menus and Parameters FUNCTION DESCRIPTION ENTRY RANGE DEFAULT CIRCL TIME Sub-Menu The CIRCL (Circulation) Time Sub-Menu is used to set the ON-OFF times for Circulation Pump. Press the Program Key to enter this Sub-Menu and view or change ON-OFF times.
TIME E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-3: TIME PROGRAM Menu Sub-Menus and Parameters (Continued) ENTRY RANGE DEFAULT MONDAY View or change the pump ON – OFF times for Monday. Press the Program Key to view current settings. Turn Rotary Knob to change displayed ON or OFF time if required. Press Program Key to store displayed ON or OFF time and sequence the display to the next function.
TIME E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-3: TIME PROGRAM Menu Sub-Menus and Parameters (Continued) FUNCTION DESCRIPTION ENTRY RANGE DEFAULT MONDAY View or change the pump ON – OFF times for Monday. Press the Program Key to view current settings. Turn Rotary Knob to change displayed ON or OFF time if required.
EXPERT E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.4 EXPERT Menu and Sub-Menus The EXPERT Menu contains the following Sub-Menus: INSTALLATION, HOT WATER, HEAT CIRCUIT 1, HEAT CIRCUIT 2 and SOLAR M/F as shown in Figures 5-7 & 5-8. As this figure shows, the EXPERT Menu includes an extensive list of Sub-Menu functions, particularly in the INSTALLATION Sub-Menu.
EXPERT E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS CONTINUED FROM SHEET 1 EXPERT HOT-WATER DHW RELIEF PARALLEL T-BOILER DHW HYST DHW DHW FOLLOWUP THERM INPUT WALL HUNG LOAD THROUGH RETURN HTG CIRCUIT 1 HC FUNCTION PUMP MODE MIXER OPEN MIXER CLOSE MAX T-FLOW MIN T-FLOW T-FROST PROT OUT-TEMP-DEL SLOPE OFFSET B-HEAT SINK RETURN HTG CIRCUIT 2 HC FUNCTION PUMP MODE MAX T-FLOW MIN T-FLOW T-FROST PROT OUT-TEMP-DEL B
EXPERT E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Figure 5-8: EXPERT Menu – 1 of 2 OMM-0093_0A GF-136-C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
EXPERT E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Figure 5-8: EXPERT Menu – 2 of 2 NOTE The shaded items in the following table indicate those parameters that change according to the boiler type and whether used singly or in a cascaded configuration. Page 40 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
EXPERT E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS NOTE Whenever “CODE NO.” is displayed, it indicates that the valid password must be entered. This is accomplished by entering code 0000 (four zeros) by pressing the Program Key four (4) times. Table 5-4: EXPERT Menu Listing FUNCTION DESCRIPTION ENTRY RANGE DEFAULT 0000 - 9999 0000 INSTALLATION Sub-Menu CODE-NO Permits entry of valid Code No.
EXPERT E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-4: EXPERT Menu Listing (Continued) FUNCTION DESCRIPTION ENTRY RANGE DEFAULT ---- ---- INSTALLATION Sub-Menu (Continued) HYSTERESIS Not Applicable FOUND MODULS Displays the number of heat modules available for service. Display CAP/MODULE Displays the maximum Kw output of each heat module.
EXPERT E8 Controller and BCM for Modulex EXT EXPERT Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-4: EXPERT Menu Listing (Continued) FUNCTION DESCRIPTION ENTRY RANGE DEFAULT INSTALLATION Sub-Menu (Continued) SEQU CHANGE Sequence change mode 01 – 06 06 SEQ SW TIME Time to sequence change (hours) 10 – 800 200 LOCK TIME Not Applicable 00 min – 30 min 00 HYST BURNER2 Not Applicable ---- ---- HS COOL-FCT Not Applicable ---- ---- T-H
E8 Controller and BCM for Modulex EXT EXPERT Installation, Operation & Maintenance Manual EXPERT CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-4: EXPERT Menu Listing (Continued) FUNCTION DESCRIPTION ENTRY DEFAULT RANGE HEAT CIRCUIT 1 & 2 Sub-Menus The Sub-Menu Functions for HEAT CIRCUIT 1 & HEAT CIRCUIT 2 are identical, except for the MIXER OPEN & MIXER CLOSE Functions which apply only to HEAT CIRCUIT 1.
E8 Controller and BCM for Modulex EXT EXPERT EXPERT Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-4: EXPERT Menu Listing (Continued) FUNCTION DESCRIPTION ENTRY RANGE DEFAULT 00-02 00 SOLAR M/F Sub-Menu MF (1-4) FUNCTION Not Applicable MF (1-4) SET TEMP Not Applicable MF (1-4) HYST (1-4) Not Applicable F15 FUNCTION F15 Function 00 = Room Sensor for Heating Circuit 2 01 = 0 – 10V iInput 02 = Light sensor RETURN Press Program Key to exit S
GENERAL DATE/TIME E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual GENERAL DATE/TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.5 EXPERT HS Menu The EXPERT HS menu is a submenu of the EXPERT menu and is used for initialization of the E8 controller. See Section 4.1 for how to use this menu to initialize the E8 controller. 5.6 GENERAL Menu The GENERAL Menu contains a DATE/TIME Menu and a SERVICE Menu. 5.6.
GENERAL DATE/TIME E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual GENERAL DATE/TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS NOTE All items in the following DATE/TIME Menu must be entered in sequence. Press the Program Key to step through the menu functions. Use the Rotary Knob to adjust/change entries. Press the Program Key to store entries and sequence to the next function. Figure 5-10: GENERAL Menu Diagram OMM-0093_0A GF-136-C AERCO International, Inc.
GENERAL DATE/TIME E8 Controller and BCM for Modulex EXT GENERAL Installation, Operation & Maintenance Manual DATE/TIME CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-6: DATE / TIME Menu Listing FUNCTION DESCRIPTION ENTRY RANGE TIME – DATE Sub-Menu This Sub-Menu is used to set the time, date, holiday schedule and, where necessary, enter clock change settings (daylight savings time, etc). TIME Set current time (min.
SERVICE E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual SERVICE CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.6.2 SERVICE Menu The SERVICE Menu contains all the test and diagnostic functions/values required for Customer Service Engineers to troubleshoot the equipment in a timely manner. The SERVICE Menu items are illustrated and described in Figures 5-11 & 5-12 and Table 5-7 respectively. Some of the functions in this Sub-Menu require a valid Code No.
SERVICE E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual SERVICE CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Figure 5-12: SERVICE Menu Page 50 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
E8 Controller and BCM for Modulex EXT SERVICE SERVICE Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-7: SERVICE Menu Listing FUNCTION DESCRIPTION REMARKS RELAY TEST Sub-Menu This Sub-Menu is used to check the status of the relays contained in the Controlller. These relays are numbered 00 through 11 and are defined as shown below. CODE NO. Entry is required to access these relays. RELAY NO.
E8 Controller and BCM for Modulex EXT SERVICE Installation, Operation & Maintenance Manual SERVICE CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS Table 5-7: SERVICE Menu Listing (Continued) FUNCTION DESCRIPTION REMARKS SENSOR TEST Sub-Menu F11 Flow temperature heating circuit 1 or temperature multifunction 1 F12 Hot water temperature lower or temperature multifunction 2 F13 Solid fuel boiler temperature or collector 2 or temperature multifunction 3 F14 Collector 1 temperature or temperature mul
E8 Controller and BCM for Modulex EXT INSTALL Installation, Operation & Maintenance Manual INSTALL CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.7 Installation Menu & E8 Controller Initial Startup See Section 4.1 for instructions for initial startup of the E8 Controller, which requires a number of one-time entries to be made in the initial INSTALLATION Menu that appear in the E8 display when the controller door is first opened.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.7.1 CAP/MODULE Function (Maximum Kilowatts per Burner) When the Program Key is pressed with CAP/MODULE displayed, the display may show “SCAN”, indicating that the Controller is searching for related MODULE (BOILER) functions. Once the scan is complete, follow instructions below. CAP/MODULE Function (Setting Max. Kw per Burner) 1. Press the Program Key.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 5: E8 CONTROLLER MENUS AND SUB-MENUS 5.7.
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E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING CHAPTER 6: E8 SETUP AND PROGRAMMING The following sections provide the detailed set-up and programming procedures necessary to configure the Modulex Boiler for service operation. NOTE When performing the following operating mode set-up procedures, refer to Chapter 3 of this document for illustrations and descriptions of the Controller operating controls and displays.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING Indoor/Outdoor Reset Configuration in USER Menu 1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position. 2. Open controller front panel. 3. Turn the Rotary Knob clockwise to the USER menu. The first sub-menu displayed will be INSTALLATION. NOTE Before continuing, check to ensure that HC FUNCTION in the EXPERT>HEATING CIRCUIT 1 menu is set to the default “00”. 4.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.1.3 Viewing the Boiler Setpoint The setpoint temperature setting is viewed in the E8 controller display as shown below. Viewing the Boiler Setpoint 1. Turn the Rotary Knob to the DISPLAY menu. The first sub-menu displayed will be INSTALLATION. 2. Press the Program Key to enter the INSTALLATION sub-menu. 3.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.2.1 Wiring Connections There are NO wiring connections required for this mode. 6.2.2 Constant Setpoint Mode Configuration The Constant Setpoint Mode is enabled using functions contained in the EXPERT menu and USER menu as shown on previous page. 6.2.3 Viewing Constant Set Point The set point is viewed in the DISPLAY menu as shown below. Viewing the Constant Setpoint 1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.2.4.1 Configuring HEATSLOPE Parameter The HEATSLOPE value is configured as shown in the instructions below. Configuring HEATSLOPE Parameter 1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position. 2. Open controller front panel. 3. Turn the Rotary Knob clockwise to the USER menu. 4. Press Program Key to select the User submenu.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.2.4.2 Configuring MAX T-FLOW and MIN T-FLOW Parameters To enter the MAX T-FLOW and MIN T-FLOW values, see instructions below. Configuring MAX T-FLOW and MIN T-FLOW Parameters 1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position. 2. Open controller front panel. 3. Turn the Rotary Knob clockwise to the EXPERT menu.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.2.4.3 Configuring MAX T-COLL Parameter To enter the MAX T-COLL value, see instructions below. Configuring MAX T-COLL Parameter 1. Set the ON/OFF switch on the front of the Modulex boiler to the ON position. 2. Open the swing-down hinged panel of the Controller. 3. Turn the Rotary Knob clockwise to the EXPERT menu. The first item (sub-menu) displayed will be INSTALLATION. 4.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.3.2 Configuring Remote Signal Source Configure the Remote Signal Source as shown in the instructions below. Configuring Remote Signal Source 1. Ensure ON/OFF switch on front of Modulex boiler is in the ON position. 2. Open Controller front panel. 3. Turn Rotary Knob clockwise to EXPERT menu.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.3.3 Setting the Voltage and Set Point Limits for U1/U2 and T1/T2 NOTE Ensure that all steps in Section 6.3.2 were completed prior to performing the following steps. NOTE When scrolling through sub-menus and functions, enter required Code 0000 only when prompted to do so. Normally, Code 0000 only needs to be entered once, unless you exit and re-enter EXPERT menu.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING T1 and T2 Settings: The previous steps set the U1 and U2 voltages which will be used to scale the minimum and maximum set point levels. To set the minimum (T1) and maximum (T2) set point temperatures which correspond to the U1 and U2 voltage levels, follow instructions below. Voltage & Set Point Limits: T1 & T2 1. Turn the Rotary Knob clockwise and scroll to CURVE 11-T1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.3.5 Viewing the Set Point The set point is displayed as shown in instructions below. NOTE When viewing the set point temperature using the steps in Section 6.3.5, you will note that the when the voltage source is equal to 0.9 Volt, the set point temperature will drop to 41°F (9°C), thereby shutting down the boiler.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.4.2 Configuring the Controller for DHW With a Tank Sensor Both EXPERT and USER Menus will be used to configure the Controller for DHW production. The DISPLAY Menu will be used to display the set point. Follow instructions below to configure the controller for DHW with a tank sensor. IMPORTANT The tank sensor MUST be connected (Section 6.4.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.4.3 Setting the DHW Set Point The set point temperature is set in the USER menu as shown in instructions below. NOTE Typically, a higher water temp is needed to heat domestic hot water to its setpoint. Do this by using EXPERT / HOT WATER / TBOILER DHW. Degrees entered are added to DHW Setpoint in USER MENU. See Section 6.2.3. Setting the DHW Set Point 1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.4.4 Displaying Temperatures Associated With DHW Functions in the DISPLAY menu are used to display the actual DHW temperature measured by the tank sensor. The swing-down hinged panel must be open to access and display these functions. 6.4.4.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 6: E8 SETUP & PROGRAMMING 6.5 DHW Operation Using an Aquastat Operation, wiring connections and Controller configuration settings for DHW heating using an aquastat are virtually identical to the procedures previously described in Section 6.4 for the tank sensor. Therefore, the following sections describe only the differences between these two types of applications. 6.5.
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E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS 120V~; Relay switching capacity 2(2)A, 250V~ 2 9 3 8 5 6 4 1 7 Figure 7-1: E8 Controller Rear Panel Terminals 7.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS Sensor Terminal Assignments (Continued) 7.1.1 Connector 7 7 7.1.2 Connector 1 1 7.1.3 Connector 5 5 7.1.4 Connector 8 => PT 1000 Sensor 8 7.1.5 Connector 3 3 7.1.6 Connector 9 9 Page 74 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS 7.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 7: E8 CONNECTOR TERMINAL ASSIGNMENTS (This Page Is Intentionally Blank) Page 76 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) CHAPTER 8: BOILER COMMUNICATIONS MODULE (BCM) When installed and enabled, the BCM enhances the range of control functions offered by the Modulex Boilers. These additional control functions include the following: • BCM provides a fault relay which energizes when any fault condition occurs in the Modulex Boiler.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) DL1 E DL2 (RED) F DL3 (GREEN) G Input Communications Connector (Modbus/Ebus) A Change-Over 3-Pos. Switch B Enable/Disable 2-Pos.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) The BCM Change-Over Series/Parallel 3-Position Switch and the Enable/Disable (I/0) 2Position Switch function as described in Table 8-1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) 8.2.1 BCM Fault Relay Wiring If desired, pins 3 and 4 of connector Y4 (Figure 8-3) can be wired to an external source to provide a remote alarm indication when the BCM Fault Relay is activated. 8.2.2 Clearing Faults A fault can be cleared by pressing and releasing the black Reset Switch on the front cover of the BCM.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) Figure 8-4: BCM Back-Up Controller Wiring OMM-0093_0A GF-136-C AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, NY 10913 Ph.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) Figure 8-5: Installing Resistor to Change Default Setpoint 8.4 BCM Configured as Primary Controller Utilizing Modbus The BCM can be configured as the Primary Controller, instead of the E8, when it is connected to a Modbus Network. However, the E8 must be disconnected from the e-Bus connection on the BCM Board (see Section 8.4.3).
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) and 7 of connector Y2 (see Figure 8-5). In addition, the BCM Fault Relay will be activated and the red Fault LED (DL2) will light. 8.4.2 Physical Modbus RS485 Wiring Modbus RS485 devices should be wired in a “Daisy-Chain” configuration similar to the example shown Figure 8-6.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) 8.4.4 AERCO BMS II/ACS Master to BCM Slave Wiring Connections. The AERCO BMS II/ACS contains a RS232 port for connection to an EMS/BAS or personal computer. In addition, the BMS II/ACS contains a RS485 port for connection to the BCM’s Modbus input. 8.4.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) feet) can usually operate satisfactorily without the terminating resistor. However, longer loop runs (over 1000 feet), may require terminating resistors. Bias may be necessary on the RS485 loop to minimize noise on the circuit. Loop bias is accomplished by activating pull-up/pull-down resistors on the last Boiler Communications Module (BCM) in the chain.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) 8.7 Modbus Network Wiring Diagram A “Sample” Modbus Network wiring diagram for an AERCO BMS II/ACS Master controlling BCM Slaves is shown in Figure 8-10. Activate the terminating resistor in the last BCM on the daisychain loop. DO NOT install the 1K bias resistor. Instead, activate the two bias DIP switches in the BMS II/ACS. Refer to GF-124 for the location of these switches.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) Figure 7-11. EMS/BAS Master Controlling Modulex Boiler Slaves 3. THE LAST BCM SLAVE ON THE RS485 LOOP MUST HAVE ITS TERMINATION RESISTOR ENABLED. ALSO, A 1K OHM BIAS RESISTOR MAY BE REQUIRED. CHECK WITH THE EMS MANUFACTURER. TO OTHER NETWORK BOILER SLAVES (3 - 9) (SEE NOTE 3) 2. IF EMS MASTER CONTAINS ONLY A RS232 PORT, A RS232-TO-RS485 CONVERTER WILL BE REQUIRED. 1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) 8.8 Modbus Software Set-Up The following sections provide the information and procedures necessary to configure the Boiler Communications Modules (BCMs) to operate on a Modbus Network. 8.8.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) 8.8.3 AERCO BMS II/ACS Modbus Control and Monitoring The BCM’s modulation output can be controlled by writing to its requested modulation level register (Standard Holding Register or Control Register #1). It will ramp up the boiler based on the settings in the Standard Holding Register or Setting Register 3000 to 3015.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 8: BOILER COMMUNICATION MODULE (BCM) start level percentage (programmed by the user into the BMS II/ACS), the BMS II/ACS will call on the second boiler to begin firing one module, and the BMS II/ACS will then split the fire rate signal between the two boilers and send each a signal equal to the start level percentage.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS 9.1 BCM Modbus Comm. & Support Requirements The Modbus communication support requirements incorporated in the BCM are as follows: 9.1.1 Function Codes The BCM supports the Modbus Function Codes shown in Table 9-1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS 9.2 BCM Controller Standard Holding Register Assignments 9.2.1 BCM Controller Standard Input Register Assignments The BCM Controller has only two Read Only Input Register addresses as shown in Table 9-3.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 9-4: BCM Standard Holding Register Address Mapping Modbus Data Address Menu Item Units and Range Default/(Comments) CONTROL REGISTERS 1 AERCO BMS II/ACS Requested Modulation Level % (0 to 100) (Read/Write) A value other than 0 requests Run mode and supersedes the value set for Max Modulation Level (address 0x03F9) 1017 Maximum Modulation Level % (0 to 100) (Valu
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 9-4: BCM Standard Holding Register Address Mapping (Continued) Modbus Data Address Menu Item Units and Range Default (Comments) CONTROL REGISTERS (Continued) Check Mode, Inserted burner control 1041 Flags (0 – 0xFF) Bit 0: BMM #0 to Bit 7: BMM #7 (Read/Write) Bit 0 (BMM #0) is auto-matically set at Check Mode start OPERATING DATA REGISTERS 0 Error Code 0 – 0xFFF
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 9-4: BCM Standard Holding Register Address Mapping (Continued) Modbus Data Address Menu Item Default (Comments) Units and Range OPERATING DATA REGISTERS (Continued) 1020 1100 1101 1102 1103 Operating Mode enum (0, 1, 2, 3, 6) 0: Standby 1: Space Heating 2: DHW 3: Check 6: Test Linked BMM Flags (0 -255) Bit 0: BMM #0 to Bit 7: BMM #7 Inserted BMM Flags (0 -25
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 9-4: BCM Standard Holding Register Address Mapping (Continued) Modbus Data Address Menu Item Units and Range Default (Comments) OPERATING DATA REGISTERS (Continued) 2n10 BMM #0 Capacity (n = 0 – 7) 2n11 BMM #n Configuration (n = 0 – 7) Flag (0, 1) 0: Space Heating Only 1: Space Heating and DHW BMM #n Operating Flags (n = 0 – 7) Flags (0-255) Bit 3: Flame detected
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 9-4: BCM Standard Holding Register Address Mapping (Continued) Units and Range Default (Comments) 3007 Pump Modulation Output @ Minimum Burner Level 0 – 10V (Value x 10) (Read/Write) 3V 3008 Pump Modulation Output @ Maximum Burner Level 0 – 10V (Value x 10) (Read/Write) 10V 3009 Burner Minimum Modulation Level 0 – 100% (Read/Write) 35% 3010 Water Δ Temp.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 9: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 9-4: BCM Standard Holding Register Address Mapping (Continued) Modbus Data Address Menu Item Units and Range Default (Comments) TEST REGISTER (Continued) Flags (0 - 0x1F80) bit 0: bit 1: bit 2: bit 7: 3100 Digital Inputs Status [0, 1] bit 8: bit 9: bit 10: bit 11: bit 12: bit 13: bit 14: bit 15: eBUS RX eBUS-1 RX eBUS -1 detect (true, false) Room Stat (open, close)
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES CHAPTER 10: E8, BCM, AND BMM FAULT CODES This section provides tables for identifying faults (with fault troubleshooting tips) and describes the procedures required to clear a displayed fault code after the cause of the fault has been corrected. Fault codes are displayed in the upper right area of the LCD display on the E8 Controller as shown in Figure 10-1.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES 10.1 Processing and Clearing Fault Codes When a fault occurs, the appropriate fault code will be displayed along with a “Flashing Triangle” (Figure 10-2).
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES 10.2.1 E8 Controller Fault Code Table The table below lists the fault codes and fault descriptions associated with the E8 Controller.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES Table 10-1: E8 Controller Fault Codes (Continued) FAULT CODE FAULT DESCRIPTION Communication Fault E 90 E 91 E 99 E 200 E 201 E 202 E 203 E 204 E 205 E 206 E 207 E8: Address 0 and 1 on BUS. IDs BUS 0 and 1 may not be used simultaneously E8: BUS ID used.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES 10.2.2 BCM and BMM Fault Code Conversion Table The table below shows how to interpret the displayed fault code, while Table 10-4, on the next page, shows a description of the fault and troubleshooting tips associated with the BCM. In order to derive the correct error code from that displayed in the E8 Controller display, use Table 10-2 below to determine the working error code.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES 10.2.3 BCM Fault Code Table The table below lists the fault codes and troubleshooting tips associated with the BCM. Table 10-3: BCM Fault Codes CODE DESCRIPTION EFFECT CORRECTION RESET 17 Boiler Pipe is frozen. FlowSensor temp. is 36°F or less. Ignition is inhibited. Pump runs for 5 min at max speed.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES 10.2.4 BMM Fault Code Table The table below lists the fault codes and troubleshooting tips associated with the BMM. Table 10-4: BMM Fault Codes CODE DESCRIPTION EFFECT 1 High Limit (STB) Thermostat activated All burners turned OFF and Pump ON at maximum speed. CORRECTION RESET Check FlowSensor thermal connection to boiler.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES Table 10-4: BMM Fault Codes (Continued) CODE DESCRIPTION EFFECT 14 Return Sensor fault All burners turned OFF. 15 Maximum Δtemperature protection. Flow temperature Return Temperature > Water Δ-Temp Protection + 50°F All burners turned OFF and Pump ON at maximum speed. 16 Boiler Pipe is frozen. FlowSensor temperature is 36°F or less.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual CHAPTER 10: E8, BCM, AND BMM FAULT CODES Table 10-4: BMM Fault Codes (Continued) CODE DESCRIPTION EFFECT 24 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. AUTOMATIC/ MANUAL 26 Fan speed out of control: It doesn't stop within 30 seconds after turned OFF.
E8 Controller and BCM for Modulex EXT Installation, Operation & Maintenance Manual Change Log Date Description Changed By 06/24/2013 Created and Released at Rev-A Curtis Harvey © AERCO International, Inc., 2013 Page 108 of 108 PRI: 06/24/2013 AERCO International, Inc. • 100 Oritani Dr.
