BMC and BMC-6X Installation and Operation Manual BMC BMC-6X AND HYDRONIC MODULATING BOILER CONTROL AND EXTENSION • INSTALLATION AND OPERATION INSTRUCTIONS MANUAL BMC Full Modulation Sequencing Control SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: B 115VAC 60Hz , 30VA MAX C CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
BMC and BMC-6X Installation and Operation Manual Contents BMC LAYOUT . . . . . . . . . . . . . . . . 3 BMC OVERVIEW . . . . . . . . . . . . . . 4 Reset Ratio/Outdoor Reset . . . . . . . . . . 5 Make Sure You Have the Right Control INITIAL SETUP . . . . . . . . . . . . . Selecting the System Features. . . . . INSTALLATION . . . . . . . . . . . . . Mounting the Enclosure . . . . . . . . Install the Sensors . . . . . . . . . . . . . . . . . . . . . . .
BMC and BMC-6X Installation and Operation Manual BMC LAYOUT Program Switch to restrict access to function changes. This switch is covered with Wiring Enclosure. The digital display shows the system status, set point, lead stage , and status of each stage. To view and adjust settings, press the appropriate buttons. Buttons function is presented on Bottom Row of display. LED indicates the associated relay status.
BMC and BMC-6X Installation and Operation Manual BMC OVERVIEW SEQUENCES UP TO 4 FULLY MODULATING STAGES. The BMC is the perfect control whenever multiple fully modulating stages are required for hydronic heating applications. The BMC controls the on/off and the modulation of each stage to maintain precise system set point control. PID TYPE LOGIC The BMC’s control algorithms allow it to look at the rate of change in the system.
BMC and BMC-6X Installation and Operation Manual UNDERSTANDING OPERATION CONCEPT The BMC also controls the system circulating pump with an adjustable Outdoor Cutoff. When the outdoor temperature is above Outdoor Cutoff, the pump is off and no heating water is circulated through the system. When the outdoor temperature drops below the Outdoor Cutoff, the system pump relay is activated and the heating water circulates through the system.
BMC and BMC-6X Installation and Operation Manual MAKE SURE YOU HAVE THE RIGHT CONTROL If you need the BCP-8W to do additional tasks that either are not listed or do not know how to set them, contact Weil McLain. INITIAL SETUP Setting an Initial Program will ease the configuration of the BMC and will give the opportunity to utilize many of the energy saving features and give more comfortable heat when needed.
BMC and BMC-6X Installation and Operation Manual System Run-On • This feature lets the BMC run the SYS relay for a longer period after the boilers have been turned off. When this relay is used to control a pump, it helps in dissipating the excess heat from the boilers combustion chamber. INSTALLATION Each of the BMC or BMC-6X consists of three primary enclosure components. • The Enclosure Display Module: contains the display, buttons, LEDs and electric wiring terminals.
BMC and BMC-6X Installation and Operation Manual INSTALL THE SENSORS Immersion Heating System Sensor Immersion Well 3/8" ID 1/2" NPT Common Supply Pipe HEATING SYSTEM SENSOR (HSS) INSTALLATION Shield LOCATING HSS • Put the Heating System sensor approximately 10' feet past the last boiler on the common supply header but before any major takeoffs. • The sensor must be located where it sees the output of all the boiler stages.
BMC and BMC-6X Installation and Operation Manual WIRING PWR L N 1 2 WIRING THE POWER (TERMINALS 1, 2) Line Bring the 120VAC 60Hz power wires through the bottom Knockout of the enclosure. Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring. Connect the hot line to terminal marked L. Connect the neutral line to the terminal marked N. Weil McLain recommends installing a surge suppressor on the power source to the BMC.
BMC and BMC-6X Installation and Operation Manual WIRING THE PROVE (TERMINALS 29, 30) • The Prove feature is provided to check system component operation and must be selected in the Startup Menu. See page 15. A typical use of this feature is to check for pump flow before firing any boiler. If the PROVE input is open on a call, the BMC will enable only the System Output. All boiler outputs will be off when the PROVE input is open. A factory-installed jumper provides the System Prove signal.
BMC and BMC-6X Installation and Operation Manual WIRING TO MODULATING MOTORS A CUR / VLT CUR The BMC can modulate any combination of the following motors. The Output Type must be selected properly before connecting any output wires to avoid damage components. See Output Type on page 11. GND mA - + VLT GND - + 13 14 15 16 1 WIRING THE 4-20MA MODULATING MOTORS (A TERMINALS 13, 14), (B TERMINALS 16, 17),... • The BMC can operate up to four 4-20 mA modulating motors.
BMC and BMC-6X Installation and Operation Manual MENU SEQUENCE ------------- SEASON -------------Winter Summer BACK STARTUP Reset Ratio START ------------- WARNING -----------THESE SETTINGS CHANGE PRIMARY SYSTEM FUNCTIONS. BACK 70 SAVE --------- RESET RATIO 1.00 OD=4.00 1.00 OD=3.00 1.00 OD=2.00 1.00 OD=1.50 1.00 OD=1.25 1.00 OD=1.00 1.25 OD=1.00 1.50 OD=1.00 2.00 OD=1.00 3.00 OD=1.00 4.00 OD=1.
BMC and BMC-6X Installation and Operation Manual ---------------- GAIN -------------- ----------- SETTINGS -----------Season Winter Set Point 70 F BACK SELECT [] SYSTEM SETTINGS1 -------- LEAD ROTATION ------Manual Time Last-On SYSTEM SETTINGS2 -- OUTDOOR SENSOR TRIM ---- +0 SELECT SAVE --- SYSTEM SENSOR TRIM ---- +0 [] 0 F BACK F SAVE -------- SYSTEM RUN-ON -------BACK SAVE ------ CONFIGURATION 1 -----v1.
BMC and BMC-6X Installation and Operation Manual STARTUP SETTINGS ALERT A good practice after performing any Startup menu modifications is to check all operating settings and adjustments to match the new settings. PROGRAM CHANGE SETTINGS To be able to change the BMC settings the Program/Run Switch must be set to Program. The switch is located under the Enclosure Wiring Cover for security. The Enclosure Wiring Cover can be securely closed using a lock.
BMC and BMC-6X Installation and Operation Manual SELECTING THE MODULATING MODE ------ MODULATION MODE ------ Normal Normal, Parallel Default: Normal Parallel Button: MENU//..../Modulating Mode • Some modulating boilers perform better as their modulation increases. For these units, it is advantageous to run one unit at high modulation than several units at lower modulation. If the units used are of this type, select Normal.
BMC and BMC-6X Installation and Operation Manual SENSOR FAULT All Off, All On Default: All On Button: MENU//..../Sensor Fault The Sensor Fault will determine the operating status of all output stages that are set to Auto when a sensor reads Short or Open. --------- SENSOR FAULT -------All Off All On BACK SAVE RESET MODE • When All-On is selected, the BMC will turn all boilers On to a 100% when System reads Short or Open and Outdoor is below Outdoor Cutoff.
BMC and BMC-6X Installation and Operation Manual OPERATING SETTINGS PROGRAM CHANGE SETTINGS PROGRAM To be able to change the BMC settings the Program/Run Switch must be set to Program. The switch is located under the Enclosure Wiring Cover for security. The Enclosure Wiring Cover can be securely closed using a lock. Winter, Summer Default: Winter Button: MENU/Season • The BMC will turn all boiler relays off when it is in Summer setting. However, a DHW call will bring boilers back on if needed.
BMC and BMC-6X Installation and Operation Manual OUTDOOR CUTOFF TEMPERATURE ------- OUTDOOR CUTOFF ------- Adjustable Off, from 20ºF/ to70ºC - 100ºF, On Default: 60ºF/ 16ºC Button: MENU/Set Point/Outdoor Cutoff in Set Point 65 F Button: MENU/Set Point/Offset/Outdoor Cutoff in Reset [] • If the outdoor sensor is installed, the Outdoor Cutoff screen will automatically appear after the temperature Set Point has been selected.
BMC and BMC-6X Installation and Operation Manual SYSTEM SETTINGS ---------- SETTINGS 1 ---------Gain +0 Lead Rotation Time Purge Delay 0.0min Lag Delay 0min BACK SELECT Button: MENU/ The Settings 1 and Settings 2 menus provide access to adjusting and fine-tuning the system for enhanced comfort and more fuel savings. The BMC behaves differently based on the selected Control Modes (see Startup Settings).
BMC and BMC-6X Installation and Operation Manual LAG DELAY ----------- LAG DELAY ----------- Adjustable from 0min to 60min Default: 0min Button: MENU//Lag Delay 0min • The Lag Delay requires the previous stage to remain at 100% modulation for the full [] period of the Lag Delay before another Stage can be activated.
BMC and BMC-6X Installation and Operation Manual • • If Setback Input is selected as a Shutdown/Tstat/Setback Mode (See page 15), the Setback will not be activated unless a Short dry contact signal is received on the Shutdown/Tstat/Setback terminals (31 and 32) as a signal. If Shutdown Input or Tstat Input is selected as a Shutdown/Tstat/Setback Mode (See page 15), the Setback will be activated only when Night Schedule time has started.
BMC and BMC-6X Installation and Operation Manual ----- SET PRESENT TIME ----- SET TIME Button: MENU///Set Time Button: MENU////Set Time • Adjust the time by selecting Time from the menu and then scrolling through the hours then select Save. Then, scroll through the minutes then select Save. If the hours are to be set to PM, scroll through the AM hours to reach the PM hours.
BMC and BMC-6X Installation and Operation Manual MAINTENANCE Button: MENU/ The Maintenance menu gives access to sensor and outputs trimming and Soft-Off. In addition, you'll have access to view the Startup configuration settings. ALERT ---------- MAINTENANCE --------System Trim +0 F Outdoor Trim +0 F Soft-Off Delay 45sec
BMC and BMC-6X Installation and Operation Manual CONFIGURATION Button: MENU// • This menu option provides a consolidated view of the BMC's Startup and Stage settings. DISPLAY The BMC display layout provides a variety of information that gives an immediate picture of the operation status. The display shows four boilers at a time. When extensions are present, the two middle buttons scrolls the screen to view additional boilers. Moreover, all the information is brightly displayed.
BMC and BMC-6X Installation and Operation Manual DISPLAY MESSAGES The BMC normal display layout reserved the second line for message indications. The following is a list of the most common Message Display Line information: • Summer The control is set to Summer. No heat is active. See Season on page 17. • Shutdown Active The Shutdown Terminals are Shorted. No boilers will be active. See Shutdown on pages 15 and 9. • Shutdown by EMS The EMS is below 2mA or above 22mA.
BMC and BMC-6X Installation and Operation Manual Auto - The BMC will control the boiler’s operation to maintain the desired Set Point. Only boilers set to Auto can be Lead boilers. Standby Standby boilers can only be activated when all boilers in Auto have been at 100% modulation for a selectable period of time. Standby is generally used when you want a specific boiler to be available in extreme load conditions. Note that a Standby boiler Cannot be a Lead boiler.
BMC and BMC-6X Installation and Operation Manual TROUBLESHOOTING SENSOR INPUTS Display shows Sensor OPEN or SHORT When OPEN, Check the sensor is connected and the wires are continuous to the BMC. Finally follow the procedure for Incorrect Temperature or Pressure Display. When SHORT Remove the wires from the sensor terminals. The display should change to read OPEN. If it does not, the BMC may be damaged. Display shows an Incorrect Temperature Remove the wires from the sensor terminals.
BMC and BMC-6X Installation and Operation Manual • Boiler Mode Settings - The BMC will only modulate boilers their mode is set to Auto or Standby. Check if any boiler stage is set to Manual, Off, or Standby. See Mode on page 25. Boilers are Short-Cycling • Lag Delay - Increase the Lag Delay only if all boilers tend to short-cycle. • Last Stage Hold - Increase the Last Stage Hold only if the lead boiler tends to short-cycle.
BMC and BMC-6X Installation and Operation Manual MULTIPLE MODULATING BOILERS DIRECT HEATING PIPING DIAGRAM Outdoor Sensor BMC Full Modulation Sequencing Control SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: B 115VAC 60Hz , 30VA MAX USE COPPER WIRE, CLASS 1 WIRE ONLY.
BMC and BMC-6X Installation and Operation Manual MULTIPLE MODULATING BOILERS DIRECT HEATING WIRING DIAGRAM BMC Full Modulation Sequencing Control SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: B 115VAC 60Hz , 30VA MAX USE COPPER WIRE, CLASS 1 WIRE ONLY. D US ENCLOSED ENERGY MANAGEMENT EQUIPMENT LISTED 99RA CAUTION: RISK OF ELECTRIC SHOCK More than one disconnect switch may be required to de-energize the equipment before servicing.
BMC and BMC-6X Installation and Operation Manual MULTIPLE MODULATING BOILERS EXTERNAL 4-20MA SET POINT USING 4-20MA EMS INTERFACE BMC Full Modulation Sequencing Control SYSTEM OUTPUT RATINGS: 120VAC, 6A RESISTIVE 1A PILOT DUTY, 15A TOTAL FOR ALL CIRCUITS A INPUT RATINGS: B 115VAC 60Hz , 30VA MAX USE COPPER WIRE, CLASS 1 WIRE ONLY.
BMC and BMC-6X Installation and Operation Manual Voltage Input: . . . . . . Power Consumption: . . Operating Temperature: Operating Humidity: . . Dimensions: . . . . . . . . Weight: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
