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Summary of Contents for Aerco 5R5-384
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• Modulex MLX Series • Modulex EXT Series • KC-1000 AERCO Control System (ACS) Front Panel Latest Update: 11/22/2017 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 1 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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.......................32 Page 2 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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3.6.4 NETWORK TIMEOUT ..................50 3.6.5 MODBUS PASS THRU ..................50 3.6 RS485 (MODBUS) MENU ....................50 3.7.1 RS485 BAUD RATE .....................50 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 3 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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3.10.1 RET TEMP BST DIS (RETURN TEMPERATURE BOOST DISABLE) ......57 3.10.2 BOOST MAX TIMER ..................58 3.10 TUNING MENU ......................58 Page 4 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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4.2.4 SELECTING BOILER OPERATING MODE ............69 4.2.5 Entering System Start Temperature ..............70 4.2.6 Entering Boiler Start and Boiler Stop Levels ............70 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 5 of 139 Phone: 800-526-0288 OMM-0081_0F...
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G.1 INTRODUCTION ......................113 G.2 AQUIRING THE PuTTY APPLICATION ..............113 G.2.1 Logging on to a Remote Machine Using PuTTY ..........113 Page 6 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
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H.1 ACS CONTROLLER STANDARD INPUT REGISTER ASSIGNMENTS ......... 121 H.2 ACS CONTROLLER STANDARD HOLDING REGISTER ASSIGNMENTS ....128 APPENDIX I: START AND STOP LEVELS ............137 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 7 of 139 Phone: 800-526-0288 OMM-0081_0F...
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AERCO Control System (ACS) (This page intentionally blank) Page 8 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
There are multiple options built in to do this. Some of these options require a mated AERCO Relay Box to be installed along with the ACS in order to effectively and safely control the supporting hydronic valves and their interaction with the boilers.
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Volts, Alternating Current Volts, Direct Current Vacuum Fluorescent Display Page 10 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
The ACS (Figure 1-1) is a rugged and flexible controller, designed to stage and coordinate the operation of up to 32 AERCO Benchmark Series, Modulex Series or KC1000 Boilers while maximizing operational efficiency. Under normal load conditions, the ACS can precisely regulate the header temperature of the boiler plant within ±2°F.
Fluorescent Display (VFD). The display is capable of displaying two lines with 16 characters per line. Virtually all of the control panel keys are identical to the C-More Control System currently used on AERCO Benchmark Series and KC1000 Boilers. This commonality will help simplify the time required for system setup of the ACS.
RS232 Port terminals on the ACS. Detailed set-up instructions and available command listings are provided in Appendix G. Most settings are also programmable using Modbus. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 13 of 139 Phone: 800-526-0288 OMM-0081_0F...
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AERCO Control System (ACS) CHAPTER 1: ACS General Information (This page intentionally blank) Page 14 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Sufficient clearances to permit maintenance and setup/operational tasks on the ACS. 2.2.1 Mounting the ACS AERCO recommends that the ACS be wall-mounted using a sheet of plywood or other suitable material. For easy viewing, the ACS controls and display should be at eye level. Mounting is accomplished using three screws (not provided).
NOTE Refer to the wiring diagram provided in Appendix E when making all wiring connections to the ACS. Page 16 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
DO NOT apply power to the ACS until all of the required external connections described in paragraphs 2.5 through 2.11 have been completed. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 17 of 139 Phone: 800-526-0288...
If desired, an optional Return Sensor may also be installed, which is the same type and part number as the Header Sensor, however it is only used for Plant DT limit operation and for monitoring purposes. Page 18 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
Terminate the cable shield at SHLD terminal 3 of the ACS. DO NOT terminate the shield at the Sensor end of the cable. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 19 of 139 Phone: 800-526-0288...
Terminate the cable shield at SHLD terminal 3 of the ACS. DO NOT terminate the shield at the Sensor end of the cable. Page 20 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
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INSTALL SENSOR ON NORTH FACING WALL OUT OF DIRECT SUNLIGHT AND AWAY FROM ALL AIR INLETS/OUTLETS Figure 2-4: Outdoor Air Sensor Installation 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 21 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
CHAPTER 2: ACS Installation 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.
Figure 2-6: Location of ACS DIP Switches AERCO RS485 (MODBUS) WIRING, BIAS, AND TERMINATION 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. Benchmark Series and KC1000 Boilers currently utilize C-More Control Systems.
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When using Method 2, activate the two bias switches in the ACS (Figure 2-6) by placing them in the down or toward the wall position toward the wall. Page 24 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
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METHOD A – BIAS & TERMINATION ACTIVATED AT C-MORE PMC BOARD Figure 2-7: RS485 (Modbus) Wiring For Benchmark Series Boilers (Sheet 1 of 2) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 25 of 139 Phone: 800-526-0288...
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METHOD B – TERMINATION ACTIVATED AT I/O BOX the LAST C-More Box. Figure 2-7: RS485 (Modbus) Wiring For Benchmark Series Boilers (Sheet 2 of 2) Page 26 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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METHOD A – BIAS & TERMINATION ACTIVATED AT C-MORE PMC BOARD Figure 2-8: RS485 (Modbus) Wiring For KC1000 Boilers (Sheet 1 of 2) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 27 of 139 Phone: 800-526-0288...
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METHOD B – TERMINATION ACTIVATED AT I/O BOX Figure 2-8: RS485 (Modbus) Wiring For KC1000 Boilers (Sheet 2 of 2) Page 28 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
JUMPER SHOWN IN “TERMINATED” (UP) POSITION BCM FRONT VIEW Figure 2-9: RS485 (Modbus) Wiring For Modulex Series Boilers 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 29 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
The bias switches in the ACS should both be turned to “ON” Figure 2-11: Sample RS485 (Modbus) Network For Modulex Series Boilers Page 30 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
ACS. If a Converter is required, it can be installed inside the wiring compartment of the ACS, or installed externally. The ACS provides an isolated 12 VDC output terminal (ISO 12V) which can be used to power AERCO’s RS485-to-RS232 Converter if needed. Refer to Figure 2-12 for sample network layouts.
The contacts for each of these relays are rated at 120 VAC, 5A and are fused internally at 5A with replaceable fuses. The contact terminals for these relays are shown in the wiring diagram in Appendix E. Page 32 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
MOUNTING & WIRING THE OPTIONAL ACS RELAY BOX The ACS (AERCO Control System) Relay Panel is used in combination with the ACS to control up to 2 isolation valves, boiler interlocks, and a Domestic Hot Water (DHW) pump in a Combination heating plant where AERCO boilers are bring used for both Building Heat and Domestic Hot Water heating.
“Site Selection and Mounting” for further installation information. Figure 2-14: AERCO Control System (ACS) Relay Box with Wiring Cover Removed and Breakout Illustration of Connection Silk-Screening Page 34 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
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Your actual wiring may vary depending on the type of valves being used: Relay Box (for ACS) Figure 2-14a: Wiring of the Relay Box (to the AERCO Control System (ACS) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913...
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AERCO Control System (ACS) CHAPTER 2: ACS Installation Figure 2-14b: ACS Wiring: DHW Option 1 (DHW Pump Enabled/Disabled by Building Controls) Page 36 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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AERCO Control System (ACS) CHAPTER 2: ACS Installation Figure 2-14c: ACS Wiring: DHW Option 2 (DHW Pump Enabled/Disabled by ACS) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 37 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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AERCO Control System (ACS) CHAPTER 2: ACS Installation Figure 2-14d: ACS Wiring: DHW Option 3 Page 38 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
This SPST contact connects to the “Setback” input of the ACS. • Valve End Switch Out This SPST contact connects to the “Interlock 1” input of the ACS. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 39 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
Valve 1 closed and Valve 2 open. Page 40 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
CHAPTER 2: ACS Installation 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.
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AERCO Control System (ACS) CHAPTER 2: ACS Installation the number of boilers to your particular system. (This page intentionally blank) Page 42 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
The display and controls are illustrated and described in Figure 3-1 and Table 3-1 respectively. Figure 3-1: ACS Front Panel Controls and Displays 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 43 of 139 Phone: 800-526-0288 OMM-0081_0F...
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ON/OFF Key Enables and disables ACS operation. ON Indicator Green ON LED lights when the ACS is enabled. Page 44 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
The menu option choices do not wrap around. To select and store a changed menu option, press the ENTER key. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 45 of 139 Phone: 800-526-0288 OMM-0081_0F...
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LEVEL 1 PWD SETUP RS232 RS485 FIELD ADJUST CONFIGURATION TUNING RELAY LEVEL 2 PWD CALIBRATION Figure 3-2: ACS Menu Structure Page 46 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Modbus value supplied to the unit. When in the Outdoor Reset Mode, this is the derived value from the charts in Appendix C. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 47 of 139 Phone: 800-526-0288...
Press the Change Key and then, Up or Down keys to view the other temperatures. Press Enter to stop at a particular boiler code. See Appendix B for definition of codes. Page 48 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
EMS. Available settings include 2400, 4800, 9600 (default), or 19200. Both the ACS and EMS MUST be set to the same baud rate to enable the communication link. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 49 of 139 Phone: 800-526-0288...
The ACS can automatically detect boilers within the “”Min Slave Addr” and “Max Slave Addr” range, or you can program the boiler addresses in the order desired. AERCO recommends programming the addresses in the desired order. When programming the boiler addresses, set the “Min Slave Addr”...
HEADER SET MODE or when the ACS operates in the Failsafe Mode and CONSTANT SETPT is selected as the FAIL SAFE MODE setting in the Configuration Menu. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 51 of 139 Phone: 800-526-0288...
In this example, the setpoint temperature is being offset -15°F on Sunday from 12:01 AM (00:01) to 8:00 AM (08 hrs). Page 52 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
The BOILER OP MODE menu option sets the control operation method for the ACS to either SEQUENTIAL or PARALLEL MODE. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 53 of 139 Phone: 800-526-0288 OMM-0081_0F...
Boilers connected to the ACS will stop. The allowable entry range is from 1% to 40% (default = 16%). See important note below. Page 54 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
This feature is active if the RET SENSOR MODE is set to NORMAL. This value defines the maximum temperature difference allowed between the Header temperature and the Return 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 55 of 139 Phone: 800-526-0288...
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. Page 56 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
Modbus fire ra te (percent level) signal to the boiler during this time. If SPECIAL SIGNAL is selected, the ACS will send an AERCO-defined signal that the boiler control will recognize as the signal to do domestic hot water heating. The default is NO SIGNAL.
‘ACS to the boiler system. Since each system is different, these PID controls can tune the ACS to the characteristics of your specific installation. The factory defaults preset by AERCO work well for most applications. In instances when there is a large error between the setpoint and the actual supply water temperature, the ACS may appear to require PID tuning.
This defines how many degrees below setpoint we can allow the temperature to drift without changing the percent level output value. The default is set to 3°. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 59 of 139 Phone: 800-526-0288...
SYS INTLK CONFIG is set for START ENABLED. Available settings include, INTERLOCK 1 (default), INTERLOCK 2, or INTERLOCK 1&2. Page 60 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
Be sure the Outdoor sensor is properly installed before adjusting this value. The allowable offset range is ±10°F. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 61 of 139 Phone: 800-526-0288 OMM-0081_0F...
This option is used to set the ACS to its factory default values. Make sure that you want to reset all options before activating. Page 62 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
The ranges and default values of the Menu Options used in the following instructions are summarized in Appendix A. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 63 of 139 Phone: 800-526-0288...
Enter Boiler Start Level Percent (default = 20%). See Appendix I. BLR STOP LEVEL Enter Boiler Stop Level Percent (default = 16%). See Appendix I. Page 64 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Set to CONSTANT SETPT if you want to maintain a Constant FAIL SAFE MODE Setpoint temperature in the event that the Remote signal is lost. (Default = SHUTDOWN) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 65 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
“ON” LED is lit. If it is not, press the ON/OFF key to activate the ACS. For further programming details, refer to Chapter 4. Page 66 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
LOAD START PCT The programming set-up instructions for the above menu options are provided in paragraphs which follow. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 67 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
Once the Reset Ratio and Building Reference Temperature have been determined, proceed to the next paragraph and enter these options. Page 68 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
Press the ENTER key to store the change. The reverse video display will revert to the normal display format indicating that the change has been stored in memory. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 69 of 139 Phone: 800-526-0288...
Press the ENTER key to store the changed temperature. The reverse video display will revert to the normal VFD display format. Page 70 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
With the ACS still in the FIELD ADJUST MENU, proceed to the next paragraph and continue the set-up procedure. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 71 of 139 Phone: 800-526-0288 OMM-0081_0F...
If the Remote Signal is set to 4 – 20 mA, the HDR HIGH LIMIT temperature defines the 20 mA value and the HDR LOW LIMIT temperature defines the 4 mA value. Page 72 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
The ACS is now programmed for operation in Remote Setpoint Mode. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 73 of 139 Phone: 800-526-0288...
BLR START LEVEL o BLR STOP LEVEL The set-up instructions for the above menu options are provided in paragraphs which follow. Page 74 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
This completes the required entries in the Field Adjust Menu. To complete the Constant Setpoint Mode set-up, select the Boiler Operating Mode as described below. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 75 of 139 Phone: 800-526-0288...
If the desired Boiler Stop Level is not displayed, repeat steps 2, 3 and 4 above for the desired Stop Level. Page 76 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
Each C-More or BCM is set to a unique address. • The ACS is programmed with the correct C-More or BCM addresses. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 77 of 139 Phone: 800-526-0288 OMM-0081_0F...
When all boilers have reached at least a 55% firing rate, any boilers that have not started have not been identified by the ACS. (Cont.) Page 78 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288...
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11. If the System Test is not completed successfully, refer to the troubleshooting procedures in this manual (Chapter 5) and the applicable O & M Manuals for the boilers included in the boiler plant. If the problem can still not be resolved, contact AERCO at 1-800-526- 0288.
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AERCO Control System (ACS) CHAPTER 4: Programing ACS Operating Modes (This page intentionally blank) Page 80 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
NORMAL. This will prevent the boilers from cycling too much at cold startup. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 81 of 139 Phone: 800-526-0288 OMM-0081_0F...
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Valve wait time has been exceeded. FAULT ALARM A boiler connected to the ACS is in fault. BOILER ERROR Page 82 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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UP %/MIN or RAMP DOWN %/MIN • PID requires adjustment. • Refer to TUNING MENU (para. 3.10). 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 83 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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• Refer to section 2.6 to 2.9 in this resister not activated at either to rise and suddenly manual. the boiler or the ACS. drops to zero. Page 84 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
SET MONTH SET DATE SET YEAR SET HOUR SET MINUTE SET DAY OF WEEK SUNDAY TO SATURDAY RS232 MENU 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 85 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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4 – 20 mA, HDR SET MODE = REMOTE 4 - 20 mA SETPT) MODBUS OFFSET ENABLE OFF, ON Page 86 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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ROTATE TIME 0 to 999 HOURS RETURN SENSOR MODE OFF, NORMAL, DHW/TANK TEMP 40°F PLANT DELTA-T LIMIT 10°F TO 100°F 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 87 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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INTERELOCK 1&2 AUX RELAY OPEN 000% 099% 045% 100% FIRE RATE, AUX RELAY CLOSE 100% AND OFF 100% AND OFF Page 88 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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RESET DEFAULTS YES (DONE If Selected) PASSTHRU WRITE? DISABLED, ENABLED DISABLED VALVE WAIT TIME 1 TO 500 SEC 120 SEC 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 89 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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AERCO Control System (ACS) APPENDIX A: ACS Menus (This page intentionally blank) Page 90 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
The 4 – 20 mA Remote Input signal is lost. ERROR MODBUS TIMEOUT The Modbus remote input information was not received within the ERROR network timeout period. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 91 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
The Blower Proof Switch opened during purge. DURING PURGE SSOV FAULT The SSOV switch opened during purge. DURING PURGE Page 92 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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The Purge Position Limit switch on the Air/Fuel valve DURING IGNITION closed during ignition. SSOV SWITCH OPEN The SSOV switch opened during standby. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 93 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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MODBUS COMM FAULT is corrupted. BOILER_RETRY_WAIT_ MESSAGE BOILER_FAULT_PURGE_ MESSAGE, BOILER_RETRY_PAUSE_ MESSAGE EXHAUST_TEMP_SENSOR_ SHORT_MESSAGE EXHAUST_TEMP_SENSOR_ OPEN_MESSAGE EXHAUST_TEMP_HIGH_ WARNING_MESSAGE EXHAUST_TEMP_HIGH_ FAULT_MESSAGE INLET_TEMP_SENSOR_ SHORT_MESSAGE Page 94 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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Code Message Description INLET_TEMP_SENSOR_ OPEN_MESSAGE INLET_TEMP_HIGH_ WARNING_MESSAGE INLET_TEMP_LOW_ WARNING_MESSAGE INLET_GAS_PRESSURE_ SENSOR_OPEN_MESSAGE GAS_PLATE_DP_SENSOR_ OPEN_MESSAGE INLET_WATER_FLOW_ SENSOR_OPEN_MESSAGE INLET_WATER_FLOW_ LOW_WARNING_MESSAGE INLET_WATER_FLOW_ HIGH_WARNING_MESSAGE 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 95 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
261 (261 – 256 = 5), the actual Fault Code is 5, which, according to Table B-6 means “Flame Loss During Run”. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 97 of 139 Phone: 800-526-0288...
No BMM detected. Ignition is not Check the MANUAL - push reset possible. BMM eBus switch or cycle power. wiring. Page 98 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Flow ON at maximum Temp Protection. temperature - speed. Return Temperature > Water Δ-Temp Protection + 50°F 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 99 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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Fan speed out of Ignition is Check fan wiring. AUTOMATIC control: It doesn't inhibited. stop within 30 seconds after turned OFF. Page 100 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Page 101
VAC) Low Water Flow. Burners turned Check water flow or AUTOMATIC Low water flow OFF. check switch. switch activated. 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 101 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
Bit 1) Bit 0) Bit 2) Bit 1) Bit 0) 08 - 09 18 - 19 28 - 29 Page 102 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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Bit 0) Bit 2) Bit 1) Bit 0) 38 - 39 48 - 49 58 - 59 68 - 69 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 103 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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Bit 3) (LSD (LSD (LSD Bit 2) Bit 1) Bit 0) Bit 2) Bit 1) Bit 0) 78 - 79 Page 104 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Therefore, use a reset ratio of 0.7 (closest to 0.714) and a building reference temperature of 113 (closest to 112.5). 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 105 of 139 Phone: 800-526-0288 OMM-0081_0F...
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200°F 214°F -15°F 105°F 120°F 135°F 150°F 165°F 180°F 195°F 210°F -20°F 108°F 124°F 140°F 156°F 172°F 188°F 204°F Page 106 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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150°F 166°F 182°F 198°F 214°F -15°F 121°F 138°F 155°F 172°F 189°F 206°F -20°F 124°F 142°F 160°F 178°F 196°F 214°F 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 107 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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128°F 144°F 160°F 176°F 192°F 208°F -5°F 131°F 148°F 165°F 182°F 199°F 216°F -10°F 134°F 152°F 170°F 188°F 206°F Page 108 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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10°F 138°F 154°F 170°F 186°F 202°F 218°F 5°F 141°F 158°F 175°F 192°F 209°F 0°F 144°F 162°F 180°F 198°F 216°F 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 109 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
NOTE This Temperature Chart is applicable to Header Sensor (and Return Sensor), P/N 64038 and Outside Air Sensor, P/N GP-122662 Page 110 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
AERCO Control System (ACS) APPENDIX E: ACS Wiring Diagram APPENDIX E: ACS WIRING DIAGRAM 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 111 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
(if your computer has more than one) and what speed (baud rate) to use when transferring data. For further configuration options (data bits, stop bits, parity, flow 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 113 of 139 Phone: 800-526-0288...
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. Page 114 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131...
For example, to set command 05 (SYSTEM OUTSIDE AIR START TEMPERATURE) to 65°F, enter: @05=650<Rtn> 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 115 of 139 Phone: 800-526-0288 OMM-0081_0F...
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0 to 100 Read Only Header Set Temperature (°F) 40 to 220 Read Only System Start Temperature (°F) 32 to 120 Page 116 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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Real Time Clock - Day Of Month 00 to 31 Present Day Real Time Clock - Month 00 to 12 Present Month 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 117 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
Page 118
Boiler 1 Address for Network Net Boiler 2 Address Boiler 2 Address for Network Net Boiler 3 Address Boiler 3 Page 118 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Page 119
Boiler 24 Address for Network Net Boiler 25 Address Boiler 25 Address for Network Net Boiler 26 Address Boiler 26 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 119 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
Page 120
Bit 5 = Interlock 2 Bit 6 = Interlock 1 Bit 7 = Empty & (Reserved For Future Expansion) Undefined Page 120 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
3 = Interlock 2 Error 4 = Indoor Air Sensor Error/ Return Sensor Error 5 = 4-20mA Input Error 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 121 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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36 (0x0024) Same As Above (Net Boiler 12) Boiler 13 Status 37 (0x0025) Same As Above (Net Boiler 13) Page 122 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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52 (0x0034) Same As Above (Net Boiler 28) Boiler 29 Status 53 (0x0035) Same As Above (Net Boiler 29) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 123 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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65 (0x0041) Net Blr 7 Outlet Temp 40°F to 220°F 66 (0x0042) Net Blr 8 Outlet Temp 40°F to 220°F Page 124 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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0 to 65535 for MLX (BCM) 2, A-5, and A-6. 93 (0x005D) Net Blr 2 Code Same as Above “ 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 125 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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Same as Above 120 (0x0078) Net Blr 29 Code Same as Above 121 (0x0079) Net Blr 30 Code Same as Above Page 126 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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123 (0x007B) Net Blr 32 Code Same as Above 124 (0x007C) (Reserved for future expansion) Thru (Not defined) 65535 (0xFFFF) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 127 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
18 (0x0012) Derivative Gain (0.00 increments) (Value x 100) 19 (0x0013) Header Temp Bandwidth 5 to 120°F Default = 70°F Page 128 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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1 to 7 Present Day Day of Week Real Time Clock 35 (0x0023) 00 to 99 Present Year Year 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 129 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
Page 130
Default = 0 58 (0x003A) Offset On Time Day 7 – Hours 00 to 23 Hours Default = 0 Page 130 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Page 131
Fri. – Hours Offset Off Time 83 (0x0053) 0 to 23 Hours Default = 0 Sat. – Hours 84 (0x0054) (Reserved) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 131 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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Address for Network Boiler 16 Default = 0 108 (0x006C) Net Boiler 17 Address Address for Network Boiler 17 Default = 0 Page 132 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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1 = All Blr Faults 135 (0x0087) 4 to 20 mA Current Offset -1.00 mA to 1.00 mA Default = 0 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 133 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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PLANT DT LIMIT 10 to 100° Default = 40° 155 (0x009B) BOILER DELAY TIME 10 to 999 Sec Default = 30 Page 134 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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0 (Off), 1 to 999 Min Default = 0 163 (0x00A3) Undefined Thru (Reserved For Future Expansion) 65535 (0Xffff) 11/22/2017 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 Page 135 of 139 Phone: 800-526-0288 OMM-0081_0F GF-131...
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AERCO Control System (ACS) APPENDIX H: ACS Modbus Address Assignments (This page intentionally blank) Page 136 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
Boiler Stop Level: 16% In order for the ACS to properly control the boilers in the Boiler Plant, the corresponding Start and Start levels must be entered in the ACS Configuration Menu for the type of AERCO boilers being controlled.
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AERCO Control System (ACS) NOTES: Page 138 of 139 AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 11/22/2017 Phone: 800-526-0288 GF-131 OMM-0081_0F...
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