Watts AERCO EXT Installation, Operation & Maintenance Manual
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Watts AERCO EXT Installation, Operation & Maintenance Manual

Modulex ufly controller & bcm
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Installation, Operation & Maintenance Manual
Modulex EXT Ufly Controller & BCM
For Modulex EXT Natural Gas Modulating and
Condensing Hot Water Boilers
Applies to Modulex models:
• EXT 450 2S
• EXT 600 2S
• EXT 800 2S
• EXT 1100 2S
• EXT 1500 2S
• EXT 2300 2S
• EXT 2600 2S
•
EXT 3000 2S
Disclaimer
The information contained in this manual is subject to change without notice
from AERCO International, Inc. AERCO makes no warranty of any kind with
respect to this material, including, but not limited to, implied warranties of
merchantability and fitness for a particular application. AERCO International is
not liable for errors appearing in this manual, not for incidental or
consequential damages occurring in connection with the furnishing,
performance, or use of these materials
OMM-0159_A • 6/28/2022
Heating and Hot Water Solutions
AERCO International, Inc. • 100 Oritani Drive • Blauvelt, NY 10913
USA: T: (845) 580-8000 • Toll Free: (800) 526-0288 • AERCO.com
Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST
© 2022 AERCO

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Summary of Contents for Watts AERCO EXT

  • Page 1 Installation, Operation & Maintenance Manual Modulex EXT Ufly Controller & BCM For Modulex EXT Natural Gas Modulating and Condensing Hot Water Boilers Applies to Modulex models: • EXT 450 2S • EXT 600 2S • EXT 800 2S • EXT 1100 2S •...

  • Page 2: Table Of Contents

    Ufly Controller and BCM for Modulex EXT Table of Contents: CHAPTER 1: INTRODUCTION ......................5 CHAPTER 2: UFLY CONTROLLER & BCM MODULES ................ 7 2.1 UFLY CONTROLLER ........................7 2.1.1 Ufly Controller Features and Functions..................7 2.1.2 Reading the Icons on Home Page .................... 8 2.1.3 Display Modes .........................
  • Page 3 Ufly Controller and BCM for Modulex EXT 6.6.1 Master BMS II/ACS or EMS/BAS Terminating Resistor and Bias ..........52 6.6.2 BCM Controller Terminating Resistor ..................52 6.7 MODBUS NETWORK WIRING DIAGRAM ................... 53 6.8 MODBUS SOFTWARE SET-UP ....................54 6.8.1 BCM Set-Up For Modbus Operation ..................54 6.8.2 AERCO ACS Modbus Control and Monitoring ................

  • Page 5: Chapter 1: Introduction

    Ufly Controller and BCM for Modulex EXT CHAPTER 1: INTRODUCTION CHAPTER 1: INTRODUCTION The information in this manual provides a guide to the operation of the Modulex Boiler using the Ufly 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.
  • Page 6 Ufly Controller and BCM for Modulex EXT CHAPTER 1: INTRODUCTION (This page intentionally blank) OMM-0159_A_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 6 of 83...

  • Page 7: Chapter 2: Ufly Controller & Bcm Modules

    Ufly Controller and BCM for Modulex EXT CHAPTER 2: Ufly CONTROLLER & BCM MODULES CHAPTER 2: UFLY CONTROLLER & BCM MODULES MODULEX boilers contain advanced and reliable electronic controls, the Ufly Controller and the BCM (Boiler Communications Module), which provide comprehensive programming and monitoring of the MODULEX boiler and its functions.

  • Page 8: Reading The Icons On Home Page

    Ufly Controller and BCM for Modulex EXT CHAPTER 2: Ufly CONTROLLER & BCM MODULES 2.1.2 Reading the Icons on Home Page Heating: Access space heating parameters including setpoint, outdoor reset and building reference temperature. Domestic Hot Water: Access domestic hot water parameters including setpoint, timed programming, and legionella protection function Solar: This menu is currently not available.

  • Page 9: Display Modes

    Ufly Controller and BCM for Modulex EXT CHAPTER 2: Ufly CONTROLLER & BCM MODULES 2.1.3 Display Modes Display Mode Display Mode Display Mode Screen Off Home Screen Menu Screen NOTE: Menu icons do not indicate operating status. OMM-0159_A_A • 6/28/2022 Technical Support •...

  • Page 10: Boiler Communication Module (Bcm)

    Ufly Controller and BCM for Modulex EXT CHAPTER 2: Ufly CONTROLLER & BCM MODULES 2.2 Boiler Communication Module (BCM) The MODULEX BCM supports full interoperability to BAS (Building Automation Systems) via Modbus protocol to enable remote communications and control. It also provides a remote alarm contact to notify customers of faults within any of the thermal modules.

  • Page 11: Chapter 3: Operation, Menu & Parameters

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS CHAPTER 3: OPERATION, MENU & PARAMETERS This chapter introduces the Ufly controller basic menu contents needed to set up the MODULEX EXT boiler. For more detailed information concerning the Ufly controller menus, operating modes and functions, refer to Section 4.

  • Page 12: Setup Menu

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 3.1 setup Menu The Setup Menu allows the user to setup time and date, program Building Reference temperatures and domestic hot water setpoint, change display and language settings, and change the password for the Devices.

  • Page 13: Setting Comfort And Eco Domestic Hot Water Setpoints

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 3.1.3 Setting Comfort and Eco Domestic Hot Water Setpoints The Comfort and Eco Domestic Hot Water Setpoints are programmed in the Setup Menu. For details on Domestic Hot Water Operation, see Section 4.4. The Ufly screen automatically turns off after 20 seconds (default) of inactivity.

  • Page 14: Password

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 3.1.6 Password For security and protection of the boiler, the default password is only available to Authorized AERCO Service technicians. To Change the password: 1. Enter the current password and click OK 2.
  • Page 15 Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS Outdoor Reset Parameter and Space Heating Setpoint are accessed via the Settings button. Building Reference Temperatures for Outdoor Reset Mode are accessed via the Heating Menu. OMM-0159_A_A • 6/28/2022 Technical Support •...

  • Page 16: Domestic Hot Water Menu

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 3.3 Domestic Hot Water Menu The Domestic Hot Water Menu provides access to parameters to provide domestic hot water (DHW) using a tank sensor. For DHW programming details, see section 4.4. The Comfort and Eco DHW Setpoints can be accessed by clicking the settings button.

  • Page 17: Devices Menu

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 3.4 Devices Menu The Devices Menu allows access to BMM (Burner Management Module) parameters, BCM parameters for functions including 0-10V operation and domestic hot water operation, and error history.

  • Page 18: Burner Menu

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS Access and clear error history. 3.5 Burner Menu The Burner Menu allows access to calibration, manual operation, and troubleshooting settings. This menu is password protected and is only for authorized AERCO technicians. 3.5.1 Service Mode/Manual Firing Rate Function 1.

  • Page 19: Manual Setpoint Function

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 6. Click on the Request +/- buttons to set the boiler manual firing rate desired. 7. If desired, user can select which burner(s) to run during manual firing rate function. a.

  • Page 20: Reset Burner Working Hours And Ignition Count

    Ufly Controller and BCM for Modulex EXT CHAPTER 3: OPERATION, MENU & PARAMETERS 3. Click on the Request +/- buttons to set the manual setpoint desired. 4. To disable the Manual Setpoint Function, select the Home button 3.5.3 Reset Burner Working Hours and Ignition Count Select one of the available burners Click the Reset button.

  • Page 21: Chapter 4: Ufly Setup And Programming

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING CHAPTER 4: UFLY 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.

  • Page 22: Indoor/Outdoor Reset Operation Configuration

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 4.1.2 Indoor/Outdoor Reset Operation Configuration The Indoor/Outdoor Reset Mode is configured in the Heating Menu as follows: I M P O R T A N T ! The outdoor air sensor MUST be connected as described in Section 4.1.1 above, prior to configuring the Controller for Indoor/Outdoor Reset Mode operation.
  • Page 23 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING a. Setpoint/OAR Max Setpoint: the maximum allowable outlet water (setpoint) temperature. b. OAR Min Outside Temp: when outside temperature is at or below this number, the unit setpoint will be the OAR Max Setpoint. c.
  • Page 24 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING The Building Ref Temp. can be programmed using three different methods: 1. Comfort: Choose this to set a Building Ref Temp that will be used 24/7. 2. Eco: Choose this to set a Building Ref Temp that will be used 24/7. Use this to set a lower Building Ref Temp, resulting to lower setpoint.
  • Page 25 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING Weekly Scheduled Building Ref Temp: The user can create 3 weekly Building Ref Temp schedules to choose from. Each day of the week can be selected from 5 choices of type of day and each type of day can be programmed with up to 3 time slots.”...
  • Page 26 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING Creating Weekly Building Ref Temp schedules: 1. Rename week type as desired (e.g., School Week, Spring Break Week, etc.). • Mon-Fri can be combined to have a common type of Day if desired. •...
  • Page 27 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 2. If there is more than one heating circuit in the system, select the one to be setup for outdoor reset. ch13 ch 13 ch ..3. Select Comfort, Eco, Week 1, Week 2 or Week 3 Building Ref Temp. For weekly Building Ref Temp, details of the program can be viewed as follows: NOTE: During periods between the programmed slots (represented by the un-shaded sections of the pie), the Eco Building Ref Temp is used.

  • Page 28: Viewing The Boiler Setpoint

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 4.1.3 Viewing the Boiler Setpoint The setpoint temperature setting is viewed in the Heating Menu. 1. Access the heating menu from the Home Screen or from Main Menu. Menu Home Screen Main Menu...

  • Page 29: 0-To-10-Volt Remote Set Point Mode

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING ch13 ch 13 ch ..3. Click the settings icon. Ch13 Comfort Time program °F room status • Set the Setpoint/OAR Max Setpoint to desired temperature • Setpoint High Limit (upper limit of setpoint) and Setpoint Low Limit (lower limit of setpoint) can also be set on this screen 4.3 0-To-10-Volt Remote Set Point Mode...

  • Page 30: 0-To-10-Volt Remote Setpoint Mode Operation Configuration

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 4.3.2 0-to-10-Volt Remote Setpoint Mode Operation Configuration The 0-to-10-volt Remote Setpoint Mode is configured as follows: 1. Access Device Management from Main Menu; select hcm > Parameter Settings 2.
  • Page 31 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 803: Enabled services 799: 0/10V input 803: Enabled services 799: 0/10V input 483: Max differential temperature 376: Input#1: function 483: Max differential temperature 376: Input#1: function °R °R 34: Burner Hysteresis 322: Pump: overrun...

  • Page 32: Domestic Hot Water Operation Using A Tank Sensor

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 4.4 Domestic Hot Water Operation Using A Tank Sensor The following procedures describe the wiring connection and Ufly Controller configuration to provide domestic hot water (DHW) using a tank sensor installed in a thermowell. 4.4.1 Sensor Wiring Connections To monitor the DHW temperature, connect the tank sensor wire leads to the Input/Output box, connector Y2, terminals 6 and 8.
  • Page 33 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING DHW Setpoint can be programmed using three different methods: 1. Comfort: Choose this to set a DHW Setpoint that will be used 24/7. 2. Eco: Choose this to set a DHW Setpoint that will be used 24/7. Use this to set a lower DHW Setpoint 3.
  • Page 34 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 2. Set time slots for each day type. Time slots are programmed in a 24-hr clock. 120 °F Creating Weekly DHW Setpoint schedules: 1. Rename week type as desired (e.g., School Week, Spring Break Week, etc.). comfort °F °F...
  • Page 35 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING Choosing the DHW Setpoint to use: 1. Select Comfort, Eco, Week 1 , Week 2 or Week 3 DHW Setpoint. 2. For weekly DHW Setpoint, details of the program can be viewed as follows: NOTE: During periods between the programmed slots (represented by the un-shaded sections of the pie), the Eco DHW Setpoint is used.

  • Page 36: Boiler & Pump Enable/Disable

    Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING Viewing the DHW Setpoint: The setpoint temperature setting is viewed in the Heating Menu. 4.5 Boiler & Pump Enable/Disable The boiler and pump can be enable/disabled via terminals TA and 9 terminal block Y2 in the Input/Output box.
  • Page 37 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING 2. Access Device Management from Main Menu; select hcm > Parameter Settings 3. Set Parameter 376. This defines the functionality of terminals TA/9 of connector Y2: • Parameter 376 is set = 0.
  • Page 38 Ufly Controller and BCM for Modulex EXT CHAPTER 4: UFLY SETUP AND PROGRAMMING (This page intentionally left blank) OMM-0159_A_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 38 of 83...

  • Page 39: Chapter 5: Input/Output Box, Bcm Terminal Assignments

    Ufly Controller and BCM for Modulex EXT CHAPTER 5: INPUT/OUTPUT BOX, BCM TERMINAL ASSIGNMENTS CHAPTER 5: INPUT/OUTPUT BOX, BCM TERMINAL ASSIGNMENTS Figure 5-1: Input/Output Box, BCM Terminals OMM-0159_A_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 39 of 83...

  • Page 40: Terminal Assignments

    Ufly Controller and BCM for Modulex EXT CHAPTER 5: INPUT/OUTPUT BOX, BCM TERMINAL ASSIGNMENTS 5.1 terminal Assignments OMM-0159_A_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 40 of 83...

  • Page 41: Chapter 6: Boiler Communications Module (Bcm)

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) The BCM (Boiler Communication Module) is an electronic module in MODULEX boilers, which supports full interoperability to BAS (Building Automation Systems) via Modbus protocol to make remote communications and control possible.
  • Page 42 Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) Figure : BCM Key and LEDs Legend OMM-0159_A_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 42 of 83...

  • Page 43: Bcm Fault Relay

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.2 BCM Fault Relay The BCM Fault Relay is activated (energized) when a fault condition occurs in the Modulex Boiler. When activated, the Fault Relay provides contact closure across pins 3 and 4 of connector Y4 in the Input/Output box.

  • Page 44: Bcm: Backup Controller Function

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) Figure 6-4: Alarm Signal location Figure 6-5: BCM Fault Relay & Reset Switch Wiring 6.3 BCM: Backup Controller Function 6.3.1 Backup Controller Setpoint The BCM is a backup controller and will assume control of the Modulex Boiler if the Ufly Controller fails.

  • Page 45: Operating The Bcm As A Backup Controller

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) setpoint equal to the value assigned for Parameter 39 (Maximum Setpoint) in the BCM. Do not change the value of Parameter 39 as it also represents the maximum setpoint for the boiler during normal operation.
  • Page 46 Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) Figure 6-7: Boiler Control Manager Screen To operate the BCM as a backup controller, press the MANUAL button on the BCM controller. The BCM can also be operated as a backup controller automatically in lieu of pressing the MANUAL button.
  • Page 47 Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 2. Scroll to Parameter 376. This parameter defines the functionality of terminals Y2 TA/9. Set Parameter 376 = 3 to automatically activate the BCM as a backup controller. NOTE: Terminals Y2 TA/9 can be used for automatic activation of BCM as a backup controller described above OR for enable/disable functionality not both.

  • Page 48: Bcm Control Of Variable Speed Primary Pump

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.4 BCM Control Of Variable Speed Primary Pump The BCM has a 0-10 V output that can be used to control a Variable Speed primary pump. There is no connection on the Modulex controller for pump mains power.
  • Page 49 Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 2. Voltage control signal configuration • Scroll to Parameter 341 and set it to the output voltage at lowest firing rate of boiler. Default is 3V. See Figure 6-10 for lowest firing rate of each Modulex boiler. •...

  • Page 50: Control Via Modbus (Through Bcm)

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.5 Control Via Modbus (Through BCM) All Modbus Networks are implemented utilizing a “Manager-Client” scenario where only one device, the “Manager”, can initiate a communication sequence. However, BCMs can only function as “Client”...

  • Page 51: Aerco Bms Ii/Acs Master To Bcm Slave Wiring Connections

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) Figure 6-12: BCM Modbus (RS485) Connections 6.5.3 AERCO BMS II/ACS Master to BCM Slave Wiring Connections. The AERCO BMS II/ACS contains a RS232 port to connect to an EMS/BAS or personal computer, plus a RS485 port for connection to the BCM’s Modbus input.

  • Page 52: Master Bms Ii/Acs Or Ems/Bas Terminating Resistor And Bias

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.6.1 Master BMS II/ACS or EMS/BAS Terminating Resistor and Bias All AERCO ACS units are equipped with a built-in terminating resistor. Therefore, when the ACS is the controlling Master, no terminating resistor needs to be added. In addition, ACS contains two Bias DIP switches which must be activated when the ACS is the controlling Master.

  • Page 53: Modbus Network Wiring Diagram

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.7 Modbus Network Wiring Diagram A “Sample” Modbus Network wiring diagram for an AERCO ACS Master controlling BCM Slaves is shown in Figure 6-14. Activate the terminating resistor in the last BCM on the daisy-chain loop. DO NOT install the 1K bias resistor.

  • Page 54: Modbus Software Set-Up

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) Figure 6-15 shows a Sample Modbus Network wiring diagram for a Master EMS/BAS controlling BCM Controller Slaves. This Figure shows an EMS or BAS Master equipped with a RS485 port. If the EMS or BAS contains a 4-Wire RS485 port, refer to Detail “A”...
  • Page 55 Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 1. Access Device Management from Main Menu; select hcm > Parameter Settings 2. Scroll to Parameter 803 and set its value to 16. This allows Control via Modbus such as via AERCO ACS or BAS/EMS.

  • Page 56: Aerco Acs Modbus Control And Monitoring

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.8.2 AERCO 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.

  • Page 57: Sequence Of Operation (Example: Four-Modulex Boiler Installation)

    Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) 6.9.1 Sequence of Operation (Example: Four-Modulex boiler installation) When there is a need for heat, ACS will send a fire rate signal to the first boiler to begin firing. The Boiler Communications Module (BCM) of the first boiler will turn on one of its modules.
  • Page 58 Ufly Controller and BCM for Modulex EXT CHAPTER 6: BOILER COMMUNICATIONS MODULE (BCM) (This page intentionally blank) OMM-0159_A_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 58 of 83...

  • Page 59: Chapter 7: Bcm Modbus And Address Assignments

    Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS 7.1 BCM Modbus Comm. & Support Requirements The Modbus communication support requirements incorporated in the BCM are as follows: 7.1.1 Function Codes The BCM supports the Modbus Function Codes shown below.

  • Page 60: Bcm Controller Standard Holding Register Assignments

    Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS 7.2 BCM Controller Standard Holding Register Assignments 7.2.1 BCM Controller Standard Input Register Assignments The BCM Controller has only two Read Only Input Register addresses as shown below. TABLE 7-3: BCM Controller Standard Input Register Address Mapping Modbus Data Menu Item...
  • Page 61 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address CONTROL REGISTERS (Read/Write) A value other than 0 AERCO BMS II/ACS requests Run mode and Requested % (0 to 100)
  • Page 62 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address 0 – 0xFFFF LSB: Error Code MSB: Identification code Error Code of fault device: (Read Only)
  • Page 63 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address CH actual target 32°F-212°F (0°C-100°C) 1400 (Read Only) temperature (Value x 10) DHW actual target 32°F-212°F (0°C-100°C)
  • Page 64 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address (Read Only) Global 1200 Monitor Only 0 – 100% modulation level from Cascade Manager BMM #n Error Code...
  • Page 65 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address Burner OFF 9°F to 36°F (5°C to 20°C) (Read/Write) 3000 Hysteresis (Value x 10)
  • Page 66 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address CH maximum target 68°F to 212°F (Read/Write) 9101 temperature. (20°C to 100°C) 185°F 0/1:...
  • Page 67 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address Pump Modulation 0 – 10V (Read/Write) 3008 Output @ Maximum (Value x 10) Burner Level Burner Minimum...
  • Page 68 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address TEST REGISTERS (Write Only) enum (0xA5/0x5A) This command is only executed in Standby mode.
  • Page 69 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS Table 7-4: BCM Standard Holding Register Address Mapping Modbus Data Menu Item Units and Range Default/(Comments) Address Flags (0 - 0xFFFF) bit 0: Relay1 [OFF, ON] bit 1: Relay2 [OFF, ON] bit 2: Relay3 [OFF, ON] bit 3: Relay4 [OFF, ON]...
  • Page 70 Ufly Controller and BCM for Modulex EXT CHAPTER 7: BCM MODBUS AND ADDRESS ASSIGNMENTS (This page intentionally left blank) OMM-0159_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 70 of 83...

  • Page 71: Chapter 8: Troubleshooting

    Ufly Controller and BCM for Modulex EXT CHAPTER 8: TROUBLESHOOTING CHAPTER 8: TROUBLESHOOTING 8.1 Ufly Controller Error Codes Fault codes are displayed in the right-hand section of the Ufly Controller display (see Figure 8-1). There are codes for the following two different devices: •...

  • Page 72: Bcm (Boiler Communications Module) Fault Codes

    Ufly Controller and BCM for Modulex EXT CHAPTER 8: TROUBLESHOOTING 8.1.1 BCM (Boiler Communications Module) Fault Codes The table below lists the fault codes and troubleshooting tips associated with the BCM. FAULT CODE DESCRIPTION EFFECT CORRECTION RESET HCM: 2 Gas Pressure Switch - Low gas pressure NOT APPLICABLE.
  • Page 73 Ufly Controller and BCM for Modulex EXT CHAPTER 8: TROUBLESHOOTING FAULT CODE DESCRIPTION EFFECT CORRECTION RESET Low system flow rate. Water flow is not HCM: 40 detected by sensor Check water flow or Burners turned OFF. AUTOMATIC Low water flowrate connected to BCM check switch.

  • Page 74: Bmm (Burner Management Module) Fault Codes

    Ufly Controller and BCM for Modulex EXT CHAPTER 8: TROUBLESHOOTING 8.1.2 BMM (Burner Management Module) Fault Codes The table below lists the fault codes and troubleshooting tips associated with the BMM. CODE DESCRIPTION EFFECT CORRECTION RESET MANUAL - push reset switch BMM: 1 All burners turned OFF High Limit (STB)
  • Page 75 Ufly Controller and BCM for Modulex EXT CHAPTER 8: TROUBLESHOOTING CODE DESCRIPTION EFFECT CORRECTION RESET If fan is stopped, check supply voltage and fan wiring. If OK, try another fan. If still not working, change the BMM. Ignition retry after 60 Air pressure switch BMM: 22 second delay and...

  • Page 76: Appendix A: Bcm Parameters

    Ufly Controller and BCM for Modulex EXT 0 APPENDIX A: BCM PARAMETERS APPENDIX A: BCM PARAMETERS This section provides the list of the parameters in the BCM. See Section 3.4 for instructions on how to navigate to the BCM parameters. PARAMETER DESCRIPTION ENTRY RANGE...
  • Page 77 Ufly Controller and BCM for Modulex EXT 0 APPENDIX A: BCM PARAMETERS PARAMETER DESCRIPTION ENTRY RANGE DEFAULT Pump: minimum control 0-10V (Minimum output pump modulation) See Section 6.4.3 Pump: maximum control 0-10V (Maximum output pump modulation) See Section 6.4.3 CH Maximum modulation 0-100% 100% CH Parallel: maximum error...
  • Page 78 Ufly Controller and BCM for Modulex EXT 0 APPENDIX A: BCM PARAMETERS PARAMETER DESCRIPTION ENTRY RANGE DEFAULT CH#1: parallel DHW (Heating/DHW Parallel Operation) 0 = DHW demand is priority, Parallel Operation is disabled. 1 = Parallel operation of space heating See Description and DHW is allowed provided the Boost Temperature setpoint (Param.
  • Page 79 Ufly Controller and BCM for Modulex EXT 0 APPENDIX A: BCM PARAMETERS PARAMETER DESCRIPTION ENTRY RANGE DEFAULT Programmable Relay #1 (BCM Y4-1/2) Function (BCM connector Y4, terminals 1 and 2) 0 = Primary Pump (boiler loop) control See Description 1 = Boiler status contact (closes when at least one burner is on, opens when all the burners are off) Programmable Relay#2 (Alarm Relay)

  • Page 80: Appendix B: Bmm Parameters

    Ufly Controller and BCM for Modulex EXT 0 APPENDIX B: BMM PARAMETERS APPENDIX B: BMM PARAMETERS This section provides the list of the parameters in the BMM boards. See Section 3.4 for instructions on how to navigate to the BMM parameters. PARAMETER DESCRIPTION ENTRY RANGE...
  • Page 81 Ufly Controller and BCM for Modulex EXT 0 APPENDIX B: BMM PARAMETERS PARAMETER DESCRIPTION ENTRY RANGE DEFAULT Burner: soft shutdown - NOT APPLICABLE. Note: Leave at default value of 0 Fan: pulse/revolution 0/1-4 Note: Leave at the default value of 2 MLX EXT 450 2S -1100 2S: 10 Fan regulation: proportional band...
  • Page 82 Ufly Controller and BCM for Modulex EXT 0 APPENDIX B: BMM PARAMETERS PARAMETER DESCRIPTION ENTRY RANGE DEFAULT 0°F/2°F – 90°F (0°C/1°C-50°C) Maximum Differential Temperature 54°F (30°C) 0 = Disabled; (Water ΔT protection) Units may be expressed in R or K Programmable Sensor #1 function - NOT APPLICABLE.
  • Page 83 Ufly Controller and BCM for Modulex EXT 0 APPENDIX B: BMM PARAMETERS Change Log: Date Description Changed By 6.28.2022 Initial Release DBarron © AERCO International, Inc., 2022 OMM-0159_A • 6/28/2022 Technical Support • (800) 526-0288 • Mon-Fri, 8 am - 5 pm EST Page 83 of 83...

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