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FULTON ModSync SE User Manual
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FULTON ModSync SE User Manual

For use on fulton hydronic boilers
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USER MANUAL
ModSync® SE
For use on Fulton Hydronic Boilers
Serial Number
Model
Fulton Order
Owner
Site Name
Date
ModSyncSE-User-Manual-211020

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Summary of Contents for FULTON ModSync SE

  • Page 1 USER MANUAL ModSync® SE For use on Fulton Hydronic Boilers Serial Number Model Fulton Order Owner Site Name Date ModSyncSE-User-Manual-211020...
  • Page 2 PAGE LEFT INTENTIONALLY BLACK...
  • Page 3 Siemens LMV3 Control Set Up................4-8 Temperature Sensor ..................... 2-2 SET UP AT THE MODSYNC® ......................4-8 Wiring ........................2-3 SETUP AT THE LMV3 CONTROLLER (AZL) ...................4-8 Fulton PURE Control™ Setup ................4-10 Operation Maintenance Sequence of Operations ..................3-2 Screen Descriptions ....................3-3 Backing up the Program ..................
  • Page 4 TABLE OF CONTENTS ModSyncSE-User-Manual-211020 PAGE LEFT INTENTIONALLY BLACK © Fulton Group N.A., Inc. 2021...
  • Page 5 INTRODUCTION INTRODUCTION INSTALLATION OPERATION MAINTENANCE SERVICE DOCUMENTS PARTS & SPECIFICATIONS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 6 The hydronic loop setpoint can be field-selected to be controlled by the ModSync®, remote 4-20mA signal, BMS, or manual input. ƒ Modbus Communication The ModSync® can communicate over the Modbus protocol to Building Management Systems. BACnet and LonWorks communication are optionally available through protocol converters. © Fulton Group N.A., Inc. 2021...
  • Page 7 ƒ BMS System Interface existing codes or standards which may be applicable. Fulton reserves Remote Enable/Disable contacts and Domestic Hot Water priority digital inputs the right to change any part of provide standard BMS interface capabilities.
  • Page 8 /professional codes or regulations. © Fulton Group N.A., Inc. 2021...
  • Page 9 INSTALLATION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS & SPECIFICATIONS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 10 • Tolerance: Grade B • Base Resistance: 100 Ω • Sheath Diameter: 38 • Sensor Length: 4” • Sensor Material Type: 303 Stainless Steel • Threaded Fitting: ¼” NPT FIGURE 1 – HYDRONIC SUPPLY SENSOR © Fulton Group N.A., Inc. 2021...
  • Page 11 All digital inputs use the controls 24DC+ for the source voltage. of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 12 Individual Boiler Circulation Pump Control Output ƒ Individual Boiler Alarm Output ƒ General Alarm Output ƒ Individual Boiler Status Output ƒ Heat Demand Status Output ƒ Individual System Pump Enable Output ƒ ƒ Individual Heat Demand Output © Fulton Group N.A., Inc. 2021...
  • Page 13 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 14 INSTALLATION SECTION 2 ModSyncSE-User-Manual-211020 PAGE LEFT INTENTIONALLY BLACK © Fulton Group N.A., Inc. 2021...
  • Page 15 OPERATION INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS & SPECIFICATIONS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 16 7. The lead boiler is disabled when the water loop temperature reaches a has been under water. Immediately call a qualified service technician to selectable value referenced around the water loop setpoint. inspect the boiler and to replace any impacted part of the control system. © Fulton Group N.A., Inc. 2021...
  • Page 17 Fulton reserves the right to change any part of Never attempt to operate a boiler this installation, operation and that has failed to pass all the safety maintenance manual without notice.
  • Page 18 /professional codes or Setpoint Screen regulations Lead / Lag Configuration Screens System Configuration Menu Alarm Status Screen Setback Schedule Screens Trending Screen Information Screen © Fulton Group N.A., Inc. 2021...
  • Page 19 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 20 ModSync®. If in alarm or otherwise disabled the L/L Position will state “Disabled” and another enabled boiler will take the place of the disabled boiler. © Fulton Group N.A., Inc. 2021...
  • Page 21 Fulton reserves Mode: Touchscreen option that allows the user to select the operation mode the right to change any part of of each boiler.
  • Page 22 Screen Contrast: Adjusts the brightness of the screen. 20 – darkest, 100 – ƒ brightest. Temp Scaling: Change the ModSync® between Celsius and Fehrenheit. ƒ Modulation Mode: Determines how the ModSync® will control the boilers. ƒ Time/Date: Allows for time/date to be adjusted. ƒ © Fulton Group N.A., Inc. 2021...
  • Page 23 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 24 Outlet Scaling: Scale the outlet temperature retransmission from the ƒ Yokogawa temperature control on the Fulton Vantage boilers. ƒ Low (4mA): The temperature value when the input is 4mA. ƒ High (20mA): The temperature value when the input is 20mA.
  • Page 25 ƒ System and Scaling Screen 3 of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 26 LMV3 Secondary Fuel Low Fire S1: For High/Low/Off boilers only. Select ƒ the calculated firing rate at the ModSync® that determines the point that the boiler decreases to low fire from high fire. 3-12 © Fulton Group N.A., Inc. 2021...
  • Page 27 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 28 » General Alarm: Configures the output as the general alarm. The output will enable whenever any alarm condition occurs. » Boiler # Status: Configures the output as a boiler status output. The output will enable whenever the corresponding boiler is running. 3-14 © Fulton Group N.A., Inc. 2021...
  • Page 29 The output will enable whenever the corresponding of practice, nor should it replace boiler has a heat demand. existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 30 » Primary Low Water: Configures the input to annunciate an alarm when a boilers primary low water is active. » Secondary Low Water: Configures the input to annunciate an alarm when a boilers Secondary low water is active. 3-16 © Fulton Group N.A., Inc. 2021...
  • Page 31 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 32 Pump’s VFD. This selection will only be available if System Pump are professional training, conduct, and strict adherence to applicable enabled and the VFD selection has been enabled. jurisdictional /professional codes or regulations 3-18 © Fulton Group N.A., Inc. 2021...
  • Page 33 Main Menu back. See Figure 13. be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 34 In order to reset the regulations remaining hours press and hold the last serviced button for 5 seconds. FIGURE 17 – MAINTENANCE CONFIGURATION SCREEN 2 3-20 © Fulton Group N.A., Inc. 2021...
  • Page 35 See figure 18. be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 36 Press the Update Settings button and the message will change to communication settings updated. The ModSync® is now properly configured with settings selected. Transmit and Receive values to the right are available to show communication status. 3-22 © Fulton Group N.A., Inc. 2021...
  • Page 37 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 38 Setback mode based on the selected schedule for the current day. Mode Select: Displays the current mode and allows the user to select the ƒ mode when the mode is in Manual mode. FIGURE 22– SETBACK SCHEDULE SCREEN 2 3-24 © Fulton Group N.A., Inc. 2021...
  • Page 39 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 40 100°F and the outdoor temp deviation is set for 5°F then the boilers will shut down on outdoor temp disable when the outdoor temperature reaches 100°F and will not re-enable until the outdoor temperature drops to 95°F. 3-26 © Fulton Group N.A., Inc. 2021...
  • Page 41 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 42 ƒ Trending jurisdictional /professional codes or regulations The trending screen allows for comparison and charting of the Loop, Setpoint, and Outdoor Temperatures. FIGURE 27 – TREND SCREEN 3-28 © Fulton Group N.A., Inc. 2021...
  • Page 43 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 44 ModSync® will enable the lead boiler. jurisdictional /professional codes or Lead Boiler Stop Deviation: Defines how many degrees above setpoint regulations ƒ before the ModSync® will disable the lead boiler. 3-30 © Fulton Group N.A., Inc. 2021...
  • Page 45 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 46 » A broad (Large) Integral will cause a more gradual response from the controller. » A narrow (Small) Integral will cause a more rapid response. Note that if you set a short Integral time, the function will respond very quickly and may overshoot the setpoint. 3-32 © Fulton Group N.A., Inc. 2021...
  • Page 47 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 48 The lead system pump will be enabled when the outdoor air temperature is below the user defined outdoor air temperature setting or anytime the system is enabled. The ModSync® will automatically rotate the lead system pump based 3-34 © Fulton Group N.A., Inc. 2021...
  • Page 49 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 50 All information in this manual is for reference and guidance purposes, and does not substitute for required professional training, conduct, and strict adherence to applicable jurisdictional /professional codes or regulations 3-36 © Fulton Group N.A., Inc. 2021...
  • Page 51 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 52 ƒ Current Lead Pump Hours: Number of hours the lead System Pump has run since the pump became the lead. ƒ Reset Lead Pump: User selection allows the manual reset of the lead lag sequence. 3-38 © Fulton Group N.A., Inc. 2021...
  • Page 53 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 54 OPERATION SECTION 3 ModSyncSE-User-Manual-211020 PAGE LEFT INTENTIONALLY BLACK 3-40 © Fulton Group N.A., Inc. 2021...
  • Page 55 NETWORK INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS & SPECIFICATIONS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 56 ModSync®. this installation, operation and maintenance manual without notice. *Please contact Fulton to request a points list mapped for your equipment. Do not install, operate, service, or repair any component of this equipment unless you are qualified and fully understand all requirements and procedures.
  • Page 57 NETWORK SECTION 4 ModSyncSE-User-Manual-211020 Port 2 Wiring Diagram (Slave) RJ-11 Type Serial Port Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 58 Modbus Wiring: The Modbus communication wiring should be done in a ƒ daisy chain configuration. The wiring should be three wire shielded. The shield should be connected to earth ground at the ModSync® only. © Fulton Group N.A., Inc. 2021...
  • Page 59 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 60 COM tab (see image below) and enable the port, make sure the professional training, conduct, Modbus address you wish to use is within the defined range and select a baud and strict adherence to applicable rate of 19200. jurisdictional /professional codes or regulations © Fulton Group N.A., Inc. 2021...
  • Page 61 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 62 4. Select parameter 146 and set to 1 for 19200 baud rate, press Enter and then Escape (+ and -). 5. Select parameter 147 and set to 0 for no parity, press Enter and then Escape (+ and -). 6. Escape to get back to the main screen. © Fulton Group N.A., Inc. 2021...
  • Page 63 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 64 ‘UniApps’ . All information in this manual is for reference and guidance purposes, 3. Login using the information provided by Fulton or your Local Rep. and does not substitute for required professional training, conduct,...
  • Page 65 It should not, however be considered as a complete code of practice, nor should it replace existing codes or standards which may be applicable. Fulton reserves the right to change any part of this installation, operation and maintenance manual without notice.
  • Page 66 NETWORK SECTION 4 ModSyncSE-User-Manual-211020 PAGE LEFT INTENTIONALLY BLACK 4-12 © Fulton Group N.A., Inc. 2021...
  • Page 67 MAINTENANCE INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS & SPECIFICATIONS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 68 ________________, ______________ may be applicable. Fulton reserves Fulton Representative that sold the equipment: the right to change any part of _______________________________ this installation, operation and maintenance manual without notice.
  • Page 69 3. Select ‘Flash Memory’ from the ‘Information Mode Main Menu’ . existing codes or standards which may be applicable. Fulton reserves 4. Select ‘Backup User Application’ from the ‘Flash Memory’ menu. the right to change any part of this installation, operation and 5.
  • Page 70 MAINTENANCE SECTION 5 ModSyncSE-User-Manual-211020 PAGE LEFT INTENTIONALLY BLACK © Fulton Group N.A., Inc. 2021...
  • Page 71 NETWORK INTRODUCTION INSTALLATION OPERATION NETWORK MAINTENANCE PARTS & SPECIFICATIONS Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 72 6:00 20:00 -If- Proving Interlock is Enabled Friday 6:00 20:00 Proving Interlock Alarm Enabled Saturday 8:00 18:00 Interlock Alarm Delay 00:30 Sunday 8:00 18:00 Questions? Call (315) 298-8510, or visit us online at www.fulton.com © Fulton Group N.A., Inc. 2021...
  • Page 73 Modsync of practice, nor should it replace existing codes or standards which Outdoor Sensor Sampling 00:30 may be applicable. Fulton reserves Outdoor Sensor Bias the right to change any part of -If- Return Sensor is Enabled this installation, operation and...
  • Page 74 Pump Monitor Delay Tuesday Pump Monitor Retry Wednesday Monitor Retry Delay Thursday -If- Proving Interlock is Enabled Friday Proving Interlock Alarm Saturday Interlock Alarm Delay Sunday Questions? Call (315) 298-8510, or visit us online at www.fulton.com © Fulton Group N.A., Inc. 2021...
  • Page 75 System Pumps Boiler 8 Configuration VFD System Pumps Interface # of VFD System Pumps Hours VFD System Pump Control Cycles System Pump Sensor Questions? Call (315) 298-8510, or visit us online at www.fulton.com Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 76 For RTD sensors use 20-24 gauge three (3) conductor wire. Maximum length for RTD wiring is 200ft. Digital I/O: 18-gauge wire (Blue 24VDC(+), Yellow 24VDC(-) ) © Fulton Group N.A., Inc. 2021...
  • Page 77 Straight Through Ethernet Cable 2-45-001138 7' Ethernet Patch Cable Communication Modules (For LMV 3 & LMV 5) 2-45-000912 RS-232/485 Converter Module for LMV 3 Questions? Call (315) 298-8510, or visit us online at www.fulton.com Questions? Please Contact Your Local Manufacturer’s Representative...
  • Page 78 3 Position Switch 2-45-000309 2 Position Switch 2-40-000715 24VAC Transformer/Power Supply 2-40-000334 Honeywell Resistor Kit 2-45-000595 Hawkeye Current Sensing Switch 2-45-001040 24VDC Power Supply Questions? Call (315) 298-8510, or visit us online at www.fulton.com © Fulton Group N.A., Inc. 2021...
  • Page 79 Fulton Group N.A., Inc. Fulton Steam Solutions, Inc., Fulton Heating Solutions, Inc. & Fulton Thermal Corporation are part of Fulton Group N.A., Inc., a global manufacturer of steam, hot water and thermal fluid heat transfer systems.