Watts AERCO Edge Operation Manual
  1. Manuals
  2. Brands
  3. Watts Manuals
  4. Controller
  5. AERCO Edge
  6. Operation manual

Watts AERCO Edge Operation Manual

Controller for benchmark and cfr boilers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
•

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the AERCO Edge and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Watts AERCO Edge

Summary of Contents for Watts AERCO Edge

  • Page 1 •...
  • Page 2 SECTION 1: General Information Table of Contents • • •...
  • Page 3 SECTION 1: General Information • • •...
  • Page 4 SECTION 1: General Information • • •...
  • Page 5 SECTION 1: General Information • • •...
  • Page 6 SECTION 1: General Information SECTION 1: GENERAL INFORMATION 1.1 Introduction This Section provides an overview on operating Benchmark (BMK) and CFR Boilers using the Edge Controller. It provides information on the various external sensors and control devices that can interface with the units using terminals in the boiler’s Input/Output (I/O) Box.
  • Page 7 SECTION 1: General Information 1.3 Power Up Upon power-on, the splash screen and Main Menu appear. However, if the Screensaver Password 1.5.1) is enabled, the splash screen remains with “LOCKED” at the bottom of the feature (see Section screen. You must enter a password to get past the splash screen (see Figure 1-1: Splash Screen 1.4 Download Latest Firmware As AERCO is continuously implementing improvements to the Controller firmware, it is possible the...
  • Page 8 SECTION 1: General Information 1.5.1 Screensaver Password By default, users that have not been given a password have Level 0 access (this allows them to view parameters but excludes them from most functionality). However, Level 0 access can be restricted to users with an Edge password by enabling Screensaver Password.
  • Page 9 SECTION 1: General Information 1.7 Edge Controller Front Panel Functionality The Edge Controller contains a highly sensitive capacitive touchscreen that continuously checks for user interaction at a high frequency. The Controller’s front panel consists of a touchscreen display along with a variety of indicators and buttons, as shown below.
  • Page 10 SECTION 1: General Information The Soft-Keys on the Controller’s front face function as follows: Controller Front Panel Controls Icon Name Description Previous Takes you to the previous screen. Takes you to the touchscreen’s Main Menu (see Figure 1.6). If pressed Home during a procedure, it aborts the procedure.
  • Page 11 SECTION 1: General Information 1.8 Touchscreen Button Functionality The touchscreen buttons function as follows: Touchscreen Controls Icon Name Description Previous Takes you to the previous screen. Takes you to the touchscreen’s Main Menu (see Figure 1.6). If pressed during Home a procedure, it aborts the procedure.
  • Page 12 SECTION 1: General Information control; it switches to the opposite option, the background color changes, and the label indicates the current state, as shown on the right-hand image. Manual Mode Disabled Manual Mode Enabled Figure 1-7: Toggle Controls Some screens include a combination of “read only” and “user-selectable” parameters. Read-Only parameters appear as plain text on a back background.
  • Page 13 SECTION 1: General Information 1. A confirmation screen appears. Select Yes to abort the process. If no action is taken within 15 seconds, or if you select No, the abort is cancelled, and the process continues. Figure 1-10: Abort Confirmation Screen 2.
  • Page 14 SECTION 1: General Information messages have red lettering. • Setpoint is not displayed on the unit if BST mode is enabled. • The Max. Fire Rate parameter is displayed when the max fire rate is set to a quantity other than 100% and the unit Target Fire Rate is -1% or more from the Max Fire Rate.
  • Page 15 SECTION 2: EZ Setup (BENCHMARK ONLY) SECTION 2: EZ SETUP (BENCHMARK ONLY) The EZ Setup screen is accessed by pressing EZ Setup on the Main Menu. The function configures the unit as either a Standalone unit or as a Client or Manager in a Boiler Sequencing Technology (BST) Cascade group.
  • Page 16 SECTION 2: EZ Setup (BENCHMARK ONLY) 2.1 Backing Up and Restoring Settings The Edge Controller provides the option of saving the value of all parameters configured during setup to either the Controller’s internal memory or to an external USB device plugged into the side of the Controller.
  • Page 17 SECTION 2: EZ Setup (BENCHMARK ONLY) 3. The Select Configuration screen appears. Press Standalone. Press Next to continue. Figure 2-3: Standalone: Select Configuration Screen 4. The Time And Date screen appears. If both are correct, press Next to continue. If not, press either field and enter the correct time (4 digits) or date (8 digits) and then press Save.
  • Page 18 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-6: Standalone: Select Boiler Application(s) Screen 2.2.1 EZ Setup: Standalone – Space Heating Application Complete these instructions only if you chose Space Heating at the end of the previous Section. Figure 2-7: Standalone – Space Heating: Select Your Boiler Application Screen 1.
  • Page 19 SECTION 2: EZ Setup (BENCHMARK ONLY) 2. If you chose Constant Setpoint in Step 1, specify it in the parameter. Pressing Next takes you to the Select BAS Mode screen; skip to Section 2.4: Completing the Installation instructions. Figure 2-9: Standalone – Space Heating: Space Heating Constant Setpoint 3.
  • Page 20 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-12: Standalone – Space Heating: Comm Settings Screen C. If you chose either BAS or PWM, the Select BAS Mode screen appears; skip to Section 2.4: Completing the Installation for instructions. 4. If you chose Direct Drive, the Select Direct Drive screen appears. Choose the Direct Drive Type. Figure 2-13: Standalone –...
  • Page 21 SECTION 2: EZ Setup (BENCHMARK ONLY) 6. If you chose Outdoor Air Temperature Reset in Step 1, fill in the four OAR (outdoor air reset) temperature and setpoint parameters, and Warm Weather Shutdown temperature. Pressing Next takes you to the Select BAS Mode screen; skip to Section 2.4: Completing the Installation instructions.

  • Page 22: Section 2.4: Completing The Installation

    SECTION 2: EZ Setup (BENCHMARK ONLY) 2. If you chose Constant Setpoint in Step 1, the DHW Constant Setpoint screen appears. Specify the domestic hot water Setpoint. Pressing Next takes you to the Select BAS Mode screen; skip to Section 2.4: Completing the Installation for instructions.
  • Page 23 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-21: Standalone – DHW: Comm Settings Screen C. If you chose BAS, the Select BAS Mode screen appears. Skip to Section 2.4: Completing the Installation for instructions. 2.2.3 EZ Setup: Standalone – Other Application Complete these instructions only if you chose Other at the end of Section 2.2.
  • Page 24 SECTION 2: EZ Setup (BENCHMARK ONLY) 2. If you chose Constant Setpoint in Step 1, the Other Heating Constant Setpoint screen appears. Specify the . Pressing Next takes you to the Select BAS Mode screen; skip to Section 2.4: Completing the Installation for instructions.
  • Page 25 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-27: Standalone – Other: Comm Settings Screen C. If you chose BAS, the Select BAS Mode screen appears; skip to Section 2.4. 2.3 EZ Setup: Boiler Sequencing Technology Cascade If you are implementing AERCO’s Boiler Sequencing Technology (BST), complete the instructions in the next section to use the EZ Setup function to setup “Client”...
  • Page 26 SECTION 2: EZ Setup (BENCHMARK ONLY) 3. On the Select Configuration screen press BST Cascade, then press Next. Figure 2-29: BST Client: Select Configuration Screen 4. The Cascade Role screen appears. Set to BST Client, then press Next. Figure 2-30: BST Client: Cascade Role Screen 5.
  • Page 27 SECTION 2: EZ Setup (BENCHMARK ONLY) 6. If a previous setup was created and saved, the Load Settings screen appears. If you want to re-load Section 2.5: EZ Setup – Restoring a Previous Setup that setup, press Yes and see for instructions.
  • Page 28 SECTION 2: EZ Setup (BENCHMARK ONLY) Main Menu → EZ 1. Go to: Setup. 2. If the unit was previously setup, the EZ Setup screen appears showing a summary of the previous setup. You can Abort and retain the previous setup or press Next to continue. 3.
  • Page 29 SECTION 2: EZ Setup (BENCHMARK ONLY) 6. Fill in the settings on the Cascade Communication screen, described below. When done, press Next to continue. Figure 2-37: BST Manager: Manager Communication Screen NOTE: These parameters also appear in Section 6.3.2, where individual settings can be changed at a later time. •...
  • Page 30 SECTION 2: EZ Setup (BENCHMARK ONLY) this screen confirms your understanding of the state of all units in the cascade. Press Next to continue. STATUS CODES STBY Standby Fault MAN Manual SLIM Setpoint Limiting Ignition Figure 2-39: BST Manager: Unit Address Screen Do not continue past this screen unless it accurately represents the cascade you are creating.
  • Page 31 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-41: BST Manager: Select Boiler Applications Screen EZ Setup: BST Manager – Single Application If a single application was chosen above, complete the instructions in the one section below that matches that Application. EZ Setup: BST Manager –...
  • Page 32 SECTION 2: EZ Setup (BENCHMARK ONLY) NOTES: • If the outdoor air sensor is not connected, the display of the OAT (Outdoor Air Temperature) at the bottom of the screen is disabled. • If the header sensor is not connected, the bottom of the screen displays HDR = --- °F. For the header sensor to function without previous setup, the default for Outdoor Air Temp Sens parameter must set to Direct (see Section 6.3.1: Cascade...
  • Page 33 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-46: BST Manager – Space Heating: SH Analog Input Screen B. If you chose either Network or BAS, the Select BAS Mode screen appears; skip to Section 2.4: Completing the Installation for instructions. 4.
  • Page 34 SECTION 2: EZ Setup (BENCHMARK ONLY) EZ Setup: BST Manager – Domestic Hot Water Application Complete these instructions only if you chose Domestic Hot Water (DHW) at the end of Section 2.3.2. Figure 2-49: BST Manager – DHW: Select Your Boiler Application 1.
  • Page 35 SECTION 2: EZ Setup (BENCHMARK ONLY) 3. If you chose Remote Setpoint in step 1, the Select Remote Setpoint Type screen appears. Choose how the unit will access the setpoint, then press Next. Figure 2-52: BST Manager – DHW: Select Remote Setpoint Screen If you chose 4-20mA, or 0-20mA, the DHW Analog Input screen appears.
  • Page 36 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-54: BST Manager – Other: Select Your Boiler Application 1. The Other Operating Mode screen appears. Choose the operating mode for the “other” application, either Constant Setpoint or Remote Setpoint, then press Next to continue. Figure 2-55: BST Manager –...
  • Page 37 SECTION 2: EZ Setup (BENCHMARK ONLY) 3. If you chose Remote Setpoint in step 1, the Select Remote Setpoint Type screen appears. Choose how the unit will access the setpoint, then press Next. Figure 2-57: BST Manager – Other: Select Remote Setpoint Type Screen If you chose either 4-20mA or 0-20mA, the Other Analog Input screen appears.
  • Page 38 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-59: BST Manager – SH & DHW: Select Your Boiler Application 1. When both Domestic Hot Water and Space Heating applications are chosen, Domestic Hot Water priority mode is automatically activated and the DHW Priority screen appears (a green border appears on the previous choice, if there was one).
  • Page 39 SECTION 2: EZ Setup (BENCHMARK ONLY) NOTES: • If the outdoor air sensor is not connected, the OAT (Outdoor Air Temperature) parameter is disabled. • If the header sensor is not connected, the bottom of the screen will display HDR = --- °F. For the header sensor to function without previous setup, the default for HDR sensor must be sensor enabled and the source is Direct.
  • Page 40 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-64: BST Manager – SH & DHW: SH Analog Input Screen B. If you chose either Network or BAS, the DHW Operating Mode screen appears (skip to Step 6). 5. If you chose Outdoor Air Temperature Reset (OATR) in Step 2, the Select Outdoor Reset Mode screen appears.
  • Page 41 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-66: BST Manager – SH & DHW: Space Heating Outdoor Reset 6. Once all Space Heating parameters have been entered, the DHW Operating Mode screen appears. Choose either Constant Setpoint or Remote Setpoint then press Next. Figure 2-67: BST Manager –...
  • Page 42 SECTION 2: EZ Setup (BENCHMARK ONLY) 8. If you chose Remote Setpoint in step 6, the Select Remote Setpoint Type screen appears. Choose how the unit will access the setpoint, then press Next. Figure 2-69: BST Manager – SH & DHW: Select Remote Setpoint Type If you chose either 4-20mA or 0-20mA, the DHW Analog Input screen appears.
  • Page 43 SECTION 2: EZ Setup (BENCHMARK ONLY) 10. If was set to either 1 Swing Valve or 2 Swing Valves in Step 1, Domestic Hot Water Priority mode is automatically activated and the DHW Priority Swing Settings screen appears. Each unit in the cascade is represented by one square in the grid. Use this screen to specify which boiler(s) are dedicated to SH and DHW, and which are Swing boilers.
  • Page 44 SECTION 2: EZ Setup (BENCHMARK ONLY) • : Choose Swing Default SH or Swing Default DHW. • : Enter the address of the unit (1 to 16) with the DHW Pump • : Choose either Constant On or Controlled. 12. Once all parameters are configured, the Select BAS Mode screen appears. Skip to Section 2.4.
  • Page 45 SECTION 2: EZ Setup (BENCHMARK ONLY) 2. If you chose Constant Setpoint in Step 1 specify the Setpoint for the domestic hot water application. Press Next; the Other Operating Mode screen appears (skip to Step 4, below). Figure 2-75: BST Manager – DHW & Other: DHW Constant Setpoint Screen 3.
  • Page 46 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-77: BST Manager – DHW & Other: DHW Analog Input Screen 4. If you chose Network or BAS, the Other Operating Mode screen appears. When all DHW parameters have been configured, the Other Operating Mode screen appears. Choose either Constant Setpoint or Remote Setpoint.
  • Page 47 SECTION 2: EZ Setup (BENCHMARK ONLY) 6. If you chose Remote Setpoint in step 4, the Select Remote Setpoint Type screen appears. Choose how the unit will access the setpoint, then press Next. Figure 2-80: BST Manager – DHW & Other: Select Remote Setpoint Type If you chose either 4-20mA or 0-20mA, the Other Analog Input screen appears.
  • Page 48 SECTION 2: EZ Setup (BENCHMARK ONLY) Figure 2-82: BST Manager – SH & Other: Select Your Boiler Application 1. The SH Operating Mode screen appears. Choose desired operating mode and press Next. Figure 2-83: BST Manager – SH & Other: SH Operating Mode •...
  • Page 49 SECTION 2: EZ Setup (BENCHMARK ONLY) 3. If you chose Remote Setpoint in step 1, the Select Remote Setpoint Type screen appears. Choose how the unit will access the setpoint, then press Next. Figure 2-85: BST Manager – SH & Other: Select Remote Setpoint Type If you chose 4-20mA, 0-20mA, 1-5V, or 0-5V, the SH Analog Input screen appears.
  • Page 50 SECTION 2: EZ Setup (BENCHMARK ONLY) • : These parameters create the associated OATR curve. Once the curve has been set up, the controller will compute the setpoint based on outside temperature. • : Threshold outside temperature above which the unit shuts down. •...
  • Page 51 SECTION 2: EZ Setup (BENCHMARK ONLY) 7. If you chose Remote Setpoint in step 5, the Select Remote Setpoint Type screen appears. Choose how the unit will access the setpoint, then press Next. Figure 2-91: BST Manager – SH & Other: Select Remote Setpoint Type A.
  • Page 52 SECTION 2: EZ Setup (BENCHMARK ONLY) 2.4 Completing the Installation Complete the instructions below to complete the installation. If the unit will communicate with a BAS, you will select and configure the communicate protocol as well. 1. If the EZ Setup Complete screen appears, skip to Step 7. 2.
  • Page 53 SECTION 2: EZ Setup (BENCHMARK ONLY) 5. If you chose Modbus RTU, the BAS Modbus RTU Settings screen appears. Fill in the parameters for communications with BAS via Modbus RTU. Press Next to complete the setup (skip to Step 7). Figure 2-96: BAS Modbus RTU Settings Screen 6.
  • Page 54 SECTION 2: EZ Setup (BENCHMARK ONLY) For instructions on saving a setup, see Section 6.1.3: Save and Transfer Settings. ⚠ If you are transferring to/from Client or Manager units in a BST Cascade, note the following: Client and Manager units use separate setup files; Client units require a Client setup file, and Manager units require a Manager setup file.
  • Page 55 SECTION 2: EZ Setup (BENCHMARK ONLY) 4. Overwrite Calibration appears. Press Yes or No to proceed. Pressing Yes will overwrite the unit’s existing combustion calibration setting, while pressing No will retain those settings. Figure 2-101: EZ Setup: Settings Upload Complete Screen 5.

  • Page 56: Section 3: Calibration

    SECTION 3: Calibration SECTION 3: CALIBRATION The Calibration screen provides a number of tools to calibrate various of the unit’s components. It is accessed by pressing Calibration on the Main Menu. Figure 3.0: Calibration Screen This Section includes the following topics: 3.1: Assisted Combustion 3.2: Manual Combustion 3.3: Input/Output:...
  • Page 57 SECTION 3: Calibration 3.1 Assisted Combustion Calibration (Benchmark Only) NOTE: Assisted Combustion Calibration is not available on CFR boilers. Complete the instructions below to perform Assisted Combustion Calibration on the current unit. If you press the Back or Home buttons at any time before completion, the calibration operation is disabled and normal operation resumes.
  • Page 58 SECTION 3: Calibration Figure 3-2: Assisted Combustion: NOx Requirement Screen 7. The unit is put in Manual mode (but is not yet firing) and a message appears saying O2 Sensor Calibration in Progress. Wait 1 to 2 minutes for this step to complete. 8.
  • Page 59 SECTION 3: Calibration 11. Once the O level has been finalized for a given valve position, the Calibration Data Recording screen appears. Enter values in the NOx, CO and Flame Strength fields from the multimeter. Press Next to continue. Figure 3.1-5: Assisted Combustion: Calibration Data Recording Screen •...
  • Page 60 SECTION 3: Calibration Main Menu → Calibration → Combustion 1. Go to: Calibration. If the O sensor is not connected, a message appears saying that combustion calibration cannot be performed and this function aborts. If that occurs, connect the O sensor and then repeat Step 1.
  • Page 61 SECTION 3: Calibration CALIBRATION PRESET FINE VP STEP TARGET CALIBRATION ACTUAL CALIBRATION STEP CONTROLS ENABLED VALUES VALUES ENTER DOWNSTREAM GAS BLOWER VOLTAGE ENTER VALUES FROM CONTROLS MULTIMETER PRESSURE HERE Figure 3-7: Manual Combustion: Manual Combustion Calibration Screen 5. Change the valve position to 30% and press Go, verify that the unit has ignited and is operating as expected, then use ...
  • Page 62 SECTION 3: Calibration 3.3 Input/Output Complete the instructions below to view the current reading of the system’s sensors, and either calibrate the sensor or enter offset values. Note, this does not apply to the two Over-Temperature Limit Switches mounted on the front of the unit just under the I/O board; instructions for checking and configuring those switches are in the Benchmark Edge: Operation-Service Manual (OMM-0137, GF-211).
  • Page 63 SECTION 3: Calibration Main Menu → Calibration → Input/Output → Temperature 1. Go to: Sensors. 2. Press the parameter and select the temperature sensor you want to view: • • Exhaust Outdoor Temp • • Air Inlet Lower Inlet • •...
  • Page 64 SECTION 3: Calibration 3.3.3 Analog Inputs The Analog Inputs screen allows you to calibrate all the available analog inputs, such as a sensor, a remote signal, or feedback from a device such as a valve. If reliable feedback or external instrumentation indicates the reading is inaccurate, you can adjust its reading via the parameter.
  • Page 65 SECTION 3: Calibration 4. This screen includes the following additional parameters: • Board Reference: Displays how the input connects to the Edge Controller, either through the unit’s wiring harness or to specific pins on the unit’s I/O Board (see the I/O board map in Section 2.11 of the Edge Installation Manual, OMM-0136, GF-210).
  • Page 66 SECTION 3: Calibration 3. If you chose Spare Analog Out 1 or 2 in step 2, the Function parameter provides a read-only display of the function the output has been assigned, either Valve or Other. 4. The Board Reference shows I/O Board pins to which the output selected in Step 2 is connected or shows “On Harness”.
  • Page 67 SECTION 3: Calibration 3.4.1 Air Fuel Valve Calibration Complete the instructions below to calibrate the Air/Fuel Valve. Figure 3-14: Subsystem: Air/Fuel Valve Calibration Screen Main Menu → Calibration → Subsystem → Air Fuel 1. Go to: Valve. 2. Before calibration, you have the option of adjusting the A/F Sensitivity. (Range: 1% to 5%) 3.
  • Page 68 SECTION 3: Calibration 3.4.2 Spark Monitor Calibration (Benchmark Units Only) The Spark Monitoring screen gives you the option of bounding the Spark Monitor’s measurement range by specifying the minimum and maximum spark current. Figure 3-16: Subsystem: Spark Monitor Screen – Spark Monitor Enabled Main Menu →...

  • Page 69: Section 4: Diagnostics

    SECTION 4: Diagnostics SECTION 4: DIAGNOSTICS The Diagnostics menu provides access to a number of tools you can use to diagnose a suspected or observed fault. It is accessed by pressing Diagnostics on the Main Menu Figure 4-1: Diagnostics Menu This Section includes the following topics: 4.6: Communication &...
  • Page 70 SECTION 4: Diagnostics To put the unit in Manual Mode: Main Menu → Diagnostics → Manual 1. Go to: Run. Figure 4-2: Diagnostics: Manual Run Screen – Manual Mode Enabled 2. Enable the toggle. The red Manual LED lights on the Controller’s front face turns on, the unit shuts down (if not already) and stays in Manual Mode until it is disabled from this screen, or until the session times-out.
  • Page 71 SECTION 4: Diagnostics 3. To perform a test, press its toggles: • Touchscreen Display Test: Sequentially displays five colors, full-screen, for 5 seconds each. Observe each screen to determine if any pixels fail to show any color. The test ends after the 5 color is displayed.
  • Page 72 SECTION 4: Diagnostics Figure 4-6: Diagnostics: Keypad and Switch Test Screen 4.3 Analog Outputs and Relays The Analog Outputs and Relays screen allows you to test the unit’s relays and analog outputs. This screen is accessible only in Manual Mode. To run relays and analog output diagnostics: Main Menu →...
  • Page 73 SECTION 4: Diagnostics Main Menu → Diagnostics → Analog Outputs and Relays → 1. Go to: Relays. Benchmark Figure 4-8: Analog Outputs and Relays: Relays Screens NOTE: Swing Valve 1 Relay does not appear on CFR units 2. Press the relay you want to test; it turns green, enabling it for 1 minute, after which it is automatically disabled.
  • Page 74 SECTION 4: Diagnostics DEFAULT MODE MANUAL MODE Figure 4-10: Analog Outputs and Relays: Analog Outputs Screen (CFR) 2. In Default mode, this screen is grey and displays the current value of all analog outputs. 3. If you press the Manual button, the unit’s fire rate is reduced to zero and the sliders turn green. You can now manually adjust the position of one or more of the outputs and verify the behavior of the selected output(s).
  • Page 75 SECTION 4: Diagnostics 4.4.1 Testing the Air/Fuel Valve Stepper Motor Main Menu → Diagnostics → Subsystems → Air Fuel Valve Stepper 1. Go to: Motor. Figure 4-12: Subsystems: Air Fuel Valve Stepper Motor Test Screen 2. Press the control to initiate the test. This will start one full cycle of the Air Fuel Valve, from fully closed to fully open then back to closed.
  • Page 76 SECTION 4: Diagnostics 4.4.3 Ignition Complete the instructions below to test the ignition system. NOTE: the Safety Shutoff Valve does not open during this test. Main Menu → Diagnostics → Subsystems → 1. Go to: Ignition. Figure 4-14: Subsystems: Ignition Screen 2.
  • Page 77 SECTION 4: Diagnostics 4.5 System From the System screen you can run a programmable profile, manually ramp the fire rate up or down, perform a pre-startup diagnostic or view a software version summary. Main Menu → Diagnostics → 1. Go to: System.
  • Page 78 SECTION 4: Diagnostics 4.5.2 Versions Version Information displays the current version of the Controller’s various firmware components. Figure 4-18: System: Versions Information Screen 4.6 Communication & Failsafe The Communication & Failsafe screen provides access to screens that can be used to verify IP, onAER and BAS communication, and check the status of communication with smart devices and available space on a USB device plugged into the side of the Controller.
  • Page 79 SECTION 4: Diagnostics 4.6.1 IP Network The IP Network option is used to check the IP interface used by onAER or BAS. Main Menu → Diagnostics → Communication & Failsafe → IP Network Go to to view the available parameters. Figure 4-21: Communication &...
  • Page 80 SECTION 4: Diagnostics 4.6.3 onAER (Benchmark Units Only) The onAER screen displays several onAER communication parameters and provides the option to perform two functionality and communication tests. Main Menu → Diagnostics → Communication & Failsafe → 1. Go to onAER. Figure 4-23: Communication &...
  • Page 81 SECTION 4: Diagnostics Figure 4-24: Communication & Failsafe: Smart Device Screen 4.6.5 USB Storage If a USB device is plugged into the port on the Controller’s left side, the USB Storage screen displays parameters about that device (if no device is plugged in the screen displays the parameter).
  • Page 82 SECTION 4: Diagnostics 2. The following is an example of the data in the Input/Output Summary screen. Air Inlet: 40°F Supply Header: 180°F Exhaust: 240°F Return Header: 180°F Outlet: 140°F Outside Temp: 40°F Lower Inlet: 40°F Supply Loop 2: 180°F Upper Inlet: 40°F Return Loop 2:...
  • Page 83 SECTION 5: Trending SECTION 5: TRENDING The Controller provides two “Trending” graphs, which each display up to four selectable parameters. It is accessed by pressing Trending on the Main Menu. Figure 5-1: Trending Screen This Section includes the following topics: 5.1: Fast Logging Settings and Graph 5.2: Slow Logging Settings and Graph The Edge Controller provides two Trending graphs:...
  • Page 84 SECTION 5: Trending 5.1 Fast Logging Settings and Graph Complete the instructions below to select the settings and display the Fast Logging graph. Main Menu → Trending → Fast Logging 1. Go to: Settings. Figure 5-2: Trending: Fast Logging Settings Screen 2.
  • Page 85 SECTION 5: Trending 5.2 Slow Logging Settings and Graph Complete the instructions below to select the parameters for the Slow Logging graph. Main Menu → Trending → Slow Logging 1. Go to: Settings. Figure 5-5: Trending: Slow Logging Settings Screen 2.
  • Page 86 SECTION 5: Trending 4. Press Back to return to the Slow Logging Settings screen. Any new selection will create a new plot; the previous selection will be deleted. 5. Press the Back button to return to the Slow Logging parameters screen. 6.

  • Page 87: Section 6: Advanced Setup

    SECTION 6: Advanced Setup SECTION 6: ADVANCED SETUP The Advanced Setup screen provides access to specific parameters. It is accessed by pressing Advanced Setting on the Main Menu. Benchmark Figure 6-1: Advanced Setting Screen This Section includes the following topics: 6.1 Access 6.4: Communication &...
  • Page 88 SECTION 6: Advanced Setup 6.1 Access The Enter Password screen allows you to log in to the system. As mentioned in Section 1.6, there are multiple passwords, each granting a specific level of access. Figure 6-2: Advanced Setup: Enter Password Screen Main Menu →...
  • Page 89 SECTION 6: Advanced Setup Main Menu → Advanced Setup → Unit → Unit 1. Go to: Settings. Figure 6-4: Unit: Unit Settings Screens (Benchmark) Figure 6-5: Unit: Unit Settings Screens (CFR) 2. The following fields are available: • Unit Serial #: Displays the unit’s factory-set serial number in a unique format of G-YY-ZZZZ or N-YY-ZZZZ.
  • Page 90 SECTION 6: Advanced Setup Figure 6-6: Unit: Enter Date & Time Screens • Time Format: Choose the 12 Hour or 24-Hour format. • Vent Type: Select from unit-type-specific venting options: PVC, cPVC, Polypro or Stainless Steel. For CFR boilers, the available venting type is Category I. •...

  • Page 91: Unit Of Measure

    SECTION 6: Advanced Setup • BST Return Display: Enables/ disables display of the BST Return Header sensor. It should be enabled only when utilizing a BST return header sensor. BST Return Display is only applicable to Benchmark boilers; it is not applicable to CFR boilers. •...
  • Page 92 SECTION 6: Advanced Setup 2. The following fields are available: Upper Left Display: Choose between: Setpoint and Water Inlet Upper Right Display: Choose between: Water Outlet and System Header Multi-Function Bar: Choose Multi-Function Bar display: Fire Rate or Valve Position. Brightness: Touchscreen brightness (range: 10 to 100%) Screensaver Password: Determines whether all users need a password to access functionality.
  • Page 93 SECTION 6: Advanced Setup 2. Choose one of the following: • To save the current settings, press Save All Settings and then complete the instructions in Section 6.2.3.1: Save Settings. AERCO strongly recommends using this option periodically to guard against the need to perform a time-consuming recreation of the original setup •...
  • Page 94 SECTION 6: Advanced Setup Restore ALL Settings Option Restore COMMON Settings Option Figure 6-11: Unit: Restore Source/Common Screens 1. Choose where the setup was saved (see Section 6.2.3.1: Save Settings): • USB: If the setup was saved to a USB device plugged into the Controller’s USB port. •...
  • Page 95 SECTION 6: Advanced Setup Main Menu → Advanced Setup → Unit → Fault 1. Go to: Management. Figure 6-13: Unit: Fault Management Screen 2. Choose the desired reset mode, Manual or Automatic, for all three fault conditions. • : Loss of electrical power. •...
  • Page 96 SECTION 6: Advanced Setup 6.2.6 Unit Application Configuration This screen shows operating mode, temperature and setpoint parameters for Standalone units. • This option is disabled (greyed out) if = BST Client or BST Manager in Section 6.3.1: Cascade Configuration, below (it appears only if = Off).
  • Page 97 SECTION 6: Advanced Setup 4. Depending on the Application and Operating Mode chosen in Steps 2 and 3, a number of additional parameters appear. The table below shows which parameters appear for each combination of Application and numbered Operating Mode. TABLE 6.2: Unit Application Configuration Parameters Unit Applications &...
  • Page 98 SECTION 6: Advanced Setup 6. If = SH, chose one of the five Unit SH Operating Mode = Constant Setpoint Unit SH Operating Mode = Remote Setpoint Figure 6-16: Unit Application Configuration, Application = SH A. If = Constant Setpt, specify the space heating setpoint in the parameter.
  • Page 99 SECTION 6: Advanced Setup Figure 6-18: Unit Application Configuration, Application = SH • Outdoor Air Temp Sens: Choose the Outdoor Sensor signal type: Network, Direct, BAS or Off. For all options except Off, the following additional parameters appear: o BST Outdoor Temp: A read-only display indicating how the unit communicates with the Outdoor Air Temp Sensor.
  • Page 100 SECTION 6: Advanced Setup 7. If = DHW, choose the for the unit, either Constant Setpt or Remote Setpt. Figure 6-19: Unit Application Configuration, Unit DHW Remote Signal = Network A. If = Constant Setpt, specify the setpoint for DHW operation in parameter.
  • Page 101 SECTION 6: Advanced Setup 8. If = Other, choose one of two , either Constant Setpt or Remote Setpt. NOTE: Unit Application = Other only applies to Benchmark boilers (not available on CFR boilers). Unit Other Operating Mode = Constant Setpoint Unit Other Operating Mode = Remote Setpoint Figure 6-20: Unit Application Configuration, Unit Application = Other = Constant Setpt, specify the “other”...
  • Page 102 SECTION 6: Advanced Setup Figure 6-21: Unit: Application Configuration, Unit Other Remote Signal = Network "Pump Off Delay" is the last setting in the Unit Application Configuration menu. 6.2.7 Firmware Update When AERCO releases a new Controller firmware version, there are two options for obtaining it; both require the firmware to first be downloaded to a USB device: Option 1: Download it to an external computer and then save it on a USB device –...
  • Page 103 SECTION 6: Advanced Setup The Intelligent BootLoader looks for the appropriate file on the USB device and looks for the most recent version of that firmware. For Example, a USB device could contain the following files: 1. BMK_V509014_Boiler Firmware 2. BMK_V509015_Boiler Firmware 3.
  • Page 104 SECTION 6: Advanced Setup 4. Chose where you want to save the current setup: • Onboard: Saves the current setup file to the Controller’s onboard memory. • USB: This option is available only if an un-encrypted USB device is plugged into the Controller’s USB port;...

  • Page 105: Ethernet Port

    SECTION 6: Advanced Setup If you are an ATT or AMT, complete the following instructions to obtain the latest Edge firmware. 1. Plug the USB device into an external computer that can write to un-encrypted USB devices. 2. Go to the following URL: http://learning.aerco.com.
  • Page 106 SECTION 6: Advanced Setup 8. Progress is displayed as files are downloaded. Once completed, the screen displays Downloads Complete. If an error message is displayed, repeat the previous step, or complete the instructions in the previous section to download the file(s) to a USB device plugged into an external computer. Figure 6-26: Firmware Update Screen NOTE: The download only needs to be performed once on a single USB device.
  • Page 107 SECTION 6: Advanced Setup Figure 6-28: Graphics Processing Screen 7. To ensure the firmware update was successful, you must now turn the boiler’s power OFF and then back ON. Continue with the next step after restarting the boiler. 8. Once the Controller restarts, set the Enable/Disable switch back to Enable and remove the USB device.
  • Page 108 SECTION 6: Advanced Setup 2. Choose Restore All Settings; the Restore Source screen appears. Figure 6-30: Restore Source Screens 3. Choose where you saved the setup (in Section 6.2.7.3), then press either: • USB if the same USB device is still plugged in. •...
  • Page 109 SECTION 6: Advanced Setup 3. The Bootloader starts but does not complete: a. Check the Status code in the upper right LED Display: i. Code 5 - USB Device Not Found. 1. The USB device is not the correct type. Obtain a correct one. 2.
  • Page 110 SECTION 6: Advanced Setup Main Menu → Advanced Setup → Unit → 1. Go to: Maintenance. Figure 6-32: Unit: 12 Month Maintenance Screen Figure 6-33: Unit: 24 Month Maintenance Screen 2. Either the 12 Month Maintenance or 24 Month Maintenance screen appears, depending on which cycle is coming up next.
  • Page 111 SECTION 6: Advanced Setup 6.3 BST Cascade The BST Cascade screen provides options to alter BST Cascade system settings. Main Menu → Advanced Setup → BST 1. Go to: Cascade. Figure 6-34: Advanced Setting: BST Cascade Screen 2. All the options on this screen are greyed out (disabled) except Cascade Configuration until BST Cascade functionality has been enabled (see Step 2 in the next Section).
  • Page 112 SECTION 6: Advanced Setup 2. To designate the current unit as a BST Client or BST Manager, press and choose BST Client or BST Manager. Unit Mode = BST Client Unit Mode = BST Manager Figure 6-36: BST Cascade: Cascade Configuration Screen 3.
  • Page 113 SECTION 6: Advanced Setup ✓ ✓ 3 DHW Temp Sensor ✓ ✓ 3a DHW Hdr Sens Point (Item 3 = Network or BAS) ✓ ✓ 3b DHW Temp Unit Addr (Item 3 =Direct) ✓ ✓ ✓ 4 Rtn Hdr Temp Sensor ✓...
  • Page 114 SECTION 6: Advanced Setup o BAS: Choose this option if header temperature is received from the site’s Building Automation System. o OFF: Disables header temperature sensor feedback functionality. • Item 3 : Choose how to communicate with the sensor: o Off: Disables DHW temperature sensor functionality. o Network: Choose this option if DHW temp sensor is wired to the Modbus transmitter.
  • Page 115 SECTION 6: Advanced Setup 5d – ▪ : The Modbus point within the Modbus address of the Outside Air Temp Sensor (Range: 0 to 255, default = 15). • Item 6 – : The variable speed pump (VSP) feature is applicable only in a primary-secondary piping arrangement.

  • Page 116: Section 6.3.1: Cascade Configuration

    SECTION 6: Advanced Setup 6.3.2 Cascade Communication The Cascade Communication screen allows you to modify individual communication parameters. NOTES: • This screen is available only after BST functionality has been enabled (see the parameter in Section 6.3.1: Cascade Configuration). If the unit is configured as a BST Manager, its parameters apply to this unit and all BST Client units.
  • Page 117 SECTION 6: Advanced Setup • : The timeout value before a Modbus Fault is declared due to no response from the BST Manager unit or (if a Manager) from the BAS. (Range: 5 – 999) • : The number of Modbus Comm errors allowed before invoking a Modbus Comm Fault.
  • Page 118 SECTION 6: Advanced Setup APPLICATION = OTHER APPLICATION = SH+DHW-1Vlv Figure 6-38: BST Cascade: Application Configuration – Example 1 Screens 2. Choose the for the unit: TABLE 6.4a: Applications – Benchmark boilers 1 SH (Space Heating) 5 SH+DHW-1-Vlv (1 Swing Valves) 2 DHW (Domestic Hot Water) 6 SH+DHW-Stpt Prty (SH Setpoint Priority) 3 Other...
  • Page 119 SECTION 6: Advanced Setup ✓ Warm Weather Shutdown ✓ OAR Min Outside Temp ✓ OAR Max Setpoint ✓ OAR Max Outside Temp ✓ OAR Min Setpoint * Outdoor Air Reset requires a header temp sensor and an outdoor air temp sensor to be connected to the one of the units in the cascade, either directly, via the network or BAS.
  • Page 120 SECTION 6: Advanced Setup TABLE 6.9: Application = Other+SH-Stpt Prty (applicable to Benchmark boilers only; not applicable to CFR boilers) Other SH PRI Setpt Mode Other SH PRI Setpoint (if Other SH PRI Setpt Mode = Constant Setpoint) Other SH PRI Remote Signl (if Other SH PRI Setpt Mode = Remote Setpoint) TABLE 6.10: Application = Other+DHW-Stpt Prty (applicable to Benchmark boilers only;...
  • Page 121 SECTION 6: Advanced Setup TABLE 6.11: Parameter Descriptions. NOTE: Applications are numbered from 1 to 8, per Table 6.4a and 6.4b, in Step 2 above. Item Name Description (Application = 1, 3 – 7, SH Operating Mode = Outdoor Air Reset, Outdoor Air Temp Sens ≠OFF in Cascade Configuration screen) The threshold outside temperature Warm Weather above which the unit shuts down.
  • Page 122 SECTION 6: Advanced Setup TABLE 6.11: Parameter Descriptions. NOTE: Applications are numbered from 1 to 8, per Table 6.4a and 6.4b, in Step 2 above. Item Name Description DHW Setpoint (Application = 6, 8) In “Setpoint Priority Mode”, when both Space Heating/Other and Offset DHW loads are active, this is the DHW Setpoint Boost Value.
  • Page 123 SECTION 6: Advanced Setup Main Menu → Advanced Setup → BST Cascade → Operating 1. Go to: Controls. Figure 6-39: BST Cascade: Operating Controls Screen Sequencing Controls The Sequencing Controls screen offers options related to sequencing of units in the plant. NOTES: •...
  • Page 124 SECTION 6: Advanced Setup 3. The remaining parameters are available on both BST Manager and BST Client units. They are available depending on the Application chosen in Section 6.3.3, as shown in the table below: TABLE 6.12: Sequencing Control Parameters Current BST Application NOTE: All applications apply to Benchmark boilers;...
  • Page 125 SECTION 6: Advanced Setup • High Fire Threshold Timer: This parameter specifies the amount of time between when the SH High-Fire Fire Rate or DHW High-Fire Fire Rate condition is met and the time the swing unit switches over to the secondary application. (Range: 1 to 30 mins.) •...
  • Page 126 SECTION 6: Advanced Setup Temperature Control The Temperature Control screen provides parameters that can be used to fine-tune the temperature responsiveness and limitations under which the plant operates. • NOTE: This screen is available only after BST Cascade functionality has been enabled (see parameter in Section 6.3.1).
  • Page 127 SECTION 6: Advanced Setup Advanced Setup → BST Cascade → Operating Controls → Valve 1. Go to: Configuration. SELECT OUTPUT = CASCADE VALVE SELECT OUTPUT = Aout 2 Figure 6-43: Operating Controls: Valve Configuration Screen 2. In , choose either: •...
  • Page 128 SECTION 6: Advanced Setup parameters apply to this unit and all BST Client units. If the unit is configured as a BST Client, the parameters configured on the BST Manager will take precedence. Advanced Setup → BST Cascade → Operating Controls → Reserve Unit 1.
  • Page 129 SECTION 6: Advanced Setup Advanced Setup → BST Cascade → Operating Controls → Setpoint 1. Go to: Range. The parameters on this screen depend which is chosen in Section 6.3.3, as shown in the table below. Application = SH (Space Heating) Application = SH+DHW-Stpt Prty Figure 6-45: Operating Controls: Setpoint Range Screen TABLE 6.13: Setpoint Range Parameters...
  • Page 130 SECTION 6: Advanced Setup 4. Set the parameter to Enabled to Disabled. If Enabled, this feature will lower the Setpoint during periods of reduced demand for heat, such as at night. If Enabled, the following additional parameters appear (these same three parameter also appear in Section 6.6.2.3 and can be changed in either screen):...
  • Page 131 SECTION 6: Advanced Setup Prior to balancing, in normal operation all isolation valves are either fully closed or fully open (0% or 100% open). Valve balancing is accomplished by reducing the isolation valve’s “fully open” position, thereby restricting the flow from the unit’s hot water outlet, as needed, until the unit’s T matches the plant’s target T.
  • Page 132 SECTION 6: Advanced Setup Figure 6-48: Operating Controls: Manual Valve Balancing Screen 4. To begin balancing, press the Start button. A screen opens prompting you to specify the A/F Valve position, which will be used on all units during balancing. AERCO suggests choosing an A/F Valve position that is typical in your normal, everyday operation, such as 40% to 60%.
  • Page 133 SECTION 6: Advanced Setup Figure 6-50: Operating Controls: Manual Valve Balancing Screen 10. Use the Valve Signal controls to adjust the voltage sent to the isolation valve. Note the following: • Before Balancing, fully open = 0.00V, fully closed = 10.00V •...
  • Page 134 SECTION 6: Advanced Setup Figure 6-51: Operating Controls: Valve Balancing – Abort Screen 15. If the system experiences three or more over-temperature faults during valve balancing, the function will be interrupted, and the following screen displayed. Abort or retry this operation. Figure 6-52: Operating Controls: Valve Balancing Stopped Screen 16.
  • Page 135 SECTION 6: Advanced Setup VALVE POSITION SIGNAL INDICATOR (LOOK FOR ARROW – SHOWN “ON”) POSITION ARROW INSIDE THIS VALVE POSITION INDICATOR “VALVE ON” ARC (SHOWN OPEN) Figure 6-53: Operating Controls: Isolation Valve 17. Repeat the previous step on all other units that have been balanced. 6.3.5 SmartPlate Communication The SmartPlate Communication screen provides parameters for configuring communication between SmartPlate units and a “Manager”...
  • Page 136 SECTION 6: Advanced Setup 2. This screen contains the following parameters: • : Quantity of SmartPlate units in BST Cascade. (Range: 0 to 6) • : The address of the first SmartPlate in the BST Cascade. (Range: 50 to 54) •...
  • Page 137 SECTION 6: Advanced Setup 1. The default is Off. To enable communication with a BAS, press and choose the protocol: • • BACnet IP Modbus TCP • • BACnet MSTP Modbus RTU Figure 6-57a: Communication & Failsafe: BAS Screen, BAS = BACnet IP Figure 6-58b: Communication &...
  • Page 138 SECTION 6: Advanced Setup Figure 6-60: Communication & Failsafe: BAS Screen, BAS = Modbus RTU 2. The table below lists the parameters available depending on the option chosen in Step 2: TABLE 6.14: BAS Parameters BACnet Modbus Parameters Available MSTP ✓...
  • Page 139 SECTION 6: Advanced Setup • : Choose whether to Enable or Disable BAS Security. This option prohibits communication to any devices as specified by the IP address and MAC address, per parameters below. If enabled, the following additional parameters appear: : Specifies the IP address of the BAS server.
  • Page 140 SECTION 6: Advanced Setup 6.4.3 Smart Devices (Benchmark Only) The Smart Devices screen provides parameters for establishing and configuring Bluetooth communication with a smart device. Main Menu → Advanced Setup → Communication & Failsafe → Smart Go to: Devices. Figure 6-62: Communication & Failsafe: Smart Devices Screen – Shown Enabled 1.
  • Page 141 SECTION 6: Advanced Setup Main Menu → Advanced Setup → Communication & Failsafe → 1. Go to: Ethernet. DHCP Enabled DHCP Disabled Figure 6-63: Communication & Failsafe: Ethernet Screen 2. If is Disabled, manually enter the communication parameters, typically provided by a network administrator, in the following parameters: •...
  • Page 142 SECTION 6: Advanced Setup 6.5 Ancillary Devices The Ancillary Devices screen allows configuration of all unit inputs and outputs. Main Menu → Advanced Setup → Ancillary 1. Go to: Devices. Figure 6-65: Advanced Setting: Ancillary Devices Screen 6.5.1 Interlocks The Controller offers two interlock circuits, Remote Interlock and Delayed Interlock, both of which can interface with an Energy Management Systems (EMS) or a Building Automation System (BAS) and auxiliary equipment such as pumps or louvers.
  • Page 143 SECTION 6: Advanced Setup 3. The following parameters configure the Delayed Interlock. This includes an adjustable delay timer, which delays the ignition sequence, allowing time for a proving switch to be made to prevent a fault. • : Choose Valve 1, Valve 2, Louver or Louver 2. •...

  • Page 144: Dhw Demand

    SECTION 6: Advanced Setup V2/Spare 1 Relay Names Spare 2 Relay Names • Damper • • Damper • Pump 2 Other • Louver • • Louver • System Pump Pump 2 • Louver 2 • Louver 2 • System Pump 4.
  • Page 145 SECTION 6: Advanced Setup 2. In the parameter, choose the analog output you want to configure. These outputs attach to the unit’s I/O box strip J5, on the pins shown below. • Spare Analog Out 1 – pin 7 Spare Analog Out 1+ pin 8 Spare Analog Out 1- •...
  • Page 146 SECTION 6: Advanced Setup 6. For all values of except Not Assigned, configure the remaining parameters for the input chosen in Step 2: • : Enter values in the Min and Max Signal Level parameters. These two values define the range of the input signal. (Range: 0 to 100). •...
  • Page 147 SECTION 6: Advanced Setup Main Menu → Advanced Setup → Performance → 2. Go to: AERtrim. Figure 6-71: Performance: AERtrim Screen AERtrim Settings AERtrim functionality is enabled/disabled and configured on this unit from the AERtrim Settings screen. NOTE: AERtrim must be activated before it can be enabled. When available, it is activated on Benchmark units before they are shipped.
  • Page 148 SECTION 6: Advanced Setup • : Specifies the amount of time for the blower speed to settle after adjusting the blower voltage. (Range: 5 to 120 seconds) • : A multiplier used to calculate an offset to the blower voltage. (Range: 0.100 to 0.500) •...
  • Page 149 SECTION 6: Advanced Setup Main Menu → Advanced Setup → Performance → AERtrim → AERtrim 1. Go to: Status. Figure 6-74: AERtrim: AERtrim Status 2. This screen displays the following “read only” parameters: • : The current Auto Calibration status. •...
  • Page 150 SECTION 6: Advanced Setup PID Setting The PID Setting screen provides access to PID parameters associated with Space Heating, Other and DHW applications, plus the option to restore factory PID defaults. Figure 6-76: Temperature Control: PID Setting This screen includes the following parameters: •...
  • Page 151 SECTION 6: Advanced Setup This screen includes the following parameters: • : These two settings create an “outlet temperature” zone in & which no Valve Position corrections will be attempted. This zone operates with an outlet temperature between Active Setpoint + Deadband High and Active Setpoint – Deadband Low. (Range: 0 to 25°F for both) •...
  • Page 152 SECTION 6: Advanced Setup 3. The following Setpoint parameters are available for all values of the parameter: • Setpoint Limiting: If Enabled, the Setpoint Limit Band appears (see below) and Setpoint Limit functionality is enabled. This functionality acts as a temperature limiting governor. Should a unit’s outlet temperature equal Setpoint High Limit, a PID function will intervene and maintain the outlet temperature at the Setpoint High Limit minus the Setpoint Limit Band: Setpoint Limit Band: (If Setpoint Limiting = Enabled): How far below Setpoint High Limit the...
  • Page 153 SECTION 6: Advanced Setup Ignition Control The Ignition Control screen displays parameters related to ignition that apply to this unit only. Figure 6-81: Fire Control: Ignition Control The following ignition control parameters are available: • : Sets the air fuel valve position at which the unit will ignite. This allows you to set the air fuel valve position during the ignition sequence (5% to 60%) •...
  • Page 154 SECTION 6: Advanced Setup • : Sets maximum allowable valve position for the unit. (Range: 40 to 100%) • : Sets blower voltage when the unit is in Standby Mode, during which the blower motor remains “ON” at low speed, to limit power cycles. AERCO recommends keeping the default.
  • Page 155 SECTION 6: Advanced Setup 6.7 Stack Guard Configuration (CFR Only) Stack Guard Configuration is only applicable to CFR boilers. It is not applicable to Benchmark boilers. The CFR boiler’s Stack Guard sensor is field-installed in the factory-provided vent starter section. The Edge controller ensures the Stack Guard temperature stays above the Stack Guard Low Limit to prevent condensation in the flue.
  • Page 156 SECTION 6: Advanced Setup Parameter Name Type Description This is the target valve position after the boiler firing rate has been increased by the Target Valve Position Read Only Fire Rate Offset. Numerical Amount of time allowed for boiler to settle before further increasing the firing rate Unit Settling Time Entry with the Fire Rate Offset.

  • Page 157: Section 7: Unit Status

    SECTION 7: Unit Status SECTION 7: UNIT STATUS The Unit Status screen provides access to a variety of parameters that show the status of the unit. In addition, in a BST Cascade, on the unit designated as a “Manager,” it provides access to screens that display parameters showing the status of the entire cascade.
  • Page 158 SECTION 7: Unit Status Unlike most areas of the system, navigation is performed exclusively with the Page Left and Page Right arrows to move from screen to screen in round-robin fashion. The order of navigation depends on whether the unit is part of a BST Cascade or a standalone unit. The order of navigation is as follows: Screen Name Standalone ✓...
  • Page 159 SECTION 7: Unit Status 7.1.1 Demand 1. Upon a demand for heat, the Demand rectangle turns green, and, if the sequence has a delay timer, those timers display appropriate values. 2. Upon expiration of the internal 4 second IGST Demand delay and the unit progresses to the Auxiliary Delay sequence.
  • Page 160 SECTION 7: Unit Status 7.1.3 Purging 1. All switches required to be met during the purge cycle (as shown above) have a checkbox, which changes to green once the switch is met. If any switch fails to be proven, its checkbox will turn red with a white X and the unit will display a fault message explaining the failure.
  • Page 161 SECTION 7: Unit Status 2. The Valve Position Out and Blower Voltage continue from the Purging sequence. 3. The Spark Current (amps draw from spark across igniter) is displayed. If this value goes outside the set threshold range (typically 0.1 to 0.4 A), the Spark Cleaning rectangle turns red and Spark Current Fault is displayed.
  • Page 162 SECTION 7: Unit Status 2. Once flame is proven: • The Ignition box turns green. • Flame Proven appears with green checkmark box and time it took for flame to be proven. • The Summary and all parameters are automatically saved, including the ignition flame strength, SSOV time to open and ignition time 3.
  • Page 163 SECTION 7: Unit Status 7.3 Plant Status (BST Manager units only) Figure 7-9: Plant Status Screen • (Outdoor Air Temp Sensor), (Rtn Hdr Temp Sensor), (Hdr Temp Sensor), (DHW Temp Sensor) and (Loop 2 Supply, not shown) are displayed when the associated sensors are enabled as part of a BST Cascade.
  • Page 164 SECTION 7: Unit Status • The data displayed on this screen depends on the Application(s) chosen in Section 6.3.3: Application Configuration. It can display data for only two applications at a time, , or • Each of the 16 possible boilers in the BST cascade is represented by a box in the grid and identified by their COM Address.
  • Page 165 SECTION 7: Unit Status On the BST Cascade Status screen, if you press on any unit, the BST Unit Status screen appears, showing the details of that particular unit. From here, you can navigate to the status screens of all the other units in the cascade using the Left and Right arrows.
  • Page 166 SECTION 7: Unit Status 7.6 SmartPlate Status If the cascade includes one or more SmartPlate units, the SmartPlate Status screen appears in the Unit Status round-robin on the BST Manager unit only. SmartPlate communication must be enabled for this Main Menu → Advanced Setup → BST Cascade → SmartPlate screen to be displayed (see Comm).
  • Page 167 SECTION 7: Unit Status 7.8 Unit Event History The Unit Event History screen is a scrollable display of unit events, faults and warnings, arranged chronologically, with the most recent on the top. Each event includes the event name, date and time, and a color-coded honeycomb in front of the event name: Red = Faults Yellow = Warnings...
  • Page 168 SECTION 7: Unit Status 7.9 Plant Event History The Plant Event History screen is displayed in the round-robin queue on BST Manager units only. It is similar to the unit Event History screen, in that it displays a list of events, however in this screen, the events can come from any unit in the cascade, with the Unit ID column indicating which unit the event occurred on, or Plant for plant level events such as communication fault with BAS.
  • Page 169 SECTION 7: Unit Status 7.11 Ignition Sequence (Summary) The Last Ignition Status screen displays a summary of the last ignition sequence, whether it is a successful or not. If unsuccessful, it shows the step that failed in red, and one or more check boxes and the status box has red X.
  • Page 170 SECTION 8: I/O Nomenclature SECTION 8: I/O NOMENCLATURE The table below list names that appear in the Controller’s menu structure. TABLE 8-1 Benchmark Boiler I/O Nomenclature Name Function Comments Relays On I/O Board (Controlled by MCB Board) Swing Valve 1 Relay Swing V1 Backup Relay Backup unit contact...
  • Page 171 SECTION 8: I/O Nomenclature TABLE 8-1 Benchmark Boiler I/O Nomenclature Name Function Comments -SmartPlate Valve input -Remote Stpt 2 - Swing V1 feedback -Swing V1 Fdbk -Swing V2 Feedback -Swing V2 Fdbk -VS Pump Feedback -Blr VSP Fdbk -Remote Setpoint 2 -DHW VSP Fdbk -NOx -SmartPlate VP...
  • Page 172 SECTION 8: I/O Nomenclature TABLE 8-2 CFR Boiler I/O Nomenclature Name Function Comments Analog Output On I/O Board Spare Analog 1 Programmable Dropdown Name list: -Fire Rate -Fire Rate -Other BLR V.S. Pump Variable Speed Pump Analog Output On Harness Blower Blower control signal Cascade Valve...
  • Page 173 SECTION 9: EDGE CONTROLLER VIEWS SECTION 9: EDGE CONTROLLER VIEWS Item Part # Description 69353-1 Edge [ii] Front Panel and MCB Kit 124960 Fish Paper, IGST 124361-1 IGST Board 124363-1 Low Water Cut Off Board 124362-1 Power Supply 64139-1 Connector Board Assembly 37142 Control Box Enclosure 38045...
  • Page 174 SECTION 9: EDGE CONTROLLER VIEWS P5 RIBBON CABLE TO I/O BOARD, 30 PIN (P/N 69355-6) P6 RIBBON CABLE TO I/O BOARD 40 PIN (P/N 639355-5) P1 SENSOR HARNESS, 12 ( P/N 63215-TAB) P2 A/F VALVE HARNESS, 18 (P/N 63218-TAB) USB PORT P3 GAS TRAIN HARNESS, 15 PIN (P/N 63271-TAB) ETHERNET PORT...
  • Page 175 SECTION 10: STARTUP, STATUS, FAULT Messages SECTION 10: STARTUP, STATUS, FAULT MESSAGES The Edge Controller displays status messages at various times showing the current state of the Controller. All status messages are displayed near the top of the touchscreen in WHITE text, just under the current screen’s title.
  • Page 176 SECTION 10: STARTUP, STATUS, FAULT Messages TABLE 10-1: Edge Controller Fault Messages FAULT MESSAGE DESCRIPTION TYPE Fault, Man. SSOV Fault During Purge The SSOV switch opened dug purge. Reset Fault, Man. Prg Switch Open During Purge Purge Position Limit switch on A/F Valve was open during purge. Reset Ignition Position Limit switch on A/F Valve opened during Fault, Man.
  • Page 177 SECTION 10: STARTUP, STATUS, FAULT Messages TABLE 10-1: Edge Controller Fault Messages FAULT MESSAGE DESCRIPTION TYPE Fault, Man. Line Voltage Out of Phase The Line (Hot) and Neutral wires are reversed. Reset Fault, Man. Stepper Motor Failure Stepper Motor failed to move Air/Fuel Valve to desired position. Reset Outlet temperature crossed the high setpoint limit.
  • Page 178 SECTION 10: STARTUP, STATUS, FAULT Messages TABLE 10-1: Edge Controller Fault Messages FAULT MESSAGE DESCRIPTION TYPE Auto Calibration In Progress calibration is underway. Message Autocal Finished calibration is complete. Warning O2 Sensor Out Of Range sensor failed during O calibration. Warning O2 Warning Service Required AERtrim has reached its limit and O2 level is still out of range.
  • Page 179 SECTION 10: STARTUP, STATUS, FAULT Messages 10.2 AERtrim MESSAGES The Edge Controller displays the following AERtrim Status and Warning messages when appropriate. TABLE 10-2: Edge Controller AERtrim Messages FAULT MESSAGE Type MESSAGE DESCRIPTION O2 Cal Purge Status auto-calibration purge has started O2 Auto Calibration In Progress Status auto-calibration is underway...

  • Page 180: Appendix A: Indoor/Outdoor Reset Ratio

    Appendix A: Indoor/Outdoor Reset Ratio Outdoor Reset Ratio Set Point High Limit Point 2 Example: Outdoor = 30 Leads to Water SP = 136.4 Point 1 Descending Outdoor Temperature Point 1: OD Air Temp = 60˚ Min Water Temp = 100˚ Point 2: OD Air Temp = -10˚...
  • Page 181 Appendix A: Indoor/Outdoor Reset Ratio Reset Ratio Formula Calculate Set point based on Outdoor temperature: Water Temp Current = (Outdoor Current - Outdoor P1) x (Water SP Temp P1 - Water SP Temp P2) + Water Temp P1 (Outdoor P1 - Outdoor P2) EXAMPLE: What is the Current Water SP Temp when Outdoor Current is 30 °F? Water Temp Current = (30 –...

  • Page 182: Appendix B: I/O Board Connections (Benchmark Boilers)

    Edge Controller Operation Manual APPENDIX B: I/O Board Connections (Benchmark Boilers) Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the Edge Controller used with your Benchmark unit does allow for some additional control and monitoring features.
  • Page 183 Edge Controller Operation Manual APPENDIX B: I/O Board Connections (Benchmark Boilers) I/O BOARD SPARK MONITOR POWER HARNESS FROM SHELL 63232 HARNESS 63216-2 CONNECTOR J24 CONNECTOR J9 DUAL FUEL SWITCH HARNESS 63239 (DUAL FUEL ONLY) CONNECTOR J10 VALVE HARNESS INTERLOCK FROM SHELL HARNESS 63216- 40 PIN RIBBON I/O HARNESS...
  • Page 184 Edge Controller Operation Manual APPENDIX B: I/O Board Connections (Benchmark Boilers) Connector Strip J3 Terminals Pin # Name Description Connection to the Supply Header temperature sensor (2 wire sensor P/N 24410, or 4 wire sensor P/N 61058) for: • Main Loop (in a Variable-Primary application) Supply Header + •...
  • Page 185 Edge Controller Operation Manual APPENDIX B: I/O Board Connections (Benchmark Boilers) Connector Strip J5 Terminals Pin # Name Description • Spare Analog In 3 - SmartPlate Valve input • Spare Analog In 1 + Swing V1 feedback • Spare Analog In 1 - Swing V2 Feedback •...
  • Page 186 Edge Controller Operation Manual APPENDIX B: I/O Board Connections (Benchmark Boilers) Connector Strip J7 Terminals Pin # Name Description • System Pump • Summer Pump • Pump 2 • Louver • Louver 2 Spare 2 Relay Com • Damper • Other Main Menu →...

  • Page 187: Appendix C: I/O Board Connections (Cfr Boilers)

    Edge Controller Operation Manual APPENDIX C: I/O Board Connections (CFR Boilers) Field Control Wiring – I/O Board Each unit is fully wired from the factory with an internal operating control system. No field control wiring is required for normal operation. However, the Edge Controller allows for some additional control and monitoring features.
  • Page 188 Edge Controller Operation Manual APPENDIX C: I/O Board Connections (CFR Boilers) I/O Board Connections The I/O board contains the terminal listed below, arranged on removable, named connector strips J3 through J7 and J14, plus Molex connectors for unit harnesses. The maximum gauge of wires connecting to the I/O board is 14.
  • Page 189 Edge Controller Operation Manual APPENDIX C: I/O Board Connections (CFR Boilers) Connector Strip J5 Terminals Pin # Name Description (NOT USED) (NOT USED) Spare Analog In 1 + Connection to one of the following signals: • SmartPlate Valve input • VS Pump Feedback (Variable Speed Pump Feedback) •...
  • Page 190 Edge Controller Operation Manual APPENDIX C: I/O Board Connections (CFR Boilers) Connector Strip J7 Terminals Pin # Name Description Aux Relay Com Connector Strip J14 Terminals Pin # Name Description BAS RS485 + Connection to the building automation system (BAS) network (Modbus RTU, BACnet BAS RS485 - MSTP).
  • Page 191 Edge Controller Operation Manual APPENDIX C: I/O Board Connections (CFR Boilers) © AERCO International, Inc., 2024 • • •...

Table of Contents