Document Outline

• FOREWARD
  • PHRASES, ABBREVIATIONS & ACRONYMS
• 1. ACS GENERAL INFORMATION
  • 1.1 SAFETY PRECAUTIONS AND WARNINGS
  • 1.2 INTRODUCTION
  • 1.3 ACS GENERAL DESCRIPTION
  • 1.4 ACS FEATURES
• 1.
• 1.1.
• 1.2.
• 1.3.
• 1.4.
  • 1.4.1 Simplified Installation and Set-Up
  • 1.4.2 User-Friendly Control System Interface
  • 1.4.3 Retention of Menu Option Settings
  • 1.4.4 Application Flexibility
  • 1.4.5 Sequential or Parallel Operation
  • 1.4.6 Accuracy
  • 1.4.7 Bumpless Transfer
  • 1.4.8 Fault Alarm Surveillance
  • 1.4.9 ACS Programming Via RS232 Port.
• 2. ACS INSTALLATION
  • 2.
  • 2.1 INTRODUCTION
  • 2.2 SITE SELECTION AND MOUNTING
    • 2.1.
    • 2.2.
    • 2.2.1 Mounting the ACS
  • 2.3 SITE SELECTION AND MOUNTING
  • 2.4 POWER WIRING
  • 2.5 SENSOR INSTALLATION AND WIRING
    • 2.3.
    • 2.4.
    • 2.5.
    • 2.5.1 Header Sensor Installation
    • 2.5.2 Return Sensor Installation
    • 2.5.3 Outdoor Air Sensor Installation
  • 2.6 RS485 (MODBUS) WIRING AT THE ACS
    • 2.6.
    • 2.6.1 ACS Bias Switches & Loop Termination Resistors
  • 2.7 RS485 (MODBUS) WIRING, BIAS, AND TERMINATION AT AERCO BOILERS
    • 2.7.
    • 2.7.1 RS485 Wiring, Termination& Bias for Benchmark Series and KC1000 Boilers
    • 2.7.2 RS485 Wiring for Modulex Series Boilers
  • 2.8 SAMPLE RS485 (MODBUS) NETWORK DIAGRAMS
  • 2.9 RS485 WIRING AT THE ACS
  • 2.10 INTERLOCK WIRING
    • 2.8.
    • 2.9.
    • 2.10.
    • 2.10.1 Interlock 1 (INT 1) Wiring
    • 2.10.2 Interlock 2 (INT 2) Wiring
  • 2.11 SETBACK WIRING
  • 2.12 RELAY WIRING
    • 2.12.1 System Start Relay
    • 2.12.2 Fault Alarm Relay
    • 2.12.3 Auxiliary Relay
  • 2.13 4-20 MA WIRING
  • 2.14 MOUNTING AND WIRING THE OPTIONAL ACS RELAY BOX
  • 2.15 RELAY PANEL INSTALLATION AND WIRING
  • 2.16 RELAY PANEL COMPONENTS
    • 2.16.1 Power
    • 2.16.2 Inputs
    • 2.16.3 Outputs
  • 2.17 RELAY PANEL OPERATION
  • 2.18 ACS PROGRAMMING FOR USE WITH THE ACS RELAY PANEL
    • 2.18.1 RS485 Menu
    • 2.18.2 Configuration Menu
• 3. OPERATION
  • 3.
  • 3.1 INTRODUCTION
  • 3.2 FRONT PANEL OPERATING CONTROLS AND DISPLAYS
  • 3.3 ACS MENU STRUCTURE
• 3.1.
• 3.2.
• 3.3.
  • 3.3.1 Menu Processing Procedure
  • 3.4 OPERATING MENU
    • 3.4.
    • 3.4.1 HEADER TEMP AND PERCENT OF LOAD
    • 3.4.2 HEADER SETPOINT
    • 3.4.3 OUTSIDE AIR TEMP
    • 3.4.4 I/O STATUS
    • 3.4.5 RETURN TEMP
    • 3.4.6 NETWORK BOILER OUTLET TEMPERATURE
    • 3.4.7 NETWORK BOILER ERROR CODE
  • 3.5 SETUP MENU
    • 3.5.
    • 3.5.1 ENTER PASSWORD
    • 3.5.2 DATE AND TIME MENU OPTIONS
  • 3.6 RS232 MENU
    • 3.6.
    • 3.6.1 RS232 MODE
    • 3.6.2 RS232 BAUD RATE
    • 3.6.3 MODBUS ADDRESS
    • 3.6.4 NETWORK TIMEOUT
    • 3.6.5 MODBUS PASS THRU
  • 3.7 RS232 MENU
    • 3.7.
    • 3.7.1 RS485 BAUD RATE
    • 3.7.2 MIN SLAVE ADDR
    • 3.7.3 MAX SLAVE ADDR
    • 3.7.4 NUMBER NETWK BLRS
    • 3.7.5 MODBUS CNTL TYPE
    • 3.7.6 NETW BOILER Xx ADDRESS=Yyy
  • 3.8 FIELD ADJUST MENU
    • 3.8.
    • 3.8.1 HEADER SET MODE
    • 3.8.2 HDR HIGH LIMIT
    • 3.8.3 HDR LOW LIMIT
    • 3.8.4 INTERNAL SETPT
    • 3.8.5 RESET RATIO
    • 3.8.6 BLDG REF TEMP
    • 3.8.7 REMOTE SIGNAL
    • 3.8.8 OFFSET ENABLE
    • 3.8.9 Offset Menu Options
    • 3.8.10 Setting Up an Offset Schedule
    • 3.8.11 Setting Up a Manual Offset Schedule
  • 3.9 CONFIGURATION MENU
    • 3.9.
    • 3.9.1 BLR CNTL SELECT
    • 3.9.2 BOILER OP MODE
    • 3.9.3 PARALLEL MODE
    • 3.9.4 SEQUENTIAL
    • 3.9.5 SYS INTLK CONFIG
    • 3.9.6 BLR START LEVEL
    • 3.9.7 BLR STOP LEVEL
    • 3.9.8 MAX POWER INPUT
    • 3.9.9 FAIL SAFE MODE
    • 3.9.10 LEAD BLR SELECT (Lead Boiler Selection)
    • 3.9.11 LAST BLR SELECT (Last Boiler Selection)
    • 3.9.12 ROTATE TIME
    • 3.9.13 RET SENSOR MODE (Return Sensor Mode)
    • 3.9.14 PLANT DT LIMIT (Plant Delta-Temperature Limit)
    • 3.9.15 BOILER DELAY
    • 3.9.16 DHW OPTION (Domestic Hot Water Option)
    • 3.9.17 NUMBER DHW BLRS (Number of Domestic Hot Water Boilers)
    • 3.9.18 DHW SIGNAL (Domestic Hot Water Signal)
    • 3.9.19 NUM DHW PRIORITY (Number of DHW Priority Boilers)
    • 3.9.20 VALVE WAIT STATES
    • 3.9.21 SYS RELAY OPTION (System Relay Option)
  • 3.10 BOOST TEMP
    • 3.10.
    • 3.10.1 RET TEMP BST DIS (RETURN TEMPERATURE BOOST DISABLE)
    • 3.10.2 BOOST MAX TIMER
  • 3.11 TUNING MENU
    • 3.11.
    • 3.11.1 PROPORTIONAL BND
    • 3.11.2 INTEGRAL GAIN
    • 3.11.3 DERIVATIVE GAIN
    • 3.11.4 Decreasing Boiler Cycles
    • 3.11.5 HI_DB_SETPT_EN (High Deadband Setpoint Enable)
    • 3.11.6 DEADBAND HIGH
    • 3.11.7 DEADBAND LOW
    • 3.11.8 SETPT DOWN RATE (Setpoint Down (descending) Rate
    • 3.11.9 DEMAND OFFSET
  • 3.12 RELAY MENU
    • 3.12.
    • 3.12.1 SYS START TEMP
    • 3.12.2 SYS START OPTION
    • 3.12.3 SYS START INTLK
    • 3.12.4 AUX RELAY OPEN
    • 3.12.5 AUX RELAY CLOSE
    • 3.12.6 FAULT ALRM RELAY
    • 3.12.7 FAULT ALARM BLRS
    • 3.12.8 FAULT ALRM CLEAR
  • 3.13 CALIBRATION MENU
    • 3.13.
    • 3.13.1 HDR SENS OFFSET
    • 3.13.2 OUTD SENS OFFSET
    • 3.13.3 4 - 20 MA OFFSET
    • 3.13.4 RETN SENS OFFSET
    • 3.13.5 RAMP UP %/MIN
    • 3.13.6 RAMP DOWN %/MIN
    • 3.13.7 RESET DEFAULTS
    • 3.13.8 PASSTHRU WRITE
    • 3.13.9 VALVE WAIT TIME
    • 3.13.10 SYSTEM OVERRIDE (Modbus Enable/Disable)
  • 3.14 ACS QUICK-START GUIDE MENU
• 3.14.
  • 3.14.1 CONSTANT SETPT MODE (Default):
  • 3.14.2 REMOTE SETPT MODE:
  • 3.14.3 OUTDOOR RESET MODE
• 4. PROGRAMMING ACS OPERATING MODES
  • 4.
  • 4.1 INTRODUCTION
  • 4.2 OUTDOOR RESET MODE
    • 4.
    • 4.1.
    • 4.2.
    • 4.2.1 Selecting Outdoor Reset Mode
    • 4.2.2 Determining Reset Schedule
    • 4.2.3 Entering Reset Ratio and Building Reference Temperature
    • 4.2.4 SELECTING BOILER OPERATING MODE
    • 4.2.5 Entering System Start Temperature
    • 4.2.6 Entering Boiler Start and Boiler Stop Levels
  • 4.3 REMOTE SETPOINT MODE
    • 4.3.
    • 4.3.1 Selecting Remote Setpoint Mode
    • 4.3.2 Entering Header High Limit and Low Limit Temperatures
    • 4.3.3 Selecting Remote Signal Type
    • 4.3.4 Selecting Boiler Operating Mode
    • 4.3.5 Entering Boiler Start & Stop Levels
  • 4.4 CONSTANT SETPOINT MODE
• 4.4.
  • 4.4.1 Selecting Constant Setpoint Mode
  • 4.4.2 Selecting Internal Setpoint Temperature
  • 4.4.3 Selecting Boiler Operating Mode
  • 4.4.4 Entering Boiler Start and Boiler Stop Levels
  • 4.5 “Temp and Load” Option
  • 4.6 “Start Enabled” Option
  • 4.7 System Initialization and Polling
  • 4.8 Testing the System
• 5. TROUBLESHOOTING
  • 5.
  • 5.1 Fault Messages And Common Problems
• APPENDIX A: ACS MENUS
• APPENDIX B: STATUS AND FAULT MESSAGES
  • B.1 C-MORE STATUS AND FAULT MESSAGES
  • B.2 CONVERSION EQUATIONS FOR TEMPERATURE VARIABLES
  • B.3 Deciphering the “FAULT Code” Reading from the BCM (used in Modulex Boilers)
  • B.4 BCM (BOILER COMMUNICATION MODULE) FAULT CODES
  • B.5 BCM (BURNER MANAGEMENT MODULE) FAULT CODES
  • B.6 ACS (AERCO CONTROL SYSTEM) I/O STATUS
• APPENDIX C: RESET SCHEDULE AND OUTDOOR RESET RATIO CHARTS
  • C.1 USING THE CHARTS TO DETERMINE RESET SCHEDULE
  • C.2 DETERMINING RESET SCHEDULE BY FORMULA
• APPENDIX D: NTC TEMPERATURE SENSOR RESISTANCE
• APPENDIX E: ACS WIRING DIAGRAM
• APPENDIX F: ACS PARTS AND ACCESSORIES
• APPENDIX G: PROGRAMMING USING RS232 COMMUNICATION
  • G.1 INTRODUCTION
  • G.2 AQUIRING THE PuTTY APPLICATION
    • G.2.1 Logging on to a Remote Machine Using PuTTY
    • G.2.2 Running a Command on a Remote Machine Using PuTTY
  • G.3 RS232 COMMUNICATION SET-UP
  • G.4 PROGRAMMING PROCEDURE
• APPENDIX H: ACS MODBUS ADDRESS ASSIGNMENTS
  • H.1 ACS CONTROLLER STANDARD INPUT REGISTER ASSIGNMENTS
  • H.2 ACS CONTROLLER STANDARD HOLDING REGISTER ASSIGNMENTS
• APPENDIX I: BOILER START AND STOP LEVELS