Aerco BMS II BOILER Bedienungsanleitung

JANUARY 19, 2011 Instruction No. AERCO INTERNATIONAL, Inc., Northvale, New Jersey,

GENERAL INFORMATION 1-2 WIRINGCOMPARTMENT COVERCONTROLPANELCLEARPLASTICCOVER Figure 1-1. Boiler Management System II (BMS) 1.4 BMS II FEATURES The f

APPENDIX H H-8 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex)

APPENDIX H H-9 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (Hex

APPENDIX H H-10 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (He

APPENDIX H H-11 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (H

APPENDIX H H-12 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (He

APPENDIX H H-13 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (

I-1

I-1 APPENDIX I _____________________________ BOILER START AND BOILER STOP LEVELS The BMS II Configuration Menu contains options for the Boiler (

GENERAL INFORMATION 1-3 Retention of Menu Option Settings By using non-volatile memory, the BMS II retains program and menu settings during shut-down

INSTALLATION 2-1 CHAPTER 2 - INSTALLATION 2.1 INTRODUCTION This Chapter provides the descriptions and procedures necessary to mount the BMS II and

INSTALLATION 2-2 198 mm (7.8")145 mm (5.7")15 mm(0.6")REAR VIEW Figure 2-1. BMS II Mounting Provisions 2.3 GENERAL WIRING REQUIREME

INSTALLATION 2-3 WARNING THE BMS II CAN BE POWERED BY SINGLE-PHASE AC VOLTAGES RANGING FROM 85 TO 265 VAC. THEREFORE, EXERCISE EXTREME CARE WHEN C

INSTALLATION 2-4 SENSORS& 4-20 mAINTERLOCKS& SETBACKRS485& RS232AC POWERRELAYS Figure 2-2. BMS II With Wiring Compartment Cover Remov

INSTALLATION 2-5 2.5 SENSOR INSTALLATION AND WIRING There are two types of sensors that can be installed: a Header Sensor and an Outside Air Sensor.

INSTALLATION 2-6 PROBE DEPTH MUSTEXTEND AT LEAST 2"INTO PIPEWELDED 1/2" COUPLING OR4"x4*x1/2"T - FITTINGHEADER SENSOR WITH THERMO

INSTALLATION 2-7 4. Terminate the cable shield at SHLD terminal 3 of the BMS II. DO NOT terminate the shield at the Sensor end of the cable. INSTA

Telephone Support Direct to AERCO Technical Support (8 to 5 pm EST, Monday through Friday): 1-800-526-0288 AER

INSTALLATION 2-8 2.6 RS485 (MODBUS) WIRING AT THE BMS II The BMS II communicates with the AERCO Boilers over a RS485 network using Modbus protocol.

INSTALLATION 2-9 BIAS DIPSWITCHESNOTE:THE BIAS DIP SWITCHES CAN BE ACCESSED FROM THE WIRING COMPARTMENT WITHOUT REMOVING THE FRONT PANEL FROM THE U

INSTALLATION 2-10 Method 1 For Method 1, the bias switches in the BMS II are left in the deactivated (up) position. ). Bias and termination are cont

INSTALLATION 2-11 METHOD 1 – BIAS & TERMINATION ACTIVATED AT C-MORE PMC BOARD Figure 2-7. RS485 (Modbus) Wiring For Benchmark Series Boiler

INSTALLATION 2-12 METHOD 2 – TERMINATION ACTIVATED AT I/O BOX Figure 2-7. RS485 (Modbus) Wiring For Benchmark Series Boilers (Sheet 2 of 2)

INSTALLATION 2-13 mA OUTRS-485 COMM.+-+-ANALOG INSENSOR COMMONOUTDOOR SENSOR INREMOTE INTL'K INB.M.S. (PWM) INSHIELD+-+-AUX SENSOR INNOT

INSTALLATION 2-14 mA OUTRS-485 COMM.+-+-ANALOG INSENSOR COMMONOUTDOOR SENSOR INREMOTE INTL'K INB.M.S. (PWM) INSHIELD+-+-AUX SENSOR INNOT U

INSTALLATION 2-15 RS485 Wiring for Modulex Series Boilers RS485 wiring connections are made at the MODBUS terminals of each Boiler’s BCM Module as sho

INSTALLATION 2-16 BMS IIRS232 PORT485 B (+)485 A (-)SHLD(TERM. 3)-+RS485COMMP/O I/O BOXC-MORESLAVENETWORK BOILER 1-+RS485COMMP/O I/O BOXC-MORESLAVENET

INSTALLATION 2-17 2.9 RS232 WIRING AT THE BMS II The BMS II communicates with an external Energy Management System (EMS) or Building Automation Syste

FOREWORD i Foreword The Model 5R5-384 Boiler Management System II (BMS II) is the latest model of AERCO’s BMS line of flexible boiler plant controll

INSTALLATION 2-18 2.10 INTERLOCK WIRING The BMS II is equipped with two interlocks designated Interlock 1 (INT 1) and Interlock 2 (INT 2). Since both

INSTALLATION 2-19 NOTE The state of the SYS START, FLT ALARM and AUX Relays are controlled by options contained in the Relay Menu described in Chapter

OPERATION 3-1 CHAPTER 3 - OPERATION 3.1 INTRODUCTION The information in this Chapter provides a guide to the operation of the BMS II using the cont

OPERATION 3-2 Table 3-1. BMS II Front Panel Controls and Displays ITEM NO. CONTROL, INDICATOR OR DISPLAY FUNCTION 1 VFD Display The Vacuum Fluores

OPERATION 3-3 3.3 BMS II MENU STRUCTURE The BMS II incorporates an extensive menu structure which permits the operator to set up, and configure the u

OPERATION 3-4 OPERATINGSETUPRS232RS485FIELD ADJUSTCONFIGURATIONTUNINGRELAYCALIBRATIONLEVEL 1 PWDLEVEL 2 PWD Figure 3-2. BMS II Menu Structure

OPERATION 3-5 NOTE Paragraphs 3.4 through 3.12 provide detailed descriptions of the options contained in each of the menus shown in Figure 3-2. The me

OPERATION 3-6 I/O STATUS I/O (Input/Output) STATUS is displayed as a hexadecimal number. The meaning of each bit is as indicated below. The higher

OPERATION 3-7 3.6 RS232 MENU The RS232 MENU options permit the BMS II to communicate with an external Energy Management System (EMS) or Computer

FOREWORD ii Phrases, Abbreviations and Acronyms - Continued Phrase, Abbreviation or Acronym Meaning Hex Hexadecimal Number (0 - 9, A - F) Hz Hertz (

OPERATION 3-8 RS485 BAUD RATE The RS485 BAUDRATE option Sets the communication baud rate for the Modbus network between the BMS II and the Boilers

OPERATION 3-9 HDR LOW LIMIT The HDR LOW LIMIT menu option sets the minimum temperature setting allowed for the Header Setpt. This setting also define

OPERATION 3-10 Setting Up An Offset Schedule The basic steps involved in setting up an automatic reset schedule consist first selecting the temperatur

OPERATION 3-11 Sequential When SEQUENTIAL MODE is selected it provides a greater turn-down ratio than the PARALLEL MODE. This is due to the fact that

OPERATION 3-12 3.10 TUNING MENU The TUNING MENU options are used to select PID (Proportional Integral Derivative) control functions incorporate

OPERATION 3-13 DERIVATIVE GAIN Derivative Gain is a function of time. It senses and responds to the rate of change of the setpoint error. A slow rat

OPERATION 3-14 FAULT ALRM RELAY This setting tells the BMS II which faults should activate the fault alarm relay. The default is ALL FAULTS. If NO I

OPERATION 3-15 RAMP UP %/MIN This sets the maximum Percent Level ramp up rate for the BMS II. The Percent Level output will follow the PID output if

OPERATION 3-16 3.13 BMS II QUICK-START GUIDE NOTE The “Quick Start” procedures in paragraph 3.13 assume that the user fully understands the BMS II me

OPERATION 3-17 REMOTE SETPT MODE Perform the procedure described for the CONSTANT SETPT MODE and then continue with the steps described below: MENU &

CONTENTS iii GF-124 – BMS II BOILER MANAGEMENT SYSTEM Operating & Maintenance Instructions TABLE OF CONTENTS CHAPTER 1 - GENERAL INFORMATION ..

OPERATION 3-18 OUTDOOR RESET MODE Perform the procedure described for the CONSTANT SETPT MODE and then continue with the steps described below: MENU

PROGRAMMING BMS II 4-1 CHAPTER 4 - PROGRAMMING BMS II OPERATING MODES 4.1 INTRODUCTION Prior to programming, the BMS-II must be mounted and all req

PROGRAMMING BMS II 4-2 Selecting Outdoor Reset Mode The Outdoor Reset Mode is selected using the Header Set Mode option in the Field Adjust Menu as f

PROGRAMMING BMS II 4-3 Selecting Boiler Operating Mode The Boiler Plant can be set for either Parallel or Sequential Mode operation. The Boiler Operat

PROGRAMMING BMS II 4-4 6. If the boiler plant contains Modulex Boilers, proceed to the next paragraph (Entering Load Start Percent). 7. If the boile

PROGRAMMING BMS II 4-5 Selecting Remote Setpoint Mode The Remote Setpoint Mode is selected using the Header Set Mode option in the Field Adjust Menu a

PROGRAMMING BMS II 4-6 1. Using the ▲ or ▼ arrow key on the keypad, scroll through the menu until REMOTE SIGNAL is displayed in the firs

PROGRAMMING BMS II 4-7 Entering Load Start Percent (Required Only for Modulex Installations) If the boiler plant contains Modulex boilers, the LOAD ST

PROGRAMMING BMS II 4-8 Selecting Internal Setpoint Temperature The Internal Setpoint Temperature is selected using in the Field Adjust Menu as follows

PROGRAMMING BMS II 4-9 Entering Load Start Percent (Required Only for Modulex Installations) If the boiler plant contains Modulex boilers, the LOAD ST

CONTENTS iv TABLE OF CONTENTS (cont.) 3.5 SETUP MENU ...

PROGRAMMING BMS II 4-10 4.7 SYSTEM INITIALIZATION AND POLLING In order for the BMS II to recognize the boilers connected to the RS485 Network, Initia

PROGRAMMING BMS II 4-11 7. Using the MENU key on the BMS II, scroll to the OPERATING MENU. The first line of the display will show the Header Temper

TROUBLESHOOTING 5-1 CHAPTER 5 - TROUBLESHOOTING 5.1 FAULT MESSAGES & COMMON PROBLEMS When a fault occurs in the boiler plant, the BMS II flash

TROUBLESHOOTING 5-2 Table 5-1. Fault Messages – Continued Fault Message Description & Possible cause CURRENT LOOP ERROR The 4-to-20-mA re

TROUBLESHOOTING 5-3 Table 5-2 Common Problems Problem Possible Causes Solution Boiler plant not started by BMS II • BMS II not turned ON. • Out

TROUBLESHOOTING 5-4 Table 5-2 Common Problems - Continued Problem Possible Causes Solution EMS cannot see BMSII • Incorrect address • Incorrec

APPENDIX A A-1 APPENDIX A _____________________________ BMS II MENUS AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAXIMUM DEFA

APPENDIX A A-2 APPENDIX A _____________________________ BMS II MENUS - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MAX

APPENDIX A A-3 APPENDIX A _____________________________ BMS II MENUS - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MA

CONTENTS v TABLE OF CONTENTS (cont.) RAMP DOWN %/MIN ...

APPENDIX A A-4 APPENDIX A _____________________________ BMS II MENUS - Continued AVAILABLE CHOICES OR LIMITS MENU LEVEL & OPTION MINIMUM MA

APPENDIX B B-1 APPENDIX B _____________________________ STATUS AND FAULT MESSAGES DISPLAY MESSAGES DESCRIPTION STATUS MESSAGES: FAIL SAFE MODE

APPENDIX C C-1 APPENDIX C _____________________________ METHODS FOR DETERMINING RESET SCHEDULE AND OUTDOOR RESET RATIO CHARTS Using the Charts to D

C-2 APPENDIX C _____________________________ Table C-1. Header Temperature for a Building Reference Temperature of 50°F RESET RATIO Air Temp 0.6

APPENDIX C C-3 APPENDIX C _____________________________ Table C-3. Header Temperature for a Building Reference Temperature of 65°F RESET RATIO Air

C-4 APPENDIX C _____________________________ Table C-5. Header Temperature for a Building Reference Temperature of 75°F RESET RATIO Air Temp 0.6 0

APPENDIX C C-5 APPENDIX C _____________________________ Table C-7. Header Temperature for a Building Reference Temperature of 90°F RESET RATIO Ai

APPENDIX D D-1 APPENDIX D _____________________________ NTC Temperature Sensor Resistance Chart Temperature (°F) Resistance (ohms) Temperatur

APPENDIX E E-1 APPENDIX E _____________________________ BMS II WIRING DIAGRAM 1112 3456+7-8 910121314OUTAIRSENSHDRSEN4-20MAINT1INT2SETBACK485 ISO

APPENDIX F F-1 APPENDIX F _____________________________ BMS II PARTS AND ACCESSORIES PART NUMBER DESCRIPTION COMMENTS 64053 Boiler Managemen

APPENDIX G G-1 APPENDIX G _____________________________ PROGRAMMING THE BMS II USING RS-232 COMMUNICATION Introduction The RS-232 port located in

APPENDIX G G-2 APPENDIX G (cont.) __________________________ Programming Procedure BMS II functions which can be viewed or changed are listed

APPENDIX G G-3 APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS No. COMMAND ENTRY RANGE FACTORY DEFAULT 00 Header Te

APPENDIX G G-4 APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS No. COMMAND ENTRY RANGE FACTORY DEFAULT 26 Not Used

APPENDIX G G-5 APPENDIX G (cont.) __________________________ Table G-1. BMS COMMANDS – (Continued) No. COMMAND ENTRY RANGE FACTORY DEFAULT 86

GENERAL INFORMATION 1-1 CHAPTER 1 - GENERAL INFORMATION 1.1 SAFETY PRECAUTIONS & WARNINGS The Warnings and Cautions appearing throughout this

APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS – (Continued) No. COMMAND ENTRY RANGE FACTORY DEFAULT 107 Net Boil

APPENDIX G G-7 APPENDIX G (cont.) __________________________ Table G-1. BMS II COMMANDS – (Continued) No. COMMAND ENTRY RANGE FACTORY DEFAU

APPENDIX H 1 APPENDIX H __________________________ BMS II MODBUS ADDRESS ASSIGNMENTS IMPORTANT All Modbus addresses specified in this manual ar

APPENDIX H H-2 H-1 BMS II STANDARD INPUT REGISTER ASSIGNMENMTS The Read Only Input Register assignments for the BMS II are listed in Table H-1 which

APPENDIX H H-3 APPENDIX H (cont.) __________________________ Table H-1. BMS II Standard Input Register Address Mapping-Cont. Modbus Data Addres

APPENDIX H H-4 APPENDIX H (cont.) __________________________ Table H-1. BMS II Standard Input Register Address Mapping-Cont. Modbus Data Address

APPENDIX H H-5 APPENDIX H (cont.) __________________________ Table H-1. BMS II Standard Input Register Address Mapping-Cont. Modbus Data Addres

APPENDIX H H-6 APPENDIX H (cont.) __________________________ H-2. BMS II Controller Standard Holding Register Assignments The Holding Register add

APPENDIX H H-7 APPENDIX H (cont.) __________________________ Table H-2. BMS II Standard Holding Register Address Mapping Modbus Data Address (H