Download EM-10 Electronic Control Manual_Eng Modes 1 thru 8

MODEL EM-10 MONITRON II
ELECTRIC BOILER CONTROL
SERVICE MANUAL
Publication No. EM-40-SM
Printed in U.S.A. 1208
Part No. 792840000
How to Use the Data Brochure
This brochure is organized into three main sections.
They are: 1) Sequence of Operation, 2) Installation, and
3) Control Settings.
The Control Settings section of this brochure describes
the various items that are adjusted and displayed by the
control. The control functions of each adjustable item are
described in the Sequence of Operation.
Table of Contents
User Interface ..................................................................2
Display and Symbol Description ......................................3
Sequence of Operation ....................................................4
Section A:General ............................................................4
Section B: Setpoint Operation ..........................................9
Section C: Dedicated DHW Operation ............................9
Section D: Outdoor Reset Operation ............................10
Section E: External Temperature Target Input................10
Section F: External Direct Drive Operation ....................11
Installation ......................................................................12
Testing ............................................................................13
Control Settings..............................................................15
DIP Switch Settings........................................................15
Mode 1 and 2 - Two Setpoint Operation ........................16
View Menu......................................................................16
Adjust Menu ..................................................................17
Mode 3 - Dedicated DHW with Parallel Piping ..............19
View Menu......................................................................19
Adjust Menu ..................................................................20
Mode 4 and 5 - Outdoor Reset / Setpoint Operation ....22
View Menu......................................................................23
Default Settings ........................................................24-26
Adjust Menu ..................................................................24
Mode 6 and 7 - External Target / Setpoint Operation ....27
View Menu......................................................................28
Adjust Menu ..................................................................29
Mode 8 - External Direct Drive Operation......................31
View Menu......................................................................31
Adjust Menu ..................................................................32
Error Messages ..............................................................33
Reload Factory Defaults ................................................34
Specifications ................................................................36
User Interface
The BTC uses a Liquid Crystal Display (LCD) as a method
of supplying information. You use the LCD in order to setup
and monitor the operation of your system. The BTC uses
three push buttons (Item, p,q) for selecting and adjusting
settings. As you program your control, record your settings
in the settings column of the Adjust menu. The table is
found in the second half of this brochure.
MENU
ITEM
The abbreviated name of the selected item will be displayed
in the item field of the display.
To view the next available item, press and release the Item
button.
Once you have reached the last available item in a menu,
pressing and releasing
the Item button will return the display
Item
to the first item in the selected menu.
All of the items displayed by the control are organized into
two menus:
1) View
2) Adjust
These menus are listed on the upper right hand side of the
display (Menu Field). The default menu for the BTC is the
View menu. While in the View menu, the VIEW segment
is displayed.
To select the Adjust menu, press and hold simultaneously
all three buttons (Item, p,q) for 1 second.
Item
ADJUST
Item
To make an adjustment to a setting in the control, begin
the Adjust menu by pressing and holding
by selecting Item
simultaneously all three buttons.
Then select the Item
desired item using the Item button. Finally,
use the p or q button to make the adjustment.
Item
Item
The display then advances to the Adjust menu and the
ADJUST segment is turned on in the display. The display
will automatically revert back to the View menu after 20
seconds of keypad
Item inactivity. Once in a menu, there will be
a group of items that can be viewed within that menu.
STATUS FIELD
Additional information can be gained by observing the
Field
Status field of the LCD. TheItem
status
field will indicate which
Displays
the
current
of the control’s outputs are currently active. Symbols in
item selected.
the status field are only visible
when the View menu is
selected.
EM-40-SM Service Manual
2
Item
Item Field
Item
Item
Display
Item
Menu Field
Displays the
current menu
Menu Field
Displays Field
the
Number
Item Field
Displays the current
item selected.
currentthe
menu
Displays
current value
of the selected item
Item Field
Number Field
Status
Field
Displays the current value
Displays the current
item selected.
Displays
the current
status of
of the selected
item
the control’s inputs, outputs
and operation
Status Field
Displays the current status of
the control’s inputs, outputs
Buttons
and operation
Selects
Menus, Items
and adjusts settings
Buttons
Item
Selects Menus, Items
and adjusts settings
Item
BOILER PUMP
Symbol Description
Displays when the boiler pump is in
operation.
DEMAND 2
Displays when a call for heat on demand
2 is present.
BOILER PUMP
BURNER
Displays
when
the boiler
is in
Displays
when
stage
1, 2, 3,pump
or 4 contact
operation.
is on.
DEMAND 2
ERROR
Displays
when
call for
heat onisdemand
Displays
when
anaerror
message
2
is
present.
present.
BURNER
WWSD
Displays
when
stage
1, 2,is3,inorWarm
4 contact
Displays
when
the
control
is
on.
Weather Shut Down.
ERROR
POINTERS
Displays when an error message is
Displays
operation as indicated by the text.
present.
WWSD 1
DEMAND
Displays
when
the for
control
Warm
Displays
when
a call
heat isonindemand
Weather
Shut
Down.
1 is present.
DEMAND 1
Displays when a call for heat on demand
1 is present.
EM-40-SM Service Manual
°F,°C
°F,°C
°FPOINTERS
or°C
Displays operation as indicated by the text.
Displays the temperature units.
°F or°C
Displays the temperature units.
3
Section A: General
POWERING UP THE CONTROL
When the control is powered up, the control turns on all
segments in the display for 2 seconds. Next, the software
version is displayed for 2 seconds. Last, the control enters
into the normal operating mode.
DISPLAY BACKLIGHT
The control’s display has a backlight that is permanently
on while the control is powered.
PIPING
The boiler can be piped in parallel or in primary/secondary to
the system. The type of piping chosen affects the location of
the control’s operating temperature sensor. The
control can either use the boiler outlet sensor or the boiler
Boiler Outlet
supply sensor.
MODE 1 (Two Setpoints with Parallel Piping)
Mode 1 is designed for setpoint operation using parallel
piping. The heat demand is available to activate a setpoint
for space heating systems. The setpoint demand is available
to activate a second setpoint for heating an indirect domestic
hot water tank.
Once a heat demand is present, the control stages the
boiler to maintain the boiler target 1 at the boiler outlet
sensor. Once a setpoint demand is present, the
control stages the boiler to maintain the boiler target 2 at the
boiler outlet sensor. If both demands are present, the control
operates at the higher of the two targets. Refer to section B
for a description of setpoint operation.
Mode 1
BTC
Sensor
PARALLEL PIPING
In parallel piping applications, the boiler outlet temperature
is typically the same as that delivered to the system.
Boiler Inlet
sensor is the boiler
Therefore the operating temperature
Sensor
outlet sensor.
Boiler Outlet
Sensor
Relay
Mode 1
BTC
Boiler
Outlet
Sensor
Relay
Boiler Outlet
Boiler Supply
Sensor Boiler InletSensor
Sensor
Boiler Outlet
PRIMARY/SECONDARY PIPING
Boiler Outlet
Sensor
Sensor
In primary/secondary applications, the boiler outlet
Boiler Inlet
is typically hotter than the
temperature (primary loop)
Sensor
system supply temperature
(secondary
loop).
This occurs
Boiler Outlet
Boiler
Supply
Sensor
Sensor
when the system supply pipe
has
a
larger
flow
rate than
Boiler Inlet
Boiler
Inlet
Sensor
the boiler outlet pipe. Therefore,
the
control
requires
an
Sensor
additional sensor (boiler supply) to measure the temperature
delivered out to the system. The operating temperature
sensor is the boiler supplyBoiler
sensor.
Inlet
Sensor
Boiler Outlet
Boiler Supply
Boiler Outlet
Boiler
Sensor
SensorSupply
Sensor
Sensor
Boiler Inlet
Boiler Inlet
Sensor
Sensor
MODES OF OPERATION (MODE)
The control allows for seven modes of operation in order to
define the control operation and piping arrangement used.
The piping arrangement can be categorized into parallel
and primary / secondary. The mode of operation is selected
using the MODE item in the Adjust menu. The temperature
being controlled out to the heating system is measured by the
operating sensor.
The piping arrangement determines which sensor the
control uses as the operating sensor. The operating sensor is
either the boiler outlet sensor or the boiler supply sensor.
4
Mode 1 Boiler Inlet Sensor
Mode
1
BTC
Boiler
BTC
Setpoints
with Primary/Secondary Piping)
MODE Outlet
2
(Two
Sensor
Mode 2 is designed for setpoint operation using primary /
secondary piping. Relay
A Relay
heat demand is available to activate
2 for space heating systems. AZone
Box
a Mode
setpoint
setpoint
demand
BTC
is available to activate a second setpoint for heating an
Boiler Inlet Sensor
indirect domestic hot water tank.
Boiler
Relay
OnceOutlet
aBoiler
heat demand is present, the control stages the
Outlet
Sensor
boiler toSensor
maintain the boiler target 1 at the boiler supply
sensor.
Once
a setpoint demand is present, the
Mode 2
Zone Box
control Boiler
stages the boiler to maintain
the boiler target 2
BTC
at the Outlet
boiler supply sensor. If both demands are
Boiler Inlet Sensor
Boiler Inlet
Sensor at the higher of the two targets.
present,Sensor
the control
operates
Refer to section B Boiler
forRelay
a description of setpoint
Supply
operation.
Sensor
Mode 2
ModeBoiler
2
Outlet
Sensor
Boiler Inlet Sensor
BTC
BTC
Zone Box
Zone Box
Relay
Boiler
Relay
Supply
Sensor
Boiler Inlet Sensor
Boiler
Boiler
Outlet
Outlet
Sensor
Sensor
Boiler
Boiler
Supply
Supply
Sensor
Sensor
Boiler Inlet Sensor
Boiler Inlet Sensor
EM-40-SM Service Manual
MODE 3
(Dedicated Domestic Hot Water Tank)
Mode 3 is designed for heating a dedicated domestic hot
water tank using parallel piping. A tank sensor creates an
internal heat demand in the control. Once an internal heat
demand is present, the control stages the boiler to
maintain the boiler target temperature at the boiler outlet
sensor. Refer to section C for a description of dedicated
domestic hot water tank operation.
Mode 3
Once a heat demand is present, the control stages the
boiler to maintain the calculated outdoor reset target at the
boiler supply sensor. Refer to section D for a description of
outdoor reset operation.
Once a setpoint demand is present, the control stages the
boiler to maintain the boiler target at the boiler supply
sensor. If both demands are present at the same time, the
control targets the higher of the two requirements. Refer to
section
ModeB5 for a description of setpoint operation.
BTC
BTC
Mode 5
Mode 3
BTC
BTC
Relay
Outdoor
Sensor
Outdoor
Sensor
Relay
Boiler
Outlet
Sensor
Boiler
Outlet
Sensor
Boiler
DHW
Outlet
Tank
Sensor
Sensor
Boiler
DHW
Outlet Boiler InletTank
Sensor
Sensor
Sensor
MODE 4
Boiler Inlet Sensor
(Outdoor Reset and Setpoint with Parallel Piping)
Mode 4 is designed for outdoor reset and setpoint operMode
4 parallel piping. The heat demand is available
ation
using
Outdoor
3 outdoor reset forBTCspaceSensor
toMode
provide
heating systems. The
Mode
4
BTC
setpoint can be used to heat
an
indirect
domestic hot
Outdoor
BTC
Sensor
water tank.
Relay
Once
is present, the control stages the
Modea3heat demand
Relay
BTC
boiler to maintain the calculated
outdoor reset target at
the boiler outlet sensor. Refer to section D for a descripBoiler
tion ofOutlet
outdoor reset operation.
Sensor
Boiler
DHW
Once Boiler
a setpoint
demand
is present, the control stages
Tank
OutletOutlet
Sensor
Sensor
the boiler
to
maintain
the
boiler target at the boiler outSensor
let sensor. If both
demands
Boiler Inlet Sensor are present at the same
time, the Boiler
control
targets
the higher of the two requireBoiler Inlet
Sensor
DHW
Outletto sectionTank
ments. Refer
B for a description of setpoint
Sensor
Sensor
operation. Boiler Inlet Sensor
Mode 4
Mode 4
Boiler Inlet Sensor
BTC
Outdoor
Sensor
BTC
Outdoor
Sensor
Relay
Boiler
Supply
Sensor
Boiler
Supply
Boiler Inlet Sensor
Sensor
Boiler Inlet Sensor
Mode 5
MODE
6 (External Target Temperature
OutdoorInput and Setpoint
BTC
Mode
6 Piping)
Sensor
with
Parallel
EMS
BTC
Mode 6 is designed for an external input signal and setpoint
Mode 6
0-10 V input
(dc)
with
parallel
piping. Relay
The BTC
external
EMSsignal can be
Mode
5
Relay
provided from a BMS, an EMS,
or
a tekmar tN4 System
Outdoor
BTC
Sensor
0-10
V (dc)can be used to heat
Control for space heating. The setpoint
Relay
an indirect domestic hot water tank.
Boiler
Relay
The external
input signal creates an internal demand and
Outlet
Sensor
changes
the boiler target according to a linear scale. The
control stages the boiler Boiler
to maintain the boiler target at the
Supply
boilerBoiler
outletBoiler
sensor. Refer
to section E for a description of
Sensor
Outlet
Outlet
external
target
temperature
operation.
Sensor
Sensor
Boiler Boiler Inlet Sensor
Outlet
Once a setpoint
is present, the control stages the
Boiler demand
Inlet Sensor
Boiler
Sensor
boiler to maintain the Supply
boiler target at the boiler outlet
Sensor
sensor. If Boiler
both Inlet
an Sensor
external input signal and a setpoint
Boiler Inlet Sensor
demand
Mode 6 are present at the same time, the control targets
the higher of the two requirements.
Refer
to section B for
EMS
BTC
a description of setpoint operation.
0-10 V (dc)
Relay
Mode 6
Boiler
Outlet
Sensor
EMS
BTC
Relay
0-10 V (dc)
Relay
Boiler
Outlet
Sensor
Boiler Inlet Sensor
MODE 5 (Outdoor Reset and Setpoint with Primary/
Secondary Piping)
Mode 5 is designed
for outdoor reset and setpoint operation
Boiler Inlet Sensor
using primary / secondary piping. The heat demand is
available to provide outdoor reset for space heating systems.
The setpoint demand can be used to heat an indirect
domestic hot water tank.
EM-40-SM Service Manual
Boiler
Outlet
Sensor
Boiler Inlet Sensor
Boiler
Outlet
Sensor
Boiler Inlet Sensor
5
Boiler
Outlet
Sensor
Boiler
Outlet
Sensor
MODE 7 (External Target Temperature Input and Setpoint
with Primary/Secondary Piping)
Boiler
Mode 7 is designed for an external input
signal and
Supply
setpoint with primary/secondary piping. The Sensor
external input
signal can be provided from a BMS, an EMS, or a tekmar
Boilerfor
Inlet
Sensorheating.
Boiler
Inlet
Sensor can be
tN4 System Control
space
The
setpoint
used to heat an indirect domestic hot water tank.
The external input signal creates an internal demand and
changes the boiler target according to a linear scale. The
control stages the boiler to maintain the boiler target at the
boiler supply sensor. Refer to section E for a description of
external target temperature operation.
Once a setpoint demand is present, the control stages the
boiler to maintain the boiler target at the boiler supply
sensor. If both an external input signal and a setpoint
demand are present at the same time, the control targets
the higher of the two requirements. Refer to section B for a
description of setpoint operation.
Mode 7
BTC
0-10 V (dc)
STAGING MODE (STGMODE)
The control can operate up to four stages in order to
supply the required target temperature. The method of
staging used by the control is either P (proportional) or
PID (Proportional & Integral & Derivative), and is selected
using the STGMODE item in the Adjust menu.
190°F
185°F
Proportional Staging
180°F
175°F
170°F
165°F
160°F
155°F
150°F
145°F
140°F
Setpoint
water
temperature
droop
Stage 4
Stage 3
Stage 2
Stage 1
tN4 System
Control
P.I.D. Staging
Relay
185°F
180°F
Boiler
Outlet
Mode
7
Sensor
BTC
0-10 V (dc)
tN4 System
Control
Stage 4
Stage 3
Stage 2
Stage 1
Relay
Boiler
Outlet
Sensor
Boiler Inlet Sensor
Boiler
Supply
Sensor
Boiler
BTC
Boiler
Outlet
Sensor
BTC
External
Control
0-10 V (dc)
Direct Drive
Boiler Inlet Sensor
Boiler
Supply
Sensor
Boiler Inlet Sensor
6
Boiler Inlet Sensor
Proportional & Integral & Derivative (PID)
PID staging allows the control to determine when the next
stage is required to turn on. After a stage is turned on in
the firing sequence, the control waits a minimum amount of
time (Stage Delay) before turning on the next stage. After
the minimum time delay between stages has expired, the
control examines the control error to determine when the
next stage is to fire. The control error is determined using
PID logic.
Proportional logic compares the actual operating sensor
temperature to the boiler target temperature. The colder the
temperature, the sooner the next stage is turned on.
Integral logic compares the actual operating sensor
temperature to the boiler target temperature over a period
of time.
Boiler
Supply
Sensor
Boiler
Boiler
Outlet
Outlet
Sensor
Sensor
Boiler Inlet Sensor
very little
temperature
droop
P.I.D. = Proportional + Integral + Derivative
MODE 8 (External Direct Drive Operation)
Mode 8 is designed forBoiler
an external input signal to directly
Supply
Sensor
control
the
staging
rate
of the boiler with either parallel
Mode 8
External
V (dc) and
BTC
BTC
or primary
/
secondary
piping. The
heat 0-10
demand
Boiler Inlet Sensor
Control
Direct Drive
setpoint demand inputs are disabled. Refer to section F for
a description of external target temperature operation.
Outlet
Mode
8
Sensor
Setpoint
175°F
170°F
165°F
175°F
170°F
165°F
160°F
155°F
150°F
145°F
140°F
Derivative logic determines how fast or slow the operating
sensor temperature
changing. If the temperature is
Proportional is
Staging
190°F
increasing
slowly, the next stage is turned on sooner. If
185°F
the
temperature is increasing quickly, the next stage is
180°F
Setpoint
turned on later, if at all.
190°F
185°F
water
Proportional
temperature Staging
droop
180°F
EM-40-SM Service Manual
Setpoint
EM-40-SM Service Manual
D
Differential
BOILER DIFFERENTIAL (DIFF)
A heat source must be operated with a differential in order to
Fixed
Differential
reduce short cycling.
The
boiler differential is divided around
the boiler target temperature. The first stage
OFF
OFF
contact will close
once theStaging
water temperature at the
Proportional
Des
iredTemperature
Temperature
operatingDesired
sensor
is 1/2 of the differential setting below the
A Minimum
On Time
C Interstage On Delay
ON
boiler target
temperature,
andON
will open once the water
B Minimum Off Time
D Interstage Off Delay
temperature at the operating sensor is 1/2 of the
Increasing Time
differential setting above the boiler target temperature.
High
Heat
Load
Low
Heat
Load
OF F
OF F
OFF
OFF
ONDesired
Des iredTemperature
Temperature
A
B
ON
ON
C
OFF
D
ON
OFF
Increasing Time
ON
ON
Differential
Differential
Differential
A
B
C
D
Manual Differential
The differential can be manually set using the DIFF setting
in the Adjust menu.
Proportional Staging
Automatic
A Minimum On Time Differential
C Interstage On Delay
Fixed
B Minimum Off
Time Differential
D Interstage Off Delay
OFF
OFF
Differential
Auto Differential Fixed Differential
Auto differential is only available when using PID staging.
B oil MAX
Boil
MAX
ON
ON
Automatic Differential
B
Boil
oil MIN
MIN
High
Heat
Load
OF F
ON
ON
OFF
Low
WWS D
WWSD
Partial
Outdoor Reset
Heat
Load
Decreasing
ONOutdoor Air TemperatureON
B oil MAX
Boil
MAX
Differential
Low
Heat
Load
Differential
Des
iredTemperature
Temperature
If the Auto Desired
Differential
is selected, the control automatically
Differential
determinesONthe Automatic
best differential
ONas the load changes,
FF
O F F loads, the
thereby improving Oefficiency.
During light
High
Partial
Outdoor
Increasing
Time to Reset
differential
is
increased
allow
longer
on
and off times to
Heat
Load the potential for short cycling. During large loads, the
reduce
ON
ON
differential is narrowed thereby improving comfort in heating
spaces by reducing temperature
swing.
OFF
OFF
OF F
Differential
Minimum On Time (MIN ON)
The minimum on time is the minimum amount of time that
a stage must be on before it is allowed to turn off. Once a
stage turns on, it cannot turn off until a minimum on time
elapses. The minimum on time is adjustable through the
MIN ON setting in the Adjust menu.
C
OFF
Differential
Interstage Off Delay (OFF DLY)
The interstage off delay is the amount of time that must
elapse before turning off the next stage. Once a stage turns
off, the next stage cannot turn off until the interstage delay
off time elapses. The interstage off delay is adjustable
through the OFF DLY setting in the Adjust menu.
B
Increasing Water Temperature
Interstage On Delay (ON DLY)
The interstage on delay is the amount of time that must
elapse before turning on the next stage. Once a stage turns
on, the next stage cannot turn on until the interstage delay
on time elapses. The interstage on delay is adjustable
through the ON DLY setting in the Adjust menu.
A
C Interstage On Delay
D Interstage Off Delay
rature
Interstage Differential (STG DIFF)
The interstage differential is the temperature drop at which
the next stage will turn on. Once a stage turns on, the
next stage cannot turn on until the temperature drops
the interstage differential below the temperature at which
the previous stage turned on. The interstage differential
is adjustable through the STG DIFF setting in the Adjust
menu.
A Minimum On Time
B Minimum Off Time
Increasing
Temperature
Proportional (P)
Proportional staging, also known as step staging, is based
on manually adjusted settings that determine when the
next stage is required to turn on. These manual settings are
based on temperature and time. The interstage differential
sets the temperature drop at which the next stage turns on.
However, in order for a stage to fire, the interstage delay
on and minimum off times must first elapse.
Proportional Staging
Increasing
Temperature
BOILER MASS (BOIL MASS)
The boiler mass setting allows the installer to adjust the
control to the thermal mass of different types of heat sources
used. The boiler mass setting automatically determines the
stage delay on, stage delay off, minimum on time and
minimum off time of the stages. A higher thermal mass
setting provides slower staging, while a lower thermal mass
provides faster staging.
Minimum Off Time (MIN OFF)
The minimum off time is the minimum amount of time that
a stage must be off before it is allowed to turn on. Once a
stage turns off, it cannot turn on until a minimum off time
elapses. The minimum off time is adjustable through the
MIN OFF setting in the Adjust menu.
Increasing
Temperature
STAGE DELAY (STG DLY)
The stage delay is the minimum time between firing first
to second stage, second to third stage, and third to fourth
stage and is determined by the Stage Delay setting. It can
be manually set, or it can be set to automatic in which the
boiler mass determines the stage delay time.
7
D
Increasing
Temperature
OFF
Load
Differential
Des ired
Desired
Temperature
Temperature
BOILER MINIMUM
(BOIL
MIN)
ON
ON temperature that
The BOIL MIN setting
is the lowest water
the control is allowed to use as a boiler target temperature.
Increasing Time
During mild conditions, if the control calculates a boiler
target temperature that is below the BOIL MIN setting, the
boiler target temperature is adjusted to at least the BOIL
MIN setting. During this condition, if the boiler is operating,
the MIN segment turns on in the LCD while the boiler
target temperature or boiler operating sensor temperature
Automatic Differential
is viewed. If the installed boiler is designed for condensing
O F F set the BOIL MIN adjustment
OF F
or low temperature
operation,
High
to OFF.Heat
ON
ON
Differential
BOILER MAXIMUM (BOIL MAX)
OFF
OFF
The BOIL
Low MAX setting is the highest water temperature that
the control
is allowed to use as a boiler target
Heat
Load
temperature.
If ON
the control does target
BOIL MAX, and the
ON
temperature at the boiler outlet sensor is near the BOIL MAX
temperature, the MAX segment turns on in the LCD while
the boiler target, boiler inlet, boiler outlet or boiler supply
temperature is viewed.
Boil
B oil MAX
MAX
Boil
B oil MIN
MIN
WWS D
WWSD
Increasing Water Temperature
Partial Outdoor Reset
BOILER OUTLET MAXIMUM
The BOIL OUT MAX setting determines the highest water
temperature allowed at the boiler outlet sensor. The boiler
stages are immediately shut off once the water temperature
exceeds the BOIL OUT MAX setting at the boiler
outlet sensor location.
BOILER PUMP OPERATION ( )
Setpoint Operation
The boiler pump contact operates when:
+ 1/2 Differential
• A heat demand is present and parallel piping (Mode 1,
Setpoint Target
3, 4, 6) is used. Parallel piping requires the boiler
pump
to operate even while the boiler is off in order
to
provide
- 1/2 Differential
heat to the system.
• While the boiler is on and primary / secondary piping
(Mode 2, 5, 7) is used. Primary / secondary piping
reduces standby
losses
by Operation
isolating the boiler from the
Dedicated
DHW
system while the boiler is off.
Tank Target
• During external direct drive operation (Mode 8), the boiler
pump contact closes whenever there is an internal heat
Tank Target - Tank Differential
demand.
• After the boiler shuts off the boiler pump remains on to
purge heat from the boiler to the system.
Reset
Ratio
BOILER PUMP PURGE
( DLY)
After the boiler is shut off, the control continues to operate
the boiler pump for a period of time. The length of time that
the boiler pump continues
to run is based on the Pump
B
Boil
oil DSGN
DS GN
DLY setting. Once the boiler turns off, the control keeps
the boiler pump running for the time selected. This setting
allows purging of any excess heat out of the boiler after the
boiler is shut off. This also helps to prevent the water in the
B
Boil
oil START
S TARinto
T steam after the boiler is shut off.
boiler from flashing
Increasing Water Temperature
OFF
Differential
FIRE DELAY (Burner symbol DLY)
Does NOT apply to electric boiler operation.
The Fire Delay is the delay time that may occur between
the time that the control closes the Stage 1 contact and
when the burner fires. This delay is usually the result of a
burner pre-purge or other forms of time delay built into the
burner’s safety circuits.
Proportional Staging
BOILER TARGET TEMPERATURE (BOIL TARGET)
A Minimum On Time
C Interstage On Delay
The boiler Btarget
temperature
is Ddetermined
from the
Minimum
Off Time
Interstage Off Delay
mode of operation and the type of demand applied. The
control displays the temperature that it is currently trying to
maintain at the operating sensor as BOIL TARGET in the
A
B
C
D
View menu. The operating sensor for modes 1, 3, 4 and
6 is the boiler outlet sensor, and the operating sensor for
modes 2, 5 and 7 is the boiler supply sensor. If the control
does not presently have a requirement for heat, it displays
Fixed
“– – – ” in the LCD. There
isDifferential
no boiler target temperature
generated in Mode 8.
When Pump DLY is set to OFF, there is no purging. When
OUTDRDSGN
OUTDR
DS GN
Pump DLY is set to ON, the pump runs continuously. When
on is selected and the control is configured for outdoor reset,
OUTDRSTART
OUTDR
S TAR T
the pump continues to run even during Warm Weather Shut
Decreasing Outdoor Air Temperature
PUMP EXERCISING
If the boiler pump has not operated at least once every 70
hours, the control turns on the output for 10 seconds. This
minimizes the possibility of the pump seizing during a long
period of inactivity.
ALERT
The control closes the alert contact whenever an error
message is present.
Decreasing Outdoor Air Temperature
8
EM-40-SM Service Manual
Section B: Setpoint Operation
A setpoint is a fixed water temperature target that the
boiler is to maintain at the operation sensor once a demand
is present. The boiler maintains the boiler target by
operating the stages using proportional or PID logic
together with the boiler differential.
Setpoint Operation
+ 1/2 Differential
Setpoint Target
- 1/2 Differential
Mode 1 or 2 and Heat Demand (Dem 1)
A heat demand is required whenever heat is required for the
DHWAOperation
primaryDedicated
heating load.
heat demand is generated when a
Targetacross the CD
voltage between 24 and 120 V (ac) isTank
applied
(common demand) and the Ht D (heat demand). Once voltage is applied, the control turns on the Dem 1 segment in the
Targetto-maintain
Tank Differential
display and control operates the boilerTank
stages
the
BOIL TARGET 1 at the boiler outlet sensor (Mode 1) or the
boiler supply sensor (Mode 2).
Mode 1 or 2 and Setpoint Demand (Dem 2)
A setpoint demand is required whenever heat is required
for the secondary heating load such as an indirect
domestic hot water tank. A setpoint demand is generated
when a voltage between 24 and 120 V (ac) is applied across
the CD (common demand) and the Set D (setpoint demand)
(pins 1 and 3). Once voltage is applied, the control turns on
the Dem 2 segment in the display and control operates the
boiler stages to maintain the BOIL TARGET 2 at the boiler
outlet sensor (Mode 1) or the boiler supply sensor (Mode 2).
Modes 4 to 7 and Setpoint Demand (Dem 2)
A setpoint demand is required whenever heat is required
for the secondary heating load such as an indirect domestic
hot water tank. A setpoint demand is generated when a
voltage between 24 and 120 V (ac) is applied across the
CD (common demand) and the Set D (setpoint demand).
Once voltage is applied, the control turns on the Dem 2
segment in the display and control operates the boiler stages
to maintain the BOIL TARGET at the boiler outlet sensor
(Mode 4, 6) or the boiler supply sensor (Mode 5, 7).
Reset Ratio
Section C: Dedicated Domestic Hot Water (DHW) Operation
B oil DSGN
Boil
DS GN
A
B
C
TARGET
OUTDRSTART
OUTDR
Ssetting
TAR T
D
Increasing Water Temperature
When mode 3 is selected, the BTC provides dedicated
DHW operation.
Proportional Staging
A DHW
tank
temperatureC Interstage
sensor On
isDelay
required to be
A Minimum On Time
connected
on
the
Com
and
the
Sup/D
terminals
(4 and 6).
BBoil
D Interstage Off Delay
S TAR TOff Time
B Minimum
oil START
The DHW tank sensor must be installed in an immersion well
to measure the tank
temperature.
OUTDR
OUTDR
DSGN
DS GN
The TANK
is used to set the desired DHW
tank temperature. The TANK DIFF setting is the differential
Decreasing
Outdoor Air Temperature
below
the target.
Once an internal demand is generated, the Dem 1 segment
turns on in the LCD. The control then closes the Pump
contact, which starts the boiler pump and the control turns
Setpoint Operation
on the boiler pump segment in the display.
control then
+ 1/2The
Differential
operates the boiler stages to maintain the programmed tank
target temperature.
Setpoint Target
1/2 Differential
Note: A voltage does not need to be -applied
to the heat
demand or the setpoint demand in this mode of operation.
Dedicated DHW Operation
Tank Target
Differential
Increasing
Temperature
Fixed
Differential
An internal heat
demand
for DHW is generated when
the measured DHW tank temperature falls below the
OFF
TANK TARGET –OFF
TANK DIFF. The internal
heat demand
Des iredonce
Desired
Temperature
Temperature
is removed
the measured DHW tank temperature
exceeds
ONthe TANK TARGET. ON
Tank Target
- Tank Differential
Increasing Time
Reset Ratio
ON
ON
Low
EM-40-SM
Heat
Load
OF F
OFF
Service Manual
OFF
Differential
OF F
ifferential
High
Heat
Load
B oil START
Boil
S TAR T
OUTDRDSGN
OUTDR
DS GN
reasing Water Temperature
B oil DSGN
Boil
DS GN
Automatic Differential
9
Setpoint Operation
A Minimum On Time
B Minimum Off Time
+ 1/2 Differential
C Interstage On Delay
D Interstage Off Delay
Setpoint Target
Section D: Outdoor Reset Operation
B
C
- 1/2 Differential
D
Differential
Increasing
Temperature
ON
ON
HEAT DEMAND (Dem 1)
Increasing
Time
A heat demand
is required
whenever heat is required in
the system. A heat demand is generated when a voltage
between 24 and 120 V (ac) is applied across the CD
(common demand) and the Ht D (heat demand) pins.
Outdoor Design (OUTDR DSGN)
The OUTDR DSGN is the outdoor air temperature that is the
typical coldest temperature of the year where the building
Dedicated
DHW is
Operation
is located. This
temperature
used when completing heat
Tank Target
loss calculations for the building.
Boiler Design (BOIL DSGN)
Tank Target
- Tank Differential
The BOIL DSGN temperature is the water
temperature
required to heat the boiler zones when the outdoor air is
as cold as the OUTDR DSGN temperature.
Reset Ratio
Once voltage is applied, the control turns on the Dem 1
segment in the display. If the control is not in warm weather
Automatic Differential
shut down (WWSD), the control calculates a boiler target
FF
OF F
basedHigh
on the reset ratioOand
outdoor air temperature.
The
pumpHeat
and the boiler stages are operated to maintain the
boilerLoad
target at
(Mode 4), or the
ON
ON the boiler outlet sensor
boiler supply sensor (Mode 5).
Differential
B oil DSGN
Boil
DS GN
OFF
Differential
OFF
B
Boil
oil START
S TAR T
If the Low
control is in WWSD, the WWSD segment is shown
in theHeat
display and the boiler target in the View menu of the
Load
display remains
ON
ON “---“ (no target).
RESET RATIO
The control uses the four following settings to determine
the reset ratio:
B oil MAX
Boil
MAX
Increasing Water Temperature
Boiler Start (BOIL START)
Partial
Outdoor
The BOIL START
temperature
isReset
the theoretical boiler supply
water temperature that the heating system requires when
the outdoor air temperature equals the OUTDR START
temperature setting. The BOIL START is typically set to
the desired building temperature.
Outdoor Start (OUTDR START)
BSTART
oil MIN
MIN temperature is the outdoor air
The OUTDR Boil
temperature at which the control provides the BOIL START
water temperature to the system. The OUTDR START
is typically set to the desired building temperature.
OUTDRDSGN
OUTDR
DS GN
OUTDRSTART
OUTDR
S TAR T
Increasing Water Temperature
A
When either mode 4 or 5 is selected, the control uses
outdoor reset to control the water temperature while a heat
demand is present. Outdoor reset calculates the boiler
target temperature based on the outdoor air temperature
Differential
and reset ratio. As aFixed
result,
the boiler target changes
proportional to the outdoor temperature. The reset ratio is
OFF Outdoor
OFF Start, Boiler Design,
determined from the Boiler
Start and Outdoor
Design
settings.
Des iredTemperature
Desired
Temperature
Decreasing Outdoor Air Temperature
Warm Weather Shut Down (WWSD)
When the outdoor air temperature rises above the WWSD
setting, the control enters WWSD and turns on the WWSD
segment in the display. Once the outdoor air temperature
falls below the WWSD setting, the control exits WWSD.
When the control is in Warm Weather Shut Down, the Dem
1 segment is displayed if there is a heat demand. However,
the control does not operate the boiler to satisfy the heat
demand. The control continues to respond to setpoint
demands.
WWS D
WWSD
Section E: External
Temperature Target Input
Decreasing
Air Temperature
When modes
6 orOutdoor
7 are selected,
the control allows for an
external control to operate the boiler temperature through
an external input signal provided by a Building Management
System (BMS), Energy Management System (EMS), or tekmar tN4 System Control. When in modes 6 or 7, the external
heat demand (CD and Ht D) are disabled. The setpoint
demand continues to operate as normal.
INTERNAL HEAT DEMAND
An internal heat demand is generated when an analog
positive 0-10 V (dc) or 2-10 V (dc) signal is applied to the
+V(in) input. The negative V (dc) signal is applied to the
Com/- input.
10
0-10 V (dc) or 0-20 mA External Input Signal
The external input signal can be selected to be either 0-10
V (dc) or 2-10 V (dc) range. When the 0-10 V (dc) range is
selected, an input voltage of 1 V (dc) corresponds to a
boiler target temperature of 50°F (10°C). An input voltage of
10 V (dc) corresponds to a boiler target temperature of
210°F (99°C). As the voltage varies between 1 V (dc) and 10
V (dc), the boiler target temperature varies linearly between
50°F (10°C) and 210°F (99°C). If a voltage below 0.5 V (dc)
is received, the boiler target temperature is displayed as “ –
– – “ indicating that there is no longer an internal heat
demand.
EM-40-SM Service Manual
A 0-20 mA signal can be converted to a 0-10 V (dc) signal
A 0-20
mA signal
canOhm
be converted
to the
a 0-10
V (dc) signal
by
installing
a 500
resistor on
external
input signal
by
installing
a
500
Ohm
resistor
on
the
external
input signal
device’s terminals.
device’s terminals.
0-10 V (dc)
0
0-20 mA*
0
Boiler Target
--- (OFF)
1
2
2
4
50°F (10°C)
68°F (20°C)
3
4
6
8
86°F (30°C)
103°F (39°C)
5
6
10
12
121°F (49°C)
139°F (59°C)
7
8
14
16
157°F (69°C)
174°F (79°C)
9
10
18
20
192°F (89°C)
210°F (99°C)
*requires a 500 ? resistor
2-10 V (dc) or 4-20 mA External Input Signal
The external input signal can be selected to be either 0-10
V (dc) or 2-10 V (dc) range. When the 2-10 V (dc) range is
selected, an input voltage of 2 V (dc) corresponds to a
Example
= 0-10
V (dc)(10°C). An input voltage of
boiler
targetRange
temperature
of 50°F
(69°C)
10 V (dc) Input
corresponds= to7 Va(dc)
boiler target157°F
temperature
of
Offset
= + 5°F (3°C)
+ 5°F (3°C)
210°F (99°C).
As the voltage
varies between
2 V (dc) and
(72°C)linearly
10 V (dc),Boiler
the Target
boiler= target temperature162°F
varies
between 50°F (10°C) and 210°F (99°C). If a voltage below
1.5 V (dc) is received the boiler target temperature is
displayed as “ – – – “ indicating that there is no longer an
internal heat demand.
A 4-20 mA signal can be converted to a 2-10 V (dc) signal
Aby4-20
mA signal
canohm
be converted
to the
a 2-10
V (dc) signal
installing
a 500
resistor on
external
input signal
by
installing
a
500
ohm
resistor
on
the
external
input signal
device’s terminals.
device’s terminals.
A 4by in
devi
A 0-20
signal can
be mA*
converted to aBoiler
0-10 VTarget
(dc) signal
2-10mA
V (dc)
4-20
by installing a 500 Ohm resistor on the external input signal
0
--- (OFF)
0
device’s terminals.
1
2
--- (OFF)
0-10 V (dc)
0-20 mA*
Boiler Target
2
4
50°F (10°C)
0
0
--- (OFF)
3
6
70°F (21°C)
1
2
50°F (10°C)
4
8
90°F (32°C)
2
4
68°F (20°C)
5
10
110°F (43°C)
3
6
86°F (30°C)
6
12
130°F (54°C)
4
8
103°F (39°C)
7
14
150°F (66°C)
5
10
121°F (49°C)
8
16
170°F (77°C)
6
12
139°F (59°C)
9
18
190°F (88°C)
7
14
157°F (69°C)
10
20
210°F (99°C)
8
16
174°F (79°C)
*requires a 500 ? resistor
9
18
192°F (89°C)
2
10
20
210°F (99°C)
OFFSET
The Offset setting
allowsa 500
the ?boiler
target temperature to
*requires
resistor
be fine tuned to the external input signal. The control reads
the external input signal and converts this to a boiler target
temperature. The Offset setting is then added to the boiler
target temperature.
Example
Range
Input
Offset
Boiler Target
= 0-10 V (dc)
= 7 V (dc)
= + 5°F (3°C)
=
157°F (69°C)
+ 5°F (3°C)
162°F (72°C)
Section F: External Direct Drive Operation
When mode 8 is selected, the control allows for an external
control to operate the boiler through an analog direct drive
input signal provided by a boiler sequencing control such as
a tekmar Boiler Control 275. When in mode 8, the
external heat demand (CD and Ht D) and the setpoint
demand (CD and Set D) are disabled.
DIRECT DRIVE INPUT SIGNAL
An external boiler sequencer provides a positive 0-10 V (dc)
input signal to the control +V(in) input. The negative V (dc)
signal is applied to the Com/- input.
The boiler burner remains off while the direct drive input
signal range is between 0 to 0.5 V (dc). The Stage 1 contact
remains on as long as the direct drive input signal is over 0.5
V (dc). The Stage 2 contact is activated once the direct drive
input signal reaches or exceeds 3.0 V (dc). Stage 3 contact
is activated once the direct drive input signal reaches or
exceeds 5.5 V (dc). Stage 4 contact is activated once the
direct drive input signal reaches or exceeds 8.0 V (dc).
EM-40-SM Service Manual
PUMP OPERATION
The pump is turned on as soon as the direct drive input
24 Rdirect drive input signal
12 C the
signal reaches 0.5 V (dc). Once
23 Alert
11
falls below 0.5 V (dc), the 10
pump
continues to operate until
+V(in) 22 Stg 4
the Pump DLY purge expires,
then
9 Com/- 21the
Stg 4pump shuts off.
8 Boil in 20 Stg 3
7 Boil O 19 Stg 3
BOILER OUTLET MAXIMUM
TEMPERATURE
18 Stg 2
6 Sys/D
5 Outis 17
Stg 2to operate the boiler
The external boiler sequencer
able
4 Com 16 Stg 1
temperature. However, the3 BOIL
Set D 15OUT
Stg 1 MAX setting limits
the highest temperature at 2the
14 Pmpoutlet sensor. Should
Ht Dboiler
13 Pmpthe BOIL OUT MAX
1 CD
the boiler outlet temperature
exceed
setting, the Stage contacts are opened to shut off the
burner. The burners remains off for the minimum off time
and the boiler outlet temperature falls 2°F (1°C) below the
BOIL OUT MAX setting.
B
A
OFF
OFF
11
C)
4
8
C)
5
10
110°F (43°C)
C)
6
12
130°F (54°C)
14
150°F (66°C)
8
16
170°F (77°C)
10
20
210°F (99°C)
C)
C)
C)
C)
F (69°C)
3°C)
F (72°C)
Installation
7
90°F (32°C)
Electrical
Connections
to
9
18
190°Fthe
(88°C) Control
The installer should
test to confirm that no voltage is
*requires a 500 ? resistor
present at any of the wires during installation. The control
includes a 24 pin connector for ease of installation.
NOTE: Figure shown should be used for checking control
only. Boiler wiring diagram should be used for checking the
rest of boiler, because interface board has different terminal
numbers.
Output Connections
Boiler Pump Contact
The Pump pins are an isolated output in the control.
There is no power available on these pins from
the control. This output is to be used as a switch to either
make or break power to the boiler pump. Since this is an
isolated contact, it may switch a voltage between 24 V (ac)
and 120 V (ac).
Stage Contacts
Stage 1, Stage 2, Stage 3, and Stage 4 are isolated
outputs in the control. There is no power available
on these pins from the control. This output is to be used as
a switch to either make or break the stage circuits. When
the control requires the stage to fire, it closes the Stage
contact.
24 R
12 C
23 Alert
11
10+V(in) 22 Stg 4
9 Com/- 21 Stg 4
8 Boil in 20 Stg 3
7 Boil O 19 Stg 3
6 Sys/D 18 Stg 2
5 Out 17 Stg 2
4 Com 16 Stg 1
3 Set D 15 Stg 1
2 Ht D 14 Pmp
1 CD 13 Pmp
B
A
OFF
OFF
Alert Contact
The Alert pin on the control is connected to an audible alarm
on the interface board which sounds an alert when it senses
an open sensor circuit.
Sensor and Unpowered Input Connections
Do not apply power to these terminals as this damages
the control.
Boiler Outlet Sensor
Connect the two wires from the Boiler Outlet Sensor to the
Com/- (common sensor) and Boil O (boiler outlet sensor)
pins. The boiler outlet sensor is used by the control to measure the boiler outlet water temperature from the boiler.
Note: The boiler outlet sensor is required for every mode of
operation.
Powered Input Connections
24 V (ac) Power
Connect the 24 V (ac) power supply to the C and R
terminals. This connection provides power to
the microprocessor and display of the control. As well, this
connection provides power to the Alert terminal from
the R terminal.
Heat Demand
To generate a heat demand, a voltage between 24 V (ac)
and 120 V (ac) must be applied across the CD (common
demand) and the Ht D (heat demand) pins.
Setpoint Demand
To generate a setpoint demand, a voltage between 24 V (ac)
and 120 V (ac) must be applied across the CD (common
demand) and the Set D (setpoint demand) pins.
Boiler Inlet Sensor
Connect the two wires from the Boiler Inlet Sensor to the
Com/- (common sensor) and Boil in (boiler inlet sensor)
pins. The boiler inlet sensor is used by the control
to measure the boiler inlet water temperature from the boiler.
Note: The boiler inlet sensor is optional for every mode
of operation.
Boiler Supply Sensor
An optional Boiler Supply Sensor may be connected to the
control. If the sensor is required, connect the two wires from
the sensor to the Com (common sensor) and Sys/D (boiler
supply) pins.
Caution: The same power supply must be used for both the
heat demand and setpoint demand circuits since they
share the CD (common demand) pin.
12
EM-40-SM Service Manual
DHW Tank Sensor
An optional DHW Tank Sensor may be connected to the
control. If the sensor is required, connect the two wires
from the sensor to the Com (common sensor) and Sys/D
(DHW) pins.
External Input
The control can accept an external input signal from an
external control. If an external input signal is required,
connect the positive 0-10 V (dc) wire to the +V(in) pin and
connect the negative 0-10 V (dc) wire to the Com/- pin.
Outdoor Sensor
An optional Outdoor Sensor may be connected to the
control. If the sensor is required, connect the two wires from
the Outdoor Sensor to the Com (common sensor) and Out
(outdoor sensor) pins. The outdoor sensor is used by the
control to measure the outdoor air temperature.
Testing
The wiring harness must be unplugged from the connector
on the control before testing. To remove the wiring harness,
push down on the tab on the connector and pull away from
the control.
The following tests are performed using standard testing
practices and procedures and should only be carried out
by properly trained and experienced persons.
the resistance of the sensor at the control. Using the chart
below, estimate the temperature measured by the sensor.
The sensor and the thermometer readings should be close.
If the meter reads a very high resistance, there may be a
broken wire, a poor wiring connection or a defective sensor.
If the resistance is very low, the wiring may be shorted,
there may be moisture in the sensor or the sensor may
be defective. To test for a defective sensor, measure the
resistance directly at the sensor location.
A good quality electrical test meter, capable of reading
from at least 0-300 V (ac) and at least 0-2,000,000 Ohms,
is essential to properly test the wiring and sensors.
Outdoor
Sensor
TEST THE SENSORS
In order to test the sensors, the actual temperature at
each sensor location must be measured. A good quality
digital thermometer with a surface temperature probe is
recommended for ease of use and accuracy. First measure
the temperature using the thermometer and then measure
Temperature
°F
-50
-45
-40
-35
-30
-25
-20
-15
-10
-5
0
5
10
15
°C
-46
-43
-40
-37
-34
-32
-29
-26
-23
-21
-18
-15
-12
-9
Resistance
490,813
405,710
336,606
280,279
234,196
196,358
165,180
139,402
118,018
100,221
85,362
72,918
62,465
53,658
EM-40-SM Service Manual
Temperature
°F
20
25
30
35
40
45
50
55
60
65
70
75
80
85
°C
-7
-4
-1
2
4
7
10
13
16
18
21
24
27
29
Resistance
46,218
39,913
34,558
29,996
26,099
22,763
19,900
17,436
15,311
13,474
11,883
10,501
9,299
8,250
Temperature
°F
90
95
100
105
110
115
120
125
130
135
140
145
150
155
°C
32
35
38
41
43
46
49
52
54
57
60
63
66
68
Resistance
7,334
6,532
5,828
5,210
4,665
4,184
3,760
3,383
3,050
2,754
2,490
2,255
2,045
1,857
Step 1
Boil
Step 2
Boil
Temperature
°F
160
165
170
175
180
185
190
195
200
205
210
215
220
225
°C
71
74
77
79
82
85
88
91
93
96
99
102
104
107
Resistance
1,689
1,538
1,403
1,281
1,172
1,073
983
903
829
763
703
648
598
553
The boiler pump is turned on.
1
Stage 1 heating element(s) on.
13
18
13,474
-5
-21
100,221
65
-35
-37
280,279
35
2
29,996
0
-18
85,362
70
21
11,883
-30
-34
234,196
40
4
26,099
5
-15
72,918
75
24
10,501
-32
196,358
7
22,763
-25
45
TEST
SUPPLY
80
27
9,299
10THE POWER
-12
62,465
-29
165,180
10
19,900
-20
50
wires
wires
Make
-9
53,658are not in85contact29with other
15sure exposed
8,250
-15
-26
139,402
55
13 measure
17,436
or grounded
surfaces.
Turn on the power
and
the
-10between
-23 the C 118,018
60 an AC
16 voltmeter,
15,311
voltage
and R pins using
the
13,474
65V (ac).18
-5 should
-21be between
100,221
Temperature
Resistance
Temperature
Resistance
reading
22 and 26
70
21
11,883
0
-18
85,362
°F
°C
°F
°C
75
24
10,501
5
-15
72,918
-50
-46
490,813
20
-7
46,218
80
27
9,299
10
-12
62,465
-43
405,710
-4
39,913
-45
25
85
29
8,250
-9
53,658
15
-40
-40
336,606
30
-1
34,558
57
2,754
96
763
135
205
105
41
5,210
175
79
1,281
140
60
2,490
210
99
703
110
43
4,665
180
82
1,172
145
63
2,255
215
102
648
46
4,184
85
1,073
115
185
CONNECTING
THE
CONTROL
150
66
2,045
220
104
598
49 all power
3,760to the devices
88 wiring 983
120 sure
190
and
Make
155
68
1,857
225
107
553harness
52
3,383
195
91
903
is125
off.
130
54
3,050
200
93
829
Reconnect the wiring harness to the connector on the
57
2,754
96
763
135
205
Temperature
Resistance
Temperature
Resistance
control by aligning the tab on the wiring harness to the tab
140
60
2,490
210
99
703
°C
°F then°Cpushing the wiring
on°Fthe connector
on the control and
145
63
2,255
215
102
648on the
90
32
7,334
160
71 The tab
1,689
harness into the connector on the control.
150
66
2,045
220
104
598
35
6,532
74
1,538
95
165
wiring
over the
tabison
the connector
1 harness
pump
turned
on.
Step
The boiler
Boil should snap
68
1,857
225
107
553
100
38
5,828
170
77
1,403
of155
the control.
-37
280,279
2
29,996
-35
35
-30
-34
234,196
40
4
26,099
-25
-32
196,358
45
7
22,763
22 to 26 V (ac)
-20
-29
165,180
50
10
19,900
-15
-26
139,402
55
13
17,436
-23
118,018
60
16
15,311
TEST -10
THE POWERED
INPUTS
65
18
13,474
-5
-21
100,221
Heat Demand
0 demand
-18 is used,
85,362measure70the voltage
21
11,883
If a heat
between
24
10,501
-15 demand)
72,918 and the75Ht D (heat
the CD5 (common
demand)
22 to
V (ac)
8026device
27 calls9,299
62,465 demand
for
pins. 10When -12the heat
heat, between
130 V (ac) should
be29measured
at
85
8,250
15
-920 and 53,658
41
5,210 Stage 1175
1,281
1052
Step
heating79
element(s)
on.
Boil
Apply
power
to the 1control.
The operation
of
the control
110
43
4,665
180
82
1,172
on power up is described in the Sequence of Operation
heating85
element(s)
on.
Step
1153 of the
46
1,073
section
Boilbrochure.
124,184 Stage 2185
the pins. When the heat demand device is off, less than 5
V (ac) should be measured.
20 to 130 V (ac)
26VV(ac)
(ac)
2022
toto
130
Setpoint Demand
If a setpoint demand is used, measure the voltage between
the CD (common demand) and the Set D (setpoint demand)
pins. When the setpoint demand device calls for heat,
20
and
130
V
(ac)
should
be
between
measured at the pins. When the setpoint demand device is
off, less than 5 V (ac) should be measured.
120
49
3,760
190
88
983
Step
3195
heating91
element(s)
on.
1254
52
3,383 Stage
903
TESTING
THE
OUTPUTS
Boil CONTROL
123
Step 1
The boiler pump is turned on.
The
has a3,050
built-in test200routine93that is 829
used to
130 control
54Boil
4205
heating
element(s)
on. is
Step
the
control
functions.
The96
test sequence
override
1355
57
2,754 Stage
763
Boilmain 1234
Step 2
Stage 1 heating element(s) on.
Boilthe p1 button
enabled
when
is
pressed
and
held
for
3 sec140
60
2,490
210
99
703
The boiler
pump
and stages
1be canonds
while
in
the
View
menu.
The
test
sequence
can
1456
63
2,255 to 4 are 215
Step
shut
off.102
Theelement(s)
alert is648 on.
Stage
2 heating
Step
3
Boil
12 the
celled
either
Item,
or q
for
10 seconds.
150 by pressing
66
2,045 closed
220p
104button. Once
598 the
test sequence is enabled, the outputs are tested in the follow155
68 the test
1,857
107element(s)
553 on.
The
control
exits
resumes
normal
Step
4
Stage 225
3and
heating
ing
sequence.
Boil
123sequence
operation.
Press
p button
3 seconds
while inon.
the
Step 5 and hold the 1234
Stagefor
4 heating
element(s)
View menu. Boil
The boiler pump and stages 1
Step 6
to 4 are shut off. The alert is
closed
for 10
seconds.
Step 1
The boiler
pump
is turned on.
Boil
The control exits the test sequence and resumes normal
operation.
Step 2
Stage 1 heating element(s) on.
Boil
1
Step 3
Boil
12
Stage 2 heating element(s) on.
Step 4
Boil
123
Stage 3 heating element(s) on.
Step 5
Boil
1234
Stage 4 heating element(s) on.
Step 6
The boiler pump and stages 1
to 4 are shut off. The alert is
closed for 10 seconds.
The control exits the test sequence and resumes normal
operation.
Test the External Input
If an external input signal is used,
20 to measure
130 V (ac) the voltage
between the Com/- and +V(in) pins. When the
external control calls for heat, between 0 and 10 V (dc)
should be measured.
14
EM-40-SM Service Manual
Control Settings
DIP Switch Settings
Note: DIP switches are located on the front of the control.
Mode 1
(A) Factory / Installer
BTC
The Factory / Installer DIP switch is used to select which
items are available to be viewed and / or adjusted in the
user interface. The Relay
Factory Access Level includes all
the settings available in the control. The Installer Access
Level includes the settings and items which are required
for system setup.
(B) Not Used
B
OFF
A
OFF
Mode 1
Factory
Installer
BTC
Relay
Boiler
Outlet
Sensor
Boiler
Outlet
Sensor
Inlet Sensor
Mode Boiler
1 and
2 – Two Setpoint Operation
Applications
Boiler Inlet Sensor
Mode
Zone
Box
Mode
1 2– Two Setpoint Operation with
Parallel
Piping
BTC
Mode 1
Relay
Mode 2 – Two Setpoint Operation with Primary /
Secondary Piping
Mode 2
Zone Box
BTC
B
BTC
OFF
A
Relay
Boiler
Outlet
Sensor
Boiler
Outlet
Sensor
Factory
Boiler
Supply
Sensor
OFF
Relay
Installer
Boiler
Outlet
Sensor
Boiler Inlet Sensor
Boiler
Supply
Sensor
Boiler Inlet Sensor
The control receives a heat demand provided from zone
valve end switches or a switching relay end switch. The
control
on the boiler pump and operates
the burners
Modeturns
2
Zone Box
BTCtarget 1 temperature at the
to maintain the setpoint boiler
boiler outlet sensor whenever a heat demand is present.
The control receives a setpoint demand from a DHW
Relay
aquastat. The control operates the burners to maintain the
setpoint boiler target 2 at the boiler outlet sensor whe
never a setpoint demand is present.
Boiler Inlet Sensor
The control receives a heat demand provided from zone
valve end switches or a switching relay end switch. The
control turns on the boiler pump and operates the burners
to maintain the boiler target 1 temperature at the boiler
supply sensor whenever a heat demand is present. The
control receives a setpoint demand from a DHW aquastat.
The control operates the burners to maintain the setpoint
boiler target 2 at the boiler supply sensor whenever a
setpoint demand is present.
Boiler
Outlet
Note: An
external relay is required to operate the DHW
Sensor
pump and
provide DHW priority if required by disabling
the boiler pump.
Boiler
Note: An external relay is required to operate the DHW
pump and provide DHW priority if required by disabling
the system pump.
Supply
Sensor
Boiler Inlet Sensor
EM-40-SM Service Manual
15
Mode 1 and 2 – Two Setpoint Operation - View Menu
View Next Item
The View menu items display current operating
temperatures and system status information. Use the
Item button to view items in this menu.
Item
Ite m F ie ld
R ang e
---,
35 to 266°F
(2 to 130°C),
OFF
14 to 266°F
VIEW MENU
(-10 to 130°C)
14 to 266°F
(-10 to 130°C)
14 to 266°F
(-10 to 130°C)
0 to 252°F
(0 to 140°C)
0 to 999
De s c riptio n
A c c es s
BOILER TARGET
The boiler target is the temperature the control is
currently trying to maintain at the boiler supply sensor
or the boiler outlet sensor.
BOILER SUPPLY
Current boiler supply water temperature as measured
by the boiler supply sensor.
Note: This item is only available when MODE is set to 2.
BOILER OUTLET
Current boiler outlet water temperature as measured
by the boiler outlet sensor.
Note: When MODE is set to 2 this item is only visible
in the Factory access level.
BOILER INLET
Current boiler inlet water temperature as measured by
the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
Factory
Installer
Factory
Installer
Factory
(Installer for
Mode 1)
Factory
Installer
BOILER DELTA T
Current temperature difference between the boiler outlet
sensor and the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
Factory
BOILER ON HOURS
The total number of running hours of the boiler since
this item was last cleared. Clear the numbers of hours
by pressing and holding the
and buttons together
while viewing this item.
Factory
After the last item, the control returns to the first item in the menu.
16
EM-40-SM Service Manual
Mode 1 and 2 – Two Setpoint Operation - Adjust Menu (1 of 2)
Enter Adjust Menu
Next Item
Item
Change Value
Item
ADJUST MENU
Item Field
The Program menu items are the programmable settings
used to operate the system. Press and hold all three
buttons simultaneously to enter the Program menu.
Range
Description
Access
1 to 8
MODE
Select the operating mode for the control.
Factory
PId or P
STAGE MODE
Select the staging operation to be either
automatic or manual.
(PId = automatic)
(P = proportional)
OFF,
70 to 220°F
(21 to 104°C)
BOILER TARGET 1
Select the boiler target temperature while a
heat demand is present.
OFF,
70 to 220°F
(21 to 104°C)
BOILER TARGET 2
Select the boiler target temperature while a
setpoint demand is present.
120 to 225°F
(49 to 107°C)
BOILER OUTLET MAXIMUM
S e l e c t th e m a x i m u m b o i l e r o u t l et
temperature. Exceeding this temperature
shuts off the boiler.
Factory
120 to 225°F
(49 to 107°C),
OFF
BOILER MAXIMUM
Select the maximum boiler target
temperature.
Factory
OFF,
80 to 180°F
(27 to 82°C)
BOILER MINIMUM
S e l e c t th e m i n i m u m b o i l e r t a r g et
temperature.
Factory
0:00 to 3:00 min
(1 second
increments)
1 (Lo) or
2 (Med) or
3 (Hi)
FIRE DELAY (Not valid for electric boiler application)
Select the amount of time required
for combustion pre-purging, ignition
a n d t h e f l a m e to b e e s t a b l i s h e d .
Note: This setting is only available when
STAGE MODE is set to PId.
BOILER MASS
Select the thermal mass of the boiler.
Note: This setting is only available when
STAGE MODE is set to PId.
Installer
Setting
Default
Setting 4
Factory
Installer
Factory
Installer
Factory
Installer
Factory
NOT VALID
FOR ELECTRIC
BOILER
APPLICATION
Factory
Installer
Continued on next page.
EM-40-SM Service Manual
17
Mode 1 and 2 – Two Setpoint Operation - Adjust Menu (2 of 2)
ADJUST MENU
Item Field
Range
Description
Access
Au, 0:30 to
9:55 min
STAGE DELAY
Select the minimum time delay between
stages.
Note: This setting is only available when
STAGE MODE is set to PId.
Au, 2 to 42°F
(1 to 23°C)
DIFFERENTIAL
Select the boiler differential.
Note: The automatic setting is only available
when STAGE MODE is set to PId staging.
Factory
0 to 10°F
(0 to 6°C)
STAGE DIFFERENTIAL
Select the interstage temperature differential
between stages for proportional staging.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 8:00 min
INTERSTAGE ON DELAY
Select the amount of time that must pass
once a stage has been turned on in order
to allow the next stage to turn on.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 4:00 min
INTERSTAGE OFF DELAY
Select the amount of time that must pass
once a stage has been turned off in order
to allow the next stage to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 5:00 min
MINIMUM ON TIME
Select the minimum amount of time that
the stage contact must remain on before it
is allowed to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 5:00 min
MINIMUM OFF TIME
Select the minimum amount of time that
the stage contact must remain off before it
is allowed to turn back on.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
OFF, 0:20 to
9:55 min, On
PUMP DELAY
Select the boiler pump purge time after
shutting off the boiler.
Factory
°F or °C
TEMPERATURE UNITS
Select to display temperature in degrees
Fahrenheit or in degrees Celsius.
Setting
Factory
Installer
Factory
Installer
After the last item, the control returns to the first item in the menu.
18
EM-40-SM Service Manual
Mode 3 – Dedicated Domestic Hot Water Tank with Parallel Piping
Application
Mode 3
BTC
Mode 3 - Dedicated DHW with Parallel Piping
The control measures the tank temperature using
a DHW sensor. Once the tank temperature falls the tank
differential below the tank setpoint, an internal
heat demand is created. The boiler pump is turned on
and the boiler is operated to maintain the tank target
temperature.
Mode 3
BTC
Boiler
DHW
Outlet
Tank
Sensor
Sensor
Boiler
DHW
OutletBoiler Inlet Sensor
Tank
Sensor
Sensor
Boiler Inlet Sensor
Mode 3 – Dedicated DHW with Parallel Piping - View Menu
View Next Item
View Next Item
Item
Item
Ite m F ie ld
Ite m F ie ld
R ang e
R-a- -n, g e
35 to 266°F
---,
(2 to 130°C),
35 to
266°F
OFF
(2 to 130°C),
OFF
The View menu items display current operating
temperatures and system status information. Use the
The button
View menu
current operating
Item
to viewitems
itemsdisplay
in this menu.
temperatures and system status information. Use the
Item button to view items in this menu.
De s c riptio n
A c c es s
De s c riptio n
TANK TARGET
The temperature that the control is trying to maintain
TANK
TARGET
in
the tank.
The temperature that the control is trying to maintain
in the tank.
BOILER OUTLET
Current boiler outlet water temperature as measured
(-10
BOILER
OUTLET
by
the boiler
outlet sensor.
14 to
to 130°C)
266°F
Current boiler outlet water temperature as measured
(-10 to 130°C)
by the boiler outlet sensor.
BOILER INLET
Current boiler inlet water temperature as measured by
14 to 266°F
BOILER
the
boilerINLET
inlet sensor.
(-10
to
130°C)
CurrentThis
boiler
inlet
wateravailable
temperature
asameasured
by
14 to 266°F
Note:
item
is only
when
boiler inlet
the boiler
inlet sensor.
sensor
is installed.
(-10 to 130°C)
Note: This item is only available when a boiler inlet
BOILER
T
sensor isDELTA
installed.
Current temperature difference between the boiler outlet
0 to 252°F
BOILERand
DELTA
T
sensor
the boiler
inlet sensor.
(00to
140°C)
Current
temperature
difference
between
boiler outlet
to 252°F
Note: This item is only
available
whenthe
a boiler
inlet
sensor
and
the
boiler
inlet
sensor.
sensor is installed.
(0 to 140°C)
Note: This item is only available when a boiler inlet
sensor is installed.
TANK
14 to 266°F
Current domestic hot water tank temperature as measured
(-10
TANK
by
the DHW tank sensor.
14 to
to 130°C)
266°F
Current domestic hot water tank temperature as measured
(-10 to 130°C)
by the DHW tank sensor.
BOILER ON HOURS
The total number of running hours of the boiler since
BOILER
0 to 999
this
itemON
wasHOURS
last cleared. Clear the numbers of hours
Thepressing
total number
of running
the boiler
since
by
and holding
the hours
and ofbuttons
together
0 to 999
this item
was last
while
viewing
thiscleared.
item. Clear the numbers of hours
by pressing and holding the and buttons together
while
viewing
item.
After the last item, the control returns to the first
item
in thethis
menu.
VIEW
MENU
VIEW
MENU
14 to 266°F
EM-40-SM
Service Manual
After the last item, the control returns to the first item in the menu.
A c c es s
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Factory
Factory
Installer
Factory
Installer
Factory
Factory
19
Mode 3 – Dedicated DHW with Parallel Piping - Adjust Menu (1 of 2)
Enter Adjust Menu
Next Item
Item
Change Value
Item
ADJUST MENU
Item Field
The Program menu items are the programmable settings
used to operate the system. Press and hold all three
buttons simultaneously to enter the Program menu.
Range
Description
Access
1 to 8
MODE
Select the operating mode for the control.
Factory
PId or P
STAGE MODE
Select the staging operation to be either
automatic or manual.
(PId = automatic)
(P = proportional)
OFF, 70 to
190°F
(21 to 88°C)
TANK TARGET
Select the dedicated domestic hot water
tank target temperature.
Au, 2 to 10°F
(1 to 6°C)
TANK DIFFERENTIAL
Select the dedicated domestic hot water tank
differential. The DHW sensor temperature
must fall below this setting before the
boiler will turn on.
120 to 225°F
(49 to 107°C)
BOILER OUTLET MAXIMUM
Select the maximum boiler outlet
temperature. Exceeding this temperature
shuts off the boiler.
0:00 to 3:00 min
(1 second
increments)
1 (Lo) or
2 (Med) or
3 (Hi)
Installer
FIRE DELAY
Select the amount of time required for
combustion pre-purging, ignition and the
flame to be established.
Note: This setting is only available when
STAGE MODE is set to Pld.
BOILER MASS
Select the thermal mass of the boiler.
Note: This setting is only available when
STAGE MODE is set to PId.
Setting
Default
Setting 4
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Factory
NOT VALID
FOR ELECTRIC
BOILER
APPLICATION
Factory
Installer
Continued on next page.
20
EM-40-SM Service Manual
Mode 3 – Dedicated DHW with Parallel Piping - Adjust Menu (2 of 2)
Item Field
Range
Description
Au, 0:30 to
9:55 min
STAGE DELAY
Select the minimum time delay between
stages.
Note: This setting is only available when
STAGE MODE is set to PId.
0 to 10°F
(0 to 6°C)
STAGE DIFFERENTIAL
Select the interstage temperature differential
between stages for proportional staging.
Note: This setting is only available when
STAGE MODE is set to P.
ADJUST MENU
0:10 to 8:00 min
0:10 to 4:00 min
0:10 to 5:00 min
0:10 to 5:00 min
INTERSTAGE ON DELAY
Select the amount of time that must pass
once a stage has been turned on in order
to allow the next stage to turn on.
Note: This setting is only available when
STAGE MODE is set to P.
INTERSTAGE OFF DELAY
Select the amount of time that must pass
once a stage has been turned off in order
to allow the next stage to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
MINIMUM ON TIME
Select the minimum amount of time that the
stage contact must remain on before it is
allowed to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
MINIMUM OFF TIME
Select the minimum amount of time that the
stage contact must remain off before it is
allowed to turn back on.
Note: This setting is only available when
STAGE MODE is set to P.
OFF, 0:20 to
9:55 min, On
PUMP DELAY
Select the boiler pump purge time after
shutting off the boiler.
°F or °C
TEMPERATURE UNITS
Select to display temperature in degrees
Fahrenheit or in degrees Celsius.
Access
Setting
Factory
Installer
Factory
Factory
Factory
Factory
Factory
Factory
Factory
Installer
After the last item, the control returns to the first item in the menu.
EM-40-SM Service Manual
21
Mode 4 and 5 – Outdoor Reset and Setpoint Operation
Applications
Mode 4 – Outdoor Reset and Setpoint with Parallel
Piping
Mode
Mode 44
Mode 5 – Outdoor Reset and Setpoint with Primary
– Secondary Piping
Mode
Mode 55
BTC
BTC
Outdoor
Outdoor
Sensor
Sensor
BTC
BTC
Relay
Relay
Boiler
Boiler
Outlet
Outlet
Sensor
Sensor
Outdoor
Outdoor
Sensor
Sensor
Relay
Relay
Boiler
Boiler
Outlet
Outlet
Sensor
Sensor
Boiler
Boiler
Supply
Supply
Sensor
Sensor
Boiler
Boiler Inlet
Inlet Sensor
Sensor
Boiler
Boiler Inlet
Inlet Sensor
Sensor
The control receives a heat demand provided from zone
valve end switches or a switching relay end switch. The
control turns on the boiler pump and operates the boiler to
maintain the outdoor reset boiler temperature at the boiler
outlet sensor. The control receives a setpoint demand from
a DHW aquastat. The control turns on the boiler pump and
operates the boiler to maintain the setpoint boiler target
temperature at the boiler outlet sensor whenever a setpoint
demand is present.
The control receives a heat demand provided from zone
pump end switches or switching relay end switch. The
control turns on the boiler pump and operates the boiler to
maintain the outdoor reset target temperature at the boiler
supply sensor. The control receives a setpoint demand
from a DHW aquastat. The control turns on the boiler pump
and operates the boiler to maintain the setpoint boiler
target temperature at the boiler supply sensor whenever a
setpoint demand is present.
Note: An external relay is required to operate the DHW
pump and provide DHW priority if required by disabling
the boiler pump.
Note: An external relay is required to operate the DHW
pump and provide DHW priority if required by disabling the
system pump or zone pumps.
22
EM-40-SM Service Manual
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - View Menu
View Next Item
The View menu items display current operating
temperatures and system status information. Use the
Item button to view items in this menu.
Item
Ite m F ie ld
R ang e
(-51 to 88°C)
OUTDOOR
Current outdoor air temperature as measured by the
outdoor sensor.
---,
35 to 266°F
(2 to 130°C),
OFF
BOILER TARGET
The boiler target is the temperature the control is
currently trying to maintain at the boiler supply sensor
or the boiler outlet sensor.
-60 to 190°F
14 to 266°F
VIEW MENU
De s c riptio n
(-10 to 130°C)
14 to 266°F
(-10 to 130°C)
14 to 266°F
(-10 to 130°C)
0 to 252°F
(0 to 140°C)
0 to 999
BOILER SUPPLY
Current boiler supply water temperature as measured
by the boiler supply sensor.
Note: This item is only available when MODE is set to 5.
BOILER OUTLET
Current boiler outlet water temperature as measured
by the boiler outlet sensor.
Note: When MODE is set to 5 this item is only visible
in the Factory access level.
BOILER INLET
Current boiler inlet water temperature as measured by
the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
BOILER DELTA T
Current temperature difference between the boiler outlet
sensor and the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
BOILER ON HOURS
The total number of running hours of the boiler since
this item was last cleared. Clear the numbers of hours
A c c es s
Factory
Installer
Factory
Installer
Factory
Installer
Factory
(Installer for
Mode 4)
Factory
Installer
Factory
Factory
while viewing this item.
After the last item, the control returns to the first item in the menu.
EM-40-SM Service Manual
23
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - Adjust Menu (1 of 3)
Enter Adjust Menu
Next Item
Item
Change Value
Item
ADJUST MENU
Item Field
The Program menu items are the programmable settings
used to operate the system. Press and hold all three
buttons simultaneously to enter the Program menu
Range
Description
Access
1 to 8
MODE
Select the operating mode for the control.
PId or P
STAGE MODE
Select the staging operation to be either
automatic or manual.
(PId = automatic)
(P = proportional)
OFF,
70 to 220°F
(21 to 104°C)
BOILER TARGET
Select the boiler target temperature while
a setpoint demand is present.
35 to 85°F
(2 to 29°C)
OUTDOOR START
Select the outdoor starting temperature
used in the reset ratio for the heating
system. Typically set to the desired building
temperature.
-60 to 32°F
(-51 to 0°C)
OUTDOOR DESIGN
Select the outdoor design temperature used
in the reset ratio for the heating system. Set
to the coldest annual outdoor temperature
in the local area.
35 to 150°F
(2 to 66°C)
BOILER START
Select the starting water temperature used
in the reset ratio calculation for the heating
system. Typically set to the desired building
temperature.
70 to 220°F
(21 to 104°C)
BOILER DESIGN
Select the boiler design water temperature
used in the reset ratio calculation for the
heating system. Set to the boiler water
temperature required to heat the building on
the coldest annual outdoor temperature.
120 to 225°F
(49 to 107°C)
BOILER OUTLET MAXIMUM
Select the maximum boiler outlet
temperature. Exceeding this temperature
shuts off the boiler.
Setting
Factory
Installer
Default
Setting 4
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Installer
Factory
Continued on next page.
24
EM-40-SM Service Manual
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - Adjust Menu (2 of 3)
Item Field
Range
Description
Access
120 to 225°F
(49 to 107°C),
OFF
BOILER MAXIMUM
Select the maximum boiler target
temperature.
Factory
OFF,
80 to 180°F
(27 to 82°C)
BOILER MINIMUM
Select the minimum boiler target
temperature.
Factory
0:00 to 3:00 min
(1 second
increments)
FIRE DELAY
Select the amount of time required for
combustion pre-purging, ignition and the
flame to be established.
Note: This setting is only available when
STAGE MODE is set to Pld.
Factory
BOILER MASS
Select the thermal mass of the boiler.
Note: This setting is only available when
STAGE MODE is set to PId.
Au, 0:30 to
9:55 min
STAGE DELAY
Select the minimum time delay between
stages.
Note: This setting is only available when
STAGE MODE is set to PId.
Au, 2 to 42°F
(1 to 23°C)
DIFFERENTIAL
Select the boiler differential.
Note: The automatic setting is only available
when STAGE MODE is set to Pld staging.
Factory
0 to 10°F
(0 to 6°C)
STAGE DIFFERENTIAL
Select the interstage temperature differential
between stages for proportional staging.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 8:00 min
INTERSTAGE ON DELAY
Select the amount of time that must pass
once a stage has been turned on in order
to allow the next stage to turn on.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 4:00 min
INTERSTAGE OFF DELAY
Select the amount of time that must pass
once a stage has been turned off in order
to allow the next stage to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
ADJUST MENU
1 (Lo) or
2 (Med) or
3 (Hi)
Setting
NOT VALID
FOR ELECTRIC
BOILER
APPLICATION
Factory
Installer
Factory
Installer
Continued on next page.
EM-40-SM Service Manual
25
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - Adjust Menu (3 of 3)
ADJUST MENU
Item Field
Range
Description
Access
0:10 to 5:00 min
MINIMUM ON TIME
Select the minimum amount of time that
the stage contact must remain on before it
is allowed to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 5:00 min
MINIMUM OFF TIME
Select the minimum amount of time that
the stage contact must remain off before it
is allowed to turn back on.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
OFF, 0:20 to
9:55 min, On
PUMP DELAY
Select the boiler pump purge time after
shutting off the boiler.
Factory
35 to 100°F
(2 to 38°C),
OFF
WARM WEATHER SHUT DOWN
Select the heating system warm weather
shut down for outdoor reset operation. Heat
demands are ignored once the outdoor air
temperature exceeds this setting.
°F or °C
TEMPERATURE UNITS
Select to display temperature in degrees
Fahrenheit or in degrees Celsius.
Setting
Factory
Installer
Default
Setting 65˚F
Factory
Installer
After the last item, the control returns to the first item in the menu.
26
EM-40-SM Service Manual
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation
Applications
Mode 6 – External Target Temperature Input and
Setpoint with Parallel Piping
Mode66
Mode
EMS
EMS
BTC
BTC
Mode 7 – External Target Temperature Input and
Setpoint with Primary – Secondary Piping
Mode77
Mode
BTC
BTC
0-10VV(dc)
(dc)
0-10
0-10VV(dc)
(dc)
0-10
Relay
Relay
tN4System
System
tN4
Control
Control
Relay
Relay
Boiler
Boiler
Outlet
Outlet
Sensor
Sensor
Boiler
Boiler
Outlet
Outlet
Sensor
Sensor
BoilerInlet
InletSensor
Sensor
Boiler
The control receives a heat demand provided from an
external target temperature input signal. The control turns
on the boiler pump and operates the boiler to maintain the
target temperature at the boiler outlet sensor. The control
receives a setpoint demand from a DHW aquastat. The
control turns on the boiler pump and operates the boiler to
maintain the setpoint boiler target temperature at the boiler
outlet sensor whenever a setpoint demand is present.
Boiler
Boiler
Supply
Supply
Sensor
Sensor
BoilerInlet
InletSensor
Sensor
Boiler
The control receives a heat demand provided from an
external target temperature input signal. The control turns
on the boiler pump and operates the boiler to maintain the
target temperature at the boiler supply sensor. The control
receives a setpoint demand from an external control. The
control turns on the boiler pump and operates the boiler to
maintain the setpoint boiler target temperature at the boiler
supply sensor whenever a setpoint demand is present.
Note: An external relay is required to operate the DHW
pump and provide DHW priority if required by disabling
the boiler pump.
EM-40-SM Service Manual
27
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation - View Menu
View Next Item
The View menu items display current operating
temperatures and system status information. Use the
Item button to view items in this menu.
Item
Ite m F ie ld
R ang e
---,
35 to 266°F
(2 to 130°C),
OFF
14 to 266°F
VIEW MENU
(-10 to 130°C)
14 to 266°F
(-10 to 130°C)
14 to 266°F
(-10 to 130°C)
0 to 252°F
(0 to 140°C)
0 to 999
De s c riptio n
A c c es s
BOILER TARGET
The boiler target is the temperature the control is
currently trying to maintain at the boiler supply sensor
or the boiler outlet sensor.
BOILER SUPPLY
Current boiler supply water temperature as measured
by the boiler supply sensor.
Note: This item is only available when MODE is set to 7.
BOILER OUTLET
Current boiler outlet water temperature as measured
by the boiler outlet sensor.
Note: When MODE is set to 7 this item is only visible
in the Factory access level.
BOILER INLET
Current boiler inlet water temperature as measured by
the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
Factory
Installer
Factory
Installer
Factory
(Installer for
Mode 6)
Factory
Installer
BOILER DELTA T
Current temperature difference between the boiler outlet
sensor and the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
Factory
BOILER ON HOURS
The total number of running hours of the boiler since
this item was last cleared. Clear the numbers of hours
by pressing and holding the and buttons together
while viewing this item.
Factory
After the last item, the control returns to the first item in the menu.
28
EM-40-SM Service Manual
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation - Adjust Menu (1 of 2)
Enter Adjust Menu
Next Item
Item
Change Value
Item
ADJUST MENU
Item Field
The Program menu items are the programmable settings
used to operate the system. Press and hold all three
buttons simultaneously to enter the Program menu.
Range
Description
1 to 8
MODE
Select the operating mode for the control.
PId or P
STAGE MODE
Select the staging operation to be either
automatic or manual.
(PId = automatic)
(P = proportional)
OFF,
70 to 220°F
(21 to 104°C)
BOILER TARGET
Select the boiler target temperature while
a setpoint demand is present.
120 to 225°F
(49 to 107°C)
BOILER OUTLET MAXIMUM
Select the maximum boiler outlet
temperature. Exceeding this temperature
shuts off the boiler.
Factory
120 to 225°F
(49 to 107°C),
OFF
BOILER MAXIMUM
Select the maximum boiler target
temperature.
Factory
OFF,
80 to 180°F
(27 to 82°C)
BOILER MINIMUM
Select the minimum boiler target
temperature.
Factory
0:00 to 3:00 min
(1 second
increments)
FIRE DELAY
Select the amount of time required for
combustion pre-purging, ignition and the
flame to be established.
Note: This setting is only available when
STAGE MODE is set to Pld.
1 (Lo) or
2 (Med) or
3 (Hi)
BOILER MASS
Select the thermal mass of the boiler.
Note: This setting is only available when
STAGE MODE is set to PId.
Au, 0:30 to
9:55 min
STAGE DELAY
Select the minimum time delay between
stages.
Note: This setting is only available when
STAGE MODE is set to PId.
Au, 2 to 42°F
(1 to 23°C)
DIFFERENTIAL
Select the boiler differential.
Note: The automatic setting is only available
when STAGE MODE is set to PId staging.
Access
Setting
Factory
Installer
Default
Setting 4
Factory
Installer
Factory
Installer
Factory
NOT VALID
FOR ELECTRIC
BOILER
APPLICATION
Factory
Installer
Factory
Installer
Factory
Continued on next page.
EM-40-SM Service Manual
29
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation - Adjust Menu (2 of 2)
ADJUST MENU
Item Field
Range
Description
Access
0 to 10°F
(0 to 6°C)
STAGE DIFFERENTIAL
Select the interstage temperature differential
between stages for proportional staging.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 8:00 min
INTERSTAGE ON DELAY
Select the amount of time that must pass
once a stage has been turned on in order
to allow the next stage to turn on.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 4:00 min
INTERSTAGE OFF DELAY
Select the amount of time that must pass
once a stage has been turned off in order
to allow the next stage to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 5:00 min
MINIMUM ON TIME
Select the minimum amount of time that
the stage contact must remain on before it
is allowed to turn off.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
0:10 to 5:00 min
MINIMUM OFF TIME
Select the minimum amount of time that
the stage contact must remain off before it
is allowed to turn back on.
Note: This setting is only available when
STAGE MODE is set to P.
Factory
OFF, 0:20 to
9:55 min, On
PUMP DELAY
Select the boiler pump purge time after
shutting off the boiler.
Factory
0:10 or 2:10
EXTERNAL INPUT SIGNAL
Select the range of the external input
signal.
Factory
OFFSET
Select the amount of offset when the boiler
target is determined from an external input
signal.
Factory
Setting
External Input Signal
-10 to +10°F
(-6 to +6°C)
Offset
°F or °C
TEMPERATURE UNITS
Select to display temperature in degrees
Fahrenheit or in degrees Celsius.
Factory
Installer
After the last item, the control returns to the first item in the menu.
30
EM-40-SM Service Manual
Mode 8
External
0-10 V (dc)
Mode 8 – External Direct
Drive
Operation
Control
Direct Drive
BTC
BTC
Application
Boiler
Boiler
Mode 8Outlet
– ExternalOutlet
Direct Drive Operation
Sensor
Sensor
The control receives a heat demand provided via an
external analog input signal from a tekmar sequencing
control (such as a 275). The control
turns on the boiler
Boiler
Supply
pump and the Stage 1, 2, 3 and 4 Sensor
contacts according to
the external input signal.
Boiler Inlet Sensor
Mode 8
BTC
Boiler
Outlet
Sensor
Boiler Inlet Sensor
BTC
External
Control
0-10 V (dc)
Direct Drive
Boiler
Outlet
Sensor
Boiler
Supply
Sensor
Boiler Inlet Sensor
Boiler Inlet Sensor
Mode 8 – External Direct Drive Operation - View Menu
View Next Item
The View menu items display current operating
temperatures and system status information. Use the
Item button to view items in this menu.
Item
14 to 266°F
(-10 to 130°C)
VIEW MENU
View
DeNext
s c riItem
ptio n
R ang e
14 to 266°F
(-10 to 130°C)
0 to 252°F
(0 to 140°C)
0 to 999
A c c es s
BOILER OUTLET
Item
Current boiler outlet water temperature as measured
by the boiler outlet sensor.
Ite m F ie ld
R ang e
BOILER INLET
14 to 266°F
Current boiler inlet water temperature as measured by
(-10 to 130°C)
the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
VIEW MENU
Ite m F ie ld
BOILER DELTA T
14 to 266°F
Current temperature difference between the boiler outlet
(-10 to 130°C)
sensor and the boiler inlet sensor.
Note: This item is only available when a boiler inlet
sensor is installed.
BOILER ON HOURS
0 to 252°F
The total number of running hours of the boiler since
(0 to 140°C)
this item was last cleared. Clear the numbers of hours
by pressing and holding the and
buttons together
while viewing this item.
After the last item, the control returns to the first item in the menu.
0 to 999
EM-40-SM Service Manual
The Vie
tempera
Item bu
Factory
Installer
BOILER OUTLET
Current boiler outlet
Factory
by the boiler outlet se
Installer
BOILER INLET
Current boiler inlet wa
the boiler inlet sensor
Factory
Note: This item is on
sensor is installed.
BOILER DELTA T
Current temperature d
sensor and the boiler
Factory
Note: This item is on
sensor is installed.
BOILER ON HOURS
The total number of r
this item was last clea
by pressing and holdi
while viewing this item
31
After the last item, the control returns to the first item in the menu
Mode 8 – External DirectDrive Operation - Adjust Menu
Enter Adjust Menu
Item
Next Item
Change Value
Item
Item Field
Range
ADJUST MENU
1 to 8
The Program menu items are the programmable settings
used to operate the system. Press and hold all three
buttons simultaneously to enter the Program menu.
Description
MODE
Select the operating mode for the
control.
Access
Setting
Factory
Installer
120 to 225°F
(49 to 107°C)
BOILER OUTLET MAXIMUM
Select the maximum boiler outlet
temperature. Exceeding this temperature
shuts off the burners.
Factory
OFF, 0:20 to
9:55 min, On
PUMP DELAY
Select the boiler pump purge time after
shutting off the burner.
Factory
°F or °C
TEMPERATURE UNITS
Select to display temperature in degrees
Fahrenheit or in degrees Celsius.
Default
Setting 4
Factory
Installer
After the last item, the control returns to the first item in the menu.
32
EM-40-SM Service Manual
Error Messages (1 of 2)
E01
The control was unable to read a piece of information from its EEPROM memory. The
control will stop operation until all settings in the Adjust menu have been checked by the
user or installer. To clear the error message, set Access Level DIP Switch A to Factory
(on position), then check all Adjust menu items.
BOILER OUTLET SENSOR SHORT CIRCUIT
The control is no longer able to read the boiler outlet sensor due to a short circuit. In this
case, if the boiler inlet sensor is present and operational, the control will operate using
the boiler inlet sensor. Otherwise, the control will not operate the boiler.
Test the boiler outlet sensor and related wiring. The error message will clear once the
error condition is corrected and a button is pressed.
BOILER OUTLET SENSOR OPEN CIRCUIT
The control is no longer able to read the boiler outlet sensor due to an open circuit. In this
case, if the boiler inlet sensor is present and operational, the control will operate using
the boiler inlet sensor. Otherwise, the control will not operate the boiler.
Test the boiler outlet sensor and related wiring. The error message will clear once the
error condition is corrected and a button is pressed.
BOILER INLET SENSOR SHORT CIRCUIT
The control is no longer able to read the boiler inlet sensor due to a short circuit. In this
case, the control will continue operation.
Test the boiler inlet sensor and related wiring. The error message will clear once the error
condition is corrected and a button is pressed.
BOILER INLET SENSOR OPEN CIRCUIT
The control is no longer able to read the boiler inlet sensor due to an open circuit. In this
case, the control will continue operation.
Test the boiler inlet sensor and related wiring. The error message will clear once the error
condition is corrected and a button is pressed.
BOILER SUPPLY SENSOR SHORT CIRCUIT
The control is no longer able to read the boiler supply sensor due to a short circuit. In
this case, if the boiler outlet sensor is operational, the control will operate based on the
boiler outlet sensor. If the boiler outlet sensor is not available and the boiler inlet sensor is
present and operational, the control will operate using the boiler inlet sensor. Otherwise,
the control will not operate the boiler.
Test the boiler supply sensor and related wiring. The error message will clear once the
error condition is corrected and a button is pressed.
BOILER SUPPLY SENSOR OPEN CIRCUIT
The control is no longer able to read the boiler supply sensor due to an open circuit. In
this case, if the boiler outlet sensor is operational, the control will operate based on the
boiler outlet sensor. If the boiler outlet sensor is not available and the boiler inlet sensor is
present and operational, the control will operate using the boiler inlet sensor. Otherwise,
the control will not operate the boiler.
Test the boiler supply sensor and related wiring. The error message will clear once the
error condition is corrected and a button is pressed.
OUTDOOR SENSOR SHORT CIRCUIT
The control is no longer able to read the outdoor sensor due to a short circuit. In this case
the control assumes an outdoor temperature of 32°F (0°C) and continues operation.
Test the outdoor sensor and related wiring. The error message will clear once the error
condition is corrected and a button is pressed.
EM-40-SM Service Manual
33
Error Messages (2 of 2)
OUTDOOR SENSOR OPEN CIRCUIT
The control is no longer able to read the outdoor sensor due to an open circuit. In this case
the control assumes an outdoor temperature of 32°F (0°C) and continues operation.
Test the outdoor sensor and related wiring. The error message will clear once the error
condition is corrected and a button is pressed.
DHW TANK SENSOR SHORT CIRCUIT
The control is no longer able to read the DHW tank sensor due to a short circuit. In this
case, the control will not operate the boiler.
Test the DHW tank sensor and related wiring. The error message will clear once the error
condition is corrected and a button is pressed.
DHW TANK SENSOR OPEN CIRCUIT
The control is no longer able to read the DHW tank sensor due to an open circuit. In this
case, the control will not operate the boiler.
Test the DHW tank sensor and related wiring. The error message will clear once the error
condition is corrected and a button is pressed.
RELOAD FACTORY DEFAULTS
To reload FACTORY DEFAULT SETTINGS, press and hold the outside
buttons (Item and Down) while powering the control up. This will reload
the FACTORY DEFAULTS.
34
EM-40-SM Service Manual
EM-40-SM Service Manual
35
Technical Data
EM-10 (Monitron II) Electric Boiler Temperature Control
Packaged weight
Dimensions
Approvals
Ambient conditions
Power supply
Pump / Stage 1 Relays
Stage 2, 3, 4 Relays
Demands
Sensors
included:
optional:
—
—
—
—
—
0.38 lb. (170 g)
Enclosure D, black noryl plastic
4-3/4” H x 2-7/8” W x 1-7/8” D (120 x 74 x 48 mm)
ANSI Z21.23, CAN 1-6.6-M78-R2001, UL873, UL840
Indoor use only, -40 to 140°F (-40 to 60°C),
< 90% RH non-condensing
— 24 V (ac) ±10% 50/60 Hz 75 VA
— 120 V (ac) 5 A 1/6 hp pilot duty 240 VA
— 120 V (ac) 3 A 1/6 hp pilot duty 240 VA
— 24 to 120 V (ac) 2 VA
— NTC thermistor, 10 kø @ 77°F (25°C ±0.2°C) ß=3892
— 1 of Universal Sensor 071 with 96" long wires (S/F P/N 790400000)
Outdoor Sensor 070 (S/F P/N 339070000)
— Universal Sensor 071
SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: (516) 484-2600
FAX: (516) 484-5921 • Canada: Slant/Fin LTD/LTEE, Mississauga, Ontario
www.slantfin.com
©Slant/Fin Corp. 2008.