Download EM-10 Electronic Control Manual_Eng Modes 1 thru 8
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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.