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EM-10 Electronic Control Manual_Eng Modes 1 thru 8

1. Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance oF eC Q oF Q oF ec Q oF ec Q 50 46 490 813 20 7 46 218 90 32 7 334 160 71 1 689 45 43 405 710 25 4 39 913 95 35 6 532 165 74 1 538 40 40 336 606 30 3 34 558 100 38 5 828 170 77 1 403 35 37 280 279 35 2 29 996 105 4 5 210 175 79 1 281 30 34 234 196 40 4 26 099 110 43 4 665 180 82 1172 25 32 196 358 45 7 22 763 115 46 4184 185 85 1 073 20 29 165 180 50 10 19 900 120 49 3 760 190 88 983 15 26 139 402 55 13 17436 125 52 3 383 195 91 903 10 221 118 018 60 16 15311 130 54 3 050 200 93 829 5 21 100 221 65 18 13 474 135 57 2 754 205 96 763 18 85 362 70 21 11 883 140 60 2 490 210 99 703 5 15 72 918 75 24 10 501 145 63 2 255 215 102 648 10 Ep 62 465 80 27 9 299 150 66 2 045 220 104 598 15 9 53 658 85 29 8 250 155 68 1 857 225 107 553 EM 40 SM Service Manual 13 TEST THE POWER SUPPLY Make sure exposed wires are not in contact with other wires or grounded surfaces Turn on the power and measure the voltage between the C and R pins using an AC voltmeter the reading should be between 22 and 26 V ac 22 to 26 V ac TEST THE POWERED INPUTS Heat Demand If a heat demand is used measure the voltage between the CD common demand and the Ht D heat demand pins When the heat demand device calls for heat between 20 and 130 V ac should be measured at
2. Item Field Range Description Access TT BOILER TARGET l H n 35 to 266 F The boiler target is the temperature the control is Factory TERT 2 to 130 C currently trying to maintain at the boiler supply sensor Installer OFF or the boiler outlet sensor BOILER SUPPLY BOILSUP o 1 H 14 to 266 F Current boiler supply water temperature as measured Factory 10 to 130 C by the boiler supply sensor Installer Note This item is only available when MODE is set to 2 gt BOILER OUTLET BOL OUT E rr 14 to 266 F Current boiler outlet water temperature as measured Factory W LIL by the boiler outlet sensor Installer for 10 to 130 C Note When MODE is set to 2 this item is only visible Mode 1 gt in the Factory access level Lu BOILER INLET BOIL IN IE xr 14 to 266 F Current boiler inlet water temperature as measured by Factory Jb the boiler inlet sensor o 10 to 130 C Note This item is only available when a boiler inlet panes sensor is installed BOILER DELTA T BOIL IF 0 to 252 F Current temperature difference between the boiler outlet w hI sensor and the boiler inlet sensor Factory 0 to 140 C T TT Note This item is only available when a boiler inlet sensor is installed BOILER ON HOURS BOIL The total number of running hours of the boiler since 0 to 999 this item was last cleared Clear the numbers of hours Factory 2 by pressi
3. Enter Adjust Menu Next am Change Valu The Program menu items are the programmable settings used to operate the system Press and hold all three tem A BN i buttons simultaneously to enter the Program menu Item Field Range Description Access Setting ADJUST Li MODE Factory 1to8 Select the operating mode for the MODE control Installer Default Setting 4 R dU MIN BOILER OUTLET MAXIMUM Cau 120 to 225 F Select the maximum boiler outlet Factory 49 to 107 C temperature Exceeding this temperature shuts off the burners mor OFF 0 20t PUMP DELAY LI min 9 55 min On Select the boiler pump purge time after Factory B5 shutting off the burner oF TEMPERATURE UNITS Factory Select to display temperature in degrees matai Fahrenheit or in degrees Celsius 32 After the last item the control returns to the first item the menu EM 40 SM Service Manual Error Messages 1 of 2 E01 crit The control was unable to read a piece of information from its EEPROM memory The Lu 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 contro
4. Setpoint very little temperature Stage 4 droop Stage 3 Stage 2 Stage 1 P I D Proportional Integral Derivative Proportional amp Integral amp 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 Derivative logic determines how fast or slow the operating sensor temperature is changing If the temperature is increasing slowly the next stage is turned on sooner If the temperature is increasing quickly the next stage is turned on later if at all EM 40 SM Service Manual 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 autom
5. 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 5 Outdoor Reset and Setpoint with Primary Secondary Piping Mode 4 Outdoor Sensor Outlet Sensor i Boiler Inlet Sensor Mode 5 Outdoor Sensor Boiler Supply 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 Note An external relay is required to operate the DHW pump and provide DHW priority if required by disabling the boiler pump 22 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 pum
6. The control receives a heat demand provided from zone The control receives a heat demand provided from zone valve end switches or a switching relay end switch The valve end switches or a switching relay end switch The control turns on the boiler pump and operates the burners control turns on the boiler pump and operates the burners to maintain the setpoint boiler target 1 temperature at the to maintain the boiler target 1 temperature at the boiler boiler outlet sensor whenever a heat demand is present supply sensor whenever a heat demand is present The The control receives a setpoint demand from a DHW control receives a setpoint demand from a DHW aquastat aquastat The control operates the burners to maintain the The control operates the burners to maintain the setpoint setpoint boiler target 2 at the boiler outlet sensor whe boiler target 2 at the boiler supply sensor whenever a never a setpoint demand is present setpoint demand is present Note An external relay is required to operate the DHW Note An external relay is required to operate the DHW pump and provide DHW priority if required by disabling pump and provide DHW priority if required by disabling the boiler pump the system pump 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
7. 0 TART MINMAX H fe Number Field Displays th t Yom MIN Seed TARGETMASSAT Boil bes pen s Be diu value STGMODETANK pnw 12 ONOFFDLY 8 8 WWWSD O status Field ee T Displays the current status of Offset External Input the control s inputs outputs Signal and operation Buttons Selects Menus Items and adjusts settings Item A y Symbol Description BOILER PUMP DEMAND 2 Boil Dem Displays when the boiler pump is in 2 Displays when a call for heat on demand operation 2 is present BURNER ERROR Displays when stage 1 2 3 or 4 contact D Displays when an error message is is on present Wisp 2 POINTERS WWSD Displays when ihe controls te Warm U Displays operation as indicated by the text Weather Shut Down p ays op y Dem DEMAND 1 F or C 1 Displays when a call for heat on demand F C 1 is present Displays the temperature units EM 40 SM Service Manual 3 Section 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
8. 35 Technical Data EM 10 Monitron Il Electric Boiler Temperature Control Packaged weight 0 38 Ib 170 g Enclosure D black plastic Dimensions 4 3 4 H x 2 7 8 W x 1 7 8 D 120 x 74 x 48 mm Approvals ANSI 221 23 CAN 1 6 6 M78 R2001 UL873 UL840 Ambient conditions Indoor use only 40 to 140 F 40 to 60 C lt 90 RH non condensing Power supply 24 V ac 10 50 60 Hz 75 Pump Stage 1 Relays 120 V ac 5 A 1 6 hp pilot duty 240 VA Stage 2 3 4 Relays 120 V ac 3 A 1 6 hp pilot duty 240 VA Demands 24 to 120 V ac 2 VA Sensors NTC thermistor 10 k 77 F 25 C 0 2 C 323892 included 1 of Universal Sensor 071 with 96 long wires S F P N 790400000 Outdoor Sensor 070 S F P N 339070000 optional Universal Sensor 071 SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 fz nt a n FAX 516 484 5921 Canada Slant Fin LTD LTEE Mississauga Ontario e www slantfin com Slant Fin Corp 2008
9. Mod EN ote When MODE is set to 5 this item is only visible ode 4 in the Factory access level BOILER INLET BOIL IE IF 14 to 266 F Current boiler inlet water temperature as measured by Factory Jb the boiler inlet sensor 10 to 130 C Note This item is only available when a boiler inlet n sensor is installed BOILER DELTA T BOIL 7 0 to 252 F Current temperature difference between the boiler outlet w sensor and the boiler inlet sensor Factory 0 to 140 C Note This item is only available when boiler inlet sensor is installed BOILER ON HOURS BOIL on The total number of running hours of the boiler since ae 0 to 999 this item was last cleared Clear the numbers of hours Factory a 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 EM 40 SM Service Manual 23 Mode 4 and 5 Outdoor Reset and Setpoint Operation Adjust Menu 1 of 3 EDS Pause Mend Meekem change value The Program menu items are the programmable settings used to operate the system Press and hold all three A buttons simultaneously to enter the Program menu Item Field Description Access Setting ADJUST LI im MODE Factory o Select the operating mode for the control Installer Default Setting 4 STAGE MODE ADJUST 2
10. Outdoor Design OUTDR DSGN The OUTDR DSGN is the outdoor air temperature that is the typical coldest temperature of the year where the building is located This temperature is used when completing heat loss calculations for the building Boiler Design BOIL DSGN 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 A Boil DSGN Boil START OUTDR DSGN Increasing Water Temperature 3 i CULA ARR 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 Section E External Temperature Target Input When modes 6 or 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 tek mar tN4 System Control When in modes 6 or 7 the e
11. Dedicated DHW with Parallel Piping 19 View 19 Duesr 20 Mode 4 and 5 Outdoor Reset Setpoint Operation 22 VIOW ICI 23 Default 24 26 Adjust 22 ceret tete tenuto coaster errantes 24 Mode 6 and 7 External Target Setpoint Operation 27 SAIL 28 Adjust 22 29 Mode 8 External Direct Drive Operation 31 a 31 Adjust 32 Error 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 A W 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 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 seg
12. 49 to 107 C Select the maximum boiler target Factory OFF temperature ADJUST BOIL LLIF OFF BOILER MINIMUM d 80 180 F Select the minimum boiler target Factory 27 to 82 C temperature FIRE DELAY Not valid for electric boiler application 0 00 to 3 00 min Select the amount of time required NOT VALID T 10 for combustion pre purging ignition FOR ELECTRIC S in Fact ge a second and the flame to be established aea BOILER DLY increments Note This setting is only available when APPLICATION STAGE MODE is set to Pld a ADJUST 1 Lo or BOILER MASS 2 Med or Select the thermal mass of the boiler Factory mm 3 Hi Note This setting is only available when Installer STAGE MODE is set to Pld 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 Setting STAGE DELAY l l Au 0 30 to Select the minimum time delay between Factory 9 55 min Sages Install SE aiy i Note This setting is only available when cun STAGE MODE is set to Pld DIFF ADJUST DIFFERENTIAL A Lu Au 2 to o F Select the boiler differential Factory 1 to 23 C Note The automatic setting is only available when STAGE MODE is set to Pld staging pem STAGE DIFFERENTIAL LIF o Select the interstage temperature differential 0 t
13. Offset 5 F 3 C 5 3 C Boiler Target 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 signal reaches 0 5 V dc Once the direct drive input signal falls below 0 5 V dc the pump continues to operate until the Pump DLY purge expires then the pump shuts off BOILER OUTLET MAXIMUM TEMPERATURE The external boiler sequencer is able to operate the
14. mi ot Select the staging operation to be either Factory Fo Lil Pld or P automatic or manual STGMODE Pld 2 automatic Installer P proportional BOIL B rer OFF BOILER TARGET Factory TARGET 70 to 220 F Select the boiler target temperature while ae 21 to 104 C a setpoint demand is present cd gt gt OUTDOOR START Lu id m Select the outdoor starting temperature START 1 35 to 85 F perat Factory 2 to 29 C used in the reset ratio for the heating Install ke system Typically set to the desired building a WY temperature gt Q OUTDR DSGN ADJUST artes arate d Ir 60 to 32 F elect the outdoor design temperature use Factory lt 51 to 0 C in the reset ratio for the heating system Set Install to the coldest annual outdoor temperature the local area BOILER START ADJUST psa 2 35 to 150 F Select the starting water temperature used Factory 2 to 66 C in the reset ratio calculation for the heating Install system Typically set to the desired building eee temperature BOILER DESIGN po eS Select the boiler design water temperature H 70 to 220 used in the reset ratio calculation for the Factory 21 to 104 C heating system Set to the boiler water Installer temperature required to heat the building on the coldest annual outdoor temperature BOILER OUTLET MAXIMUM MAX eut 120 to 225 F Select the maximum boiler outlet Factory 49 to 107 C temperature Exceeding this tempe
15. and changes the boiler target according to a linear scale The control stages the boiler to maintain the boiler target at the boiler outlet 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 outlet 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 6 0 10 V dc Boiler Inlet Sensor _ MODE 7 External Target Temperature Input and Setpoint with Primary Secondary Piping Mode 7 is designed for an external input signal and setpoint with primary secondary piping The external input signal can be provided from a BMS an EMS or a tekmar tN4 System Control for space heating The setpoint can be 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
16. in parallel or in primary secondary to the system The type of piping chosen affects the location of the controls operating temperature sensor The control can either use the boiler outlet sensor or the boiler supply sensor PARALLEL PIPING In parallel piping applications the boiler outlet temperature is typically the same as that delivered to the system Therefore the operating temperature sensor is the boiler outlet sensor Boiler Outlet Sensor 1 Boiler Inlet Sensor PRIMARY SECONDARY PIPING primary secondary applications the boiler outlet temperature primary loop is typically hotter than the system supply temperature secondary loop This occurs when the system supply pipe has a larger flow rate than the boiler outlet pipe Therefore the control requires an additional sensor boiler supply to measure the temperature delivered out to the system The operating temperature sensor is the boiler supply sensor Boiler Outlet Sensor Boiler Supply Sensor Boiler Inlet 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 senso
17. is only available when STAGE MODE is set to P Factory ON DLY 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 OFF DLY 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 MIN ON 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 MIN Li j OFF 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 gt f zl i cn 4 min LC DLY OFF 0 20 to 9 55 min On PUMP DELAY Select the boiler pump purge time after shutting off the boiler Factory ADJUST F F or C TEMPERATURE UNITS Select to display temperature in degrees Fahrenheit or in degrees Celsius Factory Installer
18. 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 OUTDR OUTDOOR SENSOR OPEN CIRCUIT ri n The control is no longer able to read the outdoor sensor due to an open circuit In this case LI nm 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 h E The control is no longer able to read the DHW tank sensor due to a short circuit In this 2 case the control will not operate the boiler TANK 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 n n The control is no longer able to read the DHW tank sensor due to an open circuit In this urn case the control will not operate the boiler TANK 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
19. sensor is required to be connected on the Com and the Sup D terminals 4 and 6 The DHW tank sensor must be installed in an immersion well to measure the tank temperature The TANK TARGET setting is used to set the desired DHW tank temperature The TANK DIFF setting is the differential below the target An internal heat demand for DHW is generated when the measured DHW tank temperature falls below the TANK TARGET TANK DIFF The internal heat demand is removed once the measured DHW tank temperature exceeds the TANK TARGET EM 40 SM Service Manual 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 on the boiler pump segment in the display The control then operates the boiler stages to maintain the programmed tank target temperature 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 TS ener EN ET TankTarget Tank Differential Section D Outdoor Reset Operation 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 and reset ratio As a result the boiler target changes proportional to the outdoor temperature The reset ratio is determ
20. the pins When the heat demand device is off less than 5 V ac should be measured 20 to 130 V ac 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 between 20 130 V should be measured at the pins When the setpoint demand device is off less than 5 V ac should be measured Test the External Input If an external input signal is used measure the voltage between the Com and V in pins When the external control calls for heat between O and 10 V dc should be measured 14 CONNECTING THE CONTROL Make sure all power to the devices and wiring harness is off Reconnect the wiring harness to the connector on the control by aligning the tab on the wiring harness to the tab on the connector on the control and then pushing the wiring harness into the connector on the control The tab on the wiring harness should snap over the tab on the connector of the control Apply power to the control The operation of the control on power up is described in the Sequence of Operation section of the brochure TESTING THE CONTROL OUTPUTS The control has a built in test routine that is used to override the main control functions The test sequence is enabled when the A button is pressed and held for 3 sec onds while in the View menu The test sequence can be can celled by pressing either
21. 0 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 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 2 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 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 by installing a 500 ohm resistor on the external input signal device s terminals 2 10 V dc 4 20 mA Boiler Target 0 0 OFF 1 2 OFF 2 4 50 F 10 C 3 6 70 F 21 C 4 8 90 F 32 C 5 10 110 F 43 C 6 12 130 F 54 C 7 14 150 F 66 C 8 16 170 F 77 C 9 18 190 F 88 C 10 20 210 F 99 C requires a 500 resistor OFFSET The Offset setting allows the boiler target temperature to 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 0 10 V dc Input 7V 69
22. 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 External Input Signal 0 10 or 2 10 EXTERNAL INPUT SIGNAL Select the range of the external input signal Factory rir LI Offset 10 to 10 F 6 to 6 C OFFSET Select the amount of offset when the boiler target is determined from an external input signal Factory ADJUST 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 EM 40 SM Service Manual Mode 8 External Direct Drive Operation Application Mode 8 External Direct Drive Operation Mode 8 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 pump and t
23. 0 V dc wire to the V in pin and connect the negative 0 10 V dc wire to the Com pin 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 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 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 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 Outdoor Sensor
24. A Note This item is only available when a boiler inlet sensor is installed TY 14 to 266 F TANK Factory rus Current domestic hot water tank temperature as measured Install TANK 10 to 130 C by the DHW tank sensor BOILER ON HOURS BOIL The total number of running hours of the boiler since dui 0 to 999 this item was last cleared Clear the numbers of hours Factory DN by pressing and holding the and W buttons together while viewing this item After the last item the control returns to the first item in the menu EM 40 SM Service Manual 19 Mode 3 Dedicated DHW with Parallel Piping Adjust Menu 1 of 2 a Ment nee ion Grange The Program menu items are the programmable settings used to operate the system Press and hold all three mm A m buttons simultaneously to enter the Program menu Item Field Range Description Access Setting Li MODE Factory 1108 HODE Select the operating mode for the control Installer Default Setting 4 STAGE MODE rm ot Select the staging operation to be either F actory Li Pld or P automatic or manual STGMODE Pld 2 automatic Installer P proportional gt i2n OFF 70to TANK TARGET Factory 190 F Select the dedicated domestic hot water E 21 to 88 C tank target temperature nstaller Fa TANK DIFFERENTIAL 4 Au 2 to 10 F Select the dedicated domestic hot water tank Factory 4 1 to 6 C diffe
25. DE is set to P v PUMP DELAY D OFF 0 20 to elect the boiler pump purge time after min 9 55 min On select the boil get ft Factory at i shutting off the boiler lt WARM WEATHER SHUT DOWN 5 35 to 100 F Select the heating system warm weather Factory 2 to 38 C shut down for outdoor reset operation Heat er Ws OFF demands are ignored once the outdoor air Default temperature exceeds this setting Setting 65 F ADJUST F TEMPERATURE UNITS Factory F or C Select to display temperature in degrees fasta Fahrenheit or in degrees Celsius 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 Mode 6 0 10 V dc Boiler Inlet Sensor 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 Note An external relay is requir
26. IF o Select the interstage temperature differential H 0 to 10 F i f between stages for proportional staging Factory 0 to 6 C ONE m Note This setting is only available when STAGE MODE is set to P INTERSTAGE ON DELAY REI FP Select the amount of time that must pass 1 00 Lf 0 10 to 8 00 min Once stage has been turned on in order Factory to allow the next stage to turn on ON DLY Note This setting is only available when STAGE MODE is set to P INTERSTAGE OFF DELAY n 3 m Select the amount of time that must pass nJ L once a stage has been turned off in order min 0 10 to 4 00 min Factory to allow the next stage to turn off OFF DLY Note This setting is only available when STAGE MODE is set to P Continued on next page EM 40 SM Service Manual 25 Mode 4 and 5 Outdoor Reset and Setpoint Operation Adjust Menu 3 of 3 em Fie escription ccess ettin Item Field ipti A Setting MINIMUM ON TIME As Select the minimum amount of time that MIN WJ Ll min 0 10 to 5 00 min the stage contact must remain on before it Factor i is allowed to turn off y ON Note This setting is only available when STAGE MODE is set to P MINIMUM OFF TIME n Select the minimum amount of time that c MIN LI Li nin 0 10 to 5 00 min the stage contact must remain off before it Factor is allowed to turn back on y OFF Note This setting is only available when STAGE MO
27. Manual Mode 3 Dedicated Domestic Hot Water Tank with Parallel Piping Application Mode 3 Dedicated DHW with Parallel Piping Mode 3 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 Dedicated DHW with Parallel Piping View Menu Hem The View menu items display current operating temperatures and system status information Use the Item button to view items in this menu Item Field Description Access ES TANK TARGET ITI 35to266F Factory TARGET 1L o The temperature that the control is trying to maintain 2 to 130 C Installer OFF in the tank BO 14 to 266 F BOILER OUTLET Factory Mou o Current boiler outlet water temperature as measured inst ll 10 to 130 C by the boiler outlet sensor Vetere gt 2 BOILER INLET Lj o IE x 14 to 266 F Current boiler inlet water temperature as measured by Factory E Iu the boiler inlet sensor 10 to 130 C Note This item is only available when a boiler inlet ees sensor is installed BOILER DELTA T BOIL T7 0 to 252 F Current temperature difference between the boiler outlet ar sensor and the boiler inlet sensor Factory 0 to 140 C s s T
28. Slant Fin MODEL EM 10 MONITRON ELECTRIC BOILER CONTROL SERVICE MANUAL UE P Dba Ekra tai 1 s MONITRON Il ELECTHIC BOILER Hern Ss 208 UG 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 einer tree aa 2 Display and Symbol Description 3 Sequence of 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 External Direct Drive Operation 11 InistallatlOTi accetto t erreur pere 12 Rp 13 Control 15 DIP Switch Settings iier rece 15 Mode 1 and 2 Two Setpoint Operation 16 MAS 16 Adjust Menu 17 Mode
29. and applied The control displays the temperature that it is currently trying to maintain at the operating sensor as BOIL TARGET in the 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 in the LCD There is no boiler target temperature generated in Mode 8 BOILER MINIMUM BOIL MIN The BOIL MIN setting is the lowest water temperature that the control is allowed to use as a boiler target temperature 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 is viewed If the installed boiler is designed for condensing or low temperature operation set the BOIL MIN adjustment to OFF BOILER MAXIMUM BOIL MAX The BOIL MAX setting is the highest water temperature that the control is allowed to use as a boiler target temperature If the control does target BOIL MAX and the 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 temperat
30. atic in which the boiler mass determines the stage delay time 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 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 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 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 intersta
31. boiler temperature However the BOIL OUT MAX setting limits the highest temperature at the boiler outlet sensor Should the boiler outlet temperature exceed the BOIL OUT MAX 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 11 Installation Electrical Connections to the Control The installer should test to confirm that no voltage is 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 12 24 11 23 Alert 10 V in 22 Stg 4 9 Com 121 Stg 4 8 Boil in20 Stg 3 CIEN 7 BoilO 19 5193 6 Sys D 18 Stg 2 5 Out 17 Stg2 4 Com 16 Stg 1 3 SetD 15 Stg 1 2 HtD 14 Pmp 1 CD 13Pmp Cl OFF A OFF Powered Input Connections 24 V ac Power Connect the 24 V ac power supply to the C and R terminals This connection provides power the microprocessor and display of the control As well this connection provides power to the Alert terminal from the R terminal Heat Demand To gene
32. differential setting below the boiler target temperature and will open once the water temperature at the operating sensor is 1 2 of the differential setting above the boiler target temperature Manual Differential The differential can be manually set using the DIFF setting in the Adjust menu Fixed Differential 1 Mosca ats or x Desired Temperature Increasing Time Differential Increasing Temperature Auto Differential Auto differential is only available when using PID staging If the Auto Differential is selected the control automatically determines the best differential as the load changes thereby improving efficiency During light loads the differential is increased to allow longer on and off times to reduce the potential for short cycling During large loads the differential is narrowed thereby improving comfort in heating spaces by reducing temperature swing Automatic Differential Differential 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 BOILER TARGET TEMPERATURE BOIL TARGET The boiler target temperature is determined from the mode of operation and the type of dem
33. e is applied the control turns on the Dem 1 segment in the display and control operates the boiler stages to maintain 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 Section C Dedicated Domestic Hot Water DHW Operation When mode 3 is selected the BTC provides dedicated DHW operation A DHW tank temperature
34. ed to operate the DHW pump and provide DHW priority if required by disabling the boiler pump EM 40 SM Service Manual Mode 7 External Target Temperature Input and Setpoint with Primary Secondary Piping Boiler Inlet Sensor 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 27 Mode 6 and 7 External Target Temperature Input and Setpoint Operation View Menu view Natitem The View menu items display current operating temperatures and system status information Use the Item button to view items in this menu Item Field Range Description Access e BOILER TARGET i H 35 to 266 The boiler target is the temperature the control is Factory inane 2 to 130 C currently trying to maintain at the boiler supply sensor Installer OFF or the boiler outlet sensor BOILER SUPPLY BOILSUP o i 7q H F 14 to 266 F Current boiler supply water temperature as measured Factory 10 to 130 C by the boiler supply sensor Installer Note This item is onl
35. ents Refer to section B for a description of setpoint operation Mode4 Outdoor Sensor Boiler Inlet Sensor MODE 5 Outdoor Reset and Setpoint with Primary Secondary Piping Mode 5 is designed for outdoor reset and setpoint operation 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 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 B for a description of setpoint operation Mode 5 Outdoor Supply Sensor Boiler Inlet Sensor MODE 6 External Target Temperature Input and Setpoint with Parallel Piping Mode 6 is designed for an external input signal and setpoint with parallel piping The external input signal can be provided from a BMS an EMS or a tekmar tN4 System Control for space heating The setpoint can be used to heat an indirect domestic hot water tank The external input signal creates an internal demand
36. ge delay on time elapses The interstage on delay is adjustable through the ON DLY setting in the Adjust menu 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 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 EM 40 SM Service Manual 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 Proportional Staging Olnterstage On Delay nterstage Off Delay Minimum On Time Minimum Off Time 6 0 ko BOILER DIFFERENTIAL DIFF A heat source must be operated with a differential in order to reduce short cycling The boiler differential is divided around the boiler target temperature The first stage contact will close once the water temperature at the operating sensor is 1 2 of the
37. he Stage 1 2 3 and 4 contacts according to the external input signal 0 10 V dc Direct Drive Boiler Supply Sensor The View menu items display current operating temperatures and system status information Use the Item button to view items in this menu Description Access BOL OUT 4 m rvr 14 to 266 F BOILER OUTLET Factory Os o Current boiler outlet water temperature as measured Install 10 to 130 C by the boiler outlet sensor nistaren gt gt BOILER INLET IE 14 to 266 F Current boiler inlet water temperature as measured by Factory gt JIL the boiler inlet sensor Kad gt 10 to 130 C Note This item is only available when a boiler inlet d sensor is installed Lu gt BOILER DELTA T BOIL IF 0 to 252 F Current temperature difference between the boiler outlet sensor and the boiler inlet sensor Factory 0 to 140 C Note This item is only available when a boiler inlet sensor is installed BOILER ON HOURS BOIL The total number of running hours of the boiler since 1771 to 999 this item was last cleared Clear the numbers of hours Factory by pressing and holding the and W buttons together while viewing this item After the last item the control returns to the first item in the menu EM 40 SM Service Manual 31 Mode 8 External DirectDrive Operation Adjust Menu ADJUST MENU
38. ined from the Boiler Start Boiler Design Outdoor Start and Outdoor Design settings HEAT DEMAND Dem 1 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 Once voltage is applied the control turns on the Dem 1 segment in the display If the control is not in warm weather shut down WWSD the control calculates a boiler target based on the reset ratio and outdoor air temperature The pump and the boiler stages are operated to maintain the boiler target at the boiler outlet sensor Mode 4 or the boiler supply sensor Mode 5 If the control is in WWSD the WWSD segment is shown in the display and the boiler target in the View menu of the display remains no target RESET RATIO The control uses the four following settings to determine the reset ratio Boiler Start BOIL START The BOIL START temperature is 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 The OUTDR START temperature is the outdoor air 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
39. 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 a this case if the boiler outlet sensor is operational the control will operate based on the 5 h 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 SUP nn this case if the boiler outlet sensor is operational the control will operate based on the urn 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 L The control is no longer able to read the outdoor sensor due to a short circuit In this case nir the control assumes an outdoor temperature of 32 F 0 C and continues operation Test the outdoor
40. l is no longer able to read the boiler outlet sensor due a short circuit In this h 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 so pp The control is no longer able to read the boiler outlet sensor due to an open circuit In this urn 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 BOL h The control is no longer able to read the boiler inlet sensor due to a short circuit In this I 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 BOIL IN nm nm The control is no longer able to read the boiler inlet sensor due to an open circuit In this urn case the control will continue operation Test the boiler inlet sensor and related wiring The error message will clear once the error condition
41. ment is displayed To select the Adjust menu press and hold simultaneously all three buttons Item A W for 1 second EJ Item A y 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 inactivity Once in a menu there will be a group of items that can be viewed within that menu 2 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 to the first item in the selected menu Item A y ADJUST To make an adjustment to a setting in the control begin by selecting the Adjust menu by pressing and holding simultaneously all three buttons Then select the desired item using the Item button Finally use the A or W button to make the adjustment B Item A STATUS FIELD Additional information can be gained by observing the Status field of the LCD The status field will indicate which of the control s outputs are currently active Symbols in the status field are only visible when the View menu is selected EM 40 SM Service Manual Menu Field T cud ee ey NEO Displays the current menu BOILSUPINOUT 74 qc Item Field
42. nd hold all three mmm A m m buttons simultaneously to enter the Program menu Item Field Description Access Setting LI MODE Factory 1to8 e Select the operating mode for the control Installer Default Setting 4 STAGE MODE E d Select the staging operation to be either Factory roo Pld or P automatic or manual STGMODE Pld 2 automatic Installer P proportional ADJUST BOIL tore OFF BOILER TARGET Factory LI LI 70 to 220 F Select the boiler target temperature while 21 to 104 C a setpoint demand is present Installer ADJUST jx d BOILER OUTLET MAXIMUM ZUL 120 to 225 F Select the maximum boiler outlet Factory gt 49 to 107 C temperature Exceeding this temperature gt shuts off the boiler Hu gt BOIL torr 120 to 225 F BOILER MAXIMUM i quu 49 to 107 C Select the maximum boiler target Factory OFF temperature un gt pen ADJUST Q OFF BOILER MINIMUM x MIN wu 80 to 180 F Select the minimum boiler target Factory 27 to 82 C temperature FIRE DELAY n 1i 0 00 to 3 00 min Select the amount of time required for NOT VALID Lf E Lh combustion pre purging ignition and the FOR ELECTRIC ge 1 second flame to be established y BOILER DLY increments Note This setting is only available when APPLICATION STAGE MODE is set to Pld ADJUST BOILER MASS 1 Lo or i 2 es r Select the thermal mass of the boiler Factory nnd 3 Hi Note This setting is only available when I
43. ng and holding the and W buttons together while viewing this item 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 Alust Menu change The Program menu items are the programmable settings used to operate the system Press and hold all three m A y buttons simultaneously to enter the Program menu Item Field Description Access Setting i155 MODE Factory t Select the operating mode for the control Installer Default Setting 4 STAGE MODE ADJUST nm Select the staging operation to be either Factory d Pld or P automatic or manual STGMODE Pld automatic Installer P proportional ADJUST Bon ron OFF BOILER TARGET 1 ee TARGET uu 70 to 220 F Select the boiler target temperature while a install 1 21 to 104 C heat demand is present iL BOILER TARGET 2 BOIL OFF Factory 2 uc 70 to 220 Select the boiler target temperature while a install e 2 21 to 104 C setpoint demand is present 0 ae Il BOILER OUTLET MAXIMUM ui MAX eG 120 to 225 F Select the maximum boiler outlet factor o y gt 49 to 107 C temperature Exceeding this temperature Q shuts off the boiler lt ADJUST 120to 225 F BOILER MAXIMUM mw
44. nstaller Hi STAGE MODE is set to Pld STAGE DELAY Au 0 30 to Select the minimum time delay between Factory P Lu QUEE mi stages STG ue Note This setting is only available when Installer STAGE MODE is set to Pld DIFF DIFFERENTIAL HR Lu Au 2 to 42 F Select the boiler differential Factor 1 to 23 C Note The automatic setting is only available y when STAGE MODE is set to Pld staging 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 DIFF ADJUST STG 10 F 0 to 6 C Description 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 Access Factory Setting 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 ADJUST OFF DLY 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 MIN ues Uni
45. o 10 F 0 to 6 C between stages for proportional staging Factory EL Note This setting is only available when STAGE MODE is set to P INTERSTAGE ON DELAY in Select the amount of time that must pass PLI Li min 0 10 to 8 00 min Once a stage has been turned on in order Factory to allow the next stage to turn on ON DLY Note This setting is only available when STAGE MODE is set to P INTERSTAGE OFF DELAY E Select the amount of time that must pass 11 1 Lis 0 10 to 4 00 min Once stage has been turned off in order Factory to allow the next stage to turn off OFF DLY Note This setting is only available when STAGE MODE is set to P MINIMUM ON TIME AA Select the minimum amount of time that MIN LI Zl Li 0 10 to 5 00 min ee remain on before it Factory ON Note This setting is only available when STAGE MODE is set to P MINIMUM OFF TIME pi Select the minimum amount of time that MIN Li the stage contact must remain off before it is allowed to turn back on ractony OFF Note This setting is only available when STAGE MODE is set to P n PUMP DELAY LC l OFF 0 20 to min 9 55 min On Select the boiler pump purge time after Factory shutting off the boiler oF TEMPERATURE UNITS Factory F or C Select to display temperature in degrees Fahrenheit in degrees Celsius Nplate After the last item the control returns to the first item in the menu EM 40 SM Service
46. or 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 2 Zone Box Boiler Outlet Sensor i Boiler Supply 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 4 Outdoor Reset and Setpoint with Parallel Piping Mode 4 is designed for outdoor reset and setpoint oper ation using parallel piping The heat demand is available to provide outdoor reset for space heating systems The setpoint can be used to heat an indirect domestic hot water tank Once a heat demand is present the control stages the boiler to maintain the calculated outdoor reset target at the boiler outlet sensor Refer to section D for a descrip tion of outdoor reset operation Once a setpoint demand is present the control stages the boiler to maintain the boiler target at the boiler out let sensor If both demands are present at the same time the control targets the higher of the two require m
47. p 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 system pump or zone pumps 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 1 temperatures and system status information Use the J Item button to view items in this menu Item Access Item Field Description OUTDR l 60 to 190 F OUTDOOR Factory Jg Current outdoor air temperature as measured by the Install 51 to 88 C outdoor sensor nsraner s i T BOILER TARGET i H H 35 to 266 F The boiler target is the temperature the control is Factory eer Q to 130 C currently trying to maintain at the boiler supply sensor Installer OFF or the boiler outlet sensor BOILER SUPPLY BOILSUP d o H 4 14 to 266 Current boiler supply water temperature as measured Factory 10 to 130 C by the boiler supply sensor Installer Note This item is only available when MODE is set to 5 Lu BOILER OUTLET BOIL OUT E n F 14 to 266 F Current boiler outlet water temperature as measured Factory by the boiler outlet sensor Installer for 10 130 Note
48. r 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 boiler from flashing into steam after the boiler is shut off When Pump DLY is set to OFF there is no purging When Pump DLY is set to ON the pump runs continuously When on is selected and the control is configured for outdoor reset the pump continues to run even during Warm Weather Shut 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 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 aaa 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 primary heating load 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 Once volt ag
49. r the control uses as the operating sensor The operating sensor is either the boiler outlet sensor or the boiler supply sensor 4 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 Boiler Outlet Sensor Boiler Inlet Sensor MODE 2 Two Setpoints with Primary Secondary Piping Mode 2 is designed for setpoint operation using primary secondary piping A heat demand is available to activate a setpoint for space heating systems A 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 supply sensor Once a setpoint demand is present the control stages the boiler to maintain the boiler target 2 at the boiler supply sens
50. rate 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 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 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 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
51. rature shuts off the boiler Continued on next page 24 EM 40 SM Service Manual Mode 4 and 5 Outdoor Reset and Setpoint Operation Adjust Menu 2 of 3 ADJUST MENU Item Field Description Access Setting ADJUST BOIL tore 120 to 225 F BOILER MAXIMUM tou 49 to 107 C Select the maximum boiler target Factory OFF temperature ADJUST BOIL 111 AF OFF BOILER MINIMUM m 80 to 180 Select the minimum boiler target Factory 27 to 82 C temperature FIRE DELAY 5 0 00to 3 00 min Select the amount of time required for NOT VALID LI Lis combustion pre purging ignition and the Factor FOR ELECTRIC ge 1 second flame to be established y BOILER DLY increments Note This setting is only available when APPLICATION STAGE MODE is set to Pld ADJUST T BOILER MASS BOIL i 2 Med or Select the thermal mass of the boiler Factory En 3 Hi Note This setting is only available when Installer STAGE MODE is set to Pld STAGE DELAY H Au 0 30 to dns the minimum time delay between Factory stages 9 55 min ee y Note This setting is only available when Installer STAGE MODE is set to Pld DIFF DIFFERENTIAL R T Au 2 to 42 F Select the boiler differential m Factory 1 to 23 C Note The automatic setting is only available when STAGE MODE is set to Pld staging DIFF STAGE DIFFERENTIAL
52. rential The DHW sensor temperature il Q TANK must fall below this setting before the x boiler will turn on ew BOILER OUTLET MAXIMUM MAX eui 120 to 225 F Select the maximum boiler outlet Factory 49 to 107 C temperature Exceeding this temperature shuts off the boiler FIRE DELAY TS 0 00 to 3 00 Select the amount of time required for NOT VALID ip combustion pre purging ignition and the Factor FOR ELECTRIC ge 1 second flame to be established y BOILER DLY increments Note This setting is only available when APPLICATION STAGE MODE is set to Pld BOILER MASS i 2 Med or Select the thermal mass of the boiler Factory 3 Hi Note This setting is only available when Installer STAGE MODE is set to Pld Continued on next page 20 EM 40 SM Service Manual Mode 3 Dedicated DHW with Parallel Piping Adjust Menu 2 of 2 ADJUST MENU Item Field ADJUST Hu STG DLY Range Au 0 30 to 9 55 min Description STAGE DELAY Select the minimum time delay between stages Note This setting is only available when STAGE MODE is set to Pld Access Factory Installer Setting DIFF ADJUST LIT STG 0 to 10 F 0 to 6 C STAGE DIFFERENTIAL Select the interstage temperature differential between stages for proportional staging Note This setting
53. same time the control targets the higher of the two requirements Refer to section B for a description of setpoint operation Mode 7 tN4 System Control 0 V dc 0 1 Boiler Inlet Sensor MODE 8 External Direct Drive Operation Mode 8 is designed for an external input signal to directly control the staging rate of the boiler with either parallel or primary secondary piping The heat demand and setpoint demand inputs are disabled Refer to section F for a description of external target temperature operation 0 10 V dc Direct Drive Boiler Inlet Sensor Boiler Inlet Sensor 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 amp Integral amp Derivative and is selected using the STGMODE item in the Adjust menu Proportional Staging 190 F 180 F etpoint 1759 dash 170 DEED sees LL E 1607 eee eeen enc rEeEr dg ate eese uicien emen iuner gene 155 F 4e temperature eH Sees eee ien esso pee caus series ses Ol00 Dire eses see hess aqme ILE n deu i ELE 14Q F ese puie poisson E ee Nen RE ES Stage 4 Stage 3 Stage 2 Stage 1 Staging 185 F 180 F
54. the Item or V button Once the test sequence is enabled the outputs are tested in the follow ing sequence Press and hold the A button for 3 seconds while in the View menu Step 1 DW soir The boiler pump is turned on Step 2 soi Era Stage 1 heating element s on Step 3 soii GU Stage 2 heating element s on Step 4 oou Ge Stage 3 heating element s on Step 5 soi Ge Stage 4 heating element s on The boiler pump and stages 1 Step 6 Q to 4 are shut off The alert is closed for 10 seconds The control exits the test sequence and resumes normal operation EM 40 SM Service Manual Control Settings DIP Switch Settings Note DIP switches are located on the front of the control B Not Used A Factory Installer The Factory Installer DIP switch is used to select which items are available to be viewed and or adjusted the user interface The Factory Access Level includes all Installer the settings available in the control The Installer Access Level includes the settings and items which are required for system setup Mode 1 and 2 Two Setpoint Operation Applications Mode 1 Two Setpoint Operation with Parallel Piping Mode 2 Two Setpoint Operation with Primary Secondary Piping Mode 1 Mode 2 Zone Box Sensor 63 Supply f Sensor Boiler Inlet Sensor Boiler Inlet Sensor Sensor
55. to the Com common sensor and Boil O boiler outlet sensor pins The boiler outlet sensor is used by the control to meas ure the boiler outlet water temperature from the boiler Note The boiler outlet sensor is required for every mode of operation 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 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 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 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 1
56. ure is viewed Partial Outdoor Reset uum m Ss is 3 WWSD Increasing Water Temperature 3 Decreasing Outdoor Air Temperature 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 The boiler pump contact operates when A heat demand is present and parallel piping Mode 1 3 4 6 is used Parallel piping requires the boiler pump to operate even while the boiler is off in order to provide 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 isolating the boiler from the System while the boiler is off During external direct drive operation Mode 8 the boiler pump contact closes whenever there is an internal heat demand After the boiler shuts off the boiler pump remains on to purge heat from the boiler to the system 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 DLY setting Once the boiler turns off the control keeps the boile
57. xternal 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 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 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 by installing a 500 Ohm resistor on the external input signal device s terminals 0 10 V dc 0 20 mA Boiler Target 0 0 OFF 1 2 50 F 10 C 2 4 68 F 20 C 3 6 86 F 30 C 4 8 103 F 39 C 5 10 121 F 49 C 6 12 139 F 59 C 7 14 157 F 69 C 8 16 174 F 79 C 9 18 192 F 89 C 10 20 210 F 99 C requires a 50
58. y available when MODE is set to 7 gt BOILER OUTLET BOL OUT 4 yt 14 to 266 F Current boiler outlet water temperature as measured Factory W ILI PE by the boiler outlet sensor Installer for C10 to Note When MODE is set to 7 this item is only visible Mode 6 gt in the Factory access level BOILER INLET BOIL IN 14 to 266 F Current boiler inlet water temperature as measured by Factory the boiler inlet sensor 710 to 130 C Note This item is only available when a boiler inlet sensor is installed BOILER DELTA T BOIL 252 F Current temperature difference between the boiler outlet w sensor and the boiler inlet sensor Factory 010 140 C Note This item is only available when a boiler inlet sensor is installed BOILER ON HOURS BOIL The total number of running hours of the boiler since 0 to 999 this item was last cleared Clear the numbers of hours Factory by pressing and holding the and W buttons together while viewing this item 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 jjis Change value The Program menu items are the programmable settings used to operate the system Press a

EM-10 Electronic Control Manual_Eng Modes 1 thru 8

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