Aerco AM Series, User Manual

Page 1: ...101_0D 04 29 2016 Ph 800 526 0288 GF 146 CS GF 146 CS USER MANUAL Cascade Sequencer Controller For AM Series Boilers and Water Heaters Latest Update 04 29 2016 This device is intended for use with following AERCO AM Series Models Water Heaters AM 399W AM 500W AM 750W AM 1000W Boilers AM 399B AM 500B AM 750B AM 1000B ...

Page 2: ...NICATIONS BOARD SWITCH TO ON 12 1 6 SETTING THE LOGIC ADDRESS FOR EACH HEATER 14 1 7 SETTING FOR USE WITH BOILERS OR WATER HEATERS 16 1 8 DEPENDENT HEATER PREPARATION SETTING PARAMETER 2003 16 1 8 1 AM Series Controller Installer Menu Navigation 17 1 9 REVIEW OF ALL PARAMETERS 18 1 10 REMOVING THE CASCADE SEQUENCER 20 CHAPTER 2 OPERATION 21 2 1 CASCADE SEQUENCER DISPLAY AND CONTROLS 21 2 2 CASCADE...

Page 3: ... information see the AM Series Modbus installation Guide TID 0123 Cascade Sequencer Controller Front Panel Cover closed The AM Series Cascade sequencer Kit is comprised of AM Series Cascade Sequencer unit P N 62110095 AM Series Cascade Sequencer User Manual OMM 0101 WARNING Installer Read the manual for the appliance s including this manual before installing Perform steps in the order given User T...

Page 4: ...n order for the AM Cascade Sequencer to operate correctly the AM Series heaters must be installed as shown in Figure 1 1 Because the cascade general sensor is installed on the Master heater the Master heater must always be the closest to the low loss header in order to provide the most accurate temperature measurement A maximum of eight 8 heaters may be connected into the cascade system NOTE Figur...

Page 5: ...used to connect boilers should be shielded type and has a maximum length of 300 ft Unshielded wire is acceptable but not recommended and the maximum length is only 60 ft Depending on the control method of your system additional wiring may be required For outdoor reset using the included outdoor temperature sensor connect the outdoor temperature sensor to terminals 14 15 of the Master boiler For re...

Page 6: ...ncer User Manual Page 6 of 28 AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 OMM 0101_0D 04 29 2016 Ph 800 526 0288 GF 146 CS Figure 1 3a Cascade Sequencing System Electrical Wiring Units without Terminals 30 and 31 ...

Page 7: ...encer User Manual OMM 0101_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 7 of 28 GF 146 CS Ph 800 526 0288 04 29 2016 Figure 1 3b Cascade Sequencing System Electrical Wiring Units with Terminals 30 and 31 ...

Page 8: ...ewdriver remove the rear cover of the Cascade Sequencer by levering up the panel via the slot as shown in Figure 1 4 Figure 1 4 Opening Rear Panel of Cascade Sequencer 2 Connect two wires each two feet 0 5m long to the two screw terminals on the Cascade Sequencer PCB as shown in Figure 1 5 Wires do not have polarity Figure 1 5 Connecting Wires to the Cascade Sequencer Terminals 3 Feed both wires t...

Page 9: ...r is the one installed closest to the low loss header To electrically prepare an AM Series heater boiler that is without terminals 30 and 31 for use as the Master appliance for the Cascade Sequencer follow the instructions below Rewiring the Master Boiler Units without Terminals 30 31 1 Using a flat head screwdriver open the communications board cover see Figure 1 7 Figure 1 7 Using Screwdriver to...

Page 10: ...pening the Wire Conduit Cover 4 From the wire conduit remove the two wires pink and yellow that are attached to the plug disconnected from the communications board in step 4 Figure 1 10 Figure 1 10 Removing Pink and Yellow Wires from Wire Conduit 5 Cut the connector from the pink and yellow wires and strip the insulation 1 4 7mm Figure 1 11 Figure 1 11 Removing 2 Wire Connector from Junction PCB W...

Page 11: ...rminal 16 See Figures 1 12 Figure 1 12 Connecting Pink Wire to Terminal 16 7 Connect the yellow wire together with the two red wires present on terminal 17 See Figures 1 13 See Figure 1 14 for final wiring diagram Figure 1 13 Connecting Yellow Wire to Terminal 17 Figure 1 14 Terminal Wiring Diagram for Master Heater NOTE Other Wiring Not Shown for Clarity Connect YELLOW Wire To Terminal 17 Connect...

Page 12: ... the S4 switch on the communications board must be set to ON as described below Setting Communications Board Switch to ON 1 Gain access to the inside of the electrical junction box by removing the unit top cover and the electrical junction box top cover see Figure 1 2 2 Locate the communication board cover inside the junction box see Figure 1 15 Figure 1 15 Locating the Communications Board inside...

Page 13: ...46 CS Ph 800 526 0288 04 29 2016 Setting Communications Board Switch to ON Continued 4 Locate S4 switch at front edge of communications board per Figure 1 17 5 Set S4 switch to ON LEFT as you are facing the unit Figure 1 17 Setting Master Heater Communications Board S4 Switch NOTE Wiring is not shown for image clarity S4 Switch ...

Page 14: ...tion box and wiring terminals within See Section 2 for operation of the unit and how access menus and parameters 1 Ensure power is turned OFF to the boiler set up as the Master heater heater 1 2 Connect the two wires from the Cascade Sequencer to terminals 16 and 17 see Figure 1 18 of the Master heater s electrical junction box Figure 1 18 Wiring to Terminals 16 and 17 on AM Unit Other wiring not ...

Page 15: ...e parameter setting Figure 1 20 and begins to blink indicating it may be adjusted Figure 1 20 Sub Menu Changing the Parameter Setting d Use the Up or Down buttons to change the parameter value up or down For the Master heater set this to 1 For each Dependent heater a different address is set from 2 to 8 depending on how many dependent heaters are in the cascade e When the desired logic address num...

Page 16: ...ld be shown on the Cascade Status Screen see section 2 2 1 7 Setting for Use with Boilers or Water Heaters The Cascade Sequencer is set at the factory for boiler applications but not for water heater applications When your system is in place and you wish to control water heaters you must ensure all parameters of the Sub Menu are set as shown in the list in Section 2 1 Select the settings in the co...

Page 17: ... After entering the Installer Menu the 2000 series of parameters are available for display and editing 2 To scroll through the list of parameters press buttons and 3 Once parameter 2003 is displayed it can be selected for editing by pressing the RESET button once the displayed value will start blinking and then using the and buttons to change the value up or down to select the following Dependent ...

Page 18: ...99 500 respectively using three 3 to eight 8 units At the end of the installation process all parameters Address Switch S4 2003 3001 and 3050 should have the values as shown on Figures 1 18a 1 18b and 1 18c If an attempt is made to operate the cascade system and the applicable parameters are not set to the values shown one or more of the heaters in the cascade will display a 116 error communicatio...

Page 19: ...0101_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 19 of 28 GF 146 CS Ph 800 526 0288 04 29 2016 Figure 1 18b AM 750 Cascade Configuration and Settings Diagram Figure 1 18c AM 399 500 Cascade Configuration and Settings Diagram ...

Page 20: ...dual units perform the following procedure Removing the Cascade Sequencer 1 Connect the Cascade Sequencer to the last dependent boiler per Section 1 6 and set cascade logic address to 0 2 One at a time connect the Cascade Sequencer to each dependent boiler per Section 1 6 and set cascade address to 0 until all dependent heaters are set to 0 3 Connect the Master boiler per Section 1 6 and set casca...

Page 21: ...in the left display field represent the firing rate and current state of the first and second burners in the master unit and are not important to the function of the cascademanager Similarly the information field only refers to the Master boiler If the outdoor temperature sensor is not connected it will display a temperature of 40 Similarly if the cascade temperature sensor is not connected it wil...

Page 22: ...e Status screen to update the status of an individual boiler or water heater Figure 2 2 Cascade Status Display When Cascade Button Pressed 2 3 Submenu Navigation and Parameter Settings The sub menu may be accessed navigated and parameters changed as instructed below Submenu Navigation and Parameter Settings 1 To access the Submenu press and hold the Home button Fig 2 1 for eight seconds then relea...

Page 23: ...or an indirect water heater Start delay time Delay for a call of the next boiler Stop delay time Delay to remove the call to the next boiler Start boiler diff Temperature differential to call the next boiler Stop boiler diff Temperature differential to remove the call to the next boiler Stop all boiler diff Temperature differential to remove the call to all boilers Max offset up Maximum difference...

Page 24: ... 1 Master Heater 2 1st Dependent Heater 3 2nd Dependent Heater 4 3rd etc 0 Stand Alone heater 1 Master Heater 2 1st Dependent Heater 3 2nd Dependent Heater 4 3rd etc Temperature Unit C F Cascade Setpoint F 68 194 140 140 140 DHW ON OFF ON OFF OFF ON only if you want to drive an indirect water heater OFF Start delay time sec 0 1200 600 600 15 Stop delay time sec 0 1200 600 600 15 Start boiler diff ...

Page 25: ... all set according to the Water Heater Settings System loop is not reaching desired setpoint Check the location of the cascade header temperature sensor Ensure that the sensor is located such that it will see flow from both the primary and secondary loops Check parameters 1120 1123 on each unit Ensure that all modules are running at maximum capacity If not wait 10 minutes for burners to modulate u...

Page 26: ...nit but the units do not display on the Sequencer screen Ensure the daisy chain wires are correctly in place Ensure the Cascade Status Menu is being displayed on the Sequencer Turn off all boilers Turn boiler 1 on and wait for the Sequencer to recognize it up to 3 minutes Then turn boiler 2 on and wait for the Sequencer to recognize it up to 3 minutes Continue for all units present Dependent boile...

Page 27: ...AM Series Cascade Sequencer User Manual OMM 0101_0D AERCO International Inc 100 Oritani Dr Blauvelt NY 10913 Page 27 of 28 GF 146 CS Ph 800 526 0288 04 29 2016 NOTES ...

Page 28: ...hange Log Date Description Changed By 11 18 2015 Rev C Combined Rev B with new Rev C manual to cover units S N 14999999 and lower and 15000000 and higher Curtis Harvey 04 29 2015 Rev D Added Cascade Sequencer part number to section Reformatted and redesigned per new standard corrected per markup per AM drawn from new manual Udated images instructions secs and troubleshooting Curtis Harvey ...