AM Series Cascade Sequencer
Contents
1. Because the cascade general sensor is installed on the Manager heater the managing 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 At the time of the installation all heaters will have the same settings After installation the heater nearest the low loss header will require some hardware adjustment to become the managing heater and the other heaters will need a change to the software settings to become the dependent heaters Instructions for doing this are provided in the following sections NOTE Figure 1 1 shows only one piping configuration example Other piping configurations are possible Contact AERCO technical support for information concerning alternative configurations Cascade Sequencer Controller Check valve Ki Dependent Dependent Dependent Managing Cascade heater 4 heater 3 heater 2 i heater 1 general up to 8 sensor Heating pump loss header Figure 1 1 Cascade Sequencing Heater Boiler Piping Installation OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 5 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 2 Electrical Installation The electrical installation must be done as shown in Figure 1 2 Installer must install all wires r2. 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Wiring the Manager Heater Communications Board Continued 3 Using a flat head screwdriver open the communications board cover see Figure 1 5 Figure 1 5 Using Screwdriver to Remove Communications Board Cover 4 Disconnect the 2 wire pink yellow plug from the communications board See Figure 1 6 Communications Board Pink Wire Unplug This Male Connector Yellow Wire Unplug Connector From Female Header Figure 1 6 Removing 2 Wire Male Connector from Communications Board 5 Open the wire conduit cover See Figure 1 7 yy 2 n m Y E Ze es E ee EE 4Rala i L UE 4 Wire Conduit Cover Figure 1 7 Opening the Wire Conduit Cover OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 9 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Wiring the Manager Heater communications Board Continued 6 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 y A ee es Figure 1 8 Removing Pink and Yellow Wires from Wire Conduit 7 Cut the connector from the pink and yellow wires and strip the insulation 1 4 7mm Yellow amp Pink wires cut from connector and stripped Fi
3. 37 ar gt Js E Rotation interval Days 1 10 5 _____5_____ ___5____ __ PValue 025 2 2 _ zo Walue 0255 8 so so DVawe ozs s o ___o____ ___o Slewrate 1255 5 ___5 ___ 5 System correction F 14 32 2214 224 Mod delay factor min 0 60 4 _____4a____ ___o TI OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 23 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 2 6 Troubleshooting Guide Below is a list of possible issues and corrective actions Troubleshooting Guide O swe U O Corrective Action Cannot set the unit address when installing cascade sequencer OR When trying to set the unit e Ensure settings and switches are correct as per Figure 1 18 address the new address does not appear on the cascade sequencer e Double check all wiring e Double check all wiring Cascade system does not e Ensure settings and switches are correct as per Figure 1 18 seem to be communicating correctly e Make sure that all units show up under the Cascade Status menu When trying to set the unit This may indicate incorrect software in the communications address 5 appears on all module Contact AERCO technical support for further units information Domestic water heating tank is Check that the parameters are all set according to the Water not reacting quickl
4. AERCO Installation and Operation Manual GF 146 CS Cascade Sequencer Controller for AM Series Models Water Heaters AM 399W AM 500W AE RECO y e AM 750W e AM 1000W AM Series Boilers a gt e AM 399B e AM 500B eta Cascade Sequencer AM 1000B Controller For AM Series Water Heaters or Boilers USER MANUAL Installation and Operation AERCO XN Cascade Sequencer Controller Front Panel Latest Update 11 25 2014 Page 1 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer Installation and Operation Manual DISCLAIMER The information contained in this manual is subject to change without notice from AERCO International Inc AERCO makes no warranty of any kind with respect to this material including but not limited to implied warranties of merchantability and fitness for a particular application AERCO International is not liable for errors appearing in this manual nor for incidental or consequential damages occurring in connection with the furnishing performance or use of these materials AERCO AERCO Technical Support Mon Fri 8am 5pm EST 1 800 526 0288 AERCO Document Conventions In this document some types of information are presented as shown in the following examples Message Type Example and Description NOTE NOTE messages indicate specific information related to the
5. Sequencer is now set up for cascade operation Ensure all switch settings match Figure 1 18 1 6 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 column for boilers if you are using boilers or select the settings in the column for water heaters if you are using water heaters 1 7 Dependent Heater Preparation Setting Parameter 2003 Parameter 2003 is factory set to 0 However this parameter should be checked for all dependent heaters to ensure parameter 2003 is set to 0 Follow the instructions in Section 1 71 next page to access the Installer Menu on the AM Series boiler or water heater controller to confirm or change parameter 2003 to zero for all dependent heaters lf you need more information concerning AM Series controller operation consult the AERCO AM Series user manual GF 146 OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 17 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 7 1 AM Series Controller Installer Menu Navigation This menu of parameters is available to qualified technicians for the purpose of analyzing the function of an
6. board at top of unit per previous wiring instructions 2 Locate S4 switch at front edge of communications board per Figure 1 13 3 Set S4 switch to ON LEFT as you are facing the unit per Figure 1 13 Figure 1 13 Setting Managing Heater Communications Board S4 Switch NOTE Wiring is not shown for image clarity Page 12 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 3 3 Manager Heater Preparation S4 Switch on the Burner 1 Board The S4 switch on the Burner 1 Master board must be set to OFF as described below Setting Manager Heater Burner 1 Master S4 Switch 1 Gain access to the Burner 1 Master Board and S4 switch by removing the front cover of managing unit Note the location of the Burner 1 Master Board in Figure 1 14 it is cyan colored in the image NOTE The model shown in Figure 1 14 is the AM1000 The AM750 does not feature Burner Board 2 In the AM399 and AM500 models the 1 Master Burner board is the one on the BOTTOM 2 Locate S4 switch opening on upper right of 1 burner board Figure 1 14 and use a small flathead screwdriver set to switch to OFF UP per Figure 1 14 detail Bes Burner 2 Board Not Present in AM750 Units STEP 2 Set S4 Switch to OFF UP Board Cover removed for clarity Burner 1 Master Board Burner 3 Board B
7. master unit and are not important to the function of the cascade manager 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 will display a temperature of roughly 12 14 degrees Cascade Setpoint Logic Address Cascade Temperature Outdoor oF Temperature Y 1 e 6 Information aldo Field Ig Cascade Information Status Button y Button Not Used KAR Not Used Reset Button Not Used OK Button To Select Parameters amp Open Accept Cover HOME Button Changes Press 8 sec to enter Sub Menu DOWN UP Buttons To Scroll Thru Parameter List eri mi or Parameter Values Figure 2 1 Cascade Sequencer Front Panel Features Lower Cover Open Page 20 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 2 2 Cascade Status Button By pressing the Cascade Status button Figure 2 1 the lower half of the display will change to show the status of the cascade boilers Figure 2 2 The designated number for each boiler in the cascade system will be displayed such as 1 2 3 4 etc up to 8 If there is a request for heating for any heater a flame icon will appear under that heater s number The absence of a flame icon under the number represents a heater in standby mode The Casca
8. 25 28 29 120VacL1 120Vac Neutral H Header Sensor Factory installed rn GROUND Local pump Max 3A Cascade Sequenc 120Wac Alarm signal System Electrical Wiring ing 2 1 Figure Page 7 of 26 PRI 11 25 14 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0101_0A GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 3 Manager Heater Preparation NOTE Ensure that the heater being wired as the managing heater is the one installed closest to the low loss header 1 3 1 Manager Heater Preparation Communications Board To electrically prepare an AM Series heater boiler for use as the Managing appliance for the Cascade Sequencer follow the instructions below Wiring the Manager Heater Communications Board 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 3 Unit Top Cover Junction Box Top Cover Screw Top Cover Communications Board Cover Figure 1 3 Accessing the Junction Box of the Managing Heater 2 Locate the communication board cover inside the junction box see Figure 1 4 E Communications Board Cover Figure 1 4 Locating the Comm Board inside the Electrical Junction Box Page 8 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI
9. 8 diagrams a cascade setup using three 3 AM1000 units with four burner boards in each unit At the end of the installation process all parameters Address Switch S4 2003 3001 and 3050 should have the values as shown on Figure 1 18 lf an attempt is made to operate the cascade system and the applicable parameters are not set to the values shown in Figure 1 18 one or more of the heaters in the cascade will display a 116 error Communication error and will stop functioning L_ I OO ra Sequencer Comm Comm Comm Board Board Board Address 1 Address 2 Address 3 q Dependant Dependant neater Heater Heater Figure 1 18 Cascade General Configuration and Settings Diagram OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 19 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL CHAPTER 2 OPERATION NOTE After turning on power wait at least 40 seconds for communication between sequencer and heaters to finish before performing any operations Wait for the cascade manager to recognize the address of the master boiler or water heater 2 1 Cascade Sequencer Display and Controls The AM Series Cascade Sequencer features a display and lower cover that is opened to reveal a number of buttons as shown in Figure 2 1 The icons labeled M and D represent the firing rate and current state of the first and second burners on the
10. GIC ADDRESS FOR EACH HEATER uti egen 15 1 0 SOE TIING FOR USE WITH BOILERS OR WATER HEATERS oia 17 1 7 DEPENDENT HEATER PREPARATION SETTING PARAMETER 20023 17 1 7 1 AM Series Controller Installer Menu Navigation 18 LO REVIEW ORAUEPARAMETERS 1 aaa 19 CHAPTER 2 OPERATION iaa 20 2 1 CASCADE SEQUENCER DISPLAY AND CONTIROLS 20 CHEN 08 be BUTTON EE EN 2 3 SUBMENU NAVIGATION AND PARAMETER SETTINGS ccc ccceceeceeeeceeeeeeeeeeeeaeeeeeeeeeeeees 21 2 4 SUBMENU PAR A WIE ME RES EE 23 2 5 MENU PARAMETER DESCRIPTIONS ooococcococcoconcononconcononcononcononnononcononnononnoncnnonconennonennoninnennonenennons 22 2 6 TROUBLESHOOTING GUIDE leet deene 24 OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 3 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL INTRODUCTION The AM Series Cascade Sequencer controller is used to control a cascade arrangement of up to eight 8 AM Series water heaters or boilers This document provides instructions for installation and operation of the cascade sequencer Please note that the cascade sequencer requires a communications board be installed in each AM Series boiler or water heater This board is present in every AM 500 750 and 1000 but is an option on the AM 399 and must be installed prior to cascade sequencer installation For further information see the AM Series Modbus installation Guide TID 0123 Page 4 o
11. Y 10913 Page 21 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Submenu Navigation and Parameter Settings Continued Use the Up or Down buttons to change the parameter value up or down When the desired value is displayed save it by pressing the Ok button To reject the change do not press OK and instead skip to the next step To leave the Sub Menu and return to the Main menu press the Menu button Figure 2 1 IMPORTANT NOTE After any change to a parameter wait at least 40 seconds before exiting the sub menu or turning the power off 2 4 Sub Menu Parameter Descriptions Below is a list of Menu parameters and descriptions The table in the next section lists the range and default settings for each parameter AM Series Cascade Sequencer Parameter Descriptions Maximum difference above the header setpoint that any one boiler is allowed to Max offset up reach Maximum difference below the header setpoint that any one boiler is allowed to Max offset down Fee Rotation interval How often the lead boiler is rotated P Value Proportional band of the PID temperature control of the cascade general sensor Integral band of the PID temperature control of the cascade general sensor Derivative band of the PID temperature control of the cascade general sensor uta Slew rate is a low level parameter It determines how fast the output of a PID can change per amount
12. ascade Sequencer INSTALLATION AND OPERATION MANUAL Change Log 11 25 2014 Rev A Released Curtis Harvey International Inc www aerco com Page 26 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS
13. d making adjustments to the unit Parameters for Burner 1 are applicable for that burner only To enter and make changes in the Installer Menu perform the following steps AM Series Controller Installer Menu Navigation and Adjustment To enter the Installer Menu press and simultaneously hold down both the RESET and D 0 OG buttons or 5 seconds until the icon is displayed St then release the buttons After entering the Installer Menu the 2000 series of parameters are available for display and editing To scroll through the list of parameters press buttons 6 in and Ti Ps 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 Su and 07 ar buttons to change the value up or down For dependent eaters select 0 4 To confirm the new value press and release the RESET button 5 To exit the Installer Menu press and hold RESET button for more than 5 seconds until the E icon is no longer shown in the display NOTE This instruction is only for setting parameter 2003 For information about other parameters in the Installer Menu refer to the AM Series user manual GF 146 Page 18 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 8 Review of All Parameters Figure 1 1
14. de Status display shown in Figure 2 2 indicates there are three heaters in the cascade with numbers 1 and 2 calling for heat and number 3 in standby mode Number Indicating Cascade Heater Flame Icon No Flame Icon Indicates Indicates a Heater is in Standby Mode Reauest for Heat 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 Press and hold the Home button Figure 2 1 for eight 8 seconds then release the button to display the Sub menu Once the Sub menu is displayed Figure 2 3 use the Up or Down buttons Figure 2 1 to scroll through the list of parameters A dot appears to the left of the parameter to indicate it is selected CASCADE Dot indicating e Boiler Address 0 selected Cascade Setpoint 125 F parameter duer siji Figure 2 3 Sub Menu Selecting the Parameter to Change When the desired parameter is displayed press the Ok button The dot will then move to the left of the parameter setting Figure 2 4 which begins to blink indicating it may be adjusted Dot indicating CASCADE parameter setting may Boiler Address 1 be changed Cascade Setpoint 125 F Setting also blinks DHW OFF Figure 2 4 Sub Menu Changing the Parameter Setting OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt N
15. e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL OO 885HC Cascade O Manager or Ge wii ui T 0 OU et Z Es 24Vdc VOLTAGE TERMINALS 120Vac VOLTAGE TERMINALS peat ingen en Ta re eege Dr e en K l 3 gt i i 1 i T em E TEI opeases sng E uN EA KiSUes Japeay apeoseg H a o Lo OSUSS Japa SpeIse SL T du apa O1 D 55 l 4 OND du gn OL 0 Io ONS ston sap sy 5 ye LSnqnoy Ser sy gt i L Snapo ser su Loy puewLuoo 4 erg E A a EE puewuco 9H srg g KA EE J 0 sosues oaping g 50 ege ontgnc El e Jostas YUE E T ene ei 27 feos Op sowe LODO E Geen up souse wooy g 64 sosuas Jepeay en FU SH Josuas Spa SH _ mm et PI Fr Je A ZP eee e Se ett rs a 3944 HOA ON wen Lie Iewen SF saij yoh ON wey HE Bs gt punas ye xew ennan durd MHO e xew sur dund MHO 120Wac Alarm signal DEPENDENT HEATER 2 E Cl ur E E Le El El El Les 120Wac Li ec 120Wac Neutral 4 Header Sensor Factory installed mmm mm gp mmm A mmm ma 120Wac Alarm signal Local pum Max 3A P WA g E a DA D UI e I m O Lu D m D Ped 102 PE 103 104 105 106 107 108 109 140 143 144 Y Lele 10 14 12 13 14 15 16 17 18 19 20 22 23 24
16. epresented by dashed lines The Cascade general sensor is present inside each heater s accessory box This sensor must be electrically wired to terminals 24 and 25 of the Managing heater 1 and placed into the low loss header of the cascade see Figure 1 1 The daisy chain wiring 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 amp 15 of the managing boiler For remote setpoint 0 10V control connect the 0 10V signal wires to terminals 22 amp 23 of the master boiler For Modbus control of the operating setpoint connect to terminals 18 19 and 20 For further information on Modbus see GF 146 MB lf there is a water heater tank present in the system whether direct or indirect the tank sensor should be placed in the bottom 1 3 of the tank and wired into terminals 12 amp 13 of the managing heater This sensor is included in the spare parts kit shipped with each unit and is the same probe as the cascade header temperature sensor For further information on all of these control modes consult the AM Series Boiler and Water Heater User Manual GF 146 Page 6 of 26 AERCO International Inc e 100 Oritani Dr
17. f 26 PRI 11 25 14 AERCO Cascade Sequencer Controller Front Panel The AM Series Cascade sequencer Kit is comprised of e AM Series Cascade Sequencer unit e 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 This manual is for use only by a qualified heating installer Failure to comply with these provisions can lead to a dangerous situation and or damage to property and equipment Installation and Alterations Only a Qualified installer must carry out the installation and calibration of the appliance s Never modify the appliance or its flue gas carrying components in any way This heater must be properly vented Failure to follow these instructions could result in personal injury or death AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Ph 800 526 0288 OMM 0101_0A GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL CHAPTER 1 INSTALLATION 1 1 Piping Installation WARNING Prior to appliance installation and or maintenance disconnect the appliance s electrical power supply and shut off the inlet gas valve Failure to follow these instructions could result in severe personal injury or death In order for the AM Cascade Sequencer to operate correctly the AM Series heaters must be installed as shown in Figure 1 1
18. gure 1 9 Removing 2 Wire Connector from Junction PCB 8 Connect the pink wire together with the two black wires present on terminal 16 See Figures 1 10 and 1 12 Pury tars SA Figure 1 10 Connecting Pink Wire to Terminal 16 Page 10 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Wiring the Manager Heater Communications Board Continued 9 Connect the yellow wire together with the two red wires present on terminal 17 See Figures 1 11 and 1 12 ee CO O OO OA O a a ore Kl Ke D e A D N 8 A W W i Wi Wi Win Wir Wir Win Wi Wi Wi hia Wi mue E HIER QA KC Connect YELLOW Wire To Terminal 17 Connect PINK Wire To Terminal 16 Existing BLACK Wires Existing RED Wires On Terminal 16 On Terminal 17 Figure 1 12 Terminal Wiring Diagram for Managing Heater NOTE Other wiring is not shown for diagram clarity OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 11 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 3 2 Manager Heater Prep S4 Switch on Communications Board The S4 switch on the communications board must be set to ON as described below Setting Manager Heater Communications Board S4 Switch to ON 1 Locate the communications
19. nd E2Prom Err is not displayed Using the Cascade Sequencer set the Address to 1 as follows Logic Address Programming Procedure a Press and hold the Home button Figure 2 1 for eight 8 seconds then release the button to display the Sub menu b Once the Sub menu is displayed Figure 1 19 use the Up or Down buttons Figure 2 1 to scroll through the list of parameters A dot appears to the left of the parameter to indicate it is selected Figure 1 19 Oo CASCADE Dot indicating e Boiler Address 0 Cascade Setpoint 125 F selected parameter E Figure 1 19 Sub Menu Selecting the Parameter to Change c When the Boiler Address parameter is selected press the Ok button The dot will then move to the left of the parameter setting Figure 2 4 which begins to blink indicating it may be adjusted Dot indicating CASCADE parameter setting Boiler Address D may be changed Cascade Setpoint DHW Setting also blinks 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 Managing heater set this to 1 For each Dependent heater a different address is set from 2 to 7 depending on how many dependent heaters in the cascade e When the desired logic address number is displayed save it by pressing the Ok button To reject the change do not press OK and instead skip to the next step f To return to the Main menu press the Menu b
20. ntinued 3 Feed both wires through the rear panel conduit opening and snap rear panel onto rear of cascade Sequencer Figure 1 17 Figure 1 17 Replacing Cascade Sequencer Rear Panel after Wiring 1 5 Setting the Logic Address for Each Heater Program the logic address of each heater using the Cascade Sequencer as described below Setting the Logic Address for Each Heater NOTE Refer to Section 1 31 for location of the electrical junction enclosure and wiring terminals mentioned below See Section 2 for how to operate the unit and access menus and parameters 1 Ensure power is turned OFF to the Managing heater 1 2 Connect the two wires from the Cascade Sequencer to terminals 16 and 17 of the Managing heater as shown in Figure 1 18 se uo PC LU me GE Terminals 16 and 17 O Figure 1 18 Wiring Cascade Sequencer t NOTE The wiring diagram shown in Figure 1 18 applies to all heaters in cascade as each will be programmed with a unique logic address using the Cascade Sequencer Other wiring is not shown for Clarity OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 15 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Setting the Logic Address for Each Heater Continued 3 Turn the power ON to the Managing heater 1 The Cascade Sequencer will also power up 4 Wait until the Cascade Sequencer recognizes the boiler a
21. of time The system correction value is added to the measured system temperature This System correction corrected value is used for control If the measured sensor value deviates from the real temperature then you can correct it with this parameter Mod delay factor Delay to the start of modulation of any boiler Page 22 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 2 5 Sub menu Parameter Range and Default settings Below is a list of the menu parameters with range and default settings There is a table in the previous section that provides a description of each parameter AM Series Cascade Sequencer Sub Menu Parameter List Factory Water Heater Custom Parameter Units Range Settings sel SOMES Settings Value O Stand Alone heater O Stand Alone heater 1 Managing Heater 1 Managing Heater Boiler address geg 2 1st Dependent Heater 2 1st Dependent Heater 3 2nd Dependent Heater 3 2nd Dependent Heater y Cascade setpoint F 65 194 ON only if you want to drive maa EE an indirect water heater 15 Start delay time 0 1200 Stop delay time 0 1200 8080 IE Startboilerdiff F 14 36 14 PO Stop boilerdiff_ F 14 59 14 PO po 6 14 Stop all boiler diff F 14 59 24 24 A Maxoffsetup F 14 50 17 Pt 4 y Macofsetdown 19 50
22. surrounding contextual information and highlighted for special attention CAUTION Cautions CAUTION messages inform of potential problems relating to the functioning of equipment safety to persons harm to the environment and or damage to property or equipment WARNING WARNING messages warn of potential dangerous situations that may result in serious injury and or death to persons or animals Text is red within a red box How Instructions are Presented Instructions are shown in a blue box with an underlined title All text excepting in accompanying illustrations is colored blue All procedures are listed in steps starting with 1 and using letters a b c etc indicating sub steps Steps that are continued on the next page have a Cont appended to the instruction title Page 2 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL TABLE OF CONTENTS INTRODUCTION WEE 4 CHAPTER 1 INSTALLATION Soria 5 e Gd e ERR WR E 3 t2 ELECTRICALINSTALLA FON EE 6 ES MANAGER HEATER PREPARATON ninia ii 8 1 3 1 Manager Heater Preparation Communications Board 8 1 3 2 Manager Heater Prep S4 Switch on COMMUNICATIONS Board 12 1 3 3 Manager Heater Preparation S4 Switch on the Burner 1 Board 13 4 PREPARING THE CASCADE SEQUENCER FOR USE sas dida 14 15 SETTING THE LO
23. urner 4 Board Figure 1 14 Locating Burner 1 Master Board and Setting S4 Switch OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 13 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL 1 4 Preparing the Cascade Sequencer for Use The Cascade Sequencer is used to program the logic address of each heater as well as control the final cascade system and must be wired as described below Preparing the Cascade Sequencer for Use 1 Using a small flat head screwdriver remove the rear cover of the Cascade Sequencer by levering up the panel via the slot as shown in Figure 1 15 Using Screwdriver in Slot Cascade a e Sequencer Rear Panel Figure 1 15 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 16 Wires do not have polarity Do 0000000 anaaga 11904 iil SY Y o 5 HI a 2 hn gt 1 ul a Ba y A Ka by vu COOHSSS at Fe AMM Install Wires into Terminals O Figure 1 16 Connecting Wires to the Cascade Sequencer Terminals Page 14 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Preparing the Cascade Sequencer for Use Co
24. utton Figure 2 1 g Wait a minimum of 4 seconds or until 1 appears in the upper left of the center box of the sequencer display IMORTANT NOTE After any change to a parameter wait at least 40 seconds before exiting the sub menu or turning the power off 6 Turn the power off to the Managing heater 1 Disconnect the two wires from terminals 16 and 17 of the Managing heater 1 Connect the two wires from the Cascade Sequencer to terminals 16 and 17 of the Dependent heater 2 9 On the communications board at top of unit set the S4 Switch see Figure 1 13 to ON 10 Turn the power ON to the Dependent heater 2 Page 16 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL Setting the Logic Address for Each Heater Continued Repeat steps a through g in Step 5 setting the logic address to 2 Turn the power OFF to the Dependent heater 2 On the communications board at top of unit set the S4 Switch see Figure 1 13 to the OFF position Disconnect the two wires from terminals 16 and 17 of the Dependent heater 2 Repeat steps 1 to 13 on each dependent heater and set the Address sequentially for each one 2 3 4 5 etc After all dependent heaters have had the logic address set wire the Cascade Sequencer to terminals 16 and 17 of the Managing heater 1 The Cascade
25. y Heater Settings e 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 e Check parameters 1120 1123 on each unit Ensure that all modules are running at maximum capacity If not wait 10 system loop is not reaching minutes for burners to modulate up and check again ered DOM e Change System Correction factor from 14 to 22 1 e Check each unit s outlet temperature on the individual boiler or water heater interface If Cascade Setpoint Max Offset Up is less than or equal to any individual unit s outlet temperature increase the Max Offset Up parameter e Check that the sensor is wired to terminals 14 amp 15 of the Outdoor air temperature master boiler sei aay sequencer e Make sure all electrical connections are tight shows 40 e Check sensor resistivity Cascade sequencer header Check that the cascade header temperature sensor is temperature displays a low installed in terminals 24 amp 25 of the master boiler or water value 10 16 F heater Page 24 of 26 AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 OMM 0101_0A PRI 11 25 14 Ph 800 526 0288 GF 146 CS AM Series Cascade Sequencer INSTALLATION AND OPERATION MANUAL NOTES OMM 0101_0A AERCO International Inc e 100 Oritani Dr e Blauvelt NY 10913 Page 25 of 26 GF 146 CS Ph 800 526 0288 PRI 11 25 14 AM Series C
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