I&O Manual - ECCS Control System - Categories On Thermal ...

INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS
ECCS CONTROL SYSTEM
ON/OFF & MODULATION
Price - $3.00
For service and repairs to the heating plant, or this panel call your heating contractor. When seeking
information from the manufacturer, provide boiler model and serial number as shown on rating label.
ECCS Control
System
Serial
Number
Type System
Heating Contractor
Address
Phone Number
Your Local Thermal Solutions Representative:
81456003R2-12/05

IMPORTANT INFORMATION - READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations required in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction
shall be consulted before installations are made.
All wiring on boilers installed in the USA shall be in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be in accordance with the Canadian Electrical Code and/or local regulations.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to
important information concerning product life.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death,
serious injury or substantial property
damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in
moderate or minor injury or property
damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property
damage.
NOTICE
Indicates special instructions on
installation, operation, or maintenance
which are important but not related to
personal injury hazards.
2

Parameter Limits and Factory Defaults
Initial Setup
Parameter
Range
Factory Setting
Password
Level
Total
Boilers
2 - 6
3 5 25
Boiler
Type, Mod or On/Off
1 - 2
1 5 25
Proportional
0 - 25
25
5 25
Integral
0 - 2
1 5 25
Derivative
0 - 1
0 5 25
Start
Trigger (% of firing rate)
50
- 100
90
2 21
Stop
Trigger (% of firing rate)
1 - 50
25
2 21
On Point (degrees below setpoint) 1 - 15
5 2 21
Off
Point (degrees above setpoint) 1 - 15
5 2 21
Start
Time Delay (seconds)
90
- 900
120
2 21
Stop
Time Delay (seconds)
0 - 1200
120
2 21
Setpoint
(degrees Fahrenheit)
140
- 230
180
1 20
DHW Priority
140
- 230
180
1 20
Local/Remote
Switch
Local/Remote
Page
Local
0 23
Rotation Time (hrs)
8 - 720
24
2 22
Rotation Enable/Disable
On-Of
f
Off
2 22
Customer
Setting
Change Sequence
Lead
Lag
Lag
Lag
Lag
Lag
#1
#2
#3
#4
#5
1 - total blr
1 2 22
1 - total blr
2 2 22
1 - total blr
3 2 22
1 - total blr
4 2 22
1 - total blr
5 2 22
1 - total blr
6 2 22
Change
Sequence Button
2 22
Enter
Lead/Lag Sequence
2 22
Outdoor Reset & WWSD
Low Air Temp
-60
- 50
10
3 23
High Water Temp
150
- 240
180
3 23
High Air Temp
50
- 120
55
3 23
Low Water Temp
140
- 180
140
3 23
WWSD System Pumps On/Off
0 - 1
0 3 25
WWSD Boilers On/Off
0 - 1
0 3 25
WWSD Enable/Disable
Outdoor
Switch
Reset Enable/Dis Switch
On - Off
On - Off
Off
3 25
Off
2 23
3

Table of Contents
i. Programmable Ranges.................................................... 3
Section 1. Component Description .................................... 5
Section 2. Principles of Operation ..................................... 6
2.1. System Description
2.2. Lead Lag
2.3. Unavailable Boilers
2.4. Auto Rotate .................................................. 7
2.5. Outdoor Reset
2.6. Warm Weather Shutdown & Enable/Disable
2.7. Modbus Communication
2.8. Trending
2.9. Local/Remote Operation
2.10 Domestic Hot Water Priority............................. 8
2.11 Alarms
Section 3. Installation.......................................................... 9
3.1.Unpacking ....................................................... 9
3.1.1. Inspection
3.2. Mounting ....................................................... 9
3.2.1. Panel
3.2.2. System Water Temp Sensor
3.2.3. Outdoor Air Temp Sensor
Figure 3.1: Panel Mounting Layout .... 10
3.3. Electrical ....................................................... 11
3.3.1. General
3.3.2. Wiring Power Supply to Panel
3.3.3. Wiring Panel to Boilers
3.3.4. Wiring Panel to Sensors
Figure 3.2: Panel Layout ............................ 12
Figure 3.3: System Wiring .......................... 13
Figure 3.4: ECCS Panel Wiring ................... 14
Figure 3.5: Boiler Wiring Diagram .............. 15
Section 5. Touch Screen Programming .............................. 19
5.1. Screen Description ....................................... 19
5.2. General Guidelines for Using the
Touchscreen ................................................. 19
Figure 5.1 Touch Screen Login .................. 19
Figure 5.2 Main Screen .............................. 20
Figure 5.3 System Setup Screen................. 20
Figure 5.4 Lead Lag Trigger Setup Screen . 21
Figure 5.5 Sequence and Rotation Screen . 22
Figure 5.6 Outdoor Reset Setup Screen ..... 23
Figure 5.7 Boiler Parameters Screen ........... 23
Figure 5.8 Alarm History Screen ................ 24
Figure 5.9 Alarm Pop Up Screen ................ 24
Figure 5.10 Warm Weather Shutdown
Screen ....................................... 25
Figure 5.11 Initial Setup Screen ................. 25
Figure 5.12 Trend Screen ........................... 26
Figure 5.13 Trend Screen Zoom Control .... 26
Figure 5.14 Time/Date Screen ...................... 27
Section 6. Troubleshooting Guide .................................... 28
Section 7. Appendix ......................................................... 30
7.A. Temperature Controller Operation for
Modulating Boilers (Modbus) ....................... 30
7.1. Description ................................................... 30
7.2. Setup ............................................................ 30
7.3. Modbus Version Used on Boilers
Controlled by the ECCS System ..................... 30
Figure 7.1 Process Data ............................. 30
7.4. Adjustments ................................................. 31
7.5. System Specifications .................................. 31
Section 4. Setting the Modbus Module Address ............. 16
4.1. Communication Setup for Boilers ................. 16
4.2. Setting the Address of the Honeywell
Modbus Module .......................................... 16
4.3. Setting the Modbus Address of the Fireye
Micro M ........................................................ 16
Figure 4.1: Honeywell S7810M Modubus
Module Mounting ..................................... 17
Figure 4.2: S7810M Address Switches and
Baud Rate Jumper ...................................... 18
4

Section 1: Component Description
COMPONENT DESCRIPTION Part #
1) ECCS Control Panel– houses the touch screen, PLC, analog input/output card, and terminal strips. ...................... 60156400
Built to UL 508A Standard. Refer to Figure 2, Panel Layout
2) System water temperature sensor with Thermowell .................................................................................................. 80160721
RTD Pt 1000
3) Outdoor air temperature sensor ................................................................................................................................. 80160722
RTD Pt. 1000
4) Touch Screen ............................................................................................................................................................. 80160912
5.7” monochromatic
5) PLC 226XM 120Vac in, 24 Vac out ......................................................................................................................... 80160910
24 Inputs
16 Outputs
6) RTD Module ............................................................................................................................................................. 80160917
2 RTD Inputs
7) Analog Input Module ............................................................................................................................................................... 80160911
4 (4-20 ma or 0-10 Vsignal inputs)
1 (output)
8) PLC Memory Cartridge ............................................................................................................................................................. 80160925
9) PLC Battery Cartridge ............................................................................................................................................................... 80160924
Components in the boiler that interface with the ECCS panel.
10) Modbus version of the boiler temperature controller ................................................................................................ 80160908
11) Honeywell Modbus Module for the Flamesafeguard. ............................................................................................... 80160909
5

Section 2: Principles of Operation
2.1 SYSTEM DESCRIPTION
The ECCS (Electronic Controls and Communication
System) is a Lead Lag sequencer for modulating and
on/off boilers capable of auto rotation, Outdoor reset,
and communication using a Modbus protocol.
All the control signals between the boiler and the ECCS
panel are transmitted over a 3 wire shielded cable using
the Modbus protocol. This includes the enable/disable
signal, the modulating signal, and the local/remote
signal.
System water temperature is continuously monitored
through the header water temperature sensor. The
system compares this temperature to the setpoint which
is fixed or generated from the outdoor reset curve. If
the system water temperature falls below the adjustable
system ON POINT set on the screen (refer to Figure
5.3) the lead boiler will turn on via a signal from the
ECCS system. For a modulating boiler, The PID
control will generate a signal and send it to the boilers
via the MODBUS. If the firing rate goes above the
START TRIGGER Point set on the screen for the
amount of time set in the START DELAY, the first lag
boiler will start. Once the lag boiler starts it will drive
to the same firing rate as the lead boiler. Both boilers
will fire in tandem, at the same firing rate. Additional
lag boilers will start by the same criteria in the order
that set as the LEAD LAG SEQUENCE. Boilers will
be shed in the reverse order of which they came on
(AKA: First On, Last Off). As load is shed the boilers
will use the STOP TRIGGER point and the STOP
DELAY parameters set on the screen.
For On/Off boilers, additional boilers will be added
when the system water temperature drops below the
system ON POINT for the time set in the boiler START
DELAY. Boilers will be shed in reverse order using
the OFF POINT and STOP DELAY parameters.
The Lead Lag (LL) system will be capable of running a
maximum number of 6 boilers. Parameters in the
temperature controller and flame safeguard are
transmitted via the Modbus connection to the PLC and
Touch screen.
2.2 LEAD LAG
2.2.1. In a Lead Lag (LL) system (refer to Figure 5.4),
one boiler is designated as a lead boiler. The lead
boiler will always be the first boiler to come on and the
last boiler to shut off. The lag boilers will always
come on after the lead in order of their number. The
first lag (lag#1) will always be the second boiler to
come on, the second lag (lag#2) will always be the
third to come on, etc. They will turn off in reverse
order.
6
2.2.2. There is a sequence preprogrammed from the
factory as a default of: Lead = boiler 1, Lag #1 =
boiler 2, Lag #2 = boiler 3, etc., in sequential order.
Sequence can be changed to any order that is
desired. Numbers cannot be duplicated or out of
range.
2.2.3. To change the lead lag sequence go to the
SEQUENCE AND ROTATION SCREEN
(Figure 5.5). From the main screen press the system
setup button, then the Enter Lead Lag Sequence
button.
2.2.4. The system will turn on the lead boiler when the
temperature drops below the System ON POINT. The
boiler will turn the lead off only if it is the only
boiler running and the temperature is above the
System OFF POINT.
The ECCS system turns on additional boilers when the
firing rate of the lead boiler rises above the START
TRIGGER (See Figure 5.4: Lead Lag Trigger Setup
Screen) point for the length of time in the BOILER
START DELAY box. The START TRIGGER is the
percentage of the firing rate that a modulating boiler
must reach in order to start the delay timer. Once the
delay timer finishes timing, the next boiler in the
sequence will start. If the firing rate drops below the
START TRIGGER before the timer is complete, the
timer will reset.
ON/OFF boilers will sequence in accordance with the
System ON and OFF POINTS. See Figure 5.4 under
Setpoint differential.
2.3. UNAVAILABLE BOILERS
2.3.1. If a boiler is unavailable for any one of the
following reasons the LL sequence will remove them
and adjust the sequence until they become available
again. The purpose of this is to save time between
stages if there is an unavailable boiler. If the
desired lead boiler is unavailable, Lag #1 will
become the lead and other boilers will shift
accordingly. The program will rotate based on the
sequence that has been entered onto the screen.
Flame fail – If the boiler has a flame failure the boiler
will be removed from the LL sequence until the unit
has been reset.
Boiler in Local mode – If the Local/Remote switch is
in Local the boiler will be removed from the LL
sequence until the unit has been placed back in
Remote.

2.3.3. When a boiler becomes available again (fault
cleared, switch from local to remote, etc.) the system
will put it back in the sequence. If the desired lead
becomes available it will start immediately and may
shut down the last boiler running in the sequence
depending on how many boilers are required.( EX: In a
3 boiler system, if 2 boilers are running and only 2 are
required when the lead comes back in service it will
shut down the last lag boiler. If 2 are running and 3 are
required it will not shut down the last lag boiler.)
2.4 AUTO ROTATE
When this function is selected by pressing the Auto
Rotate button (refer to Figure 5.5) the sequence will
automatically rotate based on how long the lead boiler
runs. The rotation time will be set by the operator.
After rotation time is reached, the Lead boiler will move
to the end of the sequence and the second boiler will
become the lead.
When the rotation time is reached, the next boiler in the
sequence will start. After the unit is running for a few
minutes the sequence will rotate, dropping out the old
lead boiler. This will insure the same amount of boilers
are running before and after rotation occurs.
If the sequence is changed manually, the rotation timer
will start from the beginning.
2.5 OUTDOOR RESET
The outdoor reset function (refer to Figure 5.6)
generates a setpoint based on a curve programmed on
the screen and the outdoor air temperature. Two points
are entered and a linear curve is generated.
An RTD temperature sensor will send a signal to the
RTD module for the PLC.
If outdoor reset is enabled through a switch on the
screen, the setpoint will be generated by the curve for
outdoor reset programmed on the screen.
2.6 WARM WEATHER SHUTDOWN/ENABLE
DISABLE
The Warm Weather Shutdown (WWSD) (refer to
Figure 5.10) function will shutdown either the boilers,
the system pumps or both depending on the selections
on the WWSD screen. When the outdoor air
temperature goes above the temperature set in the high
outdoor air temperature box on the outdoor reset
screen, shutdown will occur.
The outputs for energizing a relay for controlling the
system pumps, O:0.0 and O:0.1 (Refer to figure 3.5) will
energize when the system goes into a WWSD
condition. This is a fail-safe condition. If power is lost
to the ECCS panel the pumps will still operate.
7
Once the OAT>HAT setting, a 60 sec timer starts. If the
condition is still true at the end of the 60 seconds the
WWSD function will energize. If both the boilers and
the pumps are selected to shut down, the boilers will
shut down first and 30 seconds later the system pumps
will shut down. This is done to minimize cycling around
the HAT, which triggers the WWSD function.
The WWSD function (or can be used as an Enable/
Disable signal for all boilers) can also be activated with
an external contact closure between terminals L+ and
I:0.1 (Refer to figure 3.5). Ensure that the WWSD
function is not enabled on the ECCS panel. This will
function only when the boilers are in the remote mode
and being controlled by the ECCS panel. If the boilers
are in the local mode they will not be shut down
by this function. There will be a 1 minute delay before
shutdown once the contact is closed.
2.7 MODBUS COMMUNICATION
The ECCS Panel uses the Modbus protocol to
communicate with all the boilers in the system. The
Flame Safeguard and the temperature controller both
have Modbus communication capability. Information
such as faults, alarms, flame signal, cycles, hours,
setpoint, and on/off points can all be communicated to
the touch screen.
2.8 TRENDING
System water temperature and outdoor air temperature
are trended for total of 8 hrs (refer to Figure 5.13). The
standard screen shows one hour of time and that trend
can be zoomed in or out from 7.5 minutes to 8 hours.
Points on trend are recorded every 30 seconds.
2.9 LOCAL/REMOTE OPERATION
A Local/Remote switch is located on the Boiler
Parameter screen on the touch screen (refer to Figure
5.7). Some boilers may have an optional physical
selector switch on the front of the boiler.
The Local/Remote selector switch enables the boilers
to be controlled from either the temperature sensor on
the individual boiler (Local) or controlled from the
System water temperature sensor (Remote). If the boiler
is in the remote mode, the display on the individual
boiler temperature control will flash Re F (Remote Firing
Rate) and the remote setpoint. If in the local mode, the
display will show the local setpoint without flashing.
*Fail-safe Operation*
If power is lost to the ECCS panel, the boilers will
automatically revert back to the local mode.

2.10 DOMESTIC HOT WATER (DHW) PRIORITY
Domestic hot water priority is accomplished by
providing a contact closure to the ECCS panel from a
domestic hot water tank. The ECCS panel sends out
24V on terminal L+ and receives voltage back on
terminal I0:0 when DHW priority is called for. When
I0:0 receives a signal the following sequence occurs:
1.) The control compares the DHW setpoint (which is
set on the System Setup Screen, See Figure: 5.3.) to the
system generated by Outdoor reset curve or fixed
setpoint. If the DHW setpoint is higher, the DHW
setpoint will become the new setpoint. If the DHW
setpoint is lower than the existing setpoint it will not
change the setpoint.
2.) If the system is in the WWSD mode, the system
will be taken out of the WWSD mode and start
boilers until the system water temperature is brought
up to the DHW setpoint.
NOTICE
The ECCS System WILL NOT start any
pumps or open valves in the DHW piping.
This must be provided by others.
2.11 ALARMS
a. The ECCs will annunciate and record alarms on the
screen that come from the individual boilers. Any of
the faults from the flamesafeguard are annunciated
through Modbus communication to the ECCS panel.
The format for the alarms can be viewed in Fig 5.9.
The alarm will indicate which boiler is in alarm, the
fault code #, and a description of the 7 most common
faults. This includes Main Flame Failure, Main Flame
Ignition Failure, Pilot flame failure, Air flow failure,
lockout interlock, Running interlock and Flame
detected. If it is one of the other 100+ possible
alarms it will just display the fault code for the Flame
safeguard. In addition there are alarms for High water
temperature(above 230F), Low water temperature
(below 120F), and communication failure.
A communication failure occurs when the
communication over the Modbus is interrupted by
either losing power to the boiler or there is a break in
the wiring.
b. The ECCS stores 100+ alarms in the history
screen. Every alarm is time and date stamped when it
Occurs, when it was Acknowledged, and when it was
Cleared. See Fig 5.8. The screen does not have any
permanent memory so if the power is turned off to the
panel the alarm history is lost.
c. As long as an alarm is active, there will be a small
box with an exclamation point in it at the bottom of
the screen. This will also have the # of active
alarms at the bottom of the box.
d. External alarm indication – A 24vdc relay(supplied
by others) can be power by the ECCS between
terminals O:0.7 and M for an alarm indication. Refer
to Fig 3.4.
2.12 EXTERNAL ENABLE/DISABLE
See 2.6 Warm Weather Shut Down on page 7.
8

Section 3: Installation
3.1 UNPACKING
3.1.1. Inspection
CAUTION
Do not lay panel down on touch screen.
Panel weighs approximately 25 lbs.
Use proper lifting techniques when handling.
a. Inspect the shipment carefully for any signs of
damage. All equipment is carefully manufactured,
inspected and packed before shipment. Our
responsibility ceases upon delivery of the ECCS
panel to the carrier in good condition. The
consignee must file any claims for damage or
shortage in shipment immediately against the
carrier. Thermal Solutions Products, LLC will
allow noclaims for variances or shortages unless
presented within thirty (30) days after receipt of
equipment.
b. The ECCS system will include:
(1) Panel with touch screen mounted in front door.
PLC inside with terminal strips and breaker.
(1) System water temperature sensor and
thermowell.
(1) Outdoor air temperature sensor.
WARNING
Carefully read all instructions before
installing panel. Failure to follow all
instructions in proper order can cause
personal injury or death.
3.2 MOUNTING
3.2.1. Panel
a. The ECCS system must be installed to conform
with the requirements of the local and state
authority having jurisdiction, or in the absence of
such requirements, to the latest release of the
National Electric Code, ANSI/NFPA 70.
b. Provide clearance around panel for wiring conduit
and access to panel.
Allow 26" in front of panel to allow door to be
opened and personnel access to touch screen.
Allow 4” on bottom, top and sides to allow
clearance for conduit.
c. Mount in the vertical position. Door hinges on left
side with touch screen facing out. See Figure 3.1
for physical size and details on mounting holes.
d. Panel is rated for NEMA 12 service. When
attaching conduit, enter from bottom of panel to
prevent water from gravitating down the conduit
into the box.
3.2.2. System Water Temperature Sensor
a. Mount the thermowell and sensor in a 3/4"
coupling in the common header downstream of all
boiler connections. Maintain a minimum distance
of 10 pipe diameters for connections. See Figure
3.3 System Wiring.
3.2.3. Outdoor Air Temperature Sensor
a. Mount the temperature sensor on an outside wall
out of direct sunlight, preferably a north facing
wall.
b. Do not mount sensor near exhausts of any kind,
this may affect readings.
WARNING
Installation of this panel should be
undertaken only by trained and skilled
personnel from a qualified service agency.
9

Figure 3.1: Panel Mounting Layout
10

3.3.ELECTRICAL
NOTICE
3.3.1. General
DANGER
Always positively assure electrical power
is disconnected before attempting work
on or near electrical components or
systems. Electrical shock will/can cause
death or serious injury.
Never work on or near electrical
components when the possibility of
water contact exists. Electrical shocks
will/can result.
Power may need to be disconnected at
more than one location on one or more
voltage supplies.
Electrical work must be performed by
licensed, skilled and experienced
personnel.
Always follow the electrical diagrams
provided with the ECCS system. Consult
manufacturer if problems or questions
arise.
Always positively assure electrical work
is performed correctly according to the
authority having jurisdiction before
connecting the power supply.
a. The ECCS system must be installed to conform
with the requirements of the local and state
authority having jurisdiction, or in the absence of
such requirements, to the latest release of the
National Electric Code, ANSI/NFPA 70.
b. Panel is built and labeled to UL508A standards.
c. Refer to the wiring diagram supplied with the
panel, the wiring diagram for the boiler, the
system wiring diagram, and the Panel layout
diagram for wiring information.
d. Do not route the communication cable in conduit
with line voltage circuits.
e. Maximum wire length:
Communication bus, 4000 ft.
Low voltage conductors are not to be routed
with line voltage conductors.
3.3.2. Wiring Power Supply to Panel
a. The ECCS panel requires 120Vac brought into
the panel. Connect the 120V leg directly to the 4-
amp breaker on the terminal strip. The Neutral
wire connects to the N terminal. The ground wire
connects to the green/yellow terminal.
b. 120Vac supply to the panel must be protected by
a fused disconnect, maximum 20A (by others).
3.3.3. Wiring Panel to Boilers
a. All the wiring going from the ECCS panel to the
boilers is low voltage DC, 24V or less. Use
minimum 22ga., 3 wire shielded cable. Belden
Part# 8771 or equivalent.
b. Modbus Signal - 3 wire, 22ga. shielded cable run
from terminals A, B, C in the panel to terminals A,
B, C in THE CLOSEST BOILER. The wire must
be wired from the closest boiler to the next boiler
and repeated until the last boiler is reached. In
other words this must be a continuous chain (daisy
chain configuration). A 120-ohm resistor must be
added to the last device. (See Figure 3.3 System
Wiring). The resistor is taped to the inside of the
panel for shipping.
3.3.4. Wiring Panel to Sensors
a. System water temperature sensor - Run a 2 wire,
22 ga. shielded cable from terminals a+ and a- in
the ECCS panel to the wire leads on the
temperature sensor. Attach shield at panel to
terminal marked shield. See Figure 3.4 ECCS
Panel Wiring Diagrams.
b. Outdoor air temperature sensor - Run a 2 wire, 22
ga. shielded cable from terminals b+ and b- in the
ECCS panel to the wire leads on the outdoor
temperature sensor. Attach shield at panel to
terminal marked shield. See Figure 3.4 ECCS
Panel Wiring Diagram.
NOTICE
Sensor wiring is susceptible to electrical
interference. Insure the shield on cable is
grounded on one end only.
11

12
Figure 3.2: Panel Layout

13
Figure 3.3: System Wiring

Figure 3.4: ECCS Panel Wiring Diagram
14

15
Figure 3.5: Boiler Wiring Diagram

Section 4: Setting the Modbus Addresses
4.1 COMMUNICATION SETUP FOR BOILERS
Each Modbus device in each boiler must be addressed to
properly communicate with the ECCS system. The
Temperature Controller must be addressed through the
configuration level and the flame safeguard will be
addressed according to the following instructions. Refer to
Appendix A, system wiring, or individual component
manuals.
4.2 SETTING THE ADDRESS OF THE HONEYWELL
MODBUS MODULE
Addressing for the HW Modbus Module correlates to the
Temp Controllers Modbus addressing on the same unit.
There are 2 dials on the bottom of the module that need to
be set and a jumper that needs to be removed. Refer to
Figure 4.1: Honeywell S7810M Modbus Module Mounting
and 4.2: S7810M Address Switches and Baud Rate Jumper.
4.3 SETTING THE MODBUS ADDRESS OF THE
FIREYE MICRO M
Addressing for the Fireye correlates to the Temperature
Controllers Modbus addressing on the same unit. Refer to
MicroM manual for instructions.
Fireye MicroM
Fireye
Temperature Parameter
Controller Baud Rate @
(C113)
19,200
Unit Address
Boiler
1 0160
11
Boiler
2 0260
12
Boiler
3 0360
13
Boiler
4 0460
14
Boiler
5 0560
15
Boiler
6 0660
16
Honeywell
Temperature
Controller
(C113)
S7810M
Modbus
Module
Baud Rate @
19,200
remove
jumper
10"s
Dial
1"s
Dial
Boiler
1
0160
1 1
Boiler
2
0260
1 2
Boiler
3
0360
1 3
Boiler
4
0460
1 4
Boiler
5
0560
1 5
Boiler
6
0660
1 6
16

Figure 4.1: Honeywell S7810M Modbus TM Module Mounting
17

Note: View from bottom of module
Figure 4.2: S7810M Address Switches and Baud Rate Jumper
18

Section 5: Touch Screen Programming
5.1. SCREEN DESCRIPTION
The touch screen is 116x87mm or (5.7"). The display uses
CCFL(cold cathode Florescence Lamps) back lighting with
320x240 pixels. Resistive/analog touch screen technology.
5.2. GENERAL GUIDLENES FOR USING THE
TOUCH SCREEN
1) Touching the screen with the nail of the finger, an
eraser on a pencil, or a pen cap is more effective
than the skin on the tip of the finger.
2) All inputs will have boxes around the value. A value
without a box around it is for display only and
cannot be changed.
3) When you touch an input box, a keypad will be
displayed for entering the desired value.
4) Some inputs are password protected. If an input
box is pressed and a Login box is displayed asking
for a password, press the area where the password
should be. A keypad will be displayed to enter the
password. (See below.)
5) When the correct password is entered the box
will disapear and the desired value can now be
entered into the input box by pressing it again and
using the keypad that is displayed.
6) Entering the password once will disable the need
to enter it again on that security level and lower
for 5 minutes.
Press this area to
enter password
Figure 5.1: Touch Screen Login
19

B1 = Boiler #1
Bar graph shows
firing rate as % of
modulation
Shows Firing rate
as a numerical %
of modulation.
100% - Highfire
1% - Low fire
0% - Off
Indicates if the boiler
is the lead boiler, has
a fault, or is operating
in manual
Boiler water outlet
temperature
Press button to access alarm history
Figure 5.2: Main Screen
Press input box to enter Setpoint
Press button to enter a
curve for outdoor reset
On/off points set by
the differential on
the trigger points
Press button to go to
the trigger points
screen
Domestic Hot Water
Setpoint
Press button to
enter a Lead
Lag sequence
Figure 5.3: System Setup Screen
20

SETTING THE TRIGGERS AND THE START /STOP TIME DELAYS FOR THE LEAD LAG SYSTEM
The value entered in this box will be subtracted from the setpoint to create
the boiler On point. This On point has two separate functions–
1)If the system has ON/OFF boilers, it will use the ON POINT as a trigger
to turn on the next boiler.
2)If the system is using modulating boilers only the lead boiler will use
the on point to turn on.
0% of firing rate =
low fire
100% of firing rate
= high fire
Input box. Firing rate of
the running boiler
which when reached
will start the timer to
start the next boiler in
sequence. The limits of
this value are between
50 and 100.
Input box. Firing
rate of the running
boiler which when
reached will start
the timer to stop the
last boiler in the
sequence. The
limits of this value
are 0 - 50.
Adjustable start time
delay which delays
the starting of the next
boiler in the sequence
once the start trigger
is made. The limits of
this value are 90-900.
Adjustable stop time
delay which delays
the stopping of the last
running boiler in the
sequence once the stop
trigger is made. The
limits of this value are
0-1200.
Figure 5.4: Lead Lag Trigger Setup Screen
The value entered in this
box will be added to the
setpoint to create the
boiler Off point. This
Offpoint has two separate
functions–
1)If the system has
ON/OFF boilers, it
will use the Off point
as a trigger to turn
off the last running
boiler.
2)If the system is using
modulating boilers
only the lead boiler
will use the the Off
point to turn off.
Example, using the values above (Modulating boilers) :
Boiler 1 is on and reaches 90% of firing rate. The firing rate
will have to stay above 90% for 120 sec for the next boiler
in the sequence to start. If it drops below 90% before the 120
second time delay is complete, the timer will reset.
Example (On/Off boilers) : Assume a setpoint of 180 °F.
The On and Off points are programmed on the screen at 5
and 5. Therefore the boilers will turn on a 175 °F and off at
185 °F. The boilers have a differential of 10°F.
Boiler 1 is on and the temp at the system water temperature
sensor drops below 175 °F for 120 sec., the next boiler in the
sequence will start. If the system water temperature rises to
175 °F before the time is complete, the timer will reset.
21

ENTERING THE LEAD LAG SEQUENCE AND ROTATION TIME
NOTICE
Some boilers may shut down depending
on the new sequence entered.
The input boxes must
be pressed and a
keypad will be displayed
on the screen to enter
a new value.
When the CHANGE SEQUENCE button is pressed,
the input boxes and the sequence enter button will be
displayed.
Press and drag the
AUTO ROTATE
switch to turn on/off
the automatic
rotation of the
sequence.
Press the input box to
set rotation time. Range
is between 8 hours and
720 hours. When in the
auto rotate mode the
sequence will
automatically rotate as
follows:
Before rotation 1 (lead),
2, 3, 4, 5.
After rotation 2 (lead), 3,
4, 5, 1.
Figure 5.5: Sequence and Rotation Screen
22

Outdoor Reset Switch.
Press and drag toggle
switch from OFF to ON.
The setpoint will now
be generated by the
curve entered above.
Entering temperatures in these 4 input
boxes will generate a linear curve in
which a setpoint based on outdoor air
temperature will be generated.
This is the setpoint which
is generated based on the
outdoor air curve entered
and the outdoor air
temperature.
Pressing this button will
go to the screen to set
up the Warm Weather
Shutdown Options.
CAUTION
This system cannot protect the boiler from cold water returning back to the boiler as is the case
when coming out of a warm weather shutdown scenario. In order to protect the boiler from
condensing, a primary/secondary piping arrangement or mixing valve must be installed in the
piping.
Figure 5.6: Outdoor Reset Setup Screen
This is the setpoint of the boiler water at the outlet of
the boiler. When in local the boiler will use this as its
operating setpoint.
The values for Setpoint,
On point and Off point are
for display only and come
directly from the boiler
temperature controller via
a Modbus connection.
These values come
directly from the Flame
Safeguard via a Modbus
connection.
Pressing and dragging this
switch with your finger will
change control from local to
remote operation.
Figure 5.7: Boiler Parameters Screen
23

Pressing the Alarm History button
on the main screen will get you to
this screen
Records Date and time the fault
occurs(O), was Acknowledged(A),
and cleared(C).
Buffer can hold
up to 110 fault
messages.
Figure 5.8: Alarm History Screen
THIS BOX WILL AUTOMATICALLY APPEAR OVER ANY SCREEN WHEN A FAULT OCCURS
Boiler # fault occured on
Description
fault
of
Fault code
The Alarm Indicator will stay at the bottom of all
screens until all faults have been cleared. The # at
the bottom of the box indicates how many faults are
active. Pressing this button will bring up a screen
showing all the active alarms.
Pressing the ACK button
Acknowledges the alarm and
makes the box disappear.
Figure 5.9: Alarm Pop-up Screen
24

Figure 5.10: Warm Weather Shutdown Screen
Figure 5.11: Initial Setup Screen
25

Figure 5.12: Trend Screen
This trend will record header temperature and outdoor air temperature for up to 8 hours. Screen normally shows a one hour
snapshot. Using the – and the + keys will zoom out to 8 hours or zoom in to 7.5 minutes (refer to Figure 5.13 Trend Screen Zoom
Control). Each time a button is pressed, the graph will double or half (depending on button pressed) the time increment. Data is
recorded every 30 seconds.
Figure 5.13: Trend Screen Zoom Control
26

Figure 5.14 Time/Date Screen
In order to access the time/date screen, press an invisible button in the
upper right hand corner of the Boiler 1 Parameter Screen (figure 5.7)
27

Section 6: Trouble Shooting Guide
PROBLEM
No boilers running
Temperature
OFF POINT.
POSSIBLE CAUSE
of water higher than the
Boilers in local mode and boiler water
temperature is above OFF POINT.
POSSIBLE REMEDY
Boilers will come on automatically when system
water temperature drops below ON POINT.
Switch to remote or wait for temperature to drop
below ON POINT.
B reaker in ECCS Panel in OFF or tripped. Turn on breaker in ECCS Panel.
Touch Screen is not lit
Power feeding ECCS Panel is OFF or
tripped.
Improper power supply to panel.
Power
to screen is not connected.
Improper power supply to screen.
Turn on breaker feeding ECCS Panel.
Check power voltage and correct as needed.
Panel requires 120VAC wired to 4 amp circuit
breaker inside panel.
Check wiring and correct as needed, 24VDC
Screen uses 24VDC from PLC. Check voltage
and correct if needed.
B ad touch screen.
Replace screen.
No data being
displayed on screen
and no communication
error or data on
screen is not updating
Modbus communication wires shorted
together on any temperature controller or
flame safeguard.
Check Modbus wires A & B on all controllers for
location where wires are touching each other
and separate.
P LC not in run mode.
Flip switch on front of PLC to run position.
P ower off to boiler.
Turn power on to boiler.
Alarm "Boiler #
Communication
Failure"
Alarm "Boiler # Main
Flame Failure"
Modbus wiring disconnected on boiler
showing alarm.
Shield on wire not grounded properly.
Baud rate setting on Fireye or Honeywell
controller is wrong.
Incorrect baud rate set on temperature
controller.
Modbus wiring A, B, C is not consistent
throughout boiler devices.
Boiler address not correct on flame
safeguard or temperature controller.
Boiler has faulted on a flame failure while
in run mode.
Connect Modbus wiring (3 wire shielded cable)
to terminals A, B, C on devices.
Shield should be grounded on one end of
daisy chain only (panel end). Shields at wire
junctions should be tied together.
Set baud rate to 19,200.
Configuration parameter check C113. Second
value from right shall be a 6. Adjust as needed.
Insure same wire is daisy chained to all A
terminals, B to B terminals, and C to C
terminals.
Check appendix for correct setting on Modbus
devices. See Section 4.
Check controller manual. Reset flame
safeguard controller.
Alarm "Boiler # Pilot
Flame Failure"
Alarm "Boiler #
Airflow Switch"
B oiler has faulted while lighting pilot. Refer to boiler manual troubleshooting guide.
F an did not energize.
Refer to boiler manual troubleshooting guide.
A ir flow switch set wrong or not working. Adjust or replace switch.
F an running too slow.
Check VFD to determine cause and correct.
28

Section 7: Appendix A – Temperature Controller Operation for Modulating
Boilers (Modbus)
7.1. DESCRIPTION
The microprocessor based temperature
controller is utilized for all modulating
Thermal Solutions water boilers. The basic
function of the controller is to modulate the
firing rate of the burner in response to the
boiler heat load. The controller monitors the
boiler water temperature through the use of
a sensor located in the boiler pressure
vessel. The controller compares the boiler
water temperature to the controller’s user
defined operating set-point temperature.
An output signal from the microprocessor
varies the blower speed through the use of a
variable frequency drive (VFD). The gas
valve regulates an appropriate amount of
gas flow for a given air flow or blower
speed. The user may adjust the operating
set-point temperature for a given
application. In addition, the controller has the ability to
change to an alternate set-point through an external signal
for low load conditions (i.e. weekend use, night setback).
Outdoor reset is another standard feature, allowing the
boiler operating temperature to vary based on the outdoor
ambient temperature. The typical result is a higher seasonal
efficiency.
7.2. SET-UP
All of the control parameters have been set at the
factory. There are a few parameters called “Process
Parameters” that must be defined by a qualified
operator. The table below will help serve as a
reference and record when making adjustments.
To alter any of these process parameters follow the
following steps:
• To obtain access into the programming mode
of the controller, briefly press the button
“PGM”.
• You will see “SP1” displayed on the second
line in green LEDs. The previously set
operating temperature will be displayed on the
first line in red LEDs. To increase or decrease
the setpoint 1 value (SP1) use the up and
down arrow keys respectively (st).
• To set the value for “SP2”, briefly press the
“PGM” key and follow the same instructions
above.
• To return to the operating mode press
“EXIT”, otherwise the unit will automatically
return to the operating mode after 30 seconds
of no activity.
To make other adjustments, contact your local
representative or consult the factory.
7.3. MODBUS VERSION USED ON BOILERS CONTROLLED BY THE ECCS SYSTEM
The ECCS control system communicates with the temperature controller using a Modbus communication system. A three wire
shielded cable is connected in a daisy chain configuration to each temperature controller at the CA,CB,CG terminals. This
controller accepts modulating, enable/disable, and local/remote commands from a remote source. Information such as setpoint,
water temperature, frequency feedback, on/off points, etc can also be transmitted back to the control panel.
Parameter
Display
Value
Range
Factory
Setting
User Setting
Setpoint
1
SP1
125-200
180
Setpoint
2
SP2
125-200
0
Digital Setpoint Shift
(optional)
dSP
125-200
0
Outside Temperature
(optional)
Pre-definition of External
Setpoint (optional)
TA
SP.E
C onsult Factory
—
C onsult Factory
—
Figure 7.1 Process Data
30

Actual Boiler Water
Temperature (red display)
Setpoint value (green display)
Solid–local mode
Flashing Ref–(Remote firing rate)
Burner On
Call for Heat
Decrease Value
Indicates Manual
Operation
Limit Comparator
Increase Value
Programming Key
EXIT Key
7.4 ADJUSTMENTS
Often during troubleshooting conditions it may become
necessary to manually adjust the firing rate. Follow the
instructions below to make manual firing rate adjustments.
• Press “EXIT” button and hold for 5 -10
seconds.
• The red light above manual operation (hand)
symbol illuminates.
• Press s button to raise firing rate. Press t
button to lower firing rate.
• 0 = 50% of Maximum firing rate and 100 =
100% of Maximum firing rate
• Press “EXIT” button and hold for 5 –10
seconds to return to automatic firing rate
control.
• Automatic mode has been re-activated once
the red light above the manual operation
symbol goes out.
7.5 SYSTEM SPECIFICATIONS
Input voltage ....................................... 100-240vac 48/63hz
Operating temperature ........................................... 0-120° F
Environmental ........................................ NEMA 4 external,
Internal 95%rh noncondensing
Transducer supply ........................................ 24VDC, 30ma
Analog Input 1 ..................Pt100,Ni100, PT1000, Ni 1000,
... Thermocouple (J, K, T or N),4-20ma and Analog 0-10v
Analog Input 2 ........... 1k pot,4-20ma, 0-1VDC, 0-10 VDC
Analog Input 3 ............................................. Pt1000,Ni1000
Output 1 release to modulate...... 24-240VAC 2Amps max
Output 2 and 3 open/close .......... 24-240VAC 2Amps max
Output 4 programmable ............. 24-240VAC 2Amps max
Output 5 analog output ..... 0-10 VDC (500 ohm load min),
....................................0-20 or 4-20ma (500ohm load max)
Modbus RTU port ... 4800 Baud, 9600 Baud, 19,200 Baud
................................................................ unit Address 1-99
Size ................................... 1/8 din, 130mm mounting depth
Data storage ......................................................... EEPROM
Approvals ...................................................... UL, CSA, CE
31

NOTES

NOTES

THERMAL SOLUTIONS PRODUCTS, LLC.
(“Seller”)
LIMITED WARRANTY
LIMITED WARRANTY
Subject to the terms and conditions herein and except as provided
below with respect to products or parts not manufactured by
Thermal Solutions Products, LLC, Seller warrants to the original
owner at the original installation site that products manufactured
by Seller (“Products”) comply, at the time of manufacture, with
recognized hydronics industry regulatory agency standards and
requirements then in effect and will be free from defects in
materials and workmanship for a period of 3 years from date of
shipment (the “Warranty Period”) SPECIAL NOTE: The
warranty of any boiler found to be operating as a “Water Heater”
shall revert back to Thermal Solution’s standard water heater
warranty.
For products or parts not manufactured by Thermal Solutions,
the warranty obligations of Thermal Solutions shall, in all
respects, be limited to one year.
REMEDY
A. The sole remedy for breach of this warranty is expressly
limited to the repair or replacement of any part found to be
defective under conditions of normal use within the
Warranty Period. Labor for removal and/or installation is
not included.
B. Warranty - The owner must notify the original installer of
the Product and Seller (Attention: Thermal Solutions
Products, LLC, P.O. Box 3244, Lancaster, PA 17604-
3244), in writing, within the Warranty Period, providing a
detailed description of all claimed defects. Transportation to
a factory or other designated facility for repairs of any
products or items alleged defective shall, in all events, be the
responsibility and at the cost of the owner.
EXCLUSIONS
Seller shall have no liability for and this warranty does not cover:
A. Incidental, special or consequential damages, such as loss of
the use of products, facilities or production, inconvenience,
loss of time or labor expense involved in repairing or
replacing the alleged defective Product.
B. The performance of any Product under conditions varying
materially from those under which such Product is usually
tested under industry standards as of the time of shipment.
C. Any damage to the Product due to abrasion, erosion,
corrosion, deterioration, abnormal temperatures or the
influence of foreign matter or energy.
D. The design or operation of owner’s plant or equipment or of
any facility or system of which any Product may be made a
part.
E. The suitability of any Product for any particular application.
F. Any failure resulting from misuse, modification not
authorized by Seller in writing, improper installation or lack
of or improper maintenance.
G. Equipment furnished by the owner, either mounted or
unmounted, or when contracted for by the owner to be
installed or handled.
H. Leakage or other malfunction caused by:
1. Defective installations in general and specifically, any
installation which is made:
a. in violation of applicable state or local plumbing
housing or building codes,
b. without a certified ASME, pressure relief valve, or
c. contrary to the written instructions furnished with the
unit
2. Adverse local conditions in general and, specifically,
sediment or lime precipitation in the tubes and/or headers
or corrosive elements in the atmosphere.
3. Misuse in general and, specifically, operation and
maintenance contrary to the written instructions
furnished with the unit, disconnection, alteration or
addition of components or apparatus, not approved by
seller, operation with fuels or settings other than those
set forth on the rating plate or accidental or exterior
damage.
I. Production of noise, odors, discoloration or rusty water.
J. Damage to surrounding area or property caused by leakage
or malfunction.
K. Costs associated with the replacement and/or repair of the
unit including: any freight, shipping or delivery charges, any
removal, installation or reinstallation charges, any material
and/or permits required for installation reinstallation or
repair, charges to return the boiler and or components.
Seller’s liability under this warranty shall not in any case exceed
the amount paid for the Product found to be defective.
THIRD-PARTY WARRANTIES
For goods or components not manufactured by Seller, the
warranty obligations of Seller shall, in all respects, conform and
be limited to one year from the date of shipment
SEVERABILITY
To the extent that any provision of this warranty would be void or
prohibited under applicable law, such provisions shall be limited
in effect to the minimum extent necessary to render the remaining
provisions hereof enforceable.
NO OTHER WARRANTIES
Seller makes no implied warranty of merchantability or
fitness for a particular purpose, or other warranties with
respect to any products or services except as expressly set
forth in this limited warranty.