Weil-McLain BMC-6X manual

1 BMC and BMC-6X Installation and Operation Manual BMC SYSTEM A B C D Full Modulation Sequencing Control 1 2 RUN PROGRAM FOR ALL CIRCUITS 120VAC, 6A RESISTIVE OUTPUT RATINGS: 1A PILOT DUTY, 15A TOTAL 115VAC 60Hz , 30VA MAX INPUT RATINGS: USE COPPER WIRE, DO NOT APPLY ANY VOLTAGE TO INPUT TERMINALS 3 4 5 6 7 8 9 10 11 12 13 15 14 17 16 18 22 20 19 2[...]

2 BMC and BMC-6X Installation and Operation Manual BMC LA YOUT . . . . . . . . . . . . . . . . 3 BMC OVERVIEW . . . . . . . . . . . . . . 4 Reset Ratio/Outdoor Reset . . . . . . . . . . 5 Make Sure Y ou Have the Right Control . . 6 INITIAL SETUP . . . . . . . . . . . . . . . 6 Selecting the System Features . . . . . . . 6 INST ALLA TION . . . . . .[...]

3 BMC and BMC-6X Installation and Operation Manual BMC SYSTEM A B C D Full Modulation Sequencing Control 1 2 RUN PROGRAM FOR ALL CIRCUITS 120VAC, 6A RESISTIVE OUTPUT RATINGS: 1A PILOT DUTY, 15A TOTAL 115VAC 60Hz , 30VA MAX INPUT RATINGS: USE COPPER WIRE, DO NOT APPLY ANY VOLTAGE TO INPUT TERMINALS 3 4 5 6 7 8 9 10 11 12 13 15 14 17 16 18 22 20 19 2[...]

4 BMC and BMC-6X Installation and Operation Manual BMC OVER VIEW SEQUENCES UP T O 4 FULL Y MODULA TING ST AGES. The BMC is the perfect control whenever multiple fully modulating stages are required for hydronic heating applications. The BM C controls the on/off and the modulation of each stage to maintain precise system set point control. PID TYPE [...]

5 BMC and BMC-6X Installation and Operation Manual UNDERST ANDING OPERA TION CONCEPT The BMC has multiple operating modes that satisfy most hydronic systems. It can change the System Set Point based on outdoor temperature (Outdoor Reset) or it can modulate its stages to achieve an adjustable fixed Set Point. In Outdoor Reset, the BMC controls a ho[...]

6 BMC and BMC-6X Installation and Operation Manual MAKE SURE YOU HA VE THE RIGHT CONTROL If you need the BCP-8W to do additional tasks that either are not listed or do not know how to set them, contact W eil McLain. INITIAL SETUP Setting an Initial Program will ease the configuration of the BMC and will give the opportunity to utilize many of the [...]

7 BMC and BMC-6X Installation and Operation Manual System Run-On • This feature lets the BMC run the SYS relay for a longer period after the boilers have been turned off. When this relay is used to control a pump, it helps in dissipating the excess heat from the boilers combustion chamber . INST ALLA TION Each of the BMC or BMC-6X consists of thr[...]

8 BMC and BMC-6X Installation and Operation Manual INST ALL THE SENSORS HEA TING SYSTEM SENSOR (HSS) INST ALLA TION LOCA TING HSS • Put the Heating System sensor approximately 10' feet past the last boiler on the common supply header but before any major takeoffs. • The sensor must be located where it sees the output of all the boiler stag[...]

9 BMC and BMC-6X Installation and Operation Manual WIRING WIRING THE POWER (TERMINALS 1, 2) • Bring the 120V AC 60Hz power wires through the bottom Knockout of the enclosure. • Class 1 voltages must enter the enclosure through a different opening from any Class 2 voltage wiring. • Connect the hot line to terminal marked L. • Connect the neu[...]

10 BMC and BMC-6X Installation and Operation Manual WIRING THE PROVE (TERMINALS 29, 30) • The Prove feature is provided to check system component operation and must be selected in the Startup Menu. See page 15. • A typical use of this feature is to check for pump flow before firing any boiler . • If the PROVE input is open on a call, the BM[...]

11 BMC and BMC-6X Installation and Operation Manual WIRING TO MODULA TING MOTORS The BMC can modulate any combination of the following motors. The Output T ype must be selected properly before connecting any output wires to avoid damage components. See Output T ype on page 1 1. WIRING THE 4-20MA MODULA TING MOTORS (A TERMINALS 13, 14), (B TERMINALS[...]

12 BMC and BMC-6X Installation and Operation Manual ----------- SETTINGS ------------ Season Winter Set Point 70 F <System Settings> <Maintenance> <Histories> <System Startup> BACK SELECT BACK SAVE ------------- SEASON -------------- Winter Summer BACK SAVE ------------ SET POINT ---------- 70 F [] --------- RESET RATIO ----[...]

13 BMC and BMC-6X Installation and Operation Manual ----------- SETTINGS ------------ Season Winter Set Point 70 F <System Settings> <Maintenance> <Histories> <System Startup> BACK SELECT BACK SAVE ---------------- GAIN -------------- +0 F [] BACK SELECT ---------- SETTINGS 1 ---------- Gain +0 Lead Rotation Time Purge Delay[...]

14 BMC and BMC-6X Installation and Operation Manual ST ARTUP SETTINGS PROGRAM CHANGE SETTINGS T o be able to change the BMC settings the Program/Run Switch must be set to Program. The switch is located under the Enclosure W iring Cover for security . The Enclosure W iring Cover can be securely closed using a lock. RUN PROGRAM ST ARTUP SEQUENCE Butt[...]

15 BMC and BMC-6X Installation and Operation Manual SELECTING THE MODULA TING MODE Normal, Parallel Default: Normal Button: MENU/<System Startup>/..../Modulating Mode • Some modulating boilers perform better as their modulation increases. For these units, it is advantageous to run one unit at high modulation than several units at lower modu[...]

16 BMC and BMC-6X Installation and Operation Manual SENSOR F AUL T All Off, All On Default: All On Button: MENU/<System Startup>/..../Sensor Fault The Sensor Fault will determine the operating status of all output stages that are set to Auto when a sensor reads Short or Open. BACK SAVE --------- SENSOR FAULT -------- All Off All On RESET MODE[...]

17 BMC and BMC-6X Installation and Operation Manual OPERA TING SETTINGS PROGRAM CHANGE SETTINGS T o be able to change the BMC settings the Program/Run Switch must be set to Program. The switch is located under the Enclosure W iring Cover for security . The Enclosure W iring Cover can be securely closed using a lock. RUN PROGRAM BACK SAVE ----------[...]

18 BMC and BMC-6X Installation and Operation Manual OUTDOOR CUTOFF TEMPERA TURE Adjustable Off, from 20 º F/ to70 º C - 100 º F , On Default: 60ºF/ 16 º C Button: MENU/Set Point/Outdoor Cutoff in Set Point Button: MENU/Set Point/Offset/Outdoor Cutoff in Reset • If the outdoor sensor is installed, the Outdoor Cutoff screen will automatically [...]

19 BMC and BMC-6X Installation and Operation Manual SYSTEM SETTINGS Button: MENU/<System Settings> The Settings 1 and Settings 2 menus provide access to adjusting and fine-tuning the system for enhanced comfort and more fuel savings. The BMC behaves dif ferently based on the selected Control Modes (see Startup Settings). BACK SELECT --------[...]

20 BMC and BMC-6X Installation and Operation Manual LAG DELA Y Adjustable from 0min to 60min Default: 0min Button: MENU/<System Settings>/Lag Delay • The Lag Delay requires the previous stage to remain at 100% modulation for the full period of the Lag Delay before another Stage can be activated. For example, if the Lag Delay was set to 10 m[...]

21 BMC and BMC-6X Installation and Operation Manual • If Setback Input is selected as a Shutdown/T stat/Setback Mode (See page 15), the Setback will not be activated unless a Short dry contact signal is received on the Shutdown/T stat/Setback terminals ( 31 and 32 ) as a signal. • If Shutdown Input or T stat Input is selected as a Shutdown/T st[...]

22 BMC and BMC-6X Installation and Operation Manual SET TIME Button: MENU/<System Settings>/<Mor e Settings>/Set T ime Button: MENU/<System Settings>/<Mor e Settings>/<Day/Night Schedules>/Set T ime • Adjust the time by selecting T ime from the menu and then scrolling through the hours then select Save. Then, scroll [...]

23 BMC and BMC-6X Installation and Operation Manual MAINTENANCE Button: MENU/<Maintenance> The Maintenance menu gives access to sensor and outputs trimming and Soft-Off. In addition, you'll have access to view the Startup configuration settings. ALERT T o be able to change the BMC settings the Program/Run Switch must be set to Program. [...]

24 BMC and BMC-6X Installation and Operation Manual CONFIGURA TION Button: MENU/<Maintenance>/<Configuration> • This menu option provides a consolidated view of the BMC's Startup and Stage settings. BACK NEXT ------ CONFIGURATION 1 ------ v1.00c Reset F Normal Day/Night Schedules All Off BACK EXIT ------ CONFIGURATION 2 ------ A[...]

25 BMC and BMC-6X Installation and Operation Manual DISPLA Y MESSAGES The BMC normal display layout reserved the second line for message indications. The following is a list of the most common Message Display Line information: • Summer The control is set to Summer . No heat is active. See Season on page 17. • Shutdown Active The Shutdown T ermi[...]

26 BMC and BMC-6X Installation and Operation Manual Auto - The BMC will control the boiler ’ s operation to maintain the desired Set Point. Only boilers set to Auto can be Lead boilers. Standby Standby boilers can only be activated when all boilers in Auto have been at 100% modulation for a selectable period of time. Standby is generally used whe[...]

27 BMC and BMC-6X Installation and Operation Manual TROUBLESHOOTING SENSOR INPUTS Display shows Sensor OPEN or SHORT When OPEN, Check the sensor is connected and the wires are continuous to the BMC. Finally follow the procedure for Incorrect T emperature or Pressure Display . When SHOR T Remove the wires from the sensor terminals. The display shoul[...]

28 BMC and BMC-6X Installation and Operation Manual • Boiler Mode Settings - The BMC will only modulate boilers their mode is set to Auto or Standby . Check if any boiler stage is set to Manual, Off, or Standby . See Mode on page 25. Boilers are Short-Cycling • Lag Delay - Increase the Lag Delay only if all boilers tend to short-cycle. • Last[...]

29 BMC and BMC-6X Installation and Operation Manual MUL TIPLE MODULA TING BOILERS DIRECT HEA TING PIPING DIAGRAM Outdoor Sensor System Sensor 120V AC Boiler 1 Boiler 2 Boiler 3 Boiler 4 Building Heating Loop BMC SYSTEM A B C D Full Modulation Sequencing Control 1 2 RUN PROGRAM DO NOT APPLY ANY VOLTAGE TO INPUT TERMINALS 3 4 5 6 7 8 9 10 11 12 13 15[...]

30 BMC and BMC-6X Installation and Operation Manual MUL TIPLE MODULA TING BOILERS DIRECT HEA TING WIRING DIAGRAM Boiler 1 Boiler 2 Boiler 3 Boiler 4 Boiler 1 Boiler 2 Boiler 3 Boiler 4 4 - 20 mA Signal Outputs Outdoor Sensor System Sensor Prov e Jumper Do Not remove BMC SYSTEM A B C D Full Modulation Sequencing Control 1 2 RUN PROGRAM DO NOT APPLY [...]

31 BMC and BMC-6X Installation and Operation Manual MUL TIPLE MODULA TING BOILERS EXTERNAL 4-20MA SET POINT USING 4-20MA EMS INTERF ACE Boiler 1 Boiler 2 Boiler 3 Boiler 4 Boiler 1 Boiler 2 Boiler 3 Boiler 4 4 - 20 mA Signal Outputs System Sensor Prov e Jumper Do Not remove BMC SYSTEM A B C D Full Modulation Sequencing Control 1 2 RUN PROGRAM DO NO[...]

32 BMC and BMC-6X Installation and Operation Manual SPECIFICA TIONS V oltage Input: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 V AC 60 Hz Power Consumption: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 V A M a x Operating T empe[...]