MODEL EM-10 ELECTRIC BOILER CONTROL SERVICE MANUAL Publication No. EM-40-SM Printed in U.S.A. 914 Part No.
How to Use the Data Brochure This brochure is organized into three main sections. They are: 1) Sequence of Operation, 2) Installation, and 3) Control Settings. The Control Settings section of this brochure describes the various items that are adjusted and displayed by the control. The control functions of each adjustable item are described in the Sequence of Operation. Table of Contents User Interface ..................................................................2 Display and Symbol Description ......
Display Menu Field Displays the current menu Item Field Number Field Displays the current item selected. Displays the current value of the selected item Status Field Displays the current status of the control’s inputs, outputs and operation Buttons Selects Menus, Items and adjusts settings Item Symbol Description BOILER PUMP Displays when the boiler pump is in operation. DEMAND 2 Displays when a call for heat on demand 2 is present. BURNER Displays when stage 1, 2, 3, or 4 contact is on.
Section A: General POWERING UP THE CONTROL When the control is powered up, the control turns on all segments in the display for 2 seconds. Next, the software version is displayed for 2 seconds. Last, the control enters into the normal operating mode. DISPLAY BACKLIGHT The control’s display has a backlight that is permanently on while the control is powered. PIPING The boiler can be piped in parallel or in primary/secondary to the system.
MODE 3 (Dedicated Domestic Hot Water Tank) Mode 3 is designed for heating a dedicated domestic hot water tank using parallel piping. A tank sensor creates an internal heat demand in the control. Once an internal heat demand is present, the control stages the boiler to maintain the boiler target temperature at the boiler outlet sensor. Refer to section C for a description of dedicated domestic hot water tank operation.
MODE 7 (External Target Temperature Input and Setpoint with Primary/Secondary Piping) Mode 7 is designed for an external input signal and setpoint with primary/secondary piping. The external input signal can be provided from a BMS, an EMS, or a tekmar tN4 System Control for space heating. The setpoint can be used to heat an indirect domestic hot water tank. The external input signal creates an internal demand and changes the boiler target according to a linear scale.
Interstage On Delay (ON DLY) The interstage on delay is the amount of time that must elapse before turning on the next stage. Once a stage turns on, the next stage cannot turn on until the interstage delay on time elapses. The interstage on delay is adjustable through the ON DLY setting in the Adjust menu. Interstage Off Delay (OFF DLY) The interstage off delay is the amount of time that must elapse before turning off the next stage.
FIRE DELAY (Burner symbol DLY) Does NOT apply to electric boiler operation. The Fire Delay is the delay time that may occur between the time that the control closes the Stage 1 contact and when the burner fires. This delay is usually the result of a burner pre-purge or other forms of time delay built into the burner’s safety circuits. BOILER TARGET TEMPERATURE (BOIL TARGET) The boiler target temperature is determined from the mode of operation and the type of demand applied.
Section B: Setpoint Operation A setpoint is a fixed water temperature target that the boiler is to maintain at the operation sensor once a demand is present. The boiler maintains the boiler target by operating the stages using proportional or PID logic together with the boiler differential. Setpoint Operation + 1/2 Differential Setpoint Target - 1/2 Differential Mode 1 or 2 and Heat Demand (Dem 1) A heat demand is required whenever heat is required for the primary heating load.
Section D: Outdoor Reset Operation HEAT DEMAND (Dem 1) A heat demand is required whenever heat is required in the system. A heat demand is generated when a voltage between 24 and 120 V (ac) is applied across the CD (common demand) and the Ht D (heat demand) pins. Outdoor Design (OUTDR DSGN) The OUTDR DSGN is the outdoor air temperature that is the typical coldest temperature of the year where the building is located. This temperature is used when completing heat loss calculations for the building.
A 0-20 mA signal can be converted to a 0-10 V (dc) signal by installing a 500 Ohm resistor on the external input signal device’s terminals. 0-10 V (dc) 0-20 mA* A 4-20 mA signal can be converted to a 2-10 V (dc) signal by installing a 500 ohm resistor on the external input signal device’s terminals.
Installation Electrical Connections to the Control The installer should test to confirm that no voltage is present at any of the wires during installation. The control includes a 24 pin connector for ease of installation. NOTE: Figure shown should be used for checking control only. Boiler wiring diagram should be used for checking the rest of boiler, because interface board has different terminal numbers. Output Connections Boiler Pump Contact The Pump pins are an isolated output in the control.
DHW Tank Sensor An optional DHW Tank Sensor may be connected to the control. If the sensor is required, connect the two wires from the sensor to the Com (common sensor) and Sys/D (DHW) pins. External Input The control can accept an external input signal from an external control. If an external input signal is required, connect the positive 0-10 V (dc) wire to the +V(in) pin and connect the negative 0-10 V (dc) wire to the Com/- pin.
TEST THE POWER SUPPLY Make sure exposed wires are not in contact with other wires or grounded surfaces. Turn on the power and measure the voltage between the C and R pins using an AC voltmeter, the reading should be between 22 and 26 V (ac). 22 to 26 V (ac) TEST THE POWERED INPUTS Heat Demand If a heat demand is used, measure the voltage between the CD (common demand) and the Ht D (heat demand) pins. When the heat demand device calls for heat, between 20 and 130 V (ac) should be measured at the pins.
Control Settings DIP Switch Settings Note: DIP switches are located on the front of the control. (B) Not Used (A) Factory / Installer The Factory / Installer DIP switch is used to select which items are available to be viewed and / or adjusted in the user interface. The Factory Access Level includes all the settings available in the control. The Installer Access Level includes the settings and items which are required for system setup.
Mode 1 and 2 – Two Setpoint Operation - View Menu View Next Item The View menu items display current operating temperatures and system status information. Use the Item button to view items in this menu.
Mode 1 and 2 – Two Setpoint Operation - Adjust Menu (1 of 2) Enter Adjust Menu Next Item Item Change Value Item ADJUST MENU Item Field The Program menu items are the programmable settings used to operate the system. Press and hold all three buttons simultaneously to enter the Program menu. Range Description Access 1 to 8 MODE Select the operating mode for the control. Factory PId or P STAGE MODE Select the staging operation to be either automatic or manual.
Mode 1 and 2 – Two Setpoint Operation - Adjust Menu (2 of 2) ADJUST MENU Item Field Range Description Access Au, 0:30 to 9:55 min STAGE DELAY Select the minimum time delay between stages. Note: This setting is only available when STAGE MODE is set to PId. Au, 2 to 42°F (1 to 23°C) DIFFERENTIAL Select the boiler differential. Note: The automatic setting is only available when STAGE MODE is set to PId staging.
Mode 3 – Dedicated Domestic Hot Water Tank with Parallel Piping Application Mode 3 - Dedicated DHW with Parallel Piping The control measures the tank temperature using a DHW sensor. Once the tank temperature falls the tank differential below the tank setpoint, an internal heat demand is created. The boiler pump is turned on and the boiler is operated to maintain the tank target temperature.
Mode 3 – Dedicated DHW with Parallel Piping - Adjust Menu (1 of 2) Enter Adjust Menu Next Item Item Change Value Item ADJUST MENU Item Field The Program menu items are the programmable settings used to operate the system. Press and hold all three buttons simultaneously to enter the Program menu. Range Description Access 1 to 8 MODE Select the operating mode for the control. Factory PId or P STAGE MODE Select the staging operation to be either automatic or manual.
Mode 3 – Dedicated DHW with Parallel Piping - Adjust Menu (2 of 2) Item Field Range Description Au, 0:30 to 9:55 min STAGE DELAY Select the minimum time delay between stages. Note: This setting is only available when STAGE MODE is set to PId. 0 to 10°F (0 to 6°C) STAGE DIFFERENTIAL Select the interstage temperature differential between stages for proportional staging. Note: This setting is only available when STAGE MODE is set to P.
Mode 4 and 5 – Outdoor Reset and Setpoint Operation Applications Mode 4 – Outdoor Reset and Setpoint with Parallel Piping Mode 5 – Outdoor Reset and Setpoint with Primary – Secondary Piping Mode 5 Mode 4 BTC Outdoor Sensor BTC Relay Outdoor Sensor Relay Factory Installed Boiler Outlet Sensor Factory Installed Boiler Outlet Sensor Secondary Piping Sensor (Included) Boiler Inlet Sensor (Included) Boiler Inlet Sensor (Optional) The control receives a heat demand provided from zone valve end switch
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - View Menu View Next Item The View menu items display current operating temperatures and system status information. Use the Item button to view items in this menu. Item Ite m F ie ld R ang e (-51 to 88°C) OUTDOOR Current outdoor air temperature as measured by the outdoor sensor.
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - Adjust Menu (1 of 3) Enter Adjust Menu Next Item Item Change Value Item ADJUST MENU Item Field The Program menu items are the programmable settings used to operate the system. Press and hold all three buttons simultaneously to enter the Program menu Range Description Access 1 to 8 MODE Select the operating mode for the control. PId or P STAGE MODE Select the staging operation to be either automatic or manual.
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - Adjust Menu (2 of 3) Item Field Range Description Access 120 to 225°F (49 to 107°C), OFF BOILER MAXIMUM Select the maximum boiler target temperature. Factory OFF, 80 to 180°F (27 to 82°C) BOILER MINIMUM Select the minimum boiler target temperature. Factory 0:00 to 3:00 min (1 second increments) FIRE DELAY Select the amount of time required for combustion pre-purging, ignition and the flame to be established.
Mode 4 and 5 – Outdoor Reset and Setpoint Operation - Adjust Menu (3 of 3) ADJUST MENU Item Field Range Description Access 0:10 to 5:00 min MINIMUM ON TIME Select the minimum amount of time that the stage contact must remain on before it is allowed to turn off. Note: This setting is only available when STAGE MODE is set to P. Factory 0:10 to 5:00 min MINIMUM OFF TIME Select the minimum amount of time that the stage contact must remain off before it is allowed to turn back on.
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation Applications Mode 6 – External Target Temperature Input and Setpoint with Parallel Piping Mode 7 – External Target Temperature Input and Setpoint with Primary – Secondary Piping Mode 7 Mode 6 EMS BTC tN4 System Control BTC 0-10 V (dc) 0-10 V (dc) Relay Relay Factory Installed Boiler Outlet Sensor Factory Installed Boiler Outlet Sensor External Control Sensor Secondary Piping Sensor (Included) Boiler Inlet Sensor (Included) T
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation - View Menu View Next Item The View menu items display current operating temperatures and system status information. Use the Item button to view items in this menu.
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation - Adjust Menu (1 of 2) Enter Adjust Menu Next Item Item Change Value Item ADJUST MENU Item Field The Program menu items are the programmable settings used to operate the system. Press and hold all three buttons simultaneously to enter the Program menu. Range Description 1 to 8 MODE Select the operating mode for the control. PId or P STAGE MODE Select the staging operation to be either automatic or manual.
Mode 6 and 7 – External Target Temperature Input and Setpoint Operation - Adjust Menu (2 of 2) ADJUST MENU Item Field Range Description Access 0 to 10°F (0 to 6°C) STAGE DIFFERENTIAL Select the interstage temperature differential between stages for proportional staging. Note: This setting is only available when STAGE MODE is set to P. Factory 0:10 to 8:00 min INTERSTAGE ON DELAY Select the amount of time that must pass once a stage has been turned on in order to allow the next stage to turn on.
Mode 8 – External Direct Drive Operation Application Mode 8 – External Direct Drive Operation The control receives a heat demand provided via an external analog input signal from a tekmar sequencing control (such as a 275). The control turns on the boiler pump and the Stage 1, 2, 3 and 4 contacts according to the external input signal.
Mode 8 – External DirectDrive Operation - Adjust Menu Enter Adjust Menu Item Next Item Change Value Item Item Field Range ADJUST MENU 1 to 8 The Program menu items are the programmable settings used to operate the system. Press and hold all three buttons simultaneously to enter the Program menu. Description MODE Select the operating mode for the control. Access Setting Factory Installer 120 to 225°F (49 to 107°C) BOILER OUTLET MAXIMUM Select the maximum boiler outlet temperature.
Error Messages (1 of 2) E01 The control was unable to read a piece of information from its EEPROM memory. The control will stop operation until all settings in the Adjust menu have been checked by the user or installer. To clear the error message, set Access Level DIP Switch A to Factory (on position), then check all Adjust menu items. BOILER OUTLET SENSOR SHORT CIRCUIT The control is no longer able to read the boiler outlet sensor due to a short circuit.
Error Messages (2 of 2) OUTDOOR SENSOR OPEN CIRCUIT The control is no longer able to read the outdoor sensor due to an open circuit. In this case the control assumes an outdoor temperature of 32°F (0°C) and continues operation. Test the outdoor sensor and related wiring. The error message will clear once the error condition is corrected and a button is pressed. DHW TANK SENSOR SHORT CIRCUIT The control is no longer able to read the DHW tank sensor due to a short circuit.
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Technical Data EM-10 Electric Boiler Temperature Control Packaged weight Dimensions Approvals Ambient conditions Power supply Pump / Stage 1 Relays Stage 2, 3, 4 Relays Demands Sensors included: Factory Installed: — — — — — 0.38 lb. (170 g) Enclosure D, black noryl plastic 4-3/4” H x 2-7/8” W x 1-7/8” D (120 x 74 x 48 mm) ANSI Z21.23, CAN 1-6.
