AER 62110095 User manual

AM Series Cascade Sequencer User Manual
Page 1of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
GF-146-CS
USER MANUAL
Cascade Sequencer Controller
For AM Series Boilers and Water Heaters
Latest Update: 04/29/2016
This device is intended for use with following
AERCO AM Series Models:
Water Heaters:
•AM 399W
•AM 500W
•AM 750W
•AM 1000W
Boilers:
•AM 399B
•AM 500B
•AM 750B
•AM 1000B

AM Series Cascade Sequencer User Manual
Page 2of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
TABLE OF CONTENTS:
INTRODUCTION .................................................................................................3
CHAPTER 1: INSTALLATION .............................................................................4
1.1 PIPING INSTALLATION....................................................................................................... 4
1.2 ELECTRICAL INSTALLATION............................................................................................. 5
1.3 PREPARING THE CASCADE SEQUENCER FOR USE...................................................... 8
1.4 REWIRING THE MASTER BOILER (OLDER UNITS ONLY)............................................... 9
1.5 SETTING COMMUNICATIONS BOARD SWITCH TO ON..................................................12
1.6 SETTING THE LOGIC ADDRESS FOR EACH HEATER....................................................14
1.7 SETTING FOR USE WITH BOILERS OR WATER HEATERS............................................16
1.8 DEPENDENT HEATER PREPARATION – SETTING PARAMETER 2003 .........................16
1.8.1 AM Series Controller - Installer Menu Navigation ......................................................................... 17
1.9 REVIEW OF ALL PARAMETERS .......................................................................................18
1.10 REMOVING THE CASCADE SEQUENCER.....................................................................20
CHAPTER 2: OPERATION ................................................................................21
2.1 CASCADE SEQUENCER DISPLAY AND CONTROLS ......................................................21
2.2 CASCADE STATUS BUTTON............................................................................................22
2.3 SUBMENU NAVIGATION, AND PARAMETER SETTINGS ................................................22
2.4 SUB-MENU PARAMETER DESCRIPTIONS ......................................................................23
2.5 SUB-MENU PARAMETER RANGE AND DEFAULT SETTINGS........................................24
2.6 TROUBLESHOOTING GUIDE............................................................................................25

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 3of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
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).
Cascade Sequencer Controller Front Panel
(Cover closed)
The AM Series Cascade sequencer Kit is comprised of:
•AM Series Cascade Sequencer unit (P/N 62110095)
•AM Series Cascade Sequencer User Manual (OMM-0101)
WARNING!
Installer: Read the manual for the appliance(s), including this manual, before installing. Perform
steps in the order given.
User: 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!

AM Series Cascade Sequencer User Manual
Page 4of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
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.
Because the cascade general sensor is installed on the Master heater, the Master heater must
always be the closest to the low loss header in order to provide the most accurate temperature
measurement.
A maximum of eight (8) heaters may be connected into the cascade system.
NOTE:
Figure 1-1 shows only one piping configuration example. Other piping configurations are
possible. Contact AERCO technical support for information concerning alternative
configurations.
Figure 1-1: Cascade Sequencing Heater/Boiler Piping Installation

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 5of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
1.2 Electrical Installation
Access the electrical junction box as shown in Figure 1-2. Two wiring schematics (Figures 13a
and 13b) are shown on the following pages that show wiring for earlier and later manufactured
units. Determine which unit you have according to the two following conditions (a or b), then
wire according to the referenced figure number:
a) If terminals 30 and 31 are NOT present in the electrical junction box, refer to Figure 1-3a.
b) If terminals 30 and 31 ARE present in the electrical junction box, refer to Figure 1-3b.
Installer must install all wires represented by dashed lines in Figures 1-3a and 1-3b. 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 Master 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 & 15 of the Master boiler. For remote setpoint
(0-10V)
control, connect the 0-10V signal wires to terminals 22 & 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.
If there is a water heater tank present in the system, the tank sensor should be placed in the
bottom 1/3 of the tank. This sensor is included in the spare parts kit shipped with each unit,
and is the same probe as the cascade header temperature sensor.
If using the AM for domestic hot water only, connect the sensor leads to terminals 24 and 25.
For further information on all of these control modes, consult the AM Series Boiler and
Water Heater User Manual (GF-146).
Figure 1-2: Accessing the Junction Box of the Master Heater
Communications
Board Cover
Junction Box
Top Cover
Unit Top Cover
Top Cover Screw

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

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

AM Series Cascade Sequencer User Manual
Page 8of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
1.3 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 1-4.
Figure 1-4: Opening Rear Panel of Cascade Sequencer
2. Connect two wires, each two feet (0.5m) long, to the two screw terminals on the Cascade
Sequencer PCB, as shown in Figure 1-5. Wires do not have polarity.
Figure 1-5: Connecting Wires to the Cascade Sequencer Terminals
3. Feed both wires through the rear panel conduit opening and snap rear panel onto rear of
cascade Sequencer (Figure 1-6).
Figure 1-6: Replacing Rear Panel after Wiring
Using Screwdriver
in Slot Cascade
Sequencer
Rear Panel
Install Wires into Terminals

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 9of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
1.4 Rewiring the Master Boiler (Older Units ONLY)
IMPORTANT NOTES!
•Procedure below is ONLY for units that do NOT have terminals 30 and 31 present.
•This procedure is performed ONLY on the Master boiler.
•For AM units WITH terminals 30 and 31 present, skip directly to Section 1.5
NOTE:
Ensure that the heater being prepared as the Master heater is the one installed closest to the
low loss header.
To electrically prepare an AM Series heater/boiler that is without terminals 30 and 31 for use as
the Master appliance for the Cascade Sequencer, follow the instructions below.
Rewiring the Master Boiler (Units without Terminals 30 & 31)
1. Using a flat head screwdriver, open the communications board cover (see Figure 1-7).
Figure 1-7: Using Screwdriver to Remove Communications Board Cover
2. Disconnect the 2-wire (pink/yellow) plug from the communications board (See Figure 1-8).
Figure 1-8: Removing 2-Wire Male Connector from Communications Board
Unplug This
Male Connector
Unplug Connector
From Female Header
Pink Wire
Yellow Wire
Communications
Board

AM Series Cascade Sequencer User Manual
Page 10 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
Rewiring the Master Boiler (Units without Terminals 30 & 31) – Cont.
3. Open the wire conduit cover (See Figure 1-9).
Figure 1-9: Opening the Wire Conduit Cover
4. From the wire conduit, remove the two wires (pink and yellow) that are attached to the plug
disconnected from the communications board in step 4 (Figure 1-10).
Figure 1-10: Removing Pink and Yellow Wires from Wire Conduit
5. Cut the connector from the pink and yellow wires and strip the insulation 1/4” (7mm) (Figure
1-11).
Figure 1-11: Removing 2-Wire Connector from Junction PCB
Wire
Conduit
Cover
Wire
Conduit
Yellow & Pink
wires cut from
connector
and stripped.

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 11 of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
Rewiring the Master Boiler (Units without Terminals 30 & 31) – Cont.
6. Connect the pink wire together with the two black wires present on terminal #16 (See
Figures 1-12).
Figure 1-12: Connecting Pink Wire to Terminal #16
7. Connect the yellow wire together with the two red wires present on terminal #17 (See
Figures 1-13). See Figure 1-14 for final wiring diagram.
Figure 1-13: Connecting Yellow Wire to Terminal #17
Figure 1-14: Terminal Wiring Diagram for Master Heater
(NOTE: Other Wiring Not Shown for Clarity)
Connect YELLOW Wire
To Terminal #17
Connect PINK Wire
To Terminal #16
Existing BLACK Wires
On Terminal #16
Existing RED Wires
On Terminal #17

AM Series Cascade Sequencer User Manual
Page 12 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
1.5 Setting Communications Board Switch to ON
NOTE:
All instructions hereafter apply to all applicable AM Series units, including older and newer units.
To prepare an AM Series heater/boiler for use with the Cascade Sequencer, the S4 switch on
the communications board must be set to ON as described below.
Setting Communications Board Switch to ON
1. Gain access to the inside of the electrical junction box by removing the unit top cover and
the electrical junction box top cover (see Figure 1-2).
2. Locate the communication board cover inside the junction box (see Figure 1-15).
Figure 1-15: Locating the Communications Board inside Electrical Junction Box
3. Using a flat head screwdriver, open the communications board cover (see Figure 1-16).
Figure 1-16: Removing Communications Board Cover
Communications
Board Cover

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 13 of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
Setting Communications Board Switch to ON – Continued
4. Locate S4 switch at front edge of communications board per Figure 1-17.
5. Set S4 switch to ON (LEFT as you are facing the unit).
Figure 1-17: Setting Master Heater Communications Board S4 Switch
NOTE:
Wiring is not shown for image clarity.
S4
Switch

AM Series Cascade Sequencer User Manual
Page 14 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
1.6 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:
See Section 1.2 and Figure 1-2 for how to access the electrical junction box and wiring
terminals within. See Section 2 for operation of the unit and how access menus and parameters.
1. Ensure power is turned OFF to the boiler set up as the Master heater (heater #1).
2. Connect the two wires from the Cascade Sequencer to terminals 16 and 17 (see Figure 1-
18) of the Master heater’s electrical junction box.
Figure 1-18: Wiring to Terminals 16 and 17 on AM Unit
(Other wiring not shown for clarity)
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 connected to the same
terminals.

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 15 of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
Setting the Logic Address for Each Heater - Continued
3. Turn the power ON to the Master heater (#1). The Cascade Sequencer will also power up.
4. Wait until the Cascade Sequencer recognizes the boiler and “E2Prom Err” is not displayed.
This may take up to three minutes.
5. Using the Cascade Sequencer, set the Address to 1 as follows:
Logic Address Programming Procedure
a) Press and hold the Home button (see Figure 2-1 in Chapter 2) 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).
Figure 1-19: Sub Menu - Selecting the Parameter to Change
c) When the Boiler Address parameter is selected, press the Ok button. The dot then
appears to the left of the parameter setting (Figure 1-20) and begins to blink, indicating it
may be adjusted.
Figure 1-20: Sub Menu – Changing the Parameter Setting
d) Use the Up or Down buttons to change the parameter value up or down. For the Master
heater, set this to 1. For each Dependent heater, a different address is set, from 2 to 8,
depending on how many dependent heaters are in the cascade.
e) When the desired logic address number is displayed, save it by pressing the Ok button.
f) To return to the Main menu, press the Menu button (Figure 2-1).
g) Wait a minimum of 40 seconds until “#1” appears in the upper left of the center box of the
sequencer display.
IMPORTANT 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 Master heater.
7. Disconnect the two wires from terminals 16 and 17 of the Master heater
8. Connect the two wires from the Cascade Sequencer to terminals 16 and 17 of the first
Dependent heater (heater #2).
9. On the communications board at top of unit, set the S4 Switch (see Figure 1-17) to ON.
10. Turn the power ON to the first Dependent heater (heater #2).
Dot indicates
parameter is
selected
Blinking dot = Parameter
may be adjusted using UP
& DOWN buttons.

AM Series Cascade Sequencer User Manual
Page 16 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
Setting the Logic Address for Each Heater - Continued
11. Repeat steps a) through g) in Step 5 setting the logic address to 2.
12. Turn the power OFF to the first Dependent heater (#2).
13. Disconnect the two wires from terminals 16 and 17 of the second Dependent heater (#1).
14. Repeat steps 1 to 12 on each dependent heater and set the Address sequentially for each
AM unit in the cascade (up to seven Dependent heaters; heater #2 and up to #8).
15. After all dependent heaters have had the logic address set, wire the Cascade Sequencer to
terminals 16 and 17 of the Master heater. The Cascade Sequencer is now set up for
cascade operation. Ensure all switch settings match Figure 1-18a, 1-18b, or 1-18c in
Section 1.9, depending on which models of AM Series units are being configured.
16. When addressing has been completed, turn the units on and allow the Cascade Sequencer
to recognize each unit. All units present in the system should be shown on the Cascade
Status Screen (see section 2.2).
1.7 Setting for Use with Boilers or Water Heaters
The Cascade Sequencer is set at the factory for boiler applications, but not for water heater
applications. When your system is in place, and you wish to control water heaters, you must
ensure all parameters of the Sub Menu are set as shown in the list in Section 2.1. Select the
settings in the column for boilers if you are using boilers, or select the settings in the column for
water heaters if you are using water heaters.
1.8 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 1.8.1 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
and the desired control settings of the Master heater (Section 1.8.1) for proper cascade
operation. If you need more information concerning AM Series controller operation, consult the
AERCO AM Series user manual (GF-146), and at Rev-D for all AM Series units of serial number
15000000 and above. Refer to Rev-C for all units with serial number 14999999 and below.

AM Series Cascade Sequencer User Manual
OMM-0101_0D AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 Page 17 of 28
GF-146-CS Ph.: 800-526-0288 04/29/2016
1.8.1 AM Series Controller - Installer Menu Navigation
This Installer Menu of parameters is available to qualified technicians for the purpose of
analyzing the function of, and making adjustments to, the unit. In the case of setting up a
cascade system, it is required that parameter 2003 be set to 0 for all dependent heaters
(heaters #2 up to #8), and the Master heater (heater #1) set to the desired control mode.
To make these changes to Parameter 2003 in the Installer Menu, perform the following steps:
Installer Menu Navigation and Adjustment
1. To enter the Installer Menu, press and simultaneously hold down both the RESET and
buttons or 5 seconds until the icon is displayed. , then release the buttons.
After entering the Installer Menu, the 2000 series of parameters are available for display and
editing.
2. To scroll through the list of parameters, press buttons and .
3. Once parameter 2003 is displayed, it can be selected for editing by pressing the RESET
button once (the displayed value will start blinking) and then using the and
buttons to change the value, up or down to select the following:
•Dependent Heaters (Heaters #2 up to #8) 2003 Parameter Setting:
o0=Cascade Dependent Heater
•Master Heater (Heater #1) Control Mode 2003 Parameter Setting:
o00 = Constant Setpoint with Remote Enable
o01 = Outdoor Reset with Remote Enable
o02 = Outdoor Rest
o03 = Constant Setpoint
o04 = 0-10V Control (Remote Setpoint)
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
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), Rev-D.

AM Series Cascade Sequencer User Manual
Page 18 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
1.9 Review of All Parameters
Figures 1-18a, 1-18b, and 1-18c show the unit settings for a cascade setup for models AM
1000, AM 750, and AM 399-500, respectively, using three (3) to eight (8) units.
At the end of the installation process, all parameters (Address; Switch S4; 2003; 3001 and
3050) should have the values as shown on Figures 1-18a, 1-18b, and 1-18c.
If an attempt is made to operate the cascade system and the applicable parameters are not set
to the values shown, one or more of the heaters in the cascade will display a 116 error
(communication error) and will stop functioning.
Figure 1-18a: AM 1000 Cascade Configuration and Settings Diagram

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

AM Series Cascade Sequencer User Manual
Page 20 of 28 AERCO International, Inc. •100 Oritani Dr. •Blauvelt, NY 10913 OMM-0101_0D
04/29/2016 Ph.: 800-526-0288 GF-146-CS
1.10 Removing the Cascade Sequencer
To remove the cascade sequencer from the system and return all units to normal boiler
operation as un-sequenced, individual units, perform the following procedure:
Removing the Cascade Sequencer
1. Connect the Cascade Sequencer to the last dependent boiler per Section 1.6 and set
cascade logic address to 0.
2. One at a time, connect the Cascade Sequencer to each dependent boiler per Section 1.6
and set cascade address to 0 until all dependent heaters are set to 0.
3. Connect the Master boiler per Section 1.6 and set cascade address to 0.
4. Unwire the cascade sequencer from the system and remove all daisy chain wiring between
the heaters.