FULTON ModSync SE User manual

USER MANUAL
ModSync® SE
For use on Fulton Hydronic Boilers
Serial Number
Model
Fulton Order
Owner
Site Name
Date
ModSyncSE-User-Manual-211020

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Questions? Please Contact Your Local Manufacturer’s Representative
ModSyncSE-User-Manual-211020 TABLE OF CONTENTS
0-1
Introduction 1-1
ModSync® Features.............................................................................................. 1-2
Installation 2-1
Location................................................................................................................ 2-2
Power Supply ....................................................................................................... 2-2
Hydronic Boiler Interface...................................................................................... 2-2
Temperature Sensor............................................................................................. 2-2
Wiring................................................................................................................... 2-3
Operation 3-1
Sequence of Operations....................................................................................... 3-2
Screen Descriptions.............................................................................................. 3-3
Operation ............................................................................................................. 3-4
MAIN MENU SCREEN...................................................................................................................34
SYSTEM STATUS SCREEN.............................................................................................................35
HYDRONIC“BOILER # CONFIGURATION”SCREENS.....................................................................36
SYSTEM CONFIGURATION MENU................................................................................................37
SYSTEM AND SCALING SCREEN 1................................................................................................38
SYSTEM AND SCALING SCREEN 2..............................................................................................310
SYSTEM AND SCALING SCREEN 3..............................................................................................312
SYSTEM AND SCALING SCREEN 3..............................................................................................313
HARDWARE CONFIGURATION...................................................................................................314
PASSWORD AND SCREEN SAVER ..............................................................................................319
MAINTENANCE CONFIGURATION SCREEN 1.............................................................................320
MAINTENANCE CONFIGURATION SCREEN 2.............................................................................320
SENSOR CONFIGURATION..........................................................................................................321
BMS CONFIGURATION PORT 2................................................................................................322
ALARM CONFIGURATION...........................................................................................................323
SETBACK SCHEDULE..................................................................................................................324
Setpoint Conguration without Outdoor Reset................................................. 3-25
Setpoint Conguration with Outdoor Reset ...................................................... 3-26
OUTDOOR RESET CONFIGURATION...........................................................................................327
ALARM STATUS..........................................................................................................................328
TRENDING ..................................................................................................................................328
LEAD / LAG CONFIGURATION 1 .................................................................................................329
LEAD / LAG CONFIGURATION 2 .................................................................................................330
LEAD / LAG CONFIGURATION 3 .................................................................................................331
LEAD / LAG CONFIGURATION 4 .................................................................................................332
ISOLATION VALVE CONFIGURATION..........................................................................................333
VDF BOILER CIRCULATION PUMP CONFIGURATION.................................................................334
CONSTANT SPEED SYSTEM PUMPS 1........................................................................................335
CONSTANT SPEED SYSTEM PUMPS 2........................................................................................336
VFD SYSTEM PUMPS 1...............................................................................................................337
VFD SYSTEM PUMPS 2...............................................................................................................338
VFD SYSTEM PUMPS 3...............................................................................................................338
Network 4-1
Network Parameter Conguration and Address Listings..................................... 4-2
Port 2Wiring Diagram (Slave) RJ-11Type Serial Port.......................................... 4-3
Boiler Modbus Network (Port 3).......................................................................... 4-4
Honeywell SOLA Control Setup............................................................................ 4-5
MODBUS COMMUNICATIONTO A SOLA DISPLAY .....................................................................45
SOLA SETTING.............................................................................................................................46
Siemens LMV3 Control Set Up.............................................................................. 4-8
SET UP AT THE MODSYNC®..........................................................................................................48
SETUP AT THE LMV3 CONTROLLER AZL ...................................................................................48
Fulton PURE Control™ Setup.............................................................................. 4-10
Maintenance 5-1
Backing up the Program ...................................................................................... 5-3
Battery Replacement........................................................................................... 5-3
CommonTroubleshooting Issues......................................................................... 5-3
Warranty & Parts 6-1
Factory Default Settings....................................................................................... 6-2
Customer Settings................................................................................................ 6-4
Specications....................................................................................................... 6-6
Parts ..................................................................................................................... 6-7

© Fulton Group N.A., Inc. 2021
TABLE OF CONTENTS ModSyncSE-User-Manual-211020
0-2
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Questions? Please Contact Your Local Manufacturer’s Representative 1-1
INTRODUCTION
INTRODUCTION
1
INSTALLATION 2
OPERATION 3
MAINTENANCE 4
SERVICE DOCUMENTS 5
PARTS & SPECIFICATIONS 6

© Fulton Group N.A., Inc. 2021
INTRODUCTION ModSyncSE-User-Manual-211020 SECTION 1
1-2
Overview
The ModSync® Sequencing System is designed to maximize the seasonal
eciency of multiple hydronic condensing boiler installations. The ModSync®
provides advanced functionality over existing sequencing systems. The
ModSync®’s Outdoor Reset feature resets the hydronic loop temperature based
on the outdoor temperature. Enhanced Lead/Lag capabilities are provided
through user friendly displays and an easy to use Touchscreen Interface.
This manual details’ the ModSync® setup screens and conguration for use with
Hydronic Boilers
The ModSync® SE is a standard o the shelf model that does not incorporate any
customizable options.
ModSync® Features
Lead/Lag Control
The boilers are staged on and o to match the existing heat load. If additional
heat is needed after the lead boiler is energized the lag boiler is enabled.
This keeps the boilers operating at lower ring rates for as long as possible,
maximizing their eciency. All stages will be enabled before allowing the boilers
to operate at higher ring rates.
Outdoor Reset
The ModSync® will automatically adjust the hydronic loop setpoint based on the
outdoor temperature according to a user dened curve.
Setback Schedule
The hydronic loop setpoint can be congured to change based on whether the
building is Occupied or Unoccupied. This allows for the setpoint to be lowered
during times when the heating requirements are reduced, such as at night or
weekends.
Multiple Setpoint Control Modes
The hydronic loop setpoint can be eld-selected to be controlled by the
ModSync®, remote 4-20mA signal, BMS, or manual input.
Modbus Communication
The ModSync® can communicate over the Modbus protocol to Building
Management Systems. BACnet and LonWorks communication are optionally
available through protocol converters.
! WARNING
This manual is provided as a
guide to the correct operation and
maintenance of your equipment,
and should be read in its entirety and
be made permanently available to
the sta responsible for equipment
operation. It should not, however
be considered as a complete code
of practice, nor should it replace
existing codes or standards which
may be applicable. Fulton reserves
the right to change any part of
this installation, operation and
maintenance manual without notice.
Do not install, operate, service,
or repair any component of this
equipment unless you are qualied
and fully understand all requirements
and procedures.
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional /professional codes or
regulations.

Questions? Please Contact Your Local Manufacturer’s Representative
SECTION 1 ModSyncSE-User-Manual-211020 INTRODUCTION
1-3
Alarm Status
Boiler alarm status is monitored and annunciated via an Alarm Screen,
minimizing troubleshooting time requirements.
Alarm History
Alarm History screen provides Date, Time, and Fault information from previous
alarm occurrences.
BMS System Interface
Remote Enable/Disable contacts and Domestic Hot Water priority digital inputs
provide standard BMS interface capabilities.
Firing Rate Tuning
Boiler ring rate will automatically be adjusted to prevent high limit faults in
variable ow applications.
Auto/Manual Mode Control
The ModSync® can be congured for Automatic or Manual control of the boilers.
The Manual features help to decrease the boiler commissioning time by assisting
with verication of the communication interface.
Warm Standby
If a boiler has not run or received a call for heat recently it will be enabled at low
re for a user dened amount of time.
Transition Delay
If a rotation occurs and there is already a Lead Boiler it would delay shutting o
the running boiler(s) until the new boilers are released to modulate for a user
dened period of time (‘Delay’time) and can optionally be left enabled until a
certain setpoint is met to prevent a drop in temperature.
Boiler Isolation Valve Control
The ModSync® can be congured to control the boiler isolation valves. The
ModSync® will keep the lead boiler’s isolation valve open at all times to provide
a continuous ow path. A lag boiler’s isolation valve will be opened when the
boiler is called to run and will remain open until a user dened timeframe elapses
after the boiler is disabled. If isolation valves are selected, boiler pumps will be
unavailable.
! WARNING
This manual is provided as a
guide to the correct operation and
maintenance of your equipment,
and should be read in its entirety and
be made permanently available to
the sta responsible for equipment
operation. It should not, however
be considered as a complete code
of practice, nor should it replace
existing codes or standards which
may be applicable. Fulton reserves
the right to change any part of
this installation, operation and
maintenance manual without notice.
Do not install, operate, service,
or repair any component of this
equipment unless you are qualied
and fully understand all requirements
and procedures.
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional /professional codes or
regulations.

© Fulton Group N.A., Inc. 2021
INTRODUCTION ModSyncSE-User-Manual-211020 SECTION 1
1-4
Boiler Pump Control
The ModSync® can be congured to control the boiler circulator pumps. A
call for heat at the boiler will enable the boiler circulator pump. The pump will
remain enabled until a user dened timeframe elapses after the boiler is disabled.
The ModSync® can also be congured to control the pumps VFD speed. The
ModSync® will run the pump speed to match the boiler ring rate within a user
dened minimum and maximum speed. If boiler pumps are selected, isolation
valves will be unavailable.
System Pump Control
The ModSync® can be congured to control two (2) to four (4) system pumps.
The ModSync® will automatically rotate the lead system pump based on a user
dened number of run hours. The pumps will be enabled below a user dened
outdoor air temperature or a manual command at the ModSync®. The ModSync®
can be congured to control the pumps VFD speed. The pump frequency
reference signal will be generated utilizing user dened Proportional/Integral/
Derivative settings. The pumps can be congured to maintain the systems
dierential pressure or dierential temperature.
Configurable I/O
The ModSync® has a number of dierent congurable options available. To
accommodate these options the digital and analog inputs and outputs will need
to be congured to match the selected options.
! WARNING
This manual is provided as a
guide to the correct operation and
maintenance of your equipment,
and should be read in its entirety and
be made permanently available to
the sta responsible for equipment
operation. It should not, however
be considered as a complete code
of practice, nor should it replace
existing codes or standards which
may be applicable. Fulton reserves
the right to change any part of
this installation, operation and
maintenance manual without notice.
Do not install, operate, service,
or repair any component of this
equipment unless you are qualied
and fully understand all requirements
and procedures.
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional /professional codes or
regulations.

Questions? Please Contact Your Local Manufacturer’s Representative 2-1
INSTALLATION
INTRODUCTION
1
INSTALLATION
2
OPERATION 3
NETWORK 4
MAINTENANCE 5
PARTS & SPECIFICATIONS 6

© Fulton Group N.A., Inc. 2021
2-2
INSTALLATION ModSyncSE-User-Manual-211020 SECTION 2
! WARNING
This manual is provided as a
guide to the correct operation and
maintenance of your equipment,
and should be read in its entirety and
be made permanently available to
the sta responsible for equipment
operation. It should not, however
be considered as a complete code
of practice, nor should it replace
existing codes or standards which
may be applicable. Fulton reserves
the right to change any part of
this installation, operation and
maintenance manual without notice.
Do not install, operate, service,
or repair any component of this
equipment unless you are qualied
and fully understand all requirements
and procedures.
All information in this manual is for
reference and guidance purposes,
and does not substitute for required
professional training, conduct,
and strict adherence to applicable
jurisdictional /professional codes or
regulations
Location
The ModSync® enclosure should be located in a clean, dry environment within
visual range of the boilers. Four (4) mounting supports are provided loose in the
enclosure. Secure the supports to the enclosure and mount the ModSync® in an
easily accessible area of the boiler room. The enclosure meets NEMA
classication 4.
Power Supply
A 120VAC/60Hz/1PH electrical supply is required by the ModSync®. The hot
supply should be connected to the integral 10A circuit breaker for short circuit
protection. The neutral wire should be connected to the corresponding N
terminal block and the ground wire to the green ground terminal block provided
in the ModSync® enclosure.
Hydronic Boiler Interface
Hydronic boilers provide status feedback through Modbus communication
or using contact closures and analog (4-20mA) signals. Please reference the
associated electrical diagram to determine the communication runs required
between the ModSync® and the Hydronic boilers.
Temperature Sensor
One (1) PT100 RTD Temperature Sensor is provided with the ModSync®. The
Hydronic Loop Supply Temperature Sensor is shown in Figure 2 below.
The Hydronic Loop Supply Temperature Sensor should be mounted in a
thermowell with provided conductivity paste. The well should be located in the
common hydronic loop header after the connection point of the last hydronic
boiler in the system. The Hydronic Loop Sensor should be located such that it will
read the mixed temperature of ow through all of the condensing boilers.
The Supply Temperature can also be provided by the BMS. This option can be
user selected under the “Sensor Conguration Screen”. Refer to the Network
Section of this manual for the Modbus mapping points.
Specications:
• High Range Wire Round
(-200 to 600) ºC [-328 to 1112] ºF
• Tolerance: Grade B
• Base Resistance: 100 Ω
• Sheath Diameter: 38
• Sensor Length: 4”
• Sensor Material Type: 303 Stainless Steel
• Threaded Fitting: ¼” NPT
FIGURE 1 –
HYDRONIC SUPPLY SENSOR