Watts Aerco 64064 User manual

AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
OMM-0051_0D
GF-126
USER MANUAL
Revised: 01/20/2013
Boiler Valve Controller
(BVC)
Boiler Valve Controller Front Panel
Installation, Operation, and Maintenance
Used in:
•Benchmark Series Boilers
•KC Series Boilers
Applicable to:
•120VAC Models
(Serial# 12-840-1 and above)
•All 24VAC Models

GF-126 Boiler Valve Controller
OMM-0051_0D User Manual
Page 2 of 38 VD2: 01/20/13
AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
Disclaimer
The information contained in this manual is subject to change without notice from AERCO International,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantability and fitness for a particular application. AERCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.
Technical Support:
(Mon–Fri, 8am-5pm EST)
1-800-526-0288
www.aerco.com

GF-126 Boiler Valve Controller
OMM-0051_0D User Manual
VD2: 01/20/13 Page 3 of 38
AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
TABLE OF CONTENTS
TABLE OF CONTENTS..................................................................................................3
1. FOREWARD...............................................................................................................4
2. SAFETY PRECAUTIONS...........................................................................................5
3. GENERAL INFORMATION.........................................................................................6
3.1 INTRODUCTION................................................................................................................... 6
3.2 MOTOR OPERATED VALVE SPECIFICATIONS ....................................................................... 6
3.3 BOILER VALVE CONTROLLER GENERAL DESCRIPTIONS ....................................................... 6
3.4 USE OF THE BOILER VALVE CONTROLLER ............................................................................ 7
3.5 TRIGGERED VERSUS MANUAL OPERATION......................................................................... 7
3.6 IMPORTANT NOTES............................................................................................................. 8
3.7 PHONE SUPPORT................................................................................................................. 8
4.1BINSTALLATION..........................................................................................................9
4.1 8BINTRODUCTION................................................................................................................... 9
4.2 9BSITE SELECTION ................................................................................................................... 9
4.3 10BPREPARING &MOUNTING THE BVC .................................................................................... 9
4.3.1 Mounting the Boiler Valve Controller Enclosure ....................................................................................9
4.3.2 Drilling Access Holes for Conduit and Cable Connections ....................................................................10
4.3.3 17B Removal and Replacement of the AERCO BVC Cover...........................................................................10
4.4 WIRING REQUIREMENTS................................................................................................... 11
4.4.1 20B External Power Wiring To The Boiler Valve Controller.........................................................................11
4.4.2 21B Boiler Electrical Connections................................................................................................................11
4.4.3 22B Connecting the Required Electrical Components (4 Boiler Version).....................................................14
4.4.4 23B Connecting the Required Electrical Components (12 Boiler Version)...................................................15
4.4.5 Fuses and On/Off Switch......................................................................................................................28
5.2BOPERATION.............................................................................................................29
5.1 12BINTRODUCTION................................................................................................................. 29
5.2 13BFOUR BOILER SYSTEMS AND TWELVE BOILER SYSTEMS ................................................... 29
5.3 THE TOUCH SCREEN NAVIGATION LOGIC SEQUENCE ....................................................... 30
5.4 15BMANUAL VALVE CONTROL SCENARIOS............................................................................. 32
5.4.1 Scenario 1.............................................................................................................................................32
5.4.2 Scenario 2.............................................................................................................................................33
5.5 SEQUENCE FOR SETTING TIME DELAYS ............................................................................. 35
5.5.1 Manual Time Delay Scenario 1 ............................................................................................................35
6. SPARE PARTS.........................................................................................................37

Boiler Valve Controller (BVC) GF-126
User Manual OMM-0051_0D
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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
1. FOREWARD
The AERCO Boiler Valve Controller (BVC) is designed for variable flow heating systems. The
BVC can be configured to control each motor operated valve (MOV) independently to minimize
the system flow requirements in a multiple boiler plant. Using the BVC in your system design will
save energy, help eliminate over-temperature faults and improve the life and reliability of your
AERCO Boilers.
For example, a four BMK2.0LN installation typically requires 4 x 25 = 100 GPM minimum
system flow for stable operation. The same installation with MOVs and the AERCO Boiler Valve
Controller will allow 25 GPM minimum system flow since the system is reduced to single boiler
operation and flow is stopped on the other three boilers. As boilers are started up and turned off
based on system demand the valve controller can be configured to open and close the valves to
meet the heating demand and maintain stable temperature control without the risk of over-
temperature faults. When system demand is satisfied and all the boilers are off, the Boiler Valve
Controller opens all the MOVs, preventing system pump dead head conditions.
The valve controller has a simple, easy to use menu structure. The position of any MOV can be
selected using the BVC “Valves” Screen. However if a boiler is firing, the BVC will not allow you
to change the valve to the “CLOSED” position in order to avoid exceeding safe operating
temperature at the boiler. The factory default delay time setting is 2 minutes. The controller may
be programmed from one to thirty minutes in one-minute increments.

GF-126 Boiler Valve Controller (BVC)
OMM-0051_0D User Manual
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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
2. SAFETY PRECAUTIONS
WARNING
120 VOLTS AC IS USED IN THIS EQUIPMENT. DEATH ON
CONTACT OR SERIOUS PERSONAL INJURY MAY RESULT IF
EXPOSED CONNECTIONS ARE TOUCHED. THEREFORE,
EXERCISE EXTREME CARE WHEN CONNECTING POWER
WIRING TO THE UNIT. ALWAYS ENSURE THAT THE
EXTERNAL CIRCUIT BREAKER SUPPLYING LINE VOLTAGE
TO THE CONTROLLER IS TURNED OFF.
WARNING
THE BOILER VALVE CONTROLLER IS HOUSED IN A
LAMINATED FIBERGLASS ENCLOSURE. SINCE FIBERGLASS
IS AN INSULATOR, PROPER GROUNDING MUST BE
MAINTAINED BETWEEN THE INTERNAL EQUIPMENT AND
THE CONDUITS AND/OR CABLES ENTERING OR EXITING
THE ENCLOSURE.
WARNING
THE MOTORIZED VALVES USED IN THIS APPLICATION ARE
NOT INTENDED TO BE USED AS ISOLATION VALVES.
!!
!!
!!

Boiler Valve Controller (BVC) GF-126
User Manual OMM-0051_0D
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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
3. GENERAL INFORMATION
3.1 INTRODUCTION
This User’s Manual provides the installation and operation procedures for the AERCO Boiler
Valve Controllers (BVCs). Currently, the Boiler Valve Controllers are available in six different
models with capabilities as described in the table below. These Boiler Valve Controllers permit
AERCO Benchmark and KC1000 Boilers to be used in variable flow systems, while eliminating
the need for a dedicated bypass line.
3.2 MOTOR OPERATED VALVE SPECIFICATIONS
a) The Motor Operated Valves (MOVs) must have a “Proof of Open” switch.
•Switch “makes” when valve opens. This lets the boiler know that water is
flowing through the boiler, allowing it to safely fire.
•Switch breaks when valve closes.
b) Preferred MOVs shall be “Fail open, Power Closed”.
3.3 BOILER VALVE CONTROLLER GENERAL DESCRIPTIONS
The two Boiler Valve Controller Models are housed in NEMA Type 4X (for indoor use only)
laminated fiberglass enclosures. An illustration of the BVC box showing the front plate with the
touch screen is shown in Figure 1.
AERCO Boiler Valve Controller Models
Part
Number Control Capability Valve
Power
Supply
Maximum
Valve Load
Maximum
Inrush
Current
64064 Up to Four (4) Valves 120 VAC 1 Amp per
Valve 12 Amp per Valve
64065 Up to Twelve (12) Valves 120 VAC 1 Amp per
Valve 12 Amp per Valve
64095 Up to Four (4) Valves 120 VAC 1 Amp per
Valve
30 Amp per
Valve
64096 Up to Twelve (12) Valves 120 VAC 1 Amp per
Valve 30 Amp per Valve
64097 Up to Four (4) Valves 24 VAC 1 Amp per
Valve 30 Amp per Valve
64098 Up to Twelve (12) Valves 24 VAC 1 Amp per
Valve 30 Amp per Valve

GF-126 Boiler Valve Controller (BVC)
OMM-0051_0D User Manual
VD2: 01/20/13 Page 7 of 38
AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
Figure 1: The AERCO Boiler Valve Controller Box
3.4 USE OF THE BOILER VALVE CONTROLLER
There are two basic purposes of the BVCs. They are as follows.
1) Reduce the required minimum system water flow to minimal single boiler flow.
2) Eliminate the need for a boiler bypass flow path by being able to open up flow through the
boilers when system demand is satisfied, thereby preventing system pump dead head
conditions.
3.5 TRIGGERED VERSUS MANUAL OPERATION
The BVC operates in two modes; automated and manual. The automated mode runs without
operator intervention. Depending on the operational status of the boilers, voltages are applied to
the BVC electronic input terminals, causing the MOVs to open or close as appropriate.
The BVC may also be used manually to open and close the boiler valves as desired. For
instance, if only one of the boilers in a four boiler system is firing, it may be desirable to open
the valves on the remaining three (non-firing) boilers. This allows water circulation
commensurate with the flow requirements of the system supply heat circulation pump.
Should the BVC be used manually to change the open/close state of a MOV, the MOV may
subsequently have its open/close state changed either manually or automatically, in accordance
with the boiler system valve state open/close operational rules.

Boiler Valve Controller (BVC) GF-126
User Manual OMM-0051_0D
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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
NOTE
An operator cannot manually close a boiler valve using the BVC if that
particular boiler is firing.
3.6 IMPORTANT NOTES
The following should be noted before reading the remainder of this manual.
•The AERCO Boiler Valve Controller operates independently from the AERCO Boiler
Management System.
•The five buttons labeled F1 through F5 appearing below the touch screen are not
operational.
•If a boiler is firing, the corresponding valve cannot be manually moved to the “CLOSED”
position to avoid temperature overshoot.
•The factory default setting for the time delay is two minutes. The user may subsequently
set the time delay in minute increments from one to thirty.
•It is not recommended to lower the time delay below the two minute factory default
setting except for the purposes of servicing.
•Any time delay that is set will universally apply to all of the valves.
•To trigger the action of a touch screen button, tap the middle of the circular area
representing the button.
3.7 PHONE SUPPORT
See the inside cover of this document for information needed to contact AERCO support, in
case problems should occur.

GF-126 Boiler Valve Controller (BVC)
OMM-0051_0D User Manual
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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
4. 1BINSTALLATION
4.1 8BINTRODUCTION
This section provides the descriptions and procedures necessary to mount the Boiler Valve
Controller and connect them to all boiler plant units and related MOVs. Refer to the appropriate
wiring diagrams provided in Figure 8 when making all wiring connections between the Boiler
Valve Controller, AERCO boilers, and their associated MOVs.
4.2 9BSITE SELECTION
Ensure that the site selected for installation of the Boiler Valve Controller provides the following:
•Access to single-phase AC power at 120 VAC, 60 Hz.
•Sufficient clearances to permit maintenance and setup/operational tasks on the Boiler Valve
Controller. The BVC enclosure should be mounted with:
1) A minimum of three feet in front of the enclosure free
2) The ability to open the front cover all of the way
Always refer to local codes to insure compliance when installing and maintaining your BVC unit.
4.3 10BPREPARING & MOUNTING THE BVC
AERCO recommends that the BVC be wall-mounted using a sheet of plywood or other suitable
material. However, prior to mounting, access holes must be drilled in the laminated fiberglass
enclosure. Refer to section 4.3.1and section 4.3.2for guidelines and instructions for drilling
access holes and mounting the controller. Before any drilling and mounting of the box can be
performed it is important to carefully and safely remove and then re-install the cover.
4.3.1 Mounting the Boiler Valve Controller Enclosure
Each controller is shipped with a Mounting Foot Kit which is included inside the enclosure. This
kit contains four (4) mounting brackets and four (4) 10-32 x 7/16” flat head screws (Figure 2).
The mounting feet are attached as follows:
1. Place the mounting feet on the back side of the enclosure so that the counter sink hole is
directly over the brass insert.
2. Using a screwdriver and the 10-32 x 7/16” flat head screws, tighten the mounting feet to
the enclosure. The torque should be approximately 25 in-lb. An attached foot appears in
Figure 3 (next page).

Boiler Valve Controller (BVC) GF-126
User Manual OMM-0051_0D
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AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]AERCO International, Inc. •100 Oritani Dr. •Blauvelt, New York 10913 •Phone: [phone]
Figure 2 - Mounting Foot Kit Figure 3 - Attached Mounting Foot
3. After all four feet are attached, position the Boiler Valve Controller on the wall-mounted
plywood sheet or other suitable surface. For easy viewing, position the BVC so that the LCD
display is at eye level.
4. Mark the locations for the four slotted holes in the mounting feet.
5. Remove the BVC and drill four (4) pilot holes for the mounting screws.
6. Secure the BVC to the wall using four (4) screws (not supplied) suitable for the mounting
surface being used. The size of the screws required is to be determined in the field .Do not
over-tighten the screws.
4.3.2 Drilling Access Holes for Conduit and Cable Connections
Since the BVC does not come pre-drilled, access holes must be made to accommodate all
incoming/out-going signaling and power wiring. Power wiring should be routed through a
separate cutout to minimize electrical noise on signal leads. Access holes can be drilled in the
bottom (preferred), top, or side surfaces of the enclosure. The most common method for drilling
holes in the composite fiberglass enclosure is using a standard twist bit drill. For best results,
AERCO recommends that carbide tipped or PCD diamond tipped tools be used to avoid
chipping of the composite material. AERCO recommends that hubs be used for connecting
conduit and cabling to the enclosure.
4.3.3 17BRemoval and Replacement of the AERCO BVC Cover
Although it is unlikely that the cover will ever have to be removed and replaced, the procedure
to facilitate this process is provided should such a situation ever occur. Proceed as follows.
4.3.3.1 28BCover Removal
1. Open the enclosure completely and provide adequate support to keep the cover from being
damaged during disassembly.
2. Disconnect the RJ-11 telephone cable connectors from Port 1 on the back of the display.
Remove the cable tie so that the front panel may be removed freely.
3. Using a hammer and screwdriver, gently tap on the end of the hinge pin nearest the middle
of the enclosure (closed end) so that the pin becomes unseated at the other end (approx.
¼”).
4. Using pliers, grasp the opposite end (flattened) of the hinge pin and pull completely out.
Repeat steps 1 through 3 to remove the second hinge pin.