Weil-McLain BSC Service manual

BSC Installation and Operation Manual
550-100-074/0408
BSC
MADE IN U.S.A.
PREV.
SAFETY
GROUND
MUST BE
CONNECTED
OUTDOOR
TEMP
SYSTEM
PROVE
STAGE
A
STAGE
B
MENU FUNCTIONS
SELECT enters menus or accepts changes
ADJUST selects menu items or changes settings
BACK returns to previous menu
STAGE selects stage menus or next stage
PREV./NEXT steps through output status
SYSTEM
LINE
NEUTRAL
STAGE
HELP NEXT
PRESS TO
SELECT
BACK
ADJUST
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
B1
B2
B3
B4
NETWORK
4-20mA
SHUTDOWN
SYSTEM
TEMP
INPUTS
ACD
<A> B C D
100 53 OFF STBY
OD= 31oF SYS= 114oF
B
SYS A
OPERATING LIMIT
OUTPUTS
CDB
T
T
123456789 1110
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY
15ATOTAL
FOR ALL CIRCUITS
INPUT RATINGS:
115VAC 60Hz
30VA MAX
USE COPPER WIRE,
CLASS 1 WIRE ONLY
S
+
DO NOT APPLY ANY VOLTAGE
TO SENSOR TERMINAL
FULL MODULATION
SEQUENCING CONTROL
LOCKOUT
INPUTS
STAGE
C
STAGE
D
B5
B6
B7
B8
EMS INPUT
+SIGNAL SHIELD
12
ABCD
MODULATION OUTPUTS
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
LISTED
99RA
US
C
UL
R
GND mA Volt
-++
GND mA Volt
-++
GND mA Volt
-++
GND mA Volt
-++
INSTALLATION AND OPERATION INSTRUCTIONS MANUAL
BSC
Modulating Control
BSC-BAC
Modulating BACnet Control
BSC-8X
Modulating Extension
This Weil McLain control is strictly an operating control; it should never be used as a
primary limit or safety control. All equipment must have its own certified limit and safety
controls required by local codes. The installer must verify proper operation and correct any
safety problems prior to the installation of this Weil McLain control.
WARNING
MODULATING BOILER CONTROL WITH BACNET COMMUNICATION OPTION

2
BSC Installation and Operation Manual
Content
BSC FUNCTION CHART . . . . . . . . . . 3
BSC OVERVIEW . . . . . . . . . . . . . . 4
Reset Ratio/Outdoor Reset ..........5
INSTALLATION . . . . . . . . . . . . . . . 6
Mounting the Enclosure ............6
Wiring the Power . ...............6
Input Wiring. ................ 6
Wiring the Outdoor sensor ...........6
Wiring The System Sensor. ..........7
Wiring an External Set Point (4-20mA Input) . 7
Wiring the Shutdown . .............7
Wiring the System Prove . ...........8
Wiring the Lockout Inputs ...........8
Wiring A Setback . ...............8
Output Wiring. ............... 9
Wiring the System Output ...........9
Wiring the Stage Outputs ...........9
Modulating Output Card ..........10
BACnet Communication Wiring ......10
Wiring The BSC to Extension Panels . . . 11
USING THE MENUS. ............12
Menu Basics .................12
The Main Display. ..............12
Display Stage Modulation Status. ......12
Display Messages ..............12
SYSTEM STARTUP . . . . . . . . . . . . . 13
Startup Sequence ..............13
Sensor Type .................13
EMS Input Mode ...............13
4 & 20mA Set Points .............16
Output Type .................16
Modulating Mode . ..............16
Operating Mode ...............16
Heat/Cool Mode ...............17
Sensor Fault .................17
MENU SETTINGS . . . . . . . . . . . . . . 14
MENU SETTINGS CONTINUED. ......15
OPERATING SETTINGS . . . . . . . . . . 17
Set Point ...................17
Outdoor Cutoff Temperature .........17
Reset Ratio. .................18
Offset . ....................18
Minimum Water Temperature ........18
Gain/Throttle .................19
Lead Stage . .................19
Lead Auto Rotate. ..............19
Purge Delay .................20
Lag Delay ..................20
Standby Time. ................20
System Run-On ...............21
Setback. ...................21
Rotate Time .................21
Last-Stage-Hold ...............21
$YRLG&RQÀLFWLQJ%RLOHU/LPLWV ........22
Set Point and Default Table .........22
SECURITY . .................23
Enable the Password. ............23
Change the Password ............23
Set the Time .................23
STAGE SETTINGS . . . . . . . . . . . . . 24
The Stage Menu ...............24
Moving around the Stages Menus ......24
Mode .....................24
Ignition %. ..................25
Modulation Start ...............25
Copy Settings (Stage A Only) ........26
MAINTENANCE . . . . . . . . . . . . . . . 27
System and Outdoor Trim ..........27
Stage Output Trim ..............27
Soft-off Delay. ................27
Modulation Speed ..............27
BACNET COMMUNICATION . . . . . . . . 28
BACnet Communication Option .......28
BACnet Device ID ..............28
IP Address ..................28
Mask Address ................28
Gateway Address ..............28
BSC BACnet Variable List ..........28
TROUBLESHOOTING. ...........30
BSC SPECIFICATIONS . . . . . . . . . . . 32

3
BSC Installation and Operation Manual
BSC FUNCTION CHART
BSC
MADE IN U.S.A.
PREV.
SAFETY
GROUND
MUST BE
CONNECTED
OUTDOOR
TEMP
SYSTEM
PROVE
STAGE
A
STAGE
B
MENU FUNCTIONS
SELECT enters menus or accepts changes
ADJUST selects menu items or changes settings
BACK returns to previous menu
STAGE selects stage menus or next stage
PREV./NEXT steps through output status
SYSTEM
LINE
NEUTRAL
STAGE
HELP NEXT
PRESS TO
SELECT
BACK
ADJUST
A1
A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
B1
B2
B3
B4
NETWORK
4-20mA
SHUTDOWN
SYSTEM
TEMP
INPUTS
ACD
<A> B C D
100 53 OFF STBY
OD= 31oF SYS= 114oF
B
SYS A
OPERATING LIMIT
OUTPUTS
CDB
T
T
123456789 1110
OUTPUT RATINGS:
120VAC, 6A RESISTIVE
1A PILOT DUTY
15ATOTAL
FOR ALL CIRCUITS
INPUT RATINGS:
115VAC 60Hz
30VA MAX
USE COPPER WIRE,
CLASS 1 WIRE ONLY
S
+
DO NOT APPLY ANY VOLTAGE
TO SENSOR TERMINAL
FULL MODULATION
SEQUENCING CONTROL
LOCKOUT
INPUTS
STAGE
C
STAGE
D
B5
B6
B7
B8
EMS INPUT
+SIGNAL SHIELD
12
ENCLOSED
ENERGY
MANAGEMENT
EQUIPMENT
LISTED
99RA
US
C
UL
R
ABCD
MODULATION OUTPUTS
GND mA Volt
-++
GND mA Volt
-++
GND mA Volt
-++
GND mA Volt
-++
From heating system sensor
When closed, all stages
are turned off*
Setback
From outdoor sensor mounted
in the shade
Connect to remote 4-20mA
set point signal or to dry-contac
t
setback signal
If a unit is in LockOut, the BSC
will not consider it an active stag
e*
Depress the knob to move
forward through the menus and to
accept changes. To change a
setting's value, rotate the knob.
Depress the button to go back
through the menus
Digital display shows the system status,
setpoint, lead stage <in brackets>, and
status of each stage. To view and adjust
settings, press the Adjust/Select button.
Checks status of system
components*
Green Ground
screw must be
connected to
Earth Ground
System output controls
pumps, valves or other
system components.
The modulation outputs can be 0-5V, 0-10V,
1-5V, 2-10V, 4-20mA, 0-135 Ohm. Different output
boards mount on the back of the BSC to
determine the type of output.
Each N.O. output is wired in series
with the each unit's limit circuit.

4
BSC Installation and Operation Manual
BSC OVERVIEW
Sequences up to 4 Fully Modulating Stages
The BSC is the perfect control whenever multiple fully modulating stages are required for heating or cooling applications. The BSC
controls the modulation of each stage to maintain precise set point control.
PID Type Logic
The BSC’s control algorithm allows it to look at the rate of change in the system. If the system temperature/pressure is changing
quickly, the BSC will react quickly to adjust the stages’ modulating output. If the system temperature/pressure changes slowly, the
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around the set point.
Controls 0-5V, 0-10V, 1-5V, 2-10V, 4-20 mA, or 0-135modulating motors
The BSC is designed to accurately control the output from 0 to 100% of modulation for each of these different types of motors. One
BSC can even control two different types of motors.
Process or Normal Applications
The BSC controls the stages based on the type of logic selected. It offers a Normal (PID) logic for slow responding systems. This
option is useful in heating applications where In addition, it offers a Process option for systems that requires fast response.
Digital Display of all System Settings
The BSC’s 80 character alphanumeric digital display names each system parameter in plain English and shows its precise value. The
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Automatic Rotation among Stages
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Manual, Last-On, or Automatic every selected time period from every hour to every 41 days.
Outdoor Reset Control
The BSC has a stand-alone hydronic outdoor temperature reset function (When Sensor Type is set to Reset °F or Reset °C.). This
allows it to change the target set point based on outdoor temperature changes.
Connects to Energy Management Systems
BSCs can accept a 4-20 mA input signal from an EMS to adjust the temperature set point remotely. In addition, an Energy
Management System (EMS) or other controller can disable the BSC when there is no output requirement.
Monitors Stage Status
The BSC is designed to accept Lockout inputs from each stage. If any stage is in Lockout, the BSC will automatically skip it when
adding more capacity. If a stage goes into Lockout during normal operation, the next stage will be activated immediately to maintain
the desired output capacity.
System Output is Active when Any Stage is Active
This output can be used to activate a system pump, combustion air damper, or perform any other function that is required when any
stage is active. A System Prove input checks the status of components activated by the System output before stages can be activated.
BACnet IP Remote Communication Upgrade Available
The BSC can be upgraded to include a BACnet IP remote communication package to monitor and control all BSC functions from a
remote location.

5
BSC Installation and Operation Manual
UNDERSTANDING OPERATION CONCEPT
The BSC 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
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In Outdoor Reset, the BSC controls a hot water heating system to provide a building with
comfortable and even heat levels. The BSC varies the temperature of the circulating heating
water in response to changes in the outdoor temperature. The heating water temperature is
controlled through the modulation of the stages.
The BSC also controls the system circulating pump with an adjustable Outdoor Cutoff. When
the outdoor temperature is above Outdoor Cutoff, the pump is off and no heating water is
circulated through the system. When the outdoor temperature drops below the Outdoor Cutoff,
the system pump relay is activated and the heating water circulates through the system. The
temperature of the heating water is controlled by the Reset Ratio, Water Offset, and the Outdoor
temperature.
RESET RATIO/OUTDOOR RESET
When a building is being heated, heat escapes through the walls, doors, and windows
to the colder outside air. The colder the outside temperature, the more heat escapes. If
you can input heat into the building at the same rate that it is lost out of the building,
then the building temperature will remain constant. The Reset Ratio is an adjustment
that lets you achieve this equilibrium between heat input and heat loss.
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temperature drops, the temperature of the heating water will increase one degree. The
starting point of the curves is adjustable, but comes factory selected at 70°F Outdoor
Temperature and 100°):DWHU7HPSHUDWXUH)RUH[DPSOHZLWKD2'6<6
ratio, if the outdoor temperature is 50°F, this means the temperature has fallen 20°from
the starting point of 70°F. Therefore, the heating water temperature will increase 20°to
120°F.
Each building has different heat loss characteristics. A very well insulated building will
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2 degrees to increase the water temperature 1 degree. On the other hand, a poorly
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temperature will increase 2 degrees. The BSC has a full range of Reset Ratios to match
any buildings heat loss characteristics.
A heating curve that relies not only on Outdoor temperature but also on type of radiation
will improve heat comfort. The following are suggested initial settings for different
types of radiation based on average building insulation and heat loss. The contractor
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Type of Radiation in Building Reset Ratio Offset
Radiators (Steel & Cast Iron) 1.00 (OD) : 1.00 (SYS) Û)
Baseboard (Finned copper tube& Cast Iron) 1.00 (OD) : 1.00 (SYS) Û)
Radiant (High Mass/Concrete) 4.00 (OD) : 1.00 (SYS) Û)
Radiant (Low Mass/Joists) 2.00 (OD) : 1.00 (SYS) Û)
Fan Coils & Air Handlers 1.00 (OD) : 1.00 (SYS) Û)
Outdoor Temperature
Water Temperature
70 405060
130
120
110
100
Outdoor Temperature
Water Temperature
70 405060
110
100
90
80
Outdoor Temperature
Water Temperature
70 405060
150
140
130
120
1:4
With a 0° Offset, the
ratio curves begin at
100° Water Temperature.
With a -20° Offset,the
ratio curves begin at
80° Water Temperature.
With a +20° Offset,the
ratio curves begin at
120° Water Temperature.
1:4
1:4 1:1
1:1
1:1
4:1
4:1
4:1
90
100
+20 Offset
-20 Offset
Outdoor Temperature (in °F)
70 60 50 40 20
30 0 -10
10 -20
100
120
110
130
140
150
160
180
170
190
200
210
220
1:3 1:2 1:1.5
1:1.25
1:1
1.25:1
1.5:1
2:1
3:1
4:1
Water Temperature (in °F)
Reset Ratio Curves
Reset Ratio is Presented as
Outdoor Temp. : Water Temp. Ratio
1:4
WARNING
When controlling a non condensing
boiler directly without the use of a
mixing valve, minimum boiler water
temperature must be set to boiler
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case, system temperature must not go
below such temperature.

6
BSC Installation and Operation Manual
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e act
i
vate
d
w
h
en an out
d
oor sensor
i
s connecte
d.
I
N
S
TALLI
N
G
T
H
E
S
EN
SOR

2
Q
O
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LO
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K
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L
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K
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E
X
LOGL
Q
J
 7
K
HVHQVRUV
K
RX
OG

n
ever be in direct sunli
g
ht
.
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HVXUHW
K
H
O
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L
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L
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G
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K
DXVWIDQVYHQWVRURW
K
HU
p
oss
ibl
e
h
eat sources
.

7KHVHQVRUVKRXOGEHPRXQWHGDSSUR[LPDWHO
\
IHHWDERYH
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
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N
QX
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
to hold the conduit and enclosure base to
g
ether. Screw the cover to the base
.

,
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O
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G
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sensor an
d
wa
ll
except from t
h
e
b
ottom
.

7KHVHQVRUZLUHVFDQEHH[WHQGHGXSWRXVLQ
J
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
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t
h
e contro
l
us
i
n
g
t
h
e BSC Out
d
oor Sensor term
i
na
l
mar
k
e
d
w
i
t
h
an “O”
(
A12
).

'
RQRWUXQVHQVRUZLUHVLQFRQGXLWZLWKOLQHYROWD
J
HZLULQ
J
A
L
ERT
Determinin
g
the proper location for the Outdoor Sensor is
v
ery important. The BSC will base the heat on the outdoo
r
t
emperature in
f
ormation it receives
f
rom this location. I
f
the
s
ensor
i
s
i
n t
h
e sun, or covere
d
w
i
t
h
i
ce,
i
ts rea
di
n
g
w
ill
b
e
d
ifferent from the actual Outdoor temperature (OD)
.
Mounting Holes
MADE IN U.S.A.
SAFETY
GROUND
MUST BE
CONNECTED
LINE
NEUTRAL
12
3
Earth
Ground
120VAC
LN
Outdoor
Sensor
snap-in
location
Shield
not connected
Conduit
Outdoor Label
on back of Sens
or
Outdoor Sensor
Mounting
screws
location
Seal around
sensor and wall
Outdoor
drip-hole
OUTDOOR
TEMP
A11
A12
T
SHIELD
OUTDOOR SENSOR

7
BSC Installation and Operation Manual
WIRING THE SYSTEM SENSOR
For proper operation, the BSC must be connected to a temperature or pressure sensor located in the common header.
SYSTEM TEMPERATURE
 7KH%6&LVGHVLJQHGWREHFRQQHFWHGWRD:HLO0F/DLQWHPSHUDWXUHVHQVRU
IRULQVHUWLRQLQD,'ZHOO
 /RFDWHWKHVHQVRULQWKHFRPPRQKHDGHUZKHUHLWZLOOUHJLVWHUWKHRXWSXWRIDOOWKH
stages before any takeoffs. If the sensor cannot read the output of all the stages, it will not be able to control the system properly.
 7KHVHQVRUZLUHVFDQEHH[WHQGHGXSWR¶E\VSOLFLQJZLWKFRQGXFWRUVKLHOGHGFDEOH%HOGHQRUHTXLYDOHQW
 'RQRWUXQVHQVRUZLUHLQFRQGXLWZLWKOLQHYROWDJH
 7HPSHUDWXUHVHQVRUVKDYHQRSRODULW\&RQQHFWWKHZLUHVIURPWKHVHQVRUWRWKH%6&WHUPLQDOVPDUNHGTEMP- A1, A2.
 &RQQHFWWKHVKLHOGWRWKHFLUFOHGWHUPLQDOTEMP-A2 with one of the sensor wires.
 &XWWKHVKLHOGZLUHDWWKHVHQVRUHQG
SYSTEM PRESSURE
 7KH%6&LVGHVLJQHGWREHFRQQHFWHGWRD36,SUHVVXUHWUDQVGXFHU
+RZHYHULWFDQEHXVHGZLWKDYDULHW\RIP$WUDQVGXFHUV
See Sensor Type selection on page 13.
 /RFDWHWKHVHQVRURQWKHPDLQVXSSO\KHDGHUZKHUHLWZLOOUHJLVWHUWKHRXWSXW
of all the stages. If the sensor can not read the output of all the stages, it will
not be able to control the stages properly.
 $WWDFKDóLVRODWLRQWXEHSLJWDLOWRWKHKHDGHU
 6FUHZWKHSUHVVXUHVHQVRUWRWKHSLJWDLO7KHVHQVRUKDVó137IHPDOHWKUHDGV
 3UHVVXUHVHQVRUZLUHVFDQEHH[WHQGHGXSWRE\VSOLFLQJZLWKJDXJHVKLHOGHGZLUH
 'RQRWUXQVHQVRUZLUHLQFRQGXLWZLWKOLQHYROWDJH
 35(6685(6(16256+$9(32/$5,7<&XWWKH*UHHQZLUH:KLWHZLUHDQGWKHFOHDUWXEH2QO\WKH5HGDQG%ODFNZLUHV
should be connected.
 &RQQHFWWKH5HGZLUHIURPWKHSUHVVXUHWUDQVGXFHUWRWHUPLQDO35(66$
 &RQQHFWWKH%ODFNZLUHIURPWKHSUHVVXUHWUDQVGXFHUWRWHUPLQDO35(66$6
WIRING AN EXTERNAL SET POINT (4-20MA INPUT)
 7KH%6&FDQXWLOL]HDQH[WHUQDOVHWSRLQWDVDP$VLJQDOIURPDQ(QHUJ\0DQDJHPHQW
System (EMS) or any other signal source.
 $V\VWHPVHQVRUPXVWEHLQVWDOOHGDVGHVFULEHGLQWKHSUHYLRXVVHFWLRQ
 7KH([WHUQDO6HW3RLQWPXVWEHVHWXSFRUUHFWO\6HH(06,QSXW0RGHDQG([WHUQDO6HW
Point in the Startup menu on page 13). These settings will allow the BSC to read the
4-20mA input signal and adjust the set point based on its external set point setting.
 7KH%6&FDQVRXUFHWKHFXUUHQWIRUWKHP$LQSXW,WSURYLGHVDQH[FLWDWLRQYROWDJHRI
9'&,IXVLQJWKH%6&WRVRXUFHWKHFXUUHQWDWWDFKWKHVLGHRIWKHP$LQSXWWRWKH
BSC EMS terminal marked +. Attach the (-) side of the 4-20mA signal to the EMS terminal
marked SIGNAL.
 ,IWKH(06VRXUFHVWKHFXUUHQWSURYLGHVWKHH[FLWDWLRQYROWDJHDWWDFKWKHVLGHRIWKH
4-20mA input to the BSC EMS terminal marked SIGNAL. Attach the (-) side of the 4-20mA
input to the EMS terminal marked SHIELD.
WIRING THE SHUTDOWN
 7KLVIHDWXUHFDQEHXVHGZKHQHYHULWLVGHVLUDEOHWRWXUQRIIWKH%6&IURPDUHPRWHORFDWLRQXVLQJDQRWKHUFRQWUROOHU
 $W\SLFDOXVHIRUWKLVIHDWXUHZRXOGEHWRWXUQRIIDOOERLOHUVWDJHVZKHQDQ(06SDQHOQRORQJHUUHTXLUHVKHDWLQWKHV\VWHP
 :KHQWKH6KXWGRZQIHDWXUHLVHQDEOHGE\FORVLQJDGU\FRQWDFWDOODFWLYHVWDJHVZLOOLPPHGLDWHO\PRGXODWHGRZQWRORZ7KH\ZLOO
remain in low for the Soft-Off period (See Soft-Off Delay on page 27) and then, turn off.
 ,IWKH6\VWHP2XWSXWUHOD\ZDVDFWLYHLWZLOOUHPDLQDFWLYHXQWLOWKH6\VWHP5XQ2Q'HOD\LV
over, then it will also turn off.
 7KH6KXWGRZQVLJQDOPXVWEHDGU\FRQWDFWRQO\1RYROWDJHFDQEHSODFHGDFURVVWKH
SHUTDOWN terminals.
 %ULQJWKHWZRZLUHVIURPWKHGU\FRQWDFWWRWKHWHUPLQDOVPDUNHGSHUTDOWN- A3,A4.
A1
A2
A3 SHUTDOWN
SYSTEM
TEMP
T
SHIELD
SYSTEM SENSOR
Current Modulation Outputs in series with
+
EMS Sourcing Current
EMS INPUT
EMS
Input
+SIGNALSHIELD (+)
(-)
EMS INPUT
BSC Sources Current
24VDC Excitation Voltage
EMS
Input
+SIGNALSHIELD (+)
(-)
A3
A4
A5
A6
A7
A8 NETWORK
PRESS
4-20mA
SHUTDOWN
S
+
BLACK
Transducer
4-20mA
RED
A1
A2
A3
A4 SHUTDOWN
SYSTEM
TEMP
TShutdown Sign
al
Dry Contact

8
BSC Installation and Operation Manual
WIRING THE SYSTEM PROVE
 7KH6\VWHP3URYHIHDWXUHLVSURYLGHGWRFKHFNWKHV\VWHPFRPSRQHQWRSHUDWLRQVWDWXV
 $W\SLFDOXVHRIWKLVIHDWXUHLVWRFKHFNIRUZDWHUÀRZEHIRUH¿ULQJDQ\ERLOHUVWDJHV:KHQ
there is a call for heat, the System Output relay activates the system pump. When the pump
HVWDEOLVKHVÀRZDÀRZVZLWFKFORVHVWKHSYSTEM PROVE input terminals. Only then, can the
BSC activate and modulate the boilers as required to hold the set point.
 ,IWKHSYSTEM PROVE input is open on a call, the BSC will enable only the System Output. All Stage outputs will be off when the
SYSTEM PROVE input is open.
 $IDFWRU\LQVWDOOHGMXPSHUSURYLGHVWKH6\VWHP3URYHVLJQDO'RQRWUHPRYHWKHMXPSHUXQOHVVLWZLOOEHUHSODFHGE\D3URYHVLJQDO
 7KH6\VWHP3URYHVLJQDOPXVWEHDGU\FRQWDFWRQO\1RYROWDJHFDQEHSODFHGDFURVVWKHSYSTEM PROVE terminals.
 %ULQJWKHWZRZLUHVIURPWKHGU\FRQWDFWWRWKHWHUPLQDOVPDUNHGSYSTEM PROVE - A9,A10.
WARNING
Do not remove the factory installed System Prove jumper unless it is replaced by a System Prove signal. If the
SYSTEM PROVE input is not closed/shorted, the BSC will NOT activate the stages.
The SYSTEM PROVELQSXWFDQQRWEHXVHGDVDVDIHW\OLPLW$OOHTXLSPHQWPXVWKDYHLWVRZQFHUWL¿HGOLPLWDQG
safety controls as required by code.
WIRING THE LOCKOUT INPUTS
 7KH%6&ZLOOQRWDFWLYDWHRUPRGXODWHDQ\6WDJHLQ/RFNRXW$FORVXUH
across the pair of LOCKOUT INPUT terminals informs the BSC that the boiler stages have
encountered a safety limit and cannot be restarted.
 7KH/RFNRXWVLJQDOLVQRWDVDIHW\IHDWXUH+RZHYHUXVHRIWKH/RFNRXWZLOOGUDVWLFDOO\
LPSURYHWKH%6&VVHWSRLQWFRQWUROSHUIRUPDQFHLQWKHHYHQWRIDVWDJHJRLQJLQWRORFNRXW
when encountering a safety limit.
 $SDLURILOCKOUT INPUT terminals is provided for each stage.
 7KH/RFNRXWVLJQDOPXVWEHDGU\FRQWDFWFORVXUHIURPWKHERLOHUEHLQJFRQWUROOHGE\WKDW
VWDJHVPRGXODWLQJRXWSXW1RYROWDJHFDQEHSODFHGDFURVVWKHWHUPLQDOV
 :LUHWKH/RFNRXWVLJQDOVWRWKHLUUHVSHFWLYHSTAGE terminals.
WARNING
The LOCKOUT INPUTS cannot be used as safety limits. All equipment must
KDYHLWVRZQFHUWL¿HGOLPLWDQGVDIHW\FRQWUROVDVUHTXLUHGE\FRGH
WIRING A SETBACK
 7RXVHWKH6HWEDFNWKH(06,QSXWPRGHPXVWEHVHWWR6HWEDFN6HHSDJH13.
 7KH6HWEDFNIHDWXUHFDQEHXVHGWRVZLWFKWKH%6&WRDORZHU6HW3RLQWZKHQOHVVORDGLVUHTXLUHGGXULQJWKH
night or on the weekends when a building is unoccupied, but a minimum level of heat is still required.
 7KH6HWEDFNIHDWXUHFDQQRWEHXVHGZLWK([WHUQDO6HW3RLQWP$(06LQSXWRU5HVHWRSHUDWLRQ
 7KH6HWEDFNVLJQDOLVZLUHGLQWRWKHEMS terminals (+) and (SIGNAL).
 7KH6HWEDFNVLJQDOPXVWEHDGU\FRQWDFWRQO\1RYROWDJHFDQEHSODFHGDFURVVWKHEMS (+) and SIGNAL terminals.
 :KHQWKHSetback terminals are shorted, the Setback is enabled and the BSC will hold the lower Set Point. The lower Set Point will
DSSHDURQWKHPDLQGLVSOD\LQGLFDWLQJWKLVFRQGLWLRQStb= 150F
 :KHQWKHVKRUWLVUHPRYHGWKH%6&ZLOOUHYHUWWRWKHKLJKHUVDYHG6HW3RLQW
ALERT
The Setback is not equivalent to the 4-20mA input, even though both wire into the
EMS terminals. The 4-20mA input requires 4-20mA source that changes the Set
Point in one degree increments. The Setback provides lower Set Point.
STAGE
A
STAGE
B
B1
B2
B3
B4
LOCKOUT
INPUTS
STAGE
C
STAGE
D
B5
B6
B7
B8
B Lockout Signal
Dry Contact
EMS INPUT
+SIGNAL
SHIELD
Dry Contact
Setback Signa
l
OUTDOOR
TEMP
SYSTEM
PROVE
A7
A8
A9
A10
A11
NETWORK
T
Prove Signal
Dry Contact

9
BSC Installation and Operation Manual
OUTPUT WIRING
WIRING THE SYSTEM OUTPUT
System Output Operation in Set Point Mode
 7KH 6\VWHPUHOD\ZLOOHQHUJL]HZKHQHYHUWKHUHLVDFDOOIRURXWSXWDQGWKH6KXWGRZQIHDWXUHLVQRWDFWLYH
 8QWLOWKHSYSTEM PROVE input is shorted no Stages will be activated. If a Prove is not required, the factory-
installed jumper should remain connected.
 7KH6\VWHPZLOOUHPDLQHQHUJL]HGZKLOHDQ\6WDJHLVDFWLYH
 :KHQWKHODVW6WDJHUHOD\WXUQVRIIDQGLIWKH2XWGRRU&XWRIIZDVVHWNORUWKHRXWGRRUVHQVRUZDVQRW
LQVWDOOHGWKH6\VWHPRXWSXWFDQUHPDLQHQHUJL]HGIRUWKHSHULRGVHWE\WKH6\VWHP5XQ2Q
 $W\SLFDOXVHRIWKH6\VWHPRXWSXWLVWRDFWLYDWHDV\VWHPSXPSVWDUWHU7KHSXPSFDQUXQZKHQHYHUWKHUHLVDFDOO
IRUKHDW+RZHYHUZKHQKHDWLVQRORQJHUUHTXLUHGWKHSXPSZLOOVWD\DFWLYHIRU5XQ2Q'HOD\WRUHPRYHWKH
residual heat from the boilers.
 )RUWKH6\VWHPRXWSXWWRIXQFWLRQDUHOD\PXVWEHLQVWDOOHG7KHUHOD\LVFDSDEOHRIVZLWFKLQJ$SLORWGXW\DW
9$&DSSUR[LPDWHO\ѿ+3
System Output Operation in Reset Mode
 7KH 6\VWHPRXWSXWUHOD\ZLOOHQHUJL]HZKHQHYHUWKHRXWGRRUWHPSHUDWXUHLVEHORZWKH2XWGRRU&XWRII
 7KH6\VWHPZLOOUHPDLQFRQVWDQWO\HQHUJL]HGZKLOHWKHRXWGRRUWHPSHUDWXUHLVEHORZWKH2XWGRRU&XWRII
 :KHQWKHRXWGRRUWHPSHUDWXUHULVHV)DERYHWKH2XWGRRU&XWRIIWKH6\VWHPRXWSXWZLOOUHPDLQHQHUJL]HGIRUWKH6\VWHP5XQ2Q
and then, turn off.
Wiring the System Output
 7KH6\VWHPRXWSXWKDVRQH1RUPDOO\2SHQ12GU\FRQWDFWUHOD\,WGRHVQRWVRXUFHDQ\SRZHU
 &ODVVYROWDJHZLULQJPXVWHQWHUWKHHQFORVXUHWKURXJKDGLIIHUHQWNQRFNRXWIURPDQ\&ODVVYROWDJHZLULQJ
 (DFK12FRQWDFWLVFDSDEOHRIVZLWFKLQJ$SLORWGXW\DW9$&DSSUR[LPDWHO\ѿ+3
WIRING THE STAGE OUTPUTS
 (DFKVWDJHKDVDQRSHUDWLQJOLPLWUHOD\RXWSXWLQDGGLWLRQWRWKHPRGXODWLRQRXWSXW7KH
operating limit output can be used when a boiler requires an activation signal through its limits.
+RZHYHUVRPHQHZHUERLOHUVXWLOL]HWKHPRGXODWLRQVLJQDOWRPDQDJHWKLVIXQFWLRQ,QWKLV
case operating limit outputs are not used.
Installing the Operating Limit Output Relays
 (DFKRSHUDWLQJOLPLWRXWSXWVWDJHAthrough D) that is to be used must have a relay installed in
the socket for the limit output to function.
 7RLQVWDOODUHOD\RULHQWWKHSLQVWRPDWFKWKHVRFNHWDQGWKHQSUHVVLWJHQWO\LQWRWKH
appropriate socket.
Wiring the Stage Outputs
 (DFK6WDJHRXWSXWAthrough D) has one Normally Open (N.O.) relay contact.
 7KH12FRQWDFWVDUHGU\FRQWDFWVRQO\7KH\GRQRWVRXUFHDQ\YROWDJH
 (DFK12FRQWDFWLVFDSDEOHRIVZLWFKLQJ$SLORWGXW\DW9$&
 :LUHWKH12UHOD\FRQWDFWVLQVHULHVZLWKWKHXQLW¶VOLPLWFLUFXLW
 &ODVVYROWDJHZLULQJPXVWHQWHUWKHHQFORVXUHWKURXJKDGLIIHUHQWNQRFNRXWIURPDQ\
Class 2 voltage wiring.
WIRING TO 135:MODULATING MOTORS
 7KH%6&FDQEHHTXLSSHGWRRSHUDWHXSWRIRXU:modulating motors (BSC
ordered with 135 Ohm Output boards.) See Modulating Output Cards on page 10.
 7HUPLQDOV&&&DQG&RQWKH%6&PXVWEHFRQQHFWHGWRWKHPRGXODWLRQ
decreasing terminals on the burners (Blue/Black modulating wires).
 7HUPLQDOV&&&DQG&RQWKH%6&PXVWEHFRQQHFWHGWRWKHPRGXODWLRQ
increasing on the burners (White modulating wires).
 7HUPLQDOV&&&DQG&RQWKH%6&PXVWEHFRQQHFWHGWRWKHPRGXODWLRQ
common terminals on the burners (Red modulating wires).
SYS
34
SYSTEM
Pump
L
N
ACDB
AOPERATING LIMIT
OUTPUTS
CDB
56789 1110 12
Limit Circuit
Typical for Each Stage
ABCD
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
BRW
135 Ohm
Motor
BRW
135 Ohm
Motor
BRW
135 Ohm
Motor
BRW
135 Ohm
Motor
135 Ohm Modulation Outputs

10
BSC Installation and Operation Manual
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Card. A and B are controlled b
y
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d
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Cards Operates two 135 Ohm modulatin
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C11
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-+
4-20mA
Motor
-+
4-20mA
Motor
-+
4-20mA
Motor
-+
4-20mA
Motor
mA
Common
mA
Common
mA
Common
mA
Common
4-20 mA Modulation Outputs
ABCD
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C11
C12
0-5 V or
0-10 V
Motor
V+
GND
V+
GND
V+
GND
V+
GND
Voltage Modulation Outputs
0-5 V or
0-10 V
Motor
0-5 V or
0-10 V
Motor
0-5 V or
0-10 V
Motor
Modulating Output Cards onBack of Control
Fuse
Battery
Softwa
re
Chip
Modulating
Output Cards
Motherboard
CPU
Board
BACnet or
Ethernet
Communication
Board
DO NOT USE
THIS RS485
Connect to
BACnet Cat-5
Cable
Connect to
RS485 on
Extension Panel
BACnet Communiation
Connection to Back of Control
Motherboard
CPU
Board
BACnet or
Ethernet
Communication
Board
Connect BACnet
Cat-5 cable to
RJ45 socket
BACnet Network
BACnet HUB
or Switch
Control
Stage
A & B
Control
Stage
C & D
S
AOPERATING LIMIT
OUTPUTS
CDB
456789 1110 12
A
C1
C2
C3
V+
GND
Voltage Modulation Outputs in series with Limits
0-5 V or
0-10 V
Motor
S
AOPERATING LIMIT
OUTPUTS
CDB
456789 1110 12
A
C1
C2
C
C
urrent Modulation Outputs in series with Limits
mA
Com
-
+
4-20mA
Motor

11
BSC Installation and Operation Manual
p
W
IRIN
G
T
H
E
B
SC
T
O
EX
TEN
S
I
ON
P
ANELS
PP
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J
HV
Each extension has 8 stages with lockout inputs. The BSC can manage the Extension panels using an RS485 connection
.

7
K
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L
RQ
L
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L
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O
RVXUH $
OO
n
ecessar
y
cables come with the extension panel
.

$
QDGGLWLRQDOFDEOHZLWK56ÀDWFRQQHFWRURQRQHHQGDQGDURXQGFRQQHFWRURQWKHRWKHUHQGLVXVHGWRFRQQHFWWKH56SOXJ
o
n t
h
e ma
i
n BSC
b
oar
d
to t
h
e enc
l
osure
.

3
ULRUWRVWDUWLQ
J
WKH%6&PDNHVXUHWKDWDOO([WHQVLRQSDQHOVDUHFRQQHFWHGZLUHGDQGSRZHUHG6RZKHQWKH%6&LVSRZHUHGLW
w
ill detect all available stages, including the stages on the Extensions
.

,
I([WHQV
L
RQSDQH
O
VZHUHFRQQHFWH
G
DIWHUW
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K
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E
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G
WR
G
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K
H([WHQV
L
RQVWDJHV

7KHFRQQHFWLRQIURPWKH%6&WRWKH([WHQVLRQVFDQEHHLWKHULQSDUDOOHORULQVHULHV6HHWKHIROORZLQ
J
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UDPVIRUGHWDLOV
WARNIN
G
D
O
N
O
T
use
t
h
e
R
S
4
85
co
nn
ecto
r
o
n
t
h
e
BA
C
n
et
co
mm
u
ni
cat
i
o
n
boa
r
d
to
c
onnect to the Extension. Rather, use the RS485 on the main PCB board
.

1RWHWKDW([WHQVLRQSDQHOVGRQRWFRPHZLWK0RGXODWLQJ2XWSXW&DUGV
7K
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G
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E
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K
DVH
G
VHSDUDWH
O\
BSC PANEL
Motherboard
CPU
BACnet or
Ethernet
Board
RS485 for
Remote
communication
only
Connect to
RS485
BSC PANEL
Motherboard
CPU
BACnet or
Ethernet
Board
EXTENSION PANEL 1
Interconnect Cables
Round-to-Round Flat Cable comes with Extension
and Connector plugs to
RS485 terminals on Back of
Panel PCB board.
(Do not use RS485 on BACnet board)
RS485 for
Remote
communication
only
DIFFERENT WAYS OF CONNECTING BSC TO TWO EXTENSION PANELS
Connect to
RS485
EXTENSION PANEL 2
Connect to
RS485
EXTENSION PANEL 1
Interconnect Cables
Round-to-Round
Connect to
RS485
EXTENSION PANEL 2
Connecting two Extension Panels in Series
Connecting two Extension Panels in Parallel

12
BSC Installation and Operation Manual
USING THE MENUS
MENU BASICS
 7KHPHQXVDUHLQ(QJOLVKDQGZLOOJXLGH\RXWKURXJKWKHVHWWLQJV
 7RFKDQJHDVHOHFWLRQURWDWHWKHEODFNNQREPDUNHGADJUST and PRESS TO SELECT
(ADJUST/SELECT).
 $SRLQWHULQIURQWRIDPHQXOLQHLQGLFDWHVWKDWLWLVWKHRQHFXUUHQWO\VHOHFWHG
 :KHQWKHSRLQWHULVRQWKHVDPHOLQHDVWKHLWHPWREHVHOHFWHGSUHVVWKHEODFN
ADJUST/SELECT knob. This will either save the selection, or bring up a new screen
to make further changes to that menu item.
 7KHBACK button will return you to the previous screen without saving any changes.
 7KHSTAGE button will bring the Stage menu to the display. See Stage Settings on
page 24.
 :KHQLQWKH6WDJH0HQXWKHPREV. button will scroll through the Stages in a
descending order. See Moving Around the Stages on page 24.
 :KHQLQWKH6WDJH0HQXWKHNEXT. button will always bring the display to the Mode
menu of the current stage. See Moving Around the Stages on page 24.
 7RFKDQJHDVHOHFWLRQURWDWHWKH$DJUST/SELECT knob. Rotating the knob will
cause both the old and new value will be displayed.
 7KHBACK button will return you to the previous screen without saving any changes.
 $IWHUFKDQJLQJDYDOXHSUHVVWKHADJUST/SELECT knob. This will save the
selection to memory and return you to the previous menu.
 7RYLHZWKH%6&VVWDUWXSVHWWLQJVVWDUWZLWKWKHGHIDXOWGLVSOD\DQGWKHQSUHVVDQG
hold press the ADJUST/SELECT knob for at least three seconds. While holding the ADJUST/SELECT knob down, pressing the
NEXT button will scroll the display through the different settings including the communication settings.
THE MAIN DISPLAY
 7KHPDLQGLVSOD\VFUHHQPD\KDYHGLIIHUHQWYDOXHVLQWKHWRSWZROLQHVGHSHQGLQJ
on the application. The OD represents the current Outdoor Sensor value. The SYS
represents the current System Sensor value.
 7KHVHFRQGOLQHRIWKHGLVSOD\ZLOOGLVSOD\DQ\PHVVDJHVWKDWLVSHUWLQHQWWRWKH
current operation.
 7KHWKLUGOLQHVKRZVWKHIRXUVWDJHV7KH/HDG6WDJHZLOOEHLQEUDFNHWV)RU
example, the Lead Stage shown is <A>.
 7KHODVWOLQHVKRZVWKHPRGXODWLRQVWDWXVRIHDFKVWDJH6HHSRVVLEOHVWDJH
modulation status below.
DISPLAY STAGE MODULATION STATUS
7KH%6&ERLOHUPRGXODWLRQVWDWXVJLYHVLPPHGLDWHDFFHVVWRHDFKERLOHUVWDWXV7KHIROORZLQJOLVWVKRZVDOOSRVVLEOHERLOHUVWDWXV
  7KHVWDJHLVRIIGXHWRQRFDOOIRUKHDWFRRO
  7KHVWDJHLVPRGXODWLQJDWWKHLQGLFDWHGSHUFHQWDJH
 21 6WDJH0RGHLVVHWWR21DQGERLOHULV¿ULQJDWERLOHULVLQE\SDVV6HH0RGHRQSDJH24.
 2)) 6WDJH0RGHLVVHWWR2))DQGERLOHUVWDJHLVXQDYDLODEOHRUERLOHUGRHVQRWH[LVW6HH0RGHRQSDJH24.
 P 6WDJH0RGHLVVHWWR0DQXDODQGVHWWRWKHSHUFHQWPRGXODWLRQ6HH0RGHRQSDJH24.
 &( 7KHVWDJHRQ([WHQVLRQSDQHOLV127FRPPXQLFDWLQJEDFNWRWKH%6&6HHFRQQHFWLQJH[WHQVLRQVRQSDJH11.
 /2 7KHVWDJH/RFNRXWLQSXWWHUPLQDOVDUHVKRUWHG6HH/RFNRXWRQSDJH8.
DISPLAY MESSAGES
The BSC normal display layout reserved the second line from the top for message indications. The following is a list of the most
FRPPRQ0HVVDJH'LVSOD\/LQHLQIRUPDWLRQ
 1HWZRUN3DQHO 7KHFRQWUROKDVDFRPPXQLFDWLRQSDFNDJHLQVWDOOHGDQGWKHGLVSOD\LVGLPPHG6FUHHQ6DYHU0RGH
 6KXWGRZQ$FWLYH 7KH6KXWGRZQ7HUPLQDOVDUH6KRUWHG1RVWDJHVZLOOEHDFWLYH6HH6KXWGRZQRQSDJHV7.
 6KXWGRZQE\(06 7KH(06LVEHORZP$RUDERYHP$6HH(06LQSXWDQG([WHUQDO6HW3RLQWSDJHV13.
 3XUJH'HOD\ 7KHFXUUHQWERLOHULVLQSXUJHF\FOHDQGWKHUHPDLQLQJSXUJHWLPHLQVHFRQGVLV6HH3XUJH'HOD\RQ
page 20.
 /DJ'HOD\ 7KHOHDGVWDJHLVDWDQGWKHUHPDLQLQJSXUJHWLPHWRVWDUWWKHODJERLOHULQVHFRQGVLV6HH
Lag Delay on page 20.
<B>
<C>
---
<A> This pointer shows the currently
selected item
BACK
The BACK button returns to a
previous menu without changing
the selection
PRESS TO
SELECT
ADJUST
Pressing
The ADJUST/SELECT knob
saves the selection to memory
and returns to a previous menu
PRESS TO
SELECT
ADJUST
Rotating
The ADJUST/SELECT knob
moves the pointer up and down
selections
PREV. STAGE HELP NEXT
PRESS TO
SELECT
BACK
ADJUST
OD=54F SYS=148F
-- NETWORK PANEL --
<A> B C D
100% 50% --- OFF

13
BSC Installation and Operation Manual
 +ROGLQJ8QWLOÛ) 7KH/HDGVWDJHLVLQ/DVW6WDJH+ROG7KLVH[DPSOHVKRZVWKDWWKHOHDGVWDJHZLOOWXUQRIIZKHQ
V\VWHPWHPSHUDWXUHUHDFKHVÛ)6HH/DVW6WDJH+ROGRQSDJH21.
 6\VWHP5XQ2Q 7KH6\VWHPUHOD\LV21IRUWKH6\VWHP5XQ2Q'HOD\7KLVH[DPSOHVKRZVWKDWLWZLOOUHPDLQLQ
6\VWHP5XQ2QIRUDQDGGLWLRQDOVHFRQGVEHIRUHWXUQLQJRII6HH6\VWHP5XQ2QRQSDJH21.
 :DLWLQJIRU3URYH 7KH6\VWHPUHOD\LV21DQGWKHSURYHWHUPLQDOVDUHRSHQEHIRUHWKHOHDGERLOHUUHOD\FDQHQHUJL]H6HH
Prove wiring on page 8.
 3URYH)DLOXUH $IWHUERLOHUVKDYHUXQIRUDZKLOH3URYHVLJQDOZDVRSHQHG$OOERLOHUUHOD\VZLOOGHHQHUJL]H
+RZHYHUWKH6\VWHPUHOD\ZLOOUHPDLQHQHUJL]HG6HH3URYHZLULQJRQSDJH8.
SYSTEM STARTUP
STARTUP SEQUENCE
 :KHQSRZHUHGWKH%6&SHUIRUPVDVHOIWHVWGLDJQRVWLFVRQLWVFRPSRQHQWV
 $IWHUWKHWHVWKDYHEHHQVXFFHVVIXOO\FRPSOHWHGWKH%6&ZLOOLQLWLDOL]HWKH%6&XVLQJDGHVFHQGLQJFRXQWHUVWDUWLQJIURP
 2QWKH¿UVWSRZHUXSWKH6\VWHP6WDUWXSPHQXVFUHHQVZLOODSSHDUDIWHUWKHLQLWLDOL]DWLRQLVFRPSOHWH,ILWGRHVQWWKH%6&KDV
DOUHDG\EHHQFRQ¿JXUHG7RFKHFNWKHFRQ¿JXUDWLRQRUWRPDNHFKDQJHVIROORZWKHSURFHGXUHRQWKH6\VWHP6WDUWXSPHQX
 7KH6\VWHP6WDUWXSPHQXGHWHUPLQHVWKHKRZ%6&VKRXOGFRQWUROWKHV\VWHP7KDWLVZK\\RXWKHXVHUPXVWJRWKURXJKVHYHUDO
warning screens to indicate the importance and severity of their changes.
 3UHVVWKHADJUST/SELECT knob once on each screen to accept its value and move to the next setting.
SENSOR TYPE
Set Point: (°F, °C), Pressure: (15psi, 30psi, 100psi, 200psi, 300psi), Reset: (°F, °C)
Default: Set Point °F
SELECT: MENU/<System Startup>/..../Sensor Type
 5HVHWPRGHUHTXLUHVDQRXWGRRUVHQVRUWREHFRQQHFWHGWRWHUPLQDOV$DQG$'2
NOT select Reset without an outdoor sensor.
 7KHVDPH:HLO0F/DLQWHPSHUDWXUHVHQVRUFDQGLVSOD\LQHLWKHU)RU&
 ,I)LVVHOHFWHGDOOWHPSHUDWXUHVDQGVHWWLQJVZLOOEHGLVSOD\HGLQGHJUHHV)DKUHQKHLW
and the BSC will operate as a Set Point Control in degrees Fahrenheit.
 ,I&LVVHOHFWHGDOOWHPSHUDWXUHVDQGVHWWLQJVZLOOEHGLVSOD\HGLQGHJUHHV&HOVLXVDQG
the BSC will operate as a Set Point Control in degrees Celsius.
--- SENSOR TYPE ---
F
C
15psi
30psi
100psi
200psi
300psi
Reset F
Reset C
 6HWSRLQWPRGHGRHVQRWUHTXLUHDQRXWGRRUVHQVRU,IDQRXWGRRUVHQVRULVFRQQHFWHGLQDQ\RIWKH7HPSHUDWXUHRU3UHVVXUH6HW
Point modes it will be used only as an outdoor cutoff measurement.
 7KH%6&ZLOORQO\PHDVXUHWKHRXWSXWWHUPLQDOVRIWKHV\VWHPVHQVRUVVHOHFWHGIURPWLVPHQX
EMS INPUT MODE
Setback, EMS Control Default: Setback
SELECT: MENU/<System Startup>/..../Sensor Type/EMS Input Mode
(Not Available In Reset Sensor Types)
- EMS INPUT MODE -
Setback
EMS Control
Setback
 ,WDOORZVWKH6HW3RLQWWREHDGMXVWHGPDQXDOO\
 ,IGHVLUHGDGU\FRQWDFWVZLWFKFDQEHZLUHGDFURVVWKHEMS INPUT terminals (SIGNAL and +) to allow the panel to hold a lower
Set Point when less load is required.
 :KHQVHOHFWLQJ6HWEDFNWKHUHLVQRUHTXLUHPHQWIRUDQ\ZLULQJDFURVVWKHEMS INPUT terminals. DO NOT select EMS-Control
unless your system meets the requirements below.
External Set Point (4-20mA EMS Input)
 )RUWKLVRSWLRQDQ(06V\VWHPPXVWSURYLGHDP$VLJQDOWRDXWRPDWLFDOO\FKDQJHWKH6HW3RLQWEDVHGRQSUHSURJUDPPHG
system parameters. See Wiring External Set Point on page 7.
 $QDFWLYHVLJQDOPXVWEHZLUHGLQWRWKH%6&EMS terminals. If the BSC does not receive a signal between 2mA and 22mA, it will
NOTDFWLYDWHDQ\VWDJHV7KHGLVSOD\ZLOOLQGLFDWHShutdown by EMSRQWKHGLVSOD\PHVVDJHOLQH

14
BSC Installation and Operation Manual
--MODULATING MODE--
Normal
Parallel
MENU SETTINGS
------ SETTINGS ------
Set Point 140 F
Gain +0
Lead Stage A
<System Settings>
<System Startup>
<Maintenance>
--- SENSOR TYPE ---
F
C
15psi
30psi
100psi
200psi
300psi
Reset F
Reset C
- EMS INPUT MODE -
Setback
EMS Control
EMS 4mA SETPOINT
140 F
[]
- SYSTEM STARTUP-
SELECT
To continue
SYSTEM STARTUP
- ARE YOU SURE? -
NO
YES
EMS 20mA SETPOINT
200 F
[]
-OUTPUT TYPE A&B-
Not Installed
135ohm
0-10v
0-5v
2-10v
1-5v
4-20ma
--OPERATING MODE--
Normal
Process
---- HEAT/COOL ----
Heat
Cool
-OUTPUT TYPE C&D-
Not Installed
135ohm
0-10v
0-5v
2-10v
1-5v
4-20ma
---- SET POINT ----
140 F
[]
---- RESET RATIO ----
1.00 OD=4.00 Sys
1.00 OD=3.00 Sys
1.00 OD=2.00 Sys
1.00 OD=1.50 Sys
1.00 OD=1.25 Sys
1.00 OD=1.00 Sys
1.25 OD=1.00 Sys
1.50 OD=1.00 Sys
2.00 OD=1.00 Sys
3.00 OD=1.00 Sys
4.00 OD=1.00 Sys
Reset
Set
Point
--------- GAIN ---------
0
[]
--- LEAD STAGE ---
A
B
C
D
-------- OFFSET -------
0
[]
- OUTDOOR CUTOFF -
60
[]
MINIMUM WATER TEMP
140 F
[]
Reset
Setback
EMS Control
SET POINT & RESET
-SENSOR FAULT MODE
Shutdown
All On
Normal
Process
Reset

15
BSC Installation and Operation Manual
------ SETTINGS ------
Set Point 140 F
Gain +0
Lead Stage A
<System Settings>
<System Startup>
<Maintenance>
MENU SETTINGS CONTINUED
SYSTEM SETTINGS 1
Auto Rotate Time
Purge Delay 1.0min
Lag Delay 0min
Standby Time 10min
System Run-On 0min
<More Settings>
LEAD AUTO ROTATE
Manual
Time
Last On
---- PURGE DELAY ----
1.0min
[]
---- LAG DELAY ----
0min
[]
---- STANDBY TIME ----
10min
[]
---- SYSTEM RUN-ON ---
0min
[]
------- SETBACK -------
0 F
[]
-AUTO ROTATE PERIOD-
0.0 Hr
[]
- LAST STAGE HOLD -
0 F
[]
SYSTEM SETTINGS 2
Setback 0 F
Rotate Time 0.0min
Last Stg Hold 0 F
Password
Set Time
SYSTEM SETTINGS1
SYSTEM SETTINGS2
MAINTENANCE
System Trim +0
Outdoor Trim +0
Output Trim +0.0
Soft-Off Dly 45sec
Mod Speed 0.1min
Network Settings
---- SYSTEM TRIM ----
+0
[]
--- STAGE A TRIM ---
+0.0
[]
---- OUTDOOR TRIM ----
+0
[]
-- SOFT-OFF DELAY --
45sec
[]
------ MOD SPEED -----
0.1min
[]
--NETWORK SETTINGS-
BACnet ID: 0
IP: ---.---.---.---
Msk: ---.---.---.---
Gwy: ---.---.---.---
BACNET SETTINGS
PASSWORD ENABLED?
NO
YES
CHANGE PASSWORD?
NO
YES
-- NEW PASSWORD --
ENTER NEW PASSWORD
****
-------- LOGIN --------
ENTER PASSWORD
M***
MAINTENANCE

16
BSC Installation and Operation Manual
4 & 20MA SET POINTS
4mA Adjustable from 70ºF/21ºC to 200ºF/93ºC Default: 140ºF/ 60ºC
20mA Adjustable from 90ºF/32ºC to 240ºF/116ºC Default: 200ºF/ 93ºC
SELECT: MENU/<System Startup>/..../Sensor Type/EMS Input Mode/EMS 4mA SP
(Available In EMS Control Only)
 7KLVDOORZVWKH%6&WRUHFHLYHDQH[WHUQDOVHWSRLQWIURPDQ(06%06V\VWHP
 <RXPXVWVHOHFWWKHVHWSRLQWVDWP$PLQDQGP$PD[
 7KHP$DQGP$FDQEHVHWWRDQ\WHPSHUDWXUHSUHVVXUH
 (LWKHURUP$FDQEHWKHERWWRPRUWRSRIWKH6HW3RLQWUDQJH
EMS 4mA SETPOINT
140 F
[]
EMS 20mA SETPOINT
200 F
[]
OUTPUT TYPE
1359999P$ 'HIDXOW9
SELECT: MENU/<System Startup>/..../Output Type A&B
 7KH%6&KDVWZR0RGXODWLQJ2XWSXW&DUGVRQHIRUHYHU\WZRVWDJHV
 7KH2XWSXW&DUGVFDQEHHLWKHU&DUGVIRURKPPRGXODWLQJPRWRUVRU
&XUUHQW9ROWDJH&DUGVIRUFXUUHQWRUYROWDJHVLJQDORSHUDWLQJPRWRUV(DFKFDUG
controls two boilers (A & B) or (C & D). The Output Cards normally come pre-
installed on the back of the control main board of the BSC. See Output Cards on
page 10+RZHYHULIDQH[WHQVLRQLVLQVWDOOHGIRUDGGLWLRQDOVWDJHVWKHLQVWDOOHUPXVW
purchase and install its Output Cards separately.
 %RWKRXWSXWFDUGVPXVWEHSURJUDPPHGIRUWKHDSSURSULDWHPRGHRIRSHUDWLRQ
 ,IQRRXWSXWFDUGLVLQVWDOOHGWKHNot InstalledRSWLRQZLOODXWRPDWLFDOO\EH
selected by the control.
2873876
 2XWSXW7\SHFDQQRWEHDGMXVWHG,WZLOODXWRPDWLFDOO\EHVHOHFWHGE\WKHFRQWURO
if the corresponding Output Card is installed.
-OUTPUT TYPE A&B-
Not Installed
135ohm
0-10v
0-5v
2-10v
1-5v
4-20ma
ALERT
Connect the extension panels,
if needed for additional stages,
prior to setting the Output Type.
As the BSC will only show the
output stages it can detect.
4-20MA, 0-5V, 0-10V, 1-5V, OR 2-10V OUTPUTS
 2XWSXWVFDQEHFRQ¿JXUHGWRP$RSHUDWLRQFXUUHQWRUWKHYROWDJHUDQJHFDQEHVHOHFWHG9999
 &KHFNWKHPRGXODWLQJPRWRUWRGHWHUPLQHLWVFRQWUROUHTXLUHPHQWV
 6HOHFWWKHDSSURSULDWH2XWSXW7\SHIRUVWDJHVA& B. The BSC will then automatically bring up the screen for stages C& D.
 ,IGLIIHUHQWW\SHVRIEXUQHUVDUHEHLQJXVHGVWDJHVC& Dcan be selected to have a different Output Type from stages A& B.
MODULATING MODE
Normal, Parallel Default: Normal
SELECT: MENU/<System Startup>/..../Output Type C&D/Modulating Mode
 6RPHPRGXODWLQJERLOHUVSHUIRUPEHWWHUDVWKHLUPRGXODWLRQLQFUHDVHV)RUWKHVH
units, it is advantageous to run one unit at high modulation than several units at lower
modulation. If the units used are of this type, select Normal. This is the recommended
setting for typical steel and cast iron boilers or boilers with low turndown ratios.
 7KHUHDUHPDQ\FRQGHQVLQJERLOHUVWKDWUXQPRUHHI¿FLHQWO\DWORZHUPRGXODWLRQ,ILW
LVPRUHHQHUJ\HI¿FLHQWWRUXQVHYHUDOXQLWVDWORZHUPRGXODWLRQWKDQRQHDWKLJKVHOHFW
Parallel. This is typically used on water-tube boilers, low mass boilers, or burners with
high turndown ratios.
-MODULATING MODE -
Normal
Parallel
OPERATING MODE
Normal, Process Default: Normal
SELECT: MENU/<System Startup>/..../Modulating Mode/Operating Mode
(Available with Normal Modulating Mode Only)
 0RVWKHDWLQJDSSOLFDWLRQVGRQRWH[SHULHQFHUDSLGFKDQJHVLQWKHV\VWHP)RUWKHVH
systems, it is best to adjust the modulation based on the rate of system rise or fall. This
PID type of algorithm will help prevent short cycling of the stages, reduce thermal
shock, and maintain an accurate system temperature/pressure. If your equipment is of
this type, select Normal.
 6\VWHPVWKDWUXQIRUSURFHVVPD\H[SHULHQFHODUJHFKDQJHVLQORDGDOPRVW
instantaneously. In Process mode, the BSC will react immediately to load changes.
Large load changes may cause stages to be short cycled, as the BSC can enable and
disable stages within seconds.
-OPERATING MODE -
Normal
Process

17
BSC Installation and Operation Manual
HEAT/COOL MODE
Heat, Cool Default: Heat
SELECT: MENU/<System Startup>/..../Modulating Mode/Operating Mode/Heat-Cool
 7KH%6&RIIHUVWZRPRGHV+HDWLQJDQG&RROLQJ,Q+HDWLQJWKH%6&ZLOOPRGXODWH
stages when the system is below the set point. In addition, the system relay will
HQHUJL]HZKHQWKHRXWGRRUWHPSHUDWXUHLVDWRUEHORZWKH2XWGRRU&XWRIIVHWWLQJ
---- HEAT/COOL ----
Heat
Cool
 ,Q&RROLQJWKH%6&ZLOOPRGXODWHVWDJHVZKHQWKHV\VWHPLVDERYHWKHVHWSRLQW,Q
DGGLWLRQWKHV\VWHPUHOD\ZLOOHQHUJL]HZKHQWKHRXWGRRUWHPSHUDWXUHLVDWRUDERYHWKH
Outdoor Cutoff setting.
SENSOR FAULT
Shutdown, All On Default: All On
SELECT: MENU/<System Startup>/..../Sensor Fault Mode
The Sensor Fault will determine the operating status of all output stages that are set to
Auto when a sensor reads Short or Open.
-SENSOR FAULT MODE
Shutdown
All On
RESET MODE
 :KHQ$OO2QLVVHOHFWHGWKH%6&ZLOOWXUQDOOVWDJHV2QWRDZKHQWKH6\VWHPRU2XWGRRUUHDGVShort or Open and the
Outdoor is below Outdoor Cutoff.
 :KHQ6KXWGRZQLVVHOHFWHGWKH%6&ZLOOWXUQDOOVWDJHV2IIZKHQHLWKHU6\VWHPRU2XWGRRUVHQVRUUHDGVShort or Open.
SET POINT MODE
 :KHQ$OO2QLVVHOHFWHGWKH%6&ZLOOWXUQDOOVWDJHV2QWRDZKHQWKH6\VWHPVHQVRUUHDGVShort or Open.
 :KHQ6KXWGRZQLVVHOHFWHGWKH%6&ZLOOWXUQDOOVWDJHV2IIZKHQWKH6\VWHPVHQVRUUHDGVShort or Open.
 7KH2XWGRRU6HQVRU6KRUWRU2SHQVWDWXVZLOOQRWDIIHFWWKHFRQWURORSHUDWLRQLQ6HW3RLQWPRGH
OPERATING SETTINGS
SET POINT
See Set Points and Defaults Table on page 22.
SELECT: MENU/<System Settings>/..../Sensor Type
 7KH6HWSRLQWLVWKHWHPSHUDWXUHSUHVVXUHWKH%6&ZLOOXVHWRFRQWUROWKHV\VWHP
 7KH%6&ZLOODGGVXEWUDFWPRGXODWHRUKROGWKHVWDJHVWRPDLQWDLQWKHV\VWHP
temperature/pressure around the Set point.
---- SET POINT ----
140 F
[]
 7KHV\VWHPLVH[SHFWHGWRÀXFWXDWHDURXQGWKHVHWSRLQW7KHDPRXQWRIÀXFWXDWLRQGHSHQGVRQWKH6\VWHPDQG6WDJH6HWWLQJV
 ,IDQ2XWGRRU6HQVRUZDVFRQQHFWHGSUHVVLQJWKHADJUST/SELECT button will continue to the Outdoor Cutoff setting option.
 ,IWKH(060RGHZDV(QDEOHGVHHSDJH13), the Set Point will be set by the EMS/BMS system and will be available as a read only.
 7KHUDQJHRI6HW3RLQWLQWKH(06LVVHWLQWKH6WDUWXSPHQXDWP$DQGP$6HH(066HW3RLQWRQSDJH1.
 $Q\UHDGLQJEHORZWKHP$RUDERYHP$ZLOOLQGLFDWHDShutdown by EMSPHVVDJHRQWKH0HVVDJH/LQH
 7KH6HW3RLQWZLOOYDU\OLQHDUO\ZLWKWKHP$VLJQDOIURPWKH(06VLJQDO
OUTDOOR CUTOFF TEMPERATURE
Adjustable Off, from 20ºF/-7ºC to 100ºF/38ºC, On Default: 60ºF/16ºC
SELECT: MENU/Set Point/Outdoor Cutoff in Set Point
SELECT: MENU/Set Point/Offset/Outdoor Cutoff in Reset
 ,Q2XWGRRU5HVHWPRGH2XWGRRU&XWRIIZLOODOZD\VH[LVW+RZHYHULQ6HW3RLQW
mode, if the outdoor sensor is installed, the Outdoor Cutoff screen will automatically
appear after the temperature Set Point has been selected.
- OUTDOOR CUTOFF -
60
[]
 ,QKHDWLQJZKHQWKHRXWGRRUWHPSHUDWXUHIDOOVWRWKHDGMXVWDEOH2XWGRRU&XWRIIWHPSHUDWXUHWKH%6&ZLOOFRQWUROWKHVWDJHVWRKROG
the calculated temperature/pressure.
 :KHQWKHRXWGRRUWHPSHUDWXUHULVHVWRWKH2XWGRRU&XWRIISOXVD)GLIIHUHQWLDOWKH%6&ZLOOPRGXODWHWKHDOOVWDJHVGRZQ7KHQ
UXQWKH6RIW2IIGHOD\ZKLOHEOLQNLQJWKHVWDJHVPRGXODWLRQVWDWXVWKHQWXUQWKHPRII7KH6\VWHPUHOD\ZLOOUHPDLQHQHUJL]HGIRU
WKH5XQ2QGHOD\DQGWKHQGHHQHUJL]H
 ,QFRROLQJZKHQWKHRXWGRRUWHPSHUDWXUHULVHVWRWKHDGMXVWDEOH2XWGRRU&XWRIIWHPSHUDWXUHWKH%6&ZLOOFRQWUROWKHVWDJHVWRKROG
the calculated temperature/pressure.

18
BSC Installation and Operation Manual
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temperature and the stages will modulate to hold the target set point.
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RESET RATIO
(1.00ºOD : 4.00ºSys) to 12 (4.00ºOD : 1.00ºSys) Default: 1(1.00ºOD : 1.00ºSys)
SELECT: MENU/Set Point/Reset Ratio In Outdoor Reset Only
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outdoor temperature. With any of the ratios, the colder it becomes outside, the hotter
the temperature of the system water.
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rapidly as the outside temperature falls, hitting 240°F at 35°F outside temperature.
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as the outside temperature falls. Even at -30°F, the system water will only be 125°F,
and at 22°F outside, the system water will be 112°F. Such a low Reset Ratio might be
XVHGZLWKUDGLDQWÀRRUKHDWLQJDSSOLFDWLRQV
---- RESET RATIO ----
1.00 OD=4.00 Sys
1.00 OD=3.00 Sys
1.00 OD=2.00 Sys
1.00 OD=1.50 Sys
1.00 OD=1.25 Sys
1.00 OD=1.00 Sys
1.25 OD=1.00 Sys
1.50 OD=1.00 Sys
2.00 OD=1.00 Sys
3.00 OD=1.00 Sys
4.00 OD=1.00 Sys
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ratio, for every degree the outside temperature falls, the system water temperature is increased one degree.
 ,IUHTXLUHG Adjust the RESET RATIO in cold weather. If the ambient building temperature are cold in cold weather, move the
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 $IWHUVHOHFWLQJWKH5HVHW5DWLRSUHVVLQJWKHADJUST/SELECT button will switch to the Offset setting option.
OFFSET
Adjustable from +40Fº/+22Cºto (-40Fº/-22Cº) Default: 0Fº/0Cº
SELECT: MENU/Set Point/Offset in Outdoor Reset only
(Available with Reset Modes Only)
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of the Outdoor temperature, or the Reset Ratio that has been selected, when the Offset
setting is changed, that change is directly added to or subtracted from the calculated
temperature. For example, if the Set Point temperature was 130°F and the Offset was
changed from 0° to 10° (an increase of 10°), the Set Point would increase to 140°F.
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degree for every 1.5 degree change in the Outdoor temperature. What the Offset does
is add or subtract a constant temperature value.
 ,IUHTXLUHGAdjust the Water Offset in mild weather. If the ambient building
temperatures are too warm in the mild weather, decrease the Offset. If the ambient
building temperatures are too cold in the mild weather, increase the Offset. The rule
of thumb for baseboard radiation is to change the Offset 4°F for every 1°F you wish to
change the building temperatures. In radiant heat applications, change the Offset 1°F
or 2°F for every 1°F you wish to change the building temperature.
-------- OFFSET -------
0
[]
Outdoor Temperature (in °F)
70 60 50 40 2030 0 -1010
-20
120
140
130
150
160
170
180
100
110
Water Temperature (in °F)
Target Offset
Offset=10°F
Reset Ratio=1.5 : 1.0
Reset Ratio
Max Target
Min Target
Reset Ratio + 10F Offset
Min Target=120°F
Max Target=170
°F
MINIMUM WATER TEMPERATURE
Adjustable from 70ºF/21ºC to 180ºF/82ºC Default: 140ºF/60ºC
SELECT: MENU/Set Point/Reset Ratio/Offset/Outdoor Cutoff/Min Wtr Temp
(Available with Reset Modes Only)
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VSHFL¿FDWLRQ7KH%6&ZLOOFDOFXODWHWKH6HW3RLQWEDVHGRQWKH2XWGRRUWHPSHUDWXUH
the Reset Ratio, and the Offset value. The BSC will control all boilers to hold either
the Set Point temperature, or the Minimum Target, whichever is higher.
MINIMUM WATER TEMP
140 F
[]

19
BSC Installation and Operation Manual
GAIN/THROTTLE
Adjustable from -10 to +10 Default: 0 in Normal Operating Mode
Adjustable from 1.0 to 10.0 Default: 5 in Process Operating Mode
SELECT: MENU/Gain
NORMAL OPERATING MODE
 ,Q1RUPDO2SHUDWLQJ0RGH6HHSDJH1), the Gain adjusts the aggressiveness of
the BSC PID logic to control how much modulation is changed when the system
temperature/pressure is different from the Set Point. It is based on he rate of change.
--------- GAIN ---------
0
[]
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(for example, from 0 to -2). Wait for at least 15 minutes before evaluating how the change has affected the system.
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above the Set Point), increase the Gain by two numbers (for example, from 0 to 2). Wait for at least 15 minutes before evaluating
how the change has affected the system.
PROCESS OPERATING MODE
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modulation in one percent increments based on the Set Point and Gain value.
PROCESS GAIN/THROTTLING RANGE TABLE
System Temperature Stages Modulation
More than 1 x Gain above Set Point Lead Stage is OFF
1 x Gain above Set Point Lead Stage at 1%
0.5 x Gain above Set Point Lead Stage at 50%
At Set Point Lead Stage at 100%
0.5 x Gain below Set Point Lead Stage at 100%, 1 Lag at 50%
1 x Gain below Set Point Lead Stage at 100%, 1 Lag at 100%
2 x Gain below Set Point Lead Stage at 100%, 2 Lag at 100%
3 x Gain below Set Point All Stages at 100%
LEAD STAGE
Adjustable from A through D Default: A
SELECT: MENU/Lead Stage
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 7KH/HDG6WDJHFDQEHURWDWHGPDQXDOO\RUDXWRPDWLFDOO\7KHDXWRPDWLFURWDWLRQLV
recommended.
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available when manually selecting a new Lead Stage.
--- LEAD STAGE ---
A
B
C
D
140 F
<A> B C D
50% OFF OFF STB
LEAD AUTO ROTATE
Manual, Time, Last-On Default: Time
SELECT: MENU/System Settings/Auto Rotate
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 $XWRPDWLFDOO\URWDWLQJWKH/HDGDPRQJWKHDFWLYHVWDJHVSURPRWHVPRUHHYHQZHDURQ
the Stages and can help prolong the life of each unit.
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LEAD AUTO ROTATE
Manual
Time
Last On

20
BSC Installation and Operation Manual
MANUAL
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TIME
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WKH¿UVWURWDWLRQZLOOWDNHHIIHFWDIWHUKRXUVLIWKH7LPHZDVQRWVHW+RZHYHULIWKH7LPHZDVVHWWKHURWDWLRQZLOODOZD\VWDNH
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VWDJHVZHUHDGGHGLQWKHVHTXHQFH$%DQG&WKHQWKH\ZLOOEHWXUQHGRIILQWKHVHTXHQFH&%DQG¿QDOO\$
Note: If you do not set the system time, the BSC will assume it was installed at 2 PM.
LAST ON
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PURGE DELAY
Adjustable from 0.0 to 10.0 minutes Default: 1.0
SELECT: MENU/System Settings/Purge Delay
(Not Available in Process)
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line and can begin generating heat.
---- PURGE DELAY ----
1.0min
[]
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to fully come on line and to begin producing output. Once the Purge Delay is over, the BSC can begin adjusting its modulation.
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Purge Delay period.
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LAG DELAY
Adjustable from 0 to 60 minutes Default: 0.0min
SELECT: MENU/System Settings/Lag Delay
(Not Available in Process)
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the load.
---- LAG DELAY ----
0min
[]
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activated. For example, if the Lag Delay was set to 10 minutes, the Lead Stage would need to remain at 100% modulation for a full
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conditions become extreme.
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regardless of Modulation Start % setting, the lead stage must reach 100% and stay there before the lag Stage can be activated.
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to 0 min if you want smooth set point control of multiple units.
STANDBY TIME
Adjustable from 0 to 60 minutes Default: 10 minutes
SELECT: MENU/System Settings/Standby Time
(Not Available in Process)
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100% modulation for the full Standby Time.
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never be a Lead Stage
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temperature/pressure. Therefore, shorter Standby Times will result in smoother set
point operation in extreme conditions. Longer Standby times may prevent a Standby
boiler from starting if the other boilers can eventually meet the load or if the load
decreases.
---- STANDBY TIME ----
10min
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