Lochinvar 1.0- 1.3- 1.5 Boiler User Manual
Contents
1. 4 Typical Boiler System Wiring 12 13 Internal Faults 4 5 UNIT OPERATION Modbus Function Set 5 Unit Operation with Modbus Communications 14 17 Modbus Exception 6 6 TROUBLESHOOTING 18 19 7 DIAGRAMS Ladder Diagram Part 1 amp 2 20 21 Wiring oV 22 Revision Notes Back Cover 1 Introduction The information contained in this manual provides general guidelines for the implementation of Modbus communication with the Lochinvar SYNC boiler All Modbus networks are implemented utilizing a master slave arrangement where all SYNC boilers are slaves and the master is a building automation system capable of communicating over a RS 485 serial connection Definitions Abbreviation or Acronym Baud Baud Rate Number of data bits transmitted per second bps Hex Hexadecimal Number 0 9 A F I O Box Input Output I O LSB Least Significant Byte Modbus A serial half duplex data transmission protocol developed by AEG Modicon MSB Most Significant Byte RS232 A standard for serial full duplex FDX transmission of data based on the RS232 Standard RS485 A sta2. Modbus Instructions D Unit Operation Unit Operation with Modbus Communications control a SYNC boiler through a Building Management System communicating through Modbus the SYNC Demand Configuration must be set to a value of 4 5 or 6 These configurations allow different control points for a variety of applications The configuration can be set by selecting Main Setup Service Setup Demand Config Figure 5 1 Setup Screen The SYNC boiler is equipped with a Modbus communication timer This timer is programmable from 0 120 seconds The timer can be programmed from the Modbus Setup Menu by selecting Main gt gt Setup gt gt BMS gt gt Modbus Timeout The purpose of the timer is to ensure proper temperature data is communicated to the boiler in a timely manner Additionally it will provide for fail safe operation should Modbus communication be lost This timer will cause the unit to revert back to internal unit controls should the Modbus communication be interrupted longer than the Modbus timer The timer is reset every time a Modbus write command is received with updated temperatures or commands It is the recommendation of Lochinvar that this timer be set to the shortest value possible When controlling a SYNC boiler through a Building Automation System BAS it is very important to ensure that the correct configuration bits are sent to holding register 40001 and that the correct data and enable signals are sent to
3. 271 277 S Z S Z s 5 E o amio mn Wok OSE ae E lt m O Q ea CU A ben D Gg SS a wa aD D D 2 lt q lt m ac O zz un m u cc lt ra _ E LLO ac m NI 2 a mU E g cc gt gt C Zos zuo Zn e O lt a lt E e en I SE lt O O i Q x a oe s Wx lt x en zu I uu lt gt 3 lt SYNC Modbus Instructions 4 Wiring Requirements Figure 4 2 Control Inputs SECONDARY LOW VOLTAGE SMART TOUCH SEED g CONTROL MODULE PRIMARY SMART TOUCH CONTROL MODULE SEQUENCER BUILDING MANAGEMENT SYSTEM OUTDOOR SENSOR 2 z HW TANK SENSOR HEAT EXCHANGER 1 HEAT EXCHANGER 2 INLET SYSTEM SENSOR TEMPERATURE SENSOR ii eA HEAT EXCHANGER 1 FLOW SWITCH HEAT EXCHANGER 2 OUTLET TEMPERATURE SENSOR BLOCKED DRAIN SWITCH A HW THERMOSTAT HEAT EXCHANGER 1 Du 2 HEAT EXCHANGER 2 FLUE GAS SENSOR H lt ROOM THERMOSTAT LOW WATER CUTOFF D ZONE CONTROL TOUCH PANEL GAS PRESSURE SWITCH TOUCH DISPLAY INTERFACE IN HEAT EXCHANGER 1 HEAT EXCHANGER 2 HIGH LIMIT SENSOR y 1 FLAME SENSOR MODBUS COMMUNICATION PC INTERFACE Bd 10 Modbus
4. SYNC ING BOILER For Example Send a setpoint of 110 F The formula to use for the interpolation is Rate Command Desired Setpoint BMS Temp at Low Analog Input High Voltage Low Voltage Low Voltage BMS Temp at High Analog Input BMS Temp at Low Analog Input From the default values Desired Setpoint 110 BMS Temp at Low Analog Input 68 BMS Temp at High Analog 158 High Voltage 10 Low Voltage 2 110 69 8 10 2 179 6 69 8 2 4 92 Volts 4 92 10 x 100 49 2 49 31 Hexadecimal A value of 00 31 in hexadecimal would be written to Holding register 40003 to issue a command for a 110 F setpoint Temperature The SYNC boiler passes temperature data in degrees Celsius Also to accommodate decimal places the decimal value must be divided by 10 Here are the conversions to and from Celsius 5 9 Te 32 Te 9 5 32 Example Outdoor temperature from remote sensor on BAS System 80 F 80 F 26 7 C Data that needs to be transmitted is 26 7 10 267 267 HEX 10B Binary Outlet temperature from unit sensor 155 F 55 F 68 3 C Data transmitted from unit in HEX 2AB 683 683 10 68 3 C Decimal Binary 683 1010101011 HEX 2AB 6 Troubleshooting Should you encounter problems communicating over Modbus the following items should be checked in this order Physical Layer Communications Configuration and Port Settings Modbus Error C
5. 24 um SvNG Modbus Instructions CONDENSING BOILER 7 Diagrams Figure 7 3 Wiring Diagram LOW VOLTAGE 120 VAC DISCONNECT POWER emm HIGH VOLTAGE BEFORE SERVICING CM 1 PC INTERFACE BOX DEPICTS OPTIONAL ITEMS CONTROL LOUVER JUNCTION MODULE 1 CONTACTS RELAY LOUVER 00 1 et D se DG Ed 2 INTERFACE SHIELD 4 CASCADE RS485 SSS E 0 2 SHIELD T bi PUMP TANK lt I HW PUMP SENSOR RELAY L OUTDOOR SENSOR b I GND 120V SUPPLY I H SYSTEM SENSOR 9 emi TERNAL aut ee FIRM SHIELD LOUVER RELAY 1 MOD BUS RS485 SHIELD BK PK NE BH TANK THERMOSTAT MODULE 2 FLOW SWITCH MODULE 1 FLOW SWITCH OR B LOUVER PROVING RUNTIME CONTACTS ALARM CONTACTS I td LT T T T T FLAME ROD IAL Q BLOCKED DRAIN SW HIGH VOLTAGE SPARK LEAD Hi POT L IT l x x CONTROL MODULE 2 O lt LOW GAS PRESSURE SWITCH HIGH GAS PRESSURE 1 HIGH GAS PRESSURE 2 LOUVER RELAY 2 LOW WATER CUTOFF BOARD BK d
6. BOX CONNECTION BOARD CONNECTION BOARD LOUVER PROVING CN1 5 CN1 6 CN1 3 CN1 11 CN1 15 CONTACTS RUN TIME CN1 10 CN1 7 ALARM CONTACTS TEST SWITCH L _ PROBE NEUTRAL GROUND TERMINAL STRIP 62 120V SUPPLY lt HIGH VOLTAGE 2 JUNCTION BOX Tm SYSTEM PUMP E x CONTACTS TT 5 er 49r uer 1 PUMP BOILER PUMP 5 contacts BOILER HEX2 PUMP BOILER PUMP CONTACTS pup f y JUNCTION PHW PUN 19 6L 34 FIELD SUPPLIED EE 7 5 LOUVER La A E CONTACTS BOILER PUMP gt lal er LST Ed 3 6 PUMP CONTACTS Bs SUPPLIED LWCO DHW Puye LOW GAS HIGH GAS CONTROL PRESSURE PRESSURE MODULE 1 SWITCH SWITCH 1 X6 5 CONTROL HIGH GAS MODULE 2 PRESSURE SWITCH 2 AS CONTROL MODULE 1 CONTROL MODULE 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes AWARNING DISCONNECT POWER piacram BEFORE SERVICING 18120046 REV D Modbus Instructions
7. 5 T 00005 Tank Thermostat o Discrete Inputs 10001 Manu ResetHignlimti o peono 0 i t 1002 Flow Switch o 0o 1 10003 Gas Pressure Switch i o onoo o 1 t 10004 Louver Proving Swich o onoo 0 1 t 10005 Air Pressure Switch FlapVave 1 o onoo o 1 t 10006 Blocked Drain Switch 0 onoo o 1 t 10007 Auto Reset High im o onoo o 1 t 08 Feme 9 fFoNroeoF 0o 1 10009 Enable Room Thermostat 17 Stage O T ONTO OFF o 1 t 1000 Tank Thermostat o LLL T0017 Manual Reset Hih imiz o 3008 FowSwkh2 o ooo oa 10019 Gas Pressure o onoo o o t 10020 lowerPrwngSwich2 o onoo o 1 t 10021 Air Pressure Switch FlapVave2 o onoo o 1 1 Blocked Drain Switch 2 rowroor 0 1 1023 Fam2 0 FON 6oF 0o t LC 10033 Runtime Contacts 1 t 10034 0 1 035 CHPum o o 1 t 1036 DHWPumpi o t 038 o 1 10039 SytemPum o
8. Instructions 4 Wiring Requirements continued Figure 4 3 Control Outputs SECONDARY SMART TOUCH CONNECTION CONTROL MODULE PRIMARY SMART TOUCH CONTROL MODULE ALARM BELL RUN TIME CONTACTS HEAT EXCHANGER 1 HEAT EXCHANGER 2 BOILER PUMP SEQUENCER BUILDING SYSTEM PUMP MANAGEMENT SYSTEM TOUCH PANEL HW PUMP TOUCH DISPLAY INTERFACE p IGNITOR PC INTERFACE GAS VALVE 11 Modbus Instructions 4 Wiring Requirements Figure 4 4 Control Location CONTROLLER 2 CONTROLLER 1 MODBUS COMMUNICATION BOARD MTR01 HEAT EXCHANGER 1 HEAT EXCHANGER 2 Typical Boiler System Wiring Physical Configuration Cascade without Individual Monitoring Modbus RS485 Port on Gateway or Building System Modbus RS485 Communication Bus d a 7a a a a of unuuguuuuuuu nnuuguuuuuuu5 nguuuuuunu Cascade Daisy Chain Connection I Modbus Instructions 4 Wiring Requirements continued Physical Configuration Cascade with individual Monitoring Modbus RS485 Port on Gateway or Building System Modbus RS485 Communication Bus lt T gt gt a a a a s a innuaguuuuuus innuguuuuuuu nguauuuuuu Cascade Daisy Chain Connection Physical Configuration Direct Control Modbus RS485 Port on Gateway or Building System Modbus RS485 Communication Bus 13
9. Temperature 2 1 S Degrees Celsius 20 130 01 30020 Flue Temperature 2 O DegreesCelsius 20 130 01 30021 Firing Rate2 0 0 10 1 LLL j C LL LLL LLL LLL 30023 Boiler2StatusCode 0 NA 0 05535 1 _ 30024 Boiler2BlockingCode _ n NA 0 j6553 1 30025 Boiler2LockoutCode 0 NA 0 j6555 1 Holding Registers p s w _ 0 10 Volt Input Rate Command KP Eko 0 to ft 40004 Tank Setpoint O Degrees Celsius 0 875 05 40005 Tank Temperature O DegreesCelsius 20 130 01 40006 Outdoor Temperature O jBDegreesCelsius 40 60 0 31 40007 System Supply Temperature 0 Degrees Celsius 20 130 Configuration Bits Address 40001 contains configuration bits sent from the BAS to the boiler These bits tell the boiler to use its own internal inputs or inputs from the BAS When a bit is set to 1 the boiler will ignore the corresponding value contained internally and expect the BAS to write that value into the Holding Registers The configuration bits are as follows Bit 0 LSB Boiler Enable Bit 4 System Supply Temperature Bit 1 Tank Thermostat Bit 5 Outdoor Temperature Bit2 Rate Command 10 10V Input Setpoint Command Bit 6 Tank Temperature Bit 3 Tank Setpoint Bit 7 System Return Temperature Bit 8 15 Not Used De
10. UNPLUG THREE 3 WIRE HARNESSES Modbus Instructions CONDENSING BOILER 1 Turn OFF the main electrical power to the appliance Turn OFF the main manual gas shutoff to the appliance 3 Unplug the three 3 wire harnesses on the MTRO1 control board see FIG 6 1 4 Unscrew the four 4 mounting nuts on the MTRO1 control board and set aside Remove the MTRO1 control board see FIG 6 2 Replace install the new MTRO1 control board Replace the four 4 mounting nuts removed in Step 4 Reconnect all three 3 wire harnesses unplugged in Step 3 D iX x Turn on the main electrical power and the main manual gas shutoff to the appliance 9 Configure the MTR01 control board and unit controls per this manual and resume operation Figure 6 2 Control Panel w MTRO1 Control Board UNSCREW THE FOUR 4 MOUNTING NUTS ON THE MODBUS CONTROL BOARD 1 AND SET ASIDE TO SECURE THE NEW MTRO1 CONTROL BOARD gt TO THE CONTROL PANEL EN 49 EH Modbus Instructions CONDENSING BOILER 7 Diagrams Figure 7 1 Ladder Diagram Part 1 BOX DEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC HIGH VOLTAGE CONTROL CONTROL MODULE 1 MODULE 2 LOUVER RELAY 1 LOUVER X54 RELAY 2 X5 4 Q O FLAP T VALUE AIR PRESSURE FLAP AIR PRESSURE SWITCH VALVE SWITCH X5 14 5 X5 14 HI LIMIT HI LIMIT X6
11. due to high absolute Delta T Outlet Inlet 8 Heat Demand blocked due to Low 24 VAC 9 Outdoor shutdown 10 Block due to switch OFF boiler ON OFF of Display 12 Block due to no correct communication Cascade 16 Service function 19 DHW function Storage Tank 21 SH function Heat demand from Room Thermostat 22 SH function Heat demand from Boiler Management System 23 SH function Heat demand from Cascade 30 Heat demand activated by Freeze Protection 32 DHW Pump Delay 33 SH Pump Delay 34 No heat function after pump delay 40 Lockout 32764 Busy with updating status 32765 DHW blocked due to no present tank sensor 32766 Burner control s manually shut down 32767 Code not present Blocking Codes Input Registers 30015 and 30024 0 No blocking _ gt is divided into sub blockings 1 SH blocking 2 Blocking Due to Low 24 VAC Supply 3 Blocking due to General block 4 Blocking MRHL is open 5 Blocking due to Switched OFF boiler Display ENTER switch 6 Blocking due to wrong communication of Cascade 7 Blocking due to High Delta 8 Blocking due to High Flue Temperature Blocking due to High Outlet Temperature 10 Service blocking 12 DHW blocking high outlet temperature DHW configured as storage tank 13 Blocking anti cycling time 14 Storage Tank demand Blocked due to Fan problems 15 No system sensor connected and leader control present 16 Limit fan speed due to hig
12. holding registers 40002 40007 per the demand configuration Demand Configuration 4 In this configuration the unit is controlled by setting the setpoints locally on the boiler and providing an enable signal through Modbus communications sensors and limiting devices should be hardwired to the terminal strip on the back of the unit excluding the thermostat enable and tank thermostat enable signal These signals will be sent to the unit via Modbus The holding registers will need to be set as follows 40001 00 01 Set Configuration to read 40002 40002 00 01 Enables unit 00 00 disables unit NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing a command mW 44 m SYNC Modbus Instructions ENSING BOILER D Unit Operation continued Demand Configuration 5 In this configuration the unit is controlled by providing an enable signal and a rate command through Modbus communications The rate command will be 0 10096 of modulation All sensors and limiting devices should be hardwired to the terminal strip on the back of the unit excluding the thermostat enable and tank thermostat enable signal These signals will be sent to the unit via Modbus The holding registers will need to be set as follows Holding Registers Definition Bit Value HEX x Action 40002 00 01 Enables unit 00 00 disables unit 40003 00 Sets Modulation 96 or Setpoint NOTE ensure prope
13. 1 LC 30041 Runtime Conas o t 10042 o 1 1043 CHPum2 0 10046 GasVave2 o Modbus Instructions To 3 Memory Map SYNC Boiler Memory Map Input Registers Address Description Default Unit Min Max Resolution 30001 Discrete Inputs 1 16 NA 0 05535 1 30002 Discrete Inputs 17 32 0 065535 1 30003 Discrete Inputs 33 48 0O O 65535 1 30004 System Cascade Setpoint 0 Degrees Celsius 0 130 05 o lj 30006 CascadeToalPower 100 90 1 30007 CascadeCurenPowr o 0 800 30008 OuletSetpinti o DegreesCesus 0 130 05 30009 Outlet Temperature 0 DegreesCesus 0 130 04 30010 inlet Temperature o DegreesCelus 20 130 01 _ 3004 Flue Temperature 1 0 DegreesCelus 20 130 04 3002 FrngRatei 0 0 1 30014 1 Status Code 0 0 05535 1 30015 Boiler 1 Blocking 0 0 j6553 1 30016 Boiler 1 Lockout Code 0 X 0 65535 1 30017 OutletSetpoint2 0 DegresCelsus O 130 05 30018 jOutletTemperatue2 S Degrees Celsius 0 130 01 30019 iniet
14. 8 INLET INLET SENSOR SENSOR OUTLET OUTLET SENSOR SENSOR FLUE FLUE SENSOR SENSOR BLOCKED u DRAIN AUTO RESET AUTO RESET HIGH LIMIT 5 10 HIGH LIMIT X5 10 GAS VALVE X22 GAS VALVE x22 GAS VALVE GAS VALVE 2 1 RELAY 2 1 RELAY BLOWER 1 X5 5 BLOWER 1 X5 5 2 X5 13 2 5 13 4 X5 6 4 X5 6 5 X5 12 5 X5 12 TR1 AMO HIGH VOLTAGE SPARK LEAD CAUTION 4 CONTROL MODULE 1 HIGH VOLTAGE SPARK LEAD CONTROL CONNECTION BOARD SHIELD CASCADE RS485 SHIELD TANK SENSOR OUTDOOR SENSOR SYSTEM SENSOR EXTERNAL CONTROL V SHIELD MOD BUS RS485 SHIELD KIT NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present LADDER DIAGRAM LBL20058 REV E DISCONNECT POWER 2 See wiring diagram for additional notes BEFORE SERVICING 20 GYNG 7 Di agramss continued Figure 7 2 Ladder Diagram Part 2 BOX DEPICTS OPTIONAL ITEMS LOW VOLTAGE 120 VAC 120VAC JUNCTION BOX TERMINAL STRIP 120V SUPPLY L OFF CONTROL MODULE 1 SWITCH SYSTEM PUMP RELAY HEX 1 BOILER PUMP RELAY JUNCTION BOX OFF CONTROL MODULE 2 SWITCH HEX 2 BOILER PUMP RELAY JUNCTION
15. Count Diagnostic Bus Exception Error Count Diagnostic Return Slave Message Count Diagnostic Return Communication Error Count Diagnostic Return Slave NAK Count Diagnostic Return Slave Busy Count Diagnostic Return Bus Character Overrun Count Diagnostic Clear Overrun Counter and Flag Get Communication Event Counter Get Communication Event Log Write Multiple Coils Write Multiple Registers Report Slave ID N gt Read Write Multiple Registers SYNC Modbus Instructions 2 Configuration Modbus Exception Codes MODBUS Exception Codes Nam eng The function code received in the query is not an allowable action for the server or slave This may be because the function code is only applicable to newer ILLEGAL FUNCTION devices and was not implemented in the unit selected It could also indicate that the server or slave is in the wrong state to process a request of this type for example because it is unconfigured and is being asked to return register values The data address received in the query is not an allowable address for the server or slave More specifically the combination of reference number and transfer length is invalid For a controller with 100 registers the PDU addresses the first register as 0 and the last one as 99 If a request is submittted with a starting register address of 96 and a quantity of registers of 4 then this request will successfully operate add
16. DEVICE BUSY slave is engaged in processing a long duration program command The client or master should re transmit the message later when the server or slave is free Specialized use in conjuction with function codes 20 and 21 and reference type 6 to indicate that the extended file area failed to pass a consistency check The MEMORY PARITY ERROR server or slave attempted to read record file but detected a parity error in the memory The client or master can retry the request but service may be required on the server or slave device Specialized use in conjunction with gateways indicates that the gateway was unable to allocate an internal communication path from the input port to the output port for processing as the request Usually means that the gateway is misconfigured or overloaded GATEWAY PATH UNAVAILABLE Specialized use in conjunction with gateways indicates that no response was obtained from the target device Usually means that the device is not present on the network GATEWAY TARGET DEVICE FAILED TO RESPOND Modbus Instructions 3 Memory Map Primary Data Tables Table Data Type Read Write Discrete Inputs Coils Single Bit Read Write Input Registers 16 Bit Word Read Only Holding Registers 16 Bit Word Read Write SYNC Boiler Memory Map O 2 Address Description Defaut Unit Min Resolution 00001 Boier Enable Room Thermostat T Stage 1 O T ON O OFF O
17. NVALVE ROD FLAME ROD ewe ME HIGH VOLTAGE SPARK LEAD Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead WIRING DIAGRAM or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components LBL20045 REV F 3 Actual connector block locations may vary from those shown on diagrams Refer to actual components for proper connector block locations when using L diagrams to troubleshoot unit 22 Notes 23 Lochinvar Revision Notes Revision A ECO C04560 initial release High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway Lebanon TN 37090 615 889 8900 Fax 615 547 1000 SYNC MODB Rev A 10 09 www Lochinvar com
18. SYNC MODB Rev A SYNG CONDENSING BOILER MODBUS COMMUNICATION INSTRUCTIONS SYNC Models 1 0 1 3 1 5 This manual must only be used by a qualified heating installer service technician Read all instructions including this manual the Installation and Operation Manual and the Service Manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage Lochinvar High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference 1 INTRODUCTION 3 MEMORY Definitions 2 Primary Data Tables T Minimum System Requirements 2 SYNC Boiler Memory 7 8 2 CONFIGURATION Input Registers 8 PROC uuu uu uuu a 3 Holding Registers 8 Timing Specifications 4 Configuration Bits 8 Fly RC AE au 4 4 WIRING REQUIREMENTS Data Transmission Mode 4 Physical T 9 Modbus Board Diagnostics
19. emote control This installation may or may not have the hot water generator in close proximity to the boiler Its sensors and thermostat values are only available through the Modbus communication bus To ensure that the SYNC boiler can properly respond to a call for hot water generation the following holding registers must be set in addition to other commands Holding Registers Definition Bit Value HEX Action 40002 00 08 Enables Tank Tstat 00 00 disables unit 40005 Tank Temperature 0st Passes tank temp from remote sensor NOTE ensure proper operation re send the configuration bits to holding register 40001 prior to issuing a command For proper hexadecimal conversion of rate percentage please refer to the Rate and Temperature Conversion section on page 17 of this manual Cascade In order to operate the SYNC boiler in Cascade with Modbus Monitoring Only communications configure the leader boiler per the demand Aay SING boler Saw be equipped with the Modbus configurations in this manual Connect the remaining boilers a communication board and then be set up to operate with its in the cascade through the normal cascade communications own Internal controls If necessary Modbus can be configured wiring Cascade control can then be accomplished O d confi he leade bola as a monitoring device by selecting demand configurations 1 x P 5 3 and polling the Modbus board for the read only va
20. fault 0 CONDENSING BOILER 4 Wiring Requirements Modbus Instructions Note that when the System Supply Temperature and or the Tank Temperature are provided by the BAS they need to be refreshed every few seconds This is required in order to prevent unwanted fluctuations in these temperatures If these values are not provided every few seconds timeout is programmable the boiler will revert to its own internal control If neither of these temperatures is provided by the BAS but any of the other control signals are being provided the BAS will still need to refresh these inputs at least every 4 minutes Physical Wiring RS 485 Communication Bus Maximum Length 4000 feet Cable Specification 24 AWG A B twisted pair and GND Shielded with characteristic Impedance 120 ohm Maximum Load 32 units 32 nodes NOTE Cable must be terminated with 120 ohm impedance matching resistor on each end Figure 4 1 Terminal Strip Connections 0 D MODBUS CASCADE ca lt a a a a lt n cc 2 2 z tds E galge 2 2 m lt a a Sazasogoraz amp B z E lt 92 988208 ale ele em aal g ala Sa S a dii Al n n nn n n H n nH nin gt Z S lt S S Z S g Sa Z S TT 277
21. h outlet temperature 17 Fan min decreased due to low flame current 18 Limit max fan speed due to high Delta T 19 Limit max fan speed due to high flue temp 32767 Code not present 6 Troubleshooting continued Lockout Codes Input Registers 30016 and 30025 161 EEPROM code Parameters not Re Programmed by Lochinvar 164 EEPROM code No Reset Allowed gt 15 minutes 166 EEPROM code Auto Reset High Limit 167 EEPROM code Blocked Drain 168 EEPROM code Louver Proving 169 EEPROM code Gas Pressure Sw 170 EEPROM code Flow Switch 177 Sensor short Flue Sensor 178 Sensor 3 open Flue Sensor 179 Sensor2 short Inlet Sensor 180 Sensor 2 open Inlet Sensor 192 Sensor 1 short Outlet Sensor 193 Sensor 1 open Outlet Sensor 204 CRC EEPROM failed 205 EEPROM programmed display shows PP 206 EEPROM error in programming 207 Write error EEPROM 229 EEPROM code Watch Dog 230 EEPROM code fan low should be high 231 EEPROM code fan high should be low 232 EEPROM code no flame when running 233 EEPROM code no flame after ignition 234 EEPROM code simultaneous output APS and Fan 235 EEPROM code APS active not Closed 236 EEPROM code APS active not Open 237 EEPROM code flame out of sequence 239 EEPROM code when gas valve relay test fails 240 EEPROM code 32767 Code not present Installation Replacement Procedure Figure 6 1 MTRO1 Control Board 1
22. mple For each switch set to the 1 position it has the following value Address 0 2 0 4 0 16 32 0 0 50 Dip switch 1 1 Dip switch 2 2 Dip switch 3 4 Dip switch 4 8 Dip switch 5 16 Dip switch 6 32 Dip switch 7 64 Dip switch 8 128 Any dip switch set to 0 has a value equal to 0 2 Configuration Timing Specifications The baud rate for the Modbus board is selectable with Dip switch 9 1 19200 bps 0 9600 bps Each message is started by at least 3 5 character times of silence The maximum delay between frames is 1 5 character times When the system temperature and or tank temperature is provided by the BAS to the boiler it is critical that the temperature be updated every few seconds If the boiler does not receive updated temperatures within a timeout period installer adjustable the control will revert to using its own sensor inputs if sensors are connected The timeout is programmable by pressing the MAIN gt gt SETUP gt gt BMS buttons The timeout is adjustable between 5 and 120 seconds The default timeout is 10 seconds When the BAS is not providing either of these temperatures but is still controlling the boiler such as providing a modulation command the BAS must refresh these commands at least every 4 minutes If the commands are not refreshed the boiler will revert to operating based on its own inputs Parity Parity is set by the position of Dip switch 10 0 No Parit
23. ndard for serial transmission of data based on the RS 485 Standard RTU Remote Terminal Unit Minimum System Requirements BAS system or computer with a serial or USB port with a converter to RS 485 SYNC boiler equipped with Modbus communication board Shielded twisted pair communication cable 2 SYNC Modbus Instructions 2 Configuration The Modbus communication board is equipped with a set of ten dip switches that are used to set the board configuration address baud rate and parity settings The first eight are used to set the address of each board The ninth baud rate The tenth is parity Figure 2 1 Modbus Communication Board DIP SWITCHES LED S kitle Addressing The Modbus addressing space is comprised of 256 different Example _ From th To set the address of the Modbus board to 50 dip switches 2 5 d and o have position The address is determined a by adding the values of all the dip switches together 1 247 are free to use for each unique device e 248 255 are reserved Address Value of Dip switch 1 Value of Dip switch 2 Value of Dip switch 3 Value of Dip switch 4 Value of Dip switch 5 Value of Dip switch 6 Value of Dip switch 7 Value of Dip switch 8 To set the Modbus address the dip switches can be set in either the 0 position or the 1 position For switches set to the 1 position their value will be added together to determine the address In this exa
24. odes Unit Status Blocking Lockout Codes pU x MIT Physical Layer 1 Check that all components have power Boiler Gateway BAS Master 2 Check all wire lengths Are any drops too long 3 Check proper shield grounding 4 Check A B terminal connections 5 Check for Terminating Resistors 120 ohms 6 Check for broken wires Communications 1 Check Dip Switch Configuration of MTR 01 Board 2 Check Baud Rate 9600 19200 3 Check Parity 4 Check Slave ID 5 Check Port Setting on Master Gateway and Computers Modbus Error Codes 1 Check Modbus communication for error codes see page 6 for Modbus Exception Codes Check Modbus PDU Check Slave ID Check Modbus Command Check Configuration bits for Holding Register 40001 Check Commands and data for Holding Registers 40002 40007 Unit Status Codes See Codes in this section Boiler Status The SYNC boiler displays a boiler state code on the Building Screen to help aid in troubleshooting The boiler state indicates what the boiler is actually doing This state should be compared to the command issued and what is expected If the boiler state does not agree with the command issued check communication and configuration 18 Modbus Instructions SYNC Status Codes Input Registers 30014 and 30023 2 Heat Demand blocked due to high absolute outlet temperature 3 Heat Demand blocked due to high absolute flue temperature 4 Heat Demand blocked
25. r operation re send the configuration bits to holding register 40001 prior to issuing a command For proper hexadecimal conversion of rate percentage please refer to the Rate and Temperature Conversion section on page 17 of this manual Demand Configuration 6 In this configuration the unit is controlled by setting the modulation setpoint from 0 10096 Rate command will be 0 10096 of the modulation range sensors and limiting devices should be hardwired to the terminal strip on the back of the unit excluding the 0 10Vdc signal This signal will be sent to the unit via Modbus The holding registers will need to be set as follows 40001 00 04 Set Configuration to read 40003 40003 00 00 Sets Modulation 96 NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing a command For proper hexadecimal conversion of rate percentage please refer to the Rate and Temperature Conversion section on page 17 of this manual Hot Water Generation Hot water generation can be accomplished with one of two methods when a SYNC boiler is connected to a BAS system DHW with direct control and DHW with remote control DHW with direct control This is the typical installation with a hot water generator in close proximity to the boiler with the tank thermostat or tank temperature sensor wired to the terminal strip of the unit 15 Modbus Instructions D Unit Operation DHW with r
26. ress wise at least on registers 96 97 98 99 request is submitted with a starting register address of 96 and a quantity of ILLEGAL DATA ADDRESS registers of 5 then this request will fail with Exception Code 0x02 Illegal Data Address since it attempts to operate on registers 96 97 98 99 and 100 and there is no register with address 100 A value contained in the query data field is not an allowable value for server or slave This indicates a fault in the structure of the remainder of a complex request such as that the implied length is incorrect It specifically does NOT mean that a data item submitted for storage in a register has a value outside the expectation of the application program since the MODBUS protocol is unaware of the significance of any particular value of any particular register ILLEGAL DATA VALUE An unrecoverable error occurred while the server or slave was attempting to SLAVE DEVICE FAILURE perform the requested action Specialized use in conjunction with programming commands The server or slave has accepted the request and is processing it but a long duration of time ACKNOWLEDGE will be required to do so This response is returned to prevent a timeout error from occurring in the client or master The client or master can next issue a Poll Program Complete message to determine if processing is completed Specialized use in conjunction with programming commands The server or SLAVE
27. riables Please note that with Modbus communication connected to only the leader boiler total Cascade information can be seen through the communications link If you wish to see all the individual temperatures of each unit in the Cascade each unit will have to have a Modbus communication board However each unit can be monitored without the need to control each one individually 16 D Unit Operation continued Rate and Temperature Conversions Rate When issuing a rate command the rate can be communicated as percent modulation or a desired setpoint depending on the setting of the BMS Type in the BMS Setup Menu The proper data format for the modulation percentage is the direct conversion to hexadecimal This conversion can be accomplished through online number based converters or some scientific calculators For Example send a desired setpoint the hexadecimal value must be determined through linear interpolation of programmable parameters on the BMS Setup Menu BMS temperature set point at low analog input BMS temperature set point at high analog input These variables set the temperature values corresponding to the minimum and maximum voltage settings of the 0 10 volt signal The defaults are as follows DEFAULT DEFAULT PARAMETER VALUES DEFAULT Deg Deg F Voltages BMS setpoint at 21 69 8 low analog input BMS temperature setpoint at 179 6 high analog input Modbus Instructions
28. y 1 Odd Parity If No Parity is selected there will be two stop bits otherwise there will be one Modbus Instructions SYNC Data Transmission Mode Many Modbus bus master devices can be configured to transmit data in either Modbus RTU or Modbus ASCII modes Since RTU messages can be formatted to use fewer data bits and are therefore more efficient RTU has been chosen to be used with all Lochinvar Modbus communication Please ensure that the master device is transmitting Modbus RTU Modbus Board Diagnostics The Modbus board is equipped with three LED s for visual diagnostics Two yellow LED s and one green One yellow LED D5 is used to indicate reception of data The other yellow LED D6 is used to indicate transmission of data The green LED D7 is used to show internal faults Internal Faults Normal Operation 1 second on 1 second off Controller Fault Continuously No Burner Control Communication 0 5 seconds on 1 5 seconds off No Modbus Communication 1 5 seconds on 0 5 seconds off Modbus Communication The Modbus communication commands and exception codes that are supported by the Modbus communication board can be found on pages 5 and 6 of this manual Modbus Instructions 2 Configuration continued Modbus Function Set e Denton Diagnostic Clear Counters and Diagnostic Registers Diagnostic Return Bus Message Count Diagnostic Bus Communication Error
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