c(f,h,p)x-modb 100160882 2000001229 rev e

C(F,H,P)X-MODB_100160882_2000001229_Rev E

Th is manual must only be used by a qualifi ed 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.

� WARNING

Save this manual for future reference.

Copper-fin II/IIE Boiler, Water Heater

and Pool HeaterModBus and BACnet

Communication Instructions

Models: 402 - 2072 (Boiler & Water Heater)

Models: 502 - 2072 (Pool Heater)

Contents1. INTRODUCTION

Defi nitions .................................................................... 2Minimum System Requirements .................................. 2

2. MODBUS CONFIGURATION Addressing ................................................................... 3 Timing Specifi cations ................................................... 4 Parity ............................................................................ 4 Data Transmission Mode ............................................. 4 ModBus Board Diagnostics ......................................... 4 Internal Faults ......................................................... 4 ModBus Function Set ............................................. 5 ModBus Exception Codes ........................................... 63. MODBUS MEMORY MAP

Primary Data Tables .................................................... . 7Copper-fi n II/IIE Memory Map ..................................... 7-8

4. BACNET CONFIGURATION Addressing ................................................................... 9 Timing Specifi cations ................................................... 10 Board Diagnostics ....................................................... 10 Internal Faults ......................................................... 10

5. BACNET MEMORY MAPPrimary Data Tables .................................................... .11Copper-fi n II/IIE Memory Map.................................11-12 Input Registers ....................................................... .12 Holding Registers ................................................... .12

6. WIRING REQUIREMENTS ModBus Mounting/Wiring Instructions......................13-14 Physical Wiring............................................................. 15 Typical Boiler System Wiring .................................. 16-197. UNIT OPERATION Unit Operation with ModBus Communications ...... 20-238. TROUBLESHOOTING ........................................... 24-25.

DIAGRAMS Ladder Diagram ..................................................... 26-27 Connection Diagram ................................................28-28Revision Notes ................................................... Back Cover

1 IntroductionTh e information contained in this manual provides general guidelines for the implementation of ModBus communication with the Lochinvar Copper-fi n II/IIE.

All ModBus networks are implemented utilizing a master-slave arrangement where all Copper-fi ns are slaves and the master is a building automation system capable of communicating over a RS-485 serial connection. BACnet networks are implemented using a token passing process where multiple masters and slaves share a common RS-485 bus. Th e Lochinvar BACnet interface is a master only.

Abbreviation or Acronym MeaningASCII American Standard Code for Information Interchange

BACnet A data communication protocol for Building Automation and Control Networks

BAS Building Automation System

Baud (Baud Rate) Number of data bits transmitted per second (bps)

EMS Energy Management System

FDX Full-Duplex

HDX Half-Duplex

Hex Hexadecimal Number (0 - 9, A - F)

I/O Box Input/Output (I/O)

LSB Least Signifi cant Byte

ModBus® A serial, half-duplex data transmission protocol developed by AEG Modicon

MSB Most Signifi cant Byte

RS232 A standard for serial, full-duplex (FDX) transmission of data based on the RS232 Standard

RS485 A standard for serial transmission of data based on the RS-485 Standard

RTU Remote Terminal Unit

Defi nitions

Minimum System Requirements• BAS system or computer with a serial or USB port with a converter to RS-485.• Copper-fi n II/IIE equipped with ModBus communication board. • Shielded twisted pair communication cable.

3

2 ModBus Confi guration

AddressingTh e ModBus addressing space is comprised of 256 diff erent addresses. • 0 is reserved for broadcast messages from the master device • 1 - 247 are free to use for each unique device • 248 - 255 are reservedTo 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.Each switch set to the 1 position has the following value: 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.

Example:To set the address of the ModBus board to 50, dip switches 2, 5, and 6 have to be set to the 1 position. Th e address is determined by adding the values of all the dip switches together.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 8In this example:Address = 0 + 2 + 0 + 0 + 16 + 32 + 0 + 0 = 50

Th e ModBus communication board is equipped with a set of ten dip switches that are used to set the board confi guration (address, baud rate, and parity settings). Th e fi rst eight are used to set the address of each board. Th e ninth is baud rate. Th e tenth is parity.

DIPSWITCHES

LED'S

Figure 2-1_ModBus Communication Board

Copper-fi n II/IIE ModBus and BACnet Manual

4

2 ModBus Confi gurationTiming Specifi cationsTh e baud rate for the ModBus board is selectable with dip switch #9. 1 = 19200 bps 0 = 9600 bpsEach message is started by at least 3.5 character times of silence. Th e maximum delay between frames is 1.5 character times.When the system temperature, tank temperature, and/or 0-10V BMS voltage is provided by the BAS to the boiler, it is critical that the values be updated every few seconds. If the boiler does not receive updated values within a timeout period (installer adjustable), the control will revert to using its own readings (if connected). Th e timeout is programmable by accessing parameter H7 (see the Copper-fi n Service Manual for the procedure on how to set parameters). Th e timeout is adjustable between 1 and 255 seconds. Th e default timeout is 10 seconds.

When the BAS is not providing any of these values, but is still controlling the boiler (such as providing an enable 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.

ParityParity is set by the position of Dip switch #10. 0 = No Parity 1 = Even ParityIf No Parity is selected there will be two stop bits, otherwise there will be one.

Data Transmission ModeMany ModBus bus master devices can be confi gured 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 effi cient, RTU has been chosen to be used with all Lochinvar ModBus communication. Please ensure that the master device is transmitting ModBus RTU.

ModBus Board DiagnosticsTh e 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 transmission of data. Th e other yellow LED (D6) is used to indicate reception of data. Th e green LED (D7) is used to show internal faults.

Internal Faults: Normal Operation = 1 second bright, 1 second dim Controller Fault = Continuously on No Burner Control Communication = 0.5 seconds on, 1.5 seconds off No ModBus Communication = 1.5 seconds on, 0.5 seconds off

ModBus CommunicationTh e 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.


5

2 ModBus Confi guration (continued)

Function Sub FunctionHEX Description

Dec HEX Dec1 01 Read Coil Status

2 02 Read Input Status

3 03 Read Holding Registers

4 04 Read Input Registers

5 05 Force Single Coil

6 06 Preset Single Register

7 07 Read Exception Status

8 08 0 00 Diagnostic - Return Query Data

1 01 Diagnostic - Restart Communication

2 02 Diagnostic - Return Diagnostic Register

4 04 Diagnostic - Force Listen Mode

10 0A Diagnostic - Clear Counters and Diagnostic Registers

11 0B Diagnostic - Return Bus Message Count

12 0C Diagnostic - Bus Communication Error Count

13 0D Diagnostic - Bus Exception Error Count

14 0E Diagnostic - Return Slave Message Count

15 0F Diagnostic - Return Communication Error Count

16 10 Diagnostic - Return Slave NAK Count

17 11 Diagnostic - Return Slave Busy Count

18 12 Diagnostic - Return Bus Character Overrun Count

20 14 Diagnostic - Clear Overrun Counter and Flag

11 0B Get Communication Event Counter

12 0C Get Communication Event Log

15 0F Write Multiple Coils

16 10 Write Multiple Registers

17 11 Report Slave ID

23 17 Read / Write Multiple Registers

ModBus Function Set


6

2 ModBus Confi guration

ModBus Exception CodesCode Name Meaning

01 ILLEGAL FUNCTION

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 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 unconfi gured and is being asked to return register values.

02 ILLEGAL DATA ADDRESS

The data address received in the query is not an allowable address for the server (or slave). More specifi cally, the combination of reference number and transfer length is invalid. For a controller with 100 registers, the PDU addresses the fi rst register as 0, and the last one as 99. If a request is submitted with a starting register address of 96 and a quantity of registers of 4, then this request will successfully operate (address-wise at least) on registers 96, 97, 98, 99. If a request is submitted with a starting register address of 96 and a quantity of 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.

03 ILLEGAL DATA VALUE

A value contained in the query data fi eld 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 specifi cally 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 signifi cance of any particular value of any particular register.

04 SLAVE DEVICE FAILURE An unrecoverable error occurred while the server (or slave) was attempting to perform the requested action.

05 ACKNOWLEDGE

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 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.

06 SLAVE DEVICE BUSYSpecialized use in conjunction with programming commands. The server (or 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.

08 MEMORY PARITY ERROR

Specialized use in conjunction with function codes 20 and 21 and reference type 6, to indicate that the extended fi le area failed to pass a consistency check. The server (or slave) attempted to read record fi le, 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.

0A GATEWAY PATH UNAVAILABLE

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 misconfi gured or overloaded.

0B GATEWAY TARGET DEVICE FAILED TO RESPOND

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.

ModBus Exception Codes


7

Primary Data Tables

Table Data Type Read / WriteDiscrete Inputs Single Bit Read OnlyCoils Single Bit Read / WriteInput Registers 16-Bit Word Read OnlyHolding Registers 16 Bit Word Read / Write

Copper-fi n II/IIE Memory Map

3 ModBus Memory Map

Address Description Default Unit Min. Max. Resolution Calculation Factor

Coils00001 Stage 1 Enable 0 1=ON / 0=OFF 0 1 1 100002 Stage 2 Enable 0 1=ON / 0=OFF 0 1 1 100003 Stage 3 Enable 0 1=ON / 0=OFF 0 1 1 100004 Stage 4 Enable 0 1=ON / 0=OFF 0 1 1 100005 Tank Thermostat 0 1=ON / 0=OFF 0 1 1 1

Discrete Inputs10001 High Limits 0 1=ON / 0=OFF 0 1 1 110002 Flow Switch 0 1=ON / 0=OFF 0 1 1 110003 Gas Pressure Switch 0 1=ON / 0=OFF 0 1 1 110004 Louver Proving Switch 0 1=ON / 0=OFF 0 1 1 110005 Air Pressure Switch 0 1=ON / 0=OFF 0 1 1 110008 Flame 1 0 1=ON / 0=OFF 0 1 1 110009 Stage 1 On 0 1=ON / 0=OFF 0 1 1 110010 Tank Thermostat 0 1=ON / 0=OFF 0 1 1 110011 Stage 2 On 0 1=ON / 0=OFF 0 1 1 110012 Stage 3 On 0 1=ON / 0=OFF 0 1 1 110013 Stage 4 On 0 1=ON / 0=OFF 0 1 1 110023 Flame 2 0 1=ON / 0=OFF 0 1 1 110024 Enable 2 0 1=ON / 0=OFF 0 1 1 110033 Runtime Contacts 0 1=ON / 0=OFF 0 1 1 110034 Alarm Contacts 0 1=ON / 0=OFF 0 1 1 110035 HTR Pump 0 1=ON / 0=OFF 0 1 1 110036 DHW Pump 0 1=ON / 0=OFF 0 1 1 110037 Louver Relay 0 1=ON / 0=OFF 0 1 1 110038 Gas Valve 1 0 1=ON / 0=OFF 0 1 1 110039 System Pump 0 1=ON / 0=OFF 0 1 1 1


8

Copper-fi n II/IIE Memory Map

3 ModBus Memory Map

Confi guration BitsAddress 40001 contains confi guration bits sent from the BAS to the boiler. Th ese 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. Th e confi guration bits are as follows:

Bit 4: System Supply TemperatureBit 5: Outdoor TemperatureBit 6: Tank TemperatureBit 7: System Return TemperatureBit 8 - 15: Not Used (Default = 0)

Bit 0 (LSB): Boiler EnableBit 1: Tank Th ermostatBit 2: Rate Command / 10 - 10V Input / Set point CommandBit 3: Tank Set point

Address Description Default Unit Min. Max. Resolution Calculation Factor

10046 Gas Valve 2 0 1=ON / 0=OFF 0 1 1 110047 Gas Valve 3 0 1=ON / 0=OFF 0 1 1 110048 Gas Valve 4 0 1=ON / 0=OFF 0 1 1 1

Input Registers30001 Discrete Inputs 1 - 16 0 N/A 0 65535 1 130002 Discrete Inputs 17 - 32 0 N/A 0 65535 1 130003 Discrete Inputs 33 - 48 0 N/A 0 65535 1 130004 System / Cascade Set point 0 °C 0 130 0,5 0,530005 System Pump Speed 0 % 0 100 1 130006 Cascade Total Power 0 % 100 800 1 130007 Cascade Current Power 0 % 0 800 1 130008 Outlet Set point 0 °C 0 130 0,5 0,530009 Outlet Temperature 0 °C 0 130 0,1 0,130010 Inlet Temperature 0 °C -20 130 0,1 0,130011 Pool Temperature 0 °C -20 130 0,1 0,130012 Firing Rate 0 % 0 100 1 130014 Status Code 0 N/A 0 65535 1 130015 Blocking Code 0 N/A 0 65535 1 130016 Lockout Code 0 N/A 0 65535 1 130027 Lockout Code Leader 0 N/A 0 65535 1 130028 Lockout Code Member 1 0 N/A 0 65535 1 130029 Lockout Code Member 2 0 N/A 0 65535 1 130030 Lockout Code Member 3 0 N/A 0 65535 1 130031 Lockout Code Member 4 0 N/A 0 65535 1 130032 Lockout Code Member 5 0 N/A 0 65535 1 130033 Lockout Code Member 6 0 N/A 0 65535 1 130034 Lockout Code Member 7 0 N/A 0 65535 1 1

Holding Registers40001 Confi guration 0 N/A 0 65535 1 140002 Coils 0 N/A 0 65535 1 140003 0 - 10V Inp. / Rate Cmd / Setp. Cmd 0 % 0 100 1 140004 Pool Set point 0 °C 0 87,5 0,5 0,540005 Tank Temperature 0 °C -20 130 0,1 0,140006 Outdoor Temperature 0 °C -40 60 0,1 0,140007 System Supply Temperature 0 °C -20 130 0,1 0,140008 System Return Temperature 0 °C -20 130 0,1 0,1


9

4 BACnet Confi guration


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 8In this example:Address = 0 + 2 + 0 + 0 + 16 + 32 + 0 + 0 = 50Th e BACnet Device Instance is calculated by adding the BACnet local address to 620000. Using the above example, the Device Instance will be:Device Instance = 620000 + 50 = 620050Th e base address (620000 in this example) is model dependant and can be changed by the integrator. It can be set to any value between 0 and 4194048. Th e resulting device instance will be this value + the local address, as before. Once the base address is changed, it can be reset back to the default base address (620000 in this example) using the following procedure:1. Turn OFF power to the interface board.2. Set Dip switches 1 - 8 to the 1 position.3. Turn ON power to the interface board.4. Aft er a few seconds, turn OFF power to the interface board.5. Set Dip switches 1 - 7 to the desired local address. Set Dip switch 8 to the 0 position.6. Turn ON power to the interface board.Device NameTh e default device name is “MTR-01 BACnet.” Th is can be changed by the integrator as desired.

Th e BACnet communication board is equipped with a set of ten dip switches that are used to set the board confi guration (address and baud rate). Th e fi rst eight are used to set the address of each board. Th e ninth and tenth are baud rate.

LED’S

DIP SWITCHES

Figure 4-1_Communication Board

AddressingTh e BACnet local addressing space is comprised of 256 diff erent addresses. • 255 is reserved for broadcast messages from a master device. • 128 - 254 are free to use for slave devices only. • 0 - 127 are free to use for master or slave devices.Since the BACnet communication board is a BACnet master, address 127 is the highest address that can be used.To set the BACnet local 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.Each switch set to the 1 position has the following value: 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 = 128Any dip switch set to 0 has a value equal to 0.Example:To set the address of the BACnet board to 50, dip switches 2, 5, and 6 have to be set to the 1 position. Th e address is determined by adding the values of all the dip switches together.

10 10

4 BACnet Confi guration


Timing Specifi cationsTh e baud rate for the BACnet board is selectable with Dip switches #9 and #10.

Communication Board DiagnosticsTh e Communication 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 transmission of data. Th e other yellow LED (D6) is used to indicate reception of data. Th e green LED (D7) is used to show internal faults.

Internal Faults: Normal Operation = 1 second bright, 1 second dim Controller Fault = Continuously on No Burner Control Communication = 0.5 seconds on, 1.5 seconds off No BACnet Communication = 1.5 seconds on, 0.5 seconds off .

Switch #9 Switch#10 Baud RateOFF OFF 9600ON OFF 19200OFF ON 38400ON ON 76800

When the system temperature, tank temperature, and/or 0-10V BMS voltage is provided by the BAS to the boiler, it is critical that the values be updated every few seconds. If the boiler does not receive updated values within a timeout period (installer adjustable), the control will revert to using its own readings (if connected). Th e timeout is programmable by accessing parameter H7 (see the Copper-fi n Service Manual for the procedure on how to set parameters). Th e timeout is adjustable between 1 and 255 seconds. Th e default timeout is 10 seconds.

When the BAS is not providing any of these values, but is still controlling the boiler (such as providing an enable 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.

Object Name Object Type

ObjectInstance Units Min Max Resolution

Binary ValuesStage 1 Enable BV 0 none 0 1 1Stage 2 Enable BV 1 none 0 1 1 Stage 3 Enable BV 2 none 0 1 1Stage 4 Enable BV 3 none 0 1 1

Tank Thermostat BV 4 none 0 1 1Binary Inputs

High Limits BI 0 none 0 1 1Flow Switch BI 1 none 0 1 1

Gas Pressure Switch BI 2 none 0 1 1Louver Proving Switch BI 3 none 0 1 1

Air Pressure Switch BI 4 none 0 1 1Flame 1 BI 7 none 0 1 1

Stage 1 On BI 8 none 0 1 1Tank Thermostat BI 9 none 0 1 1

Stage 2 On BI 10 none 0 1 1Stage 3 On BI 11 none 0 1 1Stage 4 On BI 12 none 0 1 1

Flame 2 BI 22 none 0 1 1Enable 2 BI 23 none 0 1 1

Runtime Contacts BI 32 none 0 1 1Alarm Contacts BI 33 none 0 1 1

HTR Pump BI 34 none 0 1 1DHW Pump BI 35 none 0 1 1

Louver Relay BI 36 none 0 1 1Gas Valve 1 BI 37 none 0 1 1

System Pump BI 38 none 0 1 1Gas Valve 2 BI 45 none 0 1 1Gas Valve 3 BI 46 none 0 1 1Gas Valve 4 BI 47 none 0 1 1

11


5 BACnet Memory MapPrimary Data Tables

Object Type Data Type Read / WriteBinary Input (BI) Single Bit Read Only

Binary Value (BV) Single Bit Read / WriteAnalog Input (AI) 16-Bit Word Read Only

Analog Value (AV) 16 Bit Word Read / Write

Memory Map

12


4 Wiring Requirements (continued)5 BACnet Memory Map

Object Name Object Type

ObjectInstance Units Min Max Resolution

Analog InputsBinary Inputs 0 - 15 AI 0 none 0 65535 1

Binary Inputs 16 - 31 AI 1 none 0 65535 1Discrete Inputs 32 - 47 AI 2 none 0 65535 1

System / Cascade Set point AI 3 Deg C 0 130 0.5System Pump Speed AI 4 Percent 0 100 1Cascade Total Power AI 5 Percent 100 800 1

Cascade Current Power AI 6 Percent 0 800 1Outlet Set point AI 7 Deg C 0 130 0.5

Outlet Temperature AI 8 Deg C 0 130 0.1Inlet Temperature AI 9 Deg C -20 130 0.1Pool Temperature AI 10 Deg C -20 130 0.1

Firing Rate AI 11 Percent 0 100 1Status Code AI 13 none 0 65535 1

Blocking Code AI 14 none 0 65535 1Lockout Code AI 15 none 0 65535 1

Lockout Error Leader AI 26 none 0 65535 1Lockout Error Member 1 AI 27 none 0 65535 1Lockout Error Member 2 AI 28 none 0 65535 1Lockout Error Member 3 AI 29 none 0 65535 1Lockout Error Member 4 AI 30 none 0 65535 1Lockout Error Member 5 AI 31 none 0 65535 1Lockout Error Member 6 AI 32 none 0 65535 1Lockout Error Member 7 AI 33 none 0 65535 1

Analog ValuesConfi guration AV 0 none 0 65535 1

Binary Values 0 - 4 AV 1 none 0 65535 10 - 10V Inp. / Rate Cmd / Setp. Cmd AV 2 Percent 0 100 1

Tank / Pool Set point AV 3 Deg C 0 87,5 0.5Tank Temperature AV 4 Deg C -20 130 0.1

Outdoor Temperature AV 5 Deg C -40 60 0.1System Supply Temperature AV 6 Deg C -20 130 0.1

Pool /System Return Temperature AV 7 Deg. C -20 130 0.1

Memory Map (continued)

13


6 Wiring RequirementsMounting/Wiring Instructions1. Turn OFF power at the source.

2. Remove the left and right access panels to access the inside of the unit.

3. Mount the communication board as shown in FIG. 6-1. - Set dip switch settings (reference Section 2 - Confi guration) and make the necessary ground connections.

4 Locate the control panel (see FIG. 6-2 on page 10). Locate the bushing on the right-hand side of the control panel (FIG. 6-2).

5. Route the communication board harness (100172877) A1, A2, A3, and A4 housing through the bushing on the right-hand side of the control panel.

6. Locate and disconnect the controller transformer from the line voltage harness (FIG. 6-2).

7. Plug the board harness A1 into the line voltage harness connection (FIG. 6-2).

8. Plug the board harness A1 into the line voltage harness connection (FIG. 6-2).

9. Locate the digital harness connector (FIG. 6-2). Plug the board harness A3 into the digital harness connector.

10. Route 100172877 along the front edge of the unit. Note: Take care not to run the wiring over any sharp edges.

11. Locate the communication board cover. Run power A5 through the top bushing of the communication board cover.

12. Run the board harness A6 and A7 through the lower bushing of the communication board cover.

13. Wire the communication board as follows (FIG. 6-2): • Connect A5 to communication board X1 • Connect A6 to communication board X4 • Connect A7 to communication board X6

14. If it is desired to ground the communication cable shield at the heater, install a jumper wire between pins 1 and 3 of X5.

15. Replace the cover. Secure the cover using the two (2) screws provided with the communication board.

16. Test the unit before replacing the access panels.

17. Replace the left and right access panels and turn ON power at the source. Resume operation.

INSTALLATION: LOCATE BRACKET ON DV PANEL AND SECURE WITHSELF DRILLING SCREWS. ADDALUMINUM SPACERS TO BRACKETSTUDS. ADD COMMUNICATIONBOARD AND SECURE WITH MOUNTINGNUTS. ADD BOARD COVER AND SECUREWITH SHEET METAL SCREWS.REPLACEMENT: REMOVE SHEET METALSCREWS AND COMMUNICATION BOARDCOVER. REMOVE MOUNTING NUTS ANDCOMMUNICATION BOARD. REPLACE BOARDAND SECURE WITH MOUNTING NUTS. ADD BOARD COVER AND SECURE WITHSHEET METAL SCREWS.

Figure 6-1_Mounting the Communication Board

14


6 Wiring Requirements

CASCADEMODBUS

CN

1

CN

6

CN

2

TAN

K

SEN

SOR

SHIE

LD

ABSHIE

LD

+ 0-10V

- BM

S IN

+ 0-10V

- RA

TE O

UT

SHIE

LD

ABSHIE

LD35 34 33 32 31 30 29 28 27 26 25 24 23 22

A3

A1

A2

A4

A5

A6

A7

CO

NN

EC

TION

BO

AR

D

DIG

ITAL

HA

RN

ES

S

LINE

VO

LTAG

EH

AR

NE

SS

CO

MM

UN

ICA

TION

HA

RN

ES

SW

RE

20129

CO

NTR

OLLE

R TR

AN

SFO

RM

ER

CO

MM

UN

ICA

TION

BO

AR

DR

ECO

MM

END

ED H

AR

NESS

RO

UTIN

G

CO

MM

UN

ICATIO

NB

OA

RD

CO

NTR

OL

PA

NE

L

BU

SH

ING

WR

E20129

CO

NN

ECTIO

NB

OA

RD

Figure 6-2_Schematic / Wire Connections

15


6 Wiring Requirements (continued)

RS-485 Communication Bus • Maximum Length = 4000 feet • Cable Specifi cation = 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. A + (positive) B - (negative)

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. Th is is required in order to prevent unwanted fl uctuations 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

Figure 6-3_Terminal Strip Connections

BA

BA

FROMPREVIOUSHEATERTO NEXTHEATER(if used)

EXTERNALSEQUENCER/BUILDINGAUTOMATICCONTROL

MODBUS / BACNET

MODBUS / BACNET

ASHIELD

B

ASHIELD

BTO NEXT BOILER

CA

SC

ADE

MO

DBU

S

CN2

TANK

SENSOR

SHIELD

A

B

SHIELD

+ 0-10V

- BMS IN

+ 0-10V

- RATE OUT

SHIELD

A

B

SHIELD35

34

33

32

31

30

29

28

27

26

25

24

23

22

16


6 Wiring RequirementsFigure 6-4_Control Inputs

SMART SYSTEMCONTROL BOARD

LOWVOLTAGE

CONNECTIONBOARD

DHW THERMOSTAT(OPTIONAL)

ROOM THERMOSTAT/ZONE CONTROL(OPTIONAL)

SYSTEM SUPPLY/ENABLE SENSOR(OPTIONAL)

SYSTEM RETURN/POOL SENSOR(OPTIONAL ON BOILER)(STD ON POOL HEATER)

SEQUENCER BUILDINGMANAGEMENT SYSTEM(FIELD PROVIDED)

OUTDOOR SENSOR(OPTIONAL)

LOUVER PROVING SWITCH(FIELD PROVIDED)

INLET TEMPERATURESENSOR

OUTLET TEMPERATURE/LIMIT SENSOR

LOW WATER CUTOFF(OPTIONAL)

GAS PRESSURE SWITCH(OPTIONAL)

MANUAL RESET HIGHLIMIT (OPTIONAL)

AIR PRESSURE SWITCH

FLOW SWITCH

DISPLAY PANEL

PC INTERFACE(OPTIONAL)

TANK SENSOR(OPTIONAL)

SYSTEM PUMP SPEED(OPTIONAL)

CASCADE

COMMUNICATIONBOARD

(OPTIONAL)

SENSORCONNECTIONBOARD(BOILER AND POOL HEATER ONLY)

MODBUS

PC INTERFACE

17



Figure 6-5_Control Outputs

SMART SYSTEM

CONTROLBOARD

LOW VOLTAGE

CONNECTIONBOARD

THREE WAY VALVE(OPTIONAL ON BOILER)

(STD ON POOL HEATER)

LOUVER RELAY

BUILDINGMANAGEMENT

SYSTEM

RUN TIME CONTACTS

ALARM CONTACTS

ALARM(OPTIONAL)

HEATER PUMP(BOILER ONLY)

SYSTEM PUMPRELAY

DHW PUMP RELAY(BOILER)

DHW PUMP(WATER HEATER)

HOT SURFACEIGNITER

BLOWER

GAS VALVES

DISPLAY PANEL

PC INTERFACE(OPTIONAL)

CASCADE

INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERMINAL STRIP LOCATED IN THE CONTROL PANEL AREA

COMMUNICATIONBOARD

(OPTIONAL)0-10V

RATE

MODBUS

PC INTERFACE

18


6 Wiring RequirementsFigure 4-6_Control Location

COMMUNICATIONBOARD

CONTROLPANEL

Models 402 - 752

COMMUNICATIONBOARD

CONTROL PANEL

Models 992 - 2072

CONNECTIONBOARD

CONNECTIONBOARD

Typical Boiler System Wiring

BACnet or ModBus RS485 Communication Bus

BACnet or ModBus RS485 Port on Gateway or Building System

Physical Configuration: Cascade without Individual Monitoring

Cascade Daisy Chain Connection

19




Physical Configuration: Direct Control

BACnet or ModBus RS485 Port on Building System


BACnet or ModBus RS485 Port on Gateway or Building System

Physical Configuration: Cascade with individual Monitoring

Cascade Daisy Chain Connection

20


7 Unit OperationUnit Operation with ModBus / BACnet CommunicationsA Building Automation System (BAS) can monitor the Copper-fi n II/IIE without the need to change the default confi guration of the SMART SYSTEM control. When the BAS is to provide commands or values to the control, parameter H6 ModBus must be set to Active (reference the Copper-fi n II/IIE Service Manual for the procedure on how to set parameters).

Th e SMART SYSTEM control is equipped with two (2) ModBus communication timers. Th e fi rst is used whenever the control receives the system temperature and/or the tank temperature through ModBus. Th ese values need to be updated on a regular basis to prevent unwanted temperature variations. Th is timer is programmable from 1 to 255 seconds. It is Lochinvar’s recommendation that this timer be set as short as possible. Th is timeout can be adjusted by accessing parameter H7 ModBus Time. Th e timer is reset with the ModBus Time setting every time the temperatures are updated. Th e second timer is used for all other commands and values provided through ModBus. It has a fi xed timeout of four (4) minutes. If either of these timers expire before the next update, the SMART SYSTEM control will revert to using its local inputs.

When a BAS is to control a Copper-fi n II/IIE, the installer must confi gure the SMART SYSTEM control to receive commands and data through ModBus or BACnet. Th ere are several diff erent control methods available, as described in this section. Th ese methods are determined by the settings in four (4) diff erent parameters.

Control Mode 1

In this confi guration the heater is enabled and disabled through ModBus or BACnet. Th e heater uses its own local set points. All sensors and limiting devices should be connected directly to the terminal strip(s) inside the Copper-fi n II/IIE control compartment. Th e Enable 1 and/or Tank Th ermostat signals will be sent to the heater through ModBus or BACnet.

NOTE: To ensure proper operation, re-send the confi guration bits to holding register 40001 or Object AV0 prior to issuing commands.

Control Mode 2In this confi guration, each stage is enabled directly (boiler only).

Control Mode 2 - Setup (Confi guration Parameters)

To control each stage separately, access parameters H5 Sequencer, and set it to Active (reference the Copper-fi n II/IIE Service Manual for the procedure on how to set the parameters).

Control Mode 2 - Setup (Command Parameters)

Th e holding register will need to be set as follows:

NOTE: To ensure proper operation, re-send the confi guration bits to holding register 40001 or Object AV0 prior to issuing commands.

Object Holding Registers Defi nition Bit Value (HEX) Action

AV0 40001 Confi guration00 0100 0200 03

Read Enable 1 statusRead Tank Th ermostat statusRead Enable 1 and Tank Th ermostat status

AV1 40002 Coils 00 0100 0200 03

Enable 1 only activeTank Th ermostat only activeEnable 1 and Tank Th ermostat active


AV0 40001 Confi guration01 0103 0107 01

Read Enable 1 and 2 (2-stage heaters)Read Enable 1, 2, and 3 (3-stage heaters)Read Enable 1, 2, 3, and 4 (4-stage heaters)

AV1 40002 Coils

00 0100 0300 0700 0F

Enable Stage 1Enable Stages 1 and 2Enable Stages 1, 2, and 3Enable Stages 1, 2, 3, and 4

21


7 Unit Operation (continued)

Control Mode 3In this confi guration, the heater receives its enable signal and a rate command through ModBus or BACnet. All sensors and limiting devices should be connected directly to the terminal strip(s) inside the Copper-fi n II/IIE control compartment.


To send a rate signal to the SMART SYSTEM control, access parameter H3 BMS input and set it to Active (reference the Copper-fi n II/IIE Service Manual for the procedure on how to set parameters).



NOTE: To ensure proper operation, re-send the confi guration bits to holding register 40001 or Object AV0 prior to issuing commands. See the Rate and Temperature Conversions Section on page 19 for instructions on how to send the % rate.

Control Mode 4In this confi guration, the heater receives its enable signal and set points through ModBus or BACnet. All sensors and limiting devices should be connected directly to the terminal strip(s) inside the Copper-fi n II/IIE control compartment.


To send a Space Heating set point to the SMART SYSTEM control, access parameter H3 BMS input and set it to Active. Also, access parameter J1 BMS Type and set it to Set point (reference the Copper-fi n II/IIE Service Manual for the procedure on how to set parameters). Th e space heating set point will be derived from the 0-10V input value, based on the BMS settings in the control. Reference the Copper-fi n II/IIE Service Manual for details of these parameters.



NOTE: To ensure proper operation re-send the confi guration bits to holding register 40001 or Object AV0 prior to issuing commands. See the Rate and Temperature Conversions Section on page 19 for instructions on how to send the Tank/Pool set point.


AV0 40001 Confi guration 00 05 Read Enable 1 and 0-10V input

AV1 40002 Coils 00 01 Enable 1 Active

AV2 40003 0-10V Input 00 ## Sets % rate


AV0 40001 Confi guration

00 0500 0800 0900 0D

Read Enable 1 and 0-10V inputRead Tank/Pool Set pointRead Enable 1 and Pool Set pointRead Enable 1, 0-10V input, and Tank Set point

AV1 40002 Coils 00 01 Enable 1 active

AV2 40003 0-10V Input 00 ## Sets space heating set point

AV3 40004 Tank/Pool Set point 00 ## Sets Tank or Pool set point

22


7 Unit Operation

DHW with remote control:Th is 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 or BACnet communication bus.To ensure that the Copper-fi n II/IIE can properly respond to a call for hot water generation the following holding registers must be set in addition to other commands:

For proper hexadecimal conversion of rate percentage, please refer to the Rate and Temperature Conversion section on page 19 of this manual.

NOTE: To ensure proper operation re-send the confi guration bits to holding register 40001 or Object AV0 prior to issuing commands.

Control Mode 5In this confi guration, the heater receives its enable and its rate or set point using the 0-10V input through ModBus or BACnet. All sensors and limiting devices should be connected directly to the terminal strip(s) inside the Copper-fi n II/IIE control compartment.


To use the 0-10V input as an enable, access parameter H2 Enable input in the SMART SYSTEM control, and set this parameter to Inactive. Also, access parameter H3 BMS input and set it to Active. If you wish to control the set point, access parameter J1 BMS Type and set it to Set point. Th e enable function and the space heating set point will be derived from the 0-10V input value, based on the BMS settings in the control. Reference the Copper-fi n II/IIE Service Manual for the details of these parameters.



NOTE: To ensure proper operation, re-send the confi guration bits to holding register 40001 or Object AV0 prior to issuing commands. See the Rate and Temperature Conversions Section on page 19 for instructions on how to send the rate.

Hot Water GenerationHot water generation can be accomplished with one of two methods when a Copper-fi n II/IIE is connected to a BAS system, DHW with direct control, and DHW with remote control.DHW with direct control:Th is 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.


AV0 40001 Confi guration 00 04 Read 0-10V input

AV2 40003 0-10V Input 00 ## Sets space heating rate or set point


AV0 40001 Confi guration 00 4A Set Confi guration to read 40002, 4 & 5

AV1 40002 Coils 00 08 Enables Tank Tstat (00 00 disables unit)

AV3 40004 Tank Set point 0# ## Sets Set point

AV4 40005 Tank Temperature 0# ## Passes tank temp from remote sensor


CascadeIn order to operate the Copper-fi n II/IIE in Cascade with ModBus or BACnet communications, confi gure the leader boiler per the demand confi gurations in this manual. Connect the remaining boilers in the cascade through the normal cascade communications wiring. Cascade control can then be accomplished automatically through the leader boiler.Please note that with ModBus or BACnet 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.Monitoring OnlyAny Copper-fi n II/IIE can be equipped with the ModBus communication board and then be set up to operate with its own internal controls. If necessary, ModBus or BACnet can be confi gured as a monitoring device by selecting demand confi gurations 1 - 3, and polling the communication board for the read only variables.

Temperature

Th e Copper-fi n II/IIE 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:

Tc = (5/9) * (Tf-32) Tf = (9/5) * Tc+32

Example:Outdoor temperature from remote sensor on BAS System = 80°F

80°F = 26.7°CData that needs to be transmitted is 26.7 * 10 = 267

Decimal Binary HEX267 100001011 10B

Outlet temperature from unit sensor = 155°F 155°F = 68.3°CData transmitted from unit in HEX = 2AB = 683 683 ÷ 10 = 68.3 (°C)

Decimal Binary HEX683 1010101011 2AB

Rate and Temperature Conversions:

Rate

When issuing a rate command the rate can be communicated as percent modulation or a desired set point, depending on the setting of the BMS Type in the BMS Setup Menu.

Th e proper data format for the modulation percentage is the direct conversion to hexadecimal. Th is conversion can be accomplished through online number based converters or some scientifi c calculators.

For Example:

To send a desired set point, 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 inputTh ese variables set the temperature values corresponding to the minimum and maximum voltage settings of the 0-10 volt signal. Th e defaults are as follows:

Rate % HEX0 00

20 1445 2D60 3C80 5095 5F

100 64

PARAMETERDEFAULT VALUES DEFAULT

Deg C Deg F VoltagesBMS temperature set point at

low analog input 21 69.8 2

BMS temperature set point at high analog input 82 179.6 10

For Example:Send a set point of 110°F.Th e formula to use for the interpolation is:Rate Command = (Desired Set point – 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 Set point = 110BMS Temp at Low Analog Input =68BMS Temp at High Analog=158High Voltage =10Low Voltage = 2[(110-69.8)(10-2)/(179.6-69.8)] + 2 = 4.92 Volts(4.92/10) x 100 = 49.2 49 = 31 HexadecimalA value of [00][31] in hexadecimal would be written to Holding register 40003 to issue a command for a 110°F set point.

7 Unit Operation (continued)

23

24


8 Troubleshooting Should you encounter problems communicating over ModBus, the following items should be checked in this order:1. Physical Layer2. Communications Confi guration and Port Settings3. ModBus Error Codes4. Unit Status / Blocking / Lockout Codes

Physical Layer1. Check that all components have power (Boiler, Gateway, BAS Master)2. Check all wire lengths. Are any drops too long?3. Check proper shield grounding4. Check A, B terminal connections5. Check for Terminating Resistors (120 ohms)6. Check for broken wires

Communications1. Check Dip Switch Confi guration of MTR-01 Board2. Check Baud Rate (9600, 19200)3. Check Parity4. Check Slave ID5. Check Port Setting on Master, Gateway, and Computers

ModBus Error Codes1. Check ModBus communication for error codes (see page 6 for ModBus Exception Codes)2. Check ModBus PDU3. Check Slave ID4. Check ModBus Command5. Check Confi guration bits for Holding Register 400016. Check Commands and data for Holding Registers 40002 - 40007

Unit Status CodesSee Codes in this section

Boiler StatusTh e Copper-fi n II/IIE displays a boiler state code on the Building Screen to help aid in troubleshooting. Th e boiler state indicates what the boiler is actually doing. Th is 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 confi guration.

Status Codes (Input Registers 30014 and 30023)2 = Heat Demand blocked due to high absolute outlet temperature3 = Heat Demand blocked due to high absolute fl ue temperature4 = Heat Demand blocked due to high absolute Delta T (Outlet - Inlet)8 = Heat Demand blocked due to Low 24 VAC9 = Outdoor shutdown10 = Block due to switch OFF boiler (ON/OFF of Display)12 = Block due to no correct communication Cascade16 = Service function19 = DHW function Storage Tank21 = SH function Heat demand from Room Th ermostat22 = SH function Heat demand from Boiler Management System23 = SH function Heat demand from Cascade30 = Heat demand activated by Freeze Protection32 = DHW Pump Delay33 = SH Pump Delay34 = No heat function (aft er pump delay)40 = Lockout32764 = Busy with updating status32765 = DHW blocked due to no present tank sensor32766 = Burner control(s) manually shut down32767 = Code not present

Blocking Codes (Input Registers 30015 and 30024)0 = No blocking _> is divided into sub blockings1 = SH blocking2 = Blocking Due to Low 24 VAC Supply3 = Blocking due to General block4 = Blocking MRHL is open5 = Blocking due to Switched OFF boiler (Display ENTER switch)6 = Blocking due to wrong communication of Cascade7 = Blocking due to High Delta8 = Blocking due to High Flue Temperature9 = Blocking due to High Outlet Temperature10 = Service blocking12 = DHW blocking high outlet temperature (DHW confi gured as storage tank)13 = Blocking anti-cycling time14 = Storage Tank demand Blocked due to Fan problems15 = No system sensor connected and leader control present16 = Limit fan speed due to high outlet temperature17 = Fan min decreased due to low fl ame current18 = Limit max fan speed due to high Delta T19 = Limit max fan speed due to high fl ue temp32767 = Code not present

25


8 Troubleshooting (continued)

Lockout Codes (Input Register 30016)

161 = EEPROM code Parameters not Re-Programmed by Lochinvar164 = EEPROM code No Reset Allowed (> 15 minutes)166 = EEPROM code Auto Reset High Limit167 = EEPROM code Blocked Drain168 = EEPROM code Louver Proving169 = EEPROM code Gas Pressure Sw170 = EEPROM code Flow Switch177 = Sensor 3 short (Flue Sensor)178 = Sensor 3 open (Flue Sensor)179 = Sensor 2 short (Inlet Sensor)180 = Sensor 2 open (Inlet Sensor)192 = Sensor 1 short (Outlet Sensor)193 = Sensor 1 open (Outlet Sensor)204 = CRC EEPROM failed205 = EEPROM programmed (display shows “PP”)206 = EEPROM error in programming207 = Write error EEPROM229 = EEPROM code Watch Dog230 = EEPROM code fan low (should be high)231 = EEPROM code fan high (should be low)232 = EEPROM code no fl ame when running233 = EEPROM code no fl ame aft er ignition234 = EEPROM code simultaneous output APS and Fan235 = EEPROM code APS active not Closed236 = EEPROM code APS active not Open237 = EEPROM code fl ame out of sequence239 = EEPROM code when gas valve relay test fails240 = EEPROM code MRHL32767 = Code not present

Installation / Replacement Procedure

UNPLUG THREE (3) WIRE HARNESSES

Figure 8-1_MTR01 Control Board

1. Turn OFF the main electrical power to the appliance.2. Turn OFF the main manual gas shutoff to the appliance.3. Unplug the three (3) wire harnesses on the MTR01 control board (see FIG. 8-1).4. Unscrew the four (4) mounting nuts on the MTR01 control board and set aside. Remove the MTR01 control board (see FIG. 8-2).5. Replace / install the new MTR01 control board.6. Replace the four (4) mounting nuts removed in Step 4.7. Reconnect all three (3) wire harnesses unplugged in Step 3.8. Turn on the main electrical power and the main manual gas shutoff to the appliance.9. Confi gure the MTR01 control board and unit controls per this manual and resume operation.

INSTALLATION: LOCATE MODBUS BRACKET ON DV PANEL AND SECURE WITHSELF DRILLING SCREWS. ADDALUMINUM SPACERS TO BRACKETSTUDS. ADD MODBUS CONTROLBOARD (MTR01) AND SECURE WITHMOUNTING NUTS. ADD MODBUSCOVER AND SECURE WITH SHEETMETAL SCREWS.REPLACEMENT:REMOVE SHEET METAL SCREWSAND MODBUS COVER. REMOVEMOUNTING NUTS AND MODBUSCONTROL BOARD (MTR01). REPLACEBOARD AND SECURE WITH MOUNTINGNUTS. ADD MODBUS COVER ANDSECURE WITH SHEET METAL SCREWS.

Figure 8-2_Control Panel w/MTR01 Control Board

Th e lockout code (Input Register 30016) is constantly changing during operation and should not be used for lockout notifi cation until the status code (Input Register 30014) indicates a code of 40.

NOTICE

26


9 Diagrams Figure 9-1 Ladder Diagram

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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 DIAGRAMSDEPENDING UPON WHETHER UTILITIES ARE CONNECTED OR A FAULT

CONDITION IS PRESENT. SEE WIRING DIAGRAM FOR ADDITIONAL NOTES.

27


9 Diagrams (continued)

Figure 9-1 Ladder Diagram cont’d

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9 DiagramsFigure 9-2 Connection Diagram

+

+

+

+

+

+

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+

OUTDOOR

SENSOR

SYS RETURNSENSOR

SYS SUPPLYSENSOR

0-10V SYS

- PUMP IN

CN2

1

2

3

4

5

6

7

8

FIELD

SUPPLIED

WIRING

++

++++++

++

++++++

++

+++

++

++++

++

++

++++

ALARM

CONTACTS

OPENCLOSE

COM

RUNTIMECONTACTS

3-W

AY

VA

LV

ES

TA

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GS1

S1

S2

S2

S3

S3

S4

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LOUVER PROVING SWITCH

LOUVER RELAY COIL

TANK

AQUASTAT

23456789

101112

1314

1516

1718

192021

22232425262728

2930

3132333435

CN3

CN2

CN1

CN6

CN4

CN5

TANK

SENSOR

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+0-10V-RATE OUT

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SHIELD

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COMMON

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0-10V DC INFROM

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TO

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OUTPUT

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UNITS

MODBUS

BMS

1

6

2

3

4

5

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1

5

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2

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Y

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NEUTRAL

UNIT

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SYSTEM PUMP

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IND-DHW PUMP

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1

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2

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GBK/W

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CONTR

DISPLAY

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SENSOR BR

BR

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SENSOR

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BK

BR

BR

CHASSIS

GROUND

W

P

W

PR

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1

2

3

4

P

P

PR

PR

1

23

4

RW

BKG

1

23

4

WY

W/BKY

1

7

25

6

8

YBK

PW/R

R/BK

BK/R

FIELD WIRING

W

BK

G

3

1BK

W2G

3

2 Y

BL60VA

3

1 BK

W 32Y

BL

CONTROLLER

XFMR

DIGITAL HARNESS

PUMP RELAY

AC

120VAC COIL

BR/

W

W

BR BR

IGNITER

Y

Y

Y

R/BK

R

BL

1

3

5

GY

GY

G4

1

3

5

2

6

GYG

GYGY/W

GGY/W

S1/S2

S3/S4

GY/W

Y24V

GROUND

G

24V COM

13Y

R

OPT. ALARM HARNESS

R

R

1HP

MAX

120V

120V

120V/60Hz

SUPPLY

R

OPEN

COMMON

CLOSE24V

TO MONITORING DEVICE

TO MONITORING DEVICE

NEU

LINE

STAGE #1

STAGE #2

STAGE #3

STAGE #4

TANK SENSOR

AQUASTAT

M

COM

PROVE

LOW VOLT HARNES

MAIN POWER HARNESS

OPT. MODBUS HARNESS

CKT. BREAKER

2

4

1

BOILER/POOL HEATER

2 T

120V

12

0V

24

V

OUT

DOORAIR

POOL/BOILER

BK

G

RW

CN1

10K

10K

10K

10K

POOL SAFETY

SUPPLY

10K

10K

10K/20K

10K

10K/20K

Y

MODBUS

MODULECONNECTIONS

20K

10K PO

OL

SU

P

SE

NS

OR

3-WAY

VALVE

CONNECT

TO

TERMINAL

#19 (LOUVER

RELAY)

28


9 Diagrams (continued)

Figure 9-2 Connection Diagram cont’d

NOTE: NUMBER OF GAS VALVES VARIES BY MODEL

GROUND

X11X4

X9

X5

X6

X7

X8

X13F2

F4

MAIN UNIT

1

18

2

3

5

6

20

19

17

16

127

15

14

YT

WGY

BLY/G

BR/WBL

BK/RR/BK

BL/BKBR

BK

1R/BK

48

O/RPR

1

12

2

3

4

5

6

10

11

13

14

127

15

16

BLY

RW/BK

O/BKT

RGY

O/RT/W

R/OR/W

BRBR/W

1

6

2

3

4

5

BL

R/O

R/W

6

1

5

4

3

2

1

3

5

2

4

BKW

GBK/W

BK/R

CONTROLLER

SPLAY

IDENTIFICATION PLUG

MODEL SPECIFIC

CONSULT

FACTORY

T=TAN

Y=YELLOW

BR=BROWNG=GREEN

GY=GRAY

W = WHITE

BK = BLACK

PR=PURPLEBL=BLUE

P=PINK

O=ORANGE

FACTORY

OPTIONS

Y/G = YELLOW WITH GREEN STRIPE

R=RED

81213

12

W/BKW/R

R/W10

11R

W

GITAL HARNESS

GAS VALVE XFMR

FLOW

SWITCHO

O/BK

1

23

4

BL

Y

1

24

BL

YO

12

12

O

O/BK

NITER

Y

Y

Y

R/BK

R

BL

S1

1

21 3

R Y R

S2

3

21 3

R/BKY R/BK

S3

5

21 3

R/O Y R/O

S4

6

21 3

R/W Y R/W

S3

4

21 3

R/O Y R/O

S1

2

21 3

R Y R

4

1

3

5

2

6

GYG

GYGY/W

GGY/W

FLOW SWITCH

LWCO

BK

W

BL

Y

LOW GAS

SWITCH

OO/BK

BL

Y

BK

W

LO - GAS

BL

AUXILLIARY

HI-LIMIT

C NONC

C 21

GROUNDHSI

G

STAGE #1 STAGE #2STAGE #1 STAGE #3 STAGE #4STAGE #3

GY

GY

#1

GY/W

GY/W

CHASSIS

GROUND 1

2

3

PR

5

2

4

1

6

3

LWCO

24VAC

RESETPR

~~~~ ~~~~

LWCO

PROBE

TEST

~~~~

T

T

AIR PROVE

SWTICH

BLOCK

FLUE

SWITCH

BLOWER RELAY

120VAC COIL

BK/W

BKBK/W

HI/LO SPEED RELAY

120VAC COIL

W

BK/R

BK/

WR

BK

NO

COM

NC

COM

O/BK

HSI#2W

BL

R

BL

HI

O

O/BK

BL

BL

BL

CIRCUIT

BREAKER

LO

MAIN UNIT HARNESS

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

3. Actual connector block locations may vary from those shown on diagrams . Refer to actual components for

proper connector block locations when using diagrams to trouble shoot unit .

TO PREVENT ELECTRICAL SHOCK

THIS HEATER MAY BE CONNECTED TO MORE THAN ONE BRANCH CIRCUIT. MORE THAN ONE DISCONNECT SWITCH MAY BE

REQUIRED TO DE-ENERGIZE THE EQUIPMENT FOR SERVICING.

DANGER!LBL20082 REV A

G

BURNER BURNER

4

3

2

1

G

W

R

BK

2-SPD BLOWER

50VA

60VA

75VA

100VA

HI

LO

NEU

GND

HI-GAS

++

32

1

3 W

BK 1

31

GBK

SILENCING

SWITCHALARM BELL

1

6

4

5

PR

Y

1

6

23

45

BLBLY

ALARM RELAY

120VAC COIL

R

P

P

OPT. ALARM

LOW

VOLTAGE

HARNESS

CONNECTION

BOARD

W VOLT HARNESS

LOW VOLT HARNESS

4

3

2

1

G

W

R

BKHI

LO

NEU

GND

GROUNDING OPTION

JUMPER

DIGITAL

HARNESS

RBL

G

3 1

2

TOCONNECTION

BOARD

TO

PWR

TO

XFMR

MODBUS ADAPTER

G

120V

120V120V

120V

24V

120V

T

P

BL

R

R

BL

PR

2

W

FIELD

OPTIONS

WIRE COLOR REFERENCE

12

BL

O/R O

O/BK

12

12

12

O

1 2

O O/BK

O/BK

O/BK

O

12

O

1 2O/BK 1

2

G

OGY

3

12

29

30


Notes

31


Notes

Revision Notes: Revision A (ECO #C08638) initial release.

Revision B (ECO C11616) refl ects the addition of the lockout code notice on page 21 (R05772).

Revision C (PCP# 3000002377 / CN# 500002607) refl ects the addition of BACnet information and images, edits made to wording of Timing Specifi cations on pages 4 and 10, and edits made to Memory Map tables on pages 8 and 12.

Revision D (PCP# 3000007541 / CN# 500007580) refl ects the addition of references to A+ and B- on page 15.

Revision E (PCP# 3000008406 / CN# 500008361) refl ects an update to the addressing information of BACnet confi guration on page 9.

C(F,H,P)X-MODB_MM# 100160882_DIR# 2000001229_Rev E05/17

c(f,h,p)x-modb 100160882 2000001229 rev e

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