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Copper-fin II ModBus Manual

1. MODBUS 0 10V RATE CASCADE THREE WAY VALVE OPTIONAL ON BOILER STD ON POOL HEATER LOUVER RELAY BUILDING MANAGEMENT SYSTEM RUN TIME CONTACTS ALARM CONTACTS ALARM OPTIONAL HEATER PUMP BOILER ONLY SYSTEM PUMP RELAY DHW PUMP RELAY BOILER DHW PUMP WATER HEATER HOT SURFACE IGNITER BLOWER GAS VALVES DISPLAY PANEL PC INTERFACE OPTIONAL Z INDICATES CONNECTIONS MADE TO THE LINE VOLTAGE TERMINAL STRIP LOCATED IN THE CONTROL PANEL AREA 13 Copper fin II IIE Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements Figure 4 6 Control Location MODBUS COMMUNICATION BOARD 1 CONTROL PANEL CONTROL PANEL MODBUS COMMUNICATION BOARD 1 CONNECTION BOARD CONNECTION BOARD Models 402 752 Models 992 2072 Typical Boiler System Wiring Physical Configuration Cascade without Individual Monitoring ModBus RS485 Port on Gateway or Building System ModBus RS485 Communication Bus en eno eon Cascade Daisy Chain Connection 14 Copper fin Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements Physical Configuration Cascade with individual Monitoring ModBus RS485 Port on Gateway or Building System Cascade Daisy Chain Connection Physical Configuration Direct Control ModBus RS485 Port on Gateway or Building System 15 Copper fin
2. High Efficiency Water Heaters Boilers and Pool Heaters 300 Maddox Simpson Parkway 2 Lebanon 37090 Revision Notes Revision A ECO C08638 initial release 615 889 8900 Fax 615 547 1000 www Lochinvar com C F H P X MODB RevA 08 11
3. ON 0 ON O OFF Il l9 H IH Il Copper fin Boiler Water Heater and Pool ModBus Manual 3 Memory Map Copper fin Memory Map 30001 Discrete Inputs 1 16 30002 Discrete Inputs 17 32 Discrete Inputs 33 48 System Cascade Set point System Pump Speed Cascade Total Power Cascade Current Power Outlet Set point Outlet Temperature Inlet Temperature Pool Temperature Firing Rate Status Code Blocking Code Lockout Code Description as Valve 2 as Valve 3 as Valve 4 1 ON 0 OFF 1 ON 0 OFF 1 nput Registers Holding Registers Configuration Coils 0 10V Inp Rate Cmd Setp Cmd Pool Set point Tank Temperature Outdoor Temperature 40007 System Supply Temperature 40008 System Return Temperature Configuration Bits 40 60 01 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 1 Tank Thermostat Bit2 Rate Command 10 10V Input Set point Command Bit 3 Tank Set point Bit 4 System Supply Temperature Bit
4. ADVLIOA C H3MO18 e IX 5191930 8 03395 AVI3M LINN H3MO18 HOI 22 Copper fin II IIE Boiler Water Heater and Pool ModBus Manual 7 Dia grams continued Figure 7 1 Ladder Diagram cont d aM AOVAYALNI g niu _ ZX 0 8 v LNO L 9x L px OL 8x gt lt L LNO vx 9 9NO 3avosvo VS HOSN3S 9 9NO 21 8 anv L NOLLO3NNOO L 9NO L 9x 6S HOSN3S 131100 8 8 LS HOSN3S 1911 8 ZS HOSN3S LIINI 9x LNO gt lt ZS HOSN3S 9 LNO 1 89X NYNLaY 100d WALSAS gt lt 9S HOSNZIS S LNO vL 9X A1ddNns 100d WALSAS 8S HOSN3S 6L 8x 100d _ CVNO SS HOSN3S NOILO3NNOO OL 9X ES SLOVLNOO INE 9 NO Z X S NO 22 S GNO LL SNO V QHVOS NOILOANNOO O C L lt Wav iv AVIS SLOWLNOO 1 L VNO y NOI LOHNNOO QVOS AV IdSId OL 8X 98 LNO daads WALSAS T 9 8X Z LNO c QHVOS NOILOANNOO gt lt ZL 8X 9NO 3avosvo D V 2 8 Z 9NO gt lt 7 41 OL 9NO JL
5. NO AIR PROVE Las com SWTICH o SILENCING ALARM ALARM RELAY SWITCH BELL 120 COIL 477722 5 GROUNDING DIGITAL 0 lt OPTION HARNESS 94 JUMPER NC C NO AUXILLIARY HI LIMIT IDENTIFICATION PLUG PEL MODEL SPECIFIC CONSULT N 196 a FACTORY T 2 SPD BLOWER 16 WOL RBKYRIBKI Y R O Y R O RIWY RW E LT pH pM CONNECTION 4 5 DD BOARD ecd j adis id STAGE 1 STAGE 2 STAGE 3 STAGE 3 BURNER 1 HSI GROUND BLOWER RELAY HILO SPEED RELAY 120VAC pes 120VAC COIL UPON WIRE COLOR REFERENCE T TAN BK BLACK Y YELLOW PR PURPLE BR BROWN BL BLUE G GREEN P PINK GY GRAY O ORANGE R RED THIS HEATER MAY BE CONNECTED TOMORE THAN ONE BRANCH HOC MARCUNIT CIRCUIT MORE THAN ONE DISCONNECT SWITCH MAY BE Bem LBL20082 REV A REQUIRED TODEENERGIZE THE EQUIPMENT FOR SERVICING 25 Copper fin Boiler Water Heater and Pool ModBus Manual Notes 26 Copper fin Boiler Water Heater and Pool ModBus Manual Notes 27 Lochinvar
6. 5 Outdoor Temperature Bit 6 Tank Temperature Bit 7 System Return Temperature Bit 8 15 Not Used Default 0 Copper fin II IIE Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements ModBus Mounting Wiring Instructions l 2 10 11 12 14 16 17 Turn OFF power at the source Remove the left and right access panels to access the inside of the unit Mount the ModBus board as shown in FIG 4 1 Set dip switch settings reference Section 2 Configuration and make the necessary ground connections Locate the control panel see FIG 4 2 on page 10 Locate the bushing on the right hand side of the control panel FIG 4 2 Route the ModBus harness WRE20129 Al A2 A3 and A4 housing through the bushing on the right hand side of the control panel Locate and disconnect the controller transformer from the line voltage harness FIG 4 2 Plug ModBus harness Al into the line voltage harness connection FIG 4 2 Plug ModBus harness Al into the line voltage harness connection FIG 4 2 Locate the digital harness connector FIG 4 2 Plug ModBus harness A3 into the digital harness connector Route WRE20129 along the front edge of the unit Note Take care not to run the wiring over any sharp edges Locate the ModBus cover Run ModBus power A5 through the top bushing of the ModBus cover Run ModBus harness A6 and A7 through the lower bushing of the ModBus cov
7. 9 if used 28 0 10v 29 C2 aus iN o 10v 31 ICIN ouT EXTERNAL ae 32 HOW suo SEQUENCER SOOT x BUILDING SHIELD OPTIONAL MODBUS a Q AUTOMATIC A o CONTROL B 222200 35 SHIELD CN2 SHIELD TO NEXT BOILER B 11 Copper fin Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements Figure 4 4 Control Inputs OUTDOOR SENSOR OPTIONAL SYSTEM SUPPLY ENABLE SENSOR OPTIONAL SYSTEM RETURN POOL SENSOR OPTIONAL ON BOILER STD ON POOL HEATER SYSTEM PUMP SPEED OPTIONAL CASCADE DHW THERMOSTAT OPTIONAL ROOM THERMOSTAT ZONE CONTROL OPTIONAL SEQUENCER BUILDING MANAGEMENT SYSTEM FIELD PROVIDED LOUVER PROVING SWITCH FIELD PROVIDED TANK SENSOR OPTIONAL MODBUS INLET TEMPERATURE SENSOR OUTLET TEMPERATURE LIMIT SENSOR LOW WATER CUTOFF OPTIONAL GAS PRESSURE SWITCH OPTIONAL MANUAL RESET HIGH LIMIT OPTIONAL AIR PRESSURE SWITCH FLOW SWITCH DISPLAY PANEL PC INTERFACE OPTIONAL 12 L G 051 4 4 SENSOR CONNECTION BOARD LOW BOILER AND POOL HEATER CONNECTION ONLY BOARD SMART SYSTEM CONTROL MODBUS BOARD BOARD OPTIONAL PC INTERFACE Copper fin Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements continued Figure 4 5 Control Outputs LOW MODBUS VOLTAGE BOARD CONNECTION OPTIONAL BOARD
8. Control Mode 4 Setup Configuration Parameters 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 fin II IIE Service Manual for the procedure on how to set parameters 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 fin Service Manual for details of these parameters Control Mode 4 Setup Command Parameters The holding register will need to be set as follows Read Enable 1 and 0 10V input Read Tank Pool Set point Read Enable 1 and Pool Set point Read Enable 1 0 10V input and Tank Set point 40002 00 01 Enable 1 active 40003 0 10V Input 00 Sets space heating set point 40004 Tank Pool Set point 00 Sets Tank or Pool set point NOTE To ensure proper operation re send the configuration bits to holding register 40001 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 17 Copper fin Boiler Water Heater and Pool ModBus Manual 5 Unit Operation Control Mode 5 In this configuration the heater receives its enable and its rate or set point using the 0 10V input through ModBus All sensors and limiting devices should be connected directly to the terminal strip s inside the Copper
9. Heat Demand blocked due to high absolute flue temperature Heat Demand blocked 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 4 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 9 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
10. O tank A3 ens EI Su MODBUS HARNESS pi WRE20129 Qf o 10v eie ET En al 2 sue o e 5 CONNECTION RECOMMENDED HARNESS MODBUS BOARD ROUTING BOARD CONTROL PANEL MODBUS BOARD CONNECTION BOARD BUSHING WRE20129 10 Copper fin Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements 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 3 Terminal Strip Connections 22 Tank SENSOR FROM 1 Q 24 SHIELD PREVIOUS A N EU ts anne ma 26 5 2 lt HEATER as 27
11. 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 Parity Even Parity If No Parity is selected there will be two stop bits otherwise there will be one 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 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 Communication The ModBus communication commands and exception codes that are supported by the ModBus communi
12. 15 No system sensor connected and leader control present 16 Limit fan speed due to high 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 Copper fin II IIE Boiler Water Heater and Pool ModBus Manual 6 Troubleshooting continueg 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 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 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
13. B 9 SHIELD j 0 10V DC IN BMS J 1 common TO r 0 10V DC OU BMS 0 10V RATE OUT MOOD 969 OHOHOOOO OO balls SUE S MOD SHIELD j Bus Bus SHIELD N2 POOL SAFETY 0 10V SYS PUMPIN BOILER POOL HEATER OUTLET 7 SENSOR SOR W 1 INLET __ 10K SENSOR G MAIN POWER HARNESS 24V BUS HARNESS CONTROLLER oe XFMR MEC MR SYSTEM PUMP con CHASSIS ON OFF PUMP RELAY 120VAC COIL GROUND GROUND SWITCH 24 24V COM DIGITAL HARNESS m m MAIN UNIT Copper fin Boiler Water Heater and Pool ModBus Manual 7 Dia grams continued Figure 7 2 Connection Diagram cont d Notes ITAL HARNESS 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 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 LOW VOLTAGE Eg 9 e a C 0 4
14. Boiler Water Heater and Pool ModBus Manual D Unit Operation Unit Operation with ModBus Communications A Building Automation System BAS can monitor the Copper fin II IIE without the need to change the default configuration 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 fin H IIE Service Manual for the procedure on how to set parameters The SMART SYSTEM control is equipped with two 2 ModBus communication timers The first is used whenever the control receives the system temperature and or the tank temperature through ModBus These values need to be updated on a regular basis to prevent unwanted temperature variations This timer is programmable from 1 to 255 seconds It is Lochinvar s recommendation that this timer be set as short as possible This timeout can be adjusted by accessing parameter H7 ModBus Time The timer is reset with the ModBus Time setting every time the temperatures are updated The second timer is used for all other commands and values provided through ModBus It has a fixed 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 fin II IIE the installer must configure the SMART SYSTEM control to receive commands and data through ModBus There are several different control methods available as
15. C F H P X MODB Rev A Copper fin Boiler Water Heater and Pool Heater ModBus Communication Instructions Models 402 2072 Boiler amp Water Heater Models 502 2072 Pool Heater 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 _ r could result in severe personal T injury death or substantial property damage High Efficiency Water Heaters Boilers and Pool Heaters Save this manual for future reference 1 INTRODUCTION 111611 18 VEG 8 2 Holding 2 22 8 Minimum System 2 GOMMOUNAMON oo uoto tto eaten tin bea 8 2 CONFIGURATION 4 WIRING REQUIREMENTS PC SS WA eo asec pce neon d EE SUE 3 ModBus Mounting Wiring Instructions 9 10 Timing 4 Physical 11 13 METTE T E TM 4 Typical Boiler System Wiring 14 15 Data Transmission 4 5 UNIT OPERATION ModBus Boar
16. LVN gt lt OL O 8 2 6 2 6 SL 8X 6 9NO sng gt lt OL O S 8x 9 SNIAOMHd YAANOT O C VL 9X V GNO 41641 NYL v Jovis J VLS C C c ADVIS d I8vNa 15 LL 9X SL 9X OL GNO 9 9X GNO 0 6 SNO c ox 8 GNO 9L 9X L GNO 9 GNO 1 9 L GNO L QUVOd NOILOANNOO HOLIMS 56554844 SVO HOIH SStHd SVO MO lt lt HIV AAOLNO 1641 er 9X HOLIMS MOT v er z er 9 LBL20083 REV B 23 Copper fin IIE Boiler Water Heater and Pool ModBus Manual 7 Diagrams Figure 7 2 Connection Diagram ALARM CONTACTS RUNTIME CONTACTS 0 12 oe 10 00 B se 2 8 R 7 4 9 RIBK SOLANGE Crore ik e dams duds um PR 19 c 2 lo MN TANK OF AQUASTAT 4 4 TANK if SENSOR 1 224 TANK E SENSOR 7773 IUNITSI SHIELD A
17. URE WITH MOUNTING NUTS ADD MODBUS COVER AND SECURE WITH SHEET METAL SCREWS Copper fin Boiler Water Heater and Pool ModBus Manual 7 Diagrams Figure 7 1 Ladder Diagram V CLX v OLX 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 SEE WIRING DIAGRAM FOR ADDITIONAL NOTES gt ur lt 9 NY 9 01 ANIWASVDO VADVLS 8 4 GCLX JAAIWASVDEADVIS O 90 33 lVASVOz39vis 0 S OLX J3NTIVASVOL3O9VIS 2 01 L OLX 1OHLNOO Q31VH9M3LNI dldls JAVNIIASHLL 14544 LI VG C 94 VS C SA VS C vs VSL C ayog 1 9 Q31 VHOSH3LNI LX AN 138 Qqaads OVIH 1 HOLIMS 4A0 NO C AW 144 99345 d3MO 18 YAWYOASNVYLL 39v4s3 NI shadow m 7 SISSVHO Z O O cx E CCX Lex C2 7 ISH 39V1S Qc 1109 lt Z LX 0L LX gt 1109 ISH 15 LL AVIS 3 IS e ISl m mM v 191 0 9 amis L LX ONEN 28999 e AVIAN LINN 2 1 OVAOCLI C 2
18. ble 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 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 ILLEGAL DATA ADDRESS 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
19. cation board can be found on pages 5 and 6 of this manual Copper fin Boiler Water Heater and Pool ModBus Manual Description Read Coil Status Read Input Status Read Holding Registers Read Input Registers Force Single Coil Preset Single Register BEEN Head Exception Status o0 Diagnostic Return Query Data 1 Diagnostic Restart Communication Diagnostic Return Diagnostic Register Diagnostic Force Listen Mode Diagnostic Clear Counters and Diagnostic 10 OA Registers Message Count o Diagnostic Bus Communication Error Count 80 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 2 Get Communication Event Log oF Write Multiple Coils 12 Write Multiple Registers Report Slave ID Read Write Multiple Registers Copper fin Boiler Water Heater and Pool ModBus Manual 2 Configuration ModBus Exception Codes Exception Codes Code Mme meaning OOOO 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 applica
20. d Diagnostics 4 Unit Operation with ModBus Communications 16 19 Internal Falle bio orien baee toria 4 6 20 21 ModBus Function 2 7 DIAGRAMS ModBus Exception Codes 6 Ladder Diagram vecsescnedscncacetcessededebeetenteceiontedss 22 23 3 MEMORY MAP Connection 24 25 Primary Data 27 Revision 00 Back Cover Copper fin Memory 7 8 1 Introduction The information contained in this manual provides general guidelines for the implementation of ModBus communication with the Lochinvar Copper fin II IIE All ModBus networks are implemented utilizing a master slave arrangement where all Copper fins are slaves and the master is a building automation system capable of communicating over a RS 485 serial connection Definitions Abbreviation 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 85232 A stan
21. dard 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 Minimum System Requirements BAS system or computer with a serial or USB port with a converter to RS 485 Copper fin II IIE equipped with ModBus communication board Shielded twisted pair communication cable 2 Copper fin II IIE Boiler Water Heater and Pool ModBus Manual 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 Addressing The ModBus addressing space is comprised of 256 different addresses e Oisreserved for broadcast messages from the master device 1 247 are free to use for each unique device 248 255 are reserved 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 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
22. described in this section These methods are determined by the settings in four 4 different parameters Control Mode 1 In this configuration the heater is enabled and disabled through ModBus The heater uses its own local set points sensors and limiting devices should be connected directly to the terminal strip s inside the Copper fin II IIE control compartment The Enable 1 and or Tank Thermostat signals will be sent to the heater through ModBus 00 01 Read Enable 1 status 40001 Configuration 00 02 Read Tank Thermostat status 00 03 Read Enable 1 and Tank Thermostat status 00 01 Enable 1 only active 40002 Coils 00 02 Tank Thermostat only active 00 03 Enable 1 and Tank Thermostat active NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing commands Control Mode 2 In this configuration each stage 1s enabled directly boiler only Control Mode 2 Setup Configuration Parameters To control each stage separately access parameters H5 Sequencer and set it to Active reference the Copper fin II IIE Service Manual for the procedure on how to set the parameters Control Mode 2 Setup Command Parameters The holding register will need to be set as follows Holding Registers Definition Bit Value HEX Action 01 01 Read Enable 1 and 2 2 stage heaters 40001 Configuration 03 01 Read Enable 1 2 and 3 3 stage heaters 07 01 Read Enable 1 2 3 and 4 4 stag
23. e heaters Enable Stage 1 Enable Stages 1 and 2 Enable Stages 1 2 and 3 Enable Stages 1 2 3 and 4 NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing commands 16 Copper fin Boiler Water Heater and Pool ModBus Manual 5 Unit Operation continued Control Mode 3 In this configuration the heater receives its enable signal and a rate command through ModBus All sensors and limiting devices should be connected directly to the terminal strip s inside the Copper fin H IIE control compartment Control Mode 3 Setup Configuration Parameters To send a rate signal to the SMART SYSTEM control access parameter H3 BMS input and set it to Active reference the Copper fin II IIE Service Manual for the procedure on how to set parameters Control Mode 3 Setup Command Parameters The holding register will need to be set as follows Holding Registers Definition Bit Value HEX Action NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing commands See the Rate and Temperature Conversions Section on page 19 for instructions on how to send the rate Control Mode 4 In this configuration the heater receives its enable signal and set points through ModBus All sensors and limiting devices should be connected directly to the terminal strip s inside the Copper fin II IIE control compartment
24. e 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 Copper fin II IIE can properly respond to a call for hot water generation the following holding registers must be set in addition to other commands Holding Registers Detinition Bit Value HEX 40002 00 08 Enables Tank Tstat 00 00 disables unit 40005 Tank Temperature O Passes tank temp from remote sensor NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing commands For proper hexadecimal conversion of rate percentage please refer to the Rate and Temperature Conversion section on page 19 of this manual 18 Copper fin Boiler Water Heater and Pool ModBus Manual DEFAULT DEFAULT PARAMETER VALUES DEFAULT Deg C Deg F Voltages 2 5 Unit Ope ration continued Cascade In order to operate the Copper fin in Cascade with ModBus communications configure the leader boiler per the demand configurations 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 communication connected to only the leader boiler total Cascade information can be seen through the communications link If you wish to see all the individua
25. eans 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 Copper fin Boiler Water Heater and Pool ModBus Manual 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 Copper fin Memory Map Factor 00001 Stage 1 Enable 0 1 ON 0 OFF 00002 Stage 2 Enable 0 1 ON O OFF o 1 00003 Stage Enable 0 1 0 0 O 1 0 1 0N 00FF O 1 0 OFFJ 0 1 4 ME NE I 0 0 0 0 0 0 10004 Louver Proving Switch 0 1 ON O OFF 0 10005 Air Pressure Switch 0 1 ON O OFF 0 10008 Flame 1 0 1 ON O OFF 0 _ 10009 Stage 10n 0 1 ON O OFF 0 _ 10010 Tank Thermostat 0 1 ON O OFF 0 10011 Stage2On 0 1 0 0 O 10012 Stage3On 0 1 0 0 0 10013 4 0 1 0 0 O 0 uw 0 0 0 0 0 0 0 0 0 0 0 0 _0_ 0 ok H I I I I ON 0 OFF ON 0 ON 0 OFF ON 0 ON 0 ON O OFF ON 0
26. er Wire the ModBus as follows FIG 4 2 Connect A5 to ModBus board X1 Connect A6 to ModBus board X4 Connect 7 to ModBus board X6 If it is desired to ground the communication cable shield at the heater install a jumper wire between pins 1 and 3 of X5 Replace the ModBus cover Secure the cover using the two 2 screws provided with the ModBus Test the unit before replacing the access panels Replace the left and right access panels and turn ON power at the source Resume operation Figure 4 1 Mounting the ModBus Control Board INSTALLATION LOCATE MODBUS BRACKET ON DV PANEL AND SECURE WITH SELF DRILLING SCREWS ADD ALUMINUM SPACERS TO BRACKET STUDS ADD MODBUS CONTROL BOARD 1 AND SECURE WITH MOUNTING NUTS ADD MODBUS COVER AND SECURE WITH SHEET METAL SCREWS REPLACEMENT REMOVE SHEET METAL SCREWS AND MODBUS COVER REMOVE MOUNTING NUTS AND MODBUS CONTROL BOARD MTRO1 REPLACE BOARD AND SECURE WITH MOUNTING NUTS ADD MODBUS COVER AND SECURE WITH SHEET METAL SCREWS CONTROLLER TRANSFORMER pi LINE VOLTAGE 0 LT 4 Copper fin II IIE Boiler Water Heater and Pool ModBus Manual 4 Wiring Requirements Figure 4 2 Schematic Wire Connections HARNESS Ln DIGITAL HARNESS jd 1 E
27. fin control compartment Control Mode 5 Setup Configuration Parameters 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 The 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 fin II IIE Service Manual for the details of these parameters Control Mode 5 Setup Command Parameters The holding register will need to be set as follows 40003 0 10V Input 00 Sets space heating rate or set point NOTE To ensure proper operation re send the configuration bits to holding register 40001 prior to issuing commands See the Rate and Temperature Conversions Section on page 19 for instructions on how to send the rate Hot Water Generation Hot water generation can be accomplished with one of two methods when a Copper fin II IIE 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 DHW with remote control This installation may or may not hav
28. ked in this order 1 Physical Layer 2 Communications Configuration and Port Settings 3 ModBus Error Codes 4 Unit Status Blocking Lockout Codes Physical Layer 1 Check that all components have power Boiler Gateway BAS Master Check all wire lengths Are any drops too long Check proper shield grounding Check A B terminal connections Check for Terminating Resistors 120 ohms Check for broken wires E OE Communications 1l Check Dip Switch Configuration of MTR 01 Board 2 Check Baud Rate 9600 19200 3 Check Parity 4 Check Slave ID 2 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 ao Unit Status Codes See Codes in this section Boiler Status The Copper fin II IIE 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 20 Status Codes Input Registers 30014 and 30023 2 Heat Demand blocked due to high absolute outlet temperature 3
29. l 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 Only Any Copper fin can be equipped with the ModBus communication board and then be set up to operate with its own internal controls If necessary ModBus can be configured as a monitoring device by selecting demand configurations 1 3 and polling the ModBus board for the read only variables 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 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 _ 0 60 3c 80 50 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 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 BMS temperature set point at 2 69 8 low analog input BMS temperature set
30. point at 1 high analog input For Example Send a set point of 110 F The 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 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 set point Temperature The Copper fin II HE 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 T 32 Tr 9 5 T432 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 Decimal Binary HEX 267 100001011 10B Outlet temperature from unit sensor 155 F 155 68 3 C Data transmitted from unit in HEX 2AB 683 683 10 68 3 C Decimal Binary 683 1010101011 HEX 2AB 19 Copper fin Boiler Water Heater and Pool ModBus Manual 6 Troubleshooting Should you encounter problems communicating over ModBus the following items should be chec
31. set to 0 has a value equal to 0 DIP SWITCHES 08 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 The 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 8 In this example Address 0 2 0 0 164 32 0 0 50 Copper fin Boiler Water Heater and Pool ModBus Manual 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 accessing parameter H7 see the Copper fin Service Manual for the procedure on how to set parameters The timeout is adjustable between 1 and 255 seconds The default timeout is 10 seconds When the BAS is not providing either
32. 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 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 conjunction 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 m
33. when gas valve relay test fails 240 EEPROM code 32767 Code not present Installation Replacement Procedure Figure 6 1 MTRO1 Control Board UNPLUG THREE 3 WIRE HARNESSES BB oE allla 2 2 NO SENE E Turn OFF the main electrical power to the appliance Turn OFF the main manual gas shutoff to the appliance Unplug the three 3 wire harnesses the control board see FIG 6 1 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 Turn on the main electrical power and the main manual gas shutoff to the appliance Configure the MTRO1 control board and unit controls per this manual and resume operation Figure 6 2 Control Panel w MTRO1 Control Board INSTALLATION LOCATE MODBUS BRACKET ON DV PANEL AND SECURE WITH SELF DRILLING SCREWS ADD ALUMINUM SPACERS TO BRACKET STUDS ADD MODBUS CONTROL BOARD 01 AND SECURE WITH MOUNTING NUTS ADD MODBUS COVER AND SECURE WITH SHEET METAL SCREWS REPLACEMENT REMOVE SHEET METAL SCREWS AND MODBUS COVER REMOVE MOUNTING NUTS AND MODBUS CONTROL BOARD MTRO1 REPLACE BOARD AND SEC

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