Lochinvar 1.0- 1.3- 1.5 manual

SYNC-MODB Rev A Th i s m a n u a l m u s t o n l y b e u s e d b y a qualified heating installer / serv ice technician. R ead all instructions, including this manual, the Installation and Operation Man ual, and the Serv ice M anual, before installing. P erform steps in the order given. Failure to c omply could result in sever e personal injur y , d[...]

2 1 Introduction The information contained in this manual pr ovides general guidelines for the implementation of Modbus comm unication with the Lochin var SYNC boiler . All Modbus netw orks are implemented utilizing a master -slave arrangement where all SYNC boilers are sla ves and the master is a building automation system capable of communicating[...]

3 2 Configur a tion Addr essing The Modbus addr essing space is comprised of 256 different addresss. • 0 is reserved for broadcast messages fr om the master dev ice • 1 - 247 are free t o use for each unique device • 248 - 255 are reserved T o set the M odbus address the dip switches can be set in either the 0 position or the 1 position. For [...]

4 Modbus Instructions 2 Configur a tion Timing Specifications The baud rate for the M odbus 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. W hen the system temperature and/or tank t emperature is provided [...]

5 2 Configur a tion (continued) Modbus Instructions Function Sub Function HEX Description Dec HEX Dec 1 01 Read Coil S tatus 2 02 Read Input S tatus 3 03 Read Holding Registers 4 04 Read Input Registers 5 05 Force Single Coil 6 06 Preset Single Register 7 07 Read Exception S tatus 8 08 0 00 Diagnostic - Return Query Data 1 01 Diagnostic - Restart C[...]

6 Modbus Instructions 2 Configur a tion MODBUS Exception Codes Code 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 se[...]

7 Modbus Instructions Primar y Da ta T ables T able Data T ype Read / Write Discrete Inputs Single Bit Read Only Coils Single Bit Read / Write Input Registers 16-Bit Word Read Only Holding Registers 16 Bit Word Read / Write SYNC Boiler Memor y Map Coils Address Description Default Unit Min. Max. Resolution 00001 Boiler Enable / Room Thermost at 1 /[...]

8 Modbus Instructions Input Registers Address Description Default Unit Min. Max. Resolution 30001 Discrete Inputs 1 - 16 0 NA 0 65535 1 30002 Discrete Inputs 17 - 32 0 NA 0 65535 1 30003 Discrete Inputs 33 - 48 0 NA 0 65535 1 30004 System / Cascade Setpoint 0 Degrees Celsius 0 130 0,5 30006 Cascade T ot al Power 0 % 100 800 1 30007 Cascade Current [...]

9 Modbus Instructions 4 W iring Requirements RS-485 Communication Bus • Maximum L ength = 4000 feet • Cable Specification = 24 A W G / A,B (twisted pair) and GND Shielded, with characteristic Impedanc e = 120 ohm • Maximum Load = 32 units (32 nodes) NOTE: Cable m ust be terminated with 120 ohm impedance matching r esistor on each end. N ote t[...]

10 4 W iring Requirements Figure 4-2 _Control Inputs GAS PRESSURE SW ITCH ROOM THERMOST A T / ZONE CO NTROL FLOW SW ITCH SYSTEM SENSOR OUTDOOR SENSOR SEQ UENCER / B UILDI NG MANAGEME NT SYSTEM L O W V O LTAG E CONNECTION BOA RD HEA T EXCHANGER 1 / HEA T EXCHANGER 2 INLET TEMPERA TURE SENSOR HEA T EXCHANGER 1 / HEA T EXCHANGER 2 OU TLET TEMPERA TURE[...]

11 4 W iring Requirements (continued) Figure 4-3 _Control Outputs LOW VO L T A GE CONNECTION BOA RD PRIM AR Y CONTROL MO DULE ALARM BELL RUN TIME CONT ACTS SEQU ENCER / BU ILDING MANAGEM ENT SY ST EM HEA T EXCHANGER 1 / HEA T EXCHANGER 2 BOILER PUMP SYSTEM PU MP HW PUMP IGNIT OR BLOW ER GAS V AL VE PC INTERF ACE SECON DA R Y SMART T OUCH CONTROL MO[...]

12 4 W iring Requirements Figure 4-4 _Control Location CONTROLLER 1 CONTROLLER 2 MODBUS COMMUNICATI ON BOARD (MTR01) HEAT EXCHANGER 1 HEAT EXCHANGER 2 Modbus Instructions Typical Boiler System Wiring Cascade Daisy Chain Connec tion Modbus RS4 8 5 Comm unication Bu s Modbus RS4 8 5 Po r t on Gateway o r Buildin g System Physical Configuration: Casca[...]

13 4 W iring Requirements (continued) Modbus RS4 8 5 Comm unication Bu s Modbus RS4 8 5 Po r t on Gateway o r Buildin g Syst em Physical Configuration: Direct Control Cascade Daisy Chain Connection Modbus RS4 8 5 Comm unication Bu s Modbus RS4 8 5 Po r t on Gateway o r Buildin g Sy stem Physical Configuration: Cascad e w ith indiv idual Monitoring [...]

14 5 Unit Oper a tion Unit Operation with Modbus Communications T o control a SYNC boiler thr ough a Building Management S ystem comm unicating through Modbus, the SYNC Demand Configuration must be set to a value of 4, 5, or 6. These c onfigurations allow different c ont rol points for a variety of appli cations. The configuration can be set by sel[...]

15 5 Unit Oper a tion (continued) Demand Configuration 6 In this co nfiguration the unit is controlled b y setting the modulation setpoint from 0 - 100%. Rate command will be 0 - 100% of the modulation r ange. All sensors and limiting devices should be hardwired to the terminal strip on the back of the unit ex cluding the 0 - 10Vdc sign al. This si[...]

16 5 Unit Oper a tion Cascade In order t o operate the SYNC boiler 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 wir ing. Cascade control can then be ac complished automatically thr ough the leade[...]

17 T emperature The SYNC boiler passes temperature data in degrees Celsius. Also, to acc ommodate decimal places the decimal value m ust be divided by 10. Her e are the con versions to and fr om Celsius: T c = (5/9) * (T f -32) T f = (9/5) * T c +32 Example: Outdoor temperatur e from re mote sensor on BAS S ystem = 80°F 80°F = 26.7°C Data that n[...]

18 6 T roubleshooting Should you enc ounter problems c ommunicating over Modbus, the following items should be checked in this or der : 1. Physical La yer 2. Communications Co nfiguration and P ort Settings 3. Modbus Error C odes 4. U nit Status / Blocking / Lockout Codes Physical Layer 1. Check that all components hav e power (Boiler , Gatewa y , [...]

19 6 T roubleshooting (continued) Lockout Codes (Input Registers 30016 and 30025) 161 = EEPR OM code P arameters not R e-Pr ogrammed by Lochinvar 164 = EEPR OM code N o Reset Allowed (> 15 minutes) 166 = EEPR OM code A uto R eset High Limit 167 = EEPR OM code Blocked Drain 168 = EEPR OM code Louv er Pr oving 169 = EEPR OM code Gas Pr essure S w [...]

20 Modbus Instructions BOX DEPICTS OPTIONAL ITEMS LADDE R DIAGRA M LBL200 58 RE V E CONTROL MODULE 2 X5-3 X2-1 GAS V ALVE GAS V ALVE RELAY X5-5 X5-13 X5-6 X5-12 1 2 4 5 TR1 X1-7 FLAME ROD SPAR K ROD 120 V AC LOW VO L TAGE HIGH VOL T AGE CAUTION HIGH VOL TA GE SP A RK LEAD BLOWER X2-2 NOTES: 1. Whe re possi ble , swit ches are sho wn wit hout uti li[...]

21 Modbus Instructions 7 Diag r ams (continued) Figure 7-2 Ladder Diagram_Part 2 BOX DEPICTS OPTIONAL ITEMS 120 VAC 24 VAC 120VAC TERMINAL STRIP 120V SUPPLY "L" ON / OFF SWIT CH X1-6 BOILER PUMP RELAY DHW PUMP RELAY SYSTEM PUM P RELAY BLOWER RELAY X1-4 X1-2 X1-1 12 3 BLOWER X1-5 X6-8 X6-3 F5 X5-7 X6-7 NEUTRAL TERMINAL STRIP 120V SUPPL Y &[...]

22 Modbus Instructions 7 Diag r ams Figure 7-3 Wiring Diagram BOX DEPICTS OPTIONAL ITEMS OUT LET SENSOR Notes: 1. All wiring mus t be installed in accordance with: local, state, provincial and nat ional code requir ements per either N. E .C. in USA o r C. S.A. in C anad a . 2. If any original equipment wire a s supplied with the appliance must be r[...]

23 Notes[...]

Revision Notes: Revision A (ECO #C04560) initial release. SYNC-MODB Rev A 10/09[...]