HTP Mod Bus Adapter Installation manual
Below you will find brief information for Modbus Adapter 7350P-629. This manual provides guidelines for the use and installation of the Modbus communication system with HTP appliances.
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MODBUS
INSTALLATION
TROUBLESHOOTING
MOD BUS Models
7350P-629
FOR USE WITH MODCON, MODCON VWH, PIONEER, VERSA-FLAME
MANUFACTURED ON OR AFTER JULY 1, 2011
FOR USE WITH ELITE, ELITE VWH
MANUFACTURED ON OR AFTER AUGUST 1, 2011
NOTICE: HTP reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.
NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE.
120 Braley Rd. P.O. Box 429 East Freetown, MA 02717-0429 www.htproducts.com
LP-372 Rev. 6.14.13
2
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the product.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
FOREWORD
This manual provides guidelines for the use and installation of the Modbus communication system with HTP appliances.
FOR THE INSTALLER
The installer should be guided by the instructions furnished with the Modbus, local codes and utility company requirements. Preference should be given to codes and requirements where they differ from the furnished instructions.
Additional publications which should guide the installer include:
The latest version of the National Electrical Code, NFPA No. 70.
In Canada, refer to Canadian Electrical Code C 22.1, from Canadian Standards Association, 5060 Spectrum Way, Suite 100,
Mississauga, Ontario, Canada L4W 5N6.
TABLE OF CONTENTS
3
PART 1 - GENERAL INFORMATION
Modbus communication systems utilize a master-follower format where connected HTP appliances follow commands from a building management system or other Modbus master device linked over an RS-485 serial connection.
If any system component(s) is/are exposed to the following, do not operate until the affected component(s) has/have been inspected by a qualified serviceman.
1. FIRE
2. DAMAGE
3. SUBMERSION IN WATER
4
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
A. WHAT’S IN THE BOX
1. One MODBUS Adapter
2. One bag of mounting hardware
3. One mounting template
B. MINIMUM SYSTEM REQUIREMENTS
1. A Modbus master device, such as a Building Automation System (BAS) or computer with Modbus master software, and an RS-485 serial port or USB port with a converter to RS-485.
2. HTP Modbus adapter (this kit), and an HTP appliance/water heater equipped with a control with firmware revision MTSA-P110414 or greater. To determine whether your product is compatible with this adapter, refer to Figure 1.
3. Shielded twisted pair communication cable.
Figure 1
– Controller Revision Label Location
C. DEFINITIONS
Table 1 is a list of definitions used throughout this manual.
ABBREVIATION OR ACRONYM
ASCII
BAS
Baud (Baud Rate)
BMS
EMS
FDX
HDX
Hex
I/O Box
LSB
DEFINITION
American Standard Code for Information Interchange
Building Automation System
Number of data bits transmitted per second (bps)
Building Management System
Energy Management System
Full-Duplex
Half-Duplex
Hexadecimal Number (0-9, A-F)
Input/Output
Least Significant Byte
5
Modbus
MSB
RS232
RS485
RTU
PG
MB
Table 1 – Acronym definitions
A serial, half-duplex transmission protocol developed by AEG Modicon
Most Significant Byte
RS232 serial, full-duplex (FDX) transmission of data standard
RS-485 serial transmission of data standard
Remote Terminal Unit
Industry Standard liquid-tight wiring entry connector
MODBUS
PART 2 - INSTALLATION
The Modbus adapter should be mounted to a solid surface. The adapter has two tabs with four mounting holes designed specifically for this purpose.
Use the mounting screws provided with the adapter. Damage to Modbus adapter or appliance due to installation with other mounting screws IS NOT covered by warranty.
When mounting the unit, keep in mind that the top cover must be removed to connect the Modbus communication cable, and that the appliance communication wire must reach the control inside the appliance.
The Modbus adapter can be mounted on the side of the appliance OR the wall next to the appliance, as long as care is taken to avoid components behind the mounting surface. The mounting location must be within 3 feet of the appliance controller in order to be plugged into the controller programming port.
NOTE: It is not recommended to install the Modbus adapter inside the appliance housing. Doing so may affect appliance operation or damage the Modbus adapter.
Damage to Modbus adapter or appliance due to improper installation IS NOT covered by warranty.
A. WIRING REQUIREMENTS
RS-485 Communication Bus
Maximum length: 1000 feet
Cable specification: 24 AWG / A,B (twisted pair) and GND shielded, with characteristic impedance: 120 ohm
Maximum load: 32 units (32 nodes)
Wires will be passed through the PG connector on the side of the adapter, then connected to the three position connector marked “X5” on the circuit board inside the adapter. A label is provided inside the adapter to ensure proper connections of A, B, and GND. Two wires
(MB IN and MB OUT) may be attached to each X5 screw.
See Figure 2 for an example wiring diagram.
BMS G
A
B
X5
X5
MODBUS ADAPTER
APPLIANCE 1
X5
APPLIANCE X
REMOVE JUMPER
(J1) FROM THIS
ADAPTER ONLY!
Figure 2
– Jumper Configurations in a Modbus Network
B. JUMPER SETTING
The appliance display handles most of the Modbus adapter configuration. There is one jumper on the Modbus adapter. When this jumper is in place (factory default) it connects a termination resistor across the data lines of the RS-485 connection. Leave the jumper in if the Modbus adapter is at the end of the RS-485 bus. Remove the jumper if the Modbus adapter is one of many connections and not at the end of the bus. See Figures 2 and 3.
6
Figure 3
– Modbus Termination Jumper Location (Highlighted in Grey)
7
PART 3 – COMMUNICATION CONFIGURATION (APPLIANCES WITH A 3
CHARACTER RED LED DISPLAY)
A. MODBUS ENABLE
1. Press and hold ENTER and RESET simultaneously. Use the UP and DOWN arrows to show 925 on the display, then press and hold
ENTER to enter the installer menu.
2. Once in the Installer Menu, use the ENTER button to navigate to Parameter 37. When at Parameter 37, use UP or DOWN select the desired setting from the table below:
Parameter Setting
37
37
0
1
37 2
Table 2
– Parameter 37 Settings
Description
MODBUS “DISABLED” (factory default)
MODBUS “ON”
MODBUS “AUTO” (enables automatic detection of a PC or Adapter)
Please do not leave the Installer Menu after making this selection. Configure the Address, Baud Rate, and Parity settings described below.
B. MODBUS ADDRESS
NOTE: Modbus must be enabled on the appliance as outlined above for the following parameters to be viewed and changed.
The Modbus address space is comprised of 256 addresses. These are defined as follows:
Address 0 is a broadcast address. The master can send data to address 0 and all followers will process the data.
Addresses 1
– 247 are free to be assigned to Modbus devices on the bus. Each address can be assigned to only one Modbus device on the bus.
Addresses 248
– 256 are not available for use.
MODBUS ADDRESSING SUGGESTIONS*
Each device must have a unique address.
It is not recommended to use 1 as an address, as this is often the default address for various other Modbus devices that may be on the bus.
In order to keep track of addresses for future maintenance purposes, record all device addresses in the Installation and Maintenance Notes section included in this manual.
*SAVE THIS DOCUMENT IN A SECURE LOCATION FOR FUTURE REFERENCE.
To set the Modbus adapter address in the appliance installer menu:
From the Installer Menu, press the ENTER key to advance to Parameter 38. Use the UP and DOWN arrows to set the desired address.
Press the RESET button to store the address.
Press the DOWN button to advance to Parameter 39 - Baud Rate.
C. BAUD RATE
The baud rate (communication speed) can be set to either 9600 or 19200 baud. All HTP appliances, as well as any other device on the same bus and the Modbus master, must have the same baud rate setting. Select the highest baud rate that offers the most reliable communication performance over the bus.
Some things that can affect communications are:
Long wire runs
Wire quality
A noisy electrical environment
The number of devices on the bus.
These conditions may require using a lower baud rate.
Use the UP and DOWN buttons to select the desired setting from the table below:
Parameter
39
Setting
0 BAUD RATE = 9600 (factory default)
Description
39 1 BAUD RATE = 19200
Table 3 – Parameter 39 Settings
Press RESET to store the baud rate. Press the DOWN button to advance to Parameter 40 - Parity and Stop Bits.
8
D. PARITY AND STOP BITS
The parity/stop bits parameter of the Modbus adapter must be set to match the rest of the devices on the bus. Although it is common to set serial devices to use no parity, setting the parity to even or odd may improve communications reliability on all connected devices on the bus.
This parameter has 4 possible selections which should be sufficient to establish communication with other devices. These selections are outlined in Table 4.
Parameter Setting Description
40
40
0
1
No parity 1 stop bit (factory default)
No parity 2 stop bits
40 2 Even parity 1 stop bit
40 3 Odd parity 1 stop bit
Table 4 – Parameter 40 Settings
Press and Hold the RESET button to store all parameters and exit the Installer Menu.
PART 4 – COMMUNICATION CONFIGURATION (APPLIANCES WITH AN LCD TEXT
DISPLAY)
A. MODBUS ENABLE
1. Press and hold the ENTER key until you see the screen at right.
ENTER MENU CODE
925
Use the RIGHT arrow to select a character, then use the UP and DOWN arrows to select the desired character value. RIGHT arrow over to the next character and repeat the selection. Once you have 925 on the screen, press and hold ENTER on the display to enter the Installer Menu.
2. Once in the Installer Menu, use the RIGHT arrow to navigate to Parameter 37. When at Parameter 37, press ENTER. The current setting should be flashing. Press UP or DOWN to select the desired setting from Table 5:
Parameter Setting Description
37
37
OFF
ON
MODBUS “DISABLED” (factory default)
MODBUS “ON”
37 AUTOMATIC MODBUS “AUTO” (enables automatic detection of a PC or Adapter)
Table 5
– Parameter 37 Settings
FUNCTION 37
MODBUS MODE Press ENTER once the desired setting is flashing on the display. Once accepted, the
OFF 37 selection should not flash.
Please do not leave the Installer Menu. Configure the Address, Baud Rate, and Parity settings described below.
B. MODBUS ADDRESS
NOTE: Modbus must be enabled on the appliance as outlined above for the following parameter to be viewed and changed.
The Modbus address space is comprised of 256 addresses. These are defined as follows:
Address 0 is a broadcast address. The master can send data to address 0 and all followers will process the data.
Addresses 1 – 247 are free to be assigned to Modbus devices on the bus. Each address can be assigned to only one Modbus device on the bus.
Addresses 248 – 256 are not available for use.
MODBUS ADDRESSING SUGGESTIONS*
Each device must have a unique address.
It is not recommended to use 1 as an address, as this is often the default address for various Modbus devices.
In order to keep track of addresses for future maintenance purposes, record all device addresses in the Installation and Maintenance Notes section, included in this manual.
*SAVE THIS DOCUMENT IN A SECURE LOCATION FOR FUTURE REFERENCE.
In the Installer Menu, press RIGHT to advance to Parameter 38.
FUNCTION 38
MODBUS ADDRES
0 38
Press ENTER. The address value will blink. Use the UP and DOWN arrows to set the desired address. Press ENTER again to accept your selection (and stop the display from
9 blinking).
Press the RIGHT button to advance to Parameter 39 - Baud Rate.
C. BAUD RATE
The baud rate (communication speed) can be set to either 9600 or 19200 baud. All HTP appliances, as well as any other device on the same bus and the Modbus master, must have the same baud rate setting. Select the highest baud rate that offers the most reliable communication performance over the bus.
Some things that can affect communications are:
Long wire runs
Wire quality
A noisy electrical environment
The number of devices on the bus
These conditions may require using a lower baud rate.
FUNCTION 39
MODBUS SPEED
009600 39
Press ENTER. The baud rate number will blink. Use the UP and DOWN arrows to toggle between 009600 and 019200. Press ENTER again to select the baud rate and stop the display from blinking.
Press DOWN to advance to Parameter 40 - Parity and Stop Bits.
D. PARITY AND STOP BITS
The parity/stop bits parameter of the Modbus adapter must be set to match the rest of the devices on the bus. Although it is common to set serial devices to use no parity, setting the parity to even or odd may improve communications reliability on all connected devices on the bus.
This parameter has 4 possible selections which should be sufficient to establish communication with other devices. These selections are outlined in Table 6.
PARAMETER 40 SETTING TEXT DISPLAY PARITY / STOP BITS
1 ST
2 ST
E PA
O PA
Table 6
– Parameter 40 Settings
No parity 1 stop bit
No parity 2 stop bits
Even parity 1 stop bit
Odd parity 1 stop bit
FUNCTION 40
MODBUS STOP/PARITY
1 ST 40
Press ENTER. The STOP/PARITY value will blink. Use the UP and DOWN arrows to toggle between 1 ST, 2 ST, E PA, and O PA. Make your selection based on the table above. Press ENTER again to select the STOP/PARITY value and stop the display from blinking.
Configuration is now complete. Press RESET to permanently store ALL the Modbus settings.
PART 5 – GENERAL MODBUS INFORMATION
A. DATA TRANSMISSION MODE
Many Modbus master devices can be configured to transmit data in either RTU or ASCII modes. Since RTU messages use fewer data bits and are more efficient, RTU has been chosen for all communication with the Modbus adapter. Please ensure that the master device is configured for RTU communications.
B. MODBUS BOARD DIAGNOSTICS
The Modbus board is equipped with three LEDs for visual diagnostics: Two yellow and one green. These LEDs are located under the
Modbus cover. 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) shows internal faults. See Figure 4 for LED locations.
Internal Faults (Green LED):
Normal Operation = 1 second on, 1 second off
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
10
Figure 4 – Modbus Diagnostic LEDs
C. MODBUS COMMUNICATION
The Modbus communication commands can be found in Parts 3 and 4 of this manual, and exception codes supported by the communication board can be found in Part 5, Section E.
D. MODBUS FUNCTION SET
FUNCTION SUB FUNCTION
6
7
8
DEC
1
2
3
4
5
06
07
08
HEX
01
02
03
04
05
2
4
10
11
0
1
12
13
14
15
16
DEC
HEX
0A
0B
0C
0D
00
01
02
04
0E
0F
10
DESCRIPTION
Read coil status
Read input status
Read holding registers
Read input registers
Force single coil
Preset single register
Read exception status
Diagnostic
– Return query data
Diagnostic – Restart communication
Diagnostic
– Return diagnostic register
Diagnostic – Force listen mode
Diagnostic
– Clear counters and diagnostic registers
Diagnostic – Return bus message count
Diagnostic
– Return bus exception error count
Diagnostic – Bus exception error count
Diagnostic
– Return follower message count
Diagnostic – Return communication error count
Diagnostic
– Return follower NAK count
11
FUNCTION SUB FUNCTION
DEC
11
12
HEX
0B
0C
15
16
17
22
0F
10
11
23 17
24
Table 7 – Modbus function set
DEC
17
18
20
E. MODBUS EXCEPTION CODES
CODE NAME
01
02
03
04
05
06
08
0A
ILLEGAL FUNCTION
ILLEGAL DATA ADDRESS
ILLEGAL DATA VALUE
FOLLOWER DEVICE FAILURE
ACKNOWLEDGE
FOLLOWER DEVICE BUSY
MEMORY PARITY ERROR
GATEWAY PATH UNAVAILABLE
0B
GATEWAY TARGET DEVICE
FAILED TO RESPOND
Table 8
– Modbus exception codes
HEX
11
12
14
DESCRIPTION
Diagnostic – Return follower busy count
Diagnostic
– Return bus character overrun count
Diagnostic – Clear overrun counter and flag
Get communication event counter
Get communication event log
Write multiple coils
Write multiple registers
Report follower ID
Mask write register
Write multiple registers
Read FIFO Queue
MEANING
This code is received when an illegal action is entered into the building management system. This may be because the function code is only applicable to newer devices, or the follower device is in the wrong state to process a request of this type.
This code is received when an illegal data address is entered into the building management system. More specifically, the combination of reference number and transfer length is invalid.
This code indicates that an illegal value has been entered into the building management system.
An error occurred while the follower was attempting to perform the requested action.
Indicates that the server (or follower) has accepted the request, but will take a significant amount of time to process it. This response prevents a timeout error.
This is received when a follower device is busy processing a programmed command.
User should query this device at a later time.
The server (or follower) attempted to read a file, but detected a parity error in the memory. The user can retry the request, but service may be necessary to fix this error.
Indicates that the gateway was unable to allocate an internal communication path from the input port to the output port.
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.
PART 6 - REGISTER MAP
A. PRIMARY DATA TABLES
TABLE
Discrete Inputs
DATA TYPE
Single bit
Coils
Input Registers
Single bit
16-bit word
Holding Registers 16-bit word
Table 9 – Supplementary information
B. APPLIANCE MEMORY MAP
ADDRESS DESCRIPTION
00001
00005
00006
Appliance enable / Room thermostat / Stage 1
Tank thermostat
READ/WRITE
Read only
Read / Write
Read only
Read / Write
DESCRIPTION
Data can be provided by an I/O system.
Data can be altered by an application program.
Data can be provided by an I/O system.
Data can be altered by an application program.
DEFAULT
COILS
0
UNIT
1 = on, 0 = off
0 1 = on, 0 = off
MIN MAX
0
0
1
1
RESOLUTION
1
1
30001
30002
30003
30004
30005
30006
30007
30008
30009
30010
30011
30012
30013
30014
30015
30016
30017
10058
10059
10060
10061
10062
10063
10064
10065
10050
10051
10052
10053
10054
10055
10056
10057
ADDRESS
10001
10002
10003
10004
10005
10006
10007
10008
10009
10010
10011
10033
10034
10035
10036
10038
10039
10049
DESCRIPTION
Manual reset high limit 1
Flow switch 1
Gas pressure switch 1
Louver switch 1 (NOT USED)
Air pressure switch / flap valve
Blocked drain switch
Auto reset high limit 1
Flame 1
Enable / room thermostat / stage
1
Tank thermostat
Extra appliance signal
Run contacts
Alarm contact 1
(EXCEPT Versa-Hydro)
CH pump 1
DHW pump 1
Gas valve 1
System pump
Appliance 0 burning (same as
10008)
Appliance 1 burning (same as
10023)
Appliance 2 burning
Appliance 3 burning
Appliance 4 burning
Appliance 5 burning
Appliance 6 burning
Appliance 7 burning
Appliance 0 lockout (same as
10034)
Appliance 1 lockout (same as
10042)
Appliance 2 lockout
Appliance 3 lockout
Appliance 4 lockout
Appliance 5 lockout
Appliance 6 lockout
Appliance 7 lockout
Alarm relay
(Versa-Hydro ONLY)
Discrete inputs 1 - 16
Discrete inputs 17
– 32
Discrete inputs 33 – 48
System / cascade set point / system pump speed / PUMP 4
SPEED
Cascade total power
Cascade current power
Outlet set point 0
Outlet temp 0
Inlet temp 0
Flue temp 0
Firing rate 0 / Appliance 0 pump speed / Pump 5
SPEED
Appliance 0 status code
Appliance 0 blocking code
Appliance 0 lockout code
Outlet set point 1
0
0
0
0
0
0
0
0
DISCRETE INPUTS
DEFAULT
0
UNIT
1 = on, 0 = off
0
0
0
0
0
0
0
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
0
0
0
0
0
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
0
0
0
0
0
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
1 = on, 0 = off
INPUT REGISTERS
0
0
0
NA
NA
NA
0 Deg F
%
%
%
Deg F
Deg F
Deg F
Deg F
%
%
NA
NA
NA
Deg F
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
MAX
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
MIN
0
0
0
0
0
0
0
0
0
0
0
0
0
65535
65535
65535
212
100
800
800
212
266
266
266
100
100
65535
65535
65535
212
0
0
0
-76
-76
-76
0
0
0
0
0
0
-76
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
RESOLUTION
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0, 1
1
1
1
0, 1
0, 1
0, 1
0, 1
0, 1
1
0, 1
12
ADDRESS
30018
30019
30020
30021
30036
30037
30038
30039
30040
30041
30042
30043
30044
30045
30046
30047
30048
30049
30050
30022
30023
30024
30025
30026
30027
30028
30029
30030
30031
30032
30033
30034
30035
30051
30052
30053
30054
30055
DESCRIPTION
Outlet temp 1
Inlet temp 1
Flue temp 1
Firing rate 1 / Appliance 1 pump speed / Pump 4
OUTPUT
Appliance 1 status code
Appliance 1 blocking code
Appliance 1 lockout code
Appliance 2 outlet temperature
Appliance 2 firing rate
Appliance 2 status
Appliance 2 lockout code
Appliance 3 supply temperature
Appliance 3 firing rate
Appliance 3 status
Appliance 3 lockout code
Appliance 4 supply temperature
Appliance 4 firing rate
Appliance 4 status
Appliance 4 lockout code
Appliance 5 supply temperature
Appliance 5 firing rate
Appliance 5 status
Appliance 5 lockout code
Appliance 6 supply temperature
Appliance 6 firing rate
Appliance 6 status
Appliance 6 lockout code
Appliance 7 supply temperature
Appliance 7 firing rate
Appliance 7 status
Appliance 7 lockout code
Discrete inputs 49 - 64
NTC 6 temperature
NTC 7 temperature
Solar Panel temperature
Solar flow
Solar temp
DEFAULT
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
20
0
0
0
0
UNIT
%
Deg F
Seconds
Seconds
%
%
Deg F
Deg F
Deg F
0
0
0
0
Deg F
Deg F
Deg F
LPM
0 Deg F
HOLDING REGISTERS
See below
V
Deg F
Deg F
Deg F
Deg F
Deg F
NA
NA
Deg F
%
NA
NA
Deg F
%
NA
NA
Deg F
%
NA
NA
NA
%
NA
NA
NA
Deg F
%
NA
NA
Deg F
%
NA
NA
Deg F
%
40001
40002
40003
40004
40005
Configuration
Coils
0
– 10 volt / rate / set point CMD
Tank set point
Tank temperature
40006
40007
40008
Outdoor temperature
System supply temperature
System return temperature
40009
40010
I4 for direct mode
CH post purge
40011 DH post purge
40012 Solar Pump speed
40014 Extra 0
– 10 volt output
Table 10
– Modbus memory map
NOTE: Use Blocking Codes and Lockout Codes to interpret remote boiler operating conditions.
-76
-76
0
0
0
0
0
0
0
-76
0
0
0
-76
0
0
0
0
0
0
-76
0
0
0
-76
-76
-76
-76
0
14
0
-76
0
0
0
-76
0
0
0
0
0
-76
0
0
MIN
-76
-76
-76
0
C. BLOCKING CODES
NUMBER
0
11
None water pressure low
BLOCKING CODES (INPUT REGISTERS 30015 AND 30024)
DEFINITION
MAX
266
266
266
100
65535
65535
266
100
65535
65535
266
100
65535
65535
266
100
65535
65535
65535
100
65535
65535
65535
266
100
65535
65535
266
100
65535
65535
266
100
266
266
266
100
248
248
10
212
266
266
266
36
255
255
100
100
RESOLUTION
0, 1
0, 1
0, 1
0, 1
1
0, 1
1
0, 1
1
0, 1
0, 1
1
0, 1
1
1
0, 1
1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
0, 1
1
1
0, 1
0, 1
13
14
NUMBER
12
13
14
16
17
21
23
25
26
30
31
32
33
Table 11
S1 temperature high
S2 temperature high
Flue temperature high
Regulation temperature high
Not enough water flow
Anti-cycling CH max flue pressure switch/ max start cycles
Max temperature increase limiting CH
24 V to low
Water level low 1
Water level high 1
Water level low 2
Water level high 2
DEFINITION
190
191
192
193
194
195
196
197
198
199
185
186
Table 12
NUMBER
240
239
237
236
235
233
232
230
204
205
206
207
D. LOCKOUT CODES
LOCKOUT CODES (INPUT REGISTERS 30016, 30025, 30029, 30033, 30037, 30041, 30045, AND 30049)
DEFINITION
Flue thermostat open
Safety thermostat open
False Flame
APS stuck open
APS stuck closed
No flame after ignition
No flame during running
Fan fault
Parameters damaged
Parameters programmed
Error during programming
Parameter EEPROM failure
S1 maximum temperature
S2 maximum temperature
S1 shorted
S1 interrupted
S2 shorted
S2 interrupted
Low water lockout
Flue sensor shorted
Flue sensor interrupted
Low water lockout 2
ECS6 temperature lockout
ECS7 temperature lockout
E. STATUS CODES
NUMBER
0
96
100
101
Table 13
STATUS CODES (INPUT REGISTERS 30014, 30023, 30028, 30032, 30036, 30040, 30044, AND 30048)
DEFINITION
Standby
Running
DHW Mode or Blocking for Cascade
Low Water Blocking
F. CONFIGURATION BITS
Address 40001 contains configuration bits sent from the BAS to the appliance. These bits tell the appliance to use its own internal inputs, or inputs from the BAS. When a bit is set to 1, the appliance 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:
HOLDING REGISTER 40001
B0
B1
B2
B3
B4
B5
B6
B7
B8
B9
DEFINITION
Boiler enable
Tank enable
Rate command / 0 – 10V input / set point command (40003)
DHW set point (40004)
DHW temperature (40005)
Outdoor temperature (40006)
System supply temperature (40007)
System return temperature (40008)
I4 offset (40009)
CH post purge (40010)
HOLDING REGISTER 40001 DEFINITION
B10
B11
DHW post purge (40011)
Pump 4 speed (40012)
B12
B13
Pump 5 speed (40013)
Extra 0 – 10 V output (40014)
DEFINITION HOLDING REGISTER 40002
Coil 01 b0 Room thermostat
Coil 05 b4
Table 14
– Modbus holding registers
Tank thermostat
15
0 = TAKEN FROM CONTROL
1 = TAKEN FROM MODBUS
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0/1
0 = TAKEN FROM CONTROL
1 = TAKEN FROM MODBUS
0/1
0/1
0/1
0/1
PART 7 - APPLIANCE OPERATION
A. APPLIANCE OPERATION WITH MODBUS COMMUNICATIONS
The appliance is equipped with a Modbus communication timer. Timeout is set for four minutes. The purpose of the timer is to ensure proper temperature data is communicated to the appliance in a timely manner.
Additionally, the communication timer will provide fail safe operation should Modbus communication be lost. This timer will cause the appliance to revert back to internal appliance controls should the Modbus communication be interrupted longer than the Modbus timer.
The timer resets every time a Modbus write command is received with updated temperatures or commands.
The master should update temperature registers at least once per minute, but no more than once per second.
B. EXAMPLE #1
In this configuration, the appliance is controlled by setting the set points locally on the appliance and providing an enable signal through
Modbus communications.
All sensors and limiting devices (excluding the thermostat enable and tank thermostat enable signals, which will be sent to the appliance via Modbus) should be hardwired to the proper terminals in the appliance.
The holding registers need to be set as follows:
HOLDING REGISTERS
40001
40002
DEFINITION
Configuration
Coils
VALUE
00 01 Set configuration to read 40002
ACTION
00 01 Enables CH Demand (00 00 disables demand)
40002
40002
Coils
Coils
00 10 Enables DHW demand on appliance (00 00 disables demand)
00 11 Enables both CH and DHW demand. DHW demand will have priority
Table 15
C. EXAMPLE #2
1. SEND FIRING RATE COMMAND FROM MASTER
In this configuration, the appliance is controlled by setting the modulation set point from 0
– 100%. Rate command will be 0 – 100% of the modulation range. All sensors and limiting devices (excluding the 0 – 10 Vdc signal, which will be sent to the Modbus) should be hardwired to the terminal strip on the back of the appliance.
For this command to function on Munchkin and Mod Con models, set Installer Parameter 16 at 2 and Installer Parameter 17 at 1. On
Elite models, Function 16, Optional Input must be set to 0-10 volt and Function 17 0-10 volt function must be set on Temperature.
The holding registers need to be set as follows:
16
HOLDING REGISTERS
40001
40003
Table 16
DEFINITION
Configuration
Rate Command
VALUE
00 04
00 00
ACTION
Set configuration to read 40003
Sets modulation %
Register 40003 needs to receive the rate command as follows: Acceptable rang is 0 to 100. Value needs to be greater than 15 for the boiler to fire. When the command is 16, the boiler will run at minimum fan speed (firing rate). When the command is
100 the boiler will run at max fan speed (firing rate). If the command value is anywhere between 16 and 100, the boiler will run at a fan speed proportional to the command sent between minimum and maximum firing rates.
NOTE: To ensure proper operation, resend the configuration bits to holding register 40001 prior to issuing a command. For proper hexadecimal conversion of rate percentage, please refer to the rate and temperature conversion section of this manual.
2. SEND TEMPERATURE COMMAND FROM MASTER
In this configuration, the appliance is controlled by setting the boiler temperature via the Modbus adapter. The temperature range is the range of the value of Installer Parameter 12 (all except Elite) or Function 12 Min Boiler Temp on the Elite, and the temperature setting of the CH value on the User Menu (all except Elite) or CENTRAL HEAT setting on the Elite. All sensors and limiting devices (excluding the 0-10 Vdc signal, which will be sent to the Modbus) should be hardwired to the terminal strip on the appliance.
For this command to function on Munchkin and Mod Con models, Installer Parameter 16 needs to be set at 2 and Installer Parameter
17 needs to be set at 0. On Elite models, Function 16, Optional Input must be set to 0-10 volt and Function 17 0-10 volt function must be set on Temperature.
NOTE: The holding registers are same as above, in Table 15.
Register 40003 needs to receive the rate command as follows: Acceptable rang is 0 to 100. Value needs to be greater than 15 for the boiler to fire. When the command is 16, the boiler will run at minimum temperature (value of Installer Parameter 12 above). When the command is 100 the boiler will run at maximum temperature (CH temperature above). If the command value is anywhere between 16 and 100, the boiler will run at a temperature proportional to the command sent between minimum and maximum temperatures described above.
NOTE: To ensure proper operation, resend the configuration bits to holding register 40001 prior to issuing a command. For proper hexadecimal conversion of rate percentage, please refer to the rate and temperature conversion section of this manual.
D. EXAMPLE #3 – HOT WATER GENERATION
Hot water generation can be accomplished using one of two methods when an appliance 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 appliance with the tank thermostat, or tank temperature sensor, wired to the terminal strip of the appliance
DHW WITH REMOTE CONTROL
This installation may or may not have the hot water generator in close proximity to the appliance. Its sensors and thermostat values are only available through the Modbus communication bus.
To ensure that the appliance can properly respond to a call for hot water generation, the following holding registers must be set in addition to other commands:
HOLDING REGISTERS DEFINITION VALUE ACTION
40001
40002
40004
40005
Configuration
Coils
Tank set point
Tank Temperature
00 1A
00 10
0# ##
0# ##
Set configuration to read 40002, 4 and 5
Enables tank Tstat (00 00 disables appliance)
Sets set point
Passes tank temp from remote sensor
Table 17
NOTE: To ensure proper operation, resend the configuration bits to holding register 40001 prior to issuing a command. For proper hexadecimal conversion of rate percentage, please refer to the rate and temperature conversion section of this manual.
E. CASCADE
In order to operate the appliance in cascade with Modbus communications, configure the master appliance. Connect the remaining appliances in the cascade through the normal cascade communications wiring. Cascade control can then be accomplished automatically through the master appliance.
17
Please note that with Modbus communication connected only to the master appliance, only total cascade information can be seen through the communications link. Information from the follower boilers is limited to follower appliance rate command, supply temperature, fault code, and fault status.
If you want to see complete data from each follower, or use the Modbus master to control cascading of multiple appliances, each appliance will need a Modbus communication board.
Monitoring Only
Any appliance can be equipped with the Modbus communication accessory and then be set up to operate with its own internal controls.
The Modbus master can then poll the Modbus accessory for the read only variables.
F. RATE AND TEMPERATURE CONVERSIONS
Rate
When issuing a rate command, the rate can be communicated as percent modulation or a desired set point temperature depending on the setting of parameter 16 in the appliance Installer Menu. Proper data format for the modulation percentage is direct conversion to hexadecimal. This conversion can be accomplished through online number based converters or some scientific calculators.
For example:
RATE %
0
HEX
00
20
45
60
80
14
2D
3C
50
95
100
Table 18
5F
64
Temperature Conversions
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:
PARAMETER
DEFAULT VALUES
Deg C Deg F
DEFAULT
Voltages
BMS temperature set point at low analog input
BMS temperature set point at high analog input
Table 19
21
82
69.8
179.6
2
10
For example: Send a set point of 110 o
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 input = 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 o
F set point.
18
The table below lists temperature to hexadecimal conversions.
Setpoint Hex Setpoint
68 12 101
69
70
71
13
14
14
102
103
104
72 15 105
73
74
16
17
106
107
Setpoint Hex Setpoint
Hex Setpoint
2A 134
2B
2C
2C
135
136
137
2D 138
2E
2F
139
140
Hex Setpoint
Hex
42
43
44
44
45
46
47
Hex
Setpoint
167
168
169
170
171
172
173
Setpoint
Hex
5A
5B
5C
5D
5D
5E
5F
Hex
75
76
77
78
79
80
81
17
18
19
19
1A
1B
1C
108
109
110
111
112
113
114
2F
30
31
32
32
33
34
141
142
143
144
145
146
147
47
48
49
4A
4A
4B
4C
174
175
176
177
178
179
180
5F
60
61
62
62
63
64
82
83
84
1C
1D
1E
115
116
117
34
35
36
148
149
150
4C
4D
4E
MODBUS Register 40004 Setpoint Conversion Table 85 1F 118 37 151 4F
86
87
88
89
90
1F
20
21
21
22
119
120
121
122
123
37
38
39
3A
3A
152
153
154
155
156
4F
50
51
52
52
95
96
97
98
99
91
92
93
94
23
24
24
25
26
27
27
28
29
124
125
126
127
128
129
130
131
132
133
3E
3F
3F
40
41
3B
3C
3C
3D
42
157
158
159
160
161
162
163
164
165
166
56
57
57
58
59
53
54
54
55
5A 100
Temperature
2A
The Modbus adapter passes temperature data to the appliance in degrees Fahrenheit. Also, to accommodate decimal places, the decimal value must be divided by 10. The data sent over the Modbus is passed as an unsigned 16 bit integer. This poses no problem unless the data becomes negative, such as temperatures below zero. In this case, the compliment has to be calculated as follows:
Temperature to be sent over Modbus = -22 o
F. First multiply by 10. -22 X 10 = -220. Calculate compliment 65536-220 = 65316.
Decimal = 65316. Hex = FF24. Binary = 1111111100100100.
To read the outdoor temperature from the appliance, do the opposite. Read register 40006 and get 65316. Since this value is greater than 32767, the temperature is negative. To calculate the negative value: 65536 – 65316 = 220, then 220/10 = 22. 22 X -1 = -22 o
F.
For example:
Outdoor temperature from remote sensor on BAS system = 80.5
o
F.
DECIMAL HEX
805 325
Table 20
Outdoor temperature from remote sensor on BAS system = -25 o
F. Data that needs to be transmitted is -25 X 10 = -250. 65536-
250=65286
DECIMAL
65286
Table 21
Outlet temperature from appliance sensor = 155 o
F. 155 o
F X 10 = 1550.
DECIMAL
1550
Table 22
HEX
FF06
HEX
60E
G. APPLIANCE STATUS CODES
The appliance displays an appliance state code on the building screen to help aid in troubleshooting. The appliance state indicates what the appliance is actually doing. This state should be compared to the command issued and what is expected. If the appliance state does not agree with the command, check communication and configuration.
STATUS CODES (INPUT REGISTERS 30014 AND 30023)
NUMBER DEFINITION
0 standby
96 Running
100 DHW mode or blocking for Cascade
101 Low Water blocking
Table 23
19
PART 8 - TROUBLESHOOTING
Should you encounter problems communicating over Modbus, the following items should be checked in this order.
1. Physical layer
2. Communications configuration and port settings
3. Modbus error codes
4. Appliance status / blocking / lockout codes
A. PHYSICAL LAYER
1. Verify the correct Modbus communication cable (twisted pair) is being used.
2. Check that all components have power (appliance, Modbus adapter, gateway, BAS master).
3. Check for broken wires.
4. Check A, B terminal connections.
5. Check for terminating resistors (120 ohms) at each end of the RS-485 bus only.
6. Check all wire lengths. Are any drops too long?
7. Check proper shield grounding.
B. COMMUNICATIONS
1. Verify controller is configured for MODBUS (AUTO or ON)
2. Check baud rate (9600, 19200).
3. Check parity.
4. Check Modbus address.
5. Check port setting on master, gateway, and computers.
6. Check the status of the LEDs, referring to the LED Diagnostics section below.
C. LED DIAGNOSTICS
There are two yellow LED’s and one green LED on the board that provide diagnostic information.
One of the yellow LED’s (D6) is used for indicating reception of data from Modbus and the other LED (D5) indicates transmission of data to Modbus.
The green LED (D7) is used to show the following:
Internal Faults
Modbus Adapter fault: Continuously Bright
General Faults
No MODBUS (RS-485) communication: 1.5 second bright - 0.5 second off
No Burner Control (RS-232) communication: 0.5 second bright - 1.5 seconds off
In case both communication modes fail the LED will not be lit No Faults
Normal running: 1 second Bright and 1 second Dim
D. MODBUS ERROR CODES
1. Check Modbus communication error codes (see in Part 5, Section E in this manual for Modbus exception codes).
20
2. Check Follower ID.
3. Check Modbus command.
4. Check configuration bits for holding register 40001.
5. Check commands and data for holding registers 40002
– 40007.
INSTALLATION AND MAINTENANCE NOTES
_________________________________________________________________________________________
21
HTP CUSTOMER INSTALLATION RECORD FORM
The following form should be completed by the installer for you to keep as a record of the installation in case of a warranty claim. After reading the important notes at the bottom of the page, please also sign this document.
Customer’s Name:
Installation Address:
Date of Installation:
Installer’s Code/Name:
Product Serial Number(s):
Modbus Adapter Address (As Configured by the Installer)
Comments:
Installer’s Phone Number:
Signed by Installer:
Signed by Customer:
IMPORTANT NOTES:
Customer: Please only sign after the installer has reviewed the installation, safety, proper operation and maintenance of the system. In the case that the system has any problems, please call the installer. If you are unable to make contact, please contact your HTP Sales Representative.
Distributor/Dealer: Please insert contact details.
LP-372 Rev. 6.14.13
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Key Features
- Master-follower communication format
- RS-485 serial connection
- Supports Modcon, Modcon VWH, Pioneer, Versa-flame, Elite, Elite VWH
- Appliance control with Modbus communications
- Fail-safe operation if Modbus communication is lost