MODBUS / BACnet Adapter Installation Instructions

MODBUS / BACnet Adapter Installation Instructions Part # 7350P-636 For Use with BIC-928 Control Based EnduroTI and Elite Premier Boilers BIC-926 Control Based Modcon, Modcon VWH, Pioneer, and Versa Flame Products Manufactured On or After July 1, 2011, and BIC-926 Control Based Elite, Elite VWH, and Phoenix Water Heaters Manufactured On or After August 1, 2011 STOP! Follow these instructions or warranty will be void! This manual must only be used by a qualified heating installer / service technician. Read all instructions in this manual before installing. Failure to comply could result in property damage or improper appliance operation. Such damages or service calls to correct operation ARE NOT covered by warranty. The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important product information. CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage. NOTE: Contains additional information important to a procedure. Foreword This manual provides guidelines for the use and installation of the MODBUS/BACnet communication system with HTP appliances. For the Installer The installer should be guided by the instructions furnished with the MODBUS/BACnet, 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: 1. The latest version of the National Electrical Code, NFPA No. 70. In Canada, refer to Canadian Electrical Code C 22.1, from Canadian 2. Standards Association, 5060 Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5N6. 3. Local, state, provincial, and national codes, laws, regulations, and ordinances. Table of Contents Part 1 - General Information 2 A. What s in the Box 2 B. Minimum System Requirements 2 C. Definitions 2 Part 2 - Installation 2 A. BMS Wiring Requirements 3 B. Jumper Setting 3 Part 3 - Communication Configuration 4 A. MODBUS/BACnet Enable 4 B. MODBUS Address 4 C. BACnet Address 4 D. Baud Rate 5 E. Parity and Stop Bits 5 Part 4 - MODBUS Registers and BACnet Objects 5 A. Primary Data Tables 5 B. Appliance Memory Map 6 C. Configuration Bits 8 Part 5 - Appliance Operation 9 A. Appliance Operation with MODBUS and BACnet Communications 9 B. Example #1 - Enable / Disable CH and DHW Demand 9 C. Example #2 - Sending DHW Setpoint Via Direct Write Method 9 D. Example #3 - Sending Setpoint or Firing Rate from BMS 9 1. Sending Desired Setpoint from BMS to Appliance Via Simulated 0-10V Method 9 2. Send Firing Rate Command from BMS to Appliance 10 E. Example #4 - Hot Water Generation 11 F. Cascade 11 G. Temperature Conversions (MODBUS Only) 11 Part 6 - Troubleshooting 12 A. MODBUS/BACnet Board Diagnostics 12 B. Physical Layer 12 C. Communications 12 D. Error Codes 13 E. Appliance 0-7 Status Codes 13 F. Appliance 0 and Appliance 1 Blocking Codes 13 G. Appliance 0-7 Lockout Codes 14 Limited Warranty 15 Installation and Maintenance Notes 16 The manufacturer reserves the right to make changes or updates without notice and will not be held liable for errors in literature. NOTE TO CONSUMER: PLEASE KEEP ALL INSTRUCTIONS FOR FUTURE REFERENCE. 272 Duchaine Blvd. New Bedford, MA 02745 508-763-8071

2 Part 1 - General Information This adapter is capable of supporting either the MODBUS or BACnet protocols. The protocol selection is accomplished via dipswitch 10. MODBUS and BACnet communication systems utilize a master-follower format where connected HTP appliances follow commands from a building management system or other MODBUS or BACnet master device linked over an RS-485 serial connection. CAUTION If any system components are exposed to the following, do not operate until the affected components have been inspected by a qualified serviceman. 1. FIRE 2. DAMAGE 3. SUBMERSION IN WATER 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 One (1) MODBUS / BACnet Adapter One (1) Bag of Mounting Hardware One (1) Mounting Template Ensure all components are included in the shipping crate. Move components to the installation location. Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee. B. Minimum System Requirements 1. A MODBUS or BACnet master device, such as a Building Management System (BMS) or computer with MODBUS or BACnet master software, and an RS-485 serial port or USB port with a converter to RS-485. 2. HTP MODBUS/BACnet adapter (this kit), and an HTP appliance/ water heater equipped with a BIC-926 control with firmware revision MTSA-P110414 or greater. To determine whether your BIC- Figure 1 - BIC-926 Controller Revision Label Location 926 based product is compatible with this adapter, refer to Figure 1. 3. This MODBUS/BACnet adapter is also designed to work on the new BIC-928 control. There are no firmware limitations with this new control. 4. Shielded twisted pair communication cable. C. Definitions Table 1 includes a list of definitions used throughout this manual. Abbreviation or Acronym ASCII BACnet Baud (Baud Rate) BMS EMS FDX HDX Hex I/O LSB MODBUS MSB RS232 RS485 RTU PG MB American Standard Code for Information Interchange Definition BACnet is a communications protocol for Building Management and Control networks. It is an ASHRAE, ANSI, and ISO 16484-5 standard protocol. 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 A serial, half-duplex transmission protocol developed by AEG Modicon Most Significant Byte RS232 serial, full-duplex (FDX) transmission of data standard RS485 serial transmission of data standard Remote Terminal Unit Industry Standard liquid-tight wiring entry connector MODBUS Table 1 - Definitions Part 2 - Installation The MODBUS/BACnet adapter should be mounted to a solid surface. The adapter has two tabs with four mounting holes designed specifically for this purpose.

CAUTION Use the mounting template and screws provided with the adapter. Damage to the MODBUS/BACnet 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 RS-485 communication cable, and that the appliance communication wire must reach the control inside the appliance. The MODBUS/BACnet 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 input port. In BIC-926 based appliances, the four pin connector from the adapter must be plugged into the white connector labeled X3 on the control. In BIC-928 based appliances, the four pin connector from the adapter must be plugged into the black connector labeled X4 on the control. NOTE: It is not recommended to install the MODBUS/BACnet adapter inside the appliance housing. Doing so may affect appliance operation or damage the MODBUS/BACnet adapter. CAUTION Damage to MODBUS/BACnet adapter or appliance due to improper installation IS NOT covered by warranty. 3 A. BMS Wiring Requirements 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) 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. Figure 2 - Jumper Configurations in a MODBUS / BACnet Network B. Jumper Setting The appliance display handles most of the MODBUS/BACnet adapter configuration. There is one jumper on the MODBUS/BACnet 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/BACnet adapter is at the end of the RS- 485 bus. Remove the jumper if the MODBUS/BACnet adapter is one of many connections and not at the end of the bus. See Figures 2 and 3. Figure 3 - MODBUS Termination Jumper Location (Highlighted in Grey)

4 Part 3 - Communication Configuration A. MODBUS/BACnet Enable In order to enable either MODBUS or BACnet, push dipswitch 10 into the ON position to enable BAC, and the OFF position to enable MODBUS. See the dipswitch matrix below for a detailed description. Final Baud Rate Protocol 1 2 3 4 5 6 7 8 9 10 x4 BACNET OFF OFF OFF OFF OFF OFF OFF OFF x1 MODBUS Table 2 - Dipswitch Matrix LCD Display: 1. On the LCD display press and hold ENTER until you see the screen at the right. 2. Use the RIGHT arrow to select a character, then use the UP and DOWN arrows to select the desired Parameter 3 Character LED Display Setting LCD Text Display Setting Description ENTER MENU CODE 925 character value. RIGHT arrow over to the next character and repeat the selection. Once code 925 or 975 is on the screen (Installer Menu code depends on the appliance - See appliance Installation Manual for details), press and hold ENTER on the display to enter the Installer Menu. 3. Once in the Installer Menu, use the RIGHT or LEFT arrow to navigate to Parameter 37-MODBUS MODE. When at Parameter 37, press ENTER, then use UP or DOWN to select the desired setting from Table 3. 4. Press ENTER to store the MODBUS Configuration. Press the RIGHT button to advance to Parameter 38 - Address. LED Display: 1. On the LED display, press and hold TEMP and RESET simultaneously. Use the + and - arrows to show 925 on the display, then press and hold TEMP to enter the installer menu. 2. Once in the Installer Menu, use the TEMP button to navigate to Parameter 37. When at Parameter 37, use + or - to select the desired setting from Table 3. 3. Press the TEMP button to advance to Parameter 38 - Address. 37 0 OFF MODBUS/BACnet DISABLED (factory default) 37 1 AUTOMATIC MODBUS/BACnet AUTO (enables automatic detection of a PC or Adapter) 37 2 ON MODBUS/BACnet ON Table 3 - MODBUS MODE Settings Please do not leave the Installer Menu after making this selection. Continue to configure the Address, Baud Rate, and Parity settings. 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. C. BACnet Address BACnet Device Instance The unique BACnet Device instance number will consist of three (3) parts: Base Number: 600000 Family: BIC926 00000 BIC928 01000 The local address will be set by the MODBUS menu on the BIC. This address is the same as the address on the RS485 bus. Example: A BIC928 with the RS485 address of 65 will have a device ID of 601065. A BIC926 with the RS485 address of 31 will have a device ID of 600031. NOTE: MODBUS must be enabled on the appliance as outlined above for the following parameters to be viewed and changed. The BACnet address space is comprised of 256 addresses. These are defined as follows: Address 255 is a broadcast address. The master can send data to address 0 and all followers will process the data. Addresses 0 127 are free to be assigned to both Master and Follower BACnet nodes. Each address can be assigned to only one BACnet device on the bus. Addresses 128 254 are valid only for Follower nodes. ADDRESSING SUGGESTIONS* Each device must have a unique address. 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/BACnet adapter address in the appliance installer menu: LCD Display: 1. When at Parameter 38, press ENTER, then use UP or DOWN to select the desired address. 2. Press ENTER to store the MODBUS Address. 3. Press the RIGHT button to advance to Parameter 39 Baud Rate.

5 LED Display: 1. When at Parameter 38, press TEMP, then use + or - to select the desired address. 2. Press the TEMP button to advance to Parameter 39 Baud Rate. D. Baud Rate The baud rate (communication speed) can be set on the control display to either 9600 or 19200 baud. All HTP appliances, as well as any other device on the same bus and the MODBUS/BACnet 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. LCD Display: 1. When at Parameter 39, press ENTER, then use UP or DOWN to select the desired setting from Table 4. 2. Press ENTER to store the Baud Rate. 3. Press the RIGHT button to advance to Parameter 40 Parity. LED Display: 1. When at Parameter 39, press TEMP, then use + or - to select the desired setting from Table 4. 2. Press the TEMP button to advance to Parameter 40 Parity. Parameter 3 Character LED Display Setting LCD Text Display Setting Description 39 0 9600 BAUD RATE = 9600 (factory default) 39 1 19200 BAUD RATE = 19200 Table 4 - Parameter 39 Settings The final (RS-485) baud rate is determined by this setting in Control Baud Rate Setting Dipswitch 9 Position Final RS-485 Baud Rate conjunction with dipswitch 9 on the adapter. Table 5 shows all possible final baud rate selections. 9600 OFF 9600 19200 OFF 19200 E. Parity and Stop Bits 9600 ON 36400 (9600 X 4) NOTE: This setting only applies to MODBUS operation. The BACnet protocol does not utilize parity for communication and 19200 ON 76800 (19200 X 4) this setting will have no effect. Table 5 - Final Baud Rate Settings The parity/stop bits parameter of the MODBUS/BACnet 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. LCD Display: 1. When at Parameter 40, press ENTER, then use UP or DOWN to select the desired setting from the table below. 2. Press ENTER to store the Parity. 3. Press and Hold the RESET button to store all parameters and exit the Installer Menu. LED Display: 1. When at Parameter 40, press TEMP, then use + or - to select the desired setting from Table 6. 2. Press and Hold the RESET button to store all parameters and exit the Installer Menu. Part 4 - MODBUS Registers and BACnet Objects A. Primary Data Tables Parameter 3 Character LED Display Setting LCD Text Display Setting Description 40 0 1 ST No parity 1 stop bit (factory default) 40 1 2 ST No parity 2 stop bits 40 2 E PA Even parity 1 stop bit 40 3 O PA Odd parity 1 stop bit Table 6 - Parameter 40 Settings Table Data Type Read / Write Description Discrete Inputs Single bit Read only Data can be provided by an I/O system. Coils Single bit Read / Write Data can be altered by an application program. Input Registers 16-bit word Read only Data can be provided by an I/O system. Holding Registers 16-bit word Read / Write Data can be altered by an application program. Table 7 - Supplementary Information

6 B. Appliance Memory Map NOTE: BOLD ITALICS indicate objects that apply only to appliances equipped with BIC-928 operating systems. MODBUS Heating Appliance Water Heater BACNET Address Description Description Object Type Object Instance Unit Resolution Discrete Inputs Discrete Inputs 00001 En / Room Th1 / Stg 1 N/A BV 0 1 = on, 0 = off 1 00005 Tank thermostat N/A BV 4 1 = on, 0 = off 1 10001 MHRL High temp safety switch / High flue temp switch BI 0 1 = on, 0 = off 1 10002 Flow switch N/A BI 1 1 = on, 0 = off 1 10003 Gas Press. Switch N/A BI 2 1 = on, 0 = off 1 10005 Air Press Switch N/A BI 4 1 = on, 0 = off 1 10006 Blocked drain Blocked vent pressure switch BI 5 1 = on, 0 = off 1 10007 ARHL High temp safety switch / High flue temp switch BI 6 1 = on, 0 = off 1 10008 Flame 1 Flame rectification probe BI 7 1 = on, 0 = off 1 10009 Enable / STG1 N/A BI 8 1 = on, 0 = off 1 10010 Tank th N/A BI 9 1 = on, 0 = off 1 10011 STG2 / APS N/A BI 10 1 = on, 0 = off 1 10033 Run-time cont. 1 Run-time cont. 1 BI 32 1 = on, 0 = off 1 10034 Alarm cont. 1 (EXCEPT Versa Hydro) Alarm output BI 33 1 = on, 0 = off 1 10035 CH pump 1 N/A BI 34 1 = on, 0 = off 1 10036 DHW pump 1 N/A BI 35 1 = on, 0 = off 1 10038 Gas valve 1 Gas valve BI 37 1 = on, 0 = off 1 10039 Sys pump N/A BI 38 1 = on, 0 = off 1 10049 10050 Boiler 1 Run (same as 11118) Boiler 2 Run (same as 10023) Run status BI 48 1 = on, 0 = off 1 N/A BI 49 1 = on, 0 = off 1 10051 Boiler 3 Run N/A BI 50 1 = on, 0 = off 1 10052 Boiler 4 Run N/A BI 51 1 = on, 0 = off 1 10053 Boiler 5 Run N/A BI 52 1 = on, 0 = off 1 10054 Boiler 6 Run N/A BI 53 1 = on, 0 = off 1 10055 Boiler 7 Run N/A BI 54 1 = on, 0 = off 1 10056 Boiler 8 Run N/A BI 55 1 = on, 0 = off 1 10057 10058 Lockout 1 (same as 10034) Lockout 2 (same as 10042) Lockout Status BI 56 1 = on, 0 = off 1 N/A BI 57 1 = on, 0 = off 1 10059 Lockout 3 N/A BI 58 1 = on, 0 = off 1 10060 Lockout 4 N/A BI 59 1 = on, 0 = off 1 10061 Lockout 5 N/A BI 60 1 = on, 0 = off 1 10062 Lockout 6 N/A BI 61 1 = on, 0 = off 1 10063 Lockout 7 N/A BI 62 1 = on, 0 = off 1 10064 Lockout 8 N/A BI 63 1 = on, 0 = off 1 10065 Alarm relais ecs (Versa Hydro ONLY) Input Registers Input Registers BI 64 1 = on, 0 = off 1 30001 Discrete Inputs 1-16 N/A AI 0 N/A 1 30002 Discrete Inputs 17-32 N/A AI 1 N/A 1 30003 Discrete Inputs 33-48 N/A AI 2 N/A 1 30004 *System / Cascade Setp. N/A AI 3 Deg F, Off = 32 0.1

7 MODBUS Heating Appliance Water Heater BACNET Address Description Description Object Type Object Instance Unit Resolution Input Registers Input Registers 30005 System Pump 4 speed N/A AI 4 % 1 30006 Cascade Total Power N/A AI 5 % 1 30007 Cascade Current Power N/A AI 6 % 1 30008 *Outlet Setp. 1 N/A AI 7 Deg F, Off = 32 0.1 30009 Outlet Temp. 1 Upper Temp Sensor AI 8 Deg F 0.1 30010 Inlet Temp. 1 Lower Temp Sensor AI 9 Deg F 0.1 30011 Flue Temp. 1 N/A AI 10 Deg F 0.1 30012 Firing Rate 1 Firing Rate 1 AI 11 % 0.1 30013 Boil. 1 Pump speed 5 N/A AI 12 % 1 30014 Boil. 1 Status Code Status Code 1 AI 13 N/A 1 30015 Boil. 1 Blocking Code Blocking Code 1 AI 14 N/A 1 30016 Boil. 1 Lockout Code Lockout Code 1 AI 15 N/A 1 30018 Outlet Temp 2 N/A AI 17 Deg F 0.1 30021 Firing Rate 2 N/A AI 20 % 0.1 30022 Boil. 2 Pump 4 speed N/A AI 21 % 1 30023 Boil. 2 Status Code N/A AI 22 N/A 1 30024 Boil. 2 Blocking Code N/A AI 23 N/A 1 30025 Boil. 2 Lockout Code N/A AI 24 N/A 1 30026 Boiler Outlet 3 N/A AI 25 Deg F 0.1 30027 Boiler 3 Firing Rate N/A AI 26 % 1 30028 Boiler 3 Status N/A AI 27 N/A 1 30029 Boiler 3 Lockout N/A AI 28 N/A 1 30030 Boiler Outlet 4 N/A AI 29 Deg F 0.1 30031 Boiler 4 Firing Rate N/A AI 30 % 1 30032 Boiler 4 Status N/A AI 31 N/A 1 30033 Boiler 4 Lockout N/A AI 32 N/A 1 30034 Boiler Outlet 5 N/A AI 33 Deg F 0.1 30035 Boiler 5 Firing Rate N/A AI 34 % 1 30036 Boiler 5 Status N/A AI 35 N/A 1 30037 Boiler 5 Lockout N/A AI 36 N/A 1 30038 Boiler Outlet 6 N/A AI 37 Deg F 0.1 30039 Boiler 6 Firing Rate N/A AI 38 % 1 30040 Boiler 6 Status N/A AI 39 N/A 1 30041 Boiler 6 Lockout N/A AI 40 N/A 1 30042 Boiler Outlet 7 N/A AI 41 Deg F 0.1 30043 Boiler 7 Firing Rate N/A AI 42 % 1 30044 Boiler 7 Status N/A AI 43 N/A 1 30045 Boiler 7 Lockout N/A AI 44 N/A 1 30046 Boiler Outlet 8 N/A AI 45 Deg F 0.1 30047 Boiler 8 Firing Rate N/A AI 46 % 1 30048 Boiler 8 Status N/A AI 47 N/A 1 30049 Boiler 8 Lockout N/A AI 48 N/A 1 30050 Discrete Inputs 49-64 N/A AI 49 N/A 1 30051 NTC 6 temperature N/A AI 50 Deg F 0.1 30052 NTC 7 temperature N/A AI 51 Deg F 0.1 30053 NTC 9 temperature N/A AI 52 Deg F 0.1 30054 Vortex 1 flow N/A AI 53 LPM 0.1 30055 Vortex 1 temp N/A AI 54 Deg F 0.1

8 MODBUS Heating Appliance Water Heater BACNET Address Description Description Object Type Object Instance Unit Resolution Input Registers Input Registers 30056 Vortex 2 flow N/A AI 55 LPM 0.1 30057 Vortex 2 temp N/A AI 56 Deg F 0.1 30091 Total Faults N/A AI 90 1 30092 Total Last Faults N/A AI 91 1 30093 Run Hours CH AI 92 x5 30094 Run Hours DHW AI 93 x5 30095 Run Hours Cas CH N/A AI 94 x5 30096 Run Hours Cas DHW N/A AI 95 x5 30097 Power Hours AI 96 x5 30099 Start Counter AI 98 1 30100 Start Counter AI 99 1 Holding Registers 40001 Configuration Configuration AV 0 See 1 Configuration 40002 Coils Coils AV 1 Bits Section 1 40003 0-10 volt / rate / setp 0-10 volt / rate / set AV 2 V 0.1 40004 DHW setpoint DHW set AV 3 Deg F 0.1 40005 DHW temperatur DHW temp AV 4 Deg F 0.1 40006 Outdoor temp. Outdoor Sensor AV 5 Deg F 0.1 40007 Sys supply temp. N/A AV 6 Deg F 0.1 40008 Sys rtn temp. N/A AV 7 Deg F 0.1 40009 I4 for direct N/A AV 8 Deg F 0.1 40010 CH post purge N/A AV 9 Seconds 1 40011 DHW post purge N/A AV 10 Seconds 1 40012 Pump 4 Speed N/A AV 11 % 0.1 40014 Extra out ECS N/A AV 13 % 0.1 Table 8 - MODBUS and BACnet Memory Map - *Only Valid Valves During Heating Cycle C. Configuration Bits Address 40001/AV0 contains configuration bits sent from the BMS to the appliance. These bits tell the appliance to use its own internal inputs, or inputs from the BMS. When a bit is set to 1, the appliance will ignore the corresponding value contained internally and expect the BMS to write that value into the holding registers. The configuration bits are as follows: Holding Register 40001 / AV0 Decimal Value HEX Value Selected Signal (Register) to Write to 0 = Taken from Control 1 = Taken from MODBUS B0 (LSB) 1 01 Boiler enable (40002 / AV1) 0/1 B1 2 02 Tank enable (40002 / AV1) 0/1 B2 4 04 Rate command / 0-10V input / setpoint command (40003 / AV2) B3 8 08 DHW setpoint (40004 / AV3)* 0/1 Holding Register 40001 / AV0 Decimal Value HEX Value Selected Signal (Register) to Write to 0/1 0 = Taken from Control 1 = Taken from MODBUS B4 16 10 DHW temperature (40005 / AV4) 0/1 B5 32 20 Outdoor temperature (40006 / AV5) 0/1 B6 64 40 System supply temperature (40007 / AV6) 0/1 B7 128 80 System return temperature (40008 / AV7) 0/1 B8 256 100 I4 offset (40009 / AV8) 0/1 B9 512 200 CH post purge (40010 / AV9) 0/1 B10 1024 400 DHW post purge (40011 / AV10) 0/1 B11 2048 800 Pump 4 speed (40012 / AV11) 0/1 B12 4096 1000 Pump 5 speed (40013 / AV12) 0/1 B13 (MSB) 8192 2000 Extra 0-10V output (40014 / AV13) 0/1

9 Holding Register 40002 / AV1 Selected Signal (Register) to Write to) Coil 01 b0 1 01 Room thermostat Coil 05 b4 16 10 Tank thermostat Table 9 - MODBUS Holding Registers *The appliance will not respond to the internal DHW limit while the Tank Temperature AND Tank Enable is being written from MODBUS/BACnet! Part 5 - Appliance Operation A. Appliance Operation with MODBUS and BACnet Communications The appliance is equipped with a 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 communication be lost. This timer will cause the appliance to revert back to internal appliance controls should the communication be interrupted longer than the timer. The timer resets every time a 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. Monitoring Only Any appliance can be equipped with the MODBUS or BAC/net communication accessory and then be set up to operate with its own internal controls. The master can then poll the MODBUS or BAC/net accessory for the read only variables. Refer to the following examples for configuring the writable Holding Registers. B. Example #1 - Enable / Disable CH and DHW Demand In this configuration, the appliance is controlled by setting the setpoints locally on the appliance and providing an enable signal through MODBUS or BAC/net communications. All sensors and limiting devices (excluding the thermostat enable and tank thermostat enable signals, which will be sent to the appliance) should be hardwired to the proper terminals in the appliance. The holding registers need to be set as follows: Holding Registers Definition Decimal Value HEX Value Action 40001 / AV0 Configuration 3 0011 Set configuration to read 40002 40002 / AV1 Coils 1 0001 Enables CH Demand (00 00 disables demand) (boilers only) 40002 / AV1 Coils 16 0010 Enables DHW demand on appliance (00 00 disables demand) 40002 / AV1 Coils 17 0011 Enables both CH and DHW demand. DHW demand will have priority. Table 10 - Example #1 C. Example #2 - Sending DHW Setpoint Via Direct Write Method Holding Registers Definition Decimal Value HEX Value Action 40001 / AV0 Configuration 8 0010 Set configuration to read 40004/AV3 40004 / AV3 Coils Setpoint Setpoint Directly writes setpoint to water heater Table 12 - Example #2 *The appliance will not respond to the internal DHW limit while the Tank Setpoint is being written from MODBUS/BACnet! D. Example #3 - Sending Setpoint or Firing Rate from BMS 1. Sending Desired Setpoint from BMS to Appliance Via Simulated 0-10V Method In this configuration, the appliance setpoint is indirectly controlled by sending a 0 to 10v signal to it. All sensors and limiting devices (excluding the 0 10 Vdc signal, which will be sent to the MODBUS/BACnet Appliance Parameter I16 Parameter I17 adapter) should be hardwired to the correct locations on the Phoenix, Munchkin, MODCON rev2 and earlier 2 0 appliance. For this command to function, configure the appliance Elite, Elite Premier, EnduroTi 0-10 Volt Temperature according to the corresponding row in the table to the right. Table 11 - Send Desired Setpoint from BMS to Appliance To send a desired CH setpoint on an appliance, or DHW setpoint on a water heater via 40003/AV2, the value (which equates to voltage applied) must be determined through linear interpolation of programmable parameters on the BMS setup menu. Appliance temperature setpoint at low analog input = MIN BOILER TEMP (I12) in the 925 Installer Menu Appliance temperature setpoint at high analog input = CENTRAL HEAT in the 600 User Menu or PHOENIX in the User Menu 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:

10 Parameter For example: Send a setpoint of 110 o F. The formula to use for the interpolation is: Voltage to be applied = (Desired setpoint BMS temp at low analog input) (High voltage low voltage) + Low voltage (BMS temp at high analog input BMS temp at low analog input) From the default values: Desired setpoint = 110 BMS temp at low analog input = 68 BMS temp at high analog input = 180 High voltage = 10 Low voltage = 1.6 [(110-68)(10-1.6)/(180-68)] + 1.6 = 4.75 volts (4.75/10) x 100 = 47.5 48 = 30 Hexadecimal A value of [00] [30] in hexadecimal would be written to holding register 40003/AV2 to issue a command for a 110 o F setpoint. NOTE: If your particular BMS supports DECIMAL inputs, then the desired voltage level can be sent directly. In the above example, you would send 48 (4.8v) to 40003/AV2. The holding registers need to be set as follows: Holding Registers Definition Decimal Value HEX Value Action 40001 / AV0 Configuration 4 04 Set configuration to read 40002 40003 / AV2 Setpoint 0-100 00-64 Enables CH Demand (00 00 disables demand) Table 14 - Setting Holding Registers for Setpoint Register 40003/AV2 needs to receive the setpoint command as follows: Acceptable range is 0 to 100. Value needs to be greater than 15 for the appliance to fire. 10V When the command is 16, the appliance will run with the setpoint controlled by the 925 menu parameter I12 (MIN BOILER TEMP). When the command is 100 the appliance will run with the setpoint controlled by the 600 menu parameter CENTRAL HEAT on appliances or the PHOENIX setting in the water heater user menu. 1.5V If the command value is anywhere between 16 and 100, the appliance will run at a setpoint proportional to the command sent between minimum and maximum setpoints. NOTE: To ensure proper operation, resend the configuration bits to holding register 40001 / AV0 prior to issuing a command. Figure 4 - Setpoint Curve 2. Send Firing Rate Command from BMS to Appliance In this configuration, the appliance is controlled by setting the modulation 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/BACnet adapter) should be hardwired to the correct locations on the appliance. For this command to function, configure the appliance according to the corresponding row in the following table. Default Values Appliance Parameter I16 Parameter I17 Phoenix, Munchkin, MODCON rev2 and earlier 2 2 Elite, Elite Premier, EnduroTi 0-10 Volt Fan Speed Table 15 - Send Firing Rate from BMS to Appliance The holding registers need to be set as follows: Holding Registers Definition Decimal Value HEX Value Action 40001 / AV0 Configuration 4 04 Set configuration to read 40003 40003 / AV2 Rate Command 0-100 00-64 Sets Modulation % Table 16 - Setting Holding Registers for Firing Rate Default Deg C Deg F Voltages Appliance temperature setpoint at low analog input 21 68 1.6 Appliance temperature setpoint at high analog input 82 180 10 Table 13-0-10 Volt Temperature Values for Setpoint

11 Register 40003/AV2 needs to receive the rate command as follows: Acceptable range is 0 to 100. Value needs to be greater than 15 for the appliance to fire. When the command is 16, the appliance will run at minimum fan speed (firing rate). When the command is 100 the appliance will run at max fan speed (firing rate) If the command value is anywhere between 16 and 100, the appliance 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 / AV0 prior to issuing a command. E. Example #4 - Hot Water Generation Hot water generation can be accomplished using one of two methods when an appliance is Figure 5 - Firing Rate Curve connected to a BMS 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 or Customer Connection Board 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. *The appliance will not respond to the internal DHW limit while the Tank Temperature AND Tank Enable is being written from MODBUS/BACnet! 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 BACnet Decimal Value MODBUS Decimal Value HEX Value 40001 / AV0 Configuration 26 26 001A Set configuration to read 40002, 4 and 5 40002 / AV1 Coils 16 16 0010 Enables Tank Tstat (00 00 disables appliance) Action 40004 / AV3 Tank setpoint 130.0 1300 82 Sets setpoint to 130.0F Tank 40005 / AV4 150.5 1505 96 Passes tank temp from remote sensor (ex: 150.5F) to tank temperature Table 17 - Example #3 NOTE: To ensure proper operation, resend the configuration bits to holding register 40001/AV0 prior to issuing a command. For proper hexadecimal conversion of rate percentage, please refer to the rate and temperature conversion section of this manual. F. Cascade In order to operate the appliance in cascade with MODBUS or BAC/net 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. NOTE: With MODBUS or BAC/net communication connected only to the master appliance, only total cascade information can be seen through the communications link. Information from the follower appliances 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 master to control cascading of multiple appliances, each appliance will need a MODBUS or BAC/net communication board. If this is implemented, remember that each appliance will present its data as Appliance 1. You must then use the Appliance s address to determine which follower you are accessing. G. Temperature Conversions (MODBUS Only) 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. In some BMS systems, the data sent over the MODBUS is passed as an unsigned 16-bit integer (16BIT UINT). 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: Example for WRITING negative temperature values to the appliance: Temperature to be sent over MODBUS = -22 o F. First multiply by 10-22 X 10 = -220. Calculate compliment 65536-220 = 65316. Data to be sent is a decimal value of 65316.

12 Example for READING negative temperature values from the appliance: To read the outdoor temperature from the appliance, do the opposite. Read register 40006/AV5 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. NOTE: If your particular BMS supports DECIMAL outputs, then the desired temperature can be read and written directly. More examples Sending positive outdoor temperature from remote sensor on BMS system to appliance (40006/AV5) = 80.5 o F Value 16BIT Unit BMS HEX BMS Signed Decimal BMS 80.5 F 0805 325 805 Table 18 - MODBUS Positive Outdoor Temperature Conversions Sending negative outdoor temperature from remote sensor on BMS system to appliance (40006/AV5) = -25 o F. Data that needs to be transmitted is: -25 X 10 = -250. 65536-250=65286 OR -250 if supported. Value 16BIT Unit BMS HEX BMS Signed Decimal BMS -25 F 65286 FF06-205 Table 19 - MODBUS Negative Outdoor Temperature Conversions Positive outlet temperature from System sensor connected to BMS to appliance (40007/AV6) = 155 o F. 155 o F x 10 = 1550. Value 16BIT Unit BMS HEX BMS Signed Decimal BMS 155 F 1550 60E 1550 Table 20 - MODBUS Positive Outlet Temperature Conversions Part 6 - Troubleshooting Should you encounter problems communicating over MODBUS/BAC/net, the following items should be checked in this order. 1. Physical layer 2. Communications configuration and port settings 3. Error codes 4. Appliance status / blocking / lockout codes A. MODBUS/BACnet Board Diagnostics The MODBUS/BACnet board is equipped with three LEDs for visual diagnostics: Two yellow and one green. These LEDs are located under the MODBUS/BACnet cover. One yellow LED (D5) is used to indicate transmission of data. The other yellow LED (D6) is used to indicate reception of data. The green LED (D7) shows internal faults. See Figure 6 for LED locations. Internal Faults (Green LED): Normal Operation = 1 second on, 1 second dim Controller Fault = Continuously on No Burner Control Communication = 0.5 seconds on, 1.5 seconds off No MODBUS/BACnet Communication = 1.5 seconds on, 0.5 seconds off B. Physical Layer 1. Adapter and Serial Port a. Ensure adapter is plugged into the correct four pin connector i. It plugs into the WHITE connector on the BIC-926 control. ii. It plugs into the BLACK connector on the BIC-928 Figure 6 - MODBUS/BACnet Diagnostic LEDs control. b. Confirm dipswitch 10 is in the correct position for the desired protocol. c. Check for terminating resistors (120 ohms) at each end of the RS-485 bus only. 2. RS-485 a. Verify the correct MODBUS communication cable (twisted pair) is being used. b. Check A, B terminal connections and polarity c. Check for broken wires. d. Check all wire lengths. Are any drops too long? e. Check proper shield grounding. 3. Network Check that all components have power (appliance, MODBUS/BACnet adapter, gateway, BMS master). C. Communications 1. Verify controller is configured for MODBUS (AUTO or ON) 2. Confirm dipswitch 9 is in the correct position for the desired final baud rate. 3. Check baud rate (9600, 19200). 4. Check parity. 5. Check MODBUS/BACnet address.

13 6. Check port setting on master, gateway, and computers. 7. Check the status of the LEDs. Refer to Figure 6. D. Error Codes 1. Check MODBUS communication error codes below. 2. Check Follower ID. 3. Check MODBUS command. 4. Check configuration bits for holding register 40001/AV0. 5. Check commands and data for holding registers 40002/AV1 through 40007/AV6. NOTE: Use Status Codes, Blocking Codes and Lockout Codes to interpret remote appliance operating conditions. E. Appliance 0-7 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, 30023, 30028, 30032, 30036, 30040, 30044, and 30048. Points AI13, 22, 26, 30, 34, 38, 42, and 46) Number Definition Number Definition Number Definition 0 Standby 16 Service 1 31 CH None 1 Blocking Sensor Short/Interrupt 17 Water Low 1 32 DHW Post -Circulation Pump 2 Blocking Water Pressure 18 Water High 1 33 CH Post -Circulation Pump 4 Blocking 24V Low 19 Water Low 2 34 None 5 Blocking Temperature 20 Water High 2 35 Service Pump 6 DHW Function Internal 21 CH On/Off Thermostat 40 Lockout 7 DHW Function Internal 22 CH Zone Demand 51 Frost Protection Pump 8 DHW Indirect 23 CH Cascade Demand 52 Frost Protection Burner 9 DHW Direct 24 CH Pool Demand 60 Summer-Kick 10 DHW Phoenix 25 CH 61 Save EEPROM Blocking 11 DHW Spa 26 CH 96 Running 12 DHW 27 CH 100 DHW Mode or Blocking for Cascade 13 DHW 28 CH 101 Low Water Blocking 14 DHW 29 CH 15 DHW 30 CH Table 21 - Appliance 0-7 Status Codes F. Appliance 0 and Appliance 1 Blocking Codes Blocking Codes (Input Registers 30015 and 30024, AI14 and AI23) Number Appliance Fault Definition Number Appliance Fault Definition 0 None 25 Max Temperature Increase Limiting CH 11 Water Pressure Low 26 24V too Low 12 S1 Temperature High 30 Water Level Low 1 13 S2 Temperature High 31 Water Level High 1 14 Flue Temperature High 32 LEO Water Level Low 2 16 Regulation Temperature High 33 Water Level High 2 17 Not Enough Water Flow 44 Common Flue Blocking 21 Anti-Cycling CH 50 Burner Sensor Blocking 23 FLU Max Flue Pressure Switch / Max Start Cycles 60 Blocking Flue Temperature Modulation Table 22 - Appliance 0 and Appliance 1 Blocking Codes

14 G. Appliance 0-7 Lockout Codes Lockout Codes - (Input Registers 30016, 30025, 30029, 30033, 30037, 30041, 30045, and 30049 - Points AI15, 24, 28, 32, 36, 40, and 44) Number Fault Definition Number Fault Definition 0 None 206 Error During Programming 177 AD Error 207 Parameter EEPROM Failure 178 LWCO 1 Error 230 Fan LOW Error 179 LWCO 2 Error 231 Fan HIGH Error 185 ECS6 Temperature Lockout 232 No Flame During Running 186 ECS7 Temperature Lockout 233 F09 No Flame After Ignition 190 F05 S1 Maximum Temperature 235 APS Stuck Closed 191 F06 S2 Maximum Temperature 236 APS Stuck Open 192 S1 Shorted 237 F11 False Flame 193 F02 S1 Interrupted 239 F01 Safety Thermostat Open 194 S2 Shorted 240 F00 Flue Thermostat Open 195 S2 Interrupted 241 External LWCO 196 Low Water Lockout 243 Gas Pressure 197 Flue Sensor Shorted 243 Target Wall 198 Flue Sensor Interrupted 244 Burner Sensor MAX Recycling 199 Low Water Lockout 2 245 Burner Sensor Short 204 Parameters Damaged 246 Burner Sensor Interrupt 205 Parameters Programmed Table 23 - Appliance 0-7 Lockout Codes

15 Communication Adapter Limited Warranty One year warranty to assure your complete satisfaction. HTP warrants each Communication Adapter to be free from defects in material and workmanship according to the following terms, conditions, and time periods. UNLESS OTHERWISE NOTED THESE WARRANTIES COMMENCE ON THE DATE OF INSTALLATION. This limited warranty is only available to the original consumer purchaser (herinafter Owner ) of this product, and is non-transferable. COVERAGE A. Should a defect or malfunction occur within the above-stated warranty period due to defective material or workmanship, malfunction, or failure to comply with the above warranty, with such defects or malfunctioning having been verified by an authorized HTP representative, then HTP will replace the defective or malfunctioning adapter with a replacement of the nearest comparable model available at the time of replacement. Replacement adapters will be warranted for ninety (90) days. B. In the event of a failure of a replacement adapter due to defective material or workmanship, malfunction, or failure to comply with the above warranty, HTP reserves the right to refund to the Owner the published wholesale price available at the date of manufacture of the original adapter. C. If, at the time of a request for service the Owner cannot provide a copy of the original sales receipt, the warranty period for the adapter shall then be deemed to have commenced thirty (30) days after the date of manufacture of the adapter and NOT the date of installation, and be covered by the unexpired portion of the warranty detailed above. D. It is expressly agreed between HTP and the Owner that repair, replacement, or refund are the exclusive remedies of the Owner. WARRANTY EXCLUSIONS This limited warranty will not cover: 1. Any adapter purchased from an unauthorized dealer. 2. Any adapter not installed by a qualified heating installer/service technician, or installations that do not conform to ANSI, CSA, and/ or UL standards, as well as any applicable national or local building codes / ordinances and electrical trade practices. 3. Any damages, malfunctions, or failures due to improper installation. 4. Service trips to teach the Owner how to install, use, maintain, or to bring the adapter installation into compliance with local building codes and regulations. 5. Any failed components not manufactured by HTP as part of the adapter. 6. Adapters repaired or altered without the prior written approval of HTP. 7. Damages, malfunctions, or failures resulting from failure to operate and maintain the adapter in accordance with the manufacturer s provided instructions. 8. Failure caused by improper sizing of the electric service voltage, wiring or fusing. 9. Damages, malfunctions, or failures caused by operating the adapter with modified, altered, or unapproved components, or any component / attachment not supplied by HTP. 10. Damages, malfunctions, or failures caused by abuse, accident, fire, flood, freeze, lightning, acts of God, electrical spikes and the like. 11. Failures (leaks) caused by operating the adapter in a corrosive or contaminated atmosphere, as well as any damage or failure resulting from contaminated air, including, but not limited to, dirt, dust, or water being introduced into the adapter or its components. 12. Adapters replaced for cosmetic reasons. 13. Adapters that are not defective, but must be replaced during the warranty period as a result of reasonable wear and tear. 14. Components of the adapter that are subject to warranties, if any, given by their manufacturers; HTP does not adopt these warranties. 15. Damages, malfunctions, or failures resulting from the use of any attachment(s) not supplied by HTP. 16. Adapters installed outside the fifty states (and the District of Columbia) of the United States of America and Canada. PROCEDURES FOR WARRANTY SERVICE REQUESTS Any claim for warranty assistance must be made promptly. Determine if the adapter is in-warranty (that is, within the applicable warranty period) by reviewing a copy of the original sales receipt or warranty registration. The Owner must present a copy of the original sales receipt or warranty registration for a warranty service request. If the adapter is in-warranty, contact the retailer from whom the adapter was purchased (or the installer) for assistance. Be prepared to provide the retailer or installer with a copy of the original receipt, complete model and serial numbers, and the date of installation of the adapter, in addition to an explanation of the adapter problem. Warranty coverage is subject to validation of in-warranty coverage by HTP claims department personnel. All alleged defective or malfunctioning adapters must be returned to HTP via the local distribution channels where the original purchase was made. NOTE: Any adapters returned to HTP for warranty analysis will become the property of HTP and will not be returned, even if credit is denied. If all warranty conditions are satisfied, HTP will provide a replacement adapter to the retailer. For questions about the coverage of this warranty, please contact HTP at the following address or phone number: HTP, 272 Duchaine Blvd., New Bedford, MA, 02745, Attention: Warranty Service Department, 1(800) 323-9651. SERVICE, LABOR AND SHIPPING COSTS This limited warranty does not extend to shipping charges, delivery expenses, or administrative fees incurred by the Owner in repairing or replacing the Communication Adapter. This warranty does not extend to labor costs beyond the coverage specified in this warranty document. All such expenses are the Owner s responsibility. LIMITATIONS OF THIS HTP WARRANTY AND REMEDIES THE FOREGOING WARRANTIES ARE EXCLUSIVE AND ARE GIVEN AND ACCEPTED TO THE FURTHEST EXTENT UNDER APPLICABLE LAW IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ANY OBLIGATION, LIABILITY, RIGHT, CLAIM OR REMEDY IN CONTRACT OR TORT, WHETHER OR NOT ARISING FROM HTP S NEGLIGENCE, ACTUAL OR IMPUTED. THE REMEDIES OF THE OWNER SHALL BE LIMITED TO THOSE PROVIDED HEREIN TO THE EXCLUSION OF ANY OTHER REMEDIES INCLUDING WITHOUT LIMITATION, INCIDENTAL OR CONSEQUENTIAL DAMAGES, SAID INCIDENTAL AND CONSEQUENTIAL DAMAGES INCLUDING, BUT NOT LIMITED TO, PROPERTY DAMAGE, LOST PROFIT OR DAMAGES ALLEGED TO HAVE BEEN CAUSED BY ANY FAILURE OF HTP TO MEET ANY OBLIGATION UNDER THIS AGREEMENT INCLUDING THE OBLIGATION TO REPAIR AND REPLACE SET FORTH ABOVE. NO AGREEMENT VARYING OR EXTENDING THE FOREGOING WARRANTIES, REMEDIES OR THIS LIMITATION WILL BE BINDING UPON HTP. UNLESS IN WRITING AND SIGNED BY A DULY AUTHORIZED OFFICER OF HTP. THE WARRANTIES STATED HEREIN ARE NOT TRANSFERABLE AND SHALL BE FOR THE BENEFIT OF THE ORIGINAL OWNER ONLY. NO OTHER EXPRESS WARRANTIES This warranty gives the Owner specific legal rights. The Owner may also have other rights that vary from state to state. Some states do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to the Owner. These are the only written warranties applicable to this adapter manufactured and sold by HTP. HTP neither assumes nor authorizes anyone to assume for it any other obligation or liability in connection with said adapters. HTP reserves the right to change specifications or discontinue models without notice.

16 Installation and Maintenance Notes