Bryan Boilers UCG Reference Manual Download

Page: 1 / 56

Form: 2405

Universal Communication Gateway Reference Manual

Date: 01-25-2019

Revision: 8

Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970

Web:

www.bryanboilers.com

Phone:

765.473.6651

Fax:

765.473.3074

E-mail:

[email protected]

Universal Communication

Gateway Reference Manual

The Universal Communication Gateway (UCG) is an external, high performance Building

Automation multi-protocol gateway that is preconfigured to automatically communicate

between Bryan Steam’s products (hereafter called “device”) connected to the UCG and

automatically configures them for BACnet®MS/TP, BACnet IP, Metasys®N2 by JCI,

Modbus TCP/IP or LonWorks®. All Honeywell SOLA, Siemens RWF 40/55, Siemens LMV,

Honeywell RM7800 Series and the Precision Digital Trident PD765 boiler configurations

and Node-ID’s are selected through the UCG Web GUI Configurator for fast and easy

installation. A mix of multiple devices can be used on a single UCG. It is not necessary to

download any configuration files to support the required applications. The UCG is pre-

loaded with tested Profiles/Configurations for the supported devices. This document

provides the necessary information to facilitate installation of the UCG on BACnet

MS/TP, BACnet/IP, Metasys N2 and LonWorks network.

The UCG is provided as a 10” x 12” x 6” NEMA Type 1 control panel that must be

mounted and supplied with 120 VAC. Additional specifications can be found in

Section

Important

If your boiler is equipped with a Bryan Boilers Printed Circuit Board

(WD-857), devices should be pre-wired. See

section 3.1.8

Each boiler device Modbus settings must be configured to

communicate to the UCG.

Summary of Contents for UCG

Page 1: ...he Precision Digital Trident PD765 boiler configurations and Node ID s are selected through the UCG Web GUI Configurator for fast and easy installation A mix of multiple devices can be used on a single UCG It is not necessary to download any configuration files to support the required applications The UCG is pre loaded with tested Profiles Configurations for the supported devices This document pro...

Page 2: ...Honeywell RM7800 Series 10 3 1 7 Precision Digital Trident PD765 Panel Meter 11 3 1 8 Boilers Equipped with Bryan Steam Printed Circuit Board WD 857 11 3 2 Device Modbus RTU COM Settings 13 3 2 1 Honeywell Sola 13 3 2 2 Siemens RWF40 15 3 2 3 Siemens RWF55 17 3 2 4 Siemens LMV2 LMV3 18 3 2 5 Siemens LMV5 19 3 2 6 Honeywell RM7800 Series 20 3 2 7 Precision Digital Trident PD765 Panel Meter 22 4 Set...

Page 3: ...ens LMV52 Modbus RTU Mappings to BACnet Metasys N2 and LonWorks 37 5 4 Honeywell RM7800 Modbus RTU Mappings to BACnet Metasys N2 and LonWorks 38 5 5 Seimens LMV 36 Modbus RTU Mappings to BACnet Metasys N2 and LonWorks 39 5 6 Precision Digital Trident PD765 Modbus RTU Mappings to BACnet Metasys N2 and LonWorks 40 6 Troubleshooting 41 6 1 LED Diagnostics for communications between the UCG and device...

Page 4: ...ection 11 Figure 14 Bryan Steam Communication PCB WD 857 and Multi Boiler Connection 11 Figure 15 End of Line Termination 12 Figure 16 Siemens RWF55 Programing 17 Figure 17 7810M Address Switches and Baud Rate Jumper 20 Figure 18 Honeywell RM7800 Display Setup Screen 21 Figure 19 Modbus Activity on RM7800 21 Figure 20 S Bank DIP Switches 23 Figure 21 B Bank DIP Switches 23 Figure 22 A Bank DIP Swi...

Page 5: ...83 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 5 TABLES Table 1 UCG Component Description 6 Table 2 Modbus Registers 23 Table 3 BMS Protocol Selection 23 Table 4 Baud Rate 24 Table 5 Diagnostic LEDs 42 Table 6 Specifications 46 ...

Page 6: ...lers com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 6 Figure 1 UCG Component Description Item Description 1 ProtoNode 2 UCG PCB WD 856 3 Power Adapter 120Vac to 9 Vdc only for Siemens AZL 4 RJ45 Adapter only for Siemens AZL 5 UCG Power Switch 6 RS232 to RS485 Converter only for Siemens AZL Table 1 UCG Component Description 3 4 5 1 2 6 ...

Page 7: ...he section is for the set up of the UCG to communicate to the devices Modbus and to your building management system All other sections are supportive of the sections above 2 MOUNTING UCG 2 1 MOUNTING Mount the UCG in a suitable location that is easy to access Verify that the UCG power switch is in the off position Connect J1 1 L1 J1 2 L2 and J1 3 G of the UCG PCB WD 856 to a 120VAC power source 12...

Page 8: ...ter to J2 2 and J2 3 of the UCG PCB WD 856 located inside UCG After BMS connection skip to section 3 J2 1 1 2 3 LONWORKS BUILDING MANAGEMENT TWISTED PAIR Figure 5 LonWorks BMS connection 3 CONNECT AND SETUP OF BOILER DEVICES TO UCG 3 1 WIRING DEVICES TO THE UCG If your boiler is equipped with a Bryan Boilers Printed Circuit Board WD 857 see section 3 1 8 Otherwise connect all devices directly to t...

Page 9: ...CG PCB WD 856 GND DATA DATA Figure 6 Honeywell S7999 Display and UCG Connection 3 1 2 SIEMENS RWF40 Use shielded cable to connect terminals CG CB and CA of the Siemens RWF40 to terminals J3 1 GND J3 2 and J3 3 of the UCG PCB WD 856 inside the UCG See Figure 7 Figure 7 Siemens RWF40 and UCG Connection 3 1 3 SIEMENS RWF55 Use shielded cable to connect terminals R and R of the Siemens RWF55 to termin...

Page 10: ...eries flame safeguard requires a Modbus compatible Display Keyboard or Modbus Module Please see your flame safeguard manual for details 3 1 6 1 S7800A1142 KEYBOARD DISPLAY MODULE Use shielded cable to connect terminals 1 2 and 3 of the Honeywell keyboard display to terminals J3 1 GND J3 2 and J3 3 of the UCG PCB WD 856 inside the UCG The 203541 Connector may be required for connection Figure 11 Ho...

Page 11: ...cks installed on the board Standard CAT5 cable wired as T 568A or T 568B straight through can be used for the interconnection between the devices that are factory wired to the Bryan Steam Communication PCB WD 857 and P1 of the UCG PCB WD 856 inside the UCG The Bryan Steam Communication PCB does not need to be wired in sequential order as this will be handled in the device addressing Figure 14 Brya...

Page 12: ...N 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 12 Figure 15 End of Line Termination Always leave the single Red Jumper in the A position On short cabling runs which most applications are the EOL switch does not need to be turned ON The default setting for this Blue EOL switch is OFF ...

Page 13: ... 1 and 255 Use the table in section 8 to record boilers devices and Node ID The Modbus Node ID s assigned are used for designating the Device Instance for BACnet IP and BACnet MS TP The Metasys N2 and Modbus TCP IP field protocol Node IDs are automatically set to be the same value as the Node ID of the Modbus RTU device Select the device below Honeywell SOLA see section 3 2 1 Siemens RWF40 see sec...

Page 14: ...r Preferences Com 2 Tab Check the Enable Modbus Gateway box 3 2 1 2 2 TOUCH SCREEN S7999D Before powering on any of the boilers make sure that all communication wires are disconnected from each boiler and BMS Apply power to all boilers From the S7999D home screen follow these steps to enable the Modbus gateway for each SOLA Setup Display Setup COM2 Tab Enable COM2 port Check that Modbus baud rate ...

Page 15: ...git press and release it Pressing and releasing will cycle up thru the allowable values and back again Once the desired value is displayed and flashing accept it by pressing once and release it If no keys are pressed for 30 seconds at any time the controller will automatically return to the basic display Unit Address Address 0 0 0 Address 1 0 1 Address 99 9 9 Decimal place unit Baud rate No decima...

Page 16: ...70 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 16 The Remote Detection Timer setting is defaulted to 30 seconds This setting will check for a signal from building management If there is no signal the controller will revert back to local control To disable this set dtt equal to 0 ConF IntF dtt ...

Page 17: ...nnected to the UCG Press again and the bdrt will begin to flash Use the to choose the following o 1 for 9600 Baud Press so that the bdrt stops flashing Press and Adr is displayed Press again and the Adr will begin to flash Note The device address will need to be different on all devices connected to the UCG Refer to the UCG configuration sheet generally shipped with boiler for the appropriate addr...

Page 18: ...ct passcode Hold simultaneously for 3 seconds Co d E will momentarily be displayed Press to adjust for each digit of the password Press after each correct character is displayed Press again after the password is complete PA r A is momentarily displayed press simultaneously 400 S E t should be displayed press until 100 PArA is displayed Press 3 2 4 2 ADDRESS Each LMV2 LMV3 device will need to be se...

Page 19: ...e internal load controller must be turned on for controlling the load with BMS Use the display menus as shown to activate the internal load controller Params Display LoadController Configuration LC_OptMode IntLCbus 3 2 5 3 ADDRESS The address can be selected via the AZL menu The address can be set between 1 and 247 Params Display AZL Modbus Address 3 2 5 4 TRANSMISSION PARAMETERS The Baud Rate can...

Page 20: ... the BAS remote local switch is active and set to remote control of the boiler is based on the operating mode selection There are three operating modes Off The burner will remain off regardless of set point On The burner will be controlled based on the fuel rate register 45 Remote Firing Rate Control Auto The burner will be controlled based on external set point register 44 Remote Set point 3 2 6 ...

Page 21: ...hen ENTER 00 is the default address Modbus off Refer to the UCG configuration sheet generally shipped with boiler for the appropriate address and baud rate settings for each device 01 99 are available addresses Use and to select address Press ENTER The left box blinking means ModBus activity is occurring The right box blinking means this address is receiving activity see Fig 17 Figure 19 Modbus Ac...

Page 22: ...ect Use the and keys to change rates choices are 9600 19200 and 38400 Press ENTER at the Save Changes Exit No Save screen 3 2 7 PRECISION DIGITAL TRIDENT PD765 PANEL METER Press the Right arrow and Menu button simultaneously or hold the Menu button for approximately 3 seconds to access the Advanced Features Menu of the meter Prot Verify that Protocol is set to Modbus Addr Each meter must be provid...

Page 23: ...et when the field device and protocol are known at the time of ordering If needed remove the cover of the ProtoNode located inside the UCG Note If the DIP switches need to be changed then the power to the unit will need to be shut off before proceeding 4 2 1 1 BMS PROTOCOL DIP SWITCH S0 S3 The S bank of DIP switches S0 S3 are used to select BACnet MS TP BACnet IP Modbus TCP or Metasys N2 configura...

Page 24: ...n find the UCG via BACnet auto discovery Note Never set a BACnet MSTP MAC Address of the UCG to a value from 128 to 255 Addresses from 128 to 255 are Slave Addresses and cannot be discovered by BMS Front Ends that support Auto Discovery of BACnet MSTP devices Set DIP switches A0 A7 to assign MAC Address for BACnet MSTP Please refer to Section 7 2 for the complete range of MAC Addresses and DIP swi...

Page 25: ...pen the PC browser enter the default IP address of ProtoNode 192 168 1 24 which will bring you to the FST Web Configurator landing page for the ProtoNode Change the Node Offset to meet the required device instance For example Required Device Instance 20 001 Node_Offset changed to 20 000 Device 1 has a Modbus Node ID of 1 Device 2 has a Modbus Node ID of 2 Device 3 has a Modbus Node ID of 3 Device ...

Page 26: ...eb Configurator The BACnet Device Instance can range from 1 to 4 194 303 BACnet IP Addressing The BACnet device instances will be set by taking the Node_Offset found in Web Configurator and adding it to the Modbus Node ID that was assigned to the device Set the PC s IP address to be on the same subnet as the ProtoNode Open the PC browser enter the default IP address of ProtoNode 192 168 1 24 which...

Page 27: ...rect step of the Commissioning process which is different for each LonWorks Network Management Tool Figure 24 LonWorks Service Pin Location If an XIF file is required see steps in section 4 2 6 2 to generate XIF 4 2 6 2 Instructions to Upload XIF File from the UCG LER using Field Server GUI Web Server Follow the steps in section 4 3 1 Open a web browser and go to the following address IP address o...

Page 28: ... PC TO THE PROTONODE VIA THE ETHERNET PORT Figure 26 ProtoNode Ethernet Port Disable any wireless Ethernet adapters on the PC Laptop Disable firewall and virus protection software Connect a standard CAT5 Ethernet cable straight through or cross between the PC and ProtoNode inside the UCG The default IP Address of the ProtoNode is 192 168 1 24 Subnet Mask is 255 255 255 0 If the PC and the ProtoNod...

Page 29: ...TP or BACnet IP or Metasys N2 or Modbus TCP IP profiles for all of the devices for that particular protocol will be listed in the Configurator 4 3 2 1 SELECTING THE DEVICE S PROFILES THAT WILL BE CONNECTED PROTONODE When you open the Web Configurator you will see the available device Profiles on the lower left side of the screen Use the drop down box under Current Profile to view all of the availa...

Page 30: ...rs com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 30 Figure 27 Web Configurator Showing the Active Profiles to Select From Once the Profile has been selected and the Modbus Node Address has been declared click the Add button to activate the Profile for inclusion in the configuration Figure 28 Web Configurator Showing a Profile Selected ...

Page 31: ...83 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 31 Figure 29 Web Configurator Showing a Completed Profile Added Continue this process until all devices have been added Figure 30 Web Configurator Showing Completed Profiles Added ...

Page 32: ...2 4 3 3 SET IP ADDRESS FOR BACNET IP VIA GUI Open a PC web browser enter the default IP address of ProtoNode 192 168 1 24 and connect to ProtoNode The Default GUI landing page is the Web Configurator Press the Diagnostics and Debugging button at the bottom right corner of the page to go to FSGUI utility Figure 31 Default FS Web GUI Landing Page Click on setup and then Network Settings to enter the...

Page 33: ...ST Web GUI Modify the IP address N1 IP address field of ProtoNode Ethernet port If necessary change the Netmask N1 Netmask field Type in a new Subnet Mask If necessary change the IP Gateway Default Gateway field Type in a new IP Gateway Note If ProtoNode is connected to a router the IP Gateway of ProtoNode should be set to the IP address of the router that it is connected to Reset ProtoNode Unplug...

Page 34: ...nSpeed_XXX SNVT_count_f Flame signal Signal strength of the flame 0 15 VDC AI 4 AI 4 nvoFlmSignal_XXX SNVT_count_f Inlet sensor Boilers return water temperature AI 5 AI 5 nvoInletSen_XXX SNVT_temp_f DHW sensor Domestic hot water temperature AI 6 AI 6 nvoDHW_Sen_XXX SNVT_temp_f S5 sensor Header water temperature or outdoor temperature AI 7 AI 7 nvoS5Sensor_XXX SNVT_temp_f Stack sensor Temperature o...

Page 35: ...g 1 Enabled 0 Disabled BV 20 DO 20 nvi nvoBurnerSw_X XX SNVT_switch CH enable Enable Disable central heating 1 Enabled 0 Disabled BV 21 DO 21 nvi nvoCH_Enable_ XXX SNVT_switch CH setpoint Change Boiler Set point AV 22 AO 22 nvi nvoCH_SP_XXX SNVT_temp_f CH TOD setpoint Boiler Set point when Time of Day switch is on AV 23 AO 23 nvi nvoCH_TOD_SP _XXX SNVT_temp_f DHW Enable Enable Disable domestic hot...

Page 36: ...unt_inc_f Burner Alarm AI 9 AI 9 nvoBrnrAlm_XXX SNVT_count_inc_f Activation Remote Operation AV 10 AO 10 nvi nvoREM_XXX SNVT_count_inc_f Controller Off In Remote Setpoint AV 11 AO 11 nvi nvorOFF_XXX SNVT_count_inc_f Switch On Threshold Remote AV 12 AO 12 nvi nvorHYS1_XXX SNVT_count_inc_f Switch Off Threshold Down Remote AV 13 AO 13 nvi nvorHYS2_XXX SNVT_count_inc_f Switch Off Threshold Up Remote A...

Page 37: ...3 Process Setpoint AV 12 AO 12 nvi nvoProcSP_XXX SNVT_count_f 14 Hours AI 13 AI 13 nvoHours_XXX SNVT_time_hour 15 Current Lockout Error code AI 14 AI 14 nvoCrntErCd_XXX SNVT_count_f 16 Current Lockout Error diagnosis AI 15 AI 15 nvoCrntErDg_XXX SNVT_count_f 17 Current Lockout Error class AI 16 AI 16 nvoCrntErCls_XXX SNVT_count_f 18 Current Lockout Error phase AI 17 AI 17 nvoCrntErPh_XXX SNVT_count...

Page 38: ...AI 61 nvoVlvProv_XXX SNVT_switch 15 Alarm AI 62 AI 62 nvoAlarm_XXX SNVT_switch 16 Hold AI 63 AI 63 nvoHold_XXX SNVT_switch 17 Lockout AI 64 AI 64 nvoLockout_XXX SNVT_switch 18 First Out Code AI 65 AI 65 nvo1stOutCod_XXX SNVT_count_f 19 Main Valve Proof of Closure BI 66 DI 66 nvoMnVlvCls_XXX SNVT_switch 20 Burner Switch BI 67 DI 67 nvoBrnrSw_XXX SNVT_switch 21 Operating Control BI 68 DI 68 nvoOpCtr...

Page 39: ...f Point Name BACnet Object Type BACnet Object ID N2 Data Type N2 Address LonWorks Name LonWorks SNVT 1 Com Status BI 1 DI 1 nvoComStatus_XXX SNVT_switch 2 Flame Signal AI 1 AI 1 nvoFlameSig_XXX SNVT_lev_percent 3 Lockout Error Code AI 2 AI 2 nvoLckotErCd_XXX SNVT_count_f 4 Lockout Diagnostic Code AI 3 AI 3 nvoLckotDgCd_XXX SNVT_count_f 5 Control Mode BV 4 DO 4 nvi nvoCtrlMode_XXX SNVT_switch 6 Ope...

Page 40: ...nt_f 13 Relay 1 Normal Fail Safe BV 12 DO 12 nvi nvoRl1NrFlSf_XXX SNVT_switch 14 Relay 1 Operation AV 13 AO 13 nvi nvoRl1Oper_XXX SNVT_count_f 15 Relay 2 Set Point AV 14 AO 14 nvi nvoRl2SP_XXX SNVT_count_f 16 Relay 2 Reset Point AV 15 AO 15 nvi nvoRl2ResPt_XXX SNVT_count_f 17 Relay 2 Turn on Delay AV 16 AO 16 nvi nvoRl2TnOnDl_XXX SNVT_count_f 18 Relay 2 Turn off Delay AV 17 AO 17 nvi nvoRl2TnOfDl_...

Page 41: ... LEDs on ProtoNode Section 6 1 b Check baud rate parity data bits stop bits c Check Modbus device address d Verify wiring e Verify device is connected to the same subnet as the ProtoNode f Verify the Modbus device was discovered in Web Configurator Section 4 2 BMS unable to see any points or devices To fix check the following a Visual dipswitch settings using correct baud rate and device instance ...

Page 42: ... units LED will light until the unit is commissioned on the LonWorks network RUN Green The RUN LED will start flashing 20 seconds after power indicating normal operation ERR Red The SYS ERR LED will go on solid 15 seconds after power up It will turn off after 5 seconds A steady red light will indicate there is a system error on the unit If this occurs immediately report the related system error sh...

Page 43: ...that FieldServer Toolbox is loaded on the PC that is currently being used or download FieldServer Toolbox zip on the Sierra Monitor webpage under Customer Care Resource Center Software Downloads http www sierramonitor com customer care resource center filters software downloads 3 Extract the executable file and complete the installation 4 Disable any wireless Ethernet adapters on the PC Laptop 5 D...

Page 44: ...2019 Revision 8 Bryan Steam LLC 783 North Chili Avenue Peru IN 46970 Web www bryanboilers com Phone 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 44 b Select Full Diagnostic NOTE If desired the default capture period can be changed c Click on Start Diagnostic ...

Page 45: ... 765 473 6651 Fax 765 473 3074 E mail sales bryansteam com 45 d When the capture period is finished the Diagnostic Test Complete window will appear 9 Step 2 Send Log a Once the diagnostic test is complete a zip file is saved on the PC b Choose Open to launch explorer and have it point directly at the correct folder c Send the Diagnostic zip file to sales bryansteam com ...

Page 46: ...tage 120 Vac return voltage J1 3 PE Ground PE Ground RJ45 SOLA Port SOLA Port J3 3 Device RS485 Data Device RS485 Data J3 2 Device RS485 Data Device RS485 Data J3 1 Device RS485 Ground Device RS485 Ground J2 3 BMS RS485 Data BMS FTT 10 LonWorks port J2 2 BMS RS485 Data BMS FTT 10 LonWorks port J2 1 BMS RS485 Ground NA Power Requirements 120 Vac 3 5 Watts Physical Dimensions 10 in x 12 in x 6 in We...

Page 47: ...473 6651 Fax 765 473 3074 E mail sales bryansteam com 47 8 REFERENCE 8 1 WD857 Figure 34 WD 857 Printed Circuit Board 8 2 DEVICE RTU COM SETTINGS Sola RWF40 RWF55 LMV3 LMV5 RM7800 Protocol Modbus RTU Modbus RTU Modbus RTU Modbus RTU Modbus RTU Modbus RTU Baud Rate 38400 9600 9600 9600 9600 9600 Parity None None None None None None Data Bits 8 8 8 8 8 8 Stop Bits 1 1 1 1 1 1 ...

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Page 52: ...f Off On 161 On Off On Off Off Off On Off 162 On Off On Off Off Off On On 163 On Off On Off Off On Off Off 164 On Off On Off Off On Off On 165 On Off On Off Off On On Off 166 On Off On Off Off On On On 167 On Off On Off On Off Off Off 168 On Off On Off On Off Off On 169 On Off On Off On Off On Off 170 On Off On Off On Off On On 171 On Off On Off On On Off Off 172 On Off On Off On On Off On 173 On ...

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Page 55: ... 6651 Fax 765 473 3074 E mail sales bryansteam com 55 8 4 DEVICE LOG Modbus Side Boiler Device Node ID Record the boiler number device name and the node id that you have assigned to each device Copy the record and provide it to your building management station for reference Example Modbus Side Boiler Device Node ID 1 RM7800 1 1 RWF55 2 2 RM7800 3 2 RWF55 4 3 RM7800 5 3 RWF55 6 ...

Page 56: ...MV5 18 Siemens RWF40 14 Siemens RWF55 16 UCG 22 DIP switches 22 23 24 25 28 Honeywell RM7800 8 12 Honeywell SOLA 12 LMV2 3 See Siemens LMV2 3 LMV5 See Siemens LMV5 LonWorks 22 23 26 41 MAC Address 23 Metasys N2 22 23 25 28 41 Node ID 23 24 RM7800 See Honeywell RM7800 RWF40 See Siemens RWF40 RWF55 See Siemens RWF55 Siemens LMV2 LMV3 8 Siemens LMV5 8 12 Siemens RWF40 9 12 Siemens RWF55 9 12 Specific...

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