Lochinvar FTxl 400 Instructions Manual Download | Manualshive

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MODB-I-O_100161545_2000014822_Rev M

Th

is manual must only be used by a

qualifi ed heating installer / service
technician. Read all instructions,
including this manual, the Installation
and Operation Manual, and the Service
Manual, before installing. Perform
steps in the order given. Failure to
comply could result in severe personal
injury, death, or substantial property
damage.



WARNING

Save this manual for future reference.

MODBUS AND BACNET

COMMUNICATION

INSTRUCTIONS

Models:

Knight 81 - 286, Knight XL 400 - 801,

Armor 151 - 801, Outdoor Knight 151

- 286, Outdoor Knight XL 400 - 801,

Outdoor Armor 151 - 801,

AQUAS 400 - 801, FTXL 400 - 850,

Wall Mount 51 - 211, Wall Hung 55 -

399, and Wall Mount Armor 125 - 200

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Summary of Contents for FTxl 400

Page 1: ...ng Perform steps in the order given Failure to comply could result in severe personal injury death or substantial property damage WARNING Save this manual for future reference MODBUS AND BACNET COMMUNICATION INSTRUCTIONS Models Knight 81 286 Knight XL 400 801 Armor 151 801 Outdoor Knight 151 286 Outdoor Knight XL 400 801 Outdoor Armor 151 801 AQUAS 400 801 FTXL 400 850 Wall Mount 51 211 Wall Hung ...

Page 2: ... data bits transmitted per second bps EMS Energy Management System FDX Full Duplex HDX Half Duplex Hex Hexadecimal Number 0 9 A F I O Box Input Output I O LSB Least Significant Byte ModBus A serial half duplex data transmission protocol developed by AEG Modicon MSB Most Significant Byte RS232 A standard for serial full duplex FDX transmission of data based on the RS232 Standard RS485 A standard fo...

Page 3: ...l and resume operation MOUNT PRE PAINTED SHEET METAL COVER OVER THE MODBUS ASSEMBLY FOR PROTECTION FROM LINE VOLTAGE MODBUS ASSEMBLY ATTACH POWER HARNESS TO MODBUS THROUGH SHEET METAL COVER HOLE Figure 2 2a_Attach Cover to Communication Board for Models WB WA AW KB and KBX BLT7068 X4 BLT2007 X4 SHEET METAL BASE JKB40095 Figure 2 1a_Assemble Communication Board for Models WB WA AW KB and KBX NOTE K...

Page 4: ...PPLIED CABLE TIE TO CONNECT MODBUS POWER HARNESS TO BLOWER POWER WIRES RED WHITE GREEN Figure 2 4_Harness Connections_WB WA AW KB KBX OA and OK models CONNECT TO CONNECTION BOARD FROM COMMUNICATION BOARD CONNECT TO CONTROL BOARD FROM COMMUNICATION BOARD LOW VOLTAGE CONNECTION BOARD HARNESSES CAN ONLY BE CONNECTED ONE WAY Figure 2 5_Connect Communication Board to Control Board ...

Page 5: ...e wiring connections referencing FIG s 2 6b and 2 6c 5 Turn ON the main electrical power to the appliance 6 Configure the control board and unit controls per this manual and resume operation IMG01106 SECURE CONNECTION BOARD W 5X CLIPS TRANSFORMER PRIMARY 120V UNIT POWER HARNESS MODBUS POWER HARNESS PRIMARY 120V LOW VOLTAGE CONNECTION BOARD SECURE HARNESS W 3X CLIPS MODBUS MAIN CONTROL BOARD CONNEC...

Page 6: ... Step 3 Use the screw provided in kit to secure the control panel cover FIG 2 6 5 Connect the wire harnesses 100172824 100172826 and 100172828 from the appliance to the communication board following the diagram shown in FIG 2 7 6 Turn on the main electrical power and the main manual gas shutoff to the appliance 7 Configure the communication board and unit controls per this manual and resume operat...

Page 7: ...32 Dip switch 7 64 Dip switch 8 128 Any dip switch set to 0 has a value equal to 0 Example To set the address of the ModBus board to 50 dip switches 2 5 and 6 have to be set to the 1 position The address is determined by adding the values of all the dip switches together Address Value of Dip switch 1 Value of Dip switch 2 Value of Dip switch 3 Value of Dip switch 4 Value of Dip switch 5 Value of D...

Page 8: ...If the commands are not refreshed the boiler will revert to operating based on its own inputs Parity Parity is set by the position of Dip switch 10 0 No Parity 1 Even Parity If No Parity is selected there will be two stop bits otherwise there will be one Data Transmission Mode Many ModBus bus master devices can be configured to transmit data in either ModBus RTU or ModBus ASCII modes Since RTU mes...

Page 9: ...A Diagnostic Clear Counters and Diagnostic Registers 11 0B Diagnostic Return Bus Message Count 12 0C Diagnostic Bus Communication Error Count 13 0D Diagnostic Bus Exception Error Count 14 0E Diagnostic Return Slave Message Count 15 0F Diagnostic Return Communication Error Count 16 10 Diagnostic Return Slave NAK Count 17 11 Diagnostic Return Slave Busy Count 18 12 Diagnostic Return Bus Character Ov...

Page 10: ...lue outside the expectation of the application program since the MODBUS protocol is unaware of the significance of any particular value of any particular register 04 SLAVE DEVICE FAILURE An unrecoverable error occurred while the server or slave was attempting to perform the requested action 05 ACKNOWLEDGE Specialized use in conjunction with programming commands The server or slave has accepted the...

Page 11: ...ow Switch 0 1 ON 0 OFF 0 1 1 10003 Gas Pressure Switch 0 1 ON 0 OFF 0 1 1 10004 Louver Proving Switch 0 1 ON 0 OFF 0 1 1 10005 Air Pressure Switch 0 1 ON 0 OFF 0 1 1 10006 Blocked Drain Switch 0 1 ON 0 OFF 0 1 1 10007 Auto Reset High Limit 0 1 ON 0 OFF 0 1 1 10008 Flame 0 1 ON 0 OFF 0 1 1 10009 Room Thermostat 1 0 1 ON 0 OFF 0 1 1 10010 Tank Thermostat 0 1 ON 0 OFF 0 1 1 10024 Room Thermostat 2 0 ...

Page 12: ...figuration 0 NA 0 65535 1 40002 Coils 0 NA 0 65535 1 40003 0 10 Volt Input Rate Command Setpoint Command 0 0 100 1 40004 Tank Setpoint 0 Degrees Celsius 0 87 5 0 5 40005 Tank Temperature 0 Degrees Celsius 20 130 0 1 40006 Outdoor Temperature 0 Degrees Celsius 40 60 0 1 40007 System Supply Temperature 0 Degrees Celsius 20 130 0 1 40008 DHW Recirculation Temperature 0 Degrees Celsius 20 130 0 1 Memo...

Page 13: ...alue of Dip switch 5 Value of Dip switch 6 Value of Dip switch 7 Value of Dip switch 8 In this example Address 0 2 0 0 16 32 0 0 50 The BACnet Device Instance is calculated by adding the BACnet local address to 600000 Using the above example the Device Instance will be Device Instance 600000 50 600050 The base address 600000 in this example is model dependant and can be changed by the integrator I...

Page 14: ...e OFF OFF 9600 ON OFF 19200 OFF ON 38400 ON ON 76800 When the system temperature tank temperature and or 0 10V BMS voltage is provided by the BAS to the boiler it is critical that the values be updated every few seconds If the boiler does not receive updated values within a timeout period installer adjustable the control will revert to using its own readings if connected The timeout is programmabl...

Page 15: ...ssure Switch BI 4 none 0 1 1 Blocked Drain Switch BI 5 none 0 1 1 Auto Reset High Limit BI 6 none 0 1 1 Flame BI 7 none 0 1 1 Room Thermostat 1 BI 8 none 0 1 1 Tank Thermostat BI 9 none 0 1 1 Room Thermostat 2 BI 23 none 0 1 1 Run Time Contacts BI 32 none 0 1 1 Alarm Contacts BI 33 none 0 1 1 Boiler Pump BI 34 none 0 1 1 DHW Pump BI 35 none 0 1 1 Louver Relay BI 36 none 0 1 1 Gas Valve BI 37 none ...

Page 16: ...iler Pump Speed AI 12 Percent 0 100 1 Boiler Status Code AI 13 none 0 65535 1 Boiler Blocking Code AI 14 none 0 65535 1 Boiler Lockout Code AI 15 none 0 65535 1 Analog Values Configuration AV 0 none 0 65535 1 BV 0 4 AV 1 none 0 65535 1 0 10V BMS Input AV 2 Percent 0 100 1 Tank Setpoint AV 3 Deg C 0 87 5 0 5 Tank Temperature AV 4 Deg C 20 130 0 1 Outdoor Temperature AV 5 Deg C 40 60 0 1 System Supp...

Page 17: ...seconds timeout is programmable the boiler will revert to its own internal control If neither of these temperatures is provided by the BAS but any of the other control signals are being provided the BAS will still need to refresh these inputs at least every 4 minutes Physical Wiring Figure 7 1_Terminal Strip Connections LOUVER RELAY FLOW SWITCH TANK THERMOSTAT ROOM THERMOSTAT 3 SYSTEM SUPPLY SENSO...

Page 18: ...OR SENSOR SEQUENCER BUILDING MANAGMENT SYSTEM LOW VOLTAGE CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR LOUVER PROVING SWITCH FLAME SENSOR LOW WATER CUTOFF BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE SMART CONTROL MODULE AIR PRESSURE SWITCH SYSTEM PUMP SPEED CONTROL MODBUS BACNET COMMUNICATION BOARD NO DRAIN SWITCH ON MODELS WH 55 399 18 ...

Page 19: ...puts LOW VOLTAGE CONNECTION BOARD SMART CONTROL MODULE ALARM BELL LOUVER RELAY RUN TIME CONTACTS BUILDING MANAGEMENT SYSTEM BOILER PUMP SYSTEM PUMP DHW PUMP IGNITOR BLOWER GAS VALVE DISPLAY PANEL PC INTERFACE ModBus and BACnet Communication Instructions 19 ...

Page 20: ...NGER Figure 7 6_Control Location_Knight Armor Wall Mount HEAT EXCHANGER CONTROL INTEGRATED MODBUS BACNET COMMUNICATION BOARD Figure 7 7_Control Location_Knight Wall Hung HEAT EXCHANGER CONTROL INTEGRATED MODBUS BACNET COMMUNICATION BOARD Figure 7 5_Control Location_Outdoor Knight Outdoor Knight XL Outdoor Armor CONTROL INTEGRATED MODBUS BACNET COMMUNICATION BOARD HEAT EXCHANGER IMG00568 ...

Page 21: ...21 7 Wiring Requirements continued Figure 7 8_Control Location_FTXL MODBUS COMMUNICATION BOARD IMG01112 INTEGRATED CONTROL BOARD HEAT EXCHANGER ModBus and BACnet Communication Instructions ...

Page 22: ...dual Monitoring Typical Boiler Water Heater System Wiring Modbus BACnet RS485 Communication Bus Modbus BACnet RS485 Port on Gateway or Building System Physical Configuration Cascade without Individual Monitoring LEADER MEMBER 1 Cascade Daisy Chain Connection MEMBER 2 MEMBER 3 You will need a Modbus or BACnet board only for the Leader NOTICE You will need a Modbus or BACnet board for all appliances...

Page 23: ...tionally it will provide for fail safe operation should BMS communication be lost This timer will cause the unit to revert back to internal unit controls should the BMS communication be interrupted longer than the ModBus timer The timer is reset every time a write command is received with updated temperatures or commands It is the recommendation of Lochinvar that this timer be set to the shortest ...

Page 24: ...dial 2 In the BMS Menu select BMS TYPE scroll to POWER or SETPOINT and press the RIGHT SELECT SAVE key Reference FIG s 6 3 and 6 4 to set BMS Type to the appropriate operation All sensors and limiting devices should be hardwired to the terminal strip on the back of the unit excluding the thermostat enable and tank thermostat enable signal These signals will be sent to the unit via ModBus Control M...

Page 25: ...ble signal These signals will be sent to the unit via ModBus Control Mode 3 Set up Command Parameters 1 Enter the installer code 5309 2 While in the Control s Installer Main Menu scroll to and select CONTROL MODES 3 In Control Modes Menu select BMS and set to ACTIVE see FIG 6 5 on page 18 3 Press the RIGHT SELECT SAVE key The holding registers objects will need to be set as follows Object Holding ...

Page 26: ...ect BMS TSTAT and set to ACTIVE see FIG 8 6 4 Perform Step 2 to set BMS TSTAT and BMS reference FIG 8 6 5 Press the RIGHT SELECT SAVE key see FIG 8 6 to save all of the above parameter settings To ensure that the boiler water heater can properly respond to a call for hot water generation the following holding registers must be set in addition to other commands Figure 8 6_Control Modes Menu Control...

Page 27: ...ions link If you wish to see all the individual temperatures of each unit in the Cascade each unit will have to have a ModBus BACnet communication board However each unit can be monitored without the need to control each one individually Monitoring Only Any boiler water heater can be equipped with the communication board and then set up to operate with its own internal controls By default settings...

Page 28: ...Demand blocked due to high absolute flue temperature 4 Heat Demand blocked due to high absolute Delta T Outlet Inlet 8 Heat Demand blocked due to Low 24 VAC 9 Outdoor shutdown 10 Block due to switch OFF boiler ON OFF of Display 12 Block due to no correct communication Cascade 16 Service function 19 DHW function Storage Tank 21 SH function Heat demand from Room Thermostat 22 SH function Heat demand...

Page 29: ...pen Outlet Sensor 204 CRC EEPROM failed 205 EEPROM programmed display shows PP 206 EEPROM error in programming 207 Write error EEPROM 229 EEPROM code Watch Dog 230 EEPROM code fan low should be high 231 EEPROM code fan high should be low 232 EEPROM code no flame when running 233 EEPROM code no flame after ignition 234 EEPROM code simultaneous output APS and Fan 235 EEPROM code APS active not Close...

Page 30: ... 1 CN8 2 X6 2 CN8 3 X6 3 X4 1 X9 2 X4 2 X9 1 X4 3 X9 3 PC INTERFACE S2 S1a S1b S3a S3b 21 22 26 27 23 24 30 31 32 33 35 36 37 38 39 40 41 42 43 44 3 4 1 2 ALARM CONTACTS M O D B U S 29 34 10 16 14 9 5 6 7 8 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon...

Page 31: ...de requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operati...

Page 32: ...IN MODBUS A B SHIELD SHIELD CN6 X6 CN6 X6 CN6 X6 CN6 X6 CN6 X6 CN8 1 X6 1 CN8 2 X6 2 CN8 3 X6 3 X4 1 X9 2 X4 2 X9 1 X4 3 X9 3 PC INTERFACE S2 S1a S1b S3a S3b 21 22 26 27 23 24 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 3 4 1 2 ALARM CONTACTS M O D B U S 10 16 14 9 5 6 7 8 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such ac...

Page 33: ... X5 6 X5 5 X5 13 X5 14 X2 2 X2 1 BK AIR PRESSURE SWITCH BLOCKED DRAIN SWITCH O P O BK Notes 1 All wiring must be installed in accordance with local state provincial and national code requirements per either N E C in USA or C S A in Canada 2 If any original equipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum...

Page 34: ...3 X5 14 X5 6 0 10V RATE OUT IN MODBUS A B SHIELD SHIELD CN6 X6 CN8 1 X6 1 CN8 2 X6 2 CN8 3 X6 3 X4 1 X9 2 X4 2 X9 1 X4 3 X9 3 PC INTERFACE S2 S1a S1b S3a S3b 16 17 19 20 21 22 23 24 25 26 27 28 29 30 3 4 1 2 ALARM CONTACTS CN6 X6 M O D B U S 10 14 9 5 6 7 8 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states m...

Page 35: ...e appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other components 3 Ac...

Page 36: ...X6 CN6 X6 CN6 X6 CN6 X6 CN6 X6 CN8 1 X6 1 CN8 2 X6 2 CN8 3 X6 3 X4 1 X9 2 X4 2 X9 1 X4 3 X9 3 PC INTERFACE S2 S1a S1b S3a S3b 21 22 26 27 23 24 30 31 32 33 35 36 37 38 39 40 41 42 43 44 3 4 1 2 ALARM CONTACTS M O D B U S 29 34 10 16 14 9 5 6 7 8 X2 2 NOTES 1 Where possible switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from...

Page 37: ...pplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high vo ltage spark lead and ribbon cables must be purchased from the factory Use of a non approved spark lead or ribbon cables can lead to operational problems which could result in non repairable damage to the integrated controller or other c...

Page 38: ...ms to troubleshoot unit WIRING DIAGRAM LBL20426 REV C BOX DEPICTS OPTIONAL ITEMS CN2 2 CN2 3 DHW PUMP BOILER PUMP SYSTEM PUMP 120V SUPPLY L N GND L N X 7 BOX DEPICTS DUAL SENSOR SINGLE HOUSING MODBUS BOARD MTR 01 X6 1 X6 2 X6 3 X6 4 X9 1 X9 2 X9 3 X9 4 X4 1 X4 2 X4 3 X4 4 X5 1 X5 2 X1 1 X1 2 X1 3 BK W G RBLG T T T T SHIELD GROUNDING JUMPER O GY G R BK W BK GY PR 1 2 G 3 HIGH VOLTAGE LOW VOLTAGE 12...

Page 39: ... switches are shown without utilities gas water or electricity connected to the unit As such actual switch states may vary from those shown on diagrams depending upon whether utilities are connected or a fault condition is present 2 See wiring diagram for additional notes CN5 3 X4 5 3 5A CN5 6 X4 9 CN5 7 X4 1 13 X4 8 CN5 5 X4 3 LOW VOLTAGE 120 VAC HIGH VOLTAGE X5 2 X5 11 X5 10 BLOCKED DRAIN SWITCH...

Page 40: ... Troubleshooting Revision E ECO C11616 reflects the addition of the lockout code notice on page 23 R05772 Revision F ECO C11792 reflects the addition of Outdoor Knight Knight XL and Armor models Revision G ECO C13647 reflects the inclusion of AQUAS models Revision H ECO C16066 reflects the addition of FTXL model information images and diagrams Revision J PCP 3000002377 CN 500002607 reflects the ad...

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