Crest Audio Lochinvar 3.5, Instructions Manual

Page 1: ...uding 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 COMMUNICATION INSTRUCTIONS Crest Models 1 5 3 5 ...

Page 2: ... 9 Typical Boiler System Wiring 12 13 5 UNIT OPERATION Unit Operation with ModBus Communications 14 17 6 TROUBLESHOOTING 18 21 7 DIAGRAMS Ladder Diagram 22 Wiring Diagram 23 Revision Notes Back Cover Abbreviation or Acronym Meaning ASCII American Standard Code for Information Interchange BAS Building Automation System Baud Baud Rate Number of data bits transmitted per second bps EMS Energy Managem...

Page 3: ...h 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 Dip switch 6 Value of Dip switch 7 Value of Dip sw...

Page 4: ... 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 messages can be formatted to use fewer data bits and are therefore more efficient RTU has...

Page 5: ...nostic 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 Overrun Count 20 14 Diagnostic Clear O...

Page 6: ...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 request and is processing it but a...

Page 7: ...OFF 0 1 1 10006 Blocked Drain Switch 0 1 ON 0 OFF 0 1 1 10008 Flame 1 0 1 ON 0 OFF 0 1 1 10009 Enable 0 1 ON 0 OFF 0 1 1 10010 Tank Thermostat 0 1 ON 0 OFF 0 1 1 10011 Blocked Flue 0 1 ON 0 OFF 0 1 1 10013 Blower Proving Switch 2 0 1 ON 0 OFF 0 1 1 10021 Flue Damper Proving Switch 0 1 ON 0 OFF 0 1 1 10023 Flame 2 0 1 ON 0 OFF 0 1 1 10033 Run time Contacts 0 1 ON 0 OFF 0 1 1 10034 Alarm Contacts 0 ...

Page 8: ...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 System Return Temperature 0 Degrees Celsius 20 130 0 1 Crest Boiler Memory Map 3 Memory Map Configuration ...

Page 9: ...e other control signals are being provided the BAS will still need to refresh these inputs at least every 4 minutes Physical Wiring Figure 4 1_Terminal Strip Connections 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ALARM CONTACTS RUN TIME CONTACTS TANK THERMOSTAT ENABLE LOUVER PROVING LOUVER RELAY AUX SWITCH 1 AUX SWITCH 2 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 CASCADE S...

Page 10: ... CONNECTION BOARD INLET TEMPERATURE SENSOR OUTLET TEMPERATURE HI LIMIT SENSOR FLUE GAS SENSOR LOUVER PROVING SWITCH FLAME SENSOR 1 2 LOW WATER CUTOFF BLOCKED DRAIN SWITCH DISPLAY PANEL PC INTERFACE SMART CONTROL MODULE AIR PRESSURE SWITCH SYSTEM SENSOR RETURN AUX SWITCH 1 2 0 10 INPUT FROM SYSTEM PUMP BLOWER PROVING SWITCHES CASCADE INLET AIR SENSORS MANUAL RESET HIGH LIMIT VENT DAMPER PROVING SWI...

Page 11: ...ONTACTS SEQUENCER BUILDING MANAGMENT SYSTEM BOILER PUMP CONTACTOR SYSTEM PUMP CONTACTOR HWG PUMP CONTACTOR IGNITOR BLOWERS GAS VALVES BOILER RATE OUTPUT DISPLAY PANEL PC INTERFACE 120V SUPPLY SYSTEM PUMP BOILER PUMP DHW PUMP MAX 1 5 AMPS PER CONNECTION N L FIELD SUPPLIED CONTACTOR MUST BE INSTALLED LINE VOLTAGE TERMINAL STRIP 0 10V OUTPUT TO BOILER PUMP VENT DAMPER ...

Page 12: ...US COMMUNICATION BOARD MTR01 CONTROLLER Typical Boiler System Wiring Cascade Daisy Chain Connection Modbus RS485 Communication Bus Modbus RS485 Port on Gateway or Building System Physical Configuration Cascade without Individual Monitoring ModBus Instructions ...

Page 13: ...bus RS485 Port on Gateway or Building System Physical Configuration Direct Control Cascade Daisy Chain Connection Modbus RS485 Communication Bus Modbus RS485 Port on Gateway or Building System Physical Configuration Cascade with individual Monitoring ModBus Instructions ...

Page 14: ...lly it will provide for fail safe operation should ModBus communication be lost This timer will cause the unit to revert back to internal unit controls should the ModBus communication be interrupted longer than the ModBus timer The timer is reset every time a ModBus write command is received with updated temperatures or commands It is the recommendation of Lochinvar that this timer be set to the s...

Page 15: ...ystem 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 boiler with the tank thermostat or tank temperature sensor wired to the terminal strip of the unit Demand Configuration ENABLE ACTIVE BMS ACTIVE In this configuration the unit is controlled by providing an enable signal The setpoint...

Page 16: ...ensors and thermostat values are only available through the ModBus communication bus To ensure that the Crest boiler 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 Bit Value HEX Action 40001 Configuration 00 4A Set Configuration to read 40002 4 5 40002 Coils 00 08 Enables Tank Tstat 00 0...

Page 17: ...adecimal 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 Rate HEX 0 00 20 14 45 2D 60 3C 80 50 95 5...

Page 18: ...blocked due to high absolute flue temperature 4 Heat Demand blocked due to high absolute Delta T Outlet Inlet 7 Heat Demand blocked due to changed Personality Plug 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 line frequency 16 Service function 19 DHW function Storage Tank 21 SH function Heat demand from Room Thermost...

Page 19: ...e Sensor S7 Short 33 System Supply Temperature Sensor S6 Short 34 Tank Sensor S4 Short 35 Flue Sensor S3 Short 36 Inlet Sensor Short 37 Outlet Sensor S1 Short 38 Temperature Measurement Error 2 39 Temperature Measurement Error 1 45 High temperature differential between S12 and S14 46 High temperature differential between S11 and S13 48 High temperature differential between S3 and S10 49 High tempe...

Page 20: ... Speed Low 231 Small Fan Speed High 232 Flame Failure 1 233 Ignition Failure 236 Flue Damper Open 235 Small Blower Proving Switch Not Open 236 Small Blower Proving Switch Not Closed 238 Air Pressure Switch Open 239 Flame 1 Out of Sequence 240 External Manual Reset High Limit 241 Flame 2 Out of Sequence 244 Large Gas Valve Relay Failure 245 Small Gas Valve Relay Failure 246 Internal Manual Reset Hi...

Page 21: ...control boardandsetaside RemovetheMTR01controlboard see FIG 6 2 5 Replace install the new MTR01 control board 6 Replace the four 4 mounting nuts removed in Step 4 7 Reconnect all three 3 wire harnesses unplugged in Step 3 8 Turnonthemainelectricalpowerandthemainmanualgas shutoff to the appliance 9 Configure the MTR01 control board and unit controls per this manual and resume operation UNSCREW THE ...

Page 22: ...SENSOR 0 10V 0 10V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE LARGE CONNECTION BOARD CN6 1 CN3 6 CN3 7 CN3 14 CN3 13 CN3 11 CN3 9 CN3 8 CN3 1 CN3 2 CN3 3 CN3 4 CN6 2 CN6 3 CN3 10 CN3 12 MODBUS BOARD X4 1 X4 2 X4 3 X6 3 X6 1 X6 2 X8 20 X8 10 X7 8 X8 13 X8 14 X8 12 INTEGRATED CONTROL X8 5 X8 15 X7 7 X8 11 X8 6 X8 16 X8 7 X8 17 X8 1 T T T T T T T T T INLET ...

Page 23: ...OIL AUX SWITCH 1 AUX SWITCH 2 SHIELD SHIELD A B MODBUS OPTION RATE OUT BOILER PUMP OUT SYSTEM RETURN SENSOR SYSTEM SUPPLY SENSOR 0 10V 0 10V TANK SENSOR OUTDOOR SENSOR 0 10V 0 10V BMS IN SYSTEM PUMP IN SHIELD SHIELD A B CASCADE R R OR OR BL BK BR R Y OR HIGH LIMIT SWITCH R R X6 1 X6 2 X6 3 GY R PR MODBUS BOARD BL R BL R BR W OR OR W P W BL BK Y J3 5 J3 4 J3 6 LWCO BOARD J3 3 J3 2 J2 1 J2 2 X6 3 OR...

Page 24: ...Revision Notes Revision A ECO C08179 initial release FB MODB Rev A 06 11 ...