AERCO GF-129 User Manual
Installation, Operation, and Maintenance
For Interfacing AERCO Equipment to Building
ProtoNode-LER
ProtoNode-RER
P/N 64084)
AERCO/ProtoNode
GF-129
OMM-0080_0D
Gateway
USER MANUAL
(Serial Ethernet,
BACnet MS/TP, BACnet/IP, N2, or LonWorks
Automation Systems Utilizing:
Protocols
(LonWorks,
P/N 64085)
Revised: 01/17/2012
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288
USER MANUAL
AERCO/ProtoNode Gateway
OMM-0080_0D
Technical Support:
www.aerco.com
(Mon–Fri, 8am-5pm EST)
1-800-526-0288
GF-129
The information contained in this manual is subject to change without notice from AERCO International,
Inc. AERCO makes no warranty of any kind with respect to this material, including but not limited to
implied warranties of merchantability and fitness for a particular application. AERCO International is not
liable for errors appearing in this manual. Nor for incidental or consequential damages occurring in
connection with the furnishing, performance, or use of this material.
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 VD2:011712
Disclaimer
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USER MANUAL
AERCO/ProtoNode Gateway
OMM-0080_0D
GF-129
TABLE OF CONTENTS
1. Introduction ............................................................................................................................ 5
2. Bacnet/LONWorks Setup through Protocessor Protonode RER/LER ............................... 7
2.1 Installation Steps For The Customer ........................................................ 7
2.2 Record Identification Data ...................................................................... 7
2.3 Configure the DIP Switches ..................................................................... 7
2.3.1 Setting the Node/ID Device Instance (DIP Switch A0 – A7) for BACnet MS/TP,
BACnet/IP, and Metasys N2 ................................................................................................ 7
2.3.2 Setting the Serial Baud Rate (DIP Switch B0 – B3) for BACnet MS/TP & Metasys N2 .... ..7
2.3.3 Using S0 – S3 bank of DIP Switches to select and load Configuration Files ............ 8
3. Interfacing the ProtoNode to The AERCO Control System (ACS, BMS II, or BMS) ....... 11
3.1 ProtoNode RER and LER showing connection ports ................................ 11
3.2 ACS/BMS II/BMS Wiring Connections to ProtoNode RER and LER ........... 11
3.3 Modulex BCM ...................................................................................... 13
3.4 ECS .................................................................................................... 13
3.5 C-MORE .............................................................................................. 14
4. Connection from ProtoNode RER to BACnet MS/TP and Metasys N2 networks ......... 15
4.1 Wiring the ProtoNode RER to RS-485 Field Protoc ol ............................ 15
4.2 Wiring the ProtoNode LER Field Port to a LonWorks network ............... 15
4.3 Power-Up the ProtoNode RER or LER ................................................ 15
4.4 Commisioning the ProtoNode LER on a Lonworks network ................... 16
4.5 Sending Write Val ues ........................................................................ 16
5. Install and Run the Utility Software to Setup ip Address for bacnet/IP.......................... 17
5.1 Connect the PC to the ProtoNode via the Ethernet port ......................... 17
5.2 Connect to the ProtoNode using RUI (Ruinet) ........................................ 18
5.3 Set IP Address for BACnet/IP ............................................................... 18
Appendix A. Troubleshooting Tips ......................................................................................... 20
A.1 - LED Diagnostics for Modbus RTU Communications Between the Protonode
and AERCO’s Boiler Controllers ................................................................... 20
A.1.1 - ProtoNode LER - LED Locations and Functions .................................................... 20
A.1.2 - ProtoNode RER - LED Locations and Functions .................................................. 22
A.2 - Troubleshooting Procedu res for Connection Problems .......................... 23
Appendix B. Reference ............................................................................................................. 25
B.1 Specifications ...................................................................................... 25
B.1.1 Compliance with UL Regulations ............................................................................. 25
B.2 Address DIP Switch Settings ................................................................ 26
Appendix C. Configuration Information ................................................................................. 33
C.1 Default Modbus RTU COM Settings for AERCO Control lers ..................... 33
C.2 BACnet/IP, BACnet MS/TP, Metasys N2, and LonWorks Points List ......... 34
C.2.1 - Four C-Mores and One ACS/BMS II/BMS ............................................................. 34
C.2.2 - Eight C-Mores and One ACS/BMS II/BMS ............................................................ 36
C.2.3 - Twelve C-Mores and One ACS/BMS II/BMS ......................................................... 40
C.2.4 - MLX and One ACS/BMS II/BMS ............................................................................ 45
C.2.5 – ECS…………………………………………………………………………………...….47
C.2.6 - Twelve C-Mores, Six ECS/SP, Four Modulex and Two ACS/BMS II/BMS ............ 48
Appendix D. Limited 2 year Warranty .....................................................................................
63
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AERCO/ProtoNode Gateway
OMM-0080_0D
1. INTRODUCTION
GF-129
ProtoNode is an external, high performance, Building Automation multi-protocol gateway that has been
preprogrammed for AERCO’s equipment to support BACnet®
TCP, and LonWorks®
the ProtoNode and are selectable via DIP switches for fast and easy installation. There is no need to download any
configuration files to support the required applications.
This provides the necessary information to assist the Installers of the boilers/heaters with the installation of the
ProtoNode RER on BACnet MS/TP, BACnet/IP, and Metasys N2 by JCI networks and installation of the ProtoNode
LER on a LonWorks network.
BACnet International BTL certification is the highest level of BACnet conformance tests that a product can be
subjected to.
• The ProtoNode RER is BACnet BTL Certified.
• The ProtoNode LER is LonMark Certified.
The ProtoNode units feature a very small form factor, as indicated in the dimensional illustration below:
3
. All the different AERCO C-More configurations for the various protocols are stored within
1
MS/TP, BACnet/IP, Metasys®2 N2 by JCI, Modbus
Dimensions for ProtoNode LER (left) and ProtoNode RER (right)
1
BACnet is a registered trademark of ASHRAE
2
Metasys is a registered trademark of Johnson Controls Inc.
3
LonMark is a registered trademark of LonMark International
4
LonWorks is a registered trademark of Echelon Corporation
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Page 6 of 64
USER MANUAL
AERCO/ProtoNode Gateway
OMM-0080_0D
GF-129
2. BACNET/LONWORKS SETUP THROUGH PROTOCESSOR PROTONODE RER/LER
2.1 Installation Steps For The Customer
1. Set the A, B, and S DIP Switch banks for field protocol baud rate, Node-ID/Device Instance, and proper
configuration. See Section 2.3.
2. Connect the ProtoNode to the Field protocol port and AERCO’s Control System/Boiler Management
System – RS-232 or RS-485 interface. See Section 3.
3. Power up the ProtoNode RER or LER. After power up, the device is installed on BACnet MS/TP, Metasys
N2, or LonWorks for the LER.
4. Where the Field protocol is BACnet/IP, refer to Section 5 to run the Ruinet utility program to change the
IP address. No changes to the configuration file are necessary.
2.2 Record Identification Data
Each ProtoNode has a unique serial number located on the underside of the unit. The number format is FPC-N3XXXX-XXX-XXXX. This number should be recorded as it may be required for technical support. The AERCO part
numbers and model numbers are shown in the table below:
ProtoNode Model AERCO P/N Model Number
RER 64084 FPC-N34-103-126-0645
LER 64085 FPC-N35-103-401-0646
2.3 Configure the DIP Switches
2.3.1 Setting the Node/ID Device Instance (DIP Switch A0 – A7) for BACnet MS/TP, BACnet/IP, and Metasys N2
• The A Bank DIP switches on the ProtoNode RER-R allow users to set the Node-ID/Device Instance
on the Field RS-485.
• DIP switches A0 – A7 can also be used to set the MAC Address for BACnet MS/TP and BACnet/IP
Figure 1. A0 – A7 DIP Switches
• Please refer to Appendix B.2 for the full range of addresses to set Nod-ID/Device Instance..
2.3.2 Setting the Serial Baud Rate (DIP Switch B0 – B3) for BACnet MS/TP & Metasys N2
• Setting the serial baud rate to match the baud rate provided by the Building Management
System can be done through DIP Switches B0 – B3 for BACnet MS/TP.
• Metasys N2 is always defaulted to 9600 baud and the B bank is disabled.
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AERCO/ProtoNode Gateway
OMM-0080_0D
GF-129
B0 B1 B2 B3
Auto
Off
Off
Off
Off
9600
On
On
On
Off
19200
Off
Off
Off
On
38400
On
On
Off
On
57600
Off
Off
On
On
76800
On
Off
On
On
S0 S1 S2 S3
Figure 2. B0 – B3 DIP Switches
2.3.2.1 Baud Rate DIP Switch Selection
Baud B0 B1 B2 B3
2.3.3 Using S0 – S3 bank of DIP Switches to select and load Configuration Files
• The S bank of DIP switches, S0 - S3 is used to select and load a configuration file from a group of
pretested/preloaded configuration files which are stored in the ProtoNode RER (BACnet MS/TP,
BACnet/IP, Modbus TCP and/or Metasys N2) and LER (LonWorks).
Figure 3. S0 – S3 DIP Switches
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USER MANUAL
AERCO/ProtoNode Gateway
OMM-0080_0D
GF-129
2.3.3.1 ProtoNode RER: S0 – S3 (and A1*) DIP Switch Configuration Settings
S0 S1 S2 S3 A1* Profile
Off Off Off Off Off BACnet/IP/BACnet MS/TP, 1 ACS/BMS II/BMS, 4 C-More Controlled Boilers
Off Off Off Off BACnet/IP/BACnet MS/TP, 1 ACS/BMS II/BMS, 8 C-More Controlled Boilers
On
Off
On On
Off Off
On
Off
On On On
Off Off Off
On
Off
On On
Off Off
On
Off
On On On On
Off Off Off Off
On
Off Off Off BACnet/IP/BACnet MS/TP, 1 ACS/BMS II/BMS, 12 C-More Controlled Boilers
On
Off Off Off BACnet/IP/BACnet MS/TP, 1 ACS/BMS II, 4 Modulex Boilers With BCMs
Off Off BACnet/IP/BACnet MS/TP, 4 ECS/SP Systems
On
Off
On On
Off Off
On
Off
On On On
Off Off Off
Off Off BACnet/IP/BACnet MS/TP, 12 C-More, 6 ECS/SP, 4 Modulex and 2 ACS/BMS II
On
Off Off Metasys N2, 1 ACS/BMS II/BMS, 4 C-More Controlled Boi l ers
Off Off Metasys N2, 1 ACS/BMS II/BMS, 8 C-More Controlled B oi l ers
Off Metasys N2, 1 ACS/BMS II/BMS CS, 12 C-More Controlled Boilers
On
Off Metasys N2, 1 ACS/BMS II, 4 Modulex Boilers with BCMs
On
Off
Off
On On
On On
Off Metasys N2, 4 ECS/SP Systems
On
Off Metasys N2, 12 C-More, 6 ECS/SP, 4 Modulex and 2 ACS/BMS II
On
Off Modbus TCP, 1 ACS/BMS II/BMS, 4 C-More Controlled Boilers
Off Modbus TCP, 1 ACS/BMS II/BMS, 8 C-More Controlled Boilers
Off Modbus TCP, 1 ACS/BMS II/BMS, 12 C-More Controlled Boilers
Off Modbus TCP, 1 ACS/BMS II, 4 Modulex Boilers With BCMs
Modbus TCP, 4 ECS/SP Systems
On
Modbus TCP, 12 C-More, 6 ECS/SP, 4 Modulex an d 2 ACS/BMS II
On
*NOTE:
The first sixteen profiles in the chart above (Section 2.3.3.1) require that DIP
switches A1 through A8 be set to OFF, which is the default setting, so those
switches do not need to be accessed for those configurations (and so are not
shown in the above chart). However, the last two profiles do require that DIP
switch A1 be set to ON, so for those two profiles, DIP Switch A1 needs to be
changed to ON (A2 through A8 remain in the OFF position).
A photograph showing the DIP switch locations inside the unit is on the next page.
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OMM-0080_0D
GF-129
Off
Off
Off
Off
1 ACS/BMS II/BMS, 4 C-More Controlled Boilers
On
Off
Off
Off
1 ACS/BMS II/BMS, 8 C-More Controlled Boilers
Off
On
Off
Off
1 ACS/BMS II/BMS, 12 C-More Controlled Boilers
On
On
Off
Off
1 ACS/BMS II, 4 Modulex Boilers With BCMs
Off
Off
On
Off
4 ECS/SP Systems
On
Off
On
Off
12 C-More, 6 ECS/SP, 4 Modulex and 2 ACS/BMS II
A1 - A8 DIP
S-Bank DIP
ON
OFF
ON
OFF
2.3.3.2 ProtoNode RER: S0 – S3 and A1-A8 DIP Switch Locations
The S-Bank DIP switches are accessible through the top cover. However, the cover must be
removed to access the A1 through A8 switches. To remove the cover, pull it from the unit while
holding onto the 6 pin Phoenix connector.
IMPORTANT!
Do not hold the wall mount tabs when removing the cover as these
are designed to break off if not required!
Switches
Switches
(S0, S1, S2, S3)
Location of DIP Switches S0 – S3 and A1-A8
2.3.3.3 ProtoNode LER: S0 – S3 DIP Switch Configuration Settings
S0 S1 S2 S3 Profile
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USER MANUAL
AERCO/ProtoNode Gateway
OMM-0080_0D
GF-129
LonWorks
LonWorks
OEM connection
10/100
10/100
Power +/- and FG
Power +/- and FG
3. INTERFACING THE PROTONODE TO THE AERCO CONTROL SYSTEM (ACS, BMS II, OR
BMS)
3.1 ProtoNode RER and LER showing connection ports
RS-485 Port for Serial
Field Protocol
Service Pin
Port
Base T
RS-485 Port
Base T
(Frame Ground)
9-30 VDC, 12-24 VAC
OEM
Connection
RS-485 Port
(Frame Ground)
9-30 VDC, 12-24 VAC
Figure 4. ProtoNode BACnet RER (left) and LonWorks LER (right)
3.2 ACS/BMS II/BMS Wiring Connections to ProtoNode RER and LER
• When an ACS, BMS II, or BMS is being used, an RS-485-to-RS-232 converter will be required to
connect it to the ProtoNode’s RS485 port (green 6-pin Phoenix connector).
• Refer to Figures 5 and 6 to locate the internal RS-232 connector JP12 (BMS) or JP5 (BMS II/ACS) inside
the wiring area of the ACS/BMS II/BMS.
• If the AERCO RS232-to-RS485 Converter (part no. 124943) is used, the RS-232 side of the converter
contains a connector that plugs directly into header connector JP12 (BMS) or JP5 (BMS II/ACS).
• If a third party converter is used, connect the RS-232 Receive (RxD) and Transmit (TxD) wire leads to
the internal RS-232 connector (JP12 or JP5) as shown in Figures 5 and 6. DO NOT connect the wire
shield on this side of the converter.
NOTE
If a third-party RS232-to-RS485 Converter is used, consult the manufacturer’s instruction manual for signal
polarity.
• On the RS-485 side of the converter (Figure 5 to Figure 7), connect the wire leads as follows:
o Connect the TD B (+) terminal to the ProtoNode’s RS485+ Port.
o Connect the TD A (-) terminal to the ProtoNode’s RS485- Port.
o Connect the GND terminal to the ProtoNode’s RS485 Frame GND Port.
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OMM-0080_0D
RXD
TXD
GND
RS232
JP12
RS232-TO-RS485
CONVERTER
TXD
RXD
GND
GND
B (+)
A
(-)
RED (+)
BLUE (-)
GREEN (GND)
RED
ORANGE
IMPORTANT
CHECK INPUT & OUTPUT
POLARITY ON CONVERTER
BEING USED
BMS
RS232
RS485
+12V
SEE CONVERTER
INSTRUCTIONS
(124958)
ACS /BMS
Figure 5. RS-232 Connection to ACS/BMS
GF-129
ACS/BMS II
Pinouts
ProtoNode Pin # Pin assignment
Pin 1 RS-485 +
Pin 2 RS-485 -
Pin 3 RS-485 GND
Pin 4 V +
Pin 5 V -
Pin 6 FRAME GND
Figure 6. RS-232 Connection to ACS/BMS II
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TERMINATE SHIELD
TIE TOGETHER WITH
TIE TOGETHER WITH
3.3 Modulex BCM
GF-129
3.4 ECS
SHIELDS OF OTHER
FLOAT AT END OF
TO SIGNAL GROUND
UNITS AND
LINE (INSULATE)
Figure 7. RS-485 Connection to BCM
SHIELDS OF OTHER
FLOAT AT END OF
LINE (INSULATE)
Figure 8. RS-485 Connection to ECS
Connect ECS terminals HE and HF to XPC Port 1a (Figures 5-7) as follows:
• Connect the “HF” terminal to the ProtoNode’s “RS485 +” port
• Connect the “HE” terminal to the ProtoNode’s “RS485 -” port
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TERMINATE SHIELD
TO SIGNAL GROUND
UNITS AND
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OMM-0080_0D
If an Oxygen Sensor is attached to the C-
ENABLE
DISABLE
BIAS2
TERM
BIAS1
R1
S2
RS485
TIE TOGETHER WITH
.5 C-MORE
TERMINATE SHIELD
TO SIGNAL GROUND
SHIELDS OF OTHER
UNITS AND
FLOAT AT END OF
LINE (INSULATE)
Figure 8a. RS-485 Connection to C-MORE (RS-485)
GF-129
TERMINATE SHIELD
TO SIGNAL GROUND
IMPORTANT NOTE
The 4-position RS485 DIP Switch (S2) on the PMC PCB of the C-More Controller must be set as
follows:
1) The termination (TERM) and bias (BIAS1 & BIAS2) DIP Switches of S2 must be set to DISABLE.
2) If an Oxygen Sensor is connected to the C-More Controller, switch R1 (see below) should be set
to DISABLED (down). If an Oxygen Sensor is NOT connected to the C-More Controller, it should
be set to ENABLED (up). Improper setting of R1 may result in erro r m essages.
Instructions for accessing the PMC PCB and this DIP Switch can be found in Section 4.3 of ModBus
manual GF-114.
R1
More Controller, set R1 to DISABLED
(down). If an Oxygen Sensor is NOT used,
set R1 to ENABLED (up). Factory default
setting is ENABLED.
C-More Controller PMC PCB
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OMM-0080_0D
G
-
+
4. CONNECTION FROM PROTONODE RER TO BACNET MS/TP AND METASYS N2
NETWORKS
4.1 Wiring the ProtoNode RER to RS-485 Field Protocol
The Field Protocol can be connected to the 3-pin connector on the ProtoNode RER as shown:
GF-129
ProtoNode Pin # Pin assignment
Pin 1 RS-485 +
Pin 2 RS-485 -
Pin 3 RS-485 SIGNAL GND,
MS/TP or N2
Figure 9. Connection from ProtoNode to RS-485 Field Protocol –BACnet MS/TP or Metasys N2
NOTE: For information on connecting the ProtoNode RER to a BACnet/IP network, see Section 5.
4.2 Wiring the ProtoNode LER Field Port to a LonWorks network
• Connect the ProtoNode to the field network with the LonWorks terminal using a twisted pair non-
shielded cable. LonWorks has no polarity
4.3 Power-Up the ProtoNode RER or LER
Apply power to the device. Ensure that the power supply used complies with the specifications provided in
Appendix B. Ensure that the cable is grounded using the “Frame-GND” terminal.
The ProtoNode features a multi-mode power input and accepts either 9-30 VDC or 12-24 VAC.
Figure 10. Supply Voltage to ProtoNode
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Pinouts
ProtoNode Pin # Pin assignment
Pin 1 RS-485 +
Pin 2 RS-485 -
Pin 3 RS-485 GND
Pin 4 V +
Pin 5 V -
Pin 6 FRAME GND
4.4 Commissioning the ProtoNode LER on a Lonworks network
Commissioning may only be performed by the LonWorks administrator.
To commission the ProtoNode LER LonWorks port, insert a small screwdriver in the commissioning hole
on the face of the LER’s enclosure to access the Service Pin. See the illustration on the ProtoNode LER as
to which way to toggle the screw driver during commissioning.
GF-129
4.5 Sending Write Values
The administrator must setup their host management system to write through the gateway to the CMore, ACS or BMS II three or four times within the timeout value.
AERCO Device Parameter Default Value Range Menu
BMS II
C-More
ACS
Network Timeout 30 s 5 to 240 s RS-232
Network Timeout 30 s 5 to 999 s Configuration
Network Timeout 30 s 5 to 240 s RS-232
Refer to GF-112, GF-124, and GF-131 for more information.
LonWorks Service Pin
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GF-129
5. INSTALL AND RUN THE UTILITY SOFTWARE TO SETUP IP ADDRESS FOR BACNET/IP
• Download the RUINET Utilities from the ProtoCessor web site (under Tech Support – Utilities –
Utilities Software – Install.zip) or access the page at:
http://www.protocessor.com/tech_support/Design_Documents.html#US
• Run Install.zip and follow the installation instructions
• Once installed, the FieldServer Utilities can be located in the Windows Start menu as a desktop icon
5.1 Connect the PC to the ProtoNode via the Ethernet port
Figure 11. Ethernet port location of ProtoNode
• Disable any wireless Ethernet adapters on the PC/Laptop
• Disable firewall and virus protection software
• Connect a standard cat5 Ethernet cable between the PC and ProtoNode.
• The Default IP Address of the ProtoNode is 192.168.1.24, Subnet Mask is 255.255.255.0. If the PC and
the ProtoNode are on different IP Networks, assign a static IP Address to the PC on the 192.168.1.xxx
network.
• Go to > >
• Right-click on Local Area Connection > Properties
• Highlight >
• Select: Use the following IP address
• Click twice
• Go to Start > Programs > Field Server Utilities > Ruiping Utility
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• If the IP Address of the ProtoNode module appears on the screen, the ProtoNode is running.
Figure 12. RUIPING screen
5.2 Connect to the ProtoNode using RUI (Ruinet)
• Double click on the debugging utility, “RUINET” (Remote User Interface). The following screen will
appear: (if Ruinet does not automatically display the main menu, select the ProtoNode by typing the
2-digit number to the left of the title name).
GF-129
5.3 Set IP Address for BACnet/IP
• From the main menu, press “I” to enter the Edit IP Address Settings menu
• Press “1” to modify the IP address of the Ethernet adapter
• Type in a new IP address in the format 192.168.2.X and press <Enter>
• If necessary, press “2” to and change the netmask
• Type in a new Subnet Mask and press <Enter>
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Figure 13. RUINET screen
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• If necessary, press “3” to and change the IP Gateway
• Type in a new IP Gateway and press <Enter>
• Note: If the ProtoNode is connected to a router, the IP Gateway of the ProtoNode should be set to
the IP address of the router that it is connected to
• Unplug Ethernet cable from PC and do not connect to network hub or router.
GF-129
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GF-129
PWR
TX
RX
ERR
RUN
RTC
Appendix A. TROUBLESHOOTING TIPS
A.1 - LED Diagnostics for Modbus RTU Communications Between the Protonode and AERCO’s Boiler
Controllers
The AERCO/ProtoNode Gateway units feature status LEDs that indicate a number of possible activities. The
ollowing shows how to open the unit and interpret the activity of the indication LEDs.
The lid on top of the AERCO/ProtoNode Gateway must be removed in order to see the LED’s. Pull on the lid while
holding onto the 6 pin Phoenix connector.
IMPORTANT!
Do not hold the wall mount tabs when removi n g the co ver as these are
designed to break off if not required!
LED locations and function descriptions for LER and RER versions are shown in the following two subsections.
A.1.1 - ProtoNode LER - LED Locations and Functions
Figure 14. AERCO/ProtoNode Gateway LER Main Board Indication LED Locations
LED DESCRIPTION
RUN
ERR
RX
TX
PWR
RTC
The RUN LED will start flashing 20 seconds after power up, indicating normal operation.
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 ProtoNode LER. If this occurs, immediately report the
related “system error” shown in the error screen of the RUI interface to AERCO International for
evaluation.
The RX LED will flash when a message is received on the socket port.
The TX LED will flash when a message is sent on the socket port.
This is the power light and should show steady green at all times when the ProtoNode LER is powered.
Unused
AERCO International, Inc. • 100 Oritani Dr. • Blauvelt, New York 10913 • Phone: 800-526-0288 VD2:011712
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