A. O. Smith IABA Installation Manual
TM
Instruction Manual
TM
Remote Monitoring System
Important Installation Notice: To reduce installation time and avoid multiple trips to and
from the job site gathering necessary tools and materials locate the following sections in the
Table of Contents and carefully review each section before installation begins:
• System Requirements
• Tool Requirements
• Material Requirements
• Installation Sequence
Have a copy of the Instruction Manual(s) for all the water heating appliances being
connected to the iCOMM™ remote monitoring system on hand before installation begins.
Instruction Manuals can be obtained at the manufacturer’s web site or by calling the
technical support phone number listed on the back cover of this manual.
Printed 06/09 315983-000
i
COMM™ • 888 928-3702 • www.aosmithconnect.com
iCOMM™ Instruction Manual
TABLE OF CONTENTS
INTRODUCTION ........................................................... 1
System Operation & Features ................................. 1
Remote Monitoring - Internet ............................ 1
BACnet Compatibility ........................................ 1
Automated Service Notifications ....................... 1
Historical Data Graphs...................................... 1
Estimated Operating Costs ............................... 1
Appliance Run Time.......................................... 1
iCOMM™ Compatible Appliances ........................... 2
iCOMM™ System Components .............................. 2
iCOMM™ System Limitations.................................. 2
Installer Qualifications ............................................. 2
Installation Reminder............................................... 2
Instruction Manuals ................................................. 2
INSTALLATION CONSIDERATIONS ............................ 3
System Requirements ............................................. 3
Tool Requirements................................................... 4
Material Requirements ............................................ 4
INSTALLATION SEQUENCE ........................................ 5
Pre Installation Internet Check .......................... 5
Order of Installation........................................... 5
BACnet Installation............................................ 5
COMMUNICATION MODULE INSTALLATION ............. 6
Location Requirements............................................ 7
Kit Contents ............................................................. 7
Installation ............................................................... 8
Power Up Test ......................................................... 9
Service Note - CM Power Supply Test .............. 9
LEAK DETECTOR INSTALLATION............................. 10
Installation ............................................................. 10
Service Note - Alarms ..................................... 10
CONNECTING TANK TYPE WATER HEATERS.......... 11
Routing Network Cable To The CM ........................ 11
Single Appliance Networks.................................... 12
Connecting Gas Fired Water Heaters.................... 12
Connecting Electric Water Heaters........................ 14
Multiple Appliance Networks ................................. 16
Multiple Device Adapters - MDAs ................... 16
Multiple Appliance Network Guidelines........... 17
CM Communication Ports ............................... 17
MDA Connections ........................................... 18
MDA Connections - Gas Fired Water Heaters 19
MDA Connections - Electric Water Heaters .... 19
Water Heater Networks................................... 20
CONNECTING BOILERS............................................. 21
Boiler Installation Notes ......................................... 21
Routing Network Cable .......................................... 22
Boiler Networks...................................................... 23
Communication Ports............................................. 24
ALARM BOX INSTALLATION ...................................... 25
Installation.............................................................. 26
Wall Mounting.................................................. 26
Wiring .............................................................. 27
Connection & Wiring Diagrams ....................... 28
START UP.................................................................... 29
Final Installation Checks ........................................ 29
Establish The Network ........................................... 29
Assign Network Addresses .................................... 30
Establish Internet Connection ................................ 32
Registration............................................................ 33
Display Button Operation ....................................... 34
Silencing The Alarm ........................................ 34
CONNECTING BACNET.............................................. 35
Supported Water Heating Appliances.................... 35
Hardware Interface ................................................ 36
BACnet Cable Max Length & Termination ....... 36
BACnet Cable Connections............................. 37
BACnet MS/TP Network Address .......................... 38
Changing BACnet MS/TP Network Address ... 38
BMS Mode Only..................................................... 41
TROUBLESHOOTING ERROR MESSAGES .............. 42
No Units Found ...................................................... 42
No Network Found ................................................. 43
Limited Network ..................................................... 44
No Connection ....................................................... 45
Water Detected ...................................................... 46
Unit # Low Temp Alarm .......................................... 47
Unit # In Fault......................................................... 48
Unit # Invalid Model Number.................................. 49
Boiler # Does Not Support iCOMM ........................ 50
APPENDIX ................................................................... 51
Internet Communications Strategy......................... 51
Frequently Asked Questions .................................. 51
Wireless Network Guidelines ................................. 53
Wireless Network Technology ......................... 53
Recommended Router & Adapter† ................. 53
GLOSSARY.................................................................. 54
TERMS AND CONDITIONS ......................................... 55
INTRODUCTION
This manual provides installation, operational and set up instructions for the iCOMM™
remote monitoring system hardware. In this manual the terms “Appliance,” “Unit” and
“Device” are synonymous with tank type water heaters and boilers.
SYSTEM OPERATION & FEATURES
Remote Monitoring - Internet
The iCOMM™ system allows users to remotely monitor operational and diagnostic
information of iCOMM™ compatible water heating appliances. Appliances are connected to
the iCOMM™ system’s CM (communication module - page 6) and the CM is connected to
the Internet. Users log on to a secure web site maintained by the appliance manufacturer to
monitor appliances.
Operational and diagnostic information accessible through the appliance’s control system
locally can be viewed remotely from any location that has Internet access.
BACnet Compatibility
In addition to web based monitoring iCOMM™compatible water heating appliances will be
able to communicate with BACnet compliant supervisory controls and building management
systems through the iCOMM™ system’s CM - see page 35.
INTRODUCTION
Automated Service Notifications
The iCOMM™ system can automatically notify selected employees and service personnel
via email and/or cellular phone text messages whenever operational problems or user
defined Alert Conditions occur. Operational problems and conditions that can initiate an
Automated Service Notification include:
• Fault/error/lock out conditions declared by any connected water heating appliance.
• Water leaks detected by the iCOMM™ system Leak Detector component (page 10).
• Low Water Temperature Alarm (settings for this feature are made on iCOMM™ web site).
• Various user defined Alert Conditions such as maximum cycle count, run time, elapsed
time, heating time and communication failures (settings for this feature are made on
iCOMM™ web site).
Historical Data Graphs
Graphs showing operational data such as system temperature and run time for a water
heating appliance during user defined time periods are calculated and displayed online.
Estimated Operating Costs
Estimated utility costs savings (compared to standard 80% thermally efficient products) are
calculated and displayed on the iCOMM™ web site for each connected appliance.
Appliance Run Time
Appliance run time (wear) data is collected and displayed online. This data can be used to
implement planned replacement policies and to forecast and budget for replacement costs.
This can help minimize lost income due to unexpected equipment failure.
1
INTRODUCTION
ICOMM™ COMPATIBLE APPLIANCES
These include the tank type water heaters listed inTable 2 on page 11 and the boiler
products listed in Table 4 on page 21.
ICOMM™ SYSTEM COMPONENTS
The iCOMM™ system is comprised of four major components:
1 Communication Module or “CM” - see page 6.
2 Leak Detector - water leak detection device - see page 10.
3 Multiple Device Adapter or “MDA” - see page 16.
4 Alarm Box - optional system component - see page 25.
ICOMM™ SYSTEM LIMITATIONS
• The iCOMM™ system does not allow users to adjust or change appliance settings from
the iCOMM™ web site.
• The BACnet wiring terminal on the CM (Figure 2 on page 6) allows BACnet compliant
supervisory controls to monitor and control some appliance settings - see page 35.
• The iCOMM™ system does not include Internet service. System users must provide
“always on” Internet access through their own ISP (Internet Service Provider).
• The iCOMM™ system does not include a computer. System users must provide their own
computers to monitor connected appliances.
• See the Disclaimer of Consequential Damages in the Terms And Conditions section on
page 57.
INSTALLER QUALIFICATIONS
If you are not qualified, licensed and/or certified as required by the authority having
jurisdiction to perform a given task do not attempt to perform any procedures described in
this manual. If you do not understand the instructions given in this manual or do not feel
confident in your abilities to perform a given task do not attempt to perform any procedures
outlined in this manual.
INSTALLATION REMINDER
When performing any procedure outlined in this manual consider the cables, wiring and
connectors between components. Perform a close visual inspection of all cables, wiring and
connectors. Ensure all cable plugs and wiring are connected properly. Ensure wiring and
cables are routed and secured properly to provide adequate strain relief to avoid accidental
disconnection or damage.
INSTRUCTION MANUALS
Have a copy of the Instruction Manual(s) that came with the appliance(s) for each connected
appliance before starting the installation. Instruction Manuals can be obtained at the
manufacturer’s web site or by calling the technical support phone number listed on the
appliance labeling and the back cover of this manual.
2
INSTALLATION CONSIDERATIONS
MDA
Boiler
Tank Type
Water
Heater
SINGLE
PORT
MULTI
PORT
Tank Type
Water
Heater
SINGLE
PORT
MULTI
PORT
Figure 1
CM
Single Appliance Network Multiple Appliance Network
MDAs (multiple device adapter)
are not required when only one
tank type water heater is connected
to a Single Appliance Network.
(communication module)
MDAs (multiple device adapter)
required for each tank type
water heater when more than
one appliance is connected.
Boilers do not
require MDAs
INSTALLATION CONSIDERATIONS
SYSTEM REQUIREMENTS
1 Local “always on” Internet access such as a cable broadband or DSL service to the iCOMM™
system’s CM (communication module) - see page 6.
• Local Internet service must be provided to the CM’s LAN PORT via a field supplied Category 5
network cable with a RJ45 male plug end - see Figure 2 on page 6. This cable is not included with
the iCOMM™ system hardware.
• Local Internet service must use DHCP servers/routers and assign an IP address to the CM
automatically.
• Local Internet service must allow access to the iCOMM™ web site at: www.aosmithconnect.com
Network security/firewalls must not prevent the CM from accessing this web site.
2 Available 120 VAC outlet(s). A field supplied 120 VAC power strip or outlet multiplier may be
necessary to provide power for the iCOMM™ components. Field supplied extension cords may
also be necessary to bring power to the iCOMM™ components.
• One available socket at a 120 VAC wall outlet for the iCOMM™ system’s CM for all installations.
• If the optional Alarm Box (page 25) is being installed a second 120 VAC socket will be needed.
• Field supplied wireless network adapters may also require a 120 VAC socket for power.
3 Multiple Device Adapters - MDAs
• MDAs (multiple device adapter - see page 16) are required for each “tank type” water heater on all
Multiple Appliance Networks - networks with more than one water heating appliance connected.
MDAs are an accessory component that is ordered separately. Determine how many “tank type”
water heaters will be connected on all Multiple Appliance Networks. Order one MDA for each tank
type water heater before the installation begins - see Figure 1.
3
INSTALLATION CONSIDERATIONS
TOOL REQUIREMENTS
• Manufacturer’s Instruction Manual(s) that came with the appliance for all water heating appliances
being connected to the iCOMM™ system. Instruction Manuals are necessary to locate
components and for instructions on how to navigate the control system menus for each appliance.
Instruction Manuals can be obtained at the manufacturer’s web site or by calling the technical
support phone number listed on the appliance labeling and the back cover of this manual.
• Laptop Computer - Internet ready/capable portable computer - used to verify LAN connectivity to
the iCOMM™ web site and configure wireless adapters when used.
• All tools common and necessary for the installation and service of electrical hardware, network
and phone communication systems including hand tools such as short/long screw drivers, wire
strippers, hammer, torpedo level, measuring tape and a 6 foot ladder.
• Portable electric drill and the following drill bits:
• Standard metal/wood drill bit set including1/8” to 1/2” bits.
• 3/8 inch standard drill bit - for sheetrock wall mounting of CM (communication module).
• 3/8 inch masonry drill bit - for brick/concrete wall mounting of CM.
• 3/8” metal cutting drill bit to drill pilot hole for 1/2” electrical knockout cutter.
• 1/2” electrical knockout punch/die - Greenlee model GRE14722P or equivalent.
• Network (Cat 5) cable tester - recommend Fluke MT-8200-49A or equivalent.
• RJ45 plug crimping tool - recommend AMP model 3–231652–0 or equivalent professional grade
ratchet type crimp tool.
• Volt-Ohm Multi Meter - recommend Fluke 187, UEI model DL289, Fieldpiece HS36 or equivalent.
MATERIAL REQUIREMENTS
• One Cat 5 cable to connect local Internet service to the CM’s LAN PORT - see Figure 2 on page 6.
• If the CM will be connected to a BACnet MS/TP network a BACnet cable long enough to reach
between the CM’s BACnet terminal strip and the local BACnet connection point will be needed.
• A 120 VAC power strip or 120 VAC outlet multiplier may be required if there are not enough 120
VAC outlets available. This is not included with any iCOMM hardware and is to be provided by
customer if needed.
• Bulk (spooled) Category 5 network cable.
• RJ45 male network plugs.
• Additional wire tie wraps (10” to 12” length). Wire ties are included with component hardware kits.
Additional/longer wire ties may be needed to complete the installation. These are available at local
electrical supply stores and home centers.
• Additional 3/4” adhesive wire tie mounts. Wire tie mounts are included with component hardware
kits. Additional wire tie mounts may be needed to complete the installation. These are available at
local electrical supply stores and home centers.
• Additional wall anchors & screws suitable for sheetrock, concrete or brick walls. Anchors are
included with component hardware kits. Additional wall anchors may be needed to complete the
installation. These are available at local hardware stores and home centers.
4
INSTALLATION SEQUENCE
INSTALLATION SEQUENCE
Every installation will require the installation of a CM (communication module - see page 6)
and the connection of at least one water heating appliance - see page 11 and page 21.
One Leak Detector component is included with the CM and should be installed on the
equipment room floor - see page 10.
The Alarm Box (an optional component) will need to be installed if the customer has ordered
one - see page 25.
Optionally the iCOMM™ system’s CM can be connected to a BACnet compliant supervisory
control or building management system see the BACnet installation note below and the
BACnet installation section beginning on page 35.
This Instruction Manual provides step by step installation instructions for all of the above
iCOMM™ components and features. This manual also provides instructions for connecting
water heating appliances to the iCOMM™ network. The Order of Installation below shows
the general order in which an iCOMM™ remote monitoring system will be installed.
Pre Installation Internet Check
To avoid delays during Start Up ensure all the System Requirements on page 3 have been met. It is
the responsibility of the customer (not the appliance/iCOMM™ manufacturer or the installing
contractor) to ensure all system requirements are met prior to installation. Internet connectivity to the
iCOMM™ web site is a commonly overlooked requirement. Perform the following Internet connection
test to ensure this requirement has been met:
1 Connect an Internet ready portable (laptop/notebook) computer to the customer provided/
required Internet access point (male RJ45 cable) and navigate to the iCOMM™ web site at
www.aosmithconnect.com using the computer’s browser software.
If the computer is able to connect to the iCOMM™ web site continue with the installation. If the
computer is unable to connect to the iCOMM™ web site advise the customer (building/business
owner) immediately so they can take steps to provide Internet access to the iCOMM™ web site
as soon as possible.
Order of Installation
1 Install the CM (communication module) - see page 6.
2 Install the Leak Detector component - see page 10.
3 Connect any tank type water heaters that will be monitored to the network - see page 11.
4 Connect any boilers that will be monitored to the network - see page 21.
5 Install the optional Alarm Box component if present - see page 25.
6 Start up the iCOMM™ system and register all connected appliances - see page 29.
BACnet Installation
1 Notify the customer (building/business owner) when the iCOMM™ system installation is
complete so they can schedule to have the iCOMM™ system’s CM connected to their BACnet
compliant building management system - see page 35.
Connection and configuration of the CM and appliances on the customer’s building management
system should only be performed by the customer’s BACnet administrator.
5
COMMUNICATION MODULE INSTALLATION
Display
Button
(page 34)
Figure 2
Front Edge
iCOMM™ System CM (communication module)
Right Edge
Front View
LAN
Port
Internet
(page 32)
MULTI
Port
(page 17)
BACnet
Terminal Strip
(page 35)
SINGLE
Port
(page 11)
Leak Detector
Terminal Strip
(page 10)
5 VDC
Power
Supply
(page 9)
N/A
To Be
Removed
Alarm Box
Terminal Strip
(page 25)
COMMUNICATION MODULE INSTALLATION
The CM (communication module) is the heart of the iCOMM™ remote monitoring system see Figure 2. The CM connects to the Internet and transmits operational and diagnostic data
between the water heating appliances connected to it and the iCOMM™ web site.
6
COMMUNICATION MODULE INSTALLATION
LOCATION REQUIREMENTS
Choose a location to install the CM that meets the requirements below. See the System
Requirements on page 3 also.
• Must be wall mounted indoors (wall mount anchors/screws included).
• Must not be exposed to moisture.
• Must not be exposed to temperatures above 122°F (50°C) or below 32°F (0°C).
• Location must have a field supplied Cat 5 network cable with a male RJ45 plug end that provides
“always on” Internet access. Internet access must allow the CM to connect to the iCOMM™ web
site on the Internet. See System Requirements on page 3.
• Location that can be easily accessed.
• Location must have a 120 VAC outlet nearby.
• Location must permit the routing of network cables and accessory wiring to the CM.
KIT CONTENTS
The CM (communication module) installation kit comes with the items listed in Table 1.
Ensure all these parts are present before you begin the installation.
TABLE 1
Item Quantity Description
1 1 CM (communications module)
2 1 5 VDC Power Supply (plug in transformer)
3 2 Nylon Toggle Anchor
4 2 Mounting Screw
5 5 Wire tie mounts 3/4” (square adhesive/screw mounts)
65Wire tie wraps
71
8 1 Splitter – T Adaptor (Category 5 cable splitter)
9 1 Universal Knockout Bushing
10 1 Leak Detector
11 2 Adhesive Velcro strips
12 1 Installation Instructions
13 1 Registration Form
†
Category 5 network cable (25 feet)
14 25 feet 18/2 SJ wire (for Leak Detector)
†. For connecting the first water heating appliance to the CM. Longer cables can be obtained from
local computer stores/home centers or fabricated at the job site if needed.
7
COMMUNICATION MODULE INSTALLATION
Wall mount tabs
Figure 3
Wire Tie
CM (communication module)
Wrap & Mount
Ensure the CM is level
Leave some excess cable by CM when routing network cables to provide proper
strain relief. Use the included wire tie wraps and 3/4” square adhesive wire tie
mounts to secure excess cables and wiring to the wall by the CM.
Drill 3/8” diameter hole and
fold the nylon toggle anchor
in the middle.
Insert anchor into hole and Align mounting tabs of CM over
tap flush with a hammer. anchors. Insert screw and
tighten until flush with mounting
tabs. Do not overtighten.
Installing Nylon Toggle Anchors
INSTALLATION
1 Using the CM’s (communication module) mounting tabs as a template align the CM on
the wall where it is to be mounted. Mark the wall with a pencil or awl through the holes in
the mounting tabs while holding the CM level. See Figure 3 and the Location
Requirements on page 7.
2 Drill two holes in the wall where the marks were made in the Step 1 using a portable drill
and the appropriate type (standard or masonry) of 3/8” drill bit. See Tool Requirements
on page 4.
3 Insert one Nylon Toggle Anchor (Table 1 on page 7) in each hole drilled in Step 2. Gently
tap the anchors into the holes using a hammer until they are flush with the wall.
4 Align the CM with the anchors in the wall and install the two mounting screws (Table 1 on
page 7) to secure the CM to the wall.
8
COMMUNICATION MODULE INSTALLATION
5 VDC
Socket
Front Edge
Figure 4
CM (communication module)
POWER UP TEST
1 DO NOT connect the local Internet service to the CM (communication module) at this time. This
should only be done after all water heating appliances have been connected.
2 Plug the included 5 VDC Power Supply (Table 1 on page 7) into an available 120 VAC wall outlet.
Use a field supplied extension cord, power strip or outlet multiplier as necessary to access an
available 120 VAC socket.
3 Insert the 5 VDC round plug from the Power Supply into the socket labeled “5 VDC” on the front
edge of the CM - see Figure 4.
The CM should now be energized and initiate it’s boot sequence. The CM’s LCD should display a
“Booting iCOMM Please Wait” message. If the CM is not energized (no text appears on the
LCD) see the Service Note below.
Without a connection to the Internet or any water heating appliances the CM will display the “No
Units Found” and/or “No Network Found” error messages and activate it’s internal alarm
buzzer. Press the Display Button several times to silence any alarms. The CM boot sequence is
complete at this point - unplug the 5 VDC round plug from the CM.
Proceed to the Leak Detector installation section - see page 10.
Service Note - CM Power Supply Test
If no characters or messages appear on the CM’s LCD when power is applied:
• Ensure the 5 VDC Power Supply is plugged into an available 120 VAC socket.
• Ensure the round plug from the 5 VDC Power Supply is fully inserted into the 5 VDC socket
on the CM - see Figure 4.
• Ensure 120 VAC is present at the outlet the 5 VDC Power Supply (plug in transformer) is
using. Check for 120 VAC at the outlet with an AC volt meter - restore power to the outlet if
120 VAC is not present.
• Ensure the 5 VDC Power Supply is outputting 5 VDC. Using a DC volt meter (Tool
Requirements on page 4) check for DC voltage between the center and outer conductors
of the 5 VDC round plug with the Power Supply plugged in to a 120 VAC outlet. If 5 VDC is
not present - the CM Power Supply must be replaced. If 5 VDC is present call 888 9283702 for further technical assistance.
9
LEAK DETECTOR INSTALLATION
Leak Detector
Wiring Terminal
Front Edge
Leak Detector
25 ft 18/2
SJ Cord
Plastic Enclosure
Bottom of Leak Detector
should lay flat on the floor
near the storage tank in a low
traffic area. Approximately 1/4”
Figure 5
Display
Button
CM (communication module)
Service Note - Alarms
If the Leak Detector is activated by rising water the CM and Alarm Box (if so equipped - see page 25) will sound an
audible and visual alarm. The alarms can be silenced/disabled by pressing the Display Button on the CM several
times - see Figure 5. The Leak Detector must dry out completely before the alarm condition can be cleared. The Leak
Detector will air dry over time or can be dried out with compressed air or a heat gun.
(unplug from CM for wiring)
of water on the floor will activate
the Leak Detector.
LEAK DETECTOR INSTALLATION
This section provides instructions for connecting the Leak Detector to the iCOMM™
system’s CM (communication module). The Leak Detector comes with a 25 foot length of 18
gauge two conductor (18/2) SJ cord - see Figure 5. Operation is based on continuity; a water
level of approximately 1/4” will activate the Leak Detector.
INSTALLATION
1 Turn off power to the CM - unplug the 5 VDC round plug from the CM.
2 Locate the Leak Detector on the floor near the storage tank. Ensure the bottom of the Leak
Detector is laying flat on the floor. The Leak Detector does not need to be mounted or secured to
the floor. Choose a low traffic area to prevent disruption or damage to the Leak Detector.
3 Route the SJ cord from the Leak Detector back to the CM. Cut off any excess cord near the CM.
Secure the cord to walls and other suitable structures using wire tie wraps and mounts to provide
proper strain relief - see Figure 3 on page 8.
4 The wiring to the Leak Detector can be lengthened if necessary with similar 18 gauge wiring.
5 Split the end of the SJ cord and strip 1/4” of insulation from the two wires and connect them to the
“WATER DETECT” wiring terminal on the CM - see Figure 5. Unplug the “WATER DETECT”
wiring terminal from the CM when making connections and tighten terminal screws securely.
6 When Leak Detector installation is complete proceed to the Connecting Tank Type Water
Heaters or Connecting Boilers section(s) of this manual - see pages 11 and 21.
10
CONNECTING TANK TYPE WATER HEATERS
Single
Port
Multi
Port
Front Edge
Figure 6
CONNECTING TANK TYPE WATER HEATERS
This section provides instructions for connecting “tank type” water heaters to the iCOMM™
system’s CM (communication module). Tank type water heaters that are compatible with the
iCOMM™ remote monitoring system are listed in Table 2.
TABLE 2
†
Product Name Model Numbers Series Numbers Gas/Electric
Cyclone ® Xi BTH 120 - 500 100/101 and later Gas Commercial
Cyclone ® Xi BTX 100 100/101 and later Gas Commercial
Vertex 100 GDHE 50 100/101 and later Gas Residential
Gold Xi DVE 52 - 120 100 and later Electric Commercial
Custom Xi DSE 5 - 120 100 & 102 and later Electric Commercial
†. See Table 4 on page 21 for compatible boilers.
Commercial
Residential
ROUTING NETWORK CABLE TO THE CM
1 Starting at the first “tank type” water heater on the network route the included Cat 5 network cable
(see Table 1 on page 7) back to the CM (communication module - see page 6). Ensure the cable
end at the water heater has approximately 24 inches of slack at the top of the water heater for
internal connections. If the included network cable is not long enough to reach between the CM
and the first water heater on the network longer Cat 5 cables are available at local home centers
or can be fabricated in the field. If there will be any boiler products connected to the iCOMM™
network review the instructions beginning on page 21.
2 Secure the network cable to walls or other suitable structures to ensure proper strain relief using
the included wire tie wraps and 3/4” square adhesive wire tie mounts - see Table 1 on page 7.
Use wall anchors and screws (not supplied) to further secure the wire tie mounts to the surface of
walls. Additional wall anchors, wire ties and adhesive wire tie mounts are available at local home
centers if needed - see Material Requirements on page 4.
3 If there will be only one “tank type” water heater on the network (Single Appliance Network - see
page 12) plug the network cable into the “Single Port” on the front edge of the CM - see Figure 6.
4 If there will be more than one “tank type” water heater on the network or there will be one or more
boilers (page 21) on the network; plug the network cable into the “Multi Port” on the front edge of
the CM - see Multiple Appliance Networks on page 16.
5 Coil excess network cable by the CM using a wire tie wrap and mount - see Figure 3 on page 8.
11
CONNECTING TANK TYPE WATER HEATERS
SINGLE APPLIANCE NETWORKS
Single Appliance Networks are formed when only one water heating appliance is connected
to the iCOMM™ network - see Figure 15 on page 20.
Multiple Appliance Networks are formed when two or more water heating appliances are
connected to an iCOMM™ network - see Figure 15 on page 20.
If there will be boiler products connected to the iCOMM™ network review the Boilers section
of this manual beginning on page 21 before connecting any appliances to the network.
Boilers must be at the end of the network chain as shown in Figure 16 on page 23 and this
may effect network cable routing.
Proceed to Connecting Gas Fired Water Heaters below or Connecting Electric Water
Heaters on page 14.
CONNECTING GAS FIRED WATER HEATERS
Gas fired tank type water heaters require a Splitter – T Adaptor - see Table 1 on page 7.
1 Turn off power to the water heater at the on/off switch on the appliance.
2 There will always be hot surfaces on operating water heating appliances. Be careful to avoid
contact with hot pipes and other surfaces when working on or near water heating appliances.
3 Disconnect the internal network cable from the J2 socket on the display circuit board. This cable
comes from the water heater’s CCB (central control board). Access to the display circuit board on
BTH 120-500 models is from the top of the water heater. On BTX 100 and GDHE 50 models the
display housing is removed to access the display circuit board - see Figure 7 on page 13.
4 Locate a Splitter T Adaptor (included with CM and MDA hardware kits) and mount it on the water
heater away from hot surfaces & potential water leak points with included Velcro strips or wire
ties. On BTX/GDHE models mount the splitter inside the Display Housing.
5 Plug the cable end of the Splitter – T Adaptor into the J2 socket on the display circuit board - see
Figure 7 on page 13.
6 Plug the internal cable from the water heater’s CCB (previously disconnected from the display
circuit board) into one of the two female sockets on the Splitter – T Adaptor.
7 On Single Appliance Networks:
other female socket on the Splitter – T Adaptor.
Route all cabling and wires away from hot surfaces & potential water leak points.
Reinstall any circuit board splash shields removed.
Reinstall the display housing on BTX/GDHE models. Proceed to the Start Up section on page 29.
8 On Multiple Appliance Networks:
adapter). Each MDA hardware kit includes a Splitter T - Adapter - see page 16.
Install one Splitter T - Adapter as described above on each gas fired tank type water heater being
added to the network.
plug the network cable from the CM (see page 11) into the
all tank type water heaters require a MDA (multiple device
If there will only be “gas fired” tank type water heaters on the network proceed to Multiple
Appliance Networks on page 16 when finished installing the Splitter T - Adapters.
If any commercial electric water heaters are to be added to the network see page 14.
If any boilers are to be added to the network see page 21.
12
CONNECTING TANK TYPE WATER HEATERS
Splitter – T Adaptor
J2
Socket
BTH 120 - 500 Models BTX 100 & GDHE 50 Models
Display
Gas Water Heater Display Circuit Board Location
Display Housing
Display Circuit Board
The top cover is a two piece assembly.
Circuit Board
Accessing the Display Circuit Board may require
removal of the top section of the assembly. Loosen
Figure 7
and remove the two retaining screws at the back of the top section. The top section also has retaining
retaining screws
clips near the Display Circuit Board opening at the front that snap into the bottom section of the
assembly. Pull the top section up and away from the water heater once the retaining screws have been
removed. Replace the top section in the reverse order when connections are complete.
CONNECTING GAS FIRED WATER HEATERS (CONT)
13
CONNECTING TANK TYPE WATER HEATERS
Commercial Electric CCB (central control board)
Figure 8
J9 Socket
CONNECTING ELECTRIC WATER HEATERS
1 Turn off power to the water heater at the main disconnect switch or breaker.
2 There will always be hot surfaces on operating water heating appliances. Be careful to avoid
contact with hot pipes and other surfaces when working on or near water heating appliances.
3 Open the control cabinet and locate the CCB (central control board). On DSE models the CCB is
mounted on the hinged cabinet door. On DVE models the CCB is mounted on the upper left
portion of the control panel - see Figure 9 on page 15.
4 On DSE models remove one of the 1/2” knockout plugs on the left side of the control cabinet that
is at the same height as the CCB. Install a Knockout Bushing (Table 1 on page 7) in the knockout
hole - see Figure 9 on page 15
5 On DVE models that have a factory provided 1/2” knockout (left side of the top plate of the control
cabinet) remove the knockout plug. Install a Knockout Bushing (Table 1 on page 7) in the
knockout hole - see Figure 9 on page 15.
6 On DVE models that do not have a factory provided 1/2” knockout use a portable drill and a 1/2”
electrical knockout punch/die (see Tool Requirements on page 4) to add a knockout hole on the
top plate of the control cabinet. Locate the knockout hole as shown in Figure 9 on page 15. Take
steps to ensure metal shavings do not fall into any electrical components such as the CCB,
contactors or fuse blocks when cutting the knockout hole. After the knockout hole has been
added to the top plate of the control cabinet install a Knockout Bushing (Table 1 on page 7) in the
knockout hole.
7 On Single Appliance Networks:
knockout bushing and plug the cable into the J9 socket on the CCB - see Figure 8 and Figure 9
on page 15. Proceed to the Start Up section on page 29 when these connections are complete.
8 On Multiple Appliance Networks:
(multiple device adapter) - proceed to page 16.
If any gas fired tank type water heaters are to be added to the network see page 12.
If any boilers are to be added to the network see page 21.
route the network cable from the CM (see page 11) through the
all tank type water heaters on the network require a MDA
14
CONNECTING TANK TYPE WATER HEATERS
CCB (central control board) Location
DSE Model (door open) DVE Model (door removed)
CCB
CCB
Knockouts
Knockout
DVE Model (top view)
DVE Model Control Cabinet Top Plate
DVE Model 1/2” Knockout Location
Approximately 1” to edge of hole
from front and left edge of top plate
Figure 9
both sides
of control
cabinet.
CONNECTING ELECTRIC WATER HEATERS (CONT)
15
CONNECTING TANK TYPE WATER HEATERS
MDA (multiple device adapter)
End View
Figure 10
RJ45 male plug
Two RJ45
female sockets
Small green LED
light on top verifies
power from the CM
is present.
MULTIPLE APPLIANCE NETWORKS
Multiple Appliance Networks are formed by connecting network cables between multiple
tank type water heaters (or a combination of tank type water heaters and boilers) and the
iCOMM™ system’s CM (communication module) in a “daisy chain” configuration - see
Figure 15 on page 20 and Figure 16 on page 23.
Multiple Device Adapters - MDAs
“Tank type” water heaters in a Multiple Appliance Network require MDAs (multiple device
adapters) to be installed on each water heater in the network - see pages 19 and 20. MDAs
have two female RJ45 sockets and a short length of network cable with a male RJ45 plug.
There is a small green LED light on the top that verifies power from the CM is present at the
MDA - see Figure 10.
MDAs are sold separately as a kit. One MDA kit must be ordered for each tank type water
heater connected to a Multiple Device Network. Boilers do not require MDAs. Each MDA kit
comes with the items listed in Table 3. Ensure all these parts are present before you begin
the installation.
TABLE 3
Item Quantity Description
11MDA assembly
2 1 Splitter – T Adaptor (Category 5 cable splitter)
31
4 2 Adhesive Velcro strips
5 5 Wire tie mounts 3/4” (adhesive/screw mount)
6 5 Wire tie wraps
7 1 Universal Knockout Bushing (for commercial electric tank type water heaters only)
†. Cat 5 cable included for connecting one tank type water heater to the iCOMM™ network. Longer
cables can be obtained from local computer stores/home centers or fabricated in the field.
†
Category 5 network cable (25 feet)
16
CONNECTING TANK TYPE WATER HEATERS
Figure 11
Single
Port
Multi
Port
Front Edge
CM (communication module)
LAN
Port
(Internet)
Multiple Appliance Network Guidelines
1 If more than one water heating appliance will be connected to the network and any time there is
a boiler connected to the network the “MULTI PORT” socket on the CM (communication module)
must be used to connect the first appliance. See Figure 11 and Figure 15 on page 20 and Figure
16 on page 23.
2 The “SINGLE PORT” is only used when one “tank type” water heater is connected to the CM.
3 The “LAN PORT” is used to connect the CM to the local Internet service - see Figure 11.
4 Each tank type water heater on a Multiple Appliance Network must have a MDA (multiple device
adapter) installed. See Figure 10 on page 16, Figure 13 and Figure 14 on page 19. MDAs are
ordered separately. One MDA kit should be ordered for every tank type water heater being
connected to a Multiple Appliance Network.
5 Multiple Appliance Networks can have a maximum of 7 tank type water heaters connected to a
single CM - see Figure 15 on page 20. If more than 7 tank type water heaters are present
additional CMs must be installed.
CM Communication Ports
17
Loading...