Lochinvar Armor 151, Outdoor Knight 286, Armor 801, Outdoor Knight 151, Outdoor Knight XL 400 Instructions Manual

MODB-I-O_100161545_2000014822_Rev M

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

 WARNING

 is manual must only be used by a quali 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.

Save this manual for future reference.

Contents

1. INTRODUCTION

Deﬁ nitions .................................................................... 2

Minimum System Requirements .................................. 2

2. INSTALLATION Wall Mount, Armor, Knight and Knight XL, Outdoor

Armor, Outdoor Knight, and Outdoor Knight XL........ 3-4

FTXL ............................................................................ 5

Wall Hung .................................................................... 6

3. MODBUS CONFIGURATION

Addressing ................................................................... 7

Timing Speciﬁ cations ................................................... 8

Parity ............................................................................ 8

Data Transmission Mode ............................................. 8

ModBus Board Diagnostics ......................................... 8

Internal Faults ......................................................... 8

ModBus Function Set .................................................. 9

ModBus Exception Codes ........................................... 10

4. MODBUS MEMORY MAP

Primary Data Tables .................................................... 11

Memory Map............................................................11-12

Input Registers .......................................................12

Holding Registers ................................................... 12

Conﬁ guration Bits......................................................... 12

5. BACNET CONFIGURATION ....................................... 13

Addressing ................................................................... 13

Timing Speciﬁ cations ...................................................14

Communication Board Diagnostics ............................. 14

Internal Faults ......................................................... 14

6. BACNET MEMORY MAP

Primary Data Tables .................................................... 15

Crest Boiler Memory Map........................................15-16

Input Registers ............................................................15

Holding Registers ................................................... 16

7. WIRING REQUIREMENTS

Physical Wiring ............................................................ 17

Control Inputs/Outputs............................................ 18-19

Control Location.......................................................20-21

Typical Boiler/Water Heater System Wiring................ 22

8. UNIT OPERATION

Unit Operation with ModBus

Communications ..................................................... 23-27

9. TROUBLESHOOTING ........................................... 28-29

10. DIAGRAMS

Ladder & Wiring Diagrams ..................................... 30-39

Revision Notes ................................................... Back Cover

1 Introduction

 e information contained in this manual provides general guidelines for the implementation of ModBus and BACnet communication with the Lochinvar Armor water heaters (151 - 801), Wall Mount Armor (125-200), Knight (81-286), Knight XL (400 - 801), Outdoor Knight (151-286), Outdoor KnightXL (400-801), Outdoor Armor (151-801), Wall Mount (51 - 211), and Wall Hung (55 - 399) boilers.

All ModBus networks are implemented utilizing a master-slave arrangement where all boilers/water heaters are slaves and the master is a building automation system capable of communicating over a RS-485 half duplex serial connection. BACnet networks are implemented using a token passing process where multiple masters and slaves share a common RS-485 bus.  e Lochinvar BACnet interface is a master only.

Deﬁ nitions

Abbreviation or Acronym Meaning

ASCII American Standard Code for Information Interchange

BACnet A data communication protocol for Building Automation and Control Networks

BAS Building Automation System

Baud (Baud Rate) Number of 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 Signiﬁ cant Byte

ModBus A serial, half-duplex data transmission protocol developed by AEG Modicon

MSB Most Signiﬁ cant Byte

RS232

RS485 A standard for serial transmission of data based on the RS-485 Standard

RTU Remote Terminal Unit

A standard for serial, full-duplex (FDX) transmission of data based on the RS232 Standard

Minimum System Requirements

• BAS system or computer with a serial or USB port with a converter to RS-485 half duplex.

• Unit equipped with communication board.

• Shielded twisted pair communication cable.

2 Installation

ModBus and BACnet Communication Instructions

Installation procedure - for Models WB, WA, AW, KB, OA, OK and KBX

1. Turn OFF the main electrical power to the appliance.

2. Turn OFF the main manual gas shuto to the appliance.

3. Assemble the communication control board to the sheet metal base as shown in FIG. 2-1a and 2-1b, depending on model.

4. Connect the power harness from the appliance to the communication board through the sheet metal cover hole (see FIG. 2-2a and 2-2b, depending on model).

5. Using the two (2) sheet metal screws provided in the kit, attach the pre-painted sheet metal cover over the Communication board for protection from line voltage (FIG. 2-2a and 2-2b, depending on model).

6. Locate the pilot holes on the side of the jacket (le side if AW/KB/KXL or right side if WB/WA), using the sheet metal screws provided in the kit, mount the communication board assembly to the appliance (FIG. 2-3a and 2-3b, depending on model).

Wiring

7. Disconnect power to the transformer by removing connection “B”, see FIG. 2-4, page 4.

8. Connect A, C, D, and B (FIG. 2-4).

9. Connect the communication board to the control board of the appliance (see FIG. 2-5 on page 4).

10. Turn on the main electrical power and the main manual gas shuto to the appliance.

11. Con gure the control board and unit controls per this manual and resume operation.

Figure 2-2a_Attach Cover to Communication Board for Models WB, WA, AW, KB and KBX

MODBUS

ASSEMBLY

MOUNT PRE-PAINTED SHEET METAL COVER OVER THE MODBUS ASSEMBLY FOR PROTECTION FROM LINE VOLTAGE

ATTACH POWER HARNESS

TO MODBUS THROUGH

SHEET METAL COVER HOLE

Figure 2-2b_Attach Cover to Communication Board for Models OA and OK

MOUNT PRE-PAINTED

SHEET METAL COVER OVER

THE MODBUS ASSEMBLY FOR

PROTECTION FROM LINE VOLTAGE

ATTACH POW ER HARNESS

TO MODBUS THROUGH

SHEET METAL COVER HOLE

MODBUS ASSEMBLY

IMG00566

BLT7404 [X4]

Figure 2-3a_Mount Communication board to Unit for Models WB, WA, AW, KB and KBX

- LOCATE THE PILOT HOLES

- USING THE 4 SHEET METAL SCREWS PROVIDED IN THE KIT MOUNT THE MODBUS ASSEMBLY TO THE UNIT (SIDE DEPENDENT ON MODEL)

Figure 2-1a_Assemble Communication Board for Models WB, WA, AW, KB and KBX

SHEET METAL BASE

JKB40095

BLT2007 [X4]

BLT7068 [X4]

Figure 2-1b_Assemble Communication Board for Models OA and OK

BLT2007

[X4]

SHEET METAL BASE (JKB40265)

IMG00565

BLT7068 [X4]

NOTE: KB/KXL/AW - MOUNT MODBUS ASSEMBLY TO THE LEFT SIDE OFTHE JACKET. WB/WA - MOUNT MODBUS ASSEMBLY TO THE RIGHT SIDE OF THE JACKET.

Figure 2-3b_Mount Communication board to Unit for Models OA and OK

- LOCATE THE PILOT HOLES

- USING THE (2) SHEET METAL SCREWS PROVIDED IN THE KIT MOUNT THE MODBUS ASSEMBLY TO THE UNIT (SIDE AND ORIENTATION DEPENDENT ON MODEL / VERTICAL ORIENTATION SHOWN)

NOTE: OA/OK151 MOUNT MODBUS ASSEMBLY TO THE RIGHT SIDE JACKET FLANGE OA/OK400-501 MOUNT MODBUS ASSEMBLY IN HORIZONTAL ORIENTATION

IMG00567

3

ModBus and BACnet Communication Instructions

2 Installation

Figure 2-4_Harness Connections_WB, WA, AW, KB, KBX, OA, and OK models

FROM POWER HARNESS

A

B G W

ROUTE THROUGH JACKET HARNESS CLIPS

USE SUPPLIED CABLE TIE TO CONNECT MODBUS POWER HARNESS TO BLOWER POWER

WIRES (RED, WHITE, GREEN)

TO TRANSFORMER

D

C

B

W

WGB

B

W

GY

G

R

BL

G

Figure 2-5_Connect Communication Board to Control Board

CONNECT TO CONTROL BOARD FROM COMMUNICATION BOARD*

4

*HARNESSES CAN ONLY BE CONNECTED ONE WAY.

LOW VOLTAGE CONNECTION BOARD

CONNECT TO CONNECTION BOARD FROM COMMUNICATION BOARD*

2 Installation (continued)

ModBus installation procedure - for FTXL Models

ModBus and BACnet Communication Instructions

Figure 2-6a_Assemble ModBus Control Board for FTXL

2X RIVET

4X LOCKNUT

2X CLIP

4X ALUMINUM SPACER

IMG01107

1. Turn OFF the main electrical power to the appliance.

2. Turn OFF the main manual gas shuto to the appliance.

3. Assemble the ModBus control board and provided cable clamps to the control panel as shown in FIG. 2-6a.

4. Connect the ModBus power, control board and connection board wiring harnesses. Secure the wiring with the provided cable clips and route it through the bottom of the control panel. Perform the wiring connections referencing FIG.’s 2-6b and 2-6c.

5. Turn ON the main electrical power to the appliance.

6. Con gure the control board and unit controls per this manual and resume operation.

Figure 2-6b_Secure Control Board to FTXL Unit

SECURE CONNECTION BOARD W/ 5X CLIPS

MODBUS POWER HARNESS

UNIT POWER HARNESS

TRANSFORMER PRIMARY 120V

IMG01106

Figure 2-6c_Perform Wiring Connections for FTXL

LOW VOLTAGE CONNECTION BOARD

SECURE HARNESS W/ 3X CLIPS

CONNECTION BOARD /

MODBUS HARNESS

MAIN CONTROL BOARD

UNIT POWER HARNESS

MODBUS

MODBUS POWER HARNESS

PRIMARY

120V

SECURE HARNESS W/ 2X CLIPS

IMG01105

5

2 Installation

ModBus and BACnet Communication Instructions

Installation Procedure - for WH Models

1. Turn OFF the main electrical power to the appliance.

2. Turn OFF the main manual gas shuto to the appliance.

3. To assemble the communication board to the sheet metal, insert four (4) stando s into the front access panel (FIG. 2-6).

4. Place the communication board onto the stando s installed in 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 shuto to the appliance.

7. Con gure the communication board and unit controls per this manual and resume operation.

Figure 2-7_Harness Connections_WH

Figure 2-6_Assemble Communication Board_WH

INSERT

STANDOFFS

USE SCREW TO SECURE COVER

TO FRONT PANEL

(WRE20075)

(WRE20073)

G

R

B

L

(WRE20077)

G

Y

G

W

B

W W

G

B B

6

ModBus and BACnet Communication Instructions

3 ModBus Conﬁ guration

 e ModBus communication board is equipped with a set of ten dip switches that are used to set the board con guration (address, baud rate, and parity settings).  e  rst eight are used to set the address of each board.  e ninth is baud rate.  e tenth is parity.

Figure 3-1_ModBus Communication Board

DIP SWITCHES

LED’S

Addressing

 e ModBus addressing space is comprised of 256 di erent addresses.

• 0 is reserved for broadcast messages from the master device

• 1 - 247 are free to use for each unique device

• 248 - 255 are reserved

To set the ModBus address the dip switches can be set in either the 0 position or the 1 position. For switches set to the 1 position their value will be added together to determine the address.

Each switch set to the 1 position has the following value:

Dip switch 1 = 1 Dip switch 2 = 2 Dip switch 3 = 4 Dip switch 4 = 8 Dip switch 5 = 16 Dip switch 6 = 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.  e 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 switch 8

In this example:

Address = 0 + 2 + 0 + 0 + 16 + 32 + 0 + 0 = 50

7

3 ModBus Conﬁ guration

ModBus and BACnet Communication Instructions

Timing Speciﬁ cations

 e baud rate for the ModBus board is selectable with Dip switch #9.

1 = 19200 bps 0 = 9600 bps

Each message is started by at least 3.5 character times of silence.  e maximum delay between frames is 1.5 character times.

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).  e timeout is programmable as follows:

NOTICE

1. Press and hold the LEFT SELECT [MENU] key for 5 seconds.

2. Enter installer code - 5309.

3. Scroll down and select [CONTROL MODES].

4. Scroll down and select [MODBUS T/O].

5. Scroll to desired time. Press the RIGHT SELECT [SAVE] key.

Please note that the brackets ([]) denote screen status.

Data Transmission Mode

Many ModBus bus master devices can be con gured 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 e cient, RTU has been chosen to be used with all Lochinvar ModBus communication. Please ensure that the master device is transmitting ModBus RTU.

ModBus Board Diagnostics

 e ModBus board is equipped with three LED’s for visual diagnostics: Two yellow LED’s and one green. One yellow LED (D5) is used to indicate transmission of data.  e other yellow LED (D6) is used to indicate reception of data.  e green LED (D7) is used to show internal faults.

Internal Faults: Normal Operation = 1 second bright, 1 second dim Controller Fault = Continuously on No Burner Control Communication = 0.5 seconds on, 1.5 seconds o No ModBus Communication = 1.5 seconds on, 0.5 seconds o

ModBus Communication

 e ModBus communication commands and exception codes that are supported by the ModBus communication board can be found on pages 8 and 9 of this manual.

 e timeout is adjustable between 5 and 120 seconds.  e default timeout is 10 seconds.

When the BAS is not providing any of these values, but is still controlling the boiler (such as providing an enable command), the BAS must refresh these commands at least every 4 minutes. 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.

8

3 ModBus Conﬁ guration (continued)

ModBus Function Set

ModBus and BACnet Communication Instructions

Function Sub Function

HEX Description

Dec HEX Dec

1 01 Read Coil Status

2 02 Read Input Status

3 03 Read Holding Registers

4 04 Read Input Registers

5 05 Force Single Coil

6 06 Preset Single Register

7 07 Read Exception Status

8 08 0 00 Diagnostic - Return Query Data

1 01 Diagnostic - Restart Communication

2 02 Diagnostic - Return Diagnostic Register

4 04 Diagnostic - Force Listen Mode

10 0A

11 0B Diagnostic - Return Bus Message Count

Diagnostic - Clear Counters and Diagnostic Registers

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 Overrun Counter and Flag

11 0B Get Communication Event Counter

12 0C Get Communication Event Log

15 0F Write Multiple Coils

16 10 Write Multiple Registers

17 11 Report Slave ID

23 17 Read / Write Multiple Registers

9

ModBus and BACnet Communication Instructions

3 ModBus Conﬁ guration

ModBus Exception Codes

MODBUS Exception Codes

Code Name Meaning

The function code received in the query is not an allowable action for the server (or slave). This may be because the function code is only applicable to newer

01 ILLEGAL FUNCTION

02 ILLEGAL DATA ADDRESS

devices, and was not implemented in the unit selected. It could also indicate that the server (or slave) is in the wrong state to process a request of this type, for example because it is unconﬁ gured and is being asked to return register values.

The data address received in the query is not an allowable address for the server (or slave). More speciﬁ cally, the combination of reference number and transfer length is invalid. For a controller with 100 registers, the PDU addresses the ﬁ rst register as 0, and the last one as 99. If a request is submitted with a starting register address of 96 and a quantity of registers of 4, then this request will successfully operate (address-wise at least) on registers 96, 97, 98, 99. If a request is submitted with a starting register address of 96 and a quantity of registers of 5, then this request will fail with Exception Code 0x02 “Illegal Data Address” since it attempts to operate on registers 96, 97, 98, 99 and 100, and there is no register with address 100.

03 ILLEGAL DATA VALUE

04 SLAVE DEVICE FAILURE

05 ACKNOWLEDGE

06 SLAVE DEVICE BUSY

08 MEMORY PARITY ERROR

A value contained in the query data ﬁ eld is not an allowable value for server (or slave). This indicates a fault in the structure of the remainder of a complex request, such as that the implied length is incorrect. It speciﬁ cally does NOT mean that a data item submitted for storage in a register has a value outside the expectation of the application program, since the MODBUS protocol is unaware of the signiﬁ cance of any particular value of any particular register.

An unrecoverable error occurred while the server (or slave) was attempting to perform the requested action.

Specialized use in conjunction with programming commands. The server (or slave) has accepted the request and is processing it, but a long duration of time will be required to do so. This response is returned to prevent a timeout error from occurring in the client (or master). The client (or master) can next issue a Poll Program Complete message to determine if processing is completed.

Specialized use in conjunction with programming commands. The server (or slave) is engaged in processing a long -- duration program command. The client (or master) should re-transmit the message later when the server (or slave) is free.

Specialized use in conjunction with function codes 20 and 21 and reference type 6, to indicate that the extended ﬁ le area failed to pass a consistency check. The server (or slave) attempted to read record ﬁ le, but detected a parity error in the memory. The client (or master) can retry the request, but service may be required on the server (or slave) device.

0A GATEWAY PATH UNAVAILABLE

0B

GATEWAY TARGET DEVICE

FAILED TO RESPOND

10

Specialized use in conjunction with gateways, indicates that the gateway was unable to allocate an internal communication path from the input port to the output port for processing as the request. Usually means that the gateway is misconﬁ gured or overloaded.

Specialized use in conjunction with gateways, indicates that no response was obtained from the target device. Usually means that the device is not present on the network.

ModBus and BACnet Communication Instructions

4 ModBus Memory Map

Primary Data Tables

Table Data Type Read / Write

Discrete Inputs Single Bit Read Only

Coils Single Bit Read / Write

Input Registers 16-Bit Word Read Only

Holding Registers 16 Bit Word Read / Write

Memory Map

Coils

Address Description Default Unit Min. Max. Resolution

00001 Room Thermostat 1 0 1=ON / 0=OFF 0 1 1

00002 Room Thermostat 2 0 1=ON / 0=OFF 0 1 1

00003 Room Thermostat 3 0 1=ON / 0=OFF 0 1 1

00005 Tank Thermostat 0 1=ON / 0=OFF 0 1 1

Discrete Inputs

10002 Flow 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 1=ON / 0=OFF 0 1 1

10033 Run-time Contacts 0 1=ON / 0=OFF 0 1 1

10034 Alarm Contacts 0 1=ON / 0=OFF 0 1 1

10035 CH Pump 0 1=ON / 0=OFF 0 1 1

10036 DHW Pump 0 1=ON / 0=OFF 0 1 1

10037 Louver Relay 0 1=ON / 0=OFF 0 1 1

10038 Gas Valve 0 1=ON / 0=OFF 0 1 1

10039 System Pump 0 1=ON / 0=OFF 0 1 1

10044 DHW Recirculation Pump 0 1=ON / 0=OFF 0 1 1

11

ModBus and BACnet Communication Instructions

4 ModBus Memory Map

Memory Map

Input Registers

Address Description Default Unit Min. Max. Resolution

30001 Discrete Inputs 1 - 16 0 HEX 0 65535 1 30002 Discrete Inputs 17 - 32 0 HEX 0 65535 1 30003 Discrete Inputs 33 - 48 0 HEX 0 65535 1 30004 System / Cascade Setpoint 0 Degrees Celsius 0 130 0,5 30005 System Pump Speed 0 % 0 100 1 30006 Cascade Total Power 0 % 100 800 1 30007 Cascade Current Power 0 % 0 800 1 30008 Outlet Setpoint 0 Degrees Celsius 0 130 0,5 30009 Outlet Temperature 0 Degrees Celsius 0 130 0,1 30010 Inlet Temperature 0 Degrees Celsius -20 130 0,1 30011 Flue Temperature 0 Degrees Celsius -20 130 0,1 30012 Firing Rate 0 % 0 100 1 30013 Boiler Pump Speed 0 % 0 100 1 30014 Boiler Status Code 0 HEX 0 65535 1 30015 Boiler Blocking Code 0 HEX 0 65535 1 30016 Boiler Lockout Code 0 HEX 0 65535 1

Holding Registers

40001 Conﬁ guration 0 NA 0 65535 1

40002 Coils 0 NA 0 65535 1

40003

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

0-10 Volt Input / Rate Command / Setpoint Command

0 % 0 100 1

Conﬁ guration Bits

Address 40001 contains con guration bits sent from the BAS to the appliance.  ese bits tell the boiler/water heater to use its own internal inputs, or inputs from the BAS. When a bit is set to 1, the boiler/water heater will ignore the corresponding value contained internally, and expect the BAS to write that value into the Holding Registers.  e con guration bits are as follows:

Bit 0 (LSB): Boiler Enable Bit 1: Tank  ermostat Bit 2: Rate Command / 10 - 10V Input / Setpoint Command Bit 3: Tank Setpoint

Bit 4: System Supply Temperature Bit 5: Outdoor Temperature Bit 6: Tank Temperature Bit 7: System Return Temperature Bit 8 - 15: Not Used (Default = 0)

12

ModBus and BACnet Communication Instructions

Modbus Instructions

5 BACNET Conﬁ guration

 e BACnet communication board is equipped with a set of ten dip switches that are used to set the board con guration (address and baud rate).  e  rst eight are used to set the address of each board.  e ninth and tenth are baud rate.

Figure 5-1_Communication Board

DIP SWITCHES

LED’S

Addressing

 e BACnet local addressing space is comprised of 256 di erent addresses.

• 255 is reserved for broadcast messages from a master device.

• 128 - 254 are free to use for slave devices only.

• 0 - 127 are free to use for master or slave devices.

Since the BACnet communication board is a BACnet master, address 127 is the highest address that can be used.

To set the BACnet local address, the dip switches can be set in either the 0 position or the 1 position. For switches set to the 1 position their value will be added together to determine the address.

Each switch set to the 1 position has the following value:

Dip switch 1 = 1 Dip switch 2 = 2 Dip switch 3 = 4 Dip switch 4 = 8 Dip switch 5 = 16 Dip switch 6 = 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 BACnet board to 50, dip switches 2, 5, and 6 have to be set to the 1 position.  e 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 switch 8

In this example:

Address = 0 + 2 + 0 + 0 + 16 + 32 + 0 + 0 = 50

 e 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

 e base address (600000 in this example) is model dependant and can be changed by the integrator. It can be set to any value between 0 and 4194048.  e resulting device instance will be this value + the local address, as before. Once the base address is changed, it can be reset back to the default base address (600000 in this example) using the following procedure:

1. Turn OFF power to the interface board.

2. Set Dip switches 1 - 8 to the 1 position.

3. Turn ON power to the interface board.

4. A er a few seconds, turn OFF power to the interface board.

5. Set Dip switches 1 - 7 to the desired local address. Set Dip switch 8 to the 0 position.

6. Turn ON power to the interface board.

Device Name

 e default device name is “MTR-01 BACnet.”  is can be changed by the integrator as desired.

13

5 BACnet Conﬁ guration

Modbus Instructions

ModBus and BACnet Communication Instructions

Timing Speciﬁ cations

 e baud rate for the BACnet board is selectable with Dip switches #9 and #10.

Switch #9 Switch#10 Baud Rate

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).  e timeout is programmable as follows:

NOTICE

1. Press and hold the LEFT SELECT [MENU] key for 5 seconds.

2. Enter installer code - 5309.

3. Scroll down and select [CONTROL MODES].

4. Scroll down and select [MODBUS T/O].

5. Scroll to desired time. Press the RIGHT SELECT [SAVE] key.

Please note that the brackets ([]) denote screen status.

Communication Board Diagnostics

 e Communication board is equipped with three LED’s for visual diagnostics: Two yellow LED’s and one green. One yellow LED (D5) is used to indicate transmission of data.  e other yellow LED (D6) is used to indicate reception of data.  e green LED (D7) is used to show internal faults.

Internal Faults: Normal Operation = 1 second bright, 1 second dim Controller Fault = Continuously on No Burner Control Communication = 0.5 seconds on, 1.5 seconds o No BACnet Communication = 1.5 seconds on, 0.5 seconds o .

 e timeout is adjustable between 5 and 120 seconds.  e default timeout is 10 seconds.

When the BAS is not providing any of these values, but is still controlling the boiler (such as providing an enable command), the BAS must refresh these commands at least every 4 minutes. If the commands are not refreshed, the boiler will revert to operating based on its own inputs.

14

6 BACnet Memory Map

Primary Data Tables

Object Type Data Type Read / Write

Binary Input (BI) Single Bit Read Only

Binary Value (BV) Single Bit Read / Write

Analog Input (AI) 16-Bit Word Read Only

Analog Value (AV) 16 Bit Word Read / Write

Memory Map

ModBus and BACnet Communication Instructions

Object Name

Boiler Enable / Room Th. 1 BV 0 none 0 1 1

Room Th.2 BV 1 none 0 1 1

Room Th.3 BV 2 none 0 1 1

Tank Thermostat BV 4 none 0 1 1

Flow Switch BI 1 none 0 1 1

Gas Pressure Switch BI 2 none 0 1 1

Louver Proving Switch BI 3 none 0 1 1

Air Pressure 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 0 1 1

System Pump BI 38 none 0 1 1

BI Inputs 0 - 15 AI

BI Inputs 16 - 31 AI 1 none 0 1 1

BI Inputs 32 - 47 AI 2 none 0 1 1

System / Cascade Setpoint AI 3 Deg C 0 1 0.5

System Pump Speed AI 4 Percent 0 1 1

Cascade Total Power AI 5 Percent 0 1 1

Cascade Current Power AI 6 Percent 0 1 1

Outlet Setpoint AI 7 Deg C 0 1 0.5

Outlet Temperature AI 8 Deg C 0 1 0.1

Inlet Temperature AI 9 Deg C 0 1 0.1

Object

Type

Binary Values

Binary Inputs

Inputs

Object

Instance

0

Units Min Max Resolution

none 0 1 1

15

4 Wiring Requirements (continued)

6 BACnet Memory Map

Memory Map (continued)

ModBus and BACnet Communication Instructions

Modbus Instructions

Object Name

Flue Temperature AI 10 Deg C -20 130 0.1

Firing Rate AI 11 Percent 0 100 1

Boiler 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

Conﬁ guration 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 Supply Temperature AV 6 Deg C -20 130 0.1

Object

Type

Analog Values

Object

Instance

Units Min Max Resolution

16

ModBus and BACnet Communication Instructions

Modbus Instructions

7 Wiring Requirements

Note that when the System Supply Temperature and/or the Tank Temperature are provided by the BAS, they need to be refreshed every few seconds.  is is required in order to prevent unwanted  uctuations in these temperatures. If these values are not provided every few 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

RS-485 Communication Bus

• Maximum Length = 4000 feet

• Cable Speci cation = 24 AWG / A,B (twisted pair) and GND Shielded, with characteristic Impedance = 120 ohm

• Maximum Load = 32 units (32 nodes)

NOTE: Cable must be terminated with 120 ohm impedance matching resistor on each end. A + (positive) B - (negative)

Figure 7-1_Terminal Strip Connections

LOUVER RELAY

PROVING SWITCH

FLOW SWITCH

TANK THERMOSTAT

ROOM THERMOSTAT 3

ROOM THERMOSTAT 2

ROOM THERMOSTAT 1

LOUVER

COM

NO

LOW WATER

CUTOFF

FROM

A B

SHIELD SHIELD

SYSTEM PUMP

SPEED

CONTROL

BOILER

PUMP

WIRE AS

NEEDED

TO

A

BOILER

TANK SE NS OR

OUTDOOR SENSOR

SYSTEM SUPPLY SENSOR

B

A

NOTE: CONNECTION BOARD SPLIT FOR ILLUSTRATION PURPOSES

BUILDING

MANAGEMENT

SYSTEM

17

7 Wiring Requirements

Figure 7-2_Control Inputs

SYSTEM PUMP SPEED CONTROL

GAS PRESSURE SWITCH

DHW THERMOSTAT

ROOM THERMOSTAT /

ZONE CONTROL

FLOW SWITCH

SYSTEM SENSOR

OUTDOOR SENSOR

ModBus and BACnet Communication Instructions

LOW VOLTAGE

CONNECTION

BOARD

SEQUENCER / BUILDING

MANAGMENT SYSTEM

LOW WATER CUTOFF

MODBUS/BACNET

COMMUNICATION

BOARD

INLET TEMPERATURE

SENSOR

OUTLET TEMPERATURE /

HI-LIMIT SENSOR

FLUE GAS SENSOR

AIR PRESSURE SWITCH

LOUVER PROVING SWITCH

FLAME SENSOR

BLOCKED DRAIN SWITCH

(NO DRAIN SWITCH ON

MODELS WH 55 - 399)

SMART CONTROL

MODULE

18

DISPLAY PANEL

PC INTERFACE

7 Wiring Requirements (continued)

Figure 7-3_Control Outputs

ModBus and BACnet Communication Instructions

ALARM BELL

LOW VOLTAGE

CONNECTION

BOARD

LOUVER RELAY

RUN TIME CONTACTS

BUILDING MANAGEMENT

SYSTEM

BOILER PUMP

SYSTEM PUMP

DHW PUMP

SMART CONTROL

MODULE

IGNITOR

BLOWER

GAS VALVE

DISPLAY PANEL

PC INTERFACE

19

7 Wiring Requirements

ModBus and BACnet Communication Instructions

Figure 7-4_Control Location_Knight , Knight XL and Armor

CONTROL, INTEGRATED

MODBUS / BACNET

COMMUNICATION

BOARD

HEAT

EXCHANGER

Figure 7-5_Control Location_Outdoor Knight, Outdoor Knight XL, Outdoor Armor

MODBUS / BACNET COMMUNICATION BOARD

HEAT

EXCHANGER

CONTROL, INTEGRATED

Figure 7-6_Control Location_Knight/Armor Wall Mount

HEAT EXCHANGER

CONTROL, INTEGRATED

MODBUS / BACNET COMMUNICATION BOARD

IMG00568

Figure 7-7_Control Location_Knight Wall Hung

HEAT EXCHANGER

MODBUS / BACNET COMMUNICATION

CONTROL,

INTEGRATED

BOARD

20

7 Wiring Requirements (continued)

Figure 7-8_Control Location_FTXL

ModBus and BACnet Communication Instructions

MODBUS COMMUNICATION BOARD

INTEGRATED CONTROL BOARD

HEAT EXCHANGER

IMG01112

21

7 Wiring Requirements

Modbus / BACnet RS485 Communication Bus

Modbus / BACnet RS485 Port on Gateway or Building System

Modbus / BACnet RS485 Communication Bus

Typical Boiler/Water Heater System Wiring

Physical Configuration: Cascade without Individual Monitoring

Modbus / BACnet RS485 Port on Gateway or Building System

ModBus and BACnet Communication Instructions

NOTICE

LEADER

MEMBER 1

Cascade Daisy Chain Connection

MEMBER 2

You will need a Modbus or BACnet board only for the Leader.

Physical Configuration: Cascade with individual Monitoring

Cascade Daisy Chain Connection

You will need a Modbus or BACnet board for all appliances.

Physical Configuration: Direct Control

MEMBER 3

Modbus / BACnet RS485 Port on Gateway or Building System

Modbus / BACnet RS485 Communication Bus

NOTICE

You will need a Modbus or BACnet board for all appliances.

22

ModBus and BACnet Communication Instructions

8 Unit Operation

Unit Operation with ModBus or BACnet Communications

To control a boiler/water heater through a Building Management System communicating through ModBus or BACnet, the boiler/water heater control mode must be properly con gured.  ese con gurations allow di erent control points for a variety of applications.  ere are  ve (5) con guration parameters that need to be set.

General Set-up

NOTICE

1. Press and hold LEFT SELECT [MENU] key. 5. Scroll to ACTIVE.

2. Enter installer code - 5309. 6. Press the RIGHT SELECT [SAVE] key.

3. Scroll down and select [CONTROL MODES]. 7. Exit one level.

4. Select ModBus or BACnet by pressing the NAVIGATION dial. 8. Choose the appropriate Control Mode and continue set-up to complete.

Please note that the brackets ([]) denote screen status.

Figure 8-1_Control Modes (Default)

 e boiler/water heater is equipped with a ModBus communication timer.  is timer is programmable from 0 - 120 seconds.  e timer can be programmed in the ModBus T/O Menu, reference Section 3 - Timing Speci cations on page 7 of this manual.  e purpose of the timer is to ensure proper temperature data is communicated to the boiler/water heater in a timely manner. Additionally, it will provide for fail safe operation should BMS communication be lost.  is timer will cause the unit to revert back to internal unit controls should the BMS communication be interrupted longer than the ModBus timer.  e 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 value possible.

When operating o the BMS communication bus and with remote sensors connected to the Building Automation System (BAS), it is very important to ensure that the correct con guration bits are sent to holding register 40001 (ModBus) or AVO(BACnet), and that the correct data and enable signals are sent to holding registers 40002 - 40008 (ModBus) or AVO(BACnet), per the control mode.

Figure 8-2_Control Modes - ModBus Active

Control Mode 1

In this con guration the unit is controlled by setting the set points locally on the boiler/water heater and providing an enable signal through BMS communications.

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.  ese signals will be sent to the unit via ModBus or BACnet.

23

ModBus and BACnet Communication Instructions

8 Unit Operation

Control Mode 1 - Set-up (Conﬁ guration Parameters)

BMS Type default (FIG. 6-3) remains.

Object Holding Registers Deﬁ nition Bit Value (HEX) Action

AV0 40001 Con guration 00 01 Set Con guration to read 40002

AV1 40002 Coils / BV 00 01 Enables unit (00 00 disables unit)

NOTE: To ensure proper operation re-send the con guration bits to holding register 40001 or object AV0 prior to issuing a

command.

Control Mode 2

In this con guration the unit is controlled by setting the set points locally on the boiler/water heater and providing an enable signal and a rate command through ModBus or BACnet communications.

 e BMS Type will be 0 - 100% of modulation or a temperature set point.

Control Mode 2 - Set-up (Conﬁ guration Parameters)

To Set BMS Type:

1. While still in Installer Menu Set, scroll down and select [BMS] by pressing the NAVIGATION 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.

Figure 8-3_BMS Type - Set Point (Default) (KB screen shown for illustration purposes only)

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.  ese signals will be sent to the unit via ModBus.

Figure 8-4_BMS Type - Power (KB screen shown for illustration purposes only)

Control Mode 2 - Set-up (Command Parameters)

1. While in the Control’s Installer Main Menu, select [CONTROL MODES].

2. In Control Modes Menu select [BMS] and set to [ACTIVE].

3. Press the RIGHT SELECT [SAVE] key.

Figure 8-5_Control’s Installer Main Menu (KB screen shown for illustration purposes only)

24

ModBus and BACnet Communication Instructions

8 Unit Operation (continued)

Control Mode 2 - Set-up (Command Parameters) (continued)

 e holding registers/objects will need to be set as follows:

Object Holding Registers Deﬁ nition Bit Value (HEX) Action

AV0 40001 Con guration 00 05 Set Con guration to read 40002 & 3

AV1 40002 Coils / BV 00 01 Enables unit (00 00 disables unit)

AV2 40003 Rate Command 00 ## Sets Modulation % or Setpoint

NOTE: To ensure proper operation re-send the con guration bits to holding register 40001 or Object AV0 prior to issuing a

command.

For proper hexadecimal conversion of rate percentage or temperature conversion, please refer to the Rate and Temperature Conversions section on page 21 of this manual.

Control Mode 3

In this con guration the unit is controlled by setting the modulation set point from 0 - 100%.  e modulation set point will provide the enable function as well.

 e BMS Type will be 0 - 100% of modulation.

Control Mode 3 - Set-up (Conﬁ guration Parameters)

Reference FIG.’s 8-3 and 8-4 to set BMS Type to [POWER].

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.  ese 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.

 e holding registers/objects will need to be set as follows:

Object Holding Registers Deﬁ nition Bit Value (HEX) Action

AV0 40001 Con guration 00 04 Set Con guration to read 40003

AV2 40003 Rate Command 00 00 Sets Modulation %

NOTE: To ensure proper operation re-send the con guration bits to holding register 40001 or Object AV0 prior to issuing a

command.

For proper hexadecimal conversion of rate percentage, please refer to the Rate and Temperature Conversions section on page 21 of this manual.

25

ModBus and BACnet Communication Instructions

8 Unit Operation

Control Mode 4 (DHW)

Domestic Hot Water Generation (DHW) can be accomplished with one of two methods when a boiler/water heater is connected to a BAS system, DHW with direct control, and DHW with remote control.

DHW with direct control:

 is is a typical installation with a hot water generator in close proximity to the boiler/water heater with the tank thermostat or the tank temperature sensor wired to the terminal strip of the unit.

DHW with remote control:

 is installation may have the hot water generator in close proximity to the boiler/water heater. Its sensors or thermostat values are only available through the ModBus / BACnet communication bus.

Control Mode 4 - Set-up

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 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.

Figure 8-6_Control Modes Menu - Control Mode 4 - Set-up

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:

Object Holding Registers Deﬁ nition Bit Value (HEX) Action

AV0 40001 Con guration 00 4A Set Con guration to read 40002, 4 & 5

AV1 40002 Coils / BV 00 08 Enables Tank Tstat (00 00 disables unit)

AV3 40004 Tank Set Point 0# ## Sets Set Point

AV4 40005 Tank Temperature 0# ## Passes tank temp from remote sensor

NOTE: To ensure proper operation re-send the con guration bits to holding register 40001 or Object AVØ prior to issuing a

command.

For proper hexadecimal conversion of rate percentage, please refer to the Rate and Temperature Conversions section on page 21 of this manual.

26

8 Unit Operation (continued)

ModBus and BACnet Communication Instructions

Cascade

In order to operate the boiler/water heater in Cascade with ModBus or BACnet communications, con gure the Leader unit per the control modes in this manual. Connect the remaining boilers/water heaters in the Cascade through the normal daisy chain Cascade communications wiring. Cascade control can then be accomplished automatically through the Leader boiler.

Please note that with ModBus or BACnet communication connected to only the Leader unit, only total Cascade information can be seen through the communications 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, the communication board is a ready monitoring device for the read only variables by polling the board.

Rate and Temperature Conversions:

Rate

When issuing a rate command the rate can be communicated as percent modulation or a desired set point, depending on the setting of the BMS Type in the BMS Setup Menu.

 e proper data format for the modulation percentage is the direct conversion to hexadecimal.  is conversion can be accomplished through online number based converters or some scienti c calculators.

For Example:

Rate % HEX

000 20 14 45 2D 60 3C 80 50 95 5F

100 64

DEFAULT

PARAMETER

BMS temperature set point at

low analog input

BMS temperature set point at

high analog input

For Example:

Send a set point of 110°F.

 e formula to use for the interpolation is:

Rate Command =

(Desired Set point – BMS Temp at Low Analog Input) (High

Voltage-Low Voltage) + Low Voltage

(BMS Temp at High Analog Input – BMS Temp at Low

Analog Input)

From the default values:

Desired Setpoint = 110 BMS Temp at Low Analog Input =68 BMS Temp at High Analog=158 High Voltage =10 Low Voltage = 2

[(110-69)(10-2)/(158-68)] + 2 = 5.73 Volts

5.73 Volts = 57.3% Modulation

57% = 39 Hexadecimal

A value of [00][39] in hexadecimal would be written to Holding register 40003 to issue a command for a 110°F setpoint.

Temperature

 e boiler/water heater passes temperature data in degrees Celsius. Also, to accommodate decimal places the decimal value must be divided by 10.

Here are the conversions to and from Celsius:

T

Example:

Outdoor temperature from remote sensor on BAS System = 80°F

80°F = 26.7°C Data that needs to be transmitted is 26.7 * 10 = 267

c

= (5/9) * (Tf-32) Tf = (9/5) * Tc+32

VALUES

Deg C Deg F Voltages

21 70 2

82 180 10

DEFAULT

To send a desired setpoint, the hexadecimal 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

 ese variables set the temperature values corresponding to the minimum and maximum voltage settings of the 0-10 volt signal.  e defaults are as follows:

Decimal Binary HEX

267 100001011 10B

Outlet temperature from unit sensor = 155°F

155°F = 68.3°C Data transmitted from unit in HEX = 2AB = 683 683 ÷ 10 = 68.3 (°C)

Decimal Binary HEX

683 1010101011 2AB

27

9 Troubleshooting

ModBus and BACnet Communication Instructions

Should you encounter problems communicating over ModBus, the following items should be checked in this order:

1. Physical Layer

2. Communications Con guration and Port Settings

3. ModBus Error Codes

4. Unit Status / Blocking / Lockout Codes

Physical Layer

1. Check that all components have power (Boiler, Gateway, BAS Master)

2. Check all wire lengths. Are any drops too long?

3. Check proper shield grounding

4. Check A, B terminal connections

5. Check for Terminating Resistors (120 ohms)

6. Check for broken wires

Communications

1. Check Dip Switch Con guration of Communication Board

2. Check Baud Rate (9600, 19200, etc.)

3. Check Parity (ModBus only)

4. Check Slave ID

5. Check Port Setting on Master, Gateway, and Computers

ModBus Error Codes

1. Check ModBus communication for error codes (see page 9 for ModBus Exception Codes)

2. Check ModBus PDU

3. Check Slave ID

4. Check ModBus Command

5. Check Con guration bits for Holding Register 40001

6. Check Commands and data for Holding Registers 40002 - 40007

Unit Status Codes

See Codes in this section.

Boiler Status

 e boiler/water heater status code indicates what the unit is actually doing.  is status code should be compared to the command issued and what is expected. If the boiler/water heater status code does not agree with the command issued, check communication and con guration.

Status Codes (Input Register 30014 or Analog Input AI13)

2 = Heat Demand blocked due to high absolute outlet temperature 3 = Heat Demand blocked due to high absolute  ue 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  ermostat 22 = SH function Heat demand from Boiler Management System 23 = SH function Heat demand from Cascade 30 = Heat demand activated by Freeze Protection 32 = DHW Pump Delay 33 = SH Pump Delay 34 = No heat function (a er pump delay) 40 = Lockout 32764 = Busy with updating status 32765 = DHW blocked due to no present tank sensor 32766 = Burner control(s) manually shut down 32767 = Code not present

Blocking Codes (Input Register 30015 or AI14)

0 = No blocking _> is divided into sub blockings 1 = SH blocking 2 = Blocking Due to Low 24 VAC Supply 3 = Blocking due to General block 4 = Blocking MRHL is open 5 = Blocking due to Switched OFF boiler (Display ENTER switch) 6 = Blocking due to wrong communication of Cascade 7 = Blocking due to High Delta 8 = Blocking due to High Flue Temperature 9 = Blocking due to High Outlet Temperature 10 = Service blocking 12 = DHW blocking high outlet temperature (DHW con gured as storage tank) 13 = Blocking anti-cycling time 14 = Storage Tank demand Blocked due to Fan problems 15 = No system sensor connected and leader control present 16 = Limit fan speed due to high outlet temperature 17 = Fan min decreased due to low  ame current 18 = Limit max fan speed due to high Delta T 19 = Limit max fan speed due to high  ue temp 32767 = Code not present

28

9 Troubleshooting (continued)

Lockout Codes (Input Register 30016 or AI15)

ModBus and BACnet Communication Instructions

NOTICE

161 = EEPROM code Parameters not Re-Programmed by Lochinvar 164 = EEPROM code No Reset Allowed (> 15 minutes) 166 = EEPROM code Auto Reset High Limit 167 = EEPROM code Blocked Drain 168 = EEPROM code Louver Proving 169 = EEPROM code Gas Pressure Sw 170 = EEPROM code Flow Switch 177 = Sensor 3 short (Flue Sensor) 178 = Sensor 3 open (Flue Sensor) 179 = Sensor 2 short (Inlet Sensor) 180 = Sensor 2 open (Inlet Sensor) 192 = Sensor 1 short (Outlet Sensor) 193 = Sensor 1 open (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  ame when running 233 = EEPROM code no  ame a er ignition 234 = EEPROM code simultaneous output APS and Fan 235 = EEPROM code APS active not Closed 236 = EEPROM code APS active not Open 237 = EEPROM code  ame out of sequence 239 = EEPROM code when gas valve relay test fails 240 = EEPROM code MRHL 32767 = Code not present

 e lockout code is constantly changing during operation and should not be used for lockout noti cation until the status code (Input Register 30014 or AI13) indicates a code of 40.

29

10 Diagrams

Figure 10-1 Ladder Diagram_Knight/Knight Wall Mount

ModBus and BACnet Communication Instructions

30

120VAC

TERMINAL STRIP

120V SUPPLY "L"

ON / OFF

SWITCH

PC INTERFACE

ALARM

BELL

SWITCH

SILENCING

CONTACTS

RUN-TIME

CONTACTS

SYSTEM SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

SHIELD

BMS

IN

SYS PUMP

IN

BLR PUMP

OUT

RATE

OUT

SHIELD

MODBUS

SHIELD

X1-6 F2

X5-9

X4-3

CN5-5

1

2

6

13

ALARM

S6

S5

S4

A

B

+

0-10V

-

+

0-10V

-

+

0-10V

-

+

0-10V

-

A

B

3.5A

KB 801 ONLY

CN7-1

CN7-3

CONNECTION BOARD

CONNECTION

21

22

23

24

26

27

29

30

31

32

33

34

35

36

37

38

39

40

41

JUNCTION BOX

INTEGRATED CONTROL

3.15A

F1

5A

SYSTEM PUMP

BOILER PUMP

F3

.8A

24V DC

SUPPLY

120 VAC

24 VAC

LWCO

S2

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

BOARD

1

2

3

4

CN8-1

42

CN8-2 X6-2

43

CN8-3

44

RELAY

DHW PUMP

RELAY

CN7-4

CN7-2

RIBBON CABLE

CN5-1

CN5-8

CN5-2

CN5-9

CN6

CN3-9

CN3-6

CN6

X6-1

X6-3

GROUND

NEUTRAL

TERMINAL STRIP 120V SUPPLY "N"

12

BLOWER

3

INTEGRATED

X4-12

X4-9

X4-2

X4-10

X4-11

X4-5

X5-2

X5-10

X2-2

X2-1

X5-7

X5-16

X5-8

X5-15

TR2

X1-7

LOW VOLTAGE 120 VAC HIGH VOLTAGE

CONTROL

GAS VALVE

RELAY

BOX DEPICTS

OPTIONAL ITEMS

LADDER DIAGRAM

LBL20148 REV B

CN5-14 X4-8

12

CN5-10

CN5-7 X4-1

20

CN5-13

18

CN5-6

16

CN5-12

14

CN5-11

9

CN5-3

5

6

7

CN5-4 X4-4

8

X5-11

1

2

4

5

FLAME ROD

SYSTEM

PUMP

BOILER

PUMP

DHW

PUMP

CONNECTION BOARD

FLOW

SWITCH

ROOM

THERMOSTAT 1

ROOM

THERMOSTAT 2

ROOM

THERMOSTAT 3

TANK

THERMOSTAT

HIGH GAS

PRESSURE

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

GND

SYSTEM

PUMP "N"

GND

BOILER

PUMP "N"

GND

DHW

PUMP "N"

TERMINAL

STRIP

SYSTEM

X1-1

PUMP "L"

X1-2

BOILER

PUMP "L"

X1-4

DHW

PUMP "L"

X1-3

TERMINAL

STRIP

X5-1

11

19

17

15

13

LOW GAS

PRESSURE

SWITCH

10

INTEGRATED

CONTROL

X7

BLOCKED

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X4-7

X4-14

X4-6

X4-13

X6

X4-9

X4-6

X6

M O

X4-1

X9-2

D

X4-2

X9-1

B U

X4-3

X9-3

S

NOTES:

1. Where possible, switches are shown without uti lities (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.

DRAIN SWITC H

AIR PRESSURE

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

CAUTION HIGH VOLTAGE SPARK LEAD

10 Diagrams (continued)

Figure 10-2 Wiring Diagram_Knight/Knight Wall Mount

ModBus and BACnet Communication Instructions

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

CONNECTION BOARD

ALARM

CONTACT S

RUN-TIME

CONTACT S

24 VAC LOUVER

RELAY COIL

BELL JUMPER

ALARM BELL

SILENCING SWITCH

Notes:

1. All wiring must be installed in accordance with:

2. If any original equipment wire as supplied with minimum of 105°C. Exce ptions: Replacement high vo or ribbon cables can lead to operational problems w

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components diagrams to troubleshoot unit.

LOUVER

PROVING SWIT CH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

ROOM TST AT

ZONE CONTRO L 3

ROOM TST AT

ZONE CONTRO L 2

ROOM TST AT

ZONE CONTRO L 1

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

BMS

SYS PUMP

BLR PUMP

OUT

RATE

OUT

MODBUS

OPTION

LOW

WATER

CUT-OFF

SHIELD

JUMPER

A

B

IN

SHIELD

+

CASCADE

GROUNDING

-

A

B

0-10V

24 VAC

COM

1 2 3 4 5 6 7 8 9

10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31 32

CN5-1 CN5-8 CN5-2 CN5-9

CN5-3 CN5-10 CN5-11

CN5-4

CN5-5 CN5-14 CN5-12

CN5-6 CN5-13

CN5-7

BK BK BK BK BK

BK BK BK BK

CN6

33 34 35 36 37 38 39 40 41 42 43 44

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

X5-1 X5-2

local, state, provincial and national code requir the appliance must be replaced, it must be replaced

ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark le

hich could result in non-repairable damage to the integrated controller or other components.

MTR-01

CN8-1

CN8-2

CN8-3

BL

R

G

X6-3

X6-2

X6-1

X6-4

O

X4-1

GY

X4-2 X4-3

G

X4-4

BK

X1-1

W

X1-2

G

X1-3

ements per either N.E.C. in USA or C.S.A. in Canada

with wire having same wire gauge (AWG) and rated for a

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS DUAL SENSOR

SINGLE HOUSI NG

INTEGR ATED

CONTROL

X-7

X4-7

X4-14

X4-6

X4-13

X4-5 X4-12 X4-11

X4-4

X4-3

X4-8 X4-10

X4-2

X4-9

X4-1

X1-3

X1-4

X1-2

X1-6 X1-5

X1-8

X1-1

OR

BR

PR

KB ONLY

ON/OFF SWITC H

BK

W

G

R

W

1 2G3

BLOWER

5

123 4

R

X6

X9-1 X9-2 X9-3 X9-4

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

X1-7

TR2

T

W

BK

Y

BL

O

P

O/BK

R/BK

GY

P/BK

W/BK

PR

Y

BK

Y

W/R

-T

GAS VALVE @24VAC

FLAME SENSOR SPARK

ROD

CAUTION

HIGH VOLTAGE SPARK LEAD

for proper connector block locations when using

JUNCTION

BOX

L

W

TRANSFORMER

BLOCKED DRAIN SWITCH

OPERATING SENSOR S1a

HIGH LIMIT SENSOR S1b

INLET SENSO R S2

FLUE SENSOR S3a

FLUE SENSOR S3b

G

N L

G

N

L N

AIR PRESSURE SWITCH

G

GND

G

.

ad

BOX DEPICTS

OPTIONAL

ITEMS

DHW PUMP

BOILER PUMP

SYSTEM PUMP

L

120V SUPPLY

N

WIRING DIAGRAM

LBL20127 REV B

31

10 Diagrams

Figure 10-3 Ladder Diagram_Knight XL

ModBus and BACnet Communication Instructions

120VAC

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF SWITCH

PC INTERFACE

BELL

ALARM

SWITCH

SILENCING

SYSTEM SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

CASCADE

SHIELD

BMS

IN

SYS PUMP

IN

BLR PUMP

OUT

RATE

OUT

SHIELD

MODBUS

SHIELD

1

2

6

13

ALARM

CONTACTS

RUN-TIME

CONTACTS

A

B

+

-

+

-

+

-

+

-

A

B

X4-3

CN5-5

X1-6

S6

S5

S4

0-10V

X5-9

3.5A

KB 801 ONLY

CN7-1

CN7-3

CONNECTION

CONNECTION BOARD

JUNCTION BOX

INTEGRATED CONTROL

F2

3.15A

F1

5A

SYSTEM PUMP

BOILER PUMP

F3

.8A

24V DC

SUPPLY

120 VAC

24 VAC

LWCO

S2

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

BOARD

1

2

3

4

21

22

23

24

26

27

29

30

31

32

33

34

35

36

37

38

39

40

41

CN8-1

42

CN8-2 X6-2

43

CN8-3

44

RELAY

DHW PUMP

RELAY

CN7-4

CN7-2

RIBBON CABLE

CN5-1

CN5-8

CN5-2

CN5-9

CN6

CN3-9

CN3-6

CN6

X6-1

X6-3

12

X1-1

X1-2

SYSTEM PUMP

RELAY

X1-3

DHW PUMP

RELAY

X1-4

BOILER PUMP

RELAY

X5-1

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X4-7

X4-14

X4-6

X4-13

X6

X4-9

X4-6

X6

M O

X4-1

X9-2

D

X4-2

X9-1

B U

X4-3

X9-3

S

TERMINAL STRIP 120V SUPPLY "N"

BLOWER

3

11

19

17

15

13

10

INTEGRATED

CONTROL

X7

NEUTRAL

L

LOUVER

RELAY COIL

24VAC

LOUVER

IN

12

20

18

16

14

BLOCKED

DRAIN SWITCH

AIR PRESSURE

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

RELAY BOARD

9

5

6

7

8

SYSTEM

PUMP

CONTACTS

BOILER

PUMP

CONTACTS

DHW PUMP

CONTACTS

CN5-14 X4-8

CN5-10

CN5-7 X4-1

CN5-13

CN5-6

CN5-12

CN5-11

CN5-3

CN5-4 X4-4

FLAME ROD

X5-10

X5-11

1

2

4

5

SYSTEM

PUMP

BOILER

PUMP

DHW PUMP

INTEGRATED

CONTROL

X4-12

X4-9

X4-2

X4-10

X4-11

X4-5

X5-2

X2-2

GAS VALVE

X2-1

TR2

X1-7

RELAY

X5-7

X5-16

X5-8

X5-15

CONNECTION BOARD

FLOW

SWITCH

ROOM

THERMOSTAT 1

ROOM

THERMOSTAT 2

ROOM

THERMOSTAT 3

TANK

THERMOSTAT

LOW GAS

PRESSURE

SWITCH

GROUND

HIGH GAS PRESSURE

SWITCH

PROVING SWITCH

CAUTION HIGH VOLTAGE SPARK LEAD

NOTES:

1. Where possibl e, switches are shown without utiliti es (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 i s present.

2. See wiring diagram for additional notes.

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE 120 VAC HIGH VOLTAGE

LADDER DIAGRAM

L

OUT

LBL20141 REV B

32

10 Diagrams (continued)

Figure 10-4 Wiring Diagram_Knight XL

ModBus and BACnet Communication Instructions

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

CONNECTION BOARD

BELL JUMPER

ALARM BELL

SILENCING SWITCH

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSUR E

SWIT CH

FLOW

SWIT CH

TANK

THERMOSTA T

ROOM TSTAT

ZONE CONTROL 3

ROOM TSTAT

ZONE CONTROL 2

ROOM TSTAT

ZONE CONTROL 1

SYSTEM

SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

A

B

CASCADE

1 2 3 4 5 6 7 8 9

10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31 32

CN5-1 CN5-8 CN5-2 CN5-9

CN5-3 CN5-10 CN5-11

CN5-4

CN5-5 CN5-14 CN5-12

CN5-6 CN5-13

CN5-7

BK BK BK BK BK

BK BK BK BK

CN6

BMS

+

0-10V

IN

OUT

RATE

OUT

OPTION

SHIELD

LOW

WATER

SHIELD

IN

SHIELD

+

A

B

-

0-10V

24 VAC

COM

SYS PUMP

BLR PUMP

MODBUS

CUT-OFF

GROUNDING

JUMPER

Notes:

1. All wiring must be installed in accordance wit h:

2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced minimum of 105°C. Exceptions: Replacement high vo ltage spark lead and ribbon cables must be purchase or ribbon cables can lead to operational pr oblems which could result in non-repairable damage to t he integrated controller or other components.

3. Actual connector block locations m ay vary from those shown on diagrams. Refer to actual comp onents diagrams to troubleshoot unit .

33 34 35 36 37 38 39 40 41 42 43 44

X5-1 X5-2

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

MTR-01

CN8-1

CN8-2

CN8-3

BL

R

G

X6-3

X6-2

X6-1

X6-4

X4-1 X4-2 X4-3 X4-4

X1-1 X1-2 X1-3

local, state, provincial and national code requir

INTEGRATED

CONTROL

X-7

X4-7

X4-14

X4-6

X4-13

X4-5 X4-12 X4-11

X4-4

X4-3

X4-8 X4-10

X4-2

X4-9

X4-1

X6

O

X9-1 X9-2

GY

X9-3

G

X9-4

BK W

G

ements per either N.E.C. in USA or C.S.A. in Canada.

with wire having same wire gauge (A WG) and rated for a

d from the factory. Use of a non-approv ed spark lead

for proper connector block locations when using

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

CN2-4

OR

X1-3

CN2-2

BR

X1-4

CN2-3

X1-2

PR

CN2-1

X1-6

BK

X1-5

W

G

X1-8

X1-1

R

X5-7

T

X5-16

W

X5-8

BK

X5-15

Y

X5-9

X5-1

BL

O

X5-2

P

X5-10

X5-11

O/BK

X5-4

R/BK

X5-12

GY

X5-6

P/BK

X5-5

W/BK

X5-13

PR

X5-14

Y

BK

X2-2

Y

X2-1

X1-7

W/R

TR2

RELAY

BOARD

K1

K2

K3

ON/OFF

SWITCH

BLOWER

3 4

1 2

FLAME SENSOR

SPARK

ROD

JUNCTION

CN1-5

OR

CN1-6

OR

CN1-3

BR

CN1-4

BR

CN1-1

PR

CN1-2

PR

TRANSFORMER

R W

G

2

1

3

5

BLOCKED DRAIN SWITCH

AIR PRESSURE SWITCH

-T

OPERATING SENSOR S1a

-T

HIGH LIMIT SENSOR S1b

-T

INLET SENSOR S2

-T

FLUE SENSOR S3a

-T

FLUE SENSOR S3b

GAS VALVE @24VAC

G

HIGH VOLTAGE SP ARK LEADCAUTION

BOX

3.5A

KB 801

ONLY

L

DHW PUMP

BOILER PUMP

SYSTEM PUMP

L

120V

GND

SUPPLY

N

WIRING DIAGRAM

LBL20116 REV B

N

33

10 Diagrams

Figure 10-5 Ladder Diagram_Armor / Armor Wall Mount

ModBus and BACnet Communication Instructions

120VAC

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF

SWITCH

X1-6

X4-3

CN5-5

X5-9

3.5A

AW 801 ONLY

CN7-1

CN7-3

CONNECTION BOARD

JUNCTION BOX

INTEGRATED CON TROL

F2

3.15A

F1

5A

RECIRC PUMP

F3

.8A

24V DC SUPPLY

120 VAC

24 VAC

LWCO

BUILDING

RELAY

DHW PUMP

RELAY

CN7-4

CN7-2

RIBBON CABLE

GROUND

NEUTRAL

TERMINAL STRIP 120V SUPPLY "N"

12

BLOWER

3

INTEGRATED

CN5-14 X4-8

12

CN5-10

CN5-12

14

CN5-11

9

CN5-3

5

6

7

CN5-4 X4-4

8

CONTROL

X4-12

X4-10

X4-11

X4-5

BUILDING

RECIRC

PUMP

DHW PUMP

CONNECTION BOARD

FLOW

SWITCH

TANK

THERMOSTAT

HIGH GAS

PRESSURE

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

GND

SYSTEM

PUMP "N"

GND

DHW

PUMP "N"

TERMINAL

STRIP

SYSTEM

X1-1

PUMP "L"

X1-2

DHW

PUMP "L"

X1-3

TERMINAL

STRIP

X5-1

11

13

LOW GAS

PRESSURE

SWITCH

10

INTEGRATED

CONTROL

X7

PC INTERFACE

ALARM

BELL

SWITCH

SILENCING

CONTACTS

TANK

SENSOR

SHIELD

CASCADE

SHIELD

BMS

IN

RATE

OUT

SHIELD

MODBUS

SHIELD

1

2

6

13

ALARM

RUN-TIME

A

B

+

-

+

-

A

B

0-10V

S2

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

CONNECTION

BOARD

1

2

3

4

S4

16

17

19

20

21

22

23

24

25

26

27

CN8-1

28

CN8-2

29

CN8-3 X6-3

30

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

CN5-1

X4-7

X4-14

CN5-8

CN5-2

X4-6

CN5-9

X4-13

CN3-9

X4-9

CN3-6

X4-6

CN6

X6

CN6

X6

CN6

X6

CN6

X6

CN6

X6

CN6

X6

CN6

X6

M O

X4-1

X9-2

X6-1

D

X6-2

X4-2

X9-1

B U

X4-3

X9-3

S

NOTES:

1. Where possibl e, switches are shown w ithout 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.

BLOCKED

DRAIN SWITCH

AIR PRESSURE

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

HIGH VOLTAGE SPARK LEADCAUTION

X5-2

X5-10

X5-11

X2-2

X2-1

1

2

4

5

TR2

X1-7

FLAME ROD

GAS VALVE

RELAY

X5-7

X5-16

X5-8

X5-15

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

LADDER DIAGRAM

LBL20149 REV B

34

10 Diagrams (continued)

Figure 10-6 Wiring Diagram_Armor / Armor Wall Mount

ModBus and BACnet Communication Instructions

LOW VOLTAGE 120 VAC HIGH VOLTAGE

CONNECTION BOARD

ALARM

CONTACT S

RUN-TIME

CONTACT S

24 VAC LO UVER

RELAY COIL

BELL JUMPER

ALARM BELL

SILENCIN G SWITCH

Notes:

1. All wiring must be installed in accordance with:

2. If any original equipment wire as supplied with minimum of 105°C. Exceptions: Replacement high vo or ribbon cables can lead to operational problems w

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components diagrams to troubleshoot unit.

LOUVER

PROVING SWIT CH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK

THERMOSTAT

TANK

SENSOR

SHIELD

A

CASCADE

GROUNDING

SHIELD

BMS

RATE

OUT

MODBUS

OPTION

LOW

WATER

CUT-OFF

SHIELD

JUMPER

B

IN

SHIELD

+

-

+

-

A

B

0-10V

24 VAC

COM

1 2 3 4 5 6 7 8 9

10

11 12 13 14

15 16 17 18 19 20 21 22

CN5-1 CN5-8 CN5-2 CN5-9

CN5-3 CN5-10 CN5-11

CN5-4

CN5-5 CN5-14 CN5-12

CN5-6 CN5-13

CN5-7

BK BK BK BK BK

BK BK BK BK

CN6

23 24

25 26 27 28 29 30

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

X5-1 X5-2

local, state, provincial and national code requir

the appliance must be replaced, it must be replaced

ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark le

hich could result in non-repairable damage to the integrated controller or other components.

MTR-01

CN8-1

CN8-2

CN8-3

BL

R

G

X6-3

X6-2

X6-1

X6-4

O

X4-1

GY

X4-2 X4-3

G

X4-4

BK

X1-1

W

X1-2

G

X1-3

ements per either N.E.C. in USA or C.S.A. in Canada

with wire having same wire gauge (AWG) and rated for a

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSI NG

INTEGR ATED

CONTROL

COM

X1-3

X1-4

X1-2

X1-6 X1-5

X1-8

X1-1

OR/BK

PR/W

BK

W

G

R

NO

COM

NO

SWITCH

ON/OFF

R

W

1 2G3

X-7

X4-7

X4-14

X4-6

X4-13

X4-5 X4-12 X4-11

X4-4

X4-3

X4-8 X4-10

X4-2

X4-9

X4-1

BLOWER

5

123 4

R

X6

X9-1

X9-2

X9-3

X9-4

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

X1-7

TR2

T

W

BK

Y

BL

O

P

O/BK

R/BK

GY

P/BK

W/BK

PR

Y

BK

Y

W/R

-T

GAS VALVE @24VAC

FLAME SENSOR SPARK

ROD

CAUTION

HIGH VOLTAGE SPARK LEAD

for proper connector block locations when using

JUNCTION

OR

PR

TRANSFORMER

OPERATING SENSOR S1a

HIGH LIMIT SENSOR S1b

INLET SENSOR S2

FLUE SENSOR S3a

FLUE SENSOR S3b

L

BOX

L N

BLOCKED DRAIN SWITCH

AIR PRESSURE SWITCH

3.5A

AW 801

ONLY

GND

G

.

ad

DHW PUMP

BUILDING RECIRC. PUMP

L

120V SUPPLY

N

WIRING DIAGRAM

LBL20134 REV B

N

35

10 Diagrams

Figure 10-7 Ladder Diagram_Wall Hung

ModBus and BACnet Communication Instructions

120VAC

KB ONLY

PC INTERFACE

ALARM

SWITCH

SILENCING

OUTDOOR

CASCADE

SYS PUMP

BLR PUMP

MODBUS

BELL

SYSTEM SENSOR

SENSOR

RATE

TANK

SHIELD

BMS

OUT

SHIELD

TERMINAL STRIP 120V SUPPLY "L"

ON / OFF

SWITCH

X4-3

CN5-5

1

2

6

13

ALARM

CONTACTS

RUN-TIME

CONTACTS

S6

S4

A

B

+

0-10V

IN

-

+

0-10V

IN

-

+

0-10V

-

+

0-10V

-

A

B

X1-6

X5-9

KB 801 ONLY

S5

INTEGRATED CONTROL

3.5A

CN7-1

CN7-3

CONNECTION BOARD

CONNECTION

BOARD

1

2

3

4

21

22

23

24

26

27

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

SENSOR

OPERATING

SENSOR

HIGH LIMIT

SENSOR

F2

3.15A

F1

5A

F3

.8A

120 VAC

24 VAC

LWCO

INLET

FLUE

JUNCTION BOX

SYSTEM PUMP

RELAY

BOILER PUMP

RELAY

DHW PUMP

RELAY

24V DC

SUPPLY

CN7-4

CN7-2

S2

S1a

S1b

S3a

S3b

CN8-1

CN8-2 X6-2

CN8-3 X6-3

RIBBON CABLE

CN5-1

CN5-8

CN5-2

CN5-9

CN6

CN3-9

CN3-6

CN6

M O

X6-1

D B U S

GROUND

NEUTRAL

TERMINAL STR IP 120V SUPPLY "N"

12

BLOWER

3

INTEGRATED

X5-10

X5-11

1

2

4

5

X4-12

X4-1

X4-9

X4-2

X4-10

X4-11

X4-5

X5-2

X2-2

X2-1

X5-7

X5-16

X5-8

X5-15

TR2

X1-7

CONTROL

GAS VALVE

RELAY

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE 120 VAC HIGH VOLTAGE

LADDER DIAGRAM

LBL20170 REV A

CN5-14 X4-8

12

CN5-10

CN5-7

20

CN5-13

18

CN5-6

16

CN5-12

14

CN5-11

9

CN5-3

5

6

7

CN5-4 X4- 4

8

FLAME ROD

SYSTEM

PUMP

BOILER

PUMP

DHW PUMP

CONNECTION BOARD

FLOW

SWITCH

HEAT/LOOP

1

DEMAND

HEAT/LOOP

2

DEMAND

HEAT/LOOP

3

DEMAND

TANK

THERMOSTAT

HIGH GAS

PRESSURE

SWITCH

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

GND

SYSTEM

PUMP "N"

GND

BOILER

PUMP "N"

GND

DHW

PUMP "N"

TERMINAL

STRIP

SYSTEM

X1-1

PUMP "L"

X1-2

BOILER

PUMP "L"

X1-4

DHW

PUMP "L"

X1-3

TERMINAL

STRIP

X5-1

11

19

17

15

13

LOW GAS

PRESSURE

SWITCH

10

INTEGRATED

CONTROL

X7

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X4-7

X4-14

X4-6

X4-13

X6

X4-9

X4-6

X6

X4-1

X9-2

X4-2

X9-1

X4-3

X9-3

BLOCKED

DRAIN JUMPER

AIR PRESSURE

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

CAUTION HIGH VOLTAGE SPARK LEAD

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 show n on diagrams depending upon wh ether utilities are connected or a fault condition is present.

2. See wiring diagram for additional notes.

36

10 Diagrams (continued)

Figure 10-8 Wiring Diagram_Wall Hung

ModBus and BACnet Communication Instructions

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

CONNECTION BOARD

ALARM

CONTACT S

RUN-TIME

CONTACT S

24 VAC LOUVER

RELAY COIL

BELL JUMPER

ALARM BELL

SILENCI NG SWITCH

Notes:

1. All wiring must be installed in accordance with:

2. If any original equipment wire as supplied with minimum of 105°C. Exceptions: Replacement high vo or ribbon cables can lead to operational problems w

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components diagrams to troubleshoot unit.

LOUVER

PROVING SWIT CH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK THERMOSTAT HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

SYSTEM SENSOR

OUTDOOR

SENSOR

TANK

SENSOR

SHIELD

A

CASCADE

B

SHIELD

BMS

+

IN

OUT

RATE

OUT

MODBUS

OPTION

SHIELD

LOW

WATER

CUT-OFF

SHIELD

JUMPER

IN

SHIELD

-

+

-

+

-

+

-

A

B

SYS PUMP

BLR PUMP

GROUNDING

1

2

3

0-10V

24 VAC

COM

1 2 3 4 5 6 7 8 9

10

11 12 13 14 15 16 17 18 19 20

21 22 23 24 25 26 27 28 29 30 31 32

CN5-1 CN5-8 CN5-2 CN5-9

CN5-3 CN5-10 CN5-11

CN5-4

CN5-5 CN5-14 CN5-12

CN5-6 CN5-13

CN5-7

BK BK BK BK BK

BK BK BK BK

CN6

33 34 35 36 37 38 39 40 41 42 43 44

CN7-1 CN7-2 CN7-3 CN7-4

MODBUS BOARD

X5-1 X5-2

local, state, provincial and national code requir the appliance must be replaced, it must be replaced

ltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark le

hich could result in non-repairable damage to the integrated controller or other components.

MTR-01

CN8-1

CN8-2

CN8-3

BL

R

G

X6-3

X6-2

X6-1

X6-4

O

X4-1

GY

X4-2 X4-3

G

X4-4

BK

X1-1

W

X1-2

G

X1-3

ements per either N.E.C. in USA or C.S.A. in Canada

with wire having same wire gauge (AWG) and rated for a

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSI NG

INTEGR ATED

CONTROL

X-7

X4-7

X4-14

X4-6

X4-13

X4-5 X4-12 X4-11

X4-4

X4-3

X4-8 X4-10

X4-2

X4-9

X4-1

X1-3

X1-4

X1-2

X1-6 X1-5

X1-8

X1-1

OR

BR

PR

KB ONLY

ON/OFF

SWITCH

BK W

G

R

W

1 2G3

BLOWER

5

123 4

R

X6

X9-1 X9-2 X9-3 X9-4

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

X1-7

TR2

T

W

BK

Y

BL

O

P

O/BK

R/BK

GY

P/BK

W/BK

PR

Y

BK

Y

W/R

-T

GAS VALVE @24VAC

FLAME SENSOR SPARK

ROD

CAUTION

HIGH VOLTAGE SPARK LEAD

for proper connector block locations when using

JUNCTION

BOX

L

W

TRANSFORMER

BLOCKED DRAIN JUMPER

AIR PRESSURE SWITCH

OPERATING SENSOR S1a

HIGH LIMIT SENSOR S1b

INLET SENSO R S2

FLUE SENSOR S3a

FLUE SENSOR S3b

G

N L

G

N L

G

N

L

GND

N

G

.

ad

BOX DEPICTS

OPTIONAL

ITEMS

DHW PUMP

BOILER PUMP

SYSTEM PUMP

L

120V SUPPLY

N

WIRING DIAGRAM

LBL20169 REV A

37

10 Diagrams

Figure 10-9 Wiring Diagram_FTXL

CONNECTION BOARD

BELL JUMPER

ALARM BELL

SILENCING SWITCH

ALARM

CONTACTS

RUN-TIME

CONTACTS

24 VAC RECIRC

PUMP RELAY COIL

24 VAC LOUVER

RELAY COIL

LOUVER

PROVING SWITCH

GAS PRESSURE

SWITCH

FLOW

SWITCH

TANK THERMOSTAT HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

SYSTEM

SENSOR

OUTDOOR

SENSOR

DHW RECIRC SENSOR

TANK

SENSOR

SHIELD

A

CASCADE

B

SHIELD

BMS

IN

SYS PUMP

IN

BLR PUMP

OUT

RATE

OUT

SHIELD

MODBUS

OPTION

SHIELD

GROUNDING

JUMPER

3 2 1

+

0-10V

-

+

0-10V

-

+

0-10V

-

+

0-10V

-

A

B

X5-1 X5-2

13 14 15 16 17 18 19 20 21 22

23 24 25 26 27 28 29 30 31 32 33 34

35 36 37 38 39 40 41 42 43 44 45 46

1 2 3 4 5 6 7 8

9 10 11 12

CN2

CN1

CN4

CN3

MODBUS BOARD

LOW VOLTAGE 120 VAC HIGH VOLTAGE

RIBBON CABLE

CN5-12 CN5-1 CN5-9 CN5-2 CN5-10 CN5-16 CN5-11 CN5-3 CN5-8 CN5-4 CN5-15 CN5-13 CN5-6 CN5-14 CN5-7 CN5-5

CN6

CN8-1

R

G

X6-1

MTR-01

ModBus and BACnet Communication Instructions

BOX DEPICTS

OPTIONAL ITEMS

CONXUS

Y

INTEGRATED

BIC

DU

CONTROL

X-7

R/BL

BR/W

P/BL R/W

GY/BL

BL/BK

Y

BL/W

PR/BK

PR/W

O/BK

BK/W

GY/W

O/BL

DAMPER

RELAY

BK

P/W

FLUE DAMPER

M

2

3

1

X4-11 X4-07 X4-14 X4-06 X4-13

X4-12

X4-5

X4-4 X4-8

X4-10

X4-9 X4-2 X4-1

x4-3

X5-3

LWCO

BOARD

J3-6

BL

J3-5

LWCO

PROBE

LWCO RESET

T

TEST

SWITCH

PR

O/BK

O

J3-4

T

J3-3 J3-2

Y

J2-1 J2-2

X6

CN8-3

CN8-2

BL

G

R

X6-2

X6-4

X6-3

X1-1 X1-2 X1-3

X4-1 X4-2 X4-3 X4-4

O

GY

G

BK

W G

X9-1 X9-2 X9-3 X9-4

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

OR

X1-3

X1-4

X1-2

X1-6 X1-5

X1-8

X1-1

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

X5-4

X5-12

X5-6

X5-5

X5-13

X5-14

X2-2

X2-1

X1-7

TR2

CN2-4

CN2-2

BR

CN2-3

PR

CN2-1

BK

W

G

R

FAN

RELAY

R

T

W

BK

Y/BK

BL

O

BLOCKED DRAIN SWITCH

P

O/BK

R/BK

GY

P/BK

W/BK

PR

Y

BK

Y

W/R

RELAY BOARD

CN1-5

K1

CN1-6 CN1-3

K2

CN1-4

CN1-1

K3

CN1-2

ON/OFF SWITCH

W

BK

1 2G3

BLOWER

1 2 3 4 5

-T

OPERATING SENSOR S1a

-T

HIGH LIMIT SENSOR S1b

-T

INLET SENSOR S2

-T

FLUE SENSOR S3a

-T

FLUE SENSOR S3b

GAS VALVE @24VAC

FLAME SENSOR SPARK

ROD

HIGH VOLTAGE SPARK LEADCAUTION

JUNCTION

BOX

OR

BR

BR PR

PR

TRANSFORMER

G

3.5A

L

GND

N

DHW PUMP

BOILER PUMP

SYSTEM PUMP

120V SUPPLY

N

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 supplie d 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: Rep lacement high voltage 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 w hich could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when using diagrams to troubleshoot unit.

38

WIRING DIAGRAM

LBL20426 REV C

10 Diagrams (continued)

Figure 10-10 Ladder Diagram_FTXL

ModBus and BACnet Communication Instructions

120VAC

ON / OFF

SWITCH

BELL

ALARM

SWITCH

SILENCING

OUTDOOR

DHW RECTRC

CASCADE

SYS PUMP

BLR PUMP

MODBUS

TERMINAL STRIP

120V SUPPLY "L"

SYSTEM SENSOR

SENSOR

TANK

SENSOR

SHIELD

BMS

IN

OUT

RATE

OUT

SHIELD

1

2

6

13

ALARM

CONTACTS

RUN-TIME

CONTACTS

A

B

+

-

A

B

X4-3

CN5-5

X1-6

S6

S5

S7

S4

0-10V

X5-9

3.5A

CONNECTION

JUNCTION BOX

INTEGRATED CONTROL

F2

3.15A

F1

5A

SYSTEM PUMP

BOILER PUMP

F3

.8A

24V DC

SUPPLY

120 VAC

24 VAC

13

19 21

17 19

15

17

13

15 15

PRESSURE

12

10

CONXUS

DU

RIBBON CABLE

S2

INLET

SENSOR

S1a

OPERATING

SENSOR

S1b

HIGH LIMIT

SENSOR

S3a

FLUE

SENSOR

S3b

FLUE

SENSOR

BOARD

1

2

3

4

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

CN8-1

44

CN8-2

45

CN8-3 X6-3

46

BLOWER

RELAY

DHW PUMP

RELAY

CONNECTION BOARD

FLOW

SWITCH

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

HEAT/LOOP

DEMAND

TANK

THERMOSTAT

LOW GAS

SWITCH

BIC

CN5-1

CN5-9

CN5-2

CN5-9

CN6

CN6 X6

CN6

M O

X6-1

D

X6-2

B U S

TERMINAL STRIP

120V SUPPLY "N"

BLOWER

12

3

X1-1

BLOWER

RELAY

X1-2

SYSTEM PUMP

RELAY

X1-3

DHW PUMP

RELAY

X1-4

BOILER PUMP

RELAY

X5-1

1

2

3

HIGH GAS

PRESSURE

SWITCH

INTEGRATED

CONTROL

X7

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X4-7

X4-14

X4-6

X4-13

X6

X4-1

X9-2

X4-2

X9-1

X4-3

X9-3

NEUTRAL

L

GROUND

IN

SYSTEM

PUMP

CONTACTS

BOILER

PUMP

CONTACTS

DHW

PUMP

CONTACTS

RELAY BOARD

J3-6

LWCO

TEST

SWITCH

GAS VALVE

BLOWER

SPARK

ROD

J3-5

J3-3

J2-1

J2-2

10

CN5-15

14

22

20

18

16

11

9

LWCO

PROBE

LWCO RESET

RECIRC PUMP

RELAY COIL

24VAC

LOUVER

RELAY COIL

24VAC

LOUVER

PROVING SWITCH

BOARD

5

6

7

8

9

BLOCKED

DRAIN SWITCH

J3-4

J3-2

CN5-7 X4-1

CN5-6 X4-9

CN5-14

CN5-13

CN5-16

CN5-11

CN5-3

DAMPER RELAY

FLUE DAMPER

M

3

CN5-4

X5-2

X5-10

X5-11

X2-2

X2-1

1

2

4

5

TR2

X1-7

FLAME ROD

CAUTION HIGH VOLTAGE SPARK LEAD

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 whether utilities are connected or a fault condition is present.

2. See wiring diagram for additional notes.

SYSTEM

PUMP

BOILER

PUMP

DHW

PUMP

INTEGRATED

CONTROL

X4-8

X4-12

X4-2

X4-10

X5-3

X4-11

X4-5

12

X4-4

GAS VALVE

X5-7

X5-16

X5-8

X5-15

BOX DEPICTS

OPTIONAL ITEMS

LOW VOLTAGE 120 VAC HIGH VOLTAGE

LADDER DIAGRAM

L

OUT

RELAY

LBL20427 REV C

39

Revision Notes: Revision A (ECO #C06020) initial release.

Revision B (ECO #C06188) reﬂ ects updates made to the ladder and wiring diagrams (ECO #C06158).

Revision C (ECO C07191) reﬂ ects the correction information in the Parity section on page 4.

Revision D (ECO C07281) reﬂ ects the addition of Armor information Wall Hung unit information on page 13, image 5-6 on page 15 for Wiring

Requirements, Wall Hung ModBus installation procedure and images 2-6 and 2-7 on page 5, Armor Ladder and Wiring diagrams on pages 28 and 29 and Wall Hung Ladder and Wiring diagrams on pages 30 and

31. Section 2 “Installation” was created using information previously included in Section 7 “Troubleshooting”.

Revision E (ECO C11616) reﬂ ects the addition of the lockout code notice on page 23 (R05772).

Revision F (ECO C11792) reﬂ ects the addition of Outdoor Knight, Knight XL and Armor models.

Revision G (ECO C13647) reﬂ ects the inclusion of AQUAS models.

Revision H (ECO C16066) reﬂ ects the addition of FTXL model information, images and diagrams.

Revision J (PCP# 3000002377 / CN# 500002607) reﬂ ects the addition of BACnet information and images, edits made to the Memory Map tables on pages 15 and 16.

Revision K (PCP# 3000007541 / CN# 500007580) reﬂ ects the addition of references to A+ and B- on page 17.

Revision L (PCP# 3000008406 / CN# 500008361) reﬂ ects an update to the addressing information of BACnet conﬁ guration on page 13.

Revision M (PCP #3000030348 / CN #500019626) reﬂ ects the addition of the Wall Mount Armor models.

and

MODB-I-O_MM# 100161545_DIR# 2000014822_Rev M

02/19