Lochinvar SYNC Modbus Communication 10 13 15 User Manual

SYNC-MODB Rev A  
MODBUS COMMUNICATION  
INSTRUCTIONS  
SYNC Models: 1.0 - 1.3 - 1.5  
This manual must only be used by a  
qualified heating installer / service  
ƽ WARNING  
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.  
Modbus Instructions  
2 Configuration  
The Modbus communication board is equipped with a set of ten dip switches that are used to set the board configuration  
(address, baud rate, and parity settings). The first eight are used to set the address of each board. The ninth baud rate. The tenth  
is parity.  
Figure 2-1_Modbus Communication Board  
DIP SWITCHES  
LED’S  
Addressing  
The Modbus addressing space is comprised of 256 different Example:  
addresss.  
To set the address of the Modbus board to 50, dip switches 2, 5,  
and 6 have to be set to the 1 position. The address is determined  
by adding the values of all the dip switches together.  
0 is reserved for broadcast messages from the master  
device  
1 - 247 are free to use for each unique device  
248 - 255 are reserved  
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  
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.  
In this example:  
Address = 0 + 2 + 0 + 0 + 16 + 32 + 0 + 0 = 50  
For each switch set to the 1 position it 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.  
3
Modbus Instructions  
2 Configuration  
Timing Specifications  
Data Transmission Mode  
The baud rate for the Modbus board is selectable with Dip  
switch #9.  
Many Modbus bus master devices can be configured to transmit  
data in either Modbus RTU or Modbus ASCII modes. Since  
RTU messages can be formatted to use fewer data bits and are  
therefore more efficient, RTU has been chosen to be used with  
all Lochinvar Modbus communication. Please ensure that the  
master device is transmitting Modbus RTU.  
1 = 19200 bps  
0 = 9600 bps  
Each message is started by at least 3.5 character times of  
silence. The maximum delay between frames is 1.5 character  
times.  
Modbus Board Diagnostics  
The 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 reception of data. The other yellow  
LED (D6) is used to indicate transmission of data. The green  
LED (D7) is used to show internal faults.  
When the system temperature and/or tank temperature is  
provided by the BAS to the boiler, it is critical that the  
temperature be updated every few seconds. If the boiler does  
not receive updated temperatures within a timeout period  
(installer adjustable), the control will revert to using its own  
sensor inputs (if sensors are connected). The timeout is  
programmable by pressing the MAIN>>SETUP>>BMS  
buttons. The timeout is adjustable between 5 and 120  
seconds. The default timeout is 10 seconds.  
Internal Faults:  
Normal Operation = 1 second on, 1 second off  
Controller Fault = Continuously on  
No Burner Control Communication = 0.5 seconds on, 1.5  
seconds off  
No Modbus Communication = 1.5 seconds on, 0.5 seconds  
off  
When the BAS is not providing either of these temperatures,  
but is still controlling the boiler (such as providing a  
modulation 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.  
Modbus Communication  
The Modbus communication commands and exception codes  
that are supported by the Modbus communication board can  
be found on pages 5 and 6 of this manual.  
Parity  
Parity is set by the position of Dip switch #10.  
0 = No Parity  
1 = Odd Parity  
If No Parity is selected there will be two stop bits, otherwise  
there will be one.  
4
Modbus Instructions  
2 Configuration  
(continued)  
Modbus Function Set  
Function  
Sub Function  
Dec  
HEX  
Description  
Dec  
HEX  
01  
1
2
3
4
5
6
7
8
Read Coil Status  
Read Input Status  
02  
03  
Read Holding Registers  
Read Input Registers  
Force Single Coil  
04  
05  
06  
Preset Single Register  
Read Exception Status  
07  
08  
0
1
2
4
00  
01  
02  
04  
Diagnostic - Return Query Data  
Diagnostic - Restart Communication  
Diagnostic - Return Diagnostic Register  
Diagnostic - Force Listen Mode  
Diagnostic - Clear Counters and Diagnostic  
Registers  
10  
0A  
11  
12  
13  
14  
15  
16  
17  
18  
20  
0B  
0C  
0D  
0E  
0F  
10  
11  
Diagnostic - Return Bus Message Count  
Diagnostic - Bus Communication Error Count  
Diagnostic - Bus Exception Error Count  
Diagnostic - Return Slave Message Count  
Diagnostic - Return Communication Error Count  
Diagnostic - Return Slave NAK Count  
Diagnostic - Return Slave Busy Count  
Diagnostic - Return Bus Character Overrun Count  
Diagnostic - Clear Overrun Counter and Flag  
Get Communication Event Counter  
Get Communication Event Log  
12  
14  
11  
12  
15  
16  
17  
23  
0B  
0C  
0F  
10  
11  
Write Multiple Coils  
Write Multiple Registers  
Report Slave ID  
17  
Read / Write Multiple Registers  
5
Modbus Instructions  
2 Configuration  
Modbus Exception Codes  
MODBUS Exception Codes  
Meaning  
Code  
Name  
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  
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 unconfigured and is being asked to return register values.  
01  
ILLEGAL FUNCTION  
The data address received in the query is not an allowable address for the server  
(or slave). More specifically, the combination of reference number and transfer  
length is invalid. For a controller with 100 registers, the PDU addresses the first  
register as 0, and the last one as 99. If a request is submittted 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.  
02  
03  
ILLEGAL DATA ADDRESS  
A value contained in the query data field 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 specifically 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 significance of any particular value of any particular register.  
ILLEGAL DATA VALUE  
An unrecoverable error occurred while the server (or slave) was attempting to  
perform the requested action.  
04  
05  
SLAVE DEVICE FAILURE  
ACKNOWLEDGE  
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.  
06  
08  
SLAVE DEVICE BUSY  
Specialized use in conjuction with function codes 20 and 21 and reference type 6,  
to indicate that the extended file area failed to pass a consistency check. The  
server (or slave) attempted to read record file, 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.  
MEMORY PARITY ERROR  
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  
misconfigured or overloaded.  
0A  
GATEWAY PATH UNAVAILABLE  
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.  
GATEWAY TARGET DEVICE  
FAILED TO RESPOND  
0B  
6
Modbus Instructions  
3 Memory Map  
Primary Data Tables  
Table  
Discrete Inputs  
Coils  
Input Registers  
Holding Registers  
Data Type  
Single Bit  
Single Bit  
16-Bit Word  
16 Bit Word  
Read / Write  
Read Only  
Read / Write  
Read Only  
Read / Write  
SYNC Boiler Memory Map  
Coils  
Address  
00001  
00005  
Description  
Default  
Unit  
1=ON / 0=OFF  
1=ON / 0=OFF  
Min. Max. Resolution  
Boiler Enable / Room Thermostat 1 / Stage 1  
Tank Thermostat  
0
0
0
0
1
1
1
1
Discrete Inputs  
10001  
10002  
10003  
10004  
10005  
10006  
10007  
10008  
10009  
10010  
Manual Reset High Limit 1  
Flow Switch 1  
0
0
0
0
0
0
0
0
0
0
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
0
0
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Gas Pressure Switch 1  
Louver Proving Switch 1  
Air Pressure Switch / Flap Valve 1  
Blocked Drain Switch 1  
Auto Reset High Limit 1  
Flame 1  
Enable / Room Thermostat 1 / Stage 1  
Tank Thermostat  
10017  
10018  
10019  
10020  
10021  
10022  
10023  
Manual Reset High Limit 2  
Flow Switch 2  
0
0
0
0
0
0
0
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Gas Pressure Switch 2  
Louver Proving Switch 2  
Air Pressure Switch / Flap Valve 2  
Blocked Drain Switch 2  
Flame 2  
10033  
10034  
10035  
10036  
10038  
10039  
Run-time Contacts  
Alarm Contacts 1  
CH Pump 1  
DHW Pump 1  
Gas Valve 1  
0
0
0
0
0
0
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
0
0
0
0
0
0
1
1
1
1
1
1
1
1
1
1
1
1
System Pump  
10041  
10042  
10043  
10046  
Run-time Contacts 2  
Alarm Contacts 2  
CH Pump 2  
0
0
0
0
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
1=ON / 0=OFF  
0
0
0
0
1
1
1
1
1
1
1
1
Gas Valve 2  
7
Modbus Instructions  
3 Memory Map  
SYNC Boiler Memory Map  
Input Registers  
Address  
30001  
30002  
30003  
30004  
Description  
Discrete Inputs 1 - 16  
Discrete Inputs 17 - 32  
Discrete Inputs 33 - 48  
System / Cascade Setpoint  
Default  
Unit  
NA  
NA  
NA  
Min.  
Max. Resolution  
0
0
0
0
0
0
0
0
65535  
65535  
65535  
130  
1
1
1
Degrees Celsius  
0,5  
30006  
30007  
30008  
30009  
30010  
30011  
30012  
Cascade Total Power  
Cascade Current Power  
Outlet Setpoint 1  
Outlet Temperature 1  
Inlet Temperature 1  
Flue Temperature 1  
Firing Rate 1  
0
0
0
0
0
0
0
%
%
100  
0
0
800  
800  
130  
130  
130  
130  
100  
1
1
Degrees Celsius  
Degrees Celsius  
Degrees Celsius  
Degrees Celsius  
%
0,5  
0,1  
0,1  
0,1  
1
0
-20  
-20  
0
30014  
30015  
30016  
30017  
30018  
30019  
30020  
30021  
Boiler 1 Status Code  
Boiler 1 Blocking Code  
Boiler 1 Lockout Code  
Outlet Setpoint 2  
Outlet Temperature 2  
Inlet Temperature 2  
Flue Temperature 2  
Firing Rate 2  
0
0
0
0
0
0
0
0
NA  
NA  
NA  
0
0
0
0
0
-20  
-20  
0
65535  
65535  
65535  
130  
130  
130  
1
1
1
0,5  
0,1  
0,1  
0,1  
1
Degrees Celsius  
Degrees Celsius  
Degrees Celsius  
Degrees Celsius  
%
130  
100  
30023  
30024  
30025  
Boiler 2 Status Code  
Boiler 2 Blocking Code  
Boiler 2 Lockout Code  
0
0
0
NA  
NA  
NA  
0
0
0
65535  
65535  
65535  
1
1
1
Holding Registers  
40001  
40002  
Configuration  
Coils  
0
NA  
NA  
0
0
65535  
65535  
1
1
0
0-10 Volt Input / Rate Command /  
Setpoint Command  
40003  
0
%
0
100  
1
40004  
40005  
40006  
40007  
Tank Setpoint  
Tank Temperature  
Outdoor Temperature  
System Supply Temperature  
0
0
0
0
Degrees Celsius  
Degrees Celsius  
Degrees Celsius  
Degrees Celsius  
0
87,5  
130  
60  
0,5  
0,1  
0,1  
0,1  
-20  
-40  
-20  
130  
Configuration Bits  
Address 40001 contains configuration bits sent from the BAS to the boiler. These bits tell the boiler to use its own internal inputs,  
or inputs from the BAS. When a bit is set to 1, the boiler will ignore the corresponding value contained internally, and expect the  
BAS to write that value into the Holding Registers. The configuration bits are as follows:  
Bit 0 (LSB): Boiler Enable  
Bit 1: Tank Thermostat  
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)  
8
Modbus Instructions  
4 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. This is required in order to prevent unwanted fluctuations 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 Specification = 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.  
Figure 4-1_Terminal Strip Connections  
MOD BUS  
CASCADE  
9
Modbus Instructions  
4 Wiring Requirements  
Figure 4-2_Control Inputs  
SECONDARY  
SMART TOUCH  
LOW VOLTAGE  
CONNECTION  
BOARD  
CONTROL MODULE  
PRIMARY  
SMART TOUCH  
CONTROL MODULE  
SEQUENCER / BUILDING  
MANAGEMENT SYSTEM  
OUTDOOR SENSOR  
HW TANK SENSOR  
SYSTEM SENSOR  
HEAT EXCHANGER 1 /  
HEAT EXCHANGER 2 INLET  
TEMPERATURE SENSOR  
HEAT EXCHANGER 1 /  
HEAT EXCHANGER 2 OUTLET  
TEMPERATURE SENSOR  
FLOW SWITCH  
BLOCKED DRAIN SWITCH  
HEAT EXCHANGER 1 /  
HEAT EXCHANGER 2 FLUE GAS SENSOR  
HW THERMOSTAT  
ROOM THERMOSTAT /  
ZONE CONTROL  
LOW WATER CUTOFF  
TOUCH PANEL  
GAS PRESSURE SWITCH  
INTERFACE  
TOUCH DISPLAY  
HEAT EXCHANGER 1 /  
HEAT EXCHANGER 2 HIGH LIMIT SENSOR  
FLAME SENSOR  
MODBUS COMMUNICATION  
BOARD  
PC INTERFACE  
10  
Modbus Instructions  
4 Wiring Requirements  
(continued)  
Figure 4-3_Control Outputs  
SECONDARY  
SMART TOUCH  
LOW VOLTAGE  
CONNECTION  
BOARD  
CONTROL MODULE  
PRIMARY  
SMART TOUCH  
CONTROL MODULE  
ALARM BELL  
RUN TIME CONTACTS  
HEAT EXCHANGER 1 /  
HEAT EXCHANGER 2  
BOILER PUMP  
SEQUENCER / BUILDING  
MANAGEMENT SYSTEM  
SYSTEM PUMP  
TOUCH PANEL  
HW PUMP  
IGNITOR  
TOUCH DISPLAY  
INTERFACE  
PC INTERFACE  
BLOWER  
GAS VALVE  
11  
Modbus Instructions  
4 Wiring Requirements  
Figure 4-4_Control Location  
CONTROLLER 2  
CONTROLLER 1  
MODBUS  
COMMUNICATION  
BOARD (MTR01)  
HEAT EXCHANGER 1  
HEAT EXCHANGER 2  
Typical Boiler System Wiring  
Physical Configuration: Cascade without Individual Monitoring  
Modbus RS485 Port on Gateway or Building System  
Modbus RS485 Communication Bus  
Cascade Daisy Chain Connection  
12  
Modbus Instructions  
4 Wiring Requirements  
(continued)  
Physical Configuration: Cascade with individual Monitoring  
Modbus RS485 Port on Gateway or Building System  
Modbus RS485 Communication Bus  
Cascade Daisy Chain Connection  
Physical Configuration: Direct Control  
Modbus RS485 Port on Gateway or Building System  
Modbus RS485 Communication Bus  
13  
Modbus Instructions  
5 Unit Operation  
Unit Operation with Modbus Communications  
To control a SYNC boiler through a Building Management System communicating through Modbus, the SYNC Demand  
Configuration must be set to a value of 4, 5, or 6. These configurations allow different control points for a variety of applications.  
The configuration can be set by selecting Main>>Setup>>Service/Setup>>Demand Config.  
Figure 5-1_Setup Screen  
The SYNC boiler is equipped with a Modbus communication timer. This timer is programmable from 0 - 120 seconds. The timer  
can be programmed from the Modbus Setup Menu by selecting Main>>Setup>>BMS>>Modbus Timeout. The purpose of the  
timer is to ensure proper temperature data is communicated to the boiler in a timely manner. Additionally, it will provide for fail  
safe operation should Modbus communication be lost. This timer will cause the unit to revert back to internal unit controls  
should the Modbus communication be interrupted longer than the Modbus timer. The timer is reset every time a Modbus write  
command is received with updated temperatures or commands. It is the recommendation of Lochinvar that this timer be set to  
the shortest value possible.  
When controlling a SYNC boiler through a Building Automation System (BAS), it is very important to ensure that the correct  
configuration bits are sent to holding register 40001, and that the correct data and enable signals are sent to holding registers  
40002 - 40007, per the demand configuration.  
Demand Configuration 4  
In this configuration the unit is controlled by setting the setpoints locally on the boiler and providing an enable signal through  
Modbus 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. These signals will be sent to the unit via Modbus.  
The holding registers will need to be set as follows:  
Holding Registers  
Definition  
Configuration  
Coils  
Bit Value (HEX)  
Action  
40001  
00 01  
Set Configuration to read 40002  
40002  
00 01  
Enables unit (00 00 disables unit)  
NOTE: To ensure proper operation re-send the configuration bits to holding register 40001 prior to issuing a command.  
14  
Modbus Instructions  
5 Unit Operation  
(continued)  
Demand Configuration 5  
In this configuration the unit is controlled by providing an enable signal and a rate command through Modbus communications.  
The rate command will be 0 - 100% of modulation.  
All sensors and limiting devices should be hardwired to the terminal strip on the back of the unit excluding the thermostat enable  
and tank thermostat enable signal. These signals will be sent to the unit via Modbus.  
The holding registers will need to be set as follows:  
Holding Registers  
Definition  
Configuration  
Coils  
Bit Value (HEX)  
Action  
40001  
40002  
40003  
00 05  
00 01  
00 ##  
Set Configuration to read 40002 & 3  
Enables unit (00 00 disables unit)  
Sets Modulation % or Setpoint  
Rate Command  
NOTE: To ensure proper operation re-send the configuration bits to holding register 40001 prior to issuing a command.  
For proper hexadecimal conversion of rate percentage, please refer to the Rate and Temperature Conversion section on page 17  
of this manual.  
Demand Configuration 6  
In this configuration the unit is controlled by setting the modulation setpoint from 0 - 100%.  
Rate command will be 0 - 100% of the modulation range.  
All sensors and limiting devices should be hardwired to the terminal strip on the back of the unit excluding the 0 - 10Vdc signal.  
This signal will be sent to the unit via Modbus.  
The holding registers will need to be set as follows:  
Holding Registers  
Definition  
Configuration  
Rate Command  
Bit Value (HEX)  
Action  
Set Configuration to read 40003  
Sets Modulation %  
40001  
00 04  
40003  
00 00  
NOTE: To ensure proper operation re-send the configuration bits to holding register 40001 prior to issuing a command.  
For proper hexadecimal conversion of rate percentage, please refer to the Rate and Temperature Conversion section on page 17  
of this manual.  
Hot Water Generation  
Hot water generation can be accomplished with one of two methods when a SYNC boiler is connected to a BAS system, DHW  
with direct control, and DHW with remote control.  
DHW with direct control:  
This is the typical installation with a hot water generator in close proximity to the boiler with the tank thermostat, or tank  
temperature sensor, wired to the terminal strip of the unit.  
15  
Modbus Instructions  
5 Unit Operation  
DHW with remote control:  
This installation may or may not have the hot water generator in close proximity to the boiler. Its sensors and thermostat values  
are only available through the Modbus communication bus.  
To ensure that the SYNC boiler can properly respond to a call for hot water generation the following holding registers must be  
set in addition to other commands:  
Holding Registers  
Definition  
Configuration  
Coils  
Bit Value (HEX)  
Action  
40001  
40002  
40004  
40005  
00 4A  
00 08  
0# ##  
0# ##  
Set Configuration to read 40002, 4 & 5  
Enables Tank Tstat (00 00 disables unit)  
Sets Setpoint  
Tank Setpoint  
Tank Temperature  
Passes tank temp from remote sensor  
NOTE: To ensure proper operation re-send the configuration bits to holding register 40001 prior to issuing a command.  
For proper hexadecimal conversion of rate percentage, please refer to the Rate and Temperature Conversion section on page 17  
of this manual.  
Cascade  
In order to operate the SYNC boiler in Cascade with Modbus Monitoring Only  
communications, configure the leader boiler per the demand  
Any SYNC boiler can be equipped with the Modbus  
configurations in this manual. Connect the remaining boilers  
communication board and then be set up to operate with its  
in the cascade through the normal cascade communications  
own internal controls. If necessary, Modbus can be configured  
wiring. Cascade control can then be accomplished  
as a monitoring device by selecting demand configurations 1 -  
automatically through the leader boiler.  
3, and polling the Modbus board for the read only variables.  
Please note that with Modbus communication connected to  
only the leader boiler, 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 communication board. However,  
each unit can be monitored without the need to control each  
one individually.  
16  
Modbus Instructions  
5 Unit Operation  
(continued)  
For Example:  
Rate and Temperature Conversions:  
Send a setpoint of 110°F.  
Rate  
The formula to use for the interpolation is:  
Rate Command =  
When issuing a rate command the rate can be communicated  
as percent modulation or a desired setpoint, depending on the  
setting of the BMS Type in the BMS Setup Menu.  
(Desired Setpoint – BMS Temp at Low Analog Input) (High  
Voltage-Low Voltage) + Low Voltage  
The proper data format for the modulation percentage is the  
direct conversion to hexadecimal. This conversion can be  
accomplished through online number based converters or  
some scientific calculators.  
(BMS Temp at High Analog Input – BMS Temp at Low  
Analog Input)  
From the default values:  
For Example:  
Desired Setpoint = 110  
BMS Temp at Low Analog Input =68  
BMS Temp at High Analog=158  
High Voltage =10  
Rate % HEX  
0
20  
45  
60  
80  
95  
100  
00  
14  
2D  
3C  
50  
5F  
64  
Low Voltage = 2  
[(110-69.8)(10-2)/(179.6-69.8)] + 2 = 4.92 Volts  
(4.92/10) x 100 = 49.2  
49 = 31 Hexadecimal  
A value of [00][31] in hexadecimal would be written to Holding  
register 40003 to issue a command for a 110°F setpoint.  
To send a desired setpoint, the hexadecimal value must be  
determined through linear interpolation of programmable  
parameters on the BMS Setup Menu:  
Temperature  
The SYNC boiler passes temperature data in degrees Celsius.  
Also, to accommodate decimal places the decimal value must be  
divided by 10.  
- BMS temperature set-point at low analog input  
- BMS temperature set-point at high analog input  
These variables set the temperature values corresponding to  
the minimum and maximum voltage settings of the 0-10 volt  
signal. The defaults are as follows:  
Here are the conversions to and from Celsius:  
c
f
f
c
T = (5/9) * (T -32)  
T = (9/5) * T +32  
Example:  
DEFAULT  
DEFAULT  
Outdoor temperature from remote sensor on BAS System = 80°F  
VALUES  
PARAMETER  
80°F = 26.7°C  
Deg C Deg F Voltages  
Data that needs to be transmitted is 26.7 * 10 = 267  
BMS temperature setpoint at  
low analog input  
21  
69.8  
2
Decimal  
Binary  
HEX  
10B  
267  
100001011  
BMS temperature setpoint at  
high analog input  
82  
179.6  
10  
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  
1010101011  
HEX  
2AB  
683  
17  
Modbus Instructions  
6 Troubleshooting  
Should you encounter problems communicating over  
Modbus, the following items should be checked in this order:  
Status Codes (Input Registers 30014 and 30023)  
2 = Heat Demand blocked due to high absolute outlet  
temperature  
1. Physical Layer  
2. Communications Configuration and Port Settings  
3. Modbus Error Codes  
3 = Heat Demand blocked due to high absolute flue  
temperature  
4. Unit Status / Blocking / Lockout Codes  
4 = Heat Demand blocked due to high absolute Delta T  
(Outlet - Inlet)  
Physical Layer  
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  
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  
19 = DHW function Storage Tank  
21 = SH function Heat demand from Room Thermostat  
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 (after pump delay)  
40 = Lockout  
Communications  
1. Check Dip Switch Configuration of MTR-01 Board  
2. Check Baud Rate (9600, 19200)  
3. Check Parity  
4. Check Slave ID  
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  
5. Check Port Setting on Master, Gateway, and Computers  
Modbus Error Codes  
1. Check Modbus communication for error codes (see page  
6 for Modbus Exception Codes)  
2. Check Modbus PDU  
Blocking Codes (Input Registers 30015 and 30024)  
3. Check Slave ID  
4. Check Modbus Command  
0 = No blocking _> is divided into sub blockings  
1 = SH blocking  
5. Check Configuration bits for Holding Register 40001  
6. Check Commands and data for Holding Registers  
40002 - 40007  
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  
Unit Status Codes  
See Codes in this section  
8 = Blocking due to High Flue Temperature  
9 = Blocking due to High Outlet Temperature  
10 = Service blocking  
12 = DHW blocking high outlet temperature (DHW configured  
as storage tank)  
Boiler Status  
The SYNC boiler displays a boiler state code on the Building  
Screen to help aid in troubleshooting. The boiler state  
indicates what the boiler is actually doing. This state should  
be compared to the command issued and what is expected. If  
the boiler state does not agree with the command issued,  
check communication and configuration.  
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 flame current  
18 = Limit max fan speed due to high Delta T  
19 = Limit max fan speed due to high flue temp  
32767 = Code not present  
18  
Modbus Instructions  
6 Troubleshooting  
(continued)  
1. Turn OFF the main electrical power to the appliance.  
2. Turn OFF the main manual gas shutoff to the appliance.  
Lockout Codes (Input Registers 30016 and 30025)  
161 = EEPROM code Parameters not Re-Programmed by  
Lochinvar  
3. Unplug the three (3) wire harnesses on the MTR01 control  
board (see FIG. 6-1).  
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  
4. Unscrew the four (4) mounting nuts on the MTR01 control  
board and set aside. Remove the MTR01 control board (see  
FIG. 6-2).  
5. Replace / install the new MTR01 control board.  
177 = Sensor 3 short (Flue Sensor)  
178 = Sensor 3 open (Flue Sensor)  
179 = Sensor 2 short (Inlet Sensor)  
6. Replace the four (4) mounting nuts removed in Step 4.  
7. Reconnect all three (3) wire harnesses unplugged in Step 3.  
180 = Sensor 2 open (Inlet Sensor)  
8. Turn on the main electrical power and the main manual gas  
shutoff to the appliance.  
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  
9. Configure the MTR01 control board and unit controls per  
this manual and resume operation.  
Figure 6-2_Control Panel w/MTR01 Control Board  
229 = EEPROM code Watch Dog  
230 = EEPROM code fan low (should be high)  
231 = EEPROM code fan high (should be low)  
232 = EEPROM code no flame when running  
233 = EEPROM code no flame after ignition  
234 = EEPROM code simultaneous output APS and Fan  
235 = EEPROM code APS active not Closed  
236 = EEPROM code APS active not Open  
237 = EEPROM code flame out of sequence  
239 = EEPROM code when gas valve relay test fails  
240 = EEPROM code MRHL  
UNSCREW THE FOUR (4)  
MOUNTING NUTS ON THE MODBUS  
CONTROL BOARD (MTR01) AND SET  
ASIDE TO SECURE THE  
32767 = Code not present  
NEW MTR01 CONTROL BOARD  
TO THE CONTROL PANEL  
Installation / Replacement Procedure  
Figure 6-1_MTR01 Control Board  
1
UNPLUG THREE (3) WIRE HARNESSES  
2
3
19  
Modbus Instructions  
7 Diagrams  
Figure 7-1 Ladder Diagram_Part 1  
BOX DEPICTS  
OPTIONAL ITEMS  
LOW VOLTAGE  
120 VAC  
HIGH VOLTAGE  
CONTROL  
MODULE 1  
CONTROL  
MODULE 2  
LOUVER  
RELAY 1  
X8  
X6-8  
X5-7  
X5-4  
X8  
X5-7  
X5-4  
24V  
24V  
LOUVER  
RELAY 2  
FLAP  
VALVE  
AIR PRESSURE  
SWITCH  
FLAP  
VALVE  
AIR PRESSURE  
SWITCH  
X5-14  
X5-14  
HI-LIMIT  
HI-LIMIT  
X6-8  
X5-8  
INLET  
SENSOR  
INLET  
SENSOR  
X5-8  
X5-1  
X5-1  
OUTLET  
SENSOR  
OUTLET  
SENSOR  
X5-9  
X5-2  
X5-9  
X5-2  
FLUE  
SENSOR  
FLUE  
SENSOR  
X5-3  
X5-3  
BLOCKED  
DRAIN  
AUTO RESET  
HIGH LIMIT  
AUTO RESET  
HIGH LIMIT  
X5-10  
X5-10  
GAS VALVE  
GAS VALVE  
X2-2  
X2-1  
X2-2  
X2-1  
GAS VALVE  
RELAY  
GAS VALVE  
RELAY  
BLOWER  
1
2
4
5
X5-5  
BLOWER  
1
2
4
5
X5-5  
X5-13  
X5-6  
X5-13  
X5-6  
X5-12  
X5-12  
TR1  
TR1  
X1-7  
X1-7  
FLAME ROD  
FLAME ROD  
SPARK  
ROD  
SPARK  
ROD  
CAUTION HIGH VOLTAGE SPARK LEAD  
CAUTION HIGH VOLTAGE SPARK LEAD  
4
CONTROL  
MODULE 1  
CONTROL  
MODULE 2  
CONNECTION BOARD  
CN3  
X4-3  
CN4-3  
X4  
X4-3  
X4-1  
X4-2  
X4  
CN3-16  
CN3-15  
CN3-14  
CN3-13  
SHIELD  
CN4-1  
CN4-2  
CN4-4  
CN4-6  
X4-1  
X4-2  
X4-4  
X4-6  
CASCADE  
RS485  
X4-4  
SHIELD  
CN3-12  
CN3-11  
CN3-10  
CN3-9  
TANK  
SENSOR  
CN4-5  
X4-5  
X4-8  
X4-7  
X4-9  
OUTDOOR  
SENSOR  
CN4-8  
CN4-7  
CN4-9  
CN3-8  
SYSTEM  
SENSOR  
CN3-7  
CN3-6  
CN3-5  
CN3-4  
CN3-3  
CN3-2  
CN3-1  
-
EXTERNAL  
CONTROL  
CN4-10  
10VDC  
X4-10  
+
SHIELD  
MOD BUS  
RS485  
SHIELD  
MOD BUS  
KIT  
NOTES:  
1. Where possible, switches are shown without utilities (gas, water or  
LADDER DIAGRAM  
LBL20058 REV E  
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.  
20  
Modbus Instructions  
7 Diagrams  
(continued)  
Figure 7-2 Ladder Diagram_Part 2  
BOX DEPICTS  
OPTIONAL ITEMS  
LOW VOLTAGE  
120 VAC  
JUNCTION BOX  
120VAC  
NEUTRAL  
GROUND  
HIGH VOLTAGE  
TERMINAL STRIP  
120V SUPPLY "L"  
TERMINAL STRIP  
120V SUPPLY "N"  
JUNCTION BOX  
SYSTEM  
PUMP  
CONTACTS  
L1  
N / L2  
CONTROL MODULE 1  
ON / OFF  
SWITCH  
SYSTEM PUMP  
RELAY  
F5  
5A  
X1-2  
SYSTEM  
PUMP  
HEX 1  
BOILER  
PUMP  
SYSTEM PUMP  
RELAY  
X1-6  
X1-8  
CONTACTS  
HEX 1  
BOILER PUMP  
RELAY  
X1-4  
X1-3  
BOILER  
PUMP  
HEX 2  
BOILER  
PUMP  
BOILER PUMP  
RELAY  
CONTACTS  
DHW PUMP  
JUNCTION BOX  
RELAY  
(FIELD SUPPLIED)  
JUNCTION  
BOX  
LOUVER  
CONTACTS  
BOILER  
PUMP  
DHW PUMP  
RELAY  
BLOWER  
F4  
1
2
X1-1  
3.5A  
DHW  
BLOWER  
RELAY  
PUMP  
3
DHW  
PUMP  
CONTACTS  
F3  
1.25A  
(FIELD SUPPLIED)  
X1-5  
X6-8  
120 VAC  
F2  
X5-7  
DHW  
LWCO  
24 VAC  
X6-7  
X6-2  
3.5A  
PUMP  
J3-2  
X6-3  
CONTROL  
MODULE 1  
X6-5  
LOW GAS  
PRESSURE  
SWITCH  
HIGH GAS  
PRESSURE  
SWITCH 1  
CONTROL MODULE 2  
F5  
ON / OFF  
SWITCH  
CONTROL  
MODULE 2  
X6-5  
X1-2  
HIGH GAS  
PRESSURE  
SWITCH 2  
5A  
SYSTEM PUMP  
RELAY  
X1-6  
X1-8  
HEX 2  
BOILER PUMP  
RELAY  
X1-4  
X1-3  
BOILER PUMP  
RELAY  
JUNCTION  
BOX  
DHW PUMP  
RELAY  
BLOWER  
F4  
1
2
X1-1  
X6-8  
CONTROL  
MODULE 1  
3.5A  
BLOWER  
RELAY  
3
F3  
1.25A  
120 VAC  
F2  
X5-7  
X6-10  
X6-9  
24 VAC  
X6-7  
X6-2  
3.5A  
X6-1  
X6-6  
X3-2  
X3-4  
X3-1  
X3-3  
CONNECTION  
BOARD  
CONNECTION  
BOARD  
6
5
CN1-4  
CONTROL  
MODULE 2  
CN1-6  
LOUVER  
PROVING  
CN1-12  
10  
9
CN1-13  
CN1-5  
HEX 1  
FLOW  
SWITCH  
8
7
CN1-6  
CN1-3  
X6-10  
X6-9  
HEX 2  
FLOW SWITCH  
12  
11  
13  
HW  
THERMOSTAT  
14  
4
X3-2  
X3-4  
CN1-11  
CN1-15  
ENABLE  
X3-1  
X3-3  
RUN TIME  
CONTACTS  
3
1
NOTES:  
CN1-10  
CN1-7  
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.  
LWCO  
J3-5  
J3-6  
J3-4  
2. See wiring diagram for additional notes.  
ALARM  
CONTACTS  
2
CN1-8  
J3-3  
TEST SWITCH  
PROBE  
LADDER DIAGRAM  
LBL20046 REV D  
21  
Modbus Instructions  
7 Diagrams  
Figure 7-3 Wiring Diagram  
LOW VOLTAGE  
120 VAC  
HIGH VOLTAGE  
X3  
X5  
BOX DEPICTS  
OPTIONAL ITEMS  
CM 1 PC INTERFACE  
JUNCTION  
BOX  
LOUVER  
CONTROL  
MODULE 1  
CONTACTS  
R2  
R1  
LOUVER  
RELAY  
PC INTERFACE  
X8  
BOARD  
BR  
PR  
X1-4  
HEX 1  
BOILER  
PUMP  
K1  
K2  
K3  
CONNECTION BOARD  
PR  
BR  
BR  
CM 2 PC  
CN3  
PR  
X1-2  
CN3-16  
INTERFACE  
SHIELD  
SYSTEM  
PUMP  
CN4  
CN3-15  
CASCADE  
RS485  
X4  
OR  
OR  
CN3-14  
CN3-13  
CN3-12  
CN3-11  
CN3-10  
HEX 2  
SYSTEM  
PUMP  
SHIELD  
Y
X1-3  
TANK  
SENSOR  
HW PUMP  
RELAY  
GND  
GND  
ON/OFF SWITCH  
BK  
W
X1-6  
X1-5  
L
OUTDOOR  
SENSOR  
120V SUPPLY  
GND  
CN3-9  
CN3-8  
N
GND  
SYSTEM  
SENSOR  
GR  
X1-8  
X1-1  
CN3-7  
CN3-6  
CN3-5  
R
W
G
-
4
CONDUCTORS  
EXTERNAL  
CONTROL  
10VDC  
1
2
3
+
CN1  
BLOWER  
CN3-4  
SHIELD  
1
2
3
4
5
CN3-3  
LOUVER  
RELAY 1  
CN1-10  
MOD BUS  
RS485  
CN3-2  
CN1-2  
MOD BUS  
KIT  
R
X5-5  
X5-13  
CN3-1  
CN1-9  
T
SHIELD  
FLAP  
VALVE  
APS  
W
X5-6  
X5-12  
X5-4  
X5-10  
BK  
OR  
PK  
X6-2  
X6-7  
GY  
BL  
AUTO RESET LIMIT  
HI-LIMIT  
GY  
GY  
CN1-11  
CN2-14  
X6-6  
PR  
PR  
ENABLE  
X5-7  
X5-14  
CN2-13  
W
W
X6-1  
CN1-3  
TANK  
THERMOSTAT  
CN2-12  
X5-3  
X5-8  
PK  
CN1-4  
BK  
RD  
INLET  
SENSOR  
CN2-11  
T
BR  
MODULE 2  
FLOW  
SWITCH  
CN1-5  
CN2-10  
CN1-6  
T
X5-1  
X5-2  
X6-9  
X6-5  
OUTLET  
SENSOR  
OR  
CN2-9  
CN1-13  
W
Y
FLUE  
SENSOR  
MODULE  
1
OR/BK  
CN2-8  
X5-9  
X6-8  
FLOW  
CN1-14  
X6-10  
SWITCH  
PK  
RD  
CN2-7  
CN1-12  
LOUVER  
PROVING  
CN2-6  
CN1-15  
PR  
RD  
BK  
Y
X3-2  
X3-4  
X2-2  
X2-1  
GAS  
VALVE  
RD  
CN2-5  
CN2-4  
CN2-3  
CN2-2  
CN2-1  
CN1-16  
RUNTIME  
CONTACTS  
PR  
PR  
CN1-8  
CN1-7  
G
SPARK  
ROD  
PR  
RD  
X3-1  
X3-3  
ALARM  
CONTACTS  
W/RD  
CN1-1  
X1-7  
FLAME ROD  
CN2  
BLOCKED  
DRAIN  
CAUTION HIGH VOLTAGE SPARK LEAD  
CONTROL  
MODULE 2  
X8  
PR  
BR  
X1-2  
X1-4  
GY  
X1-3  
X4  
W
X1-5  
X1-6  
LOW GAS  
HIGH GAS  
BK  
PRESSURE SWITCH  
PRESSURE  
1
GR  
RD  
X1-8  
X1-1  
R
W
G
1
2
3
HIGH GAS  
PRESSURE  
BLOWER  
2
1
2
3
4
5
X6-5  
LOUVER  
RELAY 2  
RD  
T/BK  
W
X5-5  
X5-13  
T
X6-9  
X5-6  
X5-12  
FLAP VALVE  
OR/BK  
APS  
TEST  
SWITCH  
OR/BK  
X6-10  
BK  
LOW  
J3-1  
J3-2  
J3-3  
J3-4  
J3-5  
J3-6  
OR/BK  
GR/BK  
PROBE  
WATER  
CUTOFF  
BOARD  
BK  
X5-4  
X5-10  
AUTO RESET LIMIT  
HI-LIMIT  
BL  
BL/BK  
PR/BK  
X5-7  
RESET  
X5-14  
J2-1  
J2-2  
J2-3  
OR  
PK  
X5-3  
X5-8  
BK/RD  
INLET  
SENSOR  
RD/BK  
W/BK  
X5-1  
OUTLET  
SENSOR  
X5-2  
X5-9  
FLUE  
SENSOR  
Y/BK  
X6-8  
PR  
BK  
Y
X3-2  
X3-4  
X2-2  
X2-1  
GAS  
VALVE  
RD  
PR  
X3-1  
X3-3  
G
SPARK  
ROD  
RD  
X1-7  
FLAME ROD  
RD/W  
CAUTION HIGH VOLTAGE SPARK LEAD  
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.  
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a  
Notes:  
minimum of 105°C. Exceptions: Replacement 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 which 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.  
WIRING DIAGRAM  
LBL20045 REV F  
22  
Notes  
23  
Revision Notes: Revision A (ECO #C04560) initial release.  
SYNC-MODB Rev A  
10/09  

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