Raypak Network Card B6000 User Guide

CATALOG NO.: 5000.59B  
Effective Date: 4-09-08  
Replaces:  
3-15-99  
Installation and Operating Manual  
T-3  
Raypak B6000 Modbus  
System Protocol Interface  
T-3 Communications Interface  
Raypak B6000 Boiler Controller  
to Modbus Interface Card  
P/N 240729 Rev. 3  
 
T-3 (Raypak B6000 System Protocol Interface)  
Quantity  
Contents  
COMPACT DISC (CD)  
1
1
1
T-3  
EPROM (CPX.XNMn) in small black ESD box  
Check packaging for damage or missing components.  
IMPORTANT NOTICE: These instructions are intended for the use by qualified personnel only,  
specifically trained and experienced in the installation of this type of equipment and related sys-  
tem components. Installation and service personnel may be required by some states to be  
licensed. If your state is such, be sure your contractor bears the appropriate license. Only quali-  
fied persons shall attempt to repair this equipment. Repair must be according to these instruc-  
tions.  
WARNING: Improper installation, adjustment, alteration, service or maintenance may damage  
the equipment, create a hazard resulting in asphyxiation, explosion, fire, electric shock, personal  
injury or property damage and will void the warranty.  
CAUTION: ONE SUPPLY SOURCE. TO REDUCE THE RISK OF ELECTRIC SHOCK,  
DISCONNECT ALL CONNECTIONS BEFORE SERVICING.  
CAUTION: RISK OF ELECTRIC SHOCK, DISCONNECT SWITCH IS REQUIRED TO DE-  
ENERGIZE THE EQUIPMENT BEFORE SERVICING.  
NOTE: Minimum 18 AWG, 105°C, stranded wire must be used for all low voltage (less than 30  
volts) external connections to the unit. Solid conductors should not be used because they can  
cause excessive tension on contact points. Install conduit as appropriate. All high voltage  
wires must be the same size (105°C, stranded wire) as the ones on the unit or larger.  
Thank you for selecting the Raypak B6000 Boiler Management System and the Raypak  
Communication Interface. It is our sincere hope that you will enjoy its power, ease of use and  
energy saving features.  
Please follow the instructions carefully to insure proper installation.  
FORWARD  
The Raypak Communication Interface is designed to allow the Communication Interface System  
to monitor and control the Raypak B6000 Boiler Management System.  
3
 
T-3 INSTALLATION AND MOUNTING  
The T-3 Module should be mounted on a permanent base not subject to vibrations, moisture or  
dust. It should be readily accessible, for serviceability.  
DIMENSIONS AND WEIGHT  
15 3/4” H  
14 LBS  
8”  
W
5 3/4” D  
MECHANICAL INSTALLATION  
Mount the System Protocol Interface within five (5) feet of B6000 System Control Box.  
The Gateway enclosure must be mounted vertically with conduit holes facing downward. Conduit  
holes are provided to accommodate standard conduit fittings. Additional or larger conduit fit-  
tings that may be required should be located on the bottom of the module. Mount the Interface  
with 3/8” or 1/4” hardware in four (4) places.  
A Minimum of six (6) inches clearance on all sides is required and a minimum of eighteen (18)  
inches clearance from the front is required for service access. The hinged side of the box is to  
the right and the clearance (minimum 3” from bolt hole on the right side) should be sufficient to  
open the cover.  
A sub-panel containing the disconnect switches and surge suppressors is required at or near the  
equipment location(s).  
For accessibility remove the lower interior panel, by removing the four (4) access screws.  
INSTALL CONDUIT AS APPROPRIATE.  
ELECTRICAL CHARACTERISTICS  
120 VAC, 0.25A, 60 Hz  
ELECTRICAL INSTALLATION  
120 VAC FEEDER CIRCUITS  
Install a surge protection device sized appropriately for your installation.  
Install separate disconnect means for each load. Pull in appropriately sized wire for equipment  
as defined by NEC and/or local code.  
It is strongly recommended that the Communications Interface, B6000 System Control Module  
and the B6000 Boiler Control Module be supplied from the same source power.  
4
 
WIRING T-3  
1. Turn off power to the B6000 System Control Box.  
2. Open front door of System Protocol Interface Gateway Enclosure.  
3. Remove four screws and the lower cover, revealing the field wiring blocks.  
4. Attach wires from interface card to the field wiring side of left terminal block (N+, N-,  
GND, NC). Refer to diagram in this user manual.  
5. Open front door of the B6000 System Control Box.  
6. Remove four screws and the lower cover, revealing the field wiring blocks in lower left.  
7. Run RS-485 cable (provided) to the lower left field wiring terminal in the  
B6000 System Control box. Attach wires to the upper four terminals as follows:  
BLU/WHT  
WHT/BLU  
ORG/WHT  
SHIELD  
to  
to  
to  
to  
+
-
(1)  
(2)  
COM (3)  
GND (4)  
8. The EPROM (CPX.XNMn), in small black ESD box, must be installed in  
place of the current EPROM.  
9. View the B6000 System Control Board picture on the next page. Note location of  
EPROM, U4.  
10. Remove four screws holding upper panel with display screen and keypad. Carefully  
remove upper panel and turn over exposing B6000 System Control Board, (see next  
page).  
11. Using ESD procedures carefully remove the EPROM from location U4.  
12. Again using ESD procedures carefully install the EPROM labeled CPXXNM or CPXXM  
into location U4.  
13. Re-assemble B6000 System Control Box.  
14. Turn power on to B6000 System Control Box.  
15. Connect 120 VAC (hot, Neutral, ground) to T-3 at right terminal block.  
16. Re-assemble.  
5
 
B6000 SYSTEM CONTROL BOARD  
CHECK YOUR POWER SOURCE  
AC = 108 Volts AC Minimum, 132 Volts MAX  
AB = 108 Volts AC Minimum, 132 Volts MAX  
BC = Must be less than 1.0 Volts AC  
6
 
7
 
11.0.  
T-3  
Revision 1.0  
Raypak B6000 Modbus  
Protocol Interface  
Successful application of the T-3 card requires a reasonable work-  
ing knowledge of the Raypak B6000 Boiler Control, and the applica-  
tion in which the combination is to be used. For this reason, it is  
important that those responsible for implementing the T-3 satisfy  
themselves that the T-3 and B6000 Boiler Control combination will  
meet the needs of the application.  
Please Read this Notice  
This manual is provided to assist the user. Every attempt has been  
made to ensure that the information provided is accurate and a true  
reflection of the product’s installation requirements. In order to en-  
sure a complete understanding of the operation of the T-3 with B6000  
Controller, the user should read all applicable Raypak documenta-  
tion on the operation of the B6000.  
WARNING  
The T-3 card will allow remote access to commands in the  
B6000 Controller. The User is responsible for ensuring that  
any applicable regulations concerning the remote operation  
of equipment are adhered to.  
8
 
11.1. Product Specifications  
The T-3 card is a hardware product designed to be the communications front end  
for the Raypak B6000 Boiler Control and a modbus Master Host.  
The product includes the following functionality:  
Modbus Slave Specifications  
Protocol Modes:  
RTU mode with CRC-16 error checking  
Supported Modbus Function codes:  
2
3
4
6
8
Read Input Status  
Read Multiple Data Registers  
Read Input Registers  
Preset (Write) Single Data Register  
Loopback Test (Test 0 only)  
Supports broadcast commands from host  
RS-485 electrical interface  
Raypak B6000 Interface  
RS-485 electrical interface  
Emulates Raypak Modem address and functionality  
General Specifications  
Configurations via dip switches  
SlaveAddress, Baud and Parity  
Hardware Specifications  
4” X 5” form factor  
Two male 9-pin D Shell connectors  
Communications Status lights -Active and Fault for each port  
9 to 30 VDC external power  
9
 
11.2.0  
Slave Port Functionality  
Modbus Communications  
11.2.1  
The T-3 Modbus Slave card runs the RTU version of the Modbus protocol. This capability  
allows the module to communicate data from a Raypak B6000 Boiler Control to a Modbus  
Master host, and vice-versa. The module supports both point-to-point implementation as  
well as multi-drop implementations.  
The following discusses the functional capabilities of the T-3 card.  
11.2.1.1  
Command/Reply Cycle  
Successful communications between the card and a host will always con-  
sist of the following two transactions:  
Command: Message from master giving instruction to slave.  
Reply: Response to command.  
A slave station will respond to a master issued command in several ways.  
Data Message: If the command was executed by the T-3 board, the re-  
sponse message will include the data requested, or an acknowledge-  
ment that the command was executed.  
Error Message: If the command could not be executed by the T-3  
board, for whatever reason, an error response message is transmitted to  
the master. The error response message consists of the original function  
code (ORed with 80hex) and error code.  
No Reply: If the master does not detect a reply within its time-out pe-  
riod, the master should retransmit the command, before a time out error is  
issued. If the Slave could not decode the message or an error occurred  
preventing the Slave from recognizing the message, no response will be  
issued.  
11.2.1.2  
Command Types  
The T-3 can respond to three types of commands from the master;  
read data, write data, and a diagnostic command. These are overviewed  
below:  
Read Data:  
The following type of data read commands are supported:  
Read Input Status  
Read Multiple Registers  
2
3
4
Read Input Registers  
Write Data:  
6
The Following data write command is supported:  
Single Register Write  
Diagnostics:  
8
The diagnostic command is supported:  
Loopback test - Code 0  
11.2.1.3  
Command Error Checking  
When the T-3 cannot execute a command, an error code is generated and  
returned to the master. Error codes generated at the slave will usually be  
indicative of an illegal function, an illegal address, bad data, or the inability  
to complete a transaction because of a network problem.  
10  
 
11.2.1.4  
Data Integrity  
As in all good protocols, there must exist a level of data integrity  
checking to verify, with some degree of assurance, the quality of  
the transmitted data. The Modbus protocol supports two types of  
error checking:  
RTU Mode: 16 bit cyclic redundancy check (CRC-16)  
One bit parity check  
CRC-16: When the master generates a message, a 16 bit CRC  
value is added to the end of the transmitted packet. The CRC  
value is generated using a series of the bit shifts and manipulations.  
The receiving station executes the same calculation of the data  
and verifies the transmitted CRC. Any discrepancy will cause the  
message to be disregarded.  
Parity: Parity checking can be added as an additional level of data security.  
If parity checking is selected, even or odd parity can be implemented.  
11.2.2  
Modbus Register Map  
Apredefined register map has been provided for the T-3 unit. This  
map is detailed in Appendix A.  
11  
 
Hardware Setup  
11.3.0  
11.3.1.1  
1500 Interface Card Setup  
11.3.1.1 Connecting Power to the T-3 Card  
The T-3 Card requires an external source of DC voltage. The  
DC source voltage should be between 9V and 30V. The power is  
connected to TB1, located near the two 9 pin serial port connec-  
tions.  
The connection to TB1 is as follows:  
TB1-1  
TB1-2  
9-30 VDC (+)  
Common (-)  
11.3.1.2 Dip Switch Configuration  
The T-3 card is configured primarily through two sets of dip  
switches. These switches are read initially on power up only.  
The function of the dip switches is as follows (a value of one (1)  
is registered when the a switch is in the ON position):  
SW 2  
1 2  
3
4
5
6
7
8
SW 1  
OFF Position:  
OFF Position:  
1 2  
3
4
5
6
7
8
O
F
F
O
F
F
• • • • • •  
• • • • •  
ON Position:  
ON Position:  
SW1 : Modbus Port Configuration  
Switch  
Position  
Function  
Baud Rate  
Selection  
Positions  
1
1
2
3
3
0
0
0
0
1
1
1
1
2
0
0
1
1
0
0
1
1
0
1
0
1
0
1
0
1
300  
600  
1200  
2400  
4800  
9600 -  
19200  
19200  
Factory Settings  
*
*
9600, No Parity, Address Bit 1  
4
5
Parity  
Selection  
5
0
0
1
1
4
0
1
0
1
None -  
Odd  
Even  
*
Invalid  
6
7
8
Not Used  
SW2 : Modbus Slave Address Configuration  
Switch  
Position  
Function  
Baud Rate  
Address  
Select  
Positions  
1
2
3
4
5
6
7
8
1
2
3
4
5
6
7
8
Address Bit 0 Value = 1  
Address Bit 1 Value = 2 -  
Address Bit 2 Value = 4  
Address Bit 3 Value = 8  
Address Bit 4 Value = 16  
Address Bit 5 Value = 32  
Address Bit 6 Value = 64  
Address Bit 7 Value = 128  
*
12  
 
Example Addresses = 0 to 33  
Example Addresses = 34 to 63  
8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
7
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1
5
0
0
0
0
0
0
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
0
0
4
0
0
0
0
0
0
0
0
1
1
1
0
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
3
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
2
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
Address  
Invalid  
1 *  
2
3
4
5
6
7
8
8
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
7
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
6
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5
0
0
0
0
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
4
0
0
0
0
0
0
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
1
1
1
1
1
1
1
1
3
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
0
0
0
0
1
1
1
1
2
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
0
0
1
1
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
0
1
Address  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
* Indicates Factory Setting  
13  
 
The parameters are defined as follows:  
Modbus Slave Address: Each of the separate drop offs of a Modbus  
host must have a different slave address. The slave address is  
selected by encoding the slave address in a binary form using the  
dip switches.  
11.3.1.3 T-3 Jumper Configurations  
The T-3 card has five sets of jumpers on the board. Generally, the  
default jumper positions will be adequate for most applications, with  
JP4 and JP5 being the only jumpers that should ever need to be  
reviewed. For completeness, we provide the following discussion on  
all the jumper locations:  
Jumper  
JP1  
JP2  
Description  
Hardware Reset  
Raypak Port  
Power (P2)  
Positioning  
Not Used  
1-2 Non-Isolated Power  
2-3 Isolated Power  
Default  
1-2  
JP3  
JP4  
Raypak Port  
Ground (P2)  
Modbus Port (P1)  
Termination  
Resistor  
Modbus Port (P1)  
RS-232 or  
1-2 Non-Isolated Power  
2-3 Isolated Power  
1-2 Connect 120 ohms on  
Rx lines (multidrop only)  
2-3 Disconnect 120 ohms  
1-2 RS-232 Select  
1-2  
2-3  
JP5  
2-3  
2-3 RS-422/485 Select  
RS-422/485 Select  
11.3.2 B6000 Communications  
The B6000 communications interface has been hard coded (i.e., no dip switches  
are required to configure this port) to operate at the following default conditions:  
Baud  
Parity  
Stop Bits  
9600  
None  
2
The T-3 card emulates the modem card that is normally connected to the  
B6000 Controller.  
14  
 
11.4.0  
Modbus Protocol Support  
11.4.1  
Modbus Commands  
The T-3 card supports a command subset of the Modbus Specification consisting  
primarily of the Function Codes required to read and write data. The following sections  
detail the different commands supported by the card.  
Function  
Code  
2
Address  
Command  
Read Input Status  
Slave Driver  
Range  
Comments  
Module returns binary data from the  
10001  
to “Input Status” register space.  
10331 & 10833  
3
4
6
8
Read Multiple  
Registers  
40001  
to  
40138  
The Module returns word data from  
the register space. The module will  
support up to 125 words of data in  
one command.  
Read Input Registers  
30001  
to  
30138  
The module returns data from the  
“Input register” space in the module.  
The module will support up to 125  
words of data in one command.  
Single Register Write 40001 to 40030 This is a register write command  
and allowing a host to change values in  
40133 to 40138 the B6000 unit by writing a register  
value.  
Loopback Test  
Test 0  
This is a diagnostic command which  
echoes the command sent.  
11.4.2  
Modbus Error Codes  
The T-3 card supports the following Modbus Error Codes:  
Code  
Name  
Description  
0
1
2
All OK  
Illegal Functions  
Bad Data Address  
The module is operating as desired  
An illegal function code request is being attempted  
The address, or the range of addresses, covered by  
a request from the master are not within allowed  
limits.  
3
4
Bad Data Value  
The value in the data field of the command is not  
allowed.  
Incomplete Response  
Detected  
This error indicates that an incomplete response was  
received to a master query. Often this will indicate  
that the slave device may be responding too quickly  
or that there may be excessive noise on the line.  
The module busy status code is returned when a  
write command from the master has not yet been  
completed when a second write command is received  
6
Module Busy  
15  
 
11.5.0  
Diagnostics  
Several hardware diagnostics capabilities have been implemented using the LED indicator lights on  
the front of the T-3 card. The possible conditions as indicated by the lights are:  
11.5.1 LED Indicators  
Several hardware diagnostics capabilities have been implemented using the LED indicator  
lights on the front of the module. The possible conditions as indicated by the lights are:  
Name  
Modbus (P1)  
ACTIVE  
LED  
D1  
Color  
Green  
Status  
Blinking  
Indication  
The T-3 is receiving a command  
from the Modbus Host  
Steady  
ON  
or  
OFF  
The T-3 is not detecting a valid  
command. If the master is  
transmitting, be sure all dip  
switches are set correctly and that  
the cable connection is correct.  
The T-3 is processing a B6000  
command  
Raypak (P2)  
ACTIVE  
D2  
Green  
Blinking  
Steady  
ON  
or  
OFF  
ON  
Check cable connection to verify  
polarity of terminations between  
T-3 card and B6000 (See Appen-  
dix B)  
The Modbus port has detected a  
communications error condition.  
See Section 4.2  
Modbus (P1)  
COMM  
D3  
D4  
Red  
Red  
or  
ERR  
Blinking  
OFF  
ON  
No error conditions at this time.  
The T-3 card has detected a  
communications error condition.  
No error conditions at this time.  
Raypak (P2)  
FAULT  
OFF  
Should the configuration dip switches select an invalid address or an  
invalid baud rate, the LED indicators will alternate in the on/off fashion  
on 1/2 second intervals until correct values are selected.  
16  
 
11.6.0  
ProSoft Support, Service and Warranty  
11.6.1 Technical Support  
ProSoft Technology survives on its ability to provide meaningful support to its customers.  
Should any questions or problems arise, please feel free to contact us at:  
ProSoft Technology, Inc.  
9801 Camino Media  
Suite 105  
Bakersfield, CA 93311  
(805) 664-7208  
(805) 664-7233 FAX  
Before calling for support, please prepare yourself for the call. In order to provide the best  
and quickest support possible, we will most likely ask for the following information (you  
may wish to fax it to us prior to calling):  
1. Product Serial and Version Number  
2. T-3 Configuration Information  
-
-
-
Dip Switches  
Jumpers  
Communication cabling  
11.6.2 Service and Repair  
The T-3 card is an electronic product, designed and manufactured to function under  
somewhat adverse conditions. As with any product, through age, misapplication, or any  
one of many possible problems, the card may require repair.  
The T-3 product has a one year parts and labor warranty according to the limits  
specified in the warranty. Replacement and/or returns should be directed to the distribu-  
tor or Original Equipment Manufacturer from whom the product was purchased. If you  
need to return the card for repair, it is first necessary to obtain an RMAnumber from  
ProSoft Technology. Please call the factory for this number and display the number  
prominently on the outside of the shipping carton used to return the card.  
17  
 
LIMITED WARRANTY  
T-3  
SCOPE OF WARRANTY:  
Raypak, Inc. (“Raypak”) warrants to the original owner the T-3 to be free from defects in materials and workmanship under normal  
use and service for the applicable warranty period. In accordance with the terms of this Limited Warranty, RAYPAK will furnish a  
replacement or repair, at our option, any defective part which fails in normal use and service during the applicable warranty period. The  
replacement or repair will be warranted for only the unexpired portion of the original Warranty Period.  
APPLICABLE WARRANTY PERIOD  
The effective date of warranty coverage is the date of original installation, of the Control System, by a qualified electrician or by a  
RAYPAK authorized service technician. The Applicable Warranty Period is one (1) year from the effective date.  
WARRANTY EXCLUSIONS  
This Limited Warranty does not apply:  
1. if the control system is not properly installed by a qualified technician in accordance with manufacturer’s installation instructions,  
applicable codes, ordinances and good trade practices,  
2. to damage or malfunctions resulting from failure to properly install, operate or maintain the system in accordance with the  
manufacturer’s instructions;  
3. if the rating plate’(s) or serial number(s) are altered, defaced or removed;  
4. if the System is modified in any way or used with any non-factory authorized accessories or components;  
5. to damage or failure from abuse, accident, act of nature, fire, flood, freezing or the like;  
6. to accessories, rubber or plastic parts, light bulbs or glass parts;  
7. if the System is moved from its original installation site; or if the original owner no longer owns the site or the System.  
LABORAND SHIPPING COSTS  
This Limited Warranty does not cover labor costs for service, removal or reinstallation of any part nor shipping charges to or from  
RAYPAK’S designated repair center or to or from the installation site. All such costs are your responsibility.  
HOW TO MAKEAWARRANTY CLAIM  
To make a warranty claim, promptly ship (postage prepaid) or carry the defective part to a designated RAYPAK Service Dealer or  
Service Station in the United States, supplying proof of purchase and date of purchase and date of installation and the model and serial  
numbers. If you cannot locate a dealer, contact RAYPAK’S Service Department at the address/telephone listed below. Raypak reserves  
the right at all times to inspect the claimed defect and verify warranty coverage at its factory.  
EXCLUSIVE WARRANTY - LIMITATION OF LIABILITY  
This is the only warranty given by RAYPAK. No one is authorized to make any other warranties on Raypak’s behalf. ANY IMPLIED  
WARRANTIES, INCLUDING MERCHANTABILITYOR FITNESS FORAPARTICULAR PURPOSE, SHALLNOTEXTEND BEYONDTHEAPPLI-  
CABLE WARRANTYPERIOD SPECIFIEDABOVE. RAYPAK’S SOLE LIABILITY WITH RESPECTTOANYDEFECTSHALLBEAS SETFORTH  
IN THIS LIMITED WARRANTY.ANY CLAIMS FOR INCIDENTALOR CONSEQUENTIALDAMAGES (INCLUDING DAMAGE FROM WATER  
LEAKAGE) ARE EXCLUDED. Some states do not allow limitations on how long an implied warranty lasts, or for the exclusion of incidental  
or consequential damages, so the above limitation or exclusion may not apply to you.  
THIS LIMITED WARRANTY GIVES YOU SPECIFIC LEGALRIGHTS,AND YOU MAYALSO HAVE OTHER RIGHTS WHICH VARY FROM  
STATETO STATE.  
We suggest you immediately complete the information below and retain this Limited Warranty Certificate in case warranty service is  
needed.  
RAYPAK, INC. SERVICE DEPARTMENT  
2151 Eastman Avenue, Oxnard, CA 93030  
(805) 278-5300 FAX (805) 278-5489  
The following information must be provided when you write or call:  
Original Owner  
Complete Mailing Address  
City  
Daytime Telephone Number  
State  
Zip Code Installation Site  
Model Number  
Date of Installation  
Contractor/Installater  
Serial Number  
Raypak, Inc., 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 FAX (805) 278-5489  
Litho in U.S.A.  
 
APPENDIX A  
Modbus Register Map  
A-1  
19  
 
Raypak Modbus Register Assignments  
Function Function Function  
Type  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R/W  
R
2
4
3,6  
Description  
Setpoint  
30001  
30002  
30003  
30004  
30005  
30006  
30007  
30008  
30009  
30010  
30011  
30012  
30013  
30014  
30015  
30016  
30017  
30018  
30019  
30020  
30021  
30022  
30023  
30024  
30025  
30026  
30027  
30028  
30029  
30030  
30031  
30032  
40001  
40002  
40003  
40004  
40005  
40006  
40007  
40008  
40009  
40010  
40011  
40012  
40013  
40014  
40015  
40016  
40017  
40018  
40019  
40020  
40021  
40022  
40023  
40024  
40025  
40026  
40027  
40028  
40029  
40030  
40031  
40032  
Day Setpoint (Desired water temp @70F)  
Nitesetback Night Setback (Desired water temp @ 70F)  
Ratio Out  
Throttling  
Modulating Step (%) min 5% steps  
Wait State Time (Sec)  
Outdoor Cut off Temperature (O/C)  
Control Band (degrees F Tolerance from TAR) (C/B)  
Lead Boiler Number (1 to Number of Boilers)  
Number of Boilers  
TP - Boiler Pump Delay (Min) Boiler #1  
TP - Boiler Pump Delay (Min) Boiler #2  
TP- Boiler Pump Delay (Min) Boiler #3  
TP- Boiler Pump Delay (Min) Boiler #4  
TP- Boiler Pump Delay (Min) Boiler #5  
TP- Boiler Pump Delay (Min) Boiler #6  
TP- Boiler Pump Delay (Min) Boiler #7  
TP- Boiler Pump Delay (Min) Boiler #8  
TS - Ignition Time (Sec) Boiler #1  
TS - Ignition Time (Sec) Boiler #2  
TS - Ignition Time (Sec) Boiler #3  
TS - Ignition Time (Sec) Boiler #4  
TS - Ignition Time (Sec) Boiler #5  
TS - Ignition Time (Sec) Boiler #6  
TS - Ignition Time (Sec) Boiler #7  
TS - Ignition Time (Sec) Boiler #8  
Time - Hrs  
1-200 = 0.1 - 20.0 in 0.1 increments  
Delta T of all boilers in system (Normally 20 / # boilers)  
Time - Min  
Time - DWK  
Lead Change Hours  
Bit 0 = Night Setback on  
Bit 0 = Fault Status )1=system fault)  
Bit 1 = Call Out Request (1 = Yes)  
10001  
10017  
10018  
Night Setback  
Controller LED Status  
Controller LED Status  
R
R
R
R
R
R
R
R
R
R
R
R
R
30033  
30034  
30035  
30036  
30037  
30038  
30039  
30040  
30041  
30042  
30043  
40033  
40034  
40035  
40036  
40037  
40038  
40039  
40040  
40041  
40042  
40043  
Outdoor Temperature + 35  
Water Temperature + 35  
Target Temperature (TAR)  
Valve Position (0-100%) - Boiler #1  
Valve Position (0-100%) - Boiler #2  
Valve Position (0-100%) - Boiler #3  
Valve Position (0-100%) - Boiler #4  
Valve Position (0-100%) - Boiler #5  
Valve Position (0-100%) - Boiler #6  
Valve Position (0-100%) - Boiler #7  
Valve Position (0-100%) - Boiler #8  
30044  
40044  
Boiler #1 Status Word  
Boiler Not On Line  
Boiler #1  
(0 = Normal, 1 = Alarm)  
bit  
0
R
R
R
R
R
R
10209  
10210  
10211  
10212  
10213  
10214  
1
2
3
4
Boiler Operation  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
5
A-2  
20  
 
R
R
R
R
R
10215  
10216  
10217  
10218  
10219  
6
7
8
9
High Limit  
(0 = Normal, 1 = Alarm)  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
30045  
30046  
30047  
30048  
40045  
40046  
40047  
40048  
bit Boiler #2 Status Word  
Boiler #2  
R
R
R
R
R
R
R
R
R
R
R
10225  
10226  
10227  
10228  
10229  
10230  
10231  
10232  
10233  
10234  
10235  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
bit Boiler #3 Status Word  
Boiler #3  
R
R
R
R
R
R
R
R
R
R
R
10241  
10242  
10243  
10244  
10245  
10246  
10247  
10248  
10249  
10250  
10251  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
bit Boiler #4 Status Word  
Boiler #4  
R
R
R
R
R
R
R
R
R
R
R
10257  
10258  
10259  
10260  
10261  
10262  
10263  
10264  
10265  
10266  
10267  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
bit Boiler #3 Status Word  
Boiler #5  
R
R
R
R
R
R
R
R
R
R
R
10273  
10274  
10275  
10276  
10277  
10278  
10279  
10280  
10281  
10282  
10283  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
A-3  
21  
 
30049  
30050  
30035  
40049  
40050  
40051  
bit Boiler #6 Status Word  
Boiler #6  
R
R
R
R
R
R
R
R
R
R
R
10289  
10290  
10291  
10292  
10293  
10294  
10295  
10296  
10297  
10298  
10299  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
bit Boiler #7 Status Ward  
Boiler #7  
R
R
R
R
R
R
R
R
R
R
R
10305  
10306  
10307  
10308  
10309  
10310  
10311  
10312  
10313  
10314  
10315  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
bit Boiler #3 Status Ward  
Boiler #8  
R
R
R
R
R
R
R
R
R
R
R
10321  
10322  
10323  
10324  
10325  
10326  
10327  
10328  
10329  
10330  
10331  
0
1
2
3
4
5
6
7
8
9
Boiler Not On Line  
Boiler Operation  
Low Water Cutoff  
Low Pressure Water  
Low Pressure Gas  
High Pressure Gas  
High Limit  
Thermostat - Operating aquastat (not fault) (0 = Normal, 1 = Aquastat)  
Manual Override  
Flow Switch  
(0 = Normal, 1 = Alarm)  
(0 = Firing, 1 = Ready)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
(0 = Normal, 1 = Alarm)  
10 No Pilot  
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
30052  
30053  
30054  
30055  
30056  
30057  
30058  
30059  
30060  
30061  
30062  
30063  
30064  
30065  
30066  
30067  
30068  
30069  
40052  
40053  
40054  
40055  
40056  
40057  
40058  
40059  
40060  
40061  
40062  
40063  
40064  
40065  
40066  
40067  
40068  
40069  
Setpoint  
Day Setpoint (Desired water temp @70F)  
Nitesetback Night Setback (Desired water temp @ 70F)  
Ratio Out  
Throttling  
Modulating Step (%) min 5% steps  
Wait State Time (Sec)  
Outdoor Cut off Temperature (O/C)  
Control Band (degrees F Tolerance from TAR) (C/B)  
Lead Boiler Number (1 to Number of Boilers)  
Number of Boilers  
TP - Boiler Pump Delays (Min) Boiler #1  
TP - Boiler Pump Delays (Min) Boiler #2  
TP - Boiler Pump Delays (Min) Boiler #3  
TP - Boiler Pump Delays (Min) Boiler #4  
TP - Boiler Pump Delays (Min) Boiler #5  
TP - Boiler Pump Delays (Min) Boiler #6  
TP - Boiler Pump Delays (Min) Boiler #7  
TP - Boiler Pump Delays (Min) Boiler #8  
1-200 = 0.1 - 20.0 in 0.1 increments  
Delta T of all boilers in system (Normally 20 / # boilers)  
A-4  
22  
 
R
R
R
R
R
R
R
R
R
R
R
R
R
30070  
30071  
30072  
30073  
30074  
30075  
30076  
30077  
30078  
30079  
30080  
30081  
30082  
40070  
40071  
40072  
40073  
40074  
40075  
40076  
40077  
40078  
40079  
40080  
40081  
40082  
TS - Boiler Start Times (Sec) Boiler #1  
TS - Boiler Start Times (Sec) Boiler #2  
TS - Boiler Start Times (Sec) Boiler #3  
TS - Boiler Start Times (Sec) Boiler #4  
TS - Boiler Start Times (Sec) Boiler #5  
TS - Boiler Start Times (Sec) Boiler #6  
TS - Boiler Start Times (Sec) Boiler #7  
TS - Boiler Start Times (Sec) Boiler #8  
Time - Hrs  
Time - Min  
Time - DWK  
Lead Change  
Hrs Remaining  
R
10833  
30083  
40083  
Bit 0 = Setback on (1)  
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
R
30084  
30086  
30088  
30090  
30092  
30094  
30096  
30098  
30100  
30102  
30104  
30106  
30108  
30110  
30112  
30114  
30116  
30117  
30118  
30119  
30120  
30121  
30122  
30123  
30124  
30125  
30126  
30127  
30128  
30128  
40084  
40086  
40088  
40090  
40092  
40094  
40096  
40098  
40100  
40102  
40104  
40106  
40108  
40110  
40112  
40114  
40116  
40117  
40119  
40119  
40120  
40121  
40122  
40123  
40124  
40125  
40126  
40127  
40128  
40129  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Up Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Boiler Valve Down Times (Sec)  
Spare  
#1  
#2  
#3  
#4  
#5  
#6  
#7  
#8  
#1  
#2  
#3  
#4  
#5  
#6  
#7  
#8  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
2 words per  
Spare  
Spare  
Spare  
Spare  
Spare  
Spare  
O/Cdb (Off T>=C, OnT<=OC - O/Cdb)  
KPN : Proportional. Constant Numerator (0-255)  
KPD : Proportional. Constant Denominator (0-255)  
KDN : Differential. Constant Numerator (0-255)  
KDD : Differential Constant Denominator (0-255)  
Maximum Water Temp  
Maximum Water Temp Fault  
(0 = OK, 1 = Stpt > Max Temp,  
2 = nite Stpt > Max Temp, 3 = Target > Max Temp)  
R
R
R
R/W  
R/W  
R/W  
R/W  
R/W  
30130  
30131  
30132  
30133  
30134  
30135  
30136  
30137  
40130  
40131  
40132  
40133  
40134  
40135  
40136  
40137  
Water Sensor  
Outdoor Sensor  
Spare  
(0 = OK, 1 = Open, 2 = Shorted)  
(0 = OK, 1 = Open, 2 = Shorted)  
O/Cdb ( Off T > = C, On T< = OC - O/Cdb)  
KPN : Proportional. Constant Numerator (0-255)  
KPD : Proportional. Constant Denominator (0-255)  
KDN : Differential. Constant Numerator (0-255)  
KDD : Differential. Constant Denominator (0-255)  
W
30138  
40138  
Maximum Water Temperature  
A-5  
23  
 
Raypak, Inc. 2151 Eastman Avenue, Oxnard, CA 93030 (805) 278-5300 • FAX (805) 278-5489  
Litho in U.S.A.  
24  
 

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