Bryan Boilers UCG User manual

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
i
Universal Communication
Gateway Reference Manual
The Universal Communication Gateway (UCG) is an external, high performance Building
Automation multi-protocol gateway that is preconfigured to automatically communicate
between Bryan Steam’s products (hereafter called “device”) connected to the UCG and
automatically configures them for BACnet®MS/TP, BACnet IP, Metasys®N2 by JCI,
Modbus TCP/IP or LonWorks®. All Honeywell SOLA, Siemens RWF 40/55, Siemens LMV,
Honeywell RM7800 Series and the Precision Digital Trident PD765 boiler configurations
and Node-ID’s are selected through the UCG Web GUI Configurator for fast and easy
installation. A mix of multiple devices can be used on a single UCG. It is not necessary to
download any configuration files to support the required applications. The UCG is pre-
loaded with tested Profiles/Configurations for the supported devices. This document
provides the necessary information to facilitate installation of the UCG on BACnet
MS/TP, BACnet/IP, Metasys N2 and LonWorks network.
The UCG is provided as a 10” x 12” x 6” NEMA Type 1 control panel that must be
mounted and supplied with 120 VAC. Additional specifications can be found in Section
7.
Important
1. If your boiler is equipped with a Bryan Boilers Printed Circuit Board
(WD-857), devices should be pre-wired. See section 3.1.8.
2. Each boiler device Modbus settings must be configured to
communicate to the UCG.

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
2
CONTENTS
1How To Use This Manual ...............................................................7
2Mounting UCG ..............................................................................7
2.1 Mounting ........................................................................................................................... 7
2.2 Building Management System (BMS) Wiring .................................................................... 7
2.2.1 Modbus TCP/IP and BACnet/IP................................................................................... 7
2.2.2 BACnet MS/TP and Metasys N2.................................................................................. 8
2.2.3 LonWorks Network ..................................................................................................... 8
3Connect and Setup of Boiler Devices To UCG .................................8
3.1 Wiring Devices to the UCG ................................................................................................ 8
3.1.1 Honeywell SOLA.......................................................................................................... 9
3.1.2 Siemens RWF40 .......................................................................................................... 9
3.1.3 Siemens RWF55 .......................................................................................................... 9
3.1.4 Siemens LMV2…/LMV3… ............................................................................................ 9
3.1.5 Siemens LMV5…........................................................................................................ 10
3.1.6 Honeywell RM7800 Series ........................................................................................ 10
3.1.7 Precision Digital Trident PD765 Panel Meter ........................................................... 11
3.1.8 Boilers Equipped with Bryan Steam Printed Circuit Board (WD-857) ...................... 11
3.2 Device Modbus RTU COM Settings ................................................................................. 13
3.2.1 Honeywell Sola.......................................................................................................... 13
3.2.2 Siemens RWF40 ........................................................................................................ 15
3.2.3 Siemens RWF55 ........................................................................................................ 17
3.2.4 Siemens LMV2…/LMV3… .......................................................................................... 18
3.2.5 Siemens LMV5…........................................................................................................ 19
3.2.6 Honeywell RM7800 Series ........................................................................................ 20
3.2.7 Precision Digital Trident PD765 Panel Meter ........................................................... 22
4Setup UCG...................................................................................23
4.1 Devices and Point Count Availability............................................................................... 23
4.2 UCG Protocol Setup ......................................................................................................... 23
4.2.1 Configure the DIP Switches....................................................................................... 23
4.2.2 BACnet MSTP Setup .................................................................................................. 24
4.2.3 Modbus TCP/IP Setup ............................................................................................... 25
4.2.4 BACnet/IP Setup........................................................................................................ 25
4.2.5 Metasys N2 ............................................................................................................... 26
4.2.6 LonWorks .................................................................................................................. 27
4.3 Setup UCG via Web Configurator .................................................................................... 28
4.3.1 Connect the PC to the ProtoNode via the Ethernet Port ......................................... 28
4.3.2 Configure Profiles in ProtoNode’s Web Configurator .............................................. 29
4.3.3 Set IP Address for BACnet/IP via GUI........................................................................ 32

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
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5Points Lists ..................................................................................34
5.1 Honeywell Sola Modbus RTU Mappings to BACnet, Metasys N2 and LonWorks........... 34
5.2 Seimens RWF55 Modbus RTU Mappings to BACnet, Metasys N2 and LonWorks.......... 36
5.3 Siemens LMV52 Modbus RTU Mappings to BACnet, Metasys N2 and LonWorks.......... 37
5.4 Honeywell RM7800 Modbus RTU Mappings to BACnet, Metasys N2 and LonWorks .... 38
5.5 Seimens LMV 36 Modbus RTU Mappings to BACnet, Metasys N2 and LonWorks......... 39
5.6 Precision Digital Trident PD765 Modbus RTU Mappings to BACnet, Metasys N2 and
LonWorks................................................................................................................................... 40
6Troubleshooting ..........................................................................41
6.1 LED Diagnostics for communications between the UCG and devices ............................ 42
6.2 Take Diagnostic Capture with the FieldServer Utilities................................................... 43
7Specifications ..............................................................................46
8Reference....................................................................................47
8.1 WD857 ............................................................................................................................. 47
8.2 Device RTU COM Settings................................................................................................ 47
8.3 Address DIP Switch Settings ............................................................................................ 48
8.4 Device Log........................................................................................................................ 55
9Index...........................................................................................56

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
4
FIGURES
Figure 1 - UCG Component Description.......................................................................................... 6
Figure 2 - Power Connection........................................................................................................... 7
Figure 3 - Ethernet Connection on the ProtoNode......................................................................... 7
Figure 4 - BACnet MS/TP and Metasys N2 BMS Connection.......................................................... 8
Figure 5 - LonWorks BMS connection............................................................................................. 8
Figure 6 - Honeywell S7999 Display and UCG Connection ............................................................. 9
Figure 7 - Siemens RWF40 and UCG Connection............................................................................ 9
Figure 8 - Siemens RWF55 and UCG Connection............................................................................ 9
Figure 9 - Siemens LMV2.../LMV3... and UCG Connection............................................................. 9
Figure 10 - LMV 5... And UCG Connection .................................................................................... 10
Figure 11 - Honeywell RM7800 with S7800 Keyboard Display..................................................... 10
Figure 12 - RM7800 with S7810M ModBus Module .................................................................... 10
Figure 13 - Precision Digital Trident PD765 to UCG Connection .................................................. 11
Figure 14 - Bryan Steam Communication PCB (WD-857) and Multi Boiler Connection............... 11
Figure 15 - End of Line Termination.............................................................................................. 12
Figure 16 - Siemens RWF55 Programing ...................................................................................... 17
Figure 17 - 7810M Address Switches and Baud Rate Jumper ...................................................... 20
Figure 18 – Honeywell RM7800 Display Setup Screen ................................................................. 21
Figure 19 - Modbus Activity on RM7800 ...................................................................................... 21
Figure 20 - S Bank DIP Switches.................................................................................................... 23
Figure 21 - B Bank DIP Switches.................................................................................................... 23
Figure 22 - A Bank DIP Switches (MAC Address) .......................................................................... 24
Figure 23 - A Bank DIP Switches (BACnet Address) ...................................................................... 25
Figure 24 - LonWorks Service Pin Location................................................................................... 27
Figure 25 - Sample of Fserver.XIF File Being Generated............................................................... 27
Figure 26 - ProtoNode Ethernet Port............................................................................................ 28
Figure 27 - Web Configurator Showing the Active Profiles to Select From.................................. 30
Figure 28 - Web Configurator Showing a Profile Selected ........................................................... 30
Figure 29 - Web Configurator Showing a Completed Profile Added............................................ 31
Figure 30 - Web Configurator Showing Completed Profiles Added ............................................. 31
Figure 31 - Default FS Web GUI Landing Page.............................................................................. 32
Figure 32 - Changing IP Address via FST Web GUI........................................................................ 33
Figure 33 - Diagnostic LEDs........................................................................................................... 42
Figure 34 - WD-857 Printed Circuit Board .................................................................................... 47

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
5
TABLES
Table 1 - UCG Component Description........................................................................................... 6
Table 2 - Modbus Registers........................................................................................................... 23
Table 3 - BMS Protocol Selection.................................................................................................. 23
Table 4 - Baud Rate ....................................................................................................................... 24
Table 5 Diagnostic LEDs ................................................................................................................ 42
Table 6 - Specifications ................................................................................................................. 46

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
6
Figure 1 - UCG Component Description
Item
Description
1
ProtoNode
2
UCG-PCB WD-856
3
Power Adapter 120Vac to 9 Vdc (only for Siemens AZL)
4
RJ45 Adapter (only for Siemens AZL)
5
UCG Power Switch
6
RS232 to RS485 Converter (only for Siemens AZL)
Table 1 - UCG Component Description
3
4
5
1
2
6

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
7
1HOW TO USE THIS
MANUAL
This manual may be used in its entirety or
as a reference. You may need to reference
your device’s manual for information not
covered in this UCG manual. The three
main sections are as follows:
Section 2: Mounting UCG – This section
is for mounting the UCG control panel,
connecting power and building
management connections.
Section 3: Connect and Setup for Boiler
Devices to the UCG – This section is for the
connections and set-up of each device for
the Modbus communication to the UCG.
Section 4: Setup for UCG – The section is
for the set-up of the UCG to communicate
to the devices (Modbus) and to your
building management system.
All other sections are supportive of the
sections above.
2MOUNTING UCG
2.1 MOUNTING
Mount the UCG in a suitable location that is
easy to access. Verify that the UCG power
switch is in the “off” position. Connect J1-
1(L1), J1-2(L2) and J1-3(G) of the UCG-PCB
WD-856 to a 120VAC power source.
120V
FROM
SEPARATE
POWER
SUPPLY
G
L1
L2
L2
1
2
3
Figure 2 - Power Connection
2.2 BUILDING MANAGEMENT
SYSTEM (BMS) WIRING
Building Management wiring is determined
by the protocol of the BMS.
MODBUS TCP/IP and BACnet/IP see
section 2.2.1
BACNET MS/TP and METYASYS N2
see section 2.2.2
LONWORKS see section 2.2.3
2.2.1 MODBUS TCP/IP AND
BACNET/IP
Use Cat5 cable to connect the field BMS
computer to the UCG via the Ethernet
(RJ45) connection of the ProtoNode inside
the UCG. See Figure 3. After BMS
connection, skip to section 3.
Figure 3 - Ethernet Connection on the ProtoNode

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
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2.2.2 BACNET MS/TP AND
METASYS N2
Use CAT5 twisted pair cable to connect
from the field BMS computer to terminals
J2-1(GND), J2-2(Data -), and J2-3(Data +) of
the UCG-PCB WD-856 located inside UCG.
After BMS connection, skip to section 3.
+
-
G
GND
Data -
Data +
BMS (RS 485)
3
2
1GND
Data -
Data +
UCG-PCB WD-856
J2
Figure 4 - BACnet MS/TP and Metasys N2 BMS Connection
2.2.3 LONWORKS NETWORK
Use CAT5 twisted pair cable to connect the
field BMS computer to J2-2(-) and J2-3(+) of
the UCG-PCB WD-856 located inside UCG.
After BMS connection, skip to section 3.
J2
1
1
2
3
LONWORKS BUILDING
MANAGEMENT
TWISTED
PAIR
Figure 5 - LonWorks BMS connection
3CONNECT AND
SETUP OF BOILER
DEVICES TO UCG
3.1 WIRING DEVICES TO THE
UCG
If your boiler is equipped with a Bryan
Boilers Printed Circuit Board (WD-857), see
section 3.1.8. Otherwise connect all devices
directly to the UCG-PCB WD-856 located
inside UCG. The devices on this bus can be
wired in a daisy chain configuration. The
order of the interconnection is not
important.
HONEYWELL SOLA see section 3.1.1
SIEMENS RWF40 see section 3.1.2
SIEMENS RWF55 see section 3.1.3
SIEMENS LMV2…/LMV3… see
section 3.1.4
SIEMENS LMV5…see section 3.1.5
HONEYWELL RM7800 SERIES
KEYBOARD DISPLAY OR MODBUS
MODULE see section 3.1.6
PRECISION DIGITAL TRIDENT PD765
PANEL METER see section 3.1.7

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
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3.1.1 HONEYWELL SOLA
Use shielded cable to connect the
Honeywell system display’s COM2 port to
terminals J3-1(GND), J3-2(Data -), and J3-
3(Data +) of the UCG-PCB WD-856 inside
the UCG. Up to 8 SOLA controls can be
controlled from one UCG. See Figure 6.
COM 2
S7999D1006 DISPLAY
COM 1
12345678
AB C A B C
24 VAC
(COM)
24 VAC
J3
1
2
3
UCG-PCB WD-
856
GND
DATA -
DATA +
Figure 6 - Honeywell S7999 Display and UCG Connection
3.1.2 SIEMENS RWF40
Use shielded cable to connect terminals CG,
CB, and CA of the Siemens RWF40 to
terminals J3-1(GND), J3-2(-), and J3-3(+) of
the UCG-PCB WD-856 inside the UCG. See
Figure 7.
Figure 7 - Siemens RWF40 and UCG Connection
3.1.3 SIEMENS RWF55
Use shielded cable to connect terminals R-,
and R+ of the Siemens RWF55 to terminals
J3-2(-), and J3-3(+) of the UCG-PCB WD-856
inside the UCG. See Figure 8.
Figure 8 - Siemens RWF55 and UCG Connection
3.1.4 SIEMENS LMV2…/LMV3…
Use shielded cable to connect the burner
mounted OCI412.10 RS-485 interface
terminals X20.1, X20.2, and X20.3 to
terminals J3-1(GND), J3-2(-), and J3-3(+) of
the UCG-PCB WD-856 inside the UCG.
Figure 9 - Siemens LMV2.../LMV3... and UCG Connection

Form: 2405
Universal Communication Gateway Reference Manual Date: 01-25-2019
Revision: 8
Bryan Steam LLC, 783 North Chili Avenue, Peru, IN 46970 Web: www.bryanboilers.com
Phone: [phone] Fax: [phone] E-mail: [e-mail]
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3.1.5 SIEMENS LMV5…
Use CAT5 twisted pair cable to connect
from the RJ45 jack, COM2, of the Siemens
AZL to the RJ45 jack of the UCG Serial
Comm inside the UCG. See Figure 10.
Figure 10 - LMV 5... And UCG Connection
3.1.6 HONEYWELL RM7800
SERIES
The RM7800 Series flame safeguard
requires a Modbus compatible Display
Keyboard or Modbus Module. Please see
your flame safeguard manual for details.
3.1.6.1 S7800A1142 KEYBOARD
DISPLAY MODULE
Use shielded cable to connect terminals 1,
2, and 3 of the Honeywell keyboard display
to terminals J3-1(GND), J3-2(-), and J3-3(+)
of the UCG-PCB WD-856 inside the UCG.
(The 203541 Connector may be required for
connection)
Figure 11 - Honeywell RM7800 with S7800 Keyboard Display
3.1.6.2 S7810M MODBUS™ MODULE
Use shielded cable to connect terminals
6(GND), 7(+), and 8(-) of the Honeywell
S7810M ModBus Module to terminals J3-
1(GND), J3-2(-), and J3-3(+) of the UCG-PCB
WD-856 inside the UCG.
Figure 12 - RM7800 with S7810M ModBus Module