IBC BoilerNet Interface Controller II User manual

BoilerNet Interface Controller II

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Table of Contents
Introduction........................................................................................................................................................ 1
1 Configuration.............................................................................................................................................. 1
1.1 IP Setup .............................................................................................................................................. 1
1.2 BACnet Setup...................................................................................................................................... 2
1.3 Configuring Site and Alert Data ........................................................................................................... 2
1.3.1 Configuring Site Data ................................................................................................................... 4
1.3.2 Configuring the Alert Data ............................................................................................................ 6
2 SD-Card ..................................................................................................................................................... 7
3 Installation .................................................................................................................................................. 8
3.1 Location............................................................................................................................................... 8
3.2 Power and Enclosures......................................................................................................................... 8
3.3 BoilerNet Connections......................................................................................................................... 9
3.4 Configuring the Boilers ...................................................................................................................... 10
3.5 Operation .......................................................................................................................................... 11
4 Web (HTML) Interface .............................................................................................................................. 12
4.1 User Passwords ................................................................................................................................ 15
4.2 Site Data ........................................................................................................................................... 17
4.3 Alert Data .......................................................................................................................................... 19
4.4 Site Log............................................................................................................................................. 20
4.5 System Status Display....................................................................................................................... 21
4.6 Boiler Status Display ......................................................................................................................... 23
4.7 User Settings..................................................................................................................................... 24
4.8 Setbacks ........................................................................................................................................... 25
4.9 Installer Settings................................................................................................................................ 26
4.10 Load Settings .................................................................................................................................... 28
4.11 Multi-Boiler Settings........................................................................................................................... 29
4.12 Cleaning Information ......................................................................................................................... 30
4.13 Diagnostics........................................................................................................................................ 31
4.14 Boiler Logs ........................................................................................................................................ 32
4.15 Boiler Error Logs ............................................................................................................................... 33

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4.16 Run Profile ........................................................................................................................................ 34
5 BACnet Interface ...................................................................................................................................... 35
5.1 Site Requirements............................................................................................................................. 35
5.2 BACnet Objects................................................................................................................................. 38
5.3 Multi-value Objects............................................................................................................................ 41
6 Enclosure Installation Notes ..................................................................................................................... 43
7 Troubleshooting Notes ............................................................................................................................. 44
8 Bootloader Configuration.......................................................................................................................... 45
9 Technical Specifications ........................................................................................................................... 48

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Introduction
The IBC BoilerNet Interface Controller ("BIC") provides both Web and BACnet/IP interfaces to IBC’s line of
high efficiency condensing boilers, including the VFC 15-150, VFC 45-225, SL 80-399, and others. It can
interface from 1 to 24 IBC boilers using IBC’s BoilerNet communications interface.
1 Configuration
Important: The BoilerNet Interface Controller must be configured before it is put into use on your network.
An improperly configured BIC will not function correctly, and could affect the operation of other
devices on your network.
In general, you should contact your Network Administrator for assistance with configuring the BoilerNet
Interface Controller. Proper IP and BACnet addresses must be assigned to the BIC for correct operation.
Your network administrator will also likely want to know that a new device is being put into service on your
network.
1.1 IP Setup
A static IP address is highly recommended for the BoilerNet Interface Controller. If just the BACnet/IP
interface is being used without a BBMD, then a dynamic IP address may be obtained from a DHCP server.
However, if the Web Server interface or a BBMD is being used, then a static IP address is generally
required.
Note that if the BACnet/IP interface is being used, the BIC must generally be on the same network
segment, and the IP address in the same subnet, as the other BACnet devices on the network it is
intended to be communicating with. If BACnet/IP routing to other network segments, subnets, or to the
Internet is required, then a BACnet BBMD or other such routing device must already be present and
properly configured on the network. It should be noted that a standard network router will generally not
correctly route BACnet/IP packets; a BACnet BBMD or other BACnet specific routing device is required.
While any IP address can be assigned to the BIC II, it is highly recommended that only a "local" IP
address be assigned. If access to the BIC II from the Internet is desired, using either the Web or the
BACnet interfaces, it should only be from behind a properly configured firewall and/or router. Directly
connecting the BIC II to the internet without the use of a firewall is not recommended or approved of by
IBC. Please contact your network administrator for assistance.

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1.2 BACnet Setup
A unique BACnet Device ID is required for every BACnet device on a network, including the BIC II. The
BIC II will use the standard BACnet port number of 47809 (0xBAC1) by default, though this may be
different at your site, particularly if a BACnet router or BBMD is in use.
Please contact your network administrator to obtain an IP address, BACnet Device Identifier, and the port
number for the BoilerNet Interface Controller, or any other TCP/IP or BACnet configuration assistance.
1.3 Configuring Site and Alert Data
Important:
Do not remove or insert the SD-Card from the BoilerNet Interface Controller while it is powered on.
Doing so could result in data loss, and/or corruption of the SD-Card.
The SD-Card must be writable (not "locked") while in use in the BIC II.
All system configuration data is stored in the "ibc" directory on the BIC II’s SD-Card.
Figure 1

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The site information must be entered into the "site.dat" file, and optionally the "alerts.dat" file before the
BoilerNet Interface Controller can be used. There are many text editors (WordPad®, for example) can be
used to edit these files (please note that Windows NotePad®cannot be used). A computer with an
appropriate operating system and a "SD" card slot is required. Most versions of Windows®, Linux®, or
MAC®O/S should have a text editor that can be used to edit the "site.dat" and "alerts.dat" files. The
example shown here is using Windows WordPad.
Please note that some versions of Windows, particularly XP, may not properly recognize the FAT partition
on the SD-Card. DO NOT allow Windows to format the SD-Card if a prompt to this affect appears.
Cancel the operation, and use a computer with a more current version of Windows (or another O/S) and
up-to-date drivers and service patches, that properly recognizes the SD-Card.
Important:
When editing the files:
Do not alter any characters before the "=" sign in each line.
Do not enter a "\" or any other non-standard characters into any of the fields.
Do not alter any file other than the "site.dat" file on the SD-Card.
The file name is case sensitive. Do not alter or rename it.
After saving the settings, you should use the "Safely Remove" option in your computer's operating
system (if available) before removing the SD-Card from your computer.

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1.3.1 Configuring Site Data
When you open the "site.dat" file, it should appear similar to that shown in Figure 2 below.
Figure 2
Table 1 - "site.dat" Field Description
Field
Field Name
Field Description
Max. Size
1
name
The site name
40
2
ipaddr
The IP address to be used (1)
20
3
ipmask
The subnet mask (1)
20
4
ipgate
The default gateway (1)
20
5
ipdns1
The primary DNS server (1)
20
6
ipdns2
The secondary DNS server (1)(2)
20
7
ntp
The ntp server (3)
20
8
system_log
Set to "1" to enable system logging, "0" to disable
1
9
boiler_log
Set to "1" to enable the boiler event logging, "0" to disable (4)
1
10
bacnet_id
The devices BACnet Identification number
32 bit
integer
11
bacnet_port
The BACnet port number (typically 47808)
16 bit
integer
12
web_enable
Set to "1" to enable the Web (Internet) interface, "0" to disable (5)
1
13
bacnet_enable
Set to "1" to enable the BACnet interface, "0" to disable (5)
1
14
email_enable
Set to "1" to enable E-Mail Alerts, "0" to disable (6)
1
15
reconfig
Set to "1" to save the setting to internal FLASH and then use the
new settings.
1

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(1) If a dynamic IP address is to be obtained from a DHCP server, then "ipaddr", "ipmask", "ipgate", "ipdns1", and "ipdns2"
should all be set to "0.0.0.0" (a dynamic IP address is generally not recommended).
(2) "ipdns2" is optional. Set to "0.0.0.0" if not used.
(3) If a ntp server is specified, then the BACnet Time Synchronization will not be used. To use the BACnet Time
Synchronization, the ntp server parameter should be set to "0.0.0.0". Note that the BIC will only use the first BACnet time
synchronization message it receives after it starts-up. Subsequent time-sync messages will be ignored.
(4) This feature is not implemented in V1.0 of the BoilerNet Interface Controller.
(5) Enable one or both of these options.
(6) The SMTP server information in the "alerts.dat" file must be configured before enabling this option.
Important: For the BIC II to use the new settings, you must set the "reconfig" flag to "1" before saving
the file. On start-up, the BIC II reads the "site.dat" file and checks the state of this flag. If
set, it copies these settings to its internal configuration registers, resets the flag, and then
starts the system using the new settings. Be sure to record the configuration settings, or
make a backup of the "site.dat" file if you alter it.
It will take approximately 3 to 4 minutes for the BIC II to restart when the settings have been altered.

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1.3.2 Configuring the Alert Data
The "Alert Data" contains the information for accessing a SMTP mail server, allowing E-Mail Alerts to be
sent in the event a problem with a boiler is detected. All site information is stored in the "alert.dat" file in
the "ibc" directory on the BIC’s SD-Card.
When you open the "site.dat" file, it should appear similar to that shown in Figure 4 below.
Figure 3
Table 2 - "alert.dat" Field Description
Field
Field Name
Field Description
Max. Size
1
alert_from
E-Mail "from" name
40
2
alert_to
E-Mail address the alert will be sent to
40
3
smtp_server
name or IP address of the SMTP mail server
40
4
smtp_port
SMTP server port to be used
16 bit
integer
5
smtp_authentication
SMTP sever authentication type
10
6
smtp_login
SMTP server login name
40
7
smtp_password
SMTP server password
20

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2 SD-Card
The BoilerNet Interface Controller requires a standard Secure Digital Flash Card (SD-card) for operation.
Figure 4
The BIC II can support both "standard" and "SDHC" SD-Cards. A 2GB SD-card is more than sufficient for
the BIC's operation.
IBC will typically supply a SD-Card with the BIC. Please contact IBC if a new or replacement SD-Card is
required. The SD-Card is specially formatted with both a Windows compatible partition, and a "hidden"
partition that typically cannot be accessed by a Windows based computer. Do not reformat or repartition
the SD-Card.
Important:
Do not remove or insert the SD-Card from the BoilerNet Interface Controller while it is powered on;
doing so could result in data loss, and/or corruption of the SD-Card.
The BoilerNet Interface Controller will not function, or will stop functioning, if the SD-Card is not
present or is removed.
The SD-Card must be writable (not "locked") while in use in the BIC.
A card with a speed class of 4 or higher (minimum 4MB/second write speed) is required.

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3 Installation
The BoilerNet Interface Controller requires a Network (Ethernet) cable connection to the network it is to be
connected to, a BoilerNet twisted pair connection to the boilers, and a power source.
3.1 Location
Typically the BIC II will be installed in the same room as the boilers it will be interfacing to. It can also
usually be installed in a location remote to the boiler room if required. Note that the total length of the
BoilerNet twisted pair wire is limited, and is generally shorter than the permitted length of the network
(Ethernet) cable. Therefore, it is usually better to extend the network cable to BIC II’s location instead of
extending the BoilerNet twisted pair wiring to a remote location.
Also note that the maximum length of both the BoilerNet twisted pair and the network cable will vary
depending on the environmental conditions at your site. In general, keep all cable runs as short as
possible. Also try to keep data and power cables separated.
3.2 Power and Enclosures
The BoilerNet Interface Controller II requires a power source of 5VDC at 7.5 watts minimum. This is
typically supplied from a 120VAC switching power adapter; therefore there should be a 120VAC outlet
located reasonably close the where the BIC will be located. Other power supply options, including 100 to
240VAC are available, as well as Power over Ethernet (PoE).
The standard enclosure for the BoilerNet Interface Controller is not a NEMA rated enclosure, and
therefore it needs be located in a protected area away from moisture, temperature extremes, and dust.
NEMA rated enclosures for the BIC II can be supplied by IBC if required.
Please contact IBC Technologies for additional installation options and information.

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3.3 BoilerNet Connections
The BoilerNet Interface utilizes a 2-wire CAN-bus communications interface between the boilers and the
BIC II. BoilerNet wiring needs to be performed in accordance to published standards, such as ISO 11898
or SAE J2284.
A suitable cable, compliant with standards such as ISO 11898 or SAE J2284 must be used. The wiring
must also be installed in compliance with these standards.
Cerco Cable manufactures cable suitable for CAN-bus use. Cerco AT-HOM 29 #8320, or cable with
equivalent specifications from another cable manufacturer, must be used. The general specifications for
this cable are:
24 AWG shielded twisted pair
9 twists per foot
Capacitance 12.5pF/Ft (cond./cond.)
Resistance 25.5 ohms/1000'
Full specifications and information can be found on the Cerco web site: http://www.cercocable.com.
Please contact IBC if any additional information is required.
Figure 5
On the boiler's controller board, the "Boiler Net +" is the "CANH" connection, the other terminal is "Boiler
Net –", which is the "CANL" connection. On the BIC II terminal block, the red wire is the "Boiler Net +"
(CANH) connection; the white is the "Boiler Net –" (CANL) connection.
Please note that the BIC II has a 120 ohm CAN-bus terminator built into the controller board, which cannot
be disabled. Therefore, the BIC II must be wired in as either the first or last device in the BoilerNet
communications chain. The termination jumper (JA02) needs to be removed from all the boiler controller
boards with the exception of the first or last boiler of the BoilerNet chain. Please refer to Figure 6 below
for an example diagram.

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Figure 6
Please also refer to IBC document "Tech Memo 2310081 –Multiple Boiler Systems" for additional
information.
Important: The BoilerNet (CAN-bus) interface on both the BIC II and the boiler's controller can be
damaged by static electricity and other stray voltages and currents. Proper precautions must
be used when installing and handling the communications cable and wiring. DO NOT use a
continuity tester, or any other test equipment not specifically designed for use with CAN-bus
equipment, without first disconnecting all devices connected to the CAN-bus network. All
devices must also be powered off before connecting or disconnecting devices. Failure to do
so can result in damage to the BIC II and/or the boiler's controller board, which will not be
covered under warranty.
3.4 Configuring the Boilers
All the boilers that the BoilerNet Interface Controller is to interface with, and the BIC II itself, must be
connected to the same BoilerNet (twisted-pair) network. Every boiler needs to be assigned a unique
Boiler ID. This must be performed through the user interface on the boiler.
Typically the boilers will have been setup for Multi-Boiler operation with one boiler (usually Boiler ID: 1)
designated as the master. It is possible that the boilers will be operating independently, without a boiler
being designated as a master. In this case, each boiler must still be assigned a unique Boiler ID.
Note: Boiler firmware version 3.00.0 or newer is required for operation with the BoilerNet Interface
Controller. Please contact IBC if you boiler(s) require a firmware upgrade.
For more information regarding Multi-Boiler operations, please refer to IBC document "Tech Memo
2310081 –Multiple Boiler Systems". Also please consult the boiler's User Manual for information on
setting up and configuring your boiler(s).

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3.5 Operation
The BoilerNet Interface Controller’s operation is fairly straight forward. Insert the configured SD-Card into
the BIC II's SD slot, ensure the BoilerNet cables are connected, and if not using PoE, that the Ethernet
cable is connected. Then apply the power by connecting either the external 5VDC power supply, or if
using PoE, connect the Ethernet cable. You should see a green "power" light on the BIC II, as well as
activity on the network connector.
Important: Connect only one of the power sources to the BIC II. DO NOT use both the external 5VDC
power supply and PoE simultaneously; doing so may result in damage to the BIC II and/or
the power supplies.
If this is the first power-up of the BIC II for a new installation, then all the boilers that the
BIC II will be interfacing with need to be powered up and properly configured with a Boiler ID
before the BIC II is powered on. If a new boiler is ever added to the system, the BIC II will
need to be restarted before it will see the new boiler.
Note that it takes approximately 2 minutes for the BoilerNet Interface Controller II to initialize before the
BACnet or web interfaces will be available. For a first time start-up, or if Network and/or BACnet settings
have been changed, the start-up time will be approximately 4 minutes.

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4 Web (HTML) Interface
Once each Boiler has been assigned a Boiler ID through the boiler’s control panel, all other settings for the
boiler can configured using the BoilerNet Interface Controller’s Web Interface. Multiple individual boilers
can also be monitored simultaneously.
The Web Interface screens generally mirror the screens available through the boiler's controller LCD
screen and keypad. Please refer to user manual for your boiler for a description of all the individual fields
and their values. This manual assumes that the user is experienced in the setup and use of IBC boilers,
and boiler systems and installations in general.
Most standard web browsers, such as Mozilla Firefox®, Microsoft Internet Explorer®, or Google Chrome®,
can be used for accessing the BIC’s Web Interface. Typically the IP address assigned to the BIC II will be
entered directly (as shown in Figure 7), though this may vary depending on the configuration of your
network.
The BIC II's Web Interface requires the use of cookies, so you will need to configure your web browser to
allow cookies for the BIC II's "site" address. You may need to configure your browser to allow pop-up
windows for the BIC II as well. Most browsers can also be configured to display a new window as either a
"window" or a "tab", depending on your personal preference (the examples here are shown as "tabs").

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Figure 7
Only basic information regarding the BoilerNet system will be initially displayed on the opening screen.
You must "Login" using a valid user name and password to be able to access and alter detailed
information regarding the BIC II and the individual boilers on the network.
Some Web Interface screens may not be available to a user, depending on the security level that they
have been assigned. Other screens may be viewable, but altering and saving setting values will not be
permitted.

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The Web Interface and the boiler's screen and keypad should not be used simultaneously for entering or
altering settings. If a key on the boiler's keypad is pressed, then the Web Interface will be "locked out" for
a period of 2 minutes from the last key press; the operator at the boiler is given control. Viewing of
settings using the Web Interface will still be permitted, but any settings changed using the Web Interface
will not be saved until the lock-out period has expired. Note that the lock-out will apply to all web screens,
regardless of the screen the boiler or the Web Interface happens to be on at the time.
It is highly recommended that you log out of, or close, the BoilerNet Web Interface when it is not actually in
use.

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4.1 User Passwords
The Web Interface employs a password system to control access. Up to 10 User Accounts can be
configured.
Figure 8
Note that both the "User ID" and "Passwords" are case sensitive, both on this screen and when logging in
using the Web interface.
To add or change an entry, click the "Update" box for that entry first, then add or change the entry's data.
When all the desired updates have been done, click "Save". The User information will be saved by the
system, and the web page will be updated to reflect the changes.

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Table 3 –Security Levels
Level
Description
View
View access only; access to certain screens is restricted
Operator
Equivalent to the "User" access level on the boiler's controller
Supervisor
View access to all screens, write access to all but "advanced" functions
Installer
Full read/write access to all screens and functions
Generally, the "View" and "Operator" levels should be assigned to most users. "Supervisor" and "Installer"
levels should only be assigned to select personnel.
There are 2 default User ID's that will have been factory configured. User ID "ibc" is the default for all
operations, while User ID "BACnet" is for any BACnet operations that require a password. The password
for both ID's is set to "boiler" from the factory.
The "ibc" User ID cannot be deleted. It is however strongly recommended that the default password be
changed before the BIC is put into actual operation.
The "BACnet" User ID is required for any BACnet operations that use a password. Note that the security
level is not relevant for BACnet operations; the presence of the "BACnet" User ID and correct password
are what are required. If the BACnet interface is not being used, then this User ID can also be deleted if
desired. It is also strongly recommended that the default password be changed before the BIC II is put
into actual operation.