ICC Mirius Service manual

Installation Instruction Manual
INDUSTRIAL CONTROL COMMUNICATION
100318030 2000571701 (Rev. A)
PRINTED 0419
Communication Node
for EMS/BMS
Control
Models
Ethernet (ETH-1000) for BACnet IP
and Modbus TCP
Serials
Mirius (Serial RS-485) for BACnet MS/TP)
and Modbus RTU
Energy Management System
Building Management System
Installation

2
CONTENTS
INTRODUCTION........................................................................... 3
Warnings ...................................................................................3
Parts..........................................................................................3
Tools Required ..........................................................................3
General Guidelines ...................................................................3
FEATURES AND COMPONENTS ................................................ 5
DEVICE CONFIGURATIONS........................................................ 6
ETH-1000 Wiring.......................................................................6
Mirius Wiring .............................................................................6
INSTALLATION CONSIDERATIONS ............................................ 8
Touch Screen Style Display Installation ....................................8
High Efciency Water Heater Installation – (BTH Or BTX
Models)................................................................................. 8
Commercial Electric Water Heater (Touch Screen
Installation) ........................................................................... 8
Membrane Switch Style Display Installation ..........................10
High Efciency Water heater Installation............................ 10
Commercial Electric Water heater Installation.................... 10
Boiler Installation.....................................................................12
XP XWH Boiler Installation................................................. 12
ECC DEVICE VERSIONS........................................................... 13
BACnet / Gas Water Heaters ..................................................13
Product Description ............................................................ 13
Protocol Implementation Conformance
Statement (PICS) ............................................................... 14
BACnet Standardized Device Prole (Annex L): .....................14
BACnet Interoperability .............................................................14
Segmentation Capability ...........................................................14
Data Link Layer Options............................................................ 14
Device Address Binding ............................................................14
Character Sets ..........................................................................15
Data Types ................................................................................15
Object Types and Properties..................................................... 16
Device Object Listings........................................................ 16
Object Min/Max Values ............................................................. 16
BACnet/Gas Water Heaters Object List .................................... 17
Central Control Board Major State Denitions .......................... 20
Xi 1.0 Energy Management System (EMS) Control..................20
Mxi Energy Management System (EMS) Control .....................21
Fault Codes and Warnings........................................................ 22
BACnet / Electric Water Heaters ............................................23
Product Description ............................................................ 23
Protocol Implementation Conformance
Statement (PICS) ............................................................... 23
BACnet Standardized Device Prole (Annex L):.......................23
BACnet Interoperability ............................................................ 23
Data Link Layer Options............................................................ 24
Device Address Binding ............................................................24
Networking Options...................................................................24
Character Sets .......................................................................... 24
Data Types ................................................................................25
Object Types and Property Support ..........................................25
Device Object Listings........................................................ 26
Device Objects Initial Values..................................................... 26
Device Objects Minimum/Maximum Values ..............................26
Central Control Board Major State Denitions .......................... 30
Energy Management System (EMS) Control ............................ 30
Fault Codes and Warnings........................................................ 30
BACnet / Boilers......................................................................32
Product Description ............................................................ 32
Protocol Implementation Conformance
Statement (PICS) ............................................................... 32
BACnet Standardized Device Prole (Annex L): ......................32
BACnet Boiler Interoperability ................................................... 32
Segmentation Capability: .......................................................... 32
Data Link Layer Options............................................................ 33
Device Address Binding ............................................................33
Character Sets .......................................................................... 33
Data Types Supported...............................................................33
Boiler Device Object Types/Property Support.......................... 34
Object Listings.................................................................... 34
Boiler Device Object Initial Values ............................................ 34
Boiler Device Object Min/Max Values .......................................35
Boiler Slave States....................................................................36
Boiler Modbus Register Access ................................................ 36
Boiler Modulating Sensor Select/DHW Demand Switch ........... 37
Lock and Hold Codes................................................................37
Modbus / Gas Water Heaters .................................................44
Product Description ............................................................ 44
Modbus Gas Water Heater Register Listings ..................... 44
Modbus Gas Water Heater Register Properties........................ 44
Central Control Board Major State Denitions .......................... 47
Xi 1.0 Energy Management System (EMS) Control..................47
Mxi Energy Management System (EMS) Control .....................47
Fault Codes and Warnings........................................................ 48
Modbus / Electric Water Heaters.............................................49
Product Description ............................................................ 49
Electric Water Heater Register Listings.............................. 49
Modbus Electric Water Heaters Register Properties................. 49
Central Control Board Major State Denitions .......................... 52
Energy Management System (EMS) Control ............................ 52
Fault Codes and Warnings........................................................ 52
ICC PROGRAM INFORMATION................................................. 53

3
INTRODUCTION
New building construction and energy saving techniques have
driven the need for improved communications between appliances
and building environmental systems. There are several different
protocols that have developed for accomplishing this task
including BACnet and Modbus. Since appliances come with a
variety of controls, interfacing with the various protocols presents
different challenges.
Industrial Control Communications (ICC) has developed the
devices to act as a communication gateway allowing appliances
to communicate to the different building management protocols.
The ICC module translates the appliance codes and commands
into the appropriate protocol language giving the end user the
ability to monitor and control the appliance. The end user will be
able to adjust and monitor the equipment and obtain better levels
of efciency and cost savings.
The ICC module in this kit has been designed to seamlessly
integrate with the water heater controls. Once the unit is
connected to the control and to the energy management system,
the user will be able to operate the unit with the Building
Management system interface.
WARNINGS
When installing the unit, ensure that all power is off before
opening any water heater enclosure. Failure to do so could result
in electrical shock and/or possible damage to the unit.
Do not install in areas of high temperature, in excess of 167° F.
Install in areas not subject to water or excess moisture.
PARTS
Table 1. Parts Required
Item Ethernet Serial (RS-485)
ICC Module X X
Communication Cable X X
Power Adapter X X
Jumpers 4 4
Splitter X X
USB Key X X
TOOLS REQUIRED
Wire Cutters
24 AWG Wire Stripper
2.5 mm Flat Blade Screw Driver
GENERAL GUIDELINES
The module should be installed as close as practical to the water
heater control.
The ICC module uses a 120 Volt power adapter to supply 9 volts
DC for the unit. One 120 VAC outlet is required for each module
installed. The power adapter comes with a six foot length of wire.
If additional wire is needed, extra wire may be added, in
accordance with local ordinances for installation of low voltage
wire.
The ICC Gateway kit contains a USB key with the ICC
Conguration Studio program, all conguration les, parameter
lists and instructions required to install and congure to your water
heater/boiler and BMS system.
Before plugging in the ICC Gateway, install the ICC Conguration
Studio from the USB key and run the program. Once running,
select File, Open Project and browse to the USB key and select
the conguration le whose name matches the gateway,
Because some USB hubs may not supply sufcient current to run
the Gateway, insure that the ICC Gateway is connected to the
power adaptor. Then connect the ICC Gateway using the USB
cable provided. Run the ICC Gateway Studio application from the
start menu.
Each conguration has default address and BACnet instance
settings that can be changed. For Mirius gateways, the default
Modbus address is 1 and the default BACnet address is 81. For
gas models the default BACnet Instance Number is 520081 and
for electric models the default instance number is 530081. For
Ethernet Gateways, the default setting is to acquire an IP address
automatically from the router (DHCP). If a static IP address is
desired this can also be set. To change these addresses and
communication settings, use the ICC Conguration Studio
application program. The latest version of this application program
can be downloaded from:
www.iccdesigns.com/icc-conguration-studio.html
Before making any changes, it is recommended to save the
installed conguration project using the disk icon or File -> Save
Project As, then give it a name and select the folder, nally press
Save.
To change the Instance number and the Device Name, scroll
down and select the Device Object and replace the text in the
boxes in the upper right corner.
Figure 1. Changing Instance Number and Device Name
For ETH-1000 (Ethernet interface) the IP settings, including
DHCP/Static, the IP address and authentication can be changed
by selecting Ethernet from the upper left hand window and
changing the text and drop down list selection similar to changing
the Instance number above.
For Mirius (RS-485 A interface for BACnet MS/TP or ModBus
RTU), the baud rate and other serial communication parameters
can be changed by scrolling down to and selecting RS-485 A ->
ModBus RTU Slave.

4
Figure 2. Changing ModBus Parameters
The ModBus address can be changed by selecting Node under
the RS-485 A -> ModBus RTU item.
Likewise for BACnet, the baud rate and other serial
communication parameters can be changed by scrolling down to
and selecting RS-485 -> BACnet MS/TP Server. The BACnet
MAC Address can be changed by selecting Node under the
RS-485 A->BACnet MS/TP Server.
Warning: Do not change any other values other than these or the
gateway conguration may not function properly. In this
case, the le saved above can be reloaded to start over.
When changes are complete press the Download Conguration icon:
Figure 3. Changing BACnet Parameters

5
FEATURES AND COMPONENTS
Figure 4. ICC ETH-1000 (Ethernet) Version Figure 5. ICC Merius Serial RS-485 Version
• Works with Cyclone (BTH, BTX-100, BTXL-100, DVE, DSE/
DVE/DHE
• Use the ICC Control to enable/disable the water heater.
• Change Temperature Set points and differentials.
• Two models with four different congurations to connect to
BACnet and Modbus.
• Ethernet and Serial RS-485 versions available.
• Two-wire or four-wire RS-485 versions available.
• Power can be supplied via the USB cable, as a 7-24 VDC
input on the main termainal block, or via IEEE 802.3af Power
over Ethernet (PoE on ETH-1000 only).
• Congure protocols, network characteristics, and client/server
object denitions.
• Graphically interact with the interal database in real-time via
the USB connection.
• Automatically discover and congure IP settings Ethernet
gateways connected to the current subnet.
• Update rmware.
Table 2. ICC Versions
Kit Connection Part Number
Mirius Serial - RS485 (RTU/MS/TP) 100316044
ETH-1000 Ethernet - RJ-45 100316045

6
DEVICE CONFIGURATIONS
ETH-1000 WIRING
Figure 6 shows the standard conguration of the Ethernet modules.
The module has connections for 9 VDC power, three wire
connections for the communication cable, and a port for the
connection of the EMS system through Ethernet RJ-45 cable or
serial communications.
Figure 6. Standard Conguration for Ethernet Modules
Connecting of the power adapter and the boiler or water heater
communication cable to the module is accomplished on the same
end of the unit. Figure 7 is a close up of the connection terminal
and Figure 8 shows the appropriate connection to the strip using
the power adapter and communication cable.
The provided communication cable has two RJ-45 plugs.
Remove one with a wire cutter, then locate and strip the 3 wires
described below and strip 1/2 inch of insulation before connecting.
Figure 7. Connecting the Power Adapter
Brown/White Wire*
Jumper
Brown Wire*
Blue/White Wire*
Black/White Wire†
Black Wire†
*From Communication Cable
†
From 9 VDC Power Adapter Cable
RS 485
AB YZ
Power
GND
Power
Pos
Jumper
Figure 8. Connections from the Communications and Power Adapter Cables
The connections in Figure 8 are the same regardless of the
appliance or the communication protocol.
At the opposite end of the module is the connection location for
the EMS LAN connection. The EMS uses an Ethernet connection
with an RJ-45 connector. Plug the cable into the RJ-45 receptacle.
When connecting the RS-485A connections, please note the
following:
For 2-wire systems, jumper terminal A to Y. Also jumper B to Z.
Connect the RX/TX+ (plus) wire from your Building Management
System to terminal A/Y. Connect the RX/TX– (minus) wire from
your Building Management System to terminal B/Z.
For more information on connecting the ICC Gateway to your
Building Management System, please refer to the User Manual
provided on the enclosed USB key in the “Documents” folder. The
two applicable documents will be found in the Manuals.
MIRIUS WIRING
Figure 9 shows the he standard conguration of the module. Port A
of the module has connections for 9 VDC power, three wire
connections for the communication (breakout) cable, for Serial
communications to the water heater/boiler.
Figure 10 is a close up of the connection terminal and Figure 11
shows the appropriate connection to the strip using the power
adapter and communication cable.

7
Figure 9. Mirius Unit with Communications Terminal
Figure 10. Close-Up View of Connection Terminal
The provided communication cable has two RJ-45 plugs.
Remove one with a wire cutter, then locate and strip the 3 wires
described below and strip 1/2 inch of insulation before connecting.
RS485
Power
GND
Power
POS
COM BA
Blue/White Wire*
Brown Wire*
Brown/White Wire*
Black/White Wire†
Black Wire†
†From 9VDC Power Adapter Cable
* From Communicaon Cable
Figure 11. Mirius Wiring Schematic
The connections in Figure 11 are the same regardless of the
appliance or the communication protocol.
At the opposite end, Port B of the module is the connection
location for the EMS/BMS connection. See Figure 12. For
connections to the terminal use the labeling on the module as a
guide.
When connecting the RS-485A connections (BACnet or Modbus)
please note the following:
• Only 2-wire systems are supported
• Connect the RX/TX+ (plus) wire from your Building
Management System to terminal RX/D+. Connect the RX/
TX– (minus) wire from your Building Management System to
terminal TX/D-. Figure 12. Mirius Port B Terminal

8
INSTALLATION CONSIDERATIONS
There are two types of displays to consider when installing the
ICC gateway modules to the water heaters, the older type with
membrane switches and the newer style with a touch screen. The
new touch screen style display does not need the provided
RJ-485 splitter and it can be discarded.
TOUCH SCREEN STYLE DISPLAY INSTALLATION
HIGH EFFICIENCY WATER HEATER INSTALLATION – (BTH OR
BTX MODELS)
Follow the directions under general guidelines for connecting the
module to the Energy Management System and power. This
section will guide the installer on how to mount and connect the
module to the water heater. The control box and mounting location
on the water heater is on the top of the unit behind the display
module. See Figure 13.
Connection of the RJ-45 end of the communication cable to the
heater is required to plug into J13 of the control board inside the
“black controls box” (for newer models) requiring removal of two
screws holding the lid on. After plugging in the communications
cable, route the cable to the bottom side with the other cables and
put the lid back on with the two screws.
If the control board is in a “grey controls box” (for older model),
double check to make sure the display is not one with membrane
switches below and to the right of the display. If the display uses
membrane switches, please follow directions under the section
“MEMBRANE SWITCH STYLE DISPLAY INSTALLATION”. If it
has a grey box and is a touch screen display (replacement of
original) then the communications cable must be plug inside the
box to J9 or J10. This will require removal of the two screws
holding the lid on. After plugging in the communications cable,
route the cable to the right side with the other cables and put the
lid back on with the two screws.
Control
Location
Top
Figure 13. Controller Location (BTH or BTX models)
Removal of the top is not required, but it may be helpful to remove
the control box lid. Use a ladder to access the top of taller water
heaters.
Next locate the upper temperature probe and exhaust switch.
Position the module between the two about 1 inch from the central
burner opening. For the 500 MBTUH Model this would be next to
the upper temperature probe.
Figure 14. Location of Exhaust Switch and Upper Temperature Probe
Connect the three wires from the end of the communication cable
to the module in Accordance with page 4. Once the unit is
installed and connected, the building management system can be
connected to the appropriate connection point on the module.
Figure 15. Clearance of ICC Unit from Central Burner Opening
COMMERCIAL ELECTRIC WATER HEATER (TOUCH SCREEN
INSTALLATION)
Normally the commercial electric heaters have a display with
membrane switches, but may have had a replacement touch
screen or future models may one day include touch screens. If
this heater has membrane switches on the bottom and right of the
display, then see the section below COMMERCIAL ELECTRIC
WATER HEATER INSTALLATION.
Follow directions under general guidance for connecting module
to the Energy Management System and power. This section will
guide the installer on how to mount and connect the module to the
water heater.
The module should be located where it will not interfere with the
door or in a location that is acceptable to the customer. Care
should be exercised to avoid drilling the self-tapping screws into
electrical or sensitive components. Electrical power should be
disconnected before proceeding with ICC installation.
Using a flat blade screwdriver, loosen the screws holding the door
of the unit. See Figure B1. Swing the door to the open position
and locate the control board.
Figure 16. Opening the Control Board Compartment Door
Locate the module on the top of the door cabinet approximately 1
inch from the water heater jacket and on the centerline of the unit
(See Figure 17 and Figure 18).

9
Figure 17. ICC Location Relative to Water Heater Jacket
Figure 18. ICC Location Relative to Centerline
Remove the hole plug from the 0.875” knockout on the left corner
of the top panel. See Figure 19.
Plug the communications cable into D9 and run the three wire
connection up through the knockout and connect the three wires
to the module as shown on page 4. Once the unit is installed and
connected, the building management system can be connected to
the appropriate connection point on the module.
Figure 19. Location of Communications Wiring Knockout

10
MEMBRANE SWITCH STYLE DISPLAY INSTALLATION
HIGH EFFICIENCY WATER HEATER INSTALLATION
Follow the directions under general guidelines for connecting the
module to the Energy Management System and power. This
section will guide the installer on how to mount and connect the
module to the water heater.
The control box and mounting location on the water heater is on
the top of the unit behind the display module. See Figure 20.
Figure 20. Locating the Control Box
Removal of the top is not required. Use a ladder to access the top
of taller water heaters. Locate the back of the display as shown in
Figure 21. Disconnect the RJ45 plug from the display and connect
the RJ45 plug from the split communication cord into the display
receptacle. Plug the display communication cord back into the
receptacle on the split communication cord as shown in Figure 22.
Plug the supplied wiring harness with the gateway controller into
the remaining open RJ45 port on the Split Communication cord.
Figure 21. Locating the Back of the Display
Figure 22. Reconnecting the Communication cord to the Receptacle
Next locate the upper temperature probe and exhaust switch. See
Figure 23. Position the module between the two about 1 inch from
the central burner opening. See Figure 24. For the 500 MBTUH
model this would be next to the upper temperature probe.
Figure 23. Locating Upper Temperature Probe and Exhaust Switch
Figure 24. Connecting the Communications Cable to the Module
Connect the three wires from the end of the communication cable
to the module in accordance with Figure 24. Once the unit is
installed and connected, the building management system can be
connected to the appropriate connection point on the module.
COMMERCIAL ELECTRIC WATER HEATER INSTALLATION
Follow directions in Device Congurations (page 6) for connecting the
module to the Energy Management System and power. This
section will guide the installer on how to mount and connect the
module to the water heater.
The module should be located where it will not interfere with the
door or in a location that is acceptable to the customer. Care
should be exercised to avoid drilling the self tapping screws into
electrical or sensitive components. Electrical power should be
disconnected before proceeding with ICC installation.
Using a flat blade screwdriver, loosen the screws holding the door
of the unit. See Figure 25.
Swing the door to the open position and locate the back of the
display module. See Figure 26.
Figure 25. Loosening the Screws to the Door of the Unit