KWE DDR OT/BACIP Quick guide

Communication
DDR Part Number:
704501
DDR OT/BACIP Gateway
Communication Gateway
for OpenTherm to BACnet IP
Document Applicable to:
DIN Rail Mount 704501
Applicable Controls:
DDR Boiler Controls for MCA Pro /
C230 ECO-A and Gas 310 ECO Series
Technical, Installation and Configuration Information
IMPORTANT
Read and save these instructions for
future reference
Cautionary Statement
The information presented in this document is
only to be used by those familiar with its
application and use.
DDRA 015 001 v1.1 04/2010

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
2
About these instructions
Trademark Information
BACnet® is a registered
trademark of the American
Society of Heating,
Refrigerating and Air-
Conditioning Engineers, Inc.,
1791 Tullie Circle NE, Atlanta,
GA 30329.
For more information please
visit:
www.bacnet.org
www.ashrea.org
OpenTherm® is a trademark of
the OpenTherm Association.
For more information, please
visit:
www.opentherm.eu
Caution danger
Risk of injury and damage to equipment.
Attention must be paid to the warnings on
safety of persons and equipment.
Reference
Refer to another manual or other pages in
this instruction manual.
Specific information
Information must be kept in mind to maintain
comfort.
Warning
Before you operate this boiler, read this manual carefully and take extra precautions to all safety
and warning symbols or important items. The operating manual is part of the documentation along
with the boiler. The installer is required to explain your heating system and boiler operating instruc-
tions.
Notice
Please read this manual and retain for future reference. Improper installation, adjustment, altera-
tion, service or maintenance can cause injury, loss of life or property damage. Refer to this manual
for assistance or additional information or consult a qualified installer, service agency or the gas
supplier.

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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Important Regulatory and Installation Requirements
Codes
The installation of this unit must
be in accordance with local
codes.
All electrical wiring is to be done
in accordance with the latest
edition of CSA C22,1 Part 1 and/
or local codes. In the U.S. use
the National Electrical Code
ANSI/NFPA 70.
The installing contractor must
comply with the Standard of
Controls and Safety Devices for
Automatically fired Boilers, ANSI/
ASME CSD-1 where required by
the authority having jurisdiction.
Working on the equipment
The installation, adjustment,
service and maintenance of this
unit must be done by a licensed
professional heating contractor
or persons who are qualified and
experienced in the installation,
service, and maintenance of
similar products. There are no
user serviceable parts on this
control.
Power supply
Install power supply in
accordance with the regulation of
the authorities having jurisdiction
or in absence of such
requirements, in accordance with
National Codes.
 Please carefully read this manual
prior to attempting installation.
Any warranty is null and void if
these instructions are not
followed.
 The completeness and
functionality of field supplied
electrical controls and
components must be verified by
those installing the device
Purpose of Device and Operation
The DDR OT/BACIP Gateway
provides a communication
translation between OT enabled
boilers and BACnet enabled BMS
systems.
The DDR OT/BACIP Gateway may
be either part of a control panel
or stand-alone control device.
Warning
More than one live circuit. See
wiring diagram in this manual.
Turn off power supply to control
and damper/blower before
servicing. Contact with live
electrical components can result
in serious injury or death.

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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DDR OT/BACIP Gateway505
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DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
Control Installation Section 2
Control Information
Section 2.0
Information Page
What’s In The Box 6
Gateway Assembly Overview 7
Gateway Connection Overview 8
C230 ECO-A Gateway Installation Steps 9
Gas 310 ECO Gateway Installation Steps 11
Gas 310 ECO OT Module Installation Steps 12

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Control Installation Section 2
What’s in the box
Unboxing the Control
In the box, you will find the following:
Qty. Description
1 Communication Gateway (on DIN rail)
1 Gateway power supply (on DIN rail)
2 End stops (on DIN rail)
1 OT Interconnection cable
1 Gas C230 wiring harness
1 Gas C310 wiring harness
2 M5x8 Machine screws (DIN Rail)
2 M5 Lock nut (DIN Rail)
2 Power supply interconnection wires
1 DIN Rail (Gateway and Power supply
mounted)
1 Installation manual

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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Installation
1
2
3 4
5
Information
1. DIN rail for mounting of gateway and power
supply.
2. Gateway power supply.
3. Communication Gateway.
4. DIN rail locks
5. Power supply connection jumpers
Warning
When extending wire there is the possibility of exposure to
electromagnetic interference. Avoid running wires beside or
near high voltage 120/240 VAC conductors. If proximity to
high voltage conductors cannot be avoided, use stranded,
twisted pair of shield design wire. Ensure that only one end
of the shielding is grounded.

DDR OT/BACIP DDRA 015 v1.1 04/2010
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DDR OT/BACIP Gateway Overview—24VAC DIN Rail Unit
1
3
Installation (Applicable to Field Retrofit Only)
1. Mounting of the DDR OT/BACIP Gateway
is done by utilizing the supplied DIN rail.
The DIN rail is mounted inside of the
boiler control specific to the application.
Information
1
2
1. BACnet IP RJ45 connection
2. OT connection terminals A and B
3. Power Connections to power supply
Connection Overview
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Warning
When extending wire there is the possibility of exposure to
electromagnetic interference. Avoid running wires beside or
near high voltage 120/240 VAC conductors. If proximity to
high voltage conductors cannot be avoided, use stranded,
twisted pair of shield design wire. Ensure that only one end
of the shielding is grounded.

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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Installation Overview C230 ECO-A
1
1
2
2
3
Information
With the cover removed from the boiler control
and the power turned off, follow the proceeding
steps.
1. On the rear wall of the boiler control, locate
lower nylon stand-offs. Remove these two
stand-offs by either pressing out towards the
back of the control or cut with side-cutters.
2. With the two stand-offs removed, enlarge the
holes with 3/16” drill bit to allow for the M5
screws which fasten the DIN rail to the control
housing. WATCH FOR METAL SHAVINGS.
3. With the holes enlarged, insert the M5 screws
through the DIN rail out towards the back of
the control and tighten with supplied M5 lock
nut.
Note:
Remove gateway and power supply from DIN
rail. Release the fastening tabs to allow DIN rail
to be separated from housings. The end sections
do not need to be removed from DIN rail.
Caution
Ensure that boiler control power is turned off
before performing any work inside of control.

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Installation Overview C230 ECO-A
1
1
2
3
Information
With the DIN rail mounted on the rear wall of the
boiler control, follow the proceeding steps.
1. Mount the gateway and power supply onto the
mounted DIN rail by positioning the bottom DIN
rail hooks at the bottom of the DIN rail. Tilt
both units upwards and ensure upper clip hold
devices to DIN rail.
2. Locate the harness with the 230 label. Insert
black wire into the L terminal of the power
supply. Insert the blue wire into the N terminal
of the power supply. Tighten both terminals of
the power supply.
3. Locate the K1 plug harness from within the
control. Plug in the harness installed in the
previous step to the K1 plug.
4. Wire the OT communications harness into the
green OT plug. Plug can be removed by
unplugging from control. Insert wires and
tighten terminal screws. Not polarity sensitive.
Once all of the connections have been verified, the
power switch of the control can now be turned on
to perform the communication testing of the
gateway. With the BMS plug-in connection to the
gateway complete, it should be possible to start
reading information from the boiler control.
4
3
4

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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Installation Overview Gas 310 ECO
1
2
4
Information
With the cover removed from the boiler control
and the power turned off, follow the proceeding
steps.
1. Using a 3/16 drill bit, make two mounting holes
approximately 5.5cm (2 1/8”) from the bottom
of the control. We recommend making a drill
template. WATCH FOR METAL SHAVINGS.
Drill one hole approximately 5.5cm (2 1/8”)
from the bend and the other hole 13.5cm (5
1/4”) from the bend. The two holes must
correspond to the oval openings on the DIN rail.
2. Mount the gateway and power supply onto the
mounted DIN rail by positioning the bottom DIN
rail hooks at the bottom of the DIN rail. Tilt
both units upwards and ensure upper clip hold
devices to DIN rail.
3. Connect the OT cable connected to terminals A
and B of the gateway to terminal block X29,
terminals 11 and 12.
Using a small flat blade screwdriver apply
pressure into the terminal block and insert the
wires. Remove screwdriver and tug on wire to
ensure correctly inserted into terminal.
4. Locate the harness with the 310 label. Insert
black wire into the L terminal of the power
supply. Insert the blue wire into the N terminal
of the power supply. Tighten both terminals of
the power supply.
1
3
Caution
Ensure that boiler control power is turned off
before performing any work inside of control.

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Installation Overview Gas 310 ECO
1
2
2
3
Information
1. Locate the X16 plug at the back of the control.
Press on the sides of the plug and remove from
the metal wall.
Bring plug towards the front of the control.
2. Remove two screws from upper section of
control. One screw will be used to secure OT
module to control.
3. Position OT module on top of control with two
wire harnesses towards the front of the control.
Secure module with screw from previous steps.
Locate the X16A male plug of the OT module
and plug it into the X16 female socket from
previous steps.

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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Installation Overview Gas 310 ECO
1
2
3
Information
1. Showing the X16 plugged into the OT module.
2. Locate the K2/X24 and K2A/X24A connectors
on the boiler control. Press the release tab on
the K2/X24 connector and unplug from the
socket.
3. Locate the left harness connector X24A socket
on the previously installed OT module and
connect the K2/X24 plug into the X24A socket.

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Installation Overview Gas 310 ECO
2
Information
1. With the 310 harness installed into the power
supply from previous steps, route wiring across
back of control.
2. Locate the K1 plug and press in the connector
of the power supply harness into the K1 plug of
the control.
3. Find the flat ribbon cable in the boiler wiring
harness and connect one of the multi plugs into
the mating socket on the interface. Note that
the ribbon cable will have many plugs
attached that can be connected to other
accessory boards. Use nearest plug without
straining the cable against any other plug.
Once all of the connections have been verified, the
power switch of the control can now be turned on
to perform the communication testing of the
gateway. With the BMS plug-in connection to the
gateway complete, it should be possible to start
reading information from the boiler control.
1
3

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
Configuration of Gateway Overview
Configuration Information
Section 3.0
Information Page
Configuring BACnet IP Settings 16
BACnet Device Settings 17
BACnet Objects 18
Variables 19
LED Troubleshooting 20
Technical Information 21

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Configuring BACnet/IP Settings
Connect your computer DIRECTLY to the BACnet
interface of the gateway device. With no other
devices attached (an isolated network). Either set
your computer’s network connection to automatic
IP Address (DHCP), or set your computer’s IP
address to 192.168.88.90 (subnet mask
255.255.255.0)
Restart the Gateway by cycling the power off and
then on again.
Open a browser window and insert the following
URL: http://192.168.88.89/admin
The default user name / password is "admin" and
"admin" (without the quotes). This can be
renamed in the Change Password screen. At this
point you will see the Configuration pages.
IMPORTANT: Make sure that you remember any changes made here.
DDR OT/BACIP Gateway505 NR2/BACIP
Configuration of Gateway

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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NOTE: The Device ID must be unique on the
entire BACnet internetwork.
The Restore Defaults and Change Password
screens are very simplistic. When you select
Activate Configuration, it will ask you if you want
to SAVE your settings. This will then store your
new settings and reboot automatically.
You can now join the Gateway to the rest of your
network, provided you have not specified a
duplicate IP Address. Any Computer on the
network should now be able to access these
configuration screens.
BACnet Device Settings
You can now reconfigure these settings according
to your network requirements. Make sure that you
press SAVE on every screen where you make
changes. The new setting will not take effect until
the Activate Configuration screen has been
confirmed. These configuration pages can now be
accessed through both the 192.168.88.89
Address, as well as the one you have selected.
The BACnet Device Settings screen looks like this:
DDR OT/BACIP Gateway/BACIP
Configuration of Gateway Continued

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Analogue Input Overview
BACnet control mode (Manual)
This feature is enabled when AO-1 is set to 1
(BACnet control), the gateway will ignore the
thermostat (if connected) and communicate
directly with the boiler. The Control Set-point will
now determine the boiler target temperature. The
gateway no longer retrieves any values from the
thermostat, these object will change to a value of
-99.
Temperature Units
You have the ability to control whether
temperatures are displayed in Celsius or
Fahrenheit by setting AO-2 (Analog Output 2).
This will also determine whether the Control Set-
point (AO-3) is provided in ⁰C or ⁰F.
BACnet Objects
BACnet Object Description Units Source
Analog Input 1 Boiler Set-point ⁰C / ⁰F T / M
Analog Input 2 Boiler water temperature ⁰C / ⁰F B
Analog Input 3 Maximum Modulation level % T
Analog Input 4 Current Modulation level (boiler modulation) % B
Analog Input 5 Room Temperature ⁰C / ⁰F T
Analog Input 6 Room Set-point temperature ⁰C / ⁰F T
Analog Input 7 Outside Temperature ⁰C / ⁰F T
Analog Input 8 Return Water Temperature ⁰C / ⁰F B
Analog Input 9 Flue Gas Temperature ⁰C / ⁰F B
Analog Input 10 Boiler Heat Exchanger Temperature ⁰C / ⁰F B
Analog Input 11 Boiler Fan Speed Hertz B
Analog Input 12 Water Pressure Bar / PSI B
Analog Input 13 OEM Fault Code 0-255 B
Analog Input 14 OEM Diagnostic Code 0 - 65535 B
Binary Input 1 Boiler Fault (no fault / fault) 0/1 B
Binary Input 2 Flame Status (no flame / flame) 0/1 B
Binary Input 3 Fault - Service Required (not req'd / req'd) 0/1 B
Binary Input 4 Fault - Lockout Reset 0/1 B
Binary Input 5 Fault - Low Water Pressure 0/1 B
Binary Input 6 Fault - Gas / Flame 0/1 B
Binary Input 7 Fault - Air Pressure 0/1 B
Binary Input 8 Fault - Water Over-Temperature 0/1 B
Analog Output 1 Control source (Setpoint from Thermostat or Manual) 0/1
Analog Output 2 Temperature Units (⁰C / ⁰F) 0/1
Analog Output 3 Control Set-point (only if control source is Manual) ⁰C / ⁰F
Analog Output 4 Control Method (Setpoint / Modulation Controlled) 0/1
T=Thermostat B=boiler M=Manual (BACnet)
Temperature units displayed / Set-point units, is determined by Analog Output 2

DDR OT/BACIP Gateway
DDRA 015 v1.1 04/2010
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Communication Points for MCA PRO /C230 ECO-A/310 Control
Variable Read/
Write
Units Gas 310
ECO
C230/
MCAPRO
Boiler water temperature R ⁰C / ⁰F ✔ ✔
Current Modulation level (boiler modulation) R % ✔ ✔
Outside Temperature R ⁰C / ⁰F ✔ ✔
Return Water Temperature R ⁰C / ⁰F ✔ ✔
Flue Gas Temperature R ⁰C / ⁰F ✔
Boiler Heat Exchanger Temperature R ⁰C / ⁰F ✔
Boiler Fan Speed R Hertz ✔
Water Pressure R Bar / PSI ✔ ✔
Boiler Fault (no fault / fault) R 0/1 ✔ ✔
Flame Status (no flame / flame) R 0/1 ✔ ✔
Service Required (not req'd / req'd) R 0/1 ✔ ✔
Lockout - Reset R 0/1 ✔ ✔
Low Water Pressure R 0/1 ✔ ✔
Gas/Flame Fault R 0/1 ✔ ✔
Air Pressure Fault R 0/1 ✔ ✔
Water Over-Temperature R 0/1 ✔ ✔
Units (Metric/Imperial, ⁰C /⁰F, Bar/PSI) W 0/1 ✔ ✔
Set-point (Either Boiler Temp. or Modulation, see Control
Method)
W ⁰C / ⁰F ✔ ✔
Control Method (Setpoint - Boiler Temp / Modulation
Controlled)
W 0/1 ✔ ✔

DDR OT/BACIP Gateway DDRA 015 v1.1 04/2010
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Technical Information
Trouble-Shooting
Problem: LED2 is flashing
Control/BMS Mode
LED 1 flash per second—OK
LED 4 flash per second—No Communication