Bosch Heatronic 4000 BAS Integration Manual

Brand: Bosch

Introduction

The Heatronic 4000 can communicate with a Building Automation System (BAS) using either BACnet® IP or Modbus®. This manual provides information on boiler plant and system parameters accessible when building automation or management systems utilize BACnet IP or Modbus communications. The Heatronic 4000 can be configured to provide controlled access or read/write access while controlling a target temperature from the BAS connection.

Diagram: BACnet IP and Modbus Terminal Blocks

The BACnet IP terminal block features numbered connections (1-31) for various inputs such as Flow Proof, DHW, Fuel, EMS, and outputs for primary pumps, boilers, and DHW. It also includes terminals for Flow, Pressure, and Temperature sensors. The Modbus terminal block (40-42) is for A, B, and Ground connections.

Table of Contents

  • Heatronic 4000 Configuration..................................................2
  • Lock/Unlock Switch..................................................................2
  • Application Mode Setting.........................................................2
  • BAS Type Setting .....................................................................2
  • BACnet Protocol Implementation Conformance Statement (PICS).......................................................................................3
  • BACnet Connection .............................................................................3
  • Setting BACnet in the Heatronic 4000 BAS Menu................4
  • BACnet Analog Parameters....................................................6
  • BACnet Binary Parameters...........................................................7
  • Modbus Specification.......................................................................8
  • Setting Modbus in the Heatronic 4000 BAS Menu..............9
  • Modbus Parameters .......................................................................10
  • Modbus Troubleshooting ......................................................................11
  • Error Codes .................................................................................12

Heatronic 4000 Configuration

Ensure the Heatronic 4000 is set to the correct Application Mode and BAS setting before connecting to the BAS. To view menu options on the Heatronic 4000, press and hold the Home button for 3 seconds.

Navigation Controls

The navigation interface includes a [Home Button], [Item Back Button], [Next Button], and [Enter Button] for menu interaction.

Lock/Unlock Switch

The Heatronic 4000 has an 'Advanced' access level that allows unconditional access to all settings. To change from Installer or User access to Advanced level, the switch on the left side of the front display must first be set to the unlock position. The access level can be changed within the toolbox.

Application Mode Setting

The Application Mode of the Heatronic 4000 determines the options available to the BAS.

Application Mode 4000 BAS Operation
RSET (Outdoor Temperature Reset) BAS Monitor Mode (BAS Monitor is set to ON). Remote control and adjustment of Heatronic 4000 settings. Refer to the BACnet® and Modbus® parameter tables in this manual for a list of available read/write parameters.
SETP (Set Point) BAS Temperature Mode. Provides a setpoint temperature and heating demand commands for the Heatronic 4000.
DDHW (Domestic Hot Water) Provides the required commands for the primary pumps and the DHW pump of the Heatronic 4000.
EMS (Energy Management System) Remote control and adjustment of Heatronic 4000 settings. Refer to the BACnet® and Modbus® parameter tables in this manual for a list of available read/write parameters.
BAS (Building Automation System) Provides the required commands for the primary pumps and the DHW pump of the Heatronic 4000.

BAS Type Setting

Select the BAS connection type from the Heatronic 4000 BAS menu.

BAS Type 4000 BAS Operation
BACnet® IP The 4000 communicates with BAS using BACnet over Internet and Protocol (IP).
Modbus® The 4000 communicates with BAS using the Modbus protocol.

BACnet Protocol Implementation Conformance Statement (PICS)

Vendor Name: Bosch Thermotechnology Corp.

Vendor ID: 744

Product Name: Heatronic 4000

Product Model Number: 4000

Application Software Version: J1229A

Firmware Version: 33

BACnet Protocol Revision: 10

Product Description: The Heatronic 4000 is a controller capable of operating four boilers to produce heat for multiple loads. The controller uses Proportional Integral Derivative (PID) logic to accurately maintain a target temperature and offer modern features, including the ability to communicate with a Building Automation System (BAS).

BACnet Normalized Device Profile (Annex L)

BACnet® Specific Application Controller (B-ASC)

Supported by BIBBs (Annex K)

Name Description
DS-RP-B Data Sharing-Read Property-B
DS-RPM-B Data Sharing-Read Multiple Properties-B
DS-WP-B Data Sharing-Write Property-B
DM-DDB-B Device Management-Dynamic Device Binding-B
DM-DOB-B Device Management-Dynamic Object Binding-B
DM-DCC-B Device Management-Communication Control-B

The device communication control password is Bosch.

Segmentation Capability

Supported Window Size
Capable of transmitting segmented messages No
Capable of receiving segmented messages No

Supported by Standard Object Types

Can be created Erased
Analog Input No No
Analog Value No No
Binary Input No No
Binary Output No No
Binary Value No No

Data Link Layer

Supported Device Address Binding
BACnet IP (Annex J) Yes Static Device Address Binding: No

Network Security Options

Supported
Non-secure device Yes

Character Set

Supported
ANSI X3.4 Yes

BACnet Connection

Use a top or rear punch-out to bring the CAT-5E or CAT-6 cable into the wiring compartment. Connect the Heatronic 4000 to the BACnet network switch using the RJ45 port on the top edge of the control panel.

  • Cable length must not exceed 150 feet (47.5 m) for CAT-5E or 300 feet (91.4 m) for CAT-6.
  • If the cable was hand-made, verify the continuity of all cables.
Diagram: BACnet Network Connection

A diagram shows the Heatronic 4000 unit with an RJ45 port connecting to a BACnet network switch.

Setting BACnet in the Heatronic 4000 BAS Menu

Item Field Range Description
MONITOR OFF or ON
Default: OFF
Access: ADV
BAS MONITOR: Choose whether the BAS monitor is available. Requirements: This item is available only when the APP MODE is set to RSET, SETP, DDHW, or EMS.
TYPE BACn, MODB
Default: BACn
Access: ADV
BAS TYPE: Select the communication protocol used with the BAS network. Modbus communicates over RS485 and BACnet is over IP.
DEVICE ID 0 to 4, 0 to 99, 0 to 99, 0 to 99
Default: 0, 0, 0, 0
Access: ADV
BACNET DEVICE ID: Set the unique address in the BACnet network. The address is set using four sets of numbers displayed in the output fields. Press the 'Next Item' button to view and adjust each number set. Requirements: This item is available only when BAS TYPE is set to BACn.
PORT 0x1 to 0xFFFF
Default: 0xBAC0 (47808)
Access: ADV
PORT BACNET: Set the User Datagram (UDP) Port on the BACnet network. Requirements: This item is available only when BAS TYPE is set to BACn.
DHCP OFF or ON
Default: ON
Access: ADV
BACNET DHCP: Choose whether Dynamic Host Configuration Protocol (DHCP) should be used to automatically assign the IP address on the BACnet network. If ON is selected, the address is displayed in the output fields. Requirements: This item is available only when BAS TYPE is set to BACn.
IP ADDR 0 to 255, 0 to 255, 0 to 255, 1 to 254
Default: 192, 168, 0, 200
Access: ADV
BACNET IP ADDRESS: Set the IP address on the BACnet network. The address is set using four sets of numbers displayed in the output fields. Press the 'Next Item' button to view and adjust each number set. Requirements: This item is available only when BAS TYPE is set to BACn and BACn DHCP is set to OFF.
GATEWAY 0 to 255, 0 to 255, 0 to 255, 1 to 254
Default: 192, 168, 0, 1
Access: ADV
GATEWAY BACNET: Set the Gateway address on the BACnet network. The address is set using four sets of numbers displayed in the output fields. Press the 'Next Item' button to view and adjust each number set. Requirements: This item is available only when BAS TYPE is set to BACn and BACn DHCP is set to OFF.
SUBNET 0 to 255, 0 to 255, 0 to 255, 0 to 255
Default: 255, 255, 255, 0
Access: ADV
SUBNET BACNET: Set the subnet address on the BACnet network. The address is set using four sets of numbers displayed in the output fields. Press the 'Next Item' button to view and adjust each number set. Requirements: This item is available only when BAS TYPE is set to BACn and BACn DHCP is set to OFF.
BBMD TIME OFF, 30 to 65535
Default: OFF
Access: ADV
BACNET BBMD TIME: Set the BACnet Broadcast Management Device (BBMD) time-to-live used for foreign device registration. Requirements: This item is available only when BAS TYPE is set to BACn.
BBMD IP 0 to 255, 0 to 255, 0 to 255, 0 to 255
Default: 127, 127, 127, 127
Access: Adv
BACNET BBMD IP: Set the BBMD IP address on the BACnet network. The address is set using four sets of numbers displayed in the output fields. Press the 'Next Item' button to view and adjust each number set. Requirements: This item is available only when BAS TYPE is set to BACn and BBMD TIME is not set to OFF.
BBMD PORT 0x1 to 0xFFFF
Default: 0xBAC0 (47808)
Access: Adv
PORT BACNET BBMD: Set the BBMD UDP port on the BACnet network. Requirements: This item is available only when BAS TYPE is set to BACn and BBMD TIME is not set to OFF.

BACnet Analog Parameters

Analog Input Object = AI | Analog Value Object = AV | Read = R | Read/Write = R/W

(n) represents the specific boiler number, including 1, 2, 3, and 4.

Object ID Name Description Data Type Read / Write Units Range / Value
0 PRIM TARG Primary target temperature AI R °F (64) -22 to 266°F
1 PRIM MIN Minimum primary temperature AI R °F (64) 60 to 180°F
2 PRIM MAX Maximum primary temperature AI R °F (64) 90 to 225°F
3 PRIM SUP Primary temperature supplement AI R °F (64) -22 to 266°F
4 PRIM RET Primary return temperature AI R °F (64) -22 to 266°F
5 OUTDOOR (Outdoor) Outdoor air temperature AI R °F (64) -76 to 149°F
6 DHW DHW tank temperature AI R °F (64) -22 to 266°F
7 FLUE (Flue) Common flue temperature AI R °F (64) -22 to 266°F
8 Boil INLET (Boiler Inlet) Boiler inlet temperature AI R °F (64) -40 to 500°F
9 FLOW RATE (Flow Rate) Flow rate AI R GPM (89) 0 to 65535 gpm
10 ENERGY (Energy) Energy usage AI R Thermes (21) 0 to 65535 Thermes
11 PRESSURE (Pressure) System pressure AI R PSI (56) 0 to 65535 psi
12 PRIM P1 RT Primary 1 pump run time AI R Heures (71) 0 to 65535 hours
13 PRIM P2 RT Primary 2 pump run time AI R Heures (71) 0 to 65535 hours
14 DHW P RT DHW pump run time AI R Heures (71) 0 to 65535 hours
15 ERROR (Error) Current error AI R N/A (95) See error list
16, 22, 28, 34 Boil (n) TYPE (Boiler (n) Type) Boiler (n) type AI R N/A (95) 0 = MOD, 1 = 1STG
2 = 2STG, 3 = EMS
17, 23, 29, 35 Boil (n) OUT (Boiler (n) OUT) Boiler (n) outlet temperature AI R °F (64) -22 to 266°F
18, 24, 30, 36 Boil (n) MOD (Boiler (n) MOD) Boiler (n) outlet modulation AI R % (98) 0 to 100%
19, 25, 31, 37 BURNER (n) (Burner (n)) Boiler (n) run time AI R Heures (71) 0 to 65535 hours
20, 26, 32, 38 CYCLES (n) (Cycles (n)) Boiler (n) cycles AI R N/A (95) 0 to 65535
21, 27, 33, 39 PUMP (n) RT (Pump (n) RT) Boiler (n) pump run time AI R Heures (71) 0 to 65535 hours

Analog Value Objects

Object ID Name Description Data Type Read / Write Units Range / Value
0 SETPOINT (Set Point) BAS setpoint temperature AV R/W °F (64) 60 to 225°F
1 ROOM Occ Occupied space temperature AV R/W °F (64) 35 to 100°F
2 ROOM UnOcc Unoccupied space temperature AV R/W °F (64) 35 to 100°F
3 OUT DSGN (Designated Outdoor) Designated outdoor temperature AV R/W °F (64) -60 to 45°F
4 TERMINAL Terminal unit type AV R/W N/A (95) 0 = HRF1, 1 = HRF2,
2 = CONV, 3 = COIL,
4 = RAD, 5 = BASE
5 OUTDOOR (Outdoor) Outdoor air temperature AV R/W °F (64) -85 to 149°F
(-85°F = invalid temperature / no BAS sensor)

BACnet Binary Parameters

Binary Input Object = BI | Binary Output Object = BO | Binary Value Object = BV | Read = R | Write = W

(n) represents the specific boiler number, including 1, 2, 3, and 4.

Object ID Name Description Data Type Read / Write Units Range / Value
Binary Input Objects
0 PRIM P1 Primary pump 1 status BI R N/A 0 = Off, 1 = On
1 PRIM P2 Primary pump 2 status BI R N/A 0 = Off, 1 = On
2 DHW PUMP (DHW pump) DHW pump status BI R N/A 0 = Off, 1 = On
3 SETBACK (Revers) Revers status BI R N/A 0 = Off, 1 = On
4 AUX RLY Auxiliary relay status BI R N/A 0 = Off, 1 = On
5 ALERT RLY (Alert relay) Dry relay alert status BI R N/A 0 = Off, 1 = On
6 HEAT CALL (Heat call) Central heat call status BI R N/A 0 = Off, 1 = On
7 DHW CALL (DHW call) DHW call status BI R N/A 0 = Off, 1 = On
8 FUEL SWITCH (Fuel switch) Fuel switch status BI R N/A 0 = Off, 1 = On
9 FLOW PROOF (Flow validation) Primary pump flow validation status BI R N/A 0 = Off, 1 = On
10 CA PROOF (CA Validation) Air (CA) combustion validation status BI R N/A 0 = Off, 1 = On
11, 13, 15, 17 CONDENSE (n) (Condenser (n)) Boiler (n) condensation BI R N/A 0 = No, 1 = Yes
12, 14, 16, 18 B(n) PUMP (B(n) Pump) Boiler (n) pump status BI R N/A 0 = Off, 1 = On
Binary Output Objects
0 DHW PUMP (DHW pump) DHW tank pump demand BO R/W N/A 0 = Off, 1 = On
Binary Value Objects
0 BAS HEAT CALL (BAS Heat Call) BAS heat call BV R/W N/A 0 = Off, 1 = On
1 BAS PRIM PMP REQ BAS primary pump demand BV R/W N/A 0 = Off, 1 = On
2, 3, 4, 5 ENABLE B(n) (Enable B(n)) Boiler (n), Active/ Inactive BV R/W N/A 0 = Active,
1 = Inactive

Refer to the Heatronic 4000 installation and operation manual for more information.

Troubleshooting

If there is no communication, check the following items:

  • Check the Ethernet cable. Cable length must not exceed 150 feet (47.5 m) for CAT-5E or 300 feet (91.4 m) for CAT-6.
  • If the cable was hand-made, verify the continuity of all cables.

If communication is intermittent, check the following items:

  • Check the Ethernet cable. Cable length must not exceed 150 feet (47.5 m) for CAT-5E or 300 feet (91.4 m) for CAT-6.

Modbus Specification

Communication Protocol Modbus over RS485
Physical Layer RS485 two-wire with ground signal
Baud Rate 2400, 9600, 19200, 57600, 115000 (default: 19200 bps)
Recommended Cable 18 AWG twisted and shielded pair (STP)
Transmission Mode RTU or ASCII (default: RTU)
Maximum Cable Length 115000 bps: 580 feet (177 m)
57600 bps: 1158 feet (353 m)
19200, 9600, 2400 bps: 3280 feet (1000 m)
3280 feet (1000 m) for all baud rates if 120 Ohm termination resistors are used.
Start Bit 1 bit
Data Length 8 bits for RTU mode
7 bits for ASCII mode
Parity None (8 data bits, 2 stop bits)
Parity (1 data bit, 1 stop bit)
Odd (1 data bit, 1 stop bit)
(default: Parity)
Addressing 1 to 247 (default: 1)

Modbus Connection

Use a top or rear punch-out to bring the twisted pair cable from the nearest Modbus RS485 connection point into the cable space. Install the conductors B (+), A (-), and G from the Modbus point to the 4000 B (+), A (-), and 'Gnd' terminals. 'GND' (ground) should not be connected to the ground screws in the 4000.

Diagram: Modbus RS485 Wiring

The diagram shows the Modbus RS485 wiring for the Heatronic 4000, connecting terminals B (+), A (-), and Gnd.

Setting Modbus in the Heatronic 4000 BAS Menu

Item Field Range Description
MONITOR OFF or ON
Default: OFF
Access: ADV
BAS MONITOR: Choose whether the BAS monitor is available. Requirements: This item is available only when the APP MODE is set to RSET, SETP, DDHW, or EMS.
TYPE BACn, MODB
Default: BACn
Access: ADV
BAS TYPE: Select the communication protocol used with the BAS network. Modbus communicates over RS485 and BACnet is over IP.
ADDRESS 1 to 247
Default: 1
Access: ADV
MODBUS ADDRESS: Set the unique address in the Modbus network. Requirements: This item is available only when BAS TYPE is set to MODB.
DATA RTU or ASCII
Default: RTU
Access: ADV
MODBUS DATA: Choose whether the Modbus communication type should be RTU or ASCII. Requirements: This item is available only when BAS TYPE is set to MODB.
BAUD RATE 2400, 9600, 19K2, 57K6, 115K
Default: 19K2
Access: ADV
MODBUS BAUD RATE: Select the communication speed. To ensure efficient communication, the control's baud rate must be the same as the Modbus network's. Requirements: This item is available only when BAS TYPE is set to MODB.
PARITY NONE, EVEN, ODD
Default: EVEN
Access: ADV
MODBUS PARITY: Select the parity used for Modbus communication. Requirements: This item is available only when BAS TYPE is set to MODB.

Modbus Parameters

Read = R | Read/Write = R/W

(n) represents the specific boiler number, including 1, 2, 3, and 4.

Registers Parameter Name Read/Write Units Type Format Range
System Status Registers
1 Primary target temperature R °F Entry S16 -22 to 266°F
2 Minimum primary R °F Entry S16 60 to 180°F
3 Maximum primary R °F Entry S16 90 to 225°F
4 Primary temperature supply R °F Entry S16 -22 to 266°F
5 Primary return temperature R °F Entry S16 -22 to 266°F
6 Outdoor air temperature R °F Entry S16 -76 to 149°F
7 DHW Temperature R °F Entry S16 -22 to 266°F
8 Common flue temperature R °F Entry S16 -40 to 500°F
9 Boiler inlet temperature R °F Entry S16 -22 to 266°F
10 Flow R 10*GPM Entry U16 0 to 65535 gpm
11 Energy R Thermes Entry U16 0 to 65535 Thermes
12 System pressure R 10*PSI Entry U16 0 to 65535 psi
13 Primary pump 1 relay status R Enum Entry U16 0 = Off, 1 = On
14 Primary pump 2 relay status R Enum Entry U16 0 = Off, 1 = On
15 DHW pump relay status R Enum Entry U16 0 = Off, 1 = On
16 Primary pump 1 run time R Heures Entry U16 0 to 65535 hours
17 Primary pump 2 run time R Heures Entry U16 0 to 65535 hours
18 DHW tank run time R Heures Entry U16 0 to 65535 hours
19 Revers status R Enum Entry U16 0 = Occ, 1 = Inocc
20 Auxiliary relay status R Enum Entry U16 0 = Off, 1 = On
21 Relay alert status R Enum Entry U16 0 = Off, 1 = On
22 Central heat call status (CH) R Enum Entry U16 0 = Off, 1 = On
23 DHW call tank status R Enum Entry U16 0 = Off, 1 = On
24 Fuel switch status R Enum Entry U16 0 = Off, 1 = On
25 Primary pump flow validation status R Enum Entry U16 0 = Off, 1 = On
26 Air (Air Comb) combustion validation status R Enum Entry U16 0 = Off, 1 = On
27 Error codes R Enum Entry U16 See error list
System Parameter Registers
1 BAS heat call demand R/W Enum Hold U16 0 = Off, 1 = On
2 BAS target setpoint demand R/W °F Hold U16 60 to 225°F
3 Primary pump demand R/W Enum Hold U16 0 = Off, 1 = On
4 DHW tank pump demand R/W Enum Hold U16 0 = Off, 1 = On
5 Occupied space R/W °F Hold S16 35 to 100°F
6 Unoccupied space R/W °F Hold S16 35 to 100°F
7 Designated outdoor temperature R/W °F Hold S16 -60 to 45°F
8 Terminal unit type R/W Enum Hold U16 0 = HRF1, 1 = HRF2,
2 = CONV, 3 = COIL,
4 = RAD, 5 = BASE
9 Outdoor temperature R/W °F Hold S16 -85 to 149°F
(-85°F = invalid temperature / no BAS sensor)

Modbus Parameters

Read = R | Read/Write = R/W

(n) represents the specific boiler number, including 1, 2, 3, and 4.

Registers Parameter Name Read/Write Units Type Format Range
Boiler Status Records
10,11,12,13 Boiler (n), Active/Inactive R/W Enum Hold U16 0 = Active, 1 = Inactive
28,36,44,52 Boiler (n) type R Enum Entry U16 0 = MOD, 1 = 1STG
2 = 2STG, 3 = EMS
29,37,45,53 Boiler (n) condensation R Enum Entry U16 0 = No, 1 = Yes
30,38,46,54 Boiler (n) outlet temperature R °F Entry S16 -22 to 266°F
31,39,47,55 Boiler (n) modulation rate R % Entry U16 0 to 100%
32,40,48,56 Boiler (n) run time R Heures Entry U16 0 to 65535 hours
33,41,49,57 Boiler (n) cycles R Num Entry U16 0 to 65535
34,42,50,58 Boiler (n) pump status R Enum Entry U16 0 = Off, 1 = On
35,43,51,59 Boiler (n) pump run time R Heures Entry U16 0 to 65535
Product Information
60 Product Model R Num Entry U16 4000
61 Firmware Revision R Num Entry U16 Revision SVN
62 Application Version R Num Entry U16 J letter of number
(A=1, B=2, ...)

Modbus Troubleshooting

If there is no communication, check the following items:

  • Verify that the parity on Modbus terminals A and B is correct.
  • Verify that the Modbus 'GND' (ground) terminal is securely connected.
  • Verify that the baud rate is the same on both devices.

If communication is intermittent, check the following items:

  • Verify that the communication cable is of the twisted type.
  • Reliable communication depends on the cable length and baud rate used. A long cable length may require a lower baud rate.

Error Codes

Code Description Code Description
0 No error 15 Boiler sensor input
1 EEPROM error 16 Primary pump flow validation error
2 Primary sensor power error 17 Air combustion validation error
3 Primary sensor return error 18 Common flue temperature maximum warning
4 DHW sensor error 19 Heat absence warning
5 Outdoor sensor error 20 tN4 master copy
6 Common flue sensor error 21 tN4 master schedule
7 Boiler 1 outlet sensor error 22 tN4 member schedule
8 Boiler 2 outlet sensor error 23 Device lost (Bus b) tN4
9 Boiler 3 outlet sensor error 24 Device lost (Bus 1) tN4
10 Boiler 4 outlet sensor error 25 Device lost (Bus 2) tN4
11 Boiler 1 outlet temperature maximum warning 26 Device lost (Bus 3) tN4
12 Boiler 2 outlet temperature maximum warning 27 Device error (Bus b) tN4
13 Boiler 3 outlet temperature maximum warning 28 Device error (Bus 1) tN4
14 Boiler 4 outlet temperature maximum warning 29 Device error (Bus 2) tN4
30 Device error (Bus 3) tN4

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