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HeatNet Manual - IDC Associates, Inc

1. or ren Closing Contact here enables the 4 20 ma control input This Method allows direct modulation of the boiler based on a 4 20 mA control signal A control capable of transmitting a 4 20mA 0 10 VDC control signal for the purpose of modulating a boiler and to control a common system temperature must be used with this method NOTE If using 0 10 VDC signal multiply any references to current in the manual by 5 Example 5 2 5 VDC Page 40 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 36 Heating Method 5 MODBUS Optional BACnet or LonWorks bridge Protocessor Version 1 x control flue pc board 24 5 enr er e P qm Q lt rae oy oe key 6 Vee Ya TT 2 gt 1 2unec P B Lees ez 24 G G MODBUS elg s Optional BACnet or EN A PERDRE LonWorks Bridge em Protocessor USB to computer K6 e E gt
2. Uf x 20008900081 1000000006 NOT Terminated R Push both white switches down 8 to enable BACnet Lonworks or Modbus termination l MADE IN USA KN F SERIES 02 2008 e KNHNET KNHLK RZ 0D aly HEAT D 1 Dy DEMAND ENABLE DR OUR H PUMP owen AL ALARM bu Z HIGH erie RJ45 Configuration and IP connection NOTE Do not plug the Protocessor module in with power on or Protocessor module may be With the version 2 x H Net control there are pin headers located on damaged the control U shaped that the Protocessor bridge module plugs in directly Align the sockets on the Protocessor with the pin headers on the control then press into place All power for the bridge is supplied by the version 2 x control Communication from the Protocessor bridge to the H Net control is also handled through the sockets Protocessor Bridge Module Plug in LonWorks or BACnet bridge which Can be used instead of the MODBUS input 9 w a Next connect the BACnet or LonWorks network cable to the Protocessor module or configure the bridge using the software tools Once connected use the DIP switch to enable termination B 3 Shielded Twisted Pair Connection MSTP LonWorks Additional Bulletins and Instr
3. 5 15000058 EHEHHE Shielded cable Heat Net Out _ To Next Boiler Heat Net Communications Between boilers KN SERIES 02 2008 KNHNET KNHLK R2 0b Member Close to run at Local Setpoint Member Close to control all boilers amp run at System Setpoint 0 NOT Terme Push both white switches down to enable H Net Close this contact to override the Outdoor Reset or Modbus termination Termination is required slope and run at the Local System Setpoint on MASTER and last Member boiler Page 37 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 33 Heating Methods 2 and 4 AA High Fire and High Low master or member boiler Version 1 board blue version 2 board green YTLE nu 5 on eae uou 801r ji esas sus 4 1 81 3889 xn auas 2 500 a0 7 1 3 on _ 3 m 990000 e i y 1 ERI 5
4. Situation Firmware update program starts to load but then stops or does not load at all 1 Check that the termination shunts 13 and J6 are not in the termination setting If they are remove them temporarily while updating Restore them for proper communication with a building management system 2 Ensure that the USB driver for your PC Laptop computer is properly installed 3 Disconnect BMS or Protocessor Module if connected Situation All HeatNet Boilers fire at the same time 1 This is usually caused by the HeatNet addresses on the Member boilers not being set If the address on each boiler is not set then all boilers will have address 2 by default When the Master boiler calls to fire boiler 2 all boilers with address 2 will fire Set each Member boiler to a unique address from 2 16 2 Check the ADD Boiler delay time to ensure it is at a reasonable value A setting of 0 will start all the boilers at the same time Situation The boiler is showing that it is running at 45 and there is no fire in the sight glass 1 The Boiler always shows it s called for firing modulation This is not an indication of what the boiler is actually firing at If the ignition control fails to receive a call to fire last interlock closed on terminal 6 of the ignition control the display will indicate the called for Check if the ignition control is in standby if so then the HeatNet control has closed the S
5. e SEP o 5 lt 84 s te ea m From a Boiler e e q 4 Mem Bav Ime m 77 Right Angle Pins T T E oo Optional cover plate to secure Optional 2 NET Miena Termination Y BACnet LonWorks Protocessor Es 56 66 8 AA 2239 Termination J21 H NET MODBUS 27 _Straight Pins P d Optional BACnet or LonWorks Network H Link Termination Master always has 2 termination jumpers enabled Termination J21 J23 Member farthest boiler has 2 jumpers enabled Termination J21 J23 MODBUS Always A MEMBER Terminate last using J3 amp J6 Termination enabled Additional Bulletins and Instructions for Configuring BACnet or LonWorks are available on the website at http www RBIWATERHEATERS com Page 41 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 37 Heating Method 5 MODBUS Optional BACnet or LonWorks bridge Protocessor Version 2 x control green pc board DUM BEL 990 h 91198309 MII BLM 9557 M O D B U Sm Shielded or twisted pair wire to building management system RS CO 1 81 mr HE e e JSSNUHL X2 1395 X HUW 3010 044103 395 313 cr 10709 SLM 5 a
6. 9 9 7 J12A AAAA m 8 m tee HIGH FIRE DEMAND ENABLE OR 098 2 T Z 208 230 240 single phase L2 NEUTRAL R 120 60 Lao vac 0002 lt NEUTRAL 1 5 WIRING CONNECTIONS HeatNet Control REV 3 47 1 NOTE J4 can be used Figure 31 Heating Method 1 H Net Master member Version 1 x control blue pc board ant lt X voIr m erem roe s m am ain nei pem iz F3 ee 115 5 e Ez vs e 7088 55 5 9s ee 0 5 ni ee DO E 1 51 E amp Ne e TER C wx CONTROL Nort KN F SERIES 13 X 8 KNSX 2 lguey amp Member Close to run at Local Setpoint 78 NET Termination Member Close to Enabled Disabled control all boilers amp run at E
7. 10 11 SELECTING MIXEDIBOIRERS tot DIM Pt de tecti A R u ma 13 MIXED SYSTEM 1 HIGH SYSTEM TURNDOWN 13 MIXED SYSTEM 2 CONDENSING 6 16 BASE LOADING RELAY CONTROL VERSION 2 X 18 SETTING UP AM cA MM LIN 20 Heating Control MethodS e ce 21 HEATING METHOD 1 21 25 21 HEATING METHOD 21 HEATING METHOD 52h 21 HEATING METHOD EE 21 OPERATING LIMIT 21 INPUTH PRIORITIES 21 HEATING METHOD WHEAT DEMAND errs bo d LER 22 HEATING METHOD 2 STAGE CONTROL 1 72 0 0 0 23 METHOD 3 4 20MA GONTROL hl ei 23 uu u u u _ _ usss aha 23 HEATING METHOD 5 MO
8. 80 31 m n e Joins flux Siaces Pure 3 MADE IN USA KN F SERTES 02 2008 KNHNET KNHLK R2 0b Heating Method 4 Heating Method 2 Close this contact Stage Control to run boiler at Inputs High Fire AA 1 2 Stage 1 Stage 2 Page 38 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 34 Heating Method 3 4 20 ma Version 1 x control blue pc board 24 00 4 Modulation Control 4 20ma 0 10vdc Input 4 20ma 0 10vdc 4 24VDC Return e BUY 801r e s 4 SNS on 8 ne ias id 09m7 4n 599 3uees aim o g 3015100 ino wun masas 1 39895 on erg P9 Li ups mL py N e 999 8 al 2 g ain T en od 7 M e
9. 5 e e e e e 9 p 9 1 Le 55 5 FN nei e e e e e e e 2 83201831NI 297 544 32 e LT Ld no Se 2 r e 2 m D uy S 2 Jise e 6 e gt E EE E 2 E ii 3 5 e be 58 g 15 5 5 5 5 i o se a ole els 12 L 1 0 e els a 142 N Lom 5o k e ej 5 e E 8 e 2 d Kz e gt 5 5 L em Em a Kea Koa Kea 13 65 K 2 x gt gt S mz T r 5 lt i 5 d d Wee 2 zm amp 8 8 1 924 E e i 4 2 121 c M r 9 e eL e Le TTERGGK START GILRG ONTPER CIRGUATOR ee gt T TERLOCKS NORM J1 2A V F SERIES 1 KNSX 2 Bongo erc m maT 2008 FTHER DAMPER HIGH FIRE DEMAND ENABLE Heating Method 4 Close this contact Stage Control to run boiler at Inputs High Fire AA 1 2 Stage 1 Stage 2 Heating Method 2 ow 5 x
10. Y paio TIME 9 25 AM DAY OF WEEK TUE MONTH SEP DAY 27 2005 76 512 BOILER CYCLES COMBUST AIR DAMPER ALARM SI LENCE FAILSAFE MODES HEAT EXCHANGER gt DHW BOILER NO DHW SETPOINT 160 F DHW DIFF 5 USE SENSOR NO DHW PRIORITY NO POST PURGE 120S DHWMASTER TYPE LINKED COMMON IN USE YES INPUT J12B PIN 7 PROOF TIME 2 00 HeatNet Control REV 3 47 1 KN HeatNet Control Advanced Menu Tree Hydrotherm Version 3 47 gt DISTRIBUTED CTRL MODULAR BOILER SET ADAPTIVE MOD FIRING MODE gt gt CONTROL H NET H NET MASTER YES H NET ADDRESS 255 MODBUS ADDRESS 1 MODE ADAPTIVE gt ADD BOILER DELAY SHED BOILER DELAY MOD MAX DROP DOWN ON PILOT gt MODULATE DELAY TIME 4 LAST FIRE 4 ADD DELAY TIME 4 MINUTES 0 SECONDS SHED DELAY TIME DELAY RELEASE 05 2 MINUTES 0 SECONDS MODULATE DELAY TIME gt MODE TRUE 0 MINUTES MIN RUNTIME 10 HRs 10 SECONDS MIN OFFTIME PREDICT START YES gt gt STOP MOD Y gt BASE LOAD BOILERS 0 gt FIRING MODE START gt MOD 95 70 BASE LOADI
11. INWA 10718 10600600 04 RELAY 177 RELAY 177 Metus DINER fux cru que oz 45 WIRING CONNECTIONS Figure 41 Typical Single Boiler System version 2 green pc board shown HEADER SENSOR Determines Master Boiler 4 MAX SYSTEM RETURN SYSTEM PUMP OUTDOOR ENABLE 14 SENSOR gt FLOW PROVE 9 North Away FLOW PROVE From Exhaust 10 1 RETURN SUPPLY SENSOR SENSOR 3 2 2 7 1 DHW SUPPLY HeatNet Control REV 3 47 1 SYSTEM SUPPLY DHW TANK AQUASTAT 13 DHW TANK SENSOR 5 V f DHW TANK BOILER COMBUSTION COLD WATER SEEN ENABLE 12 PROVE 11 amp Hg oan eve SINE 5 E T xum 158 a wnt ce 3 3 E n o 85 N a 4 5 z 9 3 z 1 5 ATER OGE uc 20
12. 5 OOOO o e 1 S e gx 9 7 1 gt SMOOTUSINI 290 LII Bea 5 5 Fa LI Ka F3 ee 3 NE MIS 5 ES 5 e ke ge zie an T 15 one nje 1 PEN 510 es Se 8 8 0 2 Egle ele e ele 3 Kla 8 2 e 83 E 53 1 k 5 abe a sia F elle R R s ao r TSERGUC BONA 8 kx 00000000 as edad AA AAA 1 8 l aa B v HERE 9 All Temperature Sensors are 10k Thermistors grado i d Immersion sensors require a well reto Sensors require awe OPTIONAL Water Temperature Common System Supply Header TANK Cup oom in 19250 vn awe SOLAS mug eno POKER 3Jtvi35 085093 5 IVT CSHOLINS ward INIEILDOK MADE IN UGA KN F SERIES 29 B2 0b 5170 S 9 EVETEM PUIP
13. e 4 20 2 PWM Duty Cycle Ignition 100 Percent of Boilers Output 0 o Ignition After Ignition 20 for 5 1 boilers 25 for 4 1 boilers 33 for 3 1 boilers Page 47 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 43 system damper wiring d 5 090090060000 e 9 9 9 9 on e MEMBER BOILER 2 5 09000806090 0 e quy 906 9 8599 QO M MEMBER BOILER 1 Connection if Member boiler i running as Failsafe 2 E 6 6 E E 600 0 98 9 5 MASTER BOILER NOTE Ensure that the Combustion Air Damper is enabled on all Boilers for use SETUP MENU AUX FUNCTIONS C ec F Q DAMPER Prove Switch 2 Mains A DAMPER _______________ Enable DAMPER 24 VAC 24 VAC Ret Transformer Q Connect to 24 VAC DAMPER Return on each Boiler Page 48 WIRING CONNECTIONS Figure 44 Failsafe common system pump wiring HeatNet Control REV 3 47 1 ee 60001 2297900000000 6 6 2 i 2 120 VAC Return
14. HeatNet Control Menu Tree Hydrotherm Version 3 47 76 KN HeatNet Control Advanced Menu Tree Hydrotherm Version 3 47 77 5 E A 78 Thermistor 82 Stat s Screen Fault A 83 En trIleSr aaie aaae aasa aeaa Pae 85 Information contained in this publication regarding device applications and the like The Hydrotherm name and logo Mestek name and logo KN HeatNet and is provided only for your convenience and may be superseded by updates It is your H Net name and logo are registered trademarks of Mestek Incorporated in responsibility to ensure that your application meets with your specifications the U S A and other countries HYDROTHERM MAKES NO REPRESENTATIONS OR WARRANTIES OF BACnet is a registered trademark of ASHRAE LonWorks is a registered ANY KIND WHETHER EXPRESS OR IMPLIED WRITTEN OR ORAL trademark of Echelon Corporation All trademarks mentioned herein are STATUTORY OR OTHERWISE RELATED TO THE INFORMATION property of their respective companies INCLUDING BUT NOT LIMITED TO ITS CONDITION QUALITY PERFORMANCE MERCHANTABILITY OR FITNESS FOR PURPOSE http www hydrotherm com 2010 Mestek Technology Inco
15. Member If a SYS DHW HEADER sensor is not connected to J10 a boiler always defaults to the role of Member The Member boiler can operate as part of a multi boiler system or as a stand alone unit In a multi boiler system the Member typically receives its command signals from a designated Master boiler It is also capable of receiving inputs from an external control system The boiler responds to these signals to start stop the burner and or to modulate the firing rate The outlet water temperature is also monitored If the outlet temperature approaches the operating limit temperature setpoint adjustable the boilers firing rate is limited and its modulation value is reduced to minimize short cycling If the operating limit is exceeded or if an interlock trips the boiler is shut down When connected with a network cable in a Master Member role the Members status 1s interrogated by the Master boiler HeatNet Control REV 3 47 1 In a stand alone installation the Member typically receives its command signals internally and operates based upon the outlet water temperature input and the established settings in the menu Local Set point to start stop the burner and or to modulate the firing rate If the operating limit is exceeded or if an interlock trips the boiler is shut down As ina multi boiler system a stand alone Member boiler is also capable of receiving inputs from an external control system When using the H Net
16. 0 0 7 33 AVAILABLE ON BOTH V1 X AND 2 33 DHW METHOD 3 SPACE HEATING WITH DHW OVERRIDE 33 33 DHW METHOD 4 DHW USING DIRECT CONTROL 34 AVAILABLE ON BOTH V1 X AND V2 X CONTROLS assis as iiis siiis sisse 34 Wiring Connections 35 Calibraliolfis u 50 Log 51 Default Settings amp Menu Item Descriptions SETUP 52 Default Settings amp Menu Descriptions ADVANCED 56 MODBUS u SNR u u u 60 Tro bl eshootiBg S u E a ET 68 HeatNet Control Run Screen SNR 4S ARR u u u 73 Status aola ei o a P 74 STATUS INFORMATION SCREEN S L 74
17. Figure 18 Heat demand input E A Kr mer a 1e Member Close to run at Local Setpoint Master Close to control all boilers amp run rp ae pe 8t System Setpoint Master boiler The MASTER boiler controls the system using a PID algorithm Once the boiler is started a PID algorithm is used to produce a modulation percentage value from 0 100 This percentage is converted to a PWM P ulse W idth M odulation signal by each boiler The temperature of the water is maintained by sending this PWM signal to the Variable Frequency Drive which in turn controls the blower motor Since the main fuel valve is air fuel coupled to the blower the speed of the blower provides the firing rate Member boiler s A Member lacking a common system supply header sensor boiler may also be controlled by the HEAT DEMAND input LOCAL mode The member boiler will then ignore commands from the Master and maintain its own LOCAL SETPOINT at its supply sensor This can be viewed as a manual override on a member boiler Be sure to observe the use of the proper use of a Common System Damper See AUXILIARY FUNCTION OPTIONS section and any system pumps or system common interlocks Features of the HEAT DEMAND input include 1 control is designed to predict when to start and stop the boiler and keep the setpoint in or as close to the control band as
18. 5 EE 5 olo o 2 2 S SS 88040 e Add additional relays dle Ealo Edie 8 contacts for more boilers 0000000 0 1 MEMBER BOILER 1 120VAC MASTER BOILER 120VAC 120 Return O TA System Pump Voltage Return System Pump Voltage Feed S p System Pump lc System Pump Contactor 200000 0 0100004000406 E 444 M HE 4 e eee gt gt S 2 r 2 5 S System Flow 9222555555 Prove Switch e r lo e 6 1 ee 4 0000000 00000000 MADE IN USA 41 Page 49 CALIBRATION Calibration A detailed startup and walkthrough of the calibration and H Net setup is provided in the Programming Examples manual NOTICE calibration of the KN Series boiler should only be performed by a licensed technician To enter the calibration menus place the S2 switch on the main control board to the CAL position Be sure to set this switch back to NORM when the calibration is comple
19. 2400 4800 9600 19200 38400 8 1 8N1 7 5 FORMAT 8E1 8N2 801 8 bits Even Parity 1 stop bit valid settings 8E1 8N1 8N2 801 If set to YES the setpoint timer is enabled and requires a periodic update of its value to keep from timing out and retuning control to SETPOINT TIMER YES H Net control If set to NO MODBUS always has control and on a loss of MODBUS communications H Net does not assume control LOAD DEFAULTS Selecting YES will load just the factory calibration values MIN Selecting YES will load all factory defaults except the Calibration 2 FACTORY RESET values HeatNet Modbus addresses SYSTEM BOILER TYPE There are 2 Priority settings used by the MIXED boiler rotation FIRING PRIORITY algorithm Priority 2 is the default and lowest priority Priority 1 isthe BTU IN 2000 000 This is the BTU input rating of the boiler This value is not used with this version and is displayed only for reference This defines a boiler as condensing or non condensing This value is CONDENSING not used with this version and is displayed only for reference and future applications pee defines the mass of the boiler This value is not used with this MASS phe DER and is displayed only for reference and future applications LOAD FIRMWARE YES deletes the existing Firmware and allows a firmware When set to DUAL FUEL input T3 RESERVED OPTION input is used to control the
20. Day of the week to end the setback or a day range Time of the day to end the setback OPTIONS T BRIGHTNESS 5096 25 50 75 100 Displays completed boiler cycles Incremented when the main valve BOILER CYCLES turns OFF after it has been ON Does not include attempts to light TEMP SCALE KEY CLICK o Page 53 DEFAULT SETTINGS amp MENU ITEM DESCRIPTIONS HeatNet Control REV 3 47 1 AUX FUNCTIONS COMBUST AIR DAMPER The LINKED COMMON setting allows one common damper to be used and controlled by the Master Boiler All Member boilers must LINKED COMMON have their damper prove inputs wired as per Figure 43 Common INDEPENDENT system damper wiring page 48 Also see Section Optional Features Auxilliary Function Options INDEPENDENT Individual dampers are in controlled by their respective boiler If set to YES then OUTPUT RELAY 5 be used to control a combustion air damper The Master can control a common system IN USE YES damper or an individual damper Members control their respective damper independent of the Master Relay 5 is used to enable the combustion air damper See Figure 43 Common system damper wiring page 48 Needs to Prove the damper is open There are 2 inputs that may be used for the Combustion Air INPUT J10B DAMPER Damper The first is located at J10B terminals 1 and 2 legacy compatibility The second input is located at J12B terminals 7 and 8 This is the proving time in minutes
21. System Setpoint Close this contact to override the Outdoor Reset x slope and run at the Local System Setpoint H Link Termination Master always has 2 termination jumpers enabled Termination J21 J23 Member farthest boiler has 2 jumpers enabled Termination J21 J23 MODBUS Always A MEMBER Terminate last using J3 amp J6 Termination enabled Page 36 instead of J1 If RJ45 cables ends are not available use shielded or twisted pair wire Computer or Management System USB to Computer To Next Boiler From a Boiler Angle Pins mg 98 98 NO Termination PU Straight Pins Termination p H NET MODBUS Ed Newer Versions have 2 DIP switches 1 for the MODBUS and 1 for the H NET To enable the termination place both switches on the respective DIP switch to the ON position WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 32 Heating Method 1 H Net Master member Version 2 x control green pc board MU 2004 rma 15 way Lol al 3 SXO90TH31NI 8 d 5 2 n 8 n a 3310033 HINDA RJ45 Heat Net IN RJ45 Heat Net 241 5 10710 349743 36 3 21017 5 Shielded cable Heat Net IN__ 8
22. are allowed to fire above this clamped percentage up to 100 This boiler efficiency clamp is defaulted to 70 and thus limits all of the boilers individual outputs to 70 until the last boiler fires All running boilers modulate up and down together always at the same modulation rate As a general rule this percentage should be no lower than twice the minimum turndown to minimize short cycling Page 4 FEATURES amp SPECIFICATIONS When additional boilers are needed to achieve setpoint in the system the Master boiler employs an ADAPTIVE MODULATION algorithm to prevent over firing of the system The Master communicates over the H Net to view the exact status of each Member boiler When a new boiler is added the Master boiler adjusts the system modulation rate lower to compensate for the BTUs that will be introduced by the newly added boiler This adjustment occurs when the newly added Member boiler enters its ON CALL state default setting This can be changed to PILOT when the new boiler is called using the menu ADVANCED SETUP ADAPTIVE MOD DROP DOWN Once the Main Valve on the newly added boiler is opened and the DELAY RELEASE timer equals zero the PID algorithm is allowed to control the system modulation Setting the DELAY RELEASE timer will allow some soak time of the newly added boiler before releasing modulation control to the PID NOTICE The ADAPTIVE MOD menus are disabled on a Member boiler but are still visible
23. 2 Maximum heating is required START PRIORITY 1 SET Selections always the lowest runtime first NOTICE The condensing boiler set Priority 1 has a higher Priority to fire when one of these conditions is met Values are adjustable FIRST The condensing boilers Priority 1 are always started FIRST OA T gt 15F The condensing boilers Priority 1 are started when the OA temperature is greater than the Mixed Boiler Outdoor Air Temperature setting RET lt 140F The condensing boilers Priority 1 are started when the Return water temperature is less than the Mixed Boiler Return temperature setting This may not applicable in most configurations since the local return temperature on the Master is used to provide a difference temperature across the heat exchanger However the return temperature sensor may be moved on the Master to provide system return temp if the difference temp is not required STOP PRIORITY 1 SET Selections always the highest runtime first NOTICE The condensing boiler set Priority 1 has a higher Priority to stop when one of these conditions are met Values are adjustable LAST The condensing boilers Priority 1 are always stopped LAST OA T lt 15F The condensing boilers Priority 1 are stopped first when the OA temperature is less than Mixed Boiler Outdoor Air Temperature RET gt 140F The condensing boilers Priority 1 are stopped first when the Return water temperature is grea
24. 2 000 000 3 000 000 4 000 000 5 000 00 System Load Btu Hr correct this would require the KN6 to set the MOD MAX to roughly 90 Boiler System Response 3 not as efficient as it could be in order to have a linear BTU transfer when the KN20 is added fired Figure 10 Boiler System Response 3 1 KN6 1 KN20 90 Mod Max Bir 4 600 MBTU Bir 1 2 2600 1 00 1 0 10 1 1 1 0 500 000 1 000 000 1 500 000 2 000 000 2 500 00 System Load Btu Hr A KN6 running with a KN20 may not be an optimal choice unless 2 KN6 s are always functional and used in the Priority 1 set or 3 KN6s and one is allowed to be taken offline A system employing this redundancy where 1 is allowed to be taken offline is listed in the MIXED BOILER SYSTEM chart The example system uses 3 KN2s and 3 KN10s Two of the KN2s are treated as one when adding the min inputs of the Priority 1 set Page 15 SETUP amp OPERATION HeatNet Control REV 3 47 1 Figure 11 Boiler System Response 4 2 KN2s 3 KN6s Mixed System Type 2 Condensing Non Condensing Bir 1 200 MBTU Bir 1 2 400 MBTU 4 Bir 122255 1000 METO This mixed system may also have mixed boilers with Bir 1 2 3 4 5 2200 differing sizes as outlined in the Mixed System Type 1 1 00 L High System Turndown section In the following examples 0 9
25. 22 Programmable password protection to secure the programmable settings 23 Remote 4 20mA setpoint control using a mapped setpoint range to the 4 20mA control signal 24 Freeze Protection allowing automatic starting of boiler s using 2 Failsafe modes 25 Adaptive Modulation When additional boilers are called the Master adjusts all boilers fire rates to compensate 26 Mixed boiler types in a system Hardware Version 2 x Control Additional Features Identified by circuit board color GREEN 1 Support for Domestic Hot Water DHW using 10k Sensor or a dry contact input from a tank thermostat 2 Domestic Hot Water relay for use with a pump or valve 3 On board power and socket for Protocessor BACnet LonWorks module HI LO relay control option from connector J4 Resettable Fused interlock power circuit Additional terminal connector for H Net shielded cable Backwards compatible to Version 1 x hardware Communications board integrated with the main board from version 1 x control 9 Base Loading of 1 boiler FEATURES amp SPECIFICATIONS HeatNet Control REV 3 47 1 Specifications Control Environment Input Power Relays AC Interlocks Control Inputs Dimensions Temperature Sensors USB RS485 MODBUS Boiler to Boiler Network Microprocessor based PID modulating control NOT a safety limit 40 F to 140 F lt 90 RH non condensing 24 VAC 500 ma System
26. Air temperature rises above 72F While in this state the OR OVR input on J12A can be used to bring the boiler system on to maintain the water setpoint at the LOCAL or SYSTEM SETPOINT value During WWS operation the System pump will not be enabled just the Local pump unless the SETUP SYSTEM PUMP OVR ENAB IN WWS is set to ON This is the System Pump Priority mode When SETUP SYSTEM PUMP OVR ENAB IN WWS is set to OFF the system pump will not come on while in WWS with the OR OVR override input closed Sensors The H Net control supports a standard 10K thermistor Type ACI 10K CP These sensors can be calibrated to the control by entering the sensor menu and placing a precision 10k resistor on an input NOTICE Immersion sensors must have wells Security A password can be used to lock out control and setup features It can be enabled but is shipped in the disabled state Diagnostics The H Net control can display and identify faults in a meaningful way If an interlock trips it will be indicated in the main screen display along with an audible alarm mounted on control board and a set of relay contacts will close record of this with a time stamp will also be entered into the log as an aide in the diagnosis of the event The log can be downloaded and a histogram used to display the data If using Modbus BACnet or LonWorks software flag bits in registers are available Open and shorted sensors are checked contin
27. Cutoff 2 Variable Frequency Drive 3 Gas Pressure High amp Low 4 Spare for user or Factory 5 Operator 6 Water Flow Switch 7 Factory 8 Low Voltage Interlocks 3 24VAC USB Port for Programming new firmware qon p wem pe em pedo npe OOF ABE NEU e mo 8 vie Big 1 e 1 E ag 8 SEDES anus 5007839 VY e E _ e 55 Si me FACTORY E COCCO High voltage e eL e 120VAC B iss ge e si interlocks and sp 3 385 in DIHET zz ds Firing status 2 3 eo 9 3 2 2 2 3 6 SN u r 33 3 i 2 0 uu e K Kt 1 2 5 k 5 88006300 1 COBRLAYYKEVPAD 4 1 8 ii e 1 M a 1 MADE IN USA 8 o o o KN F SERIES 02 20 7KNHLK Wo ab aji KNHNET ere e Combustion Damper
28. DUAL FUEL OPTION relay via K8 contacts on NO OPTION J4 2 amp 6 When set to NO OPTION the input T3 RESERVED DUAL FUEL OPTION relay K8 on J4 2 amp 6 is inactive OPTION NO OPTION BASE LOAD When set to BASE LOAD the Option Relay K8 on J4 2 amp 6 is used as an enable contact for a base load boiler The J4 1 amp 5 0 10vdc 4 20mA output is used to modulate the base load relay if it is of the modulating type Page 59 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 MODBUS Communications The KN Series control can be controlled using Modbus commands to Enable Disable the boiler system A connection to the Console Modbus Port on the Communications board is required The Master Boiler assumes the role of MEMBER RTU 192Kb 8 bits Even Parity 1 stop bit when connected to a BMS Building Management System The Member Boilers should not be connected to a BMS system other than to view Read Only addresses Refer to http www hydrothermkn com website for greater detail on communicating with Modbus BACnet or LonWorks protocols Figure 46 MODBUS Input Output Variables Read Write HeatDemand Heat Demand Request Setting the state 40001 1 bit unsigned H member of this variable will put the boiler System Setpoint Timer The system setpoint timer and system setpoint work in tandem to externally control i e a BMS building management system the operating setpoint The setpoint countdown timer should be loaded with
29. Ifthe Ignition Control is active but the front panel display is inactive check a Cable and cable polarity from the control board to the display b 114 on control board 120vac is routed from here to the transformer The transformer returns 24vac to power the control c Check for 120 on the primary of the transformer and 24vac on the secondary If one of the 24vac interlocks has been shorted to ground or the 24vac output is low the transformer may be damaged or a 24vac circuit may be miss wired NOTICE The H Net control is equipped with resettable fuses on the power input circuit Wiring power incorrectly to the unit will cause these fuses to open Once the incorrect wiring is corrected the fuses should reset themselves in less than 5 minutes Situation You get the error message for the Combustion Air Damper 1 The prove switch for the combustion air damper is not closing Check to make sure the dampers are being controlled by the output relay Also check to make sure the prove switch is wired and working properly 2 If 1 has been done and you are using SPARE 1 and you continue to get the error message check the sensor TYPE specified for sensor 5 in the sensors menu If it Page 68 HeatNet Control REV 3 47 1 is set to NONE the controller will not recognize the closed circuit Set the Sensor 5 to ON OFF 3 If you are not using the combustion air damper then it needs to be disabled in the AUX FUNCTIO
30. TEMP BASE LOAD BOILER CALL SERVICE HeatNet Control REV 3 47 1 If a call is made to the ignition control to start and the HeatNet control detects a blower start but no Pilot within two minutes the boiler locks out This log entry indicates that the blower was ON with no flame in the boiler Freeze up protection These log entries indicate that HeatNet has either discovered a boiler or lost a boiler using it s auto detection algorithm If the Fail Safe modes are active these log entries indicate that they became active for some reason and the boiler had entered Fail Safe mode The Base load Boiler Relay K8 is Active if ON Inactive if OFF If the H Net control closes the last interlock string connected to the ignition control and the ignition control never closes its Blower Relay the H Net control will wait 2 minutes The H Net control will then retry for the duration of the local pump post purge time and then retry the ignition sequence During this time retry will be displayed in the status screen After 5 attempts the H Net control will lock out and display call service Page 87 HydroTherm VT IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONT 158 1L4 905 672 2991 FAX 905 672 2883 www hydrothermkn com A MESTEK COMPANY
31. The HeatNet series control will remain powered to display the fault latch the alarm relay audible beeper and to access the log The interlock is located on J5 HIGH LIMIT Ensure power is present on the input to the High Limit Control SPARE 4 This is a reserved interlock input that is user defined The interlock is located on 152 SPARE 4 FAULT SYSTEM SET USER INTERLOCK 160 F DELTA TEMPERATURE WARNING If the temperature difference across the boiler measured from RETURN water to SUPPLY water exceeds the EXCHR DELTA T RANGE setting this message will be displayed 1 2 INPUT SYSTEM SET 160 F HeatNet Control REV 3 47 1 LOW WATER CUTOFF If there is a low water condition reported by the low water cutoff switch this fault is displayed Check that there is water flow and water in the boiler There is a reset switch located on the LWCO box The interlock connection is located on 152 LWCO FAULT SYSTEM SET LOW WATER CUTOFF 160 F VAR FREQ DRIVE The variable frequency drive which controls the blower if supported reports this fault in the event of over current or other conditions that would cause it to shut down If this is the case check the fault indicators on the VFD The interlock is located on 75 VFD FAULT SYSTEM SET VAR FREQ DRIVE 160 F GAS PRESSURE The gas pressure switches high pressure and low pressure are connected in series so if either trip a fault will be rep
32. a high system turndown and provide some fault tolerance Fault tolerance allows for one boiler in the Priority 1 system to fail and any boiler s in the Priority 2 system to fail and still provide near linear continuity BTU response when adding boilers This is illustrated in the following examples using the Boiler System Response graphs HeatNet Control REV 3 47 1 The KN Mixed Boiler System examples is advantageous in providing low BTU input for light loads and high BTUs for heavy loads The effective system turndown minimizes short cycling when light loads are present by assigning smaller boilers to Priority 1 running them first and then stopping them last NOTICE In order to achieve the high effective turndown smaller boilers are required plumbing considerations need to be considered here due to differing flow volume characteristics through the large and small boilers Example Systems Figure 4 Boiler System System Effective KN20 KN20 10 0 KN20 KN20 KN20 KN10 KN10 500 500 500 500 With the traditional Non Mixed boiler system the effective turndown increases by the turndown ratio for every boiler added The min fire rate is equal to the minimum BTUs that can be delivered to the system Number of boilers Turndown Ratio Effective System Turndown 5 5 1 1 Figure 5 Mixed Boiler System System Effective Priority 1 Priority 2 Turn
33. any RUN IN LOCAL IF communications coming from the Master boiler this boiler will run H NET COMM LOST in LOCAL The boiler will continue to run in LOCAL until communications is re established or this entry is set to OFF This entry may be set to one of the temperature sensors SUPPLY HEADER RETURN or turned OFF default If this entry is set to a LOW TEMP OFF sensor and the temperature falls below TEMP the boiler will automatically start and run the water temperature up to the LOCAL Setpoint and then shut OFF TEMP lt 40F 40 F 35 200 F This is the temperature that the selected sensor must fall below for the boiler to start Page 54 DEFAULT SETTINGS amp MENU DESCRIPTIONS HeatNet Control REV 3 47 1 DEFAULT HEAT EXCHANGER This is the maximum differential temperature the heat exchanger can EXCHR DELTA T 100 F 1 to 120 F see before the LIMIT RATE feature is activated and a log entry is made Limit to Half Rate When set to YES and the maximum differential temperature delta T has been exceeded the fire rate called for is cut in half In other words if we are calling for 80 modulation and have exceeded the delta T the boiler will only fire at 40 The delta T needs to drop 10F below the maximum delta T to reset this limit FPP RATE YES The message 1 2 INPUT will be displayed on a member boiler and a Master Boiler will display the Modulation for the system even though it is running at of
34. boiler becomes available and needs to fire the Base Load boiler will remain firing until the temperature exceeds the band This is provided to keep the system from entering a no heat situation CONTROL METHODS Heating Control Methods An overview of the 5 methods for controlling the KN series boiler are presented here They are outlined in more detail at the end of this section See Figure 31 page 36 through Figure 37 page 42 Heating Method 1 The first method is to use the KN Series boiler in its stand alone modulating method This method uses a PID algorithm to maintain a setpoint and is enabled using the HEAT DEMAND input Closing a relay contact or switch across the HEAT DEMAND input will cause the Master boiler to control all member boilers using H Net A member boiler may also be controlled by the HEAT DEMAND input LOCAL mode The member boiler will then ignore commands from the Master and maintain its LOCAL SETPOINT at the supply sensor Heating Method 2 The second method is to view the KN boiler as two separate boilers or as a HIGH LOW boiler using 1 amp 2 Heating Method 3 The third method is to allow a remote 4 20 ma or 0 10 VDC signal to control the firing rate modulation of the boiler using the 4 20ma input along with the 4 20ma REMOTE ENABLE input Heating Method 4 The fourth method turns the boiler ON and OFF 100 modulation using the AA terminal Heating Method 5 The fifth meth
35. enter the DOMESTIC HOT WATER menu When prompted for DHW BOILER enter NO We will enter YES when we are finished entering all parameters 3 Change the DHW SETPOINT to the desired target temperature of the water in the tank Once the control determines there 15 a call for DHW the DHW SETPOINT is loaded and the Master boiler will target this new setpoint 4 Now change the DHW DIFF to the desired differential This setting corresponds to the minimum water temperature required in the tank DHW heating will be initiated when the DHW tank s water temperature is below the DHW SETPOINT DHW DIFF 5 How long the temperature of the tank stays below the DHW SETPOINT DHW DIFF is used to determine when boilers are started along with the ADD BOILER DELAY 6 Scroll down to USE SENSOR Press the SELECT key and select YES then press the SELECT key again This will allow the boiler to control the tank temperature using its sensor 7 Press the DOWN arrow key again to position the cursor beside the menu item DHW PRIORITY Setting this value to YES will turn OFF the system pump when the DHW mode is active Setting this value to NO leaves the system pump on 8 Press the DOWN arrow again and the menu item POST PURGE should appear This is the time that the DHW pump relay remains energized after the DHW SETPOINT has been satisfied Once Page 31 OPTIONAL FEATURES the tank has reached setpoint all boilers will shut 2 off Usin
36. event is displayed so that easy indexing can be done using the arrow keys The second line displays the Water temperature of the boiler s output supply and the Setpoint temperature The third line displays the Outside Air temperature and the Modulation PWM signal sent to the Variable Frequency drive 20 min 80 Max The bottom line is used to record the control state of the boiler The control state is defined as the Boiler s that is running the Circulator Pump state and the ignition condition Main Figure 45 Log entry display Time Stamp gt HeatNet Control REV 3 47 1 Valve Pilot Valve Blower and the Ignition alarm The of boilers that are displayed is limited to 7 if the boiler is the MASTER If boilers 8 and up need to be viewed the Boiler Control Pro software will need to be used The Last 2 characters on the fourth line indicate the heating mode the control is in The modes are No Call for Heat HD Heat Demand MASTER and Local modulation control using PID control MASTER and MEMBER RM Remote Modulation from 4 20ma input HF High Fire from ALL T inputs closed or the AA input 1T Low Fire from any 1 T input closed Low Fire or High Fire 2T Mid Fire from any 2 T inputs closed Low fire or High Fire Option input Active HT H Net Control using the Heat Link communications cable The bottom line is also used to indicate an interlock or limit that has tripped It m
37. firmware this setting was also called the CONSOLE ADDRESS 2 The control BAUD rate must be set to 19200 and the DATA FORMAT must be set to SEI 8 data bits even parity 1 stop bit On older legacy versions of firmware the DATA FORMAT was called PARITY which must be set to EVEN These settings are set in HeatNet Control REV 3 47 1 the ADVANCED SETUP gt COMMUNICATIONS menu Check the termination on the BMS Modbus port If the control is the first or last device on the Modbus RTU network it should be terminated For the short cable runs for instance when using a BACnet or LonWorks bridge on a Revision 1 x board the termination should be in but usually doesn t matter Check the wiring The Modbus RTU RS485 connections on the HeatNet control are A B and G ground Some systems use opposite polarity A B Always use the polarity to determine the proper connections A ground wire must always be used and a shielded twisted wire is STRONGLY suggested The HeatNet LonWorks and BACnet bridges plug directly into Revision 2 x boards Legacy boards Revision 1 x required a ProtoCarrier to provide power and the RS485 signal conversion to the bridge The RS845 signal conversion chips are easily damaged by electrical noise ground loops and large differences in ground potential between devices on the network This is acommon problem faced by all RS485 devices not just the HeatNet control To help eliminate
38. for the combustion air damper prove switch It is sensed at SPARE 1 or J12B Pin 7 If J10B is used legacy Sensor 5 must be set to ON OFF in the sensors menu in order to detect the prove switch being made If the damper faults a retry will occur every 10 minutes in attempt to open the damper If Using J12B in a common damper configuration wiring is done PROOF TIME 0 4min beginning with the Master boiler J12B Pins 7 8 are connected to the prove switch of the combustion damper Pin 8 is supplying 24 VAC and pin 7 is the sense input A second wire is connected to J12B pin 7 of the Master and the other end connected to the first member boilers J12B pin 7 If another member boiler is present connect another wire to the J12B Pin 7 terminal of the first member and the other end to the second member boiler J12B pin 7 Continue this method for each additional boiler ALARM ALARM SILENCE This menu allows the configuration of the Alarm Silence switch It ALARM SILENCE IN YES can be disabled so that the Alarm Silence switch can not silence the USE alarm until the alarm is cleared ALARM SILENCE NO The default value is to enable the ALARM SILENCE switch This setting allows the Alarm Switch to be looked at using another INPUT J10B SPARE 2 input This input should not be changed but allows for custom configurations to resolve conflicts FAILSAFE MODES MODES If this entry is set to ON and the Member boiler does not see
39. possible If PREDICTIVE START is enabled the boiler may start when it is in the band and not below it This will help to maintain a more accurate temperature relative to the setpoint See also ADVANCED SETUP FIRING MODE PRDICTIVE START to disable this feature 2 The control can also use the Outdoor Reset feature This feature allows the setpoint to be changed automatically based on the outside air temperature If this feature is used the control input OR OVR OUTDOOR RESET OVERRIDE can be used to override the Outdoor Reset feature and run from the local setpoint A contact closure on the input can also override this method 3 Firmware Version 2 0 added a 4 20ma setpoint control function that works in conjunction with this mode This CONTROL METHODS function translates a 4 20ma control signal to a setpoint mapped between 50F and 220F These 2 temperatures are adjustable to provide a setpoint range The minimum start current is also adjustable between 3 71 5ma The setpoint control feature is used in conjunction with the REMOTE ENABLE input on J12A This feature is enabled in the SETPOINTS menu as SETPT SOURCE 4 20ma 4 Firmware version 2 2 added support for a common system damper Heat Exchanger support and starting the Master first for common venting For an overview of each of the menu settings see DEFAULT SETTINGS section Heating Method 2 STAGE Control T1 T2 The boiler can also be operated in 2
40. sensor is connected to J10 SYS DHW HEADER terminals The sensor is auto detected The master senses and controls the common system header loop water temperature using a system setpoint It uses any boilers it finds over the H Net communications cable to accomplish this It can also monitor the Outside Air OA temperature to provide outdoor reset functionality Only one master is allowed in a system When operating as a master the boiler provides a control method using a PID algorithm to regulate water temperature This algorithm allows a single boiler Master or multiple Master Member boilers Figure 1 Heat band BOILERS UPPER HEAT STAGED po BAND LIMIT _ _ Y oreet MM e SIN REN Sak SETPOINT LOWERHEAT i BAND LIMIT WATER P TEMPERATURE Time The control algorithm is based upon a Heat Band at the center of which is the setpoint While below the Heat Band boilers are staged on and modulated up until the Heat Band 15 entered Once in the Heat Band modulation is used to maintain setpoint Boilers are shut down only when the top of the Heat Band is breached Timers are also used to prevent short cycling While staging the boilers on a modulation clamp ADVANCED SETUP MODULAR BOILER SET MOD MAX LAST FIRE is used to hold the boilers at a lower fire rate until the last boiler is fired Once the last boiler fires the modulation clamp is removed and all boilers
41. separate stages using the inputs 1 and T2 inputs Its intended use is with an external stage controller with no analog or modulation outputs Closing only one of these contacts tells the boiler to operate at MINIMUM FIRE 1 Closing the other contact will fire the boiler at MAXIMUM output the same rate as closing the AA input Figure 19 Stage control input Method 2 4 Stage Control Inputs Stage 1 Stage 2 NOTICE The maximum output of the boiler is based on the MAX setting in the calibration mode and not the nameplate rating The AA HEAT DEMAND LOCAL input the H Net the 4 20ma input will all override the stage control inputs HeatNet Control REV 3 47 1 Heating Method 3 4 20ma Control Placing a current source between the and 4 20ma inputs will allow remote control of the boilers firing rate An adjustable starting mA current signal here will start and then fire the boiler at the minimum fire rate See ADVANCED SETUP 4 20mA INPUT See section OPTIONAL FEATURES Using the 4 20ma input for extensive detail A 20ma signal will fire the boiler at the maximum firing rate The input current signal is viewed as a percentage to the boiler from 0 to 100 0 20mA This means that a 20 4mA input signal is required to start the boiler but since the boiler is classified as having example 4 1 turn down ratio the boiler can only be fired as low as 2596 of output Any signal between 20 and 25
42. stamp Advanced PID algorithm optimized for the KN Series boilers 4 Dedicated temperature sensor inputs for Outside Air Temperature Supply Boiler Outlet Temperature Return Boiler Inlet Temperature and Header Common System Supply Temperature Automatically detects the optional temperature sensors on power up Menu driven calibration and setup menus with a bright Adj 4 line Vacuum Fluorescent Display 8 Dedicated 24vac interlock monitors and 8 dedicated 120vac system monitors used for diagnostics and providing feedback of faults and system status Multiple circulator pump control modes Combustion Air Damper control with proof time support for a common combustion air damper USB RS485 network plug in to allow firmware updates or custom configurations Optional BACnet or LonWorks interface Page 6 HeatNet Control REV 3 47 1 16 Alarm Relay dry contacts and Audible Alarm 17 Runtime hours and Cycles based on Main Valve Open 18 Outdoor Air Reset with programmable setpoint and ratio 19 Time of Day clock to provide up to 4 night setback temperatures 20 Failsafe mode when a Building Management System is controlling setpoint If communications is lost the boiler system automatically transfers to local boiler setpoint control 21 Rotation Methods Lead Lag True Rotation based on boiler runtime is default First On First Off FOFO Last On First Off LOFO and MIXED are optional
43. the Modulation is gt START lt OA T 40 140 The base load relay K8 will close when the OA temp is gt T START RET 60 150F The base load relay K8 will close when the Return temp is gt T FIRST STOP MOD gt T START gt RET 20 20 100 20 20 100 The base load relay K8 will open when the Modulation is lt 40 100 F The base load relay K8 will open when the OA temp is gt T 60 150 F The base load relay K8 will open when the Return temp is lt T This setting allows a wait time before firing the base load boiler once 0 60 minutes SE the start condition is met Sensors can only be changed when there is no call for heat The boiler must be in STANDBY The first 4 sensor s are reserved as OUTSIDE water SUPPLY outlet water RETURN inlet and system HEADER temperature If the HEADER sensor is used 2 that boiler performs the tasks of the MASTER boiler If the HEADER sensor is set to NONE its function is the MEMBER The remaining 2 sensors perform as user selections and provide functions such as Combustion Air Proving STOP FIRST STOP lt MOD STOP gt OA STOP lt RET DELAY TIME SENSOR There 4 sensor types NONE do not use this sensor TYPEZ 10k thermistor ON OFF 5 volts supplied out to detect a contact switch closure Placing a precision 10k TYPEZ precision resistor across the sensor input selected
44. the presence of the version 2 x control These features include 1 Support for Domestic Hot Water using a temperature sensor or a dry contact from a tank thermostat Also a separate relay contact fora DHW pump or Valve is provided On Board HeatNet and Modbus connections Also added a second terminal connector for daisy chaining the H Net connections when using shielded wire Added a low fire hold switch for ease in calibrating Added U shaped socket system for mounting the Protocessor module No other wiring connectors are required when connecting BACnet amp LonWorks other than the BACnet or LonWorks network cable Support for the KN XLF with 12 VDC 1 amp power control for the Pilot assembly Interlock string is now fused with a resettable fuse onboard F4 OPTIONAL FEATURES Domestic Hot Water Methods The Version 2 x control supports Domestic Hot Water control using 4 methods When using the Domestic Hot Water methods the wire jumper JPS1 on each control board providing Domestic Hot Water must be cut to limit the boiler s maximum output temperature of 200F Refer to Figure 42 for control input and output locations Figure 28 Jumper JPS1 The following Domestic Hot Water setup information will include a walkthrough using the menus DHW METHOD 1 DHW Tank Sensor Input Available on V2 X Controls ONLY DHW METHOD 1a DHW Heating ONLY using a Single Boiler DHW MASTER and Member b
45. this rate This method helps protect the heat exchanger from damage due to excessive delta T s If this Master boiler is running DOMESTIC HOT WATER version 2 x control Setting this value to YES enables the Boiler System for DHW DEW operation DHW settings are only looked at if set to YES DHW SETPOINT 160 F 40 200 F Setpoint that the boiler system will target when a call for DHW DHW SETPOINT DHW DIFF if DHW water temperature is less DHW DIFF 5 F 1 30 F than this temperature the Boiler System will enter DHW Heating mode Once the DHW SETPOINT is reached DHW mode is exited If this entry is set to YES the DHW 10k Sensor is looked to for USE SENSOR controlling DHW water temperature If set to NO A thermostat is used If the DHW PRIORITY is set to YES then when there is a call for DHW PRIORITY DHW the system pump shuts off If NO the system pump stays POST PURGE 0 600 secs is the time that the DHW relay remains on after the DHW call This parameter can only be used if USE SENSOR is set to YES and there is NO Header sensor Present If set to YES this boiler becomes the DHW Master Boiler and will 2 DHW MASTER NO use HeatNet to control member boilers based on the DHW Sensor DHW SETPOINT and DHW DIFF If set to NO only this boiler will run in DHW mode SYSTEM CLOCK TIME This time needs to be entered at first turn on and the eve
46. to determine if the sensor is present 30119 BoilerO8ReturnT emp Go z it signe 2 250 F 30120 BoilerO9ReturnTemp 9 Boiler01 Master Boiler02 Member01 30121 Boiler10ReturnTemp 30122 Boiler11ReturnTemp Boiler16 Member15 30123 Boileri 2ReturnTemp 30124 Boiler1 3ReturnTemp 30125 Boiler14ReturnTemp 30126 Boileri 5ReturnTemp 30127 Boiler16ReturnTemp 30128 BoilerO1CyclesHigh16 30129 Boiler01CyclesLow16 Boiler 1 16 Cycles High Upper 30130 BoilerO2CyclesHigh16 Low Lower 16 bit counters To get the 30131 BoilerO2CyclesLow16 actual cycle count for any given boiler the high and low 16 bit counters 30132 BoilerO3CyclesHigh16 must be combined concatenated into 30133 BoilerO3CyclesLow16 a single 32 bit counter as 30134 BoilerO4CyclesHigh16 Boiler CyclesHigh16 Boiler CyclesL 30135 04 16 ow16 16 bit unsigned 0 4294967295 30136 BoilerO5CyclesHigh16 Example 30137 05 16 Boiler01Cycles 01 0 16 65536 30138 BoilerO6CyclesHigh16 Boiler01CyclesLow16 30139 BoilerO6CyclesLow16 01 Master 30140 BoilerO7CyclesHigh16 BoilerO2 Member01 30141 BoilerO7CyclesLow16 ae Boiler16 Member15 30142 BoilerO8CyclesHigh16 30143 BoilerO8CyclesLow16 Page 64 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 47 MODBUS Input Variables Read Only 30144 Boiler
47. will fire the boiler at the minimum fire rate If the MINIMUM setting of the boiler is set above the example 4 1 turndown of 2596 such as 33 a control signal change between 2596 and 33 will not change the boilers firing rate Once the control signal rises above the MINIMUM fire rate the control signal will then affect control of the boilers fire rate The AA terminal the HEAT DEMAND and the H Net NETWORK are the only inputs that will override the 4 20ma input Heating Method 4 AA Input HIGH FIRE input Control The AA input will fire the boiler at HIGH fire maximum output of the boiler No other inputs can override this input Figure 20 AA High fire input Method 4 Close this contact to run boiler at High Fire AA Page 23 CONTROL METHODS Heating Method 5 MODBUS communications The fifth method uses an RS485 digital communications cable with the MODBUS protocol to control the boiler using the H Net network The Boiler or Boiler network will run as in Method 1 but instead of the HEAT DEMAND input a software form of the HEAT DEMAND input is used 40001 Boiler System Enable Disable See MODBUS COMMUNICATIONS section Figure 21 MODBUS connections version 1 x board Computer or Management Systeg USB to Computer To next Boiler From a Boiler bus RJ45 Modbus TwistedPair gae To Building Management System The System Setpoint Timer also need
48. would create a higher turndown See EXCEPTION NOTES Mod MAX Priority 1 Min Priority 1 s Priority 2 Min Max Input of Priority 1 boiler Priority 1 s Example 2 KN6s 2 KN20s Redundancy 120 400 600 87 No Redundancy 120 2 400 600 2 54 Page 14 HeatNet Control REV 3 47 1 EXCEPTION NOTES 1 Mixing more than two different size type boilers becomes more complex than the scope of this manual and is not recommended 2 Ifusing more than one Priority 1 boiler and the calculated value is lt Priority 2 Priority 1 Max Input Use this result PLUS note 3 value as the ModMax 3 Always add a few 3 5 to the calculated MOD MAX value to allow a guard band tolerance 4 If boilers are of different sizes try to use larger Priority 2 boilers If the calculated Mod MAX value is greater than 99 the combination cannot be used since short cycling will occur Once the Priority 1 and Priority 2 boilers are selected they can be multiplied in each Priority set to achieve the desired system design BTUs If the of boilers becomes a large number a Priority 1 boiler with a higher Min Input may need to be selected While considering the MOD MAX value the lower the MOD MAX the greater the combustion efficiency since it effectively limits the input rate The Typical Efficiency of Non Condensing Boilers chart can help illustrate how the MOD MAX value can affect the
49. 0 condensing high mass boilers will be used with non 0 80 condensing low mass boilers The reason for creating a 0 70 mixed system is primarily to control the system cost 5 0 60 B 050 For the examples the RBI FIII series water heaters will be used These boilers non Condensing fully modulating 0 30 low mass and HeatNet compatible Also consider the 0 20 SMITH series 28 with the HeatNet option in the Priority 2 0 10 1 set 0 00 L 0 1 000 000 2 000 000 3 000 000 4 000 000 5 000 00 System Load Btu Hr Figure 12 Mixed Boiler System The above Boiler System Response 4 graph illustrates System Effective Priority 1 Priority 2 another system where 80 is used as the MOD MAX MMBTU Turndown KN 5 1 MB MW 3 1 5 750 3 45 28 01 00 KN6 6 750 750 clamp In summary the system should be tuned using the boiler selection charts and the MOD MAX value so that boilers are brought on and fired in their respective efficiency curve 1000 1000 while maintaining continuity in BTUs Since selecting the 23 eae Priority 1 boiler is integral to the fault tolerance of the system it is important to note any discontinuities in BTUs if a Priority 1 boiler fails when multiple Priority 1 boilers are used Figure 13 Mixed Boilers Example Condensing Non Condensing PRIORITY 1 PRIORITY 2 Condensing Set Non Condensing Set 1 1 1 1 1 3 4 5 FIRING M
50. 00 000 2 000 000 3 000 000 4 000 000 5 000 00 System Load Btu Hr NOTICE When running non condensing boilers at low input rates the risk of condensing should be considered The Boiler System Response 1 chart illustrates how each boiler in the example is brought on and fires to 60 drops to a lower fire rate and then adds the next boiler vertical dashed lines Once all boilers are firing the modulation is released allowing all boilers to fire to 100 So for the first 2500 MBTH of load the combustion efficiency is maximized by running the boilers from low to middle input rates Now if a 2 boiler system one of the KN6s amp two KN20s brought offline using 1 KN6 with 1 KN20 and MOD set to 60 the KN6 would fire to 360 MBTUs and wait for the KN20 Boiler System Response 2 graph Once the KN20 fired the input rate would jump to 520 MBTUs 400M KN20 20 the 120M KN6 20 There would be 160 MBTUS more than needed The PID algorithm would then compensate for the large discontinuity over fire bump in BTUs and the KN20 would shut off short cycle This discontinuity is observed in the graph below Boiler System Response 2 where the jump from the KN6 60 to the firing of the KN20 is apparent HeatNet Control REV 3 47 1 Figure9 Boiler System Response 2 1 KN6 1 KN20 60 Mod Max Bir 1 600 MBTU Bir 1 2 2600 MBTU 1 00 1 0 10 1 1 1 000 000
51. 00F with a 20F Operating Limit Band When the boiler is trying to deliver 180F to the load it s supply temperature would be a minimum of 180F The beginning of the Operating Limit Band looks at supply temp would be 200F 20F 180F Now when the Master is trying to maintain setpoint at 180F the boiler is trying to reduce input beginning at 180 at its supply sensor and as a result fighting the setpoint The Operating Limit band needs to be reduced in this case while taking into account the Heat Band differential Situation The Master boiler sees all of the Member boilers in the system but does not fire any of the Members 1 Ifthe Master modulates to 100 without firing a Member boiler and the Member boilers are seen by the Master in menu SETUP BOILERS then the Member boilers are sending back offline status to the Master a The Member boilers may have an alarm or error condition which would be indicated by a blinking boiler in the Boilers Firing screen b Ensure the HeatNet is set up properly Amber lights blink on HeatNet Jacks Only one Master boiler TROUBLESHOOTING c Ifthe Member boiler is in Local Mode then it also would not be called and report unavailable to the Master d Ifthe Local flow switch for the Local pump is wired to the System flow switch input this would also create an offline condition The Member needs to detect system flow or have a jumper across that sensor inputin order for the Member boil
52. 4 30035 30036 30037 30038 30039 30040 30041 _ 30042 30043 30044 30045 30046 30047 30048 30049 30050 30051 30052 30053 30054 30055 30056 30057 30058 30059 30060 30061 30062 30063 Page 62 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 47 MODBUS Input Variables Read Only 16 bit unsigned 30096 015 30097 BoilerO2SupplyTemp Boiler 1 16 supply temperature if 30098 BoilerO3SupplyTemp available See BoilerStatus2 to determine if the sensor is present 30099 BoilerO4SupplyTemp 16 bit signed 0 01 Boiler 1 16 stage control input flags These bits indicate the state of the stage control inputs See the values column for a list of conditions See the BoilerStatus3 Table below 32 250 F 30100 055 01 Master 02 Member01 30101 BoilerO6Supply Temp 30102 BoilerO7SupplyTemp 30103 BoilerO8SupplyTemp Boiler16 Member15 Page 63 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 47 MODBUS Input Variables Read Only 30112 BoilerO1ReturnTemp 30113 BoilerO2ReturnTemp 30114 BoilerO3ReturnTemp 30115 BoilerO4ReturnTemp 30116 BoilerobReturnTemp 30117 BoilerO6ReturnTemp Boiler 1 16 return temperature if 30118 BoilerO7ReturnTemp available See BoilerStatus2
53. 783 Sire 3 z P 26 e we zs E Hd 8 m 2 2 g IGN Control gt gt ag 53 Connections Si 5 s d e u 2 8 2 5 09966009 T P n 3 g gt f I 5 Lou A 6 Aur AL gt 1 g Miet Tat 10 8 ORM KN F SERCES 02 2008 KNHNET KNHLK 22 Ob 9 ALARM fas pure e Heat Demand Page 46 Note When using DHW MASTER YES a Heat Demand signal must be used to activate the system WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 42 Using a 4 20 signal for direct modulation A control signal greater Oma 4mA than 4 2mA adjustable 20 will start boiler N NNNN SNS GQ 4 Output Range From gt SS Control GY Once boiler starts the control signal must drop below 4 01 mA to stop Boiler 0 Control Signal Display input of control when running Percent of Boilers 100 lt lt INPUT Control Signal to MAX Output MAX OUTPUT 20 for 5 1 boilers e 0 20 25 for 4 1 boilers 100 SS S Percent of Boilers OUTPUT SSS 33 Boiler Output 20 the minimum speed the VFD will run 209 80 100 x 4
54. AL SET SYSTEM SET HeatNet Control REV 3 47 1 Press theUP or Down Arrow Keys to navigate the display screen RUN 100 SYSTEM SET 158 F The SETPOINT can be RUN 100 HEADER adjusted by pressing and 142 holding the SELECT button until the SETPOINT flashes Then use the UP and DOWN RUN 100 SUPPLY buttons to change the value pu Prssing the SELECT button CELO 162 saves the value CALIBRATE v RUN 96100 OUTSIDE RUN 96100 MINIMUM CALIBRATE Cop 50 F 25 RUN 100 RETURN RUN 100 IGNITION CALIBRATE 90 F 30 100 STATUS RUN 100 MAX OUTPUT CALIBRATE 1 57 90 RUN 96100 BLRS FIRING RUN 100 Cum 12 ui RUN 100 DELTA TEMP RUN 100 DELTA TEMP CALIBRATE cin 25 F rurunmi 25 F RUN 100 DHW TEMP RUN 100 DHW TEMP 457 F 157 F RUN 100 DHW SETPT RUN 100 DHW SETPT chup 160 F 160 OPERATION HeatNet Control REV 3 47 1 Status Information Whenever an is displayed on the RUN screen it indicates that there is more information available about the current running conditions This information can be viewed by going to STATUS screen as shown on the previous page For more information on the parameters discussed here please see the Default Settings
55. DBUS COMMUNICATIONS nan r 24 Using the 4 20ma input OPTIONALL 1 U an tace ce u 25 Circulator P mp Options nta Iia eru eot ore ion 26 Auxiliary Function Opti onsS uu reo aba aq aaa 27 Outdoor Reset U U u u u u u u 28 iu SD 28 diee c ER 28 DONATO SUS M 28 Page 2 TABLE OF CONTENTS HeatNet Control REV 3 47 1 Communications T 29 Failsate 0065 29 FAILSAFE 29 Version 2 X 00 30 Domestic Hot Water Methods u u 31 DHW METHOD 1 DHW TANK SENSOR INPUT 0 n 31 AVAILABEEON V2XCGONTROES 31 DHW METHOD 14 DHW HEATING ONLY USING A SINGLE BOILER OR A DHW MASTER AND MEMBER BOILER S EMPLOYING H NET 31 DHW METHOD 18 DHW AND SPACE HEATING USING A MASTER BOILER AND MEMBER BOILER S EMPLOYING H NET 32 DHW METHOD 2 DHW HEADER SENSOR
56. DHW METHOD 3 Space Heating with DHW Override Available on both V1 X and V2 X Controls This method is for controlling DHW utilizing a tank thermostat connected to a Master or Member boiler This method can be used instead of the 10 thermistor sensor When the thermostat contact closes across the input OA OVR J12A 7 amp 8 the control will sense this closure and enter the DHW heating mode In this mode the boiler will fire to 100 and be regulated by the OPERATE LIM setting located in SETUP SETPOINTS The OP LIM BAND can be used to keep the boiler from short cycling too much by limiting the firing rate as it approaches the OPERATE LIM 1 Wire the dry contact from the thermostat on the tank to the input on J12A terminal 7 amp 8 Also at this time wire any pump or valve from the DHW Pump relay normally open contact 713 Page 33 OPTIONAL FEATURES terminals 9 10 to control flow of the heating water into the tank s coil Enter the DOMESTIC HOT WATER MENU When prompted for DHW BOILER enter NO We will enter YES when we are finished entering all parameters Follow the same steps as used to program the 10k thermistor sensor method but when asked to USE SENSOR select NO Set the DHW MASTER to NO A thermostat can only control 1 boiler H Net is not available with a thermostat on the tank Go to the DHW BOILER enter and select YES The Master or Member will now control the temperature in the tank Pa
57. ELECT key again This will allow the boiler to control the tank temperature using its sensor Press the DOWN arrow key again to position the cursor beside the menu item DHW PRIORITY Setting this value to YES will turn OFF the system pump when the DHW mode is active Setting this value to NO leaves the system pump on Press the DOWN arrow again and the menu item POST PURGE should appear This is the time that the DHW pump relay remains energized after the DHW SETPOINT has been satisfied If there is no HEAT DEMAND signal once the tank has reached setpoint all boilers will shut off and the post purge time will begin If there is a HEAT DEMAND Signal when the tank has reached setpoint the boilers will continue running to provide space heating and the DHW pump relay will be de energized immediately Using the POST PURGE time to dump the boiler s heat into the tank may heat the tank above the setpoint temperature Care should be taken here Press the DOWN arrow again and the menu item DHW MASTER will be displayed Set it to NO for this DHW Method NOTE This DHW Method requires no Heat Demand signal to control the temperature in the tank As soon as the DHW Tank Temperature drops below DHW SETPOINT DHW DIFF a boiler will be enabled OPTIONAL FEATURES NOTE DHW MASTER YES is only to be used WITHOUT a Header Sensor When both a Header Sensor and a DHW Tank Sensor are installed because it has a HEADER Sensor the Boiler wi
58. F COMBUST AIR DAMPER If the combustion air damper has been selected for use AUX FUNCTIONS and the proof switch does not make this fault will be displayed FAULT SYSTEM SET COMBUSTION AIR DAMPER 160 F When the master boiler receives a call for heat and needs to start a boiler the DAMPER relay closes on J13 If the combustion air damper does not prove within the proof time specified in the combustion air damper menu the boiler will not start and then display the fault A combustion damper fault on a boiler can only be cleared by power cycling Page 84 HeatNet Control REV 3 47 1 OPEN SENSOR If the open sensor fault is displayed the sensor in the position reported was originally detected but has since opened The boiler will shut down on any OPEN sensor except the OUSTSIDE AIR sensor FAULT SYSTEM SET OPEN OUTSIDE SENSOR 160 F SHORTED SENSOR If the shorted sensor fault is displayed the sensor in the position reported was originally detected but has since shorted The boiler will shut down on any SHORTED sensor except the OUSTSIDE AIR sensor FAULT SYSTEM SET SHORTED OUTSIDE SENSOR 160 F AIR SWITCH If the IGNITION control closes its blower relay the control does not see the PILOT relay close within 2 minutes and the AIR PRESSURE switch is made this message will be displayed This alarm protects the boiler from freeze ups being caused by a blower bringing in co
59. HOOTING Situation Unable to change the of Boilers in the BOILERS menu 1 In H Net method the KN Series control auto detects the boilers in the system and adjusts the of boilers accordingly 2 Using H NET if the of Boilers is not being adjusted properly to the actual amount of boilers in the system check each boiler There can only be 1 master boiler but there can be up to 15 member boilers Currently a total of 16 boilers in a system Situation The boilers menu only indicates 1 boiler but there are member boilers connected and the amber light blinks on all of the boilers communication s jacks 1 Ensure that the latest version of firmware is installed on all boilers All boilers in a system must have the same firmware revision 2 Ensure the proper termination is set on the Master and the last Member boiler Situation You get the error message WATER FLOW SWITCH or WAITING FOR FLOW 1 Ifthe control does not sense a closed circuit at input connection WTR FLW Check to make sure the circuit for the circulator pump is correct that the pump is being energized and that the flow prove switch is working properly 2 If there is no flow prove switch check to make sure that a jumper wire has been hooked up to J11B WTR FLW interlock Situation H Net boilers are detected but then lost and then detected again etc 1 The H Net communications cable may be receiving interference from the blower ign
60. KNCT2 1011 HydroTherm CERTIFIED Series Gas fired direct vent Cast iron boilers Models KN 6 through KN 30 HeatNet manual Control adjustment and operation instructions for Hydrotherm firmware version 3 49 This instruction manual applies only to Hydrotherm firmware version 3 49 on version 2 x control boards Current firmware is backwards compatible with version 1 x boards but some current features may not be available To replace firmware on an existing boiler contact the factory to obtain the original firmware file or for assistance in applying current firmware to an older version control board Also read and follow KN Series Gas Boiler Installation and Operating Instructions This manual is intended only for use by a qualified heating installer technician Read and follow this manual all supplements and related instructional information provided with the boiler Install start and service the boiler only in the sequence and methods given in these instructions Failure to do so can result in severe personal injury death or substantial property damage Do not use the boiler during construction Construction dust and particulate particularly drywall dust will cause contamination of the burner resulting in possible severe personal injury death or substantial property damage The boiler can only be operated with a dust free air supply Follow the instruction manual procedures to duct air to the boil
61. NG STOP FIRST SENSORS DELAY TIME 10mins 4 20mA INPUT SENSOR SETUP gt START PRIORITY 1 SENSOR SET FIRST BEBE STOP PRIORITY 1 CAL BRATE NO SET LAST gt gt 4mA SETPOINT 68 F 20mA SETPOINT 200 F PLACE PRECISION PRIORITY NORMAL ON CHANNEL CHANGE PASSWORD P TRIM gt TRIM VALUE SET 4 COMMJNICATIONS yBAUD 19200 PASSWORD y DATA FORMAT 8E1 COMMUNICATIONS SETPOINT TIMER ON LOAD DEFAULTS SYSTEM gt FACTORY CAL NO FACTORY RESET NO gt BOILER TYPE LOAD FIRMWARE OPTION NO OPTION gt BTU IN FIRING PRIORITY 2 2000 000 CONDENSING YES MASS Page 77 WORKSHEET HeatNet Control REV 3 47 1 Worksheet BOILERS of BOILERS LEAD STAGE HEAT BAND SETPOINTS LOCAL SETPOINT OPERATE LIMIT OP LIM BAND SETPOINT SOURCE OUTDOOR AIR RESET OA RESET WARM WEATHER SD WWS SETPOINT SET OA SETPOINTS WATER TEMP HIGH OA TEMP WATER TEMP LOW OA TEMP PUMP OPTIONS SYSTEM PUMP POST PURGE TIME ALWAYS ENABLED SUMMER PUMP JOG LOCAL PUMP DELTA TEMP ENAB DELTA TEMP POST PRGE TIME ALWAYS ENABLED PUMP VALVE OPTION REMAINS ON LOCAL PUMP VFD FLOW PROVE NIGHT SETBACK SETBACK ENTRY ENTRY IS SETBACK SETBACK TIME Page 78 WORKSHEET HeatNet Control REV 3 47 1 TME ssi OPTIONS TEMP SCALE KEY CLICK SKIP PASSWORD BRIGHTNESS LOG RUNTIME RUN HOURS DATA LOG ENTRY SIZE BOILER CYCLES AUX FUNC
62. NS menu Situation The display is displaying random characters or the control keeps resetting There may exist a grounding problem with the controller or one of the boilers pumps contactors or other devices connected to it If all grounding is correct there may be an issue with radiated or induced electrical noise interference This may be caused by arcing across a contactor s contacts when starting a pump motor or a large electrical load It may also be caused by the ignition transformer being improperly grounded or the spark gap set incorrectly 1 Attempt to identify the noise source 2 Whatis the boiler controller trying to do at the time of the failure 3 Isthe boiler on the same circuit as the noise source the boiler should have isolated power 4 Are shielded sensor wires used Ensure the shields are grounded only at the boiler control end 5 Are any sensors or sensor wires located near a transmitting antenna Move sensor Situation There are no heating boilers on 1 Check the settings for WWS SETPOINT WARM WEATHER SHUTDOWN if the outdoor air temperature is above the WWS SETPOINT and WARM WEATHER SHUTDOWN is set to YES the circulator pump relay will be locked out and the heating boilers will not fire 2 Ifthe water temperature is within the heating band around the setpoint boilers will not come on The water temperature must fall below the lower band limit to begin firing boilers TROUBLES
63. O9CyclesHigh16 Figure 48 MODBUS BoilerStatus Flags SSS 65 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 49 MODBUS BoilerStatus2 Flags ere NN s This BoilerStatus2 Heat Demand Flag is combination of the Heat Demand input and the Modbus Heat Demand 40001 Page 66 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 50 MODBUS BoilerStatus3 Flags Heat Demand Local Override 0 off 1 1 ____ m oe masa 4 x 11 0 7 5 2 4 7 This BoilerStatus3 Heat Demand Flag is Heat Demand input On member boilers this indicates a Local Override Page 67 TROUBLESHOOTING Troubleshooting This section is included as an aide to help troubleshoot problems with the setup and operation of the boiler See Appendix A for additional fault messages Situation Nothing happens when the power switch is turned on 1 Check For 120 240 VAC on the Service connector J1 Verify the line power is connected as per wiring diagram The Power switch light ON Position should illuminate if this is wired correctly If the light does not illuminate on the power switch ensure that J7 is connected to the main board and the power switch 2
64. ODE menu gt MODE MIXED BOILER TYPE menu gt FIRING PRIORITY 2 master boiler only MIN RUNTIME 10 5 all boilers in set BTU IN 2000 000 MIN OFF TIME 0s CONDENSING NO PREDICT START YES MASS LOW BOILER TYPE menu FIRING PRIORITY 1 all boilers in set BTU IN 2000 000 CONDENSING YES MASS MEDIUM Page 16 SETUP amp OPERATION HeatNet Control REV 3 47 1 Figure 14 Boiler Btu Chart MBH Figure 15 KN Boiler Btu Chart MBH Moa Max 350 525 700 875 11 1 2M 70 Mod Max 200 aso 75o soo 250 375 500 625 750 875M 50 Using the boiler charts and the examples used in Mixed System Type 1 High System Turndown a mixed hybrid boiler system can be designed The Priority 1 boilers should be setup so as to keep the non condensing boilers from seeing return water temperatures of less than 140F to ensure a long heat exchanger life Since the boiler is non condensing the efficiency vs input is relatively flat The MOD MAX value will not have the same impact if the non condensing boilers were placed in the Priority 1 set Page 17 CONTROL METHODS Base Loading Relay Control Version 2 x control The control has the ability to control 1 base load boiler using the K8 Relay contacts on J4 pins 2 amp 6 In order to connect to this plug 2 wires with pins are required and inserted in J4 Base Loading via relay requires these 2 flying leads loose wires avail
65. PTION is set to BASE LOAD The Base Load Relay K8 will not be enabled used unless this is selected 2 Now The ADVANCED SETUP BASE LOAD BASE LOAD BOILERS must be set to 1 3 When the START condition in the BASE LOAD BOILERS menu is met the K8 relay will close But only when the DELAY TIME under the BASE LOAD BOILERS menu expires 24 VAC HeatNet Control REV 3 47 1 no overlap A selection for stopping the boiler now needs to be determined Setting the Stop qualifier Modulation to 40 or a low fire rate will shut the Base Load boiler off and allow the 3 smaller boilers to modulate up again short cycle of the Base Load boiler Use the Delay Timer and Min OFF timer The Stop qualifier OA T gt xxF may also be used if the system design temperature is known Then let the Base Load boiler cycle off its limits whether a 2 stage Hi Lo or modulating boiler The default setting is for the Base Load boiler to stop first once the water temperature exceeds the top of the heating band Base Load RIB Relay Enable Input on Base Load Boiler 24 VAC Return or Chassis Ground mmm 9 e e 2 e Base Load Relay 1 56 85096066 d 3 0 710 9 ME gt 49 e 6000001 19 CONTROL METHODS Setting up base loading The base load boiler is controlled using a set of contacts to enable it location J4 Enabling Disablin
66. Pump Damper Circulator Alarm DHW Pump v2 x 8A 250 VAC resistive K8 on J4 2 amp 6 for Base Loading version 2 x Control 24 VAC 120 VAC input AA Heat Demand 4 20ma Enable OA override T1 T2 dry contact inputs 4 20mA 0 10 VDC 20mA source current 9 wide 6 high 2 deep NTC thermistor 10K 77 F 335 67K 40 F 185 150 F 1 F 1 0 Modbus RTU HeatNet H Net Optional LonWorks BACnet available bridge to MODBUS port Page 7 FEATURES amp SPECIFICATIONS HeatNet Control REV 3 47 1 Components amp Accessories Part Number Component 02 4277 KN Series Control Board Version 1 x 16 0038 KN Series Control Board Version 2 x 02 4279 RS485 Communications Board 02 4278 Graphics Display Board 02 3926 Temperature probe bullet type 1x 250 inch ACI A0K CP BP 02 4283 Supply Header Return Sensors ACI 10k CP I NW 02 4285 Sensor with well ACI CP I 2 5 02 4286 Sensor with well ACI CP I 4 02 4281 Strap on sensor ACI 10k CP S 02 4280 Outside Air Sensor with Housing ACI 10k CP O 42 9529 Installation amp Operation Manual 40 5409 RJ45 Communications Cable Assembly 25 feet 40 5411 Ribbon Cable Assembly Display Control 58 1833 10k ohm Calibration Resistor 40 5408 USB Cable Assembly 6ft 60 5631 Terminal Block Screwdriver Contact Factory MODBUS to BACnet bridge Contact Factory MODBUS to LonWorks bridge Page 8 SETUP amp OPERATION SETUP amp OPERATION Basic Multi Boil
67. System Pump gt prove switch Combustion Air Damper D 1 Local Pump Valve Alarm Domestic Hot Water Pump Valve Page 44 Low Fire Hold Fires the boiler at the minimum rate while in Calibrate This functions exactly as the T1 input Calibrate or Normal run state WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 40 Temperature sensors Top board version 1 blue Bottom board version 2 green REQUIRED Water Temperature OUT supply of Boiler OPTIONAL Outside Air Temperature Sensor rt REQUIRED Water Temperature INLET return of Boiler OPTIONAL Water Temperature Common System Supply Header REQUIRED Water Temperature OUT supply of Boiler OPTIONAL Outside Air Temperature Sensor 8 All Temperature Sensors are 10k Thermistors IF CONNECTED BOILER MASTER Immersion sensors require a well 9 on p ms epu Bg paves 5 0 0 0 0 0
68. TIONS COMBUST AIR DAMPER TYPE IN USE INPUT PROOF TIME ALARM SILENCE SWITCH IN USE INPUT FAILSAFE MODES H NET COMM LOST LOW TEMP TEMP lt HEAT EXCHANGER EXCHGR DELTA T LIMIT gt HALF RATE DHW SETPOINT DHW DIFF USE SENSOR DHW PRIORITY POST PURGE DHW MASTER SYSTEM CLOCK Page 79 WORKSHEET START PRIORITY 1 4 20mA INPUT 4mA SETPOINT Page 80 HeatNet Control REV 3 47 1 WORKSHEET HeatNet Control REV 3 47 1 SYSTEM BOILER TYPE LOAD FIRMWARE OPTION CALIBRATION SETTINGS Page 81 THERMISTOR RESISTANCE TEMPERATURE TABLE HeatNet Control REV 3 47 1 Thermistor Resistance Temperature Table Resistance Temp C Resistance 122 150 302 186 1 Page 82 APPENDIX Status Screen Fault Display There are numerous interlock switches and software limits that are detected Each of these when tripped will produce a display message an audible beeping and an alarm relay closure The fault is displayed first then after a second the time the fault occurred is displayed This cycle will keep occurring until the fault is cleared These faults and interlocks are HIGH LIMIT When the high limit aquastat trips the following message is displayed FAULT SYSTEM SET 160 F HIGH LIMIT FAULT SYSTEM SET 10 27 9 16 160 F The high limit interlock breaks power to the ignition control shutting it off and effectively removes any chance of the gas valve receiving power
69. URES Ensure that this Member boiler s Damper and System pump control are configured correctly with the assumption that the Master is not powered Also ensure that any other System settings related to outside air temperature sensing and system interlocks are set to provide safe operation Low Temperature Protection LOW TEMP or RETURN OFF SUPPLY HEADER DHW This mode may be used by the MASTER or MEMBER boiler and can be used as a type of freeze protection In this mode you may select which Sensor you wish to monitor or you may opt to turn this mode OFF If you select a sensor you may then associate it with a temperature at which the boiler will turn ON Once the temperature at this sensor falls below the LOW TEMP temperature the boiler will start and fire to its LOCAL setpoint Once the Boiler reaches it s setpoint it will turn OFF Using the Base Load Relay Version 2 x If there are no boilers available to fire offline or faulted and there are no boilers in local override and there is a call for heat The Base Load relay will close If a boiler becomes available and needs to fire the Base Load boiler will remain firing until the temperature exceeds the band This is provided to keep the system from entering a no heat situation Page 30 HeatNet Control REV 3 47 1 Version 2 x Control The second generation HeatNet control incorporates some new and additional features The firmware automatically detects
70. a stand alone boiler 2 A boiler in a Boiler Network using the HeatNet H Net protocol 3 member boiler to a boiler management system with multiple input control methods The primary purpose of the control is to maintain the boiler water temperature at the supply or the header sensor using a target setpoint While performing this task the control also monitors dedicated external limits in a limit string and provides an orderly shutdown and fault indication in the event of a tripped limit The monitored limits include a HIGH LIMIT AQUASTAT LOW WATER CUTOFF GAS PRESSURE FLOW IGNITION CONTROL fault GAS VALVE alarm VARIABLE FREQUENCY DRIVE alarm and other optional or user selectable limits NOTICE The HIGH LIMIT circuit is independent of the control and shuts down the ignition control and the boiler if the control board or other component of the boiler was to malfunction The control will continue to function and report the fault but its ability to control the boiler will end HeatNet Control REV 3 47 1 Each KN Series boiler employing this control can function as either a master or a member This allows one boiler Master to be in control of target temperature The other boilers Members only respond to the commands issued by the Master If using an external control all boilers can be setup as members The following will define the roles of master and member Master A boiler becomes a master when a temperature
71. a timeout value in seconds 40002 SetpointTimer 16 bit unsigned prior to writing the system setpoint When 0 65535 seconds the timer reaches zero the control assumes that the BMS is no longer operating and the local setpoint saved on the control is reloaded This is failsafe feature used to help safeguard the system in case of BMS failure If the setpoint timer is not written a default timeout value of 60 seconds is assumed in heating mode 40003 Setpoint 8 bit unsigned System Setpoint see SetpointTimer 40 220 F 40004 OAResetEnable 1 bit unsigned Enables Disables outdoor air reset mode j 40005 OARSetpoint 8 bit unsigned 1 0 ntdoorairreset setpoint Temperature at 40 100 F which boiler shuts down Boiler water temperature setpoint when 40006 OARHighWaterTemp 8 bit unsigned 1 0 Utdoor air temperature is at the high 60 150 F outdoor air temperature setpoint OARHiAirTemp 40007 OARHighAirTemp 8bitunsigned 50 90 0 1 heat demand 40010 SetMonth 8 bit unsigned Set real time clock month see SetClock 0 40011 SetDay 8 bit unsigned Set real time clock day see SetClock 40012 8 bit unsigned a Set real time clock year see SetClock 40009 OARLowAirTemp 8 bit signed 35 40 F Header Supply temperature setpoint when 40008 OARLowWaterTemp 8 bit unsigned io nO i at dne lew 70 220 F outdoor air tempera
72. able from the factory to be inserted into J4 pins 2 amp 6 These 2 wires then make up the Normally Open contacts This feature also requires a rev 2 x control board and can be used on Master or Member boilers It is not applicable in version 1 x control boards no relay The solid state relay K8 with contact connections on J4 2 amp J4 6 has a rating of 0 1 to 1 Amp If the base load boiler is of the modulating type a 4 20mA signal is also provided on J4 pins 1 and 5 Jumper shunt J18 will then need to be set to 4 20mA position Two additional wires available from the factory will need to be added to the J4 pins at 1 amp 5 Pin 1 is the output of the 4 20mA transmitter and pin 5 is the output This modulating control signal is used to modulate the base load boiler along with the HeatNet boilers in parallel The ADAPTIVE MOD does not function in lowering the modulation rate when the base load boiler is added The PID will adapt to the newly fired base load boiler and lower its modulation rate when the increase in water temperature is observed Figure 16 Base loading with KN boilers Boilers BASE LOADING menu gt LOAD 1 master boiler only START gt MOD 95 STOP FIRST DELAY TIME 10mins SYSTEM menu master boiler only gt BOILER TYPE LOAD FIRMWARE OPTION BASELOAD Page 18 HeatNet Con
73. ader water temperature s setpoint When boiler is to be fired in a multi boiler system header water temperature is below the heating band the Master checks the HeatNet boilers it has available Then the Master checks if a Lead Boiler is to be used LEAD BOILER 0 The Master boiler then looks at which type of firing rotation it has selected LOFO FOFO TRUE runtime or MIXED In our example we will use the TRUE runtime rotation since it is the default The Master now checks all of the runtimes to determine Which boiler has the least runtime based on the MIN HeatNet Control REV 3 47 1 RUNTIME setting in ADVANCED SETUP FIRING The MIN RUNTIME setting is the minimum runtime interval in hours that is used to compare boiler to boiler runtimes Once the boiler to fire has been determined the Master sends the command over the H Net cable to fire that boiler and resets the ADD BOILER delay timer to prepare for the next boiler to fire If the header water temperature is still below the heating band and the ADD BOILER delay timer has expired to zero the process is repeated until the header water temperature enters the heating band When a boiler receives a command to fire it 1 The system pump relay is enabled and the H Net control displays Flow Wait until the flow switch closes between J11A 1 amp 2 within the programmed time 10 240 seconds 2 Allelements in the interlock string terminated between J11A an
74. all for heat any control input This mode will stop the circulator pump when the call for heat is lost and the pump post purge time has been satisfied 3 The third mode works much the same as mode 2 but it allows the inlet sensor RETURN to be used with the outlet sensor SUPPLY to keep the pump on until a delta difference temperature is met A return temperature sensor is required for this mode because the delta temperature SUPPLY RETURN measured is across the boiler In this mode the post purge time is also used After the delta temp has been met the post purge time needs to expire before the pump is turned off This mode works much the same as mode 2 PUMP VALVE OPTION This is a special feature of the local circulator pump to prevent deadheading water flow when all boilers are off When this feature is enabled the master boiler will enable its local circulator pump valve when NO boilers are running If boilers are running in LOCAL override and not controlled by H NET but are visible to H NET the pump s on these boilers are presumed ON In this situation the master will not enable its circulator pump valve unless it is running Another feature of the PUMP VALVE OPTION is to control a local primary pump using a Variable Frequency Drive This feature may be required when a secondary system pump is also variable speed To enable this feature SETUP PUMP OPTIONS LOCAL PUMP PUMP VALVE OPTION LOCAL PUMP VFD ON Setting th
75. allows calibration of the sensor input CALIBRATE 4 20 INPUT When using 4 20mA setpoint control in SETPOINTS SETPOINT SOURCE This is the temperature when a 4ma signal is applied and o 50 F 50 220 F is tied to the BOILER START mA The Setpoint will then be mapped from 4mA 20 and example default of 50 220F 20mA SETPOINT 220 F 50 220 F This is the setpoint temperature when 20mA signal is applied This is the current value which will start the boiler There is a 1mA BOILER START 4 11mA 3 71 5 0mA hysteresis value So if the Boiler starts at 4 mA it shuts off a 4 01mA If the Priority is set to NORMAL the boiler responds to its HEAT DEMAND inputs in the Priority that is outlined in the Control Methods section If the PRIORITY is set to HIGHEST The 4 20ma input responds at the highest Priority level same as the AA input PRIORITY NORMAL This method may be used by an external control to override the HeatNet control and fire the boiler using this external control external control override This allows for complex DHW control systems Page 58 DEFAULT SETTINGS amp MENU DESCRIPTIONS HeatNet Control REV 3 47 1 PASSWORD AAAAAA Provides a limited access for security though restoring system defaults will reset the password to the value AAAAAA COMMUNICATIONS BAUD 19200 bas This is the Baud rate for serial communication from the MODBUS 19200 38400 port Selectable from 1200
76. amp Menu Item Descriptions SETUP starting on page 52 limit clamp input clamp Page 74 This screen indicates that the boiler s SUPPLY Temperature has gone above the OPERATOR LIMIT This will mainly be seen on member boilers to show why they are not available to fire This screen indicates that the boiler s SUPPLY temperature has risen inside the OPERATOR LIMIT BAND This screen indicates the boiler s input is being limited by the MOD MAX value to optimize system efficiency This will only be seen a MASTER boiler OPERATION HeatNet Control REV 3 47 1 Status information screens This screen indicates the control is attempting to re retry strt initiate the ignition control because the ignition control did not begin PRE PURGE For more information see CALL SERVICE LOG entry LLL This screen indicates that the boiler s has received heat demand but it s MINIMUM OFF time has not expired ADAPTIVE IN This Screen indicates that the boiler s input is temporarily being limited to optimize the boiler s efficiency This screen indicates that the boiler is running in H NET LOST LOCAL MODE because it has lost H NET communications with the MASTER and the failsafe mode has been activated V FE TI EV 75 OPERATION HeatNet Control REV 3 47 1 KN H
77. ay also indicate a sensor that has failed When this occurs the normal bottom line in the display is not visible and the sensor fault is displayed For details on messages that appear on the fourth line See Appendix B Event number E Water Setpoint 3 05 42P 10 20 127 Outside Air mE OA 6 5 4 MOD 5 7 2 Modulation PWM Temperature 1 Boiler 1 On Boiler 2 _ 7 3 Circulator Pump System Pump D DHW Pump ver 2 x control M Main Valve open NC No Call for Heat HD Heat Demand RM Remote Mod 4 20ma HF 1T 2T 3T T inputs Fire Rates HT H NET Control H Honeywell Alarm P Pilot Valve open Blower ON Page 51 DEFAULT SETTINGS amp MENU ITEM DESCRIPTIONS HeatNet Control REV 3 47 1 Default Settings amp Menu Descriptions SETUP DEFAULT BOILERS OF BOILERS 1 16 If operating as a member LEAD BOILER 0 16 of first boiler to run determines the fire order in rotation A of first boiler to run determines the fire order in rotation A 0 LEAD BOILER Se disables the Lead Boiler function Firing Mode determines lead HEAT BAND 2 50 F Differential temp around setpoint used to stage boiler s OFF ON HNT M 16 This line displays the boilers auto detected by H Net While M is the Master boiler the numbers are t
78. ble is connected between boilers and one is configured as a MASTER requires HEADER sensor then the MEMBER boilers will be controlled over the network by the MASTER Priority 4 The 4 20ma 0 10VDC input in tandem with the 4 20ma REMOTE ENABLE input is next Any signal over 4 02ma or 2 01VDC will start and operate the boiler if the REMOTE ENABLE is closed Priority 5 The lowest Priority is using the boiler as 2 stages HIGH LOW These are the T1 and T2 inputs Each of these control methods will now be explained in more detail Heating Method 1 HEAT DEMAND Closing a relay contact switch or jumper across the HEAT DEMAND input will enable this method This method allows operation as a setpoint control As a setpoint control the Master defined by having a common system supply header sensor on the H Net network can command the boiler fire rate of all Member boilers The Master can call as many boilers that it has available boilers are auto detected over the H Net cable by the Master to meet its SYSTEM SETPOINT The H Net cable must be connected and will cause the amber light on the communications board to flash The amber light indicates an H Net master is broadcasting control information and a system heartbeat The AA terminal the FAILSAFE mode active 4 20ma at PRIORITY HIGHEST and the HEAT DEMAND input LOCAL on a Member are the only inputs that will override the H Net control Page 22 HeatNet Control REV 3 47 1
79. curve typical WATER TEMPERATURE SETPOINT 0 Outside Temp The above chart shows how the water temperature setpoint changes with the Outside air temperature The four values of 180 10 and 140 70 are the default values WATER TEMP 180 F Water temp LOW OA TEMP 10 F outside air temp WATER TEMP 140 F Water temp HIGH OA TEMP 70 F outside air temp Outside air temperature WWS Setpoint 72 F where Warm Weather Shutdown occurs The chart depicts what the water temperature setpoint will equal with a corresponding outside air temperature At an outside temperature of 10 and below the water temperature setpoint will be limited to 180F With an outdoor temperature of 70F and above the water temperature will be limited to 140F The water temperature setpoint will track along the charts plotted line with corresponding outside temperatures The OR Outdoor Reset Override input on J12A can be used to override this Outside Air Setpoint and maintain the Page 28 HeatNet Control REV 3 47 1 water setpoint at the LOCAL or SYSTEM SETPOINT value when a contact is closed across this input This can be used as a Domestic Hot Water demand input Another function of the OUTDOOR RESET is the Winter Summer mode W arm W eather S hutdown With the WWS SETPOINT set to 72F and WARM WEATHER SD set to ON the boiler system will enter summer shutdown when the Outside
80. d The concept is that periodically or every time a setpoint is written the BMS must write this value If the value reaches zero 0 the HeatNet control assumes that the BMS in no longer functional and safe operational values for the setpoints will be restored As an example if it is decided that the BMS will write the Page 72 HeatNet Control REV 3 47 1 control every 5 minutes you may decide to write 600 seconds 10 minutes to the setpoint timer If after 10 minutes 5 minutes longer than the normal write interval the BMS has not written the timer the saved setpoint values will be restored As a convenience the SETPOINT TIMER is automatically loaded with 60 seconds if it has fallen below 60 each time the setpoint is written If you decide to take advantage of this convenience you would need to write the setpoint periodically at less than 1 minute intervals Newer firmware versions allow the SETPOINT TIMER failsafe feature to be disabled by writing a zero 0 to the timer The feature will automatically revert back to the enabled state whenever the control is reset or power cycled The SETPOINT TIMER failsafe feature can permanently disabled or enabled in firmware versions 3 35 or greater This setting can be changed in the ADVANCED SETUP gt COMMUNICATIONS menu OPERATION KN HeatNet Control Run Screen MASTER SYSTEM SET Hold theBACK button down for 5 seconds lt to enter the SETUP menus MEMBER LOC
81. d J11B must be closed before the sequence is allowed to continue 3 If all interlocks are closed relay K5 is enabled to command the combustion air damper open If used The H Net control displays Damp Wait until the damper endswitch to closes 4 Relay is enabled energizing the local pump if used The H Net control commences its Flow Wait timer adjustable 10 240 sec The flow switch contact is interrogated on terminals J11 B 5 and 6 5 With all the interlocks closed the boiler start relay K1 is enabled and energizes terminal 6 on the ignition control 6 The ignition control begins its cycle and provides an output signal from terminal 4 to the H Net control The H Net control responds and provides an output signal to the which sets the blower to the programmed pre purge speed 7 After air flow is established the ignition control waits for the air switch to close When the air switch closes it provides an input to terminal 7 and pre purge timing commences The H Net display indicates Pre Purge 8 When purge is complete the ignition control energizes the pilot gas valve from terminal 8 and the spark generator from terminal 10 beginning a 10 second pilot flame establishing period PFEP The H Net control responds and provides an output signal to the VFD which sets the blower to the programmed ignition speed The H Net display indicates 9 At the end of the PFEP the spark generator is de
82. d or is not met such as with OA T or RET temp the PRIORITY 2 set of boilers will fire first next based on runtime This has the effect of flipping the Priority of the sets Stopping Boilers When boiler is to be stopped water temp is above the heating band the Master checks the HeatNet boilers it has available The Master boiler then looks at which boilers are returning Priority firing status set on a boiler in ADVANCED SETUP FIRING MODE MODE MIXED SET LAST example If the Stop condition for Priority 1 is met the Master or Member boiler that is configured as PRIORITY 1 with the highest runtime will be stopped LAST example As long as the stop condition and SHED DELAY time are met all remaining PRIORITY 1 set of boilers will stop based on runtime If the Stop condition changes and or is not met such as with OA T or RET temp the PRIORITY 2 set of boilers will stop first next based on their highest runtime A boiler s firing Priority can be designated as such in ADVANCED SETUP SYSTEM BOILER TYPE FIRING PRIORITY 1 menu on each boiler A Priority of 17 is the highest priority a 2 the lowest default is always 2 SETUP amp OPERATION Figure 3 Mixed Boilers Example Condensing Non Condensing PRIORITY 1 Condensing Sel FIRING MODE menu SMODE MIXED master boiler only MIN RUNTIME 10HRs MIN OFF TIME Os PREDICT START YES BOILER TYPE menu gt FIRING PRIORITY 1 all boilers in se
83. down 5 1 4 1 2 KN10 KN10 KN6 KN6 KN2 2 KN10 KN10 With the mixed boiler system a lower minimum fire rate BTU can be delivered to the system by using small boilers with larger boilers This works in much the same way as base loading KN10 KN10 Page 13 SETUP amp OPERATION Figure6 Boiler Btu Chart MBH ena ne ovo Max input 200 1mm iom 160M 320M 480M 800M 1 6 2 4 Mod Max 140M 280m 420M 1 4MM 2 1MM Mod 120M 240m 360M 1 2 1 Mod Max 100M 200m 500M E When selecting the Priority 1 boiler s for a high effective system turndown the BTU Min Input is selected first See KN Fusion amp Boiler Btu Chart Next the MOD MAX value of this Priority 1 boiler needs to be greater than Mod MAX Priority 1 s Min Input Priority 2 s Min Input Max Input of the Priority 1 boiler The reason for this is keep the continuity of BTUs linear without a BTU bump discontinuity when boilers are added or shed This is illustrated in the Boiler System Response 2 graph If redundancy is not required the min inputs of the Priority 1 boilers may be summed to lower the Mod Max value so smaller Priority 1 boilers can be used The sum of the min inputs would then need to be divided by the sum of the Max Input of the Priority 1 boilers The effect of this
84. e e o a eYeYeYeYeYeYeYe OOOO 4 9 2 1 Ex T 2 5 lt 111 51 1 J 2 S20 1831NI 29052 LiT Boo umper in this e xi ob 18 J10 iti f 3 rz 0 e position Tor 5 5 aoe 5 5 4 20 e e ela e e e e in e ES B e 8 8 2 iB J lt 5 ios REG 5 2 9 ch nje iL 8 E10 e e Fx 5 3 9 8 S g g e 0 K3 a K 66 K2 d 2 02 le e EU Kia 4 2 0 6 6 6 6 6 6 6 0 6 3 e rog e ej e js 19000000000 x gt DISPLAY 5 55 x 5 5 5 L 5 Im n a le e 1 23 amje e i 1 le N 0 6 9 0 e e 9 TNTERLOGK START 0 e ee 3 gt INTERLOCeS NTROL A A A 1 3128 KN F SERIES ES KNSX 1 2 BOILR2 BOILR3 ALARM 2006 OTHER DAMPER e Closing Contact here enables the 4 20 ma control input This Method allows direct modulation of the boiler based on a 4 20 mA control signal A control capable of transmitting a 4 20mA 0 10 VDC control signal for
85. eatNet Control Menu Tree Hydrotherm Version 3 47 HOME SCREEN RUN 100 SYSTEM SET Press and HOLD BACK button down for 5 u zt seconds to enter the ERES 140 F menu screen MAIN MENU SCREEN gt SETUP KN SERIES V3 47 ADVANCED SETUP BOILERS VIEW LOG SETPOINTS OUTDOOR AIR RESET gt OF BOILERS 1 LEAD BOILER 0 7 BAND 40 MENUS HNT 42 SS 2 v 3 05 42 10 14 13 LOCAL SET 2 127 F SET 140 F OPERATE LIM OA 65 F MOD 57 OPLIM BAND F P HD SETPT SOURCE AUTO L pfp Reset OFF WARM WEATHER SD OFF WWS SETPOINT 68 SET SETPOINTS WATER TEMP AT HIGH OA TEMP ABBE NEXT WATER AT LOW OA TEMP F BACK gt PUMP OPTIONS gt SYSTEM PUMP NIGHT SETBACK Sj LOCAL PUMP POST TIME 5m OPTIONS PUMP VALVE OPTION ALWAYS ENABLED OFF LOG RUNTIME FLOW PROVE _ 105 SUMMER PUMP JOG OFF 8 TEMP OFF DELTA TEMP 10 POST TIME 5m ALWAYS ENABLED OFF PUMP VALVE L REMAINS ON OFF SKIP PASSWORD LOCAL PUMP VFD OFF BRI GHTNESS 50 v RUN HOURS LOG RUNTIME p _ ___ AUX FUNCT ONS DOMESTIC HOT WATER SYSTEM CLOCK
86. een added to help protect systems from loss of heat conditions When using one of these modes ensure that you connect any DAMPER control or system pump control to safely allow operation with the assumption that the MASTER boiler or BMS system is DOWN FAILSAFE REQUIREMENTS 1 Since the Member boiler that will be assigned the Failsafe duty will always turn the system pump ON this boiler should not be used for DHW heating If the Master controls the system pump then the Failsafe Member boiler would need to control the system pump in parallel with the Master boiler Wire the System Pump contacts in parallel with the Master 2 Ifthe combustion air damper is used as a common system damper the Failsafe boiler should be wired to control the damper in parallel with the Master boiler HeatNet Control REV 3 47 1 3 Failsafe boiler must have the LOCAL SETPOINT set to the same setpoint temperature as the Master boiler s SYSTEM SETPOINT Be aware that the boiler may start without a call for heat in the FAILSAFE MODES FAILSAFE MODES can be accessed through the SETUP AUX FUNCTIONS FAILSAFE MODES The following are types of Failsafe conditions 1 Building Management System Failure Ifa BMS system is controlling the setpoint and enabling the boiler system a timer is provided to allow operation of the system in the event that communications are lost with the BMS system The HeatNet boiler system will run locally if communicatio
87. efficiency by limiting the input until all boilers have fired Non condensing boiler efficiency is relatively flat compared with condensing as illustrated in the Typical Efficiency of Condensing Boiler graph Figure7 Typical efficiency of condensing boilers GAMA BTS2000 method 100 98 20 input 96 94 40 input 7 60 INPUT 90 80 input 88 F w 86 100 input 84 60 F 80 100 F 120 F 140 F 160 F 92 Efficiency GAMA BTS 2000 method Return water temperature 20 F rise SETUP amp OPERATION In the Mixed Boiler System table line 1 KN6s are set as Priority 1 and KN10 s set as Priority 2 With MOD MAX of 60 each KN6 can run to 360M 720M total before a is called ON Add Delay timer set long enough Once both KN6s are running and the KN10 is then called on and running all 3 boilers will drop to a total of the 720M BTUs The sum of the KN6 KN6 and KN10 About 33 modulation 33 600M 33 600M 33 1MM or 198M 198 330M 726M and operate at higher combustion efficiencies 33 is roughly between the top two lines on the Typical Efficiency of Condensing Boilers chart Figure 8 Boiler System Response 1 2 KN2s 3 KN6s Bir 1 200 MBTU Bir 1 2 400 MBTU Bir 1 2 3 1000 MBTU 1 2 3 4 1600 MBTU Blr 1 2 3 4 5 2200 MBTU 0 1 0
88. energized If the pilot flame is detected by the UV scanner the ignition control energizes the main gas valve from terminal 9 The H Net display indicates 10 If main flame is detected H Net control holds the burner at the low fire rate for the MODULATION DELAY time period After this timer expires the PID allows the boiler to modulate and places the boiler into the running state Page 9 SETUP amp OPERATION As boilers are added to the system settings in the ADVANCED SETUP ADAPTIVE MOD DROP DOWN menu determines when the modulation rate drops down to compensate for the newly added BTUs For the drop down to be active one boiler needs to be running when a new boiler is added see Introduction The KN SERIES H Net Control Master If all boilers are firing the modulation rate is released to go to 100 If all boilers are not firing the modulation is limited to the MOD MAX clamp value The MOD MAX clamp is used to keep the boilers running as efficiently as possible The following Mixed Boiler System Operation Selecting Mixed Boilers section outlines this with examples Once the header water temperature is in the heating band only the modulation rate is used to achieve the target setpoint The system will maintain the setpoint until the load demand increases or decreases As the load decreases the header water temperature will start approaching the top of the band The PID now lowers the modulation rate to the boil
89. er System Operation NOTICE For boiler system setup installations please refer to Refer to the 2008 ASHRAE Handbook 12 or later revision A basic multi boiler system typically uses boilers of the same size and type With HeatNet this includes 1 Master and 1 15 Member boilers The boilers are connected together using an H Net communications cable effectively creating 1 boiler This allows the system heating BTUs to be evenly distributed amongst all of the boilers See Figure 41 Typical Single Boiler System page 46 Figure2 Basic multiple boiler system Master Members 1 to 15 boilers total A basic multi boiler system can be configured using the boiler menus to create custom systems features These features are best described in the section Default Settings amp Menu Item Description page 52 Along with these menu items are hardware support for many auxiliary functions Once the system has been properly setup all default menu values used and H Net addresses assigned the system is enabled by placing the REMOTE LOCAL switch to the LOCAL position on the Master boiler All Member boilers must have their respective switches in the REMOTE position When the Master boiler s Heat Demand input LOCAL switch closes the system becomes operational and will fire as many boilers as it needs to maintain the he
90. er air intake If the boiler has been contaminated by operation with contaminated air follow the instruction manual guidelines to clean repair or replace the boiler if necessary Affix these instructions near to the boiler Instruct the building owner to retain the instructions for future use by a qualified service technician and to follow all guidelines in the User s Information Manual Copyright 2011 Mestek Inc TABLE OF CONTENTS HeatNet Control REV 3 47 1 TABLE OF CONTENTS TABLE OF CONTENTS u u u u u u 2 ei 4 THEKNSSERIES HEATNET GONTROL ig ete cbe anna Qul 4 Feat res amp 066 6 ka ua 6 SBD6 GIfiCationS 7 Components amp Accessories u noniine 8 COMPONENT 423223 cr ote rice Su haya hiss a B ir 8 4 lt lt 2 9 BASIC SYSTEM OPERATION 9 MIXED BOILER TYPES USING PRIORITY 10 MIXED BOIEER OYSTEM 0
91. er is not of the modulating type stopping the Base Load boiler will require that the size of the Base Load boiler in BTUs is known relative to the HeatNet boilers Boiler selection is ideally having more total BTUs in the HeatNet boilers than total BTUs of the Base Load boiler This will prevent short cycling Example 4 2 million BTU HeatNet boilers 8 million BTUs and 1 6 million BTU Base Load boiler When all 4 HeatNet boilers are running 95 the Base Load boiler is called on demand is approx 8 million BTUs As the Base load boiler comes on it introduces 6 million BTUs and the HeatNet boilers modulate down to 25 for a total output of 2 million BTUs and running at high efficiency The HeatNet boilers can now modulate to the load from 1 6 million BTUs 20 mod to another 8 million BTUs CONTROL METHODS Not Preferred Example of having a larger Base Load boiler that is not of the modulating type If there is a 6 Million BTU Base Load boiler running with 3 2 million BTU HeatNet boilers a short cycling situation will arise when the 3 2 million BTU boilers are running 95 and the Base Load boiler is called on At this point there is a need for approximately 6 million BTUs The 3 smaller boilers will then modulate down to low fire At this point the 3 smaller boilers need to shut off or the Base load boiler needs to shut off There is Figure 17 Base loading relay 1 First ensure that the ADVANCED SETUP SYSTEM O
92. er to report available status The Local flow prove switch must be wired to the Water Flow interlock sensor input Situation We are trying to use a 0 10VDC control signal but when we send it 10 VDC only 7 VDC is measured at terminal J10B 6 amp 7 1 The HeatNet control was designed to use a 4 20mA control input If a 0 10 VDC control signal is to be used it must supply at least 20mA O 10 VDC control signals are not recommended due to line loss and the ability of the control signal to reject noise So if using a 0 10 VDC control signal it must be able to supply the 20mA Situation We are using a BACnet or LonWorks bridge We can talk to the bridge but all of the data is zero 0 or invalid This condition usually indicates that the bridge is not communicating with the HeatNet control When operating properly the bridge continuously reads data from the boiler on the Modbus port into an internal buffer When a BACnet or LonWorks read request is received the buffered values are placed in a BACnet or LonWorks packet and sent If the bridge has never been able to successfully read data from the control all data points will have their default value which is typically zero In this situation the control will also not respond to write commands for instance changing the setpoint 1 control s MODBUS ADDRESS must set to 1 This is set in the ADVANCED SETUP gt DISTRIBUTED CONTROL menu On older legacy
93. ers attempting to keep the temperature within the heating band If the system is delivering too many BTUs the water temperature will cross the top of the heating band When the header water temperature first exceeds the top of the heating band the boilers are again checked for the one with the most runtime The selected boiler will turn off immediately and a shed boiler delay timer will be loaded with the delay time This time will need to expire before the next boiler will be stopped but only if the header water temperature remains above the heating band This timer is used to allow the header water temperature to return back into the band when a boiler is stopped When a boiler is stopped there is a fixed rate of BTUs Min Fire that will be removed PID discontinuity to modulate from Min Fire to 0 BTUs on a boiler The timer allows for this loss of BTUs This cycle will continue until the call for heat is satisfied or the Warm Weather Shutdown feature is enabled Mixed Boiler Types Using Priority Sets Using the Basic Multi Boiler System Operation a MIXED boiler Priority method may be added to control condensing non condensing base load or other boiler SETs in a system together These sets compose a system which provides for optimal performance and economy Having dedicated sets of boilers gives the system engineer a tool to create many different boiler systems A boiler set can be constructed by simply setting the firing Prior
94. ettings do not apply to the Priority 1 set the conditional settings will apply to the Priority 2 boiler set Start Stop Priority Conditions The following is an example using mixed condensing and non condensing boilers FIRE FIRST Condensing boilers may be configured to fire first set to PRIORITY 1 when 1 The Return water temperature is below 140F and condensing occurs The Master s return water sensor would need to be moved to the header return 2 The Outside Air Temperature is above a setpoint determined by the system configuration This setpoint ensures that the more efficient condensing boilers run first during shoulder months Spring and Fall when minimal heating is required Below this setpoint larger boilers should be brought on first to base load the system 3 Greater efficiency is required Page 11 SETUP amp OPERATION STOP FIRST Condensing boilers may be configured to stop first set to PRIORITY 1 when The Return water temperature is above 140 and condensing is minimized thus leaving the larger lower cost boilers running to carry the load 1 The Outside Air Temperature is below an adjustable setpoint determined by the system configuration This setpoint ensures that the larger non condensing boilers run during the coldest months when maximum heating 15 required Above this setpoint smaller condensing boilers should be brought on first to run the system as efficiently as possible
95. ftware faults Reset Instruction Firmware or Default load When the control is reset this log entry captures the reason the reset occurred W Watchdog Firmware code ran erroneous code and rebooted P Power ON Power switch toggled B Brown out Microcontroller saw a voltage less than 4 5 VDC OUTDOOR RESET This log entry indicates that Warm Weather Shutdown is in effect Page 85 APPENDIX B Line 4 Message HIGH DELTA TEMP SHUTDOWN UV TEST HIGH LIMIT EXCEEDED IGNITION CTRL ALARM DOMESTIC HOT WATER LOW WATER CUTOFF VAR FREQ DRIVE GAS PRESSURE SPARE 4 OP LIMIT MECH START FAILED RETRY OP LIMIT REMOTE OPEN OUTSIDE SENSOR SUPPLY SENSOR RETURN SENSOR HEADER SENSOR DHW SENSOR SHORTED OUTSIDE SENSOR SUPPLY SENSOR RETURN SENSOR Page 86 HeatNet Control REV 3 47 1 This log entry occurs when the temperature across the heat exchanger has been greater than the EXCHR DELTA T RANGE degrees F After 24 hours of continuous runtime the ignition control module needs to check it s UV detection circuit An orderly shutdown and then a restart will occur This log entry indicates that this has taken place This is not a fault If the mechanical aguastat trips due to it s high temperature setting having been exceeded this log entry will occur The ignition control module has faulted while performing an ignition sequence or while monitoring flame during normal operation If
96. g limit the maximum output will be lessened by 10 With a band of 20 degrees for every degree that it approaches the band the maximum output will be lessened by 5 You can think of this operating limit as a smart aquastat which prevents the High Limit from tripping This method minimizes boiler short cycling when using external inputs The minimum setting is degree and effectively turns the limit band OFF The default setting is 20F Input Priorities The KN Series control inputs are prioritized so that multiple levels of external control can be employed at the same time This means that if we are firing the boiler with a low Priority input and a higher Priority input is called for the boiler will now fire at the higher Priority input When the high Priority input is removed the boiler will revert back to the lower Priority input that is still being called Priority 1 The AA terminal has absolute control and if used will always fire the boiler at 10046 output regardless of any other input The 4 20mA input may be raised to this Priority using ADVANCED SETUP 4 20mA 21 CONTROL METHODS Priority 2 The HEAT DEMAND input is the next and provides the means to operate the boiler in LOCAL MODE when an external control is not present has failed or needs to be enabled or disabled A member can override the H Net commands using this input Priority 3 If a HeatNet H Net Network ca
97. g the POST PURGE time to dump the boiler s heat into the tank may heat the tank above the setpoint temperature Care should be taken here 9 Press the DOWN arrow again and the menu item DHW MASTER will be displayed If this item is set to YES once the DHW MASTER receives a HEAT DEMAND signal it will call other boilers it has available using H Net Setting to NO requires no Heat Demand signal and will only enable the single boiler when the DHW Tank Temperature drops below DHW SETPOINT DHW DIFF NOTE DHW MASTER YES is to be only be used WITHOUT a Header Sensor 10 Finally go to DHW BOILER Select YES If JPS1 has not been cut a message will appear instructing to do so Once this is done the stand alone boiler will control the temperature in the tank or the DHW Master will control the temperature in the tank using as many boilers as 6 it has available on H Net NOTE DHW BOILER Does not need to be set to YES on MEMBER boilers only the DHW MASTER or on a stand alone boiler providing 7 NOTE JPS1 MUST be cut on all boilers providing DHW DHW METHOD 1b Combo DHW and Space 8 Heating using a MASTER Boiler and Member boiler s employing H Net This method utilizes a 10k thermistor connected to the DHW Sensor input of a MASTER boiler a DHW tank AND a HEADER sensor This Method works the same as DHW METHOD 1 but also has the ability to provide space heating Setting up the DHW portion of
98. g this relay contact can be done using any combination of 3 qualifiers to start the boiler and 4 to stop the boiler These qualifiers are 1 Modulation a START menu item The relay contact will close when the MOD from the Master boiler exceeds this value ADVANCE SETUP BASE LOADING START gt MOD b STOP menu item The relay contact will open when the MOD from the Master boiler falls below this value ADVANCE SETUP BASE LOADING STOP lt MOD NOTICE If the START gt MOD value is set to a value higher than the ADVANCED SETUP MOD MAX all boilers will be firing before this modulation rate is reached This will ensure that all available boilers are firing before the base load boiler relay is enabled c Setting the STOP lt MOD to a value slightly above the min fire rate of the system will ensure that the base load boiler will stop before the first condensing boiler stops This is due to the Modulation rate being close to the min modulation rate before the water temperature exceeds the top of the heating band 2 Outside Air Temperature a START menu item The relay contact will close to enable the boiler when the OA T read from the Outside Air Temperature sensor if Equipped falls below this temperature ADVANCE SETUP BASE LOADING START lt b STOP menu item The relay contact will open to disable the boiler when the OA T read from the Outside Air Temperature sensor if equipped rises above this va
99. ge 34 HeatNet Control REV 3 47 1 DHW METHOD 4 DHW using Direct Control Available on both V1 X and V2 X Controls Firmware Version 3 0 adds the ability to set the 4 20 mA input to HIGH PRIORITY This can be set in menu ADVANCED SETUP 4 20mA INPUT This allows a member boiler to be taken offline and directly modulated by an external control If the Master is using it for heating and the 4 20mA is set to HIGH PRIORITY an external control can now output a 4 20mA signal which will take over the boiler s fire rate and override all other heating demand inputs This is typically used for DHW control WIRING CONNECTIONS HeatNet Control REV 3 47 1 Wiring Connections Figure 29 Power connections Version 1 X control factory wiring blue pc board 1 SO IC ges em sero aro un pupa 4 6 s e e ele Ye Ye Ye Ye 4 5 JYNLZ 51 1 S 2071831NI I 2 9 208 230 240 single phase 120 vac 60Hz 1 ee e e e e e e e 5 NEUTRAL 9 909 90 0
100. grounding problems nylon standoffs are required to isolate the bridge from the boiler chassis The ProtoCarrier should also be powered from the 24VDC output on the HeatNet control to help eliminate electrical noise VFD and spark pickup power spikes etc on the power supply lines Please download complete HeatNet bridge installation instructions from the product web Site a When the ProtoCarrier is functional the small green surface mount TX and RX LEDs near the 6 pin connector power and communications should be flashing regularly b Ifthe TX LED flashes very briefly about once per minute the ProtoCarrier has most likely been damaged please contact Tech Services c If either LED is always on the ProtoCarrier has most likely been damaged please contact Tech Services Page 71 TROUBLESHOOTING Situation We are using a Building Management System BMS to control the boilers We can write the setpoints but they keep changing back to their default values after approximately 60 seconds 1 When using a BMS the setpoint values work in conjunction with the SETPOINT TIMER The SETPOINT TIMER is a failsafe feature used to help detect that a BMS is no longer working or communicating with the control The time must be regularly loaded with a predetermined number of seconds 1 65535 Every second this value will decremented If it reaches zero the local permanently saved values for the setpoints will be loade
101. he H Net address of each boiler from 2 16 SETPOINTS LOCAL SETPT 160 F 40 220 F Local setpoint used to maintain temperature of SETPT SOURCE When running as a member boiler shuts off when supply o temperature reached 452900 Boiler restarts at lower temp of OP LIM BAND or 10F whichever is lower LOCAL SETPT 160 F 40 220 F Local setpoint used to maintain temperature of SETPT SOURCE AUTO AUTO Local System WWS Setpoint is used OUTDOOR AIR RESET OA RESET Feras Outdoor reset ratio boiler water temp outside air temp If set to YES the boiler system shuts down when the WARM WEATHER SD temperature exceeds the WWS SETPOINT Temperature at which boiler shuts down operation is below this If boiler is running using either OA RESET or WWS and the OA Ed o WWS E TE MUT input is closed the RESET slope is overridden and runs at local setpoint until OA OVR input opens WATER TEMP At 140 F 60 150 F HIGH OA TEMP WATER TEMP At 10 F 35 40 F Header Supply setpoint when OA Temp is at LOW OA TEMP LOW OA TEMP PUMP OPTIONS ON OFF Used with Outdoor Reset Jogs pump for POST PRGE time when SUMMER PUMP JOC MON SUN system is in summer shutdown Jog once a week 12 00 AM Priority mode for the system pump while in Warm Weather hutdown ON The system pump is allowed to run in WWS when OVR ENAB IN WWS OFF ON OFF the OR OVR override input is closed When
102. is Option to ON will map the control signal on J4 pins 1 and 5 to the modulation rate 2 wires need to be run from J4 1 and J4 5 to the VFD s input connection Ensure that the J18 shunt jumper on the control board is in position PWM O0 10 HeatNet Control REV 3 47 1 Auxiliary Function Options Relay K5 and the terminal J13 DAMPER is used to control a combustion air damper The Spare 1 input on J10B or J12B is used to detect the dry contact proof switch from the damper The J12B is the preferred connection J10B is used for backwards compatibility A proof time of up to 4 minutes can be set before the boiler can start or an alarm condition will occur The Combustion Damper can be setup in the SETUP AUX FUNCTIONS menu The Master boiler controls the system damper so in the event this damper fails to open the system will not start If the Master boiler s system damper fails then no call for heat will be made to the member boiler s Each member boiler can control its own damper and is independent of the Master boiler when a call for heat is made to the member This allows for separate dampers for each member boiler They can be wired to J12B terminals 7 and 8 If a common system damper is used controlled by the Master boiler each individual boiler must prove that the combustion air damper is open when it is placed in LOCAL This may be done using J12B terminal 7 on all boilers wired to the damper s prove switch Terminal 7 i
103. ition or other form of radiated electrical noise Termination of the jumpers may not be correct or there is more than one master a Ensure that the termination jumpers are set on the MASTER boiler and only the LAST MEMBER boiler of the other member boilers should have their termination jumpers in the non terminated position HeatNet Control REV 3 47 1 b There may be 2 or more MASTER boilers Ensure that only one header sensor is present and connected to the SYS DHW input There should be no wires or sensors connected to the SYS DHW input if the boiler is operating as a member This input is auto detected and defines the boiler as a MASTER c Ensure the cable to connect the H Net is of a shielded or twisted pair type Shielding of the cable 15 required d Minimize the electrical interference by routing the communications cable away from electrical noise sources such as Motors ignition controls contactors etc Situation Only the MASTER boiler Fires but the system has many boilers and is using H Net 1 In order for the MASTER boiler to act as a MASTER the header sensor must be set to TYPEZ and there must be a header sensor present At power up the header sensor is auto detected If the temperature of the header sensor at power up is greater than 25 F and less than 240 F it is considered a valid sensor The boiler will default to the MEMBER mode if the temperature is not in this range and can only be run l
104. ity on each boiler to be in a set at the same priority Page 10 HeatNet Control REV 3 47 1 Setting all example condensing boilers to the highest Priority of 1 and then setting all example non condensing boilers to a Priority of 2 will create 2 sets of boilers one condensing and the other non condensing Once this is done the Priority 1 set of condensing boilers will have a firing order that has a higher Priority and is independent of the other non condensing set with the lower priority The boiler set with the highest Priority can then be fired based on a conditional settings menu The lower Priority set will follow Mixed Boiler System Operation Starting Boilers When a boiler is to be fired water temp is below the heating band the Master checks the HeatNet boilers it has available The Master boiler then looks at which boilers are returning Priority firing status set on a boiler in ADVANCED SETUP SYSTEM BOILER TYPE PRIORITY If the Start condition for the Priority Iset is met ADVANCED SETUP FIRING MODE MODE MIXED SET FIRST example the Master or Member boiler that is configured as PRIORITY 1 with the lowest runtime will be fired FIRST example As long as the start condition for Priority 1 is met all boilers in the PRIORITY 1 set will fire based on runtime Once all boilers in the PRIORITY 1 set have fired the PRIORITY 2 set of boilers will fire based on runtime If the Start condition changes an
105. ld outside air with no fire FAULT SYSTEM SET AIR SWITCH BLOWER 160 F CALL SERVICE If the H Net control closes the last interlock string entering the ignition control and the ignition control never closes its Blower Relay the H Net control will wait 2 minutes The H Net control will then retry for the duration of the local pump post purge time and then retry the ignition sequence During this time retry strt will be displayed in the status screen After 5 attempts the H Net control will lock out and display call service FAULT SYSTEM SET CALL SERVICE 160 F APPENDIX HeatNet Control REV 3 47 1 Line 4 Log Entries The following table lists the messages on line 4 of the log s display Time Stamp Snapshot Water Setpoint Pade 8 5 Water Temperature Out H 2 0 1 2 5 1 4 0 os OA 65 F MOD 57 jue GAS PRESSURE Ri Line 4 Message Line 4 Message Description SETBACK IS ACTIVE If any of the 4 temperature setbacks are active these log entries will be SETBACK EXPIRED displayed in the log NO LOCAL FLOW If the test for flow fails these log entries will be displayed The flow proving NO SYSTEM FLOW switches are wired to J11A and J11B If the combustion air damper is used and does not prove across J10B COMBESTION DAMPER or J12B DAMPER this message is displayed SYSTEM RESET O stack overflow U Stack Underflow both are so
106. ler to accumulate some soak time LOFO Boilers are fired Last On First Off starting with Lead Boiler FOFO Boilers are fired First On First Off TRUE Boilers are fired based on the runtime they report back to the Master boiler Boilers with the least runtime are fired first and boilers with the most runtime are stopped first MIXED Different types of boilers can be mixed in a system and fired based on 2 Priority sets Boilers are started and stopped with in the Priority sets based on their runtime hours When the firing rotation is based on runtime this value represents the interval in hours of runtime before rotation occurs Boiler to Boiler YES Predicts the boiler restart point in the heating band while the temperature of the boiler is drifting down through the band The purpose of this is to ensure the temperature remains in the temperature band It also minimizes temperature swings when the boiler is stopped and started at low inputs Page 57 DEFAULT SETTINGS amp MENU ITEM DESCRIPTIONS HeatNet Control REV 3 47 1 BASE LOAD BOILERS Version 2 x control This setting works in conjunction with the ADVANCED SETUP BASE LOAD BOILERS 0 1 SYSTEM OPTION setting BASE LOAD Currently only 1 base load boiler is supported using relay K8 on the Version 2 x control START gt MOD START gt MOD START lt OA T Used in Conjunction with DELAY TIME START gt RET START gt MOD 100 20 100 The base load relay K8 will close when
107. ll recognize itself as a MASTER When DHW BOILER is also set to YES the MASTER will automatically call on other boilers when the DHW Tank Temperature drops below DHW SETPOINT DHW DIFF even when no Heat Demand signal is present However the MASTER will only enable boilers for space heating in response to a Heat Demand signal 10 Finally go to DHW BOILER Select YES If JPS1 has not been cut a message will appear instructing to do so Once this is done the MASTER boiler will control the temperature in the tank using as many boilers as it has available on H Net NOTE DHW BOILER Does not need to be set to YES on MEMBER boilers only the MASTER boiler NOTE JPS1 MUST be cut on all boilers providing DHW DHW METHOD 2 DHW Header Sensor Input Available on both V1 X and V2 X Controls 1 This method will control a tank temperature when the tank temperature setpoint needs to be maintained for extended periods with minimal cycling Multiple boilers can be used via the H Net as this method employs the same PID algorithm as for space heating For this method a tank temperature band needs to be tolerated JPS1 MUST be cut on all boilers providing DHW to ensure the maximum output temperature of all boiler is limited for DHW operation 2 Usethe Heat Demand Control Method 1 located in the CONTROL METHODS section on page 22 Instead of placing the Header sensor in the Header pipe place it in a well in the tank The tem
108. llow the circulator pump to be turned on whenever there is a call for heat any control input This mode will stop the circulator pump when the call for heat is lost and the pump post purge time has been satisfied The summer pump jog is a special feature that can be selected when the system is in summer shutdown OUTDOOR RESET The jog allows the system circulator pump to run for the pump purge time once a week It can be set to any day of the week and will occur at 12 01 AM The system flow proving switch is implemented using SPARE 3 System Water Flow If a flow switch is connected to the WTR FLW interlock the HeatNet control will wait up to 240 seconds to prove flow This time is adjustable under SETUP PUMP OPTIONS The default flow proving time is 10 seconds It can be increased to allow OPTIONAL FEATURES slower valves to open before flow is established If flow is interrupted after it has been established an error will be displayed and the boiler will cycle OFF As long as there is a call for heat every 10 minutes the circulator pump will try to re establish flow and start the boiler again The local circulator pump is supported by 3 modes and 2 features 1 first mode allows the circulator pump to remain unless the control s outside high air temperature setting has been met when using Warm Weather Shutdown 2 The second mode will allow the circulator pump to be turned on whenever there is a c
109. lue ADVANCE SETUP BASE LOADING STOP gt OA T NOTICE If the OA T qualifier is used as the Start and Stop qualifier ensure that there is at least a few degrees difference for hysteresis Page 20 HeatNet Control REV 3 47 1 3 Return Water Temperature a START menu item The relay contact will close to enable the boiler when the RET read from the Return Water Temperature sensor if Equipped falls below this temperature ADVANCE SETUP BASE LOADING START gt RET b STOP menu item The relay contact will open to disable the boiler when the RET temperature read from the Return Water Temperature sensor if Equipped rises above this temperature ADVANCE SETUP BASE LOADING STOP lt RET 4 FIRST a STOP menu item The relay contact will open to disable the boiler when the temperature exceeds the heating band This gives the result of stopping the Base Load boiler First Default setting Delay time The DELAY TIME is also included to hold off starting the boiler until the delay time is met Once the start condition qualifier term is met the DELAY TIME will start counting down When the time expires the base load relay contacts will close ADVANCE SETUP BASE LOADING DELAY TIME It is adjustable in a range of 0 to 60 minutes Base Load Failsafe If there are no boilers available to fire offline or faulted and there are no boilers in local override and there is a call for heat The J4 Base Load relay will close If a
110. network cable in a Master Member system the system setpoint is sent from the Master as a digital signal along with the modulation value to control firing rate It also receives its command to start or stop over the H Net cable Also the SYSTEM CLOCK only needs to be set on the MASTER The Master will then set the time on all member boilers If not using the H Net protocol cable an external control can send a 4 20ma signal along with a 4 20ma enable signal to control the firing rate or setpoint The boiler may also be treated as a 2 stage boiler or an ON OFF boiler using the dedicated T inputs Page 5 FEATURES amp SPECIFICATIONS Features amp Specifications Features Overview Hardware Version 1 x Control Identified by circuit board color BLUE 1 10 11 12 13 14 15 Five levels of external control inputs including modulation and staging that provide application flexibility Digital Communications Control analog 4 20ma and 0 10 control supported but not required a Boiler to Boiler HeatNet H Net b Building Management System MODBUS Optional BACnet or LonWorks to Boiler Distributed control using the HeatNet H Net protocol for up to 16 boilers Eliminates the need for wall mounted controls Analog Control 4 20ma and 0 10vdc 20mA minimum current signals supported System Boiler operating status text display Interlock Event and System logging with a time
111. no jumper to 24VDC RET This allows one 4 20ma transmitter to control multiple boilers A free floating 250 ohm resistor is viewed by the BMS or external control s 4 20ma transmitter across the and 4 20ma terminals with this method Figure 24 4 20 connections 24VDC 4 20ma 0 10vdc O 4 20ma 0 10vdc O 24VDC Return xri rg cir oes Do ola alan ao Closing a contact here enables the 4 20 control signal input HeatNet Control REV 3 47 1 The 4 20 ma input uses a 250 ohm sense resistor to convert the current to a voltage from to 5 volts DC for the control to use For this reason a 1 5 VDC control voltage may also be used across the 4 20mA input but it still needs to supply the necessary current i e 20mA This resistor is located on the bottom side of the control board When a 4 02 ma signal is sensed the boiler will initiate a start sequence and fire the boiler at its minimum setting if the REMOTE ENABLE input is closed This is typically 25 of the boilers output 4 1 turndown If jumper shunt is set to the PWM O0 10 position the 4 20mA input will accept a 0 10 VDC signal The operating range will be from 2 10 VDC or twice what was previously stated for the 1 5 VDC functionality To convert a 0 10VDC signal to mA divide by 500 ohms NOTE Due to the inability of control voltage methods 1 5 2 10 VDC to reject noise the
112. ns is lost and this timer expires due to the lack of being updated The system setpoint timer and system setpoint work in tandem to externally control i e BMS building management system the operating setpoint The setpoint countdown timer should be loaded with a timeout value in seconds prior to writing the system setpoint When the timer reaches zero the control assumes that the BMS is no longer operating and the local setpoint saved on the control is reloaded If the setpoint timer is not written a default timeout value of 60 seconds is assumed The timer is automatically reloaded with the default value when a setpoint is written NOTICE The BMS mode is always on and no menu item is available 2 HeatNet Communications Lost SETUP AUX FUNCTIONS FAILSAFE MODES H NET COMM LOST This mode allows a member boiler to run in LOCAL if the communications link via the H NET cable is lost This includes the MASTER boiler losing its Control board Communications board or the power on the MASTER is switched OFF When this MODE is set to ON and if the member boiler loses it s link heartbeat packet over the H NET cable to the MASTER Boiler this MEMBER will fire to the LOCAL setpoint NOTICE The heartbeat packet over the H NET cable needs to be lost for 10 minutes This MEMBER boiler will continue to run at the LOCAL setpoint until H NET communications from the MASTER boiler is re established Page 29 OPTIONAL FEAT
113. nt that MONTH ___ ______ power has been lost for more than 3 days The time is only required 7 PRESS SEL SAVE The SEL key must be pressed after all time values have been entered to save all time values at once Page 55 DEFAULT SETTINGS amp MENU ITEM DESCRIPTIONS HeatNet Control REV 3 47 1 Default Settings amp Menu Item Descriptions ADVANCED SETUP DISTRIBUTED CTRL CONTROL HN Displays method of operation HeatNet H Net Auto detected based on the HEADER sensor If the HEADER sensor is present and is set to TYPEZ the KN vzs Series control is run as a H Net MASTER YES If the HEADER sensor is not TYPEZ H Net MASTER NO The local address is the address of a member device This is normally in the range of 2 through 16 But if the KN Series control is H NET ADDRESS 255 2 16 a MASTER then the default address is 255 The ADDRESS is synonymous with boiler The MODBUS address is for communicating with Laptop PC or MODBUS ADDRESS 1 1 247 other MODBUS capable device It is the 2nd communication port reserved for host control MODULAR BOILER SET This is the delay time in 30sec intervals before starting a new boiler Boiler 1 is started immediately after call for heat If a second ADD BOILER DELAY Tomine gue cM boiler needs to start the ADD BOILER DELAY will need to expire before starting This is the delay time in 30
114. ntroduce a minimum amount of BTUs into the system Section SETUP amp OPERATION Page 56 DEFAULT SETTINGS amp MENU DESCRIPTIONS HeatNet Control REV 3 47 1 ADAPTIVE MOD MOD MODE ADAPTIVE i m mE EMEN BE MIN RUNTIME 1 255 This is the time in minutes that the boiler must remain OFF before it PREDICT START YES NO If MODulation MODE is set to ADAPTIVE on the Master boiler the Master lowers the system modulation rate of all currently running boilers before a newly started boiler enters the Main Valve state Upon entering the Main Valve state of a newly fired boiler the Master waits the DELAY RELEASE time before allowing the PID to resume modulation control With MOD MODE set to ORIG KN The Master boiler keeps firing at the current modulation rate when a new boiler is added and lets the PID adjust modulation rate accordingly If drop down is set to ON PILOT and MOD MODE ADAPTIVE and when a newly added boiler starts the system waits until it enters its PILOT state before bring the system modulation down This allows for the system to prepare for the new energy that is to be introduced If DROP DOWN is set to immediately the system modulation is lowered as soon as the newly added boiler is called Once the Main Valve opens on the newly added boiler and the MOD MODE ADAPTIVE the Master waits this amount of time before releasing the PID to control modulation This allows for the newly added boi
115. ocally or by external inputs a Ifthe LOAD FACTORY DEFAULTS has been used to restore all the default settings the header sensor has been set to NONE This needs to be set as stated in 1 and the header sensor will need to be replaced or the temperature brought into a valid range power cycle of the boiler will detect the sensor if it is in the range as stated in 1 b The H Net needs a communications cable daisy chained between boilers Ensure that a good connection is made on the communications board and that the lights on the dual RJ45 jack flash roughly twice a second The MASTER is the only one that should flash with no communications cables plugged in Situation in CALIBRATE and cannot fire the boiler to adjust it 1 Only one but any one of the T1 T2 inputs be used to start the boiler All other inputs are disabled This method prevents an external control or Building Management System from trying to control the boiler while it is offline and being calibrated If the boiler is Page 69 TROUBLESHOOTING being used as a staged boiler controlled by an external control the staged inputs need to be disconnected before CALIBRATION since more than one of the T inputs may be closed by the external control Situation You have forgotten the password 2 Asa last resort you can turn the controller off then depress and hold the ESC key while turning it back on This will load the default password
116. od uses an RS485 digital communications cable with the MODBUS protocol The boiler is controlled by writing and reading registers using MODBUS commands A bridge module may also be used to convert BACnet or LonWorks protocols to MODBUS HeatNet Control REV 3 47 1 NOTICE Short cycling may occur when a firing rate is sent to a member boiler that would cause the supply temperature to rise high enough to trip the operating limit low flow rate After the supply temperature falls the boiler would restart and the process may continue A member boiler would use its supply outlet sensor to protect itself from short cycling by limiting the firing rate coming from the Master This occurs in the event that the member s supply temperature increases above the OPERATE LIMIT OPERATE LIMIT BAND Operating Limit When the master boiler or an external control input is used to control a member boiler i e AA T1 T2 4 20ma Net a software operating limit on the member boiler will be used to limit the maximum output of the member boiler This operating limit can be adjusted in the SETUP SETPOINTS OPERATING LIMIT There is also an associated operating limit band that must be set in conjunction with the operating limit to help prevent this LIMIT from being reached Its purpose is to limit the output of the boiler as it approaches the operating limit If the band is set to 10 degrees then for every degree that it approaches the operatin
117. oiler s employing H Net This method utilizes a 10k thermistor connected to the DHW Sensor input of a DHW MASTER or a stand alone boiler and a DHW tank WITHOUT a HEADER sensor It requires a DHW setpoint and other parameters to be set This method is used when the water temperature in the tank needs to be no greater than the setpoint with little overshoot of temperature One of its limitations is that it may short cycle It functions much in the same way a tank thermostat works HeatNet Control REV 3 47 1 This method works with 2 settings A target tank water setpoint DHW SETPOINT and a start add boiler temperature setting DHW DIFF Boilers are started as long as the tank s water temperature is below the DHW SETPOINT DHW DIFF The first boiler is started immediately The next boiler s is started after the ADD BOILER DELAY time expires Boilers are not added when the temperature is above the DHW SETPOINT DHW DIFF and below the DHW SETPOINT Once the DHW SETPOINT is reached all boilers shut off This limits the tank temperature to the setpoint post purge time of the DHW pump Setting up this method is done via the menus in SETUP DOMESTIC HOT WATER 1 Connect a 10k thermistor from the DHW tank s sensor well to J10B terminals 1 amp 2 on the DHW MASTER or stand alone boiler Wire any pump or valve from the DHW Pump relay normally open contact to control flow of the heating water into the tank s coil 2 Next
118. or 4 v eee LN L4 5 Ta S ee FACTORY els 5 gt 5 Jig e e e High voltage 120VAC N 8 NY interlocks 121 zo Firing status B e 5 8 2 e e elle ele ele elle e gt a ES 5 2 0000000000 668 15 9192090000000 1 yom T DISPLAY 5 88 8 5 5 2 8 amp 6 1 996723 e e e eee M M N e 1 Oe CaL e ee e o o ee 000000 0 INTERLOCKS ONTROL tier AS 128 KN F SERIES 1 KNSX RI 2 7 pA HEAT REMOTE A 2006 HIGH FIRE DEMAND ENABLE OR OUR OO OO OO OO System Pump gt Combustion Air Enables Combustion Air Damper prove switch Enables local boiler Circulator pump valve Calibrate or Normal run state Alarm contacts close during a fault condition Page 43 WIRING CONNECTIONS Figure 39 Relays Interlocks and Boiler Status Version 2 x cont HeatNet Control REV 3 47 1 rol green pc board Priority The Highest priority SYSTEM FLOW PROVE 1 Low Water
119. orted here A reset switch is located on the gas pressure switches The interlock is located on J15B GAS PR FAULT SYSTEM SET GAS PRESSURE 160 F SYSTEM WATER FLOW Once the HeatNet series boiler receives a call for heat it closes the system circulator pump relay It then waits 10 seconds or more adjustable to prove flow If there is no flow the flow switch alarm will be set Every 10 seconds the circulator pump relay will cycle ON for 10 seconds and then OFF for 10 seconds to try and establish flow The interlock connection is located on 152 SYSTEM WTR FLOW FAULT SYSTEM SET SYSTEM FLOW SWITCH 160 F Page 83 APPENDIX WTR FLW LOCAL Once the HeatNet series boiler receives a call for heat it closes the LOCAL PUMP V ALVE relay It then waits 10 seconds or more adjustable to prove flow If there is no flow the flow switch alarm will be set Every 10 seconds the circulator pump relay will cycle ON for 10 seconds and then OFF for 10 seconds to try and establish flow The interlock connection is located on J5B WTR FLW FAULT SYSTEM SET WATER FLOW SWITCH 160 IGNITION CTRL ALARM The ignition control alarm is displayed if the ignition control detects a fault This could be a flame failure air proving switch or other fault associated with the ignition control When this fault occurs you will need to refer to the ignition control for the reason FAULT SYSTEM SET IGNITION CTRL ALARM 160
120. peed will be set here to provide the rate for ignition While in Standby no call for heat on inputs the Ignition percent may be preset before firing the boiler To set the ignition rate while running any 1 and only 1 of the T inputs must be closed Pressing the SELECT key here will cause the IGNITION setting to flash and the boiler will ramp to the ignition setting Adjust it using the arrow keys and then press the SELECT key until the value stops flashing The new setting is now saved LOG ENTRY Log Entry The KN Series H Net control contains a log that records the major activity events in the operation of the boiler This activity includes interlock faults boiler starting and stopping events power cycles misc faults and types of calls for heat control inputs Setting the time clock to an accurate time and date is very useful when events are recorded since the control will time stamp each snapshot If the system is configured to run with HeatNet then only the Master boilers SYSTEM TIME needs to be entered The Master will then set the time on all Member boilers The log is primarily used as a troubleshooting and diagnostic tool but may be used as a performance tool to view run time cycles An event in time of the boiler s state is presented via multiple screens Each screen event can be stepped through using the arrow keys The top line displays the time and date the event occurred In the top right corner the
121. perature at which boilers are staged ON and then OFF is controlled by the SETUP BOILERS HEAT BAND differential This can be understood by referring to the INTRODUCTION section on the MASTER in the beginning of this manual This differential has the added effect of heating the tank above the tank s setpoint temperature If HeatNet Control REV 3 47 1 the tank setpoint is set to 140F and the heat band is set to 1OF then the tank temperature will rise to 145F before the first boiler turns off setpoint 140 band 2 With 2 boilers running the SHED BOILER DELAY time could add to the tank temperature So to ensure that all boilers are shut off at the upper point of the heat band set the SHED BOILER DELAY time to 0 This will effectively turn off all boilers at the upper heat band point of example 145F Now there is one more thing to consider the pump s post purge time Dumping the heat from all boilers that were running using a pump post purge cycle will have an effect on the tank s water temperature Consider this when establishing the local pump s POST PURGE TIME 3 Connect the Local Pump relay contact on J13 to enable the DHW pump Set its post purge time to dump the boiler s heat into the tank when the boiler shuts off Be aware that this may heat the tank above the setpoint s upper heat band temperature 4 Enable the system by placing the LOCAL REMOTE switch on the Master to the LOCAL position
122. ratures must be known Selecting Mixed Boilers There are a few factors to consider when choosing which type of boilers to use in a mixed system These factors need to be considered when boilers are added or shed When BTUs are introduced into the system by adding boilers the amount of introduced BTUs should be smooth linear If these factors are not considered discontinuity in BTUs may occur when boilers are added and as a result short cycling will occur 1 Turndown This is the ratio of minimum fire rate to maximum fire rate Example a 20 minimum modulation 5 1 turndown 100 mod 20 mod A 1 million BTU boiler 200 000 BTUs minimum input 2 MOD MAX CLAMP This value determines the maximum modulation at which the boilers will fire to until all available boilers are firing 3 Total System BTUs 4 Desired Effective Turndown This is the lowest firing rate of the system relative to the maximum firing rate of the system The larger the value the lower the BTUs that can be delivered to a light load 5 Piping Mixed System Type 1 High System Turndown The following examples are of mixed boiler systems with high effective system turndown and fault tolerance built in When boiler types are the same the system turndown is limited to the boiler s min input and fault tolerance is always present When the system has mixed boiler types consideration needs to be taken on what types can be mixed properly to achieve
123. rporated Printed in the U S A All Rights Reserved Page 3 FEATURES amp SPECIFICATIONS Introduction The KN Series HeatNet Control The KN Series boiler control is designed to provide the KN Series of boilers with an integrated boiler management system on every boiler Designed for the Air Fuel coupled KN Series boilers the KN Series HeatNet control provides for optimized heating efficiency without the need for a wall mount control Since the KN Series modular control method is based on digital communications analog control signals are not required Although the use of analog control signals is still supported 4 20mA control loops and 0 10vdc 20mA minimum control voltages a higher level of control precision repeatability and feedback is gained with digital communications control With the KN Series optimized heating efficiency is accomplished by setting the Modulation Maximum Mod Max setting to exploit the inverse efficiency curve This value can be adjusted so that as each boiler is added it operates at its maximum turndown This allows the maximum number of boilers to operate at their lowest inputs until all boilers are firing Once all boilers are firing full range modulation control is allowed An outdoor reset function is also provided to assist in the optimized heating efficiency of the KN Series boilers The KN Series boiler with the KN Series H Net control can be operated in multiple ways 1 As
124. s If using the direct modulation mode by applying a 4 20ma current only the BOILER START x xx setting applies Firmware Version 3 0 adds the ability to set the 4 20 mA input to HIGH PRIORITY This can be set in menu ADVANCED SETUP 4 20mA INPUT This allows a member boiler to be taken offline and directly modulated by an external control If the Master is using it for heating and the 4 20mA is set to HIGH PRIORITY an external control can now output a 4 20mA signal which will take over the boiler s fire rate This is typically used for DHW control Page 26 HeatNet Control REV 3 47 1 Circulator Pump Options There are provisions for a system pump and a local pump This is to allow for primary secondary loop configurations The system circulator pump is implemented using the K4 RELAY and normally open contacts at J13 BOILER 2 OTHER or marked SYSTEM PUMP depending on the revision control board The pumps require motor contactors to isolate the on board relay contacts The on board relays should never be used to energize pumps directly Figure 26 Pump connections _ l Domestic Hot Water System Pump Pump Valve Combustion Air Damper Alarm Local Pump Valve The system circulator pump is supported by 2 modes and a special feature 1 The first mode will allow the circulator pump to remain on unless the control s outside high air temperature setting has been met when using OUTDOOR AIR RESET 2 The second mode will a
125. s the sense input and terminal 8 is 24 VAC Connecting a wire to terminal 8 is not recommended See Figure 43 Common system damper wiring Page 48 A separate independent 24 V AC source is recommended to be used for the damper prove switch when a common system damper is used If you use terminal 8 to supply power from the Maste r and the Master is powered OFF no boiler will be allowed to fire due to the loss of power through the prove switch A backup boiler will also need to have the damper relay contacts wired in parallel with the Master for when the Master is powered OFF A second wire on the Master J12B terminal 7 is then connected The other end of this wire is then run to the first Member boiler J12B terminal 7 If another member boiler is present a second wire can be connected to the first member boiler J12B terminal 7 and the other end connected to the other boiler J12 terminal 7 This method can be continued if additional boilers are present This input must be selected in the SETUP AUX FUNCTIONS COMBUST AIR DAMPER menu Page 27 OPTIONAL FEATURES Outdoor Reset The Outdoor reset feature allows the water setpoint temperature to change dynamically with the outside air temperature It also provides an adjustable temperature that shuts the boiler boiler system down when the outside temperature rises above it Firmware version 2 3 and up separates the Warm Weather Shutdown from the Outdoor Reset Figure 27 Outdoor reset
126. s to be loaded periodically to allow the H Net system to fallback to Method 1 in the event communications is lost from the Building Management System BMS The MODBUS protocol allows writing and reading registers using MODBUS commands Page 24 HeatNet Control REV 3 47 1 Protocessor option An optional BACnet or LonWorks bridge module can be used to connect the MODBUS network to a BACnet or LonWorks network Figure 23 Protocessor bridge module option RJ45 Configuration and IP connection Protocessor Bridge Module Plug in gt LonWorks BACnet bridge which Can be used instead of the MODBUS input ES _ Twisted Pair Connection MSTP This method allows enabling and disabling the boiler or H Net system changing setpoints reading boiler s status or temperatures remotely using digital commands See the section MODBUS Communications OPTIONAL FEATURES Using the 4 20ma input OPTIONAL The 4 20ma input is designed to operate per the ISA 50 1 standard It will support Type 2 Type 3 and Type 4 Transmitter Receiver circuits The Type 2 and Type 3 circuit may use the supplied 24VDC and 24VDC RET connections J10B to power a remote transmitter The ma terminal will need to have a jumper connected to the adjacent 24VDC RET terminal to reference the signal ground With the type 4 configuration multiple boilers up to 5 may be connected in series using the ma ma ma ma scheme
127. second intervals before stopping a gt boiler boiler is stopped immediately when the top of the heat band SHED BOILER DELAY Amins 0 15min is exceeded If a second boiler needs to stop the SHEDBOILER DELAY will need to expire before stopping MODULATE DELAY TO esce 0 60min This is the time the boiler remains in min fire before it relinquishes TIME control to the modulation signal This value represents the maximum of input on the boilers if all the available boilers are not firing Once all boilers are firing this clamp is removed and all boilers are allowed to modulate up to 100 When this value is limiting the input an is displayed and the INPUT CLAMP message is displayed in the STATUS screen This value is derived by multiplying twice the minimum fire rate of the boiler with the least turndown 2 turndown 20 5 1 25 4 1 33 3 1 In mixed boiler size configurations more than 2 boilers MOD MAX LAST FIRE 7096 25 10096 in a system or when bumps in the temperature occur as boilers are added and subtracted this value may need adjustment The adjustments will help produce smooth temperature control when each boiler is started and stopped This method ensures that once a new boiler starts to fire and holds its fire rate at the minimum setting it does not add its BTU output to a boiler already firing at 100 The boilers can not be fired starting 0 but start at a minimum example 20 and i
128. set to OFF the system pump will not come on while in WWS with the OR OVR override input closed Page 52 Boiler water temp setpoint when OA temp is at HIGH OATEMP These four setpoints determine the OA reset slope DEFAULT SETTINGS amp MENU DESCRIPTIONS HeatNet Control REV 3 47 1 ON Use Delta temperature to shut pump off when temperature across boiler is less than DELTA TEMP setting 10 F 2 50 F 2 minutes 1 60min Time in minutes to keep local circ pump on after boiler stops DELTA TEMP ENAB OFF DELTA TEMP POST PRGE TIME ALWAYS ENABLED OFF PUMP VALVE OPTIONS MASTER PUMP VALVE Pump never shuts off ON The master boiler will keep its pump valve on when no boilers are running Prevents deadheading the system flow ON Outputs 0 10VDC or 4 20mA signal from pins 1 amp that is LOCAL PUMP VFD ON OFF proportional to the fire rate of the boiler Connect to a VFDcontrolling a Local pump 10 240 sec This is an adjustable flow proving time to allow slower valves to open before proving flow NIGHT SETBACK 1 4 Four setbacks to adjust setpoint during a time period REMAINS ON ON OFF FLOW PROVE SETBACK ENTRY ENTRY IS OFF SETBACK START DAY MON TIME 12 00AM END DAY MON TIME 12 00AM Enable or disable the use of this setback 20 F 0 50 F Temporarily subtracts this temp from the setpoint Day of the week to begin setback or a day range Time to begin setback
129. status flags These bits e RR S sn other conditions See the values See the BoilerStatus1 and 30020 Boilero3Status1 16 bit unsigned column for a list of conditions BoilerStatus2 Tables below 01 Master 02 Member01 Boiler16 Member15 Page 61 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 47 MODBUS Input Variables Read Only 30048 BoilerO1 RuntimeHigh16 30049 BoilerO1 RuntimeLow1 9 6 Boiler 1 16 Runtime seconds High 30050 BoilerO2RuntimeHigh16 Upper and Low Lower 16 bit 1 Boilero2Runti counters To get the actual runtime for 3005 any given boiler the high and low 30052 BoilerO3RuntimeHigh16 16 bit counters must be combined 30053 Boilero3RuntimeLow16 concatenated into a single 32 bit counter as 30054 BoilerO4RuntimeHigh16 30055 Boilero4RuntimeLow16 Boiler RuntimeHigh1 6 Boiler Runti meLow16 30056 BoilerOS5RuntimeHigh16 16 bit unsigned 0 4294967295 seconds Example 30057 BoilerOS5RuntimeLow16 Boiler01Runtime 30058 Boiler06RuntimeHigh16 Boiler01RuntimeHigh16 65536 30059 Boiler06RuntimeLow16 s 30060 Boiler07RuntimeHigh16 01 Master 30061 BoilerO7RuntimeLow16 Boiler02 Member01 30062 Boiler08RuntimeHigh16 30063 16 BoilerO9RuntimeHigh16 30025 30026 30027 30028 30029 30090 30031 30032 30033 3003
130. t BT 2000 000 YES E EDIUM CONDENSING MASS In the example Mixed Boilers Condensing Non Condensing condensing boilers and non condensing boilers are used but other combinations may also be used Another example could use 2 small boilers and set them to Priority 1 and then use 3 larger boilers and set them to Priority 2 Using these Priority settings with the conditions menu the small boilers can run first during the shoulder months Spring and Fall and the larger boilers can fire last during the colder Winter season base loading set Before the MIXED method can be used the firing mode on the Master boiler must be set to MIXED ADVANCED SETUP FIRING MODE MODE MIXED Pressing the SELECT key when the cursor is pointing to MIXED will enter the conditions menu The START and STOP conditions for starting and stopping the Priority boiler set may be configured here Temperatures are adjustable START PRIORITY 1 gt SET FIRST STOP PRIORITY 1 SET OAT lt 15 F Once the conditions menu has been entered the firing order and stop order of the Priority boiler set can be selected based on up to 3 conditions in the conditional settings HeatNet Control REV 3 47 1 PRIORITY 2 Non Condensing Sel BOILER TYPE menu gt FIRING PRIORITY 2 all boilers in set BTU IN 2000 000 CONDENSING NO MASS LOW menu All conditional settings apply to the Priority 1 boiler set When the conditional s
131. tart It is adjustable from 3 7ma to 5ma Hysteresis of 1ma is always in effect So if the starting ma 4 10ma the boiler will start when the control current applied achieves this value of 4 10ma The boiler must drop 1ma below this to turn OFF Page 25 OPTIONAL FEATURES in this example 4 00ma This hysteresis value is not adjustable When using the 4 20ma setpoint control a band may now be set at which the 4 20ma signal will operate over The lower setpoint is defined as SETPOINT and the upper setpoint is defined as 20ma SETPOINT The 4ma SETPOINT is linked to the BOILER START x xxma where this starting current is the lower setpoint So if we set the 4ma SETPOINT to 130F and the 20ma SETPOINT at 180F we will have established the band Once a starting control current of BOILER START 4 1mA is applied and the 4 20 REMOTE ENABLE INPUT is closed the boiler will start and the setpoint will be set to 130F If a control current of 10ma is applied the boiler will track on a linear slope towards the 20ma SETPOINT settling at a SETPOINT of 149F As the current increases to 20ma the SETPOINT will indicate 180F The Default setting is SETPOINT 50 and 20ma SETPOINT 220F for backwards compatibility with the older version NOTE anytime a new firmware version is uploaded to the control these values return these defaults NOTICE Anytime a new firmware version is uploaded to the control these values return to these default
132. tart contact on J5 10 Limits and is waiting for the Blower relay to close on the ignition control which is monitored on J5 3 of the HeatNet control Page 70 HeatNet Control REV 3 47 1 Situation can hear the blower ramping up and down and the firing rate is changing but the display indicates it is running at the same modulation rate 1 The Boiler always shows it s called for firing modulation This is not an indication of what the boiler is actually firing at In this case the boiler is trying to meet the called for modulation which is displayed but is unable to do so The boiler protects itself by looking at it s supply water temperature and the temperature is probably in the Operating Limit Band While in the operating limit band the HeatNet control limits the input of the boiler The boiler tries to deliver the most input it can in an attempt to meet the called for modulation without tripping the operating limit 2 Ifthe boiler is constantly varying in blower speed and in the operating limit band there may be not enough flow through the boiler or the Operating Limit Operating Limit Band may be improperly set The Operating Limit Operating Limit Band should not overlap the heating band This may occur when a building management system is controlling the setpoint and is setting the setpoint in the operating limit band 3 Example Setpoint set to 180F by Building Management and the Operating Limit is set to 2
133. te otherwise no external control inputs will work except T1 T2 the display will always indicate CALIBRATE and some of the runtime temperatures will not be displayed The MIN setting the MAX setting and the Ignition setting can be adjusted in the calibration displays The values can be changed while running ONLY IN MINIMUM FIRE any but only one of the T inputs closed Prior to ignition the values may be changed but the blower will not operate NOTICE If a version 2 0 control board is used a Low Fire Hold switch is located near the Calibration switch Page 50 HeatNet Control REV 3 47 1 Press the arrow keys until MIN VFD is shown in the display along with the minimum percentage value at which the boiler is to run at min fire While in Standby no call for heat on inputs the minimum percent may be preset To set the minimum rate while running any 1 and only 1 of the T inputs must be closed in order to set the boiler to MINIMUM fire Press the SELECT key for approximately 1 second The Percentage value will start flashing indicating that it can be adjusted Adjust the Minimum value to the desired setting using the arrow keys The Minimum setting is clamped to its lowest rated setting and cannot be adjusted below this Once you are done with this setting press the SELECT key until the value stops flashing The new setting is now saved Press the Arrow key to select the IGNITION percent The Blower s
134. ted in SETUP AUX FUNCTIONS HEAT EXCHANGER prevent the Master from going to input when a high DELTA T is reached This method would lead to the non condensing boilers carrying the load when the system temperature stabilizes above 140 since non condensing boilers will start first with the Return water temperature is gt 140F The condensing boilers can then be stopped first when the RET water temperature is above the 140F Remember any combination of the Start and Stop conditions may be applied for best performance and economy in the system Base load boilers can also be mixed in the same way as condensing and non condensing boilers The base load boiler s can be prioritized in one set example Priority 2 and non base load boilers Priority 1 The non base load boilers can then be set to fire first and once they are all firing the base load boiler would fire SETUP amp OPERATION To minimize the cycling of a large base load boiler consider using the stop condition Change it to the OA T lt 15 Outside Air Temperature condition This setting may be used to stop the Priority 1 boiler set when the OA drops below the OA T setpoint thus leaving the large base loaded boiler on and shutting off the condensing boilers first This is also true when using the OA T setting to start the Priority 1 boiler set when the OA T is above the start setpoint To use temperatures as start and stop conditions the system design tempe
135. ter than the Mixed Boiler Return temperature This may not Page 12 HeatNet Control REV 3 47 1 applicable in most configurations since the local return temperature on the Master is used to provide a difference temperature across the heat exchanger However the return temperature sensor may be moved on the Master to provide system return temp if the difference temp is not required Start stop settings Any combination of Start Conditions and Stop Conditions can be used to optimize the mixing of condensing Priority 1 and non condensing boilers Priority 2 for best performance economy The default settings for the start and stop conditions of the condensing set are START PRIORITY 1 gt SET FIRST STOP PRIORITY 1 SET LAST The default start setting always starts the condensing boilers Priority 1 example first except for the lead boiler setting The lead boiler will always start first if enabled unless there is a boiler already running this includes a Member boiler in LOCAL The default stop condition setting always stops the condensing boilers Priority 1 last If prolonging the life of the heat exchanger s on non condensing boilers is very important consider starting the condensing boilers KN series when the return water temperature is below 140F NOTICE The return water temperature sensor would need to be moved from the Master s return inlet to the system return The EXCHGR DELTA may need to be adjus
136. the purpose of modulating a boiler and to control a common system temperature must be used with this method NOTE If using a 0 10 VDC signal multiply any references to current in the manual by 5 Example Sma 5 2 5 VDC Page 39 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 35 Heating Method 3 4 20 ma Version 2 x control green pc board 24 VDC Modulation Control Input Qu 24 VDC Return SUIT 4546 MODH 68 90 NC 1845 2 AE T HB 5 1 5 592 199055 30194190 113 018 95435 18201 Ud 929 oan 3001 0 SV 01 30 9 MZ 5 H 3 Jumper in this position for 4 20ma 290 2 Hit Yd ATHA 1019 3305 30814 k HILINE 08003 6 BUT 1 1 st 99 ee Hoa MS LOTEA 0220000001 0220000006 000060882 034 0 e T2 RELRY e se HNI SYSTEM PUIP PUMP fus Sdetuse PUMP 02 2008 KNHNET KNHLK R2 0D
137. the gas valve proving circuit if equipped detects a gas pressure problem Indicates a call for DHW heating by either the DHW sensor or an external thermostat These log entry faults are result of the interlocks connected to the 24VAC interlock inputs J11A and J11B Low Water Cutoff Low water condition in boiler Var Freq Drive The blowers Variable Frequency Drive has a problem Spare 4 User installed interlock Op Lim Mech An external operator aquastat If the H Net control closes the last interlock string entering the ignition control and the ignition control never closes its Blower Relay the H Net control will wait 2 minutes The H Net control will then retry for the duration of the local pump post purge time and then retry the ignition sequence During this time retry will be displayed in the status screen After 5 attempts the H Net control will lock out and display call service The Log will report the retries The is the firmware Operating Limit as defined in SETUP SETPOINTS OPERATE LIM When the Supply temperature exceeds this value this event is logged If one of the 10k thermistor sensors was detected to be open or not connected this fault will be logged 11 one of the 10k thermistor sensors was detected to be shorted this fault will be logged APPENDIX B Line 4 Message HEADER SENSOR DHW SENSOR AIR SWITCH BLOWER LOST BOILER FOUND BOILER FAIL SAFE H NET LOST FAIL SAFE LOW
138. this method is done via the menus in SETUP DOMESTIC HOT WATER For information on setting up the space heating portion of the method Refer to Heat Demand Control Method 1 located in the CONTROL METHODS section on page 22 1 Connect a 10k thermistor from the DHW tank s sensor well to J10B terminals 1 amp 2 on the MASTER and connect a Header Sensor to the SYSTEM HEADER input Wire any pump or valve from the DHW Pump relay normally open contact to control flow of the heating water into the tank s coil Page 32 HeatNet Control REV 3 47 1 Next enter the DOMESTIC HOT WATER menu When prompted for DHW BOILER enter NO We will enter YES when we are finished entering all parameters Change the DHW SETPOINT to the desired target temperature of the water in the tank Once the control determines there is a call for DHW the DHW SETPOINT is loaded and the Master boiler will target this new setpoint Now change the DHW DIFF to the desired differential This setting corresponds to the minimum water temperature required in the tank DHW heating will be initiated when the DHW tank s water temperature is below the DHW SETPOINT DHW DIFF Since the same the ADD BOILER DELAY time is used for space heating and DHW how long the temperature of the tank stays below the DHW SETPOINT DHW DIFF has to be considered when setting the ADD BOILER DELAY Scroll down to USE SENSOR Press the SELECT key and select YES then press the S
139. trol REV 3 47 1 Enable the base load feature by setting ADVANCED SETUP SYSTEM OPTION to BASE LOAD This setting the OPTION Relay to be used as control for a Base Load Boiler 1 ADVANCED SETUP SYSTEM OPTION to BASE LOAD This setting the OPTION Relay to be used as control for a Base Load Boiler 2 The ADVANCED SETUP BASE LOAD BOILERS BASE LOAD BOILERS to 1 Currently allows 1 base load boiler 3 TheSTART amp STOP qualifier condition to the method discussed below 4 TheDELAY TIME to the amount of time required after the start qualifier condition has been met to start the boiler If a MINIMUM OFF time of the Base Load boiler is needed the Base Load boiler will share the MIN OFF TIME of the boiler controlling it If the base load boiler was running and shuts off the MIN OFF TIME will need to expire before the boiler can start again Once this time expires the DELAY TIME also needs to expire to start the boiler This will help in minimizing short cycle conditions and can be set ADVANCED SETUP FIRING MODE MODE MIN OFF TIME Preferred A modulating base load boiler that can accept a 4 20mA control signal such as the SMITH 28 series is preferred or a non modulating base load boiler that is sized correctly to the H Net boilers The Smith 28 series also has a HeatNet option A 135 ohm input for the base load boiler will need a converter from 4 20mA to 135 ohm http www smithboiler com If the base load boil
140. ture setpoint OARLoAirTemp 40013 8 bit unsigned Set real time clock hour see SetClock 40014 SetMinute 8 bit unsigned Set real time clock minute see SetClock Page 60 MODBUS COMMUNICATIONS HeatNet Control REV 3 47 1 Figure 46 MODBUS Input Output Variables Read Write 40015 SetSecond 8 bit unsigned Set real time clock second see SetClock Set real time clock weekday see 1 Monday 7 40016 SetWeekday 8 bit unsigned SetClock Sunday Set write the real time clock Do Not Write more than once per minute To write the real time clock the system variables SetMonth SetMonth SetDay SetYear SetHour SetMinute SetSecond 0 no action 40017 SetClock 1 bit u eignea SetWeekday must first be loaded with the 1 set write the clock correct date and time Then a 1 must be written to the state portion of this system variable to write the new date and time to the system clock Figure 47 MODBUS Input Variables Read Only Lao Raw A D vate fom spare impu 2760 0 92767 Laos se bsionea Raw AD value fom spare 2input 327681032767 20009 sbtunsinea Reartmeciookmonn a e e ea 1 9 ver 0 0 Caoa Hour 8btunetred 9 2 wine a otunsionea Realtime cockminus 30017 Boiler 1 16
141. uctions for Configuring BACnet or LonWorks are available on the website at http www RBIWATERHEATERS com Page 42 WIRING CONNECTIONS HeatNet Control REV 3 47 1 Figure 38 Relays Interlocks and Boiler Status Version 1 x control blue pc board The HIGHEST priority interlock that opens will be displayed as the fault Priority Highest priority is farthest to left as viewed SYSTEM FLOW PROVE Low Water Cutoff Variable Frequency Drive Gas Pressure High amp Low Spare for user or Factory Operator Water Flow Switch Factory NOTE Spare interlocks can be used Q N Low Voltage Interlocks gt 299 solr 801 9 o o NI pos 39995 34995 Ec Dus es pee S e oe n dri sd 8 9 5 eY Ye Ye Ye Te oo 2 e 1 2 COSE NP SURE po
142. uously so that in the event of a sensor failure the system shuts down and the alarm relay is closed OPTIONAL FEATURES If a pump fails flow switch required or the flow switch fails the boiler will cycle the start condition every 10 minutes in an attempt get the boiler restarted If the damper fails to open and never closes its proof switch a retry algorithm will attempt a retry Every 10 minutes the damper relay will cycle and try to open the damper again If the H Net control closes the last interlock string connected to the ignition control and the ignition control never closes its Blower Relay the H Net control will wait 2 minutes The H Net control will then retry for the duration of the local pump post purge time and then retry the ignition sequence During this time retry strt will be displayed in the status screen After 5 attempts the H Net control will lock out and display call service Communications The H Net control has the ability to communicate using the MODBUS protocol with a building management system Most registers and functions are available for MODBUS access Access is allowed using the RS485 MODBUS PORT connecter on the communication board Version 2 x Control has these connections integrated on the main board An optional BACNet or LonWorks bridge module can be used to connect the MODBUS network to a BACnet or LonWorks network See Method 5 control Failsafe Modes FAILSAFE MODES have b
143. use of the 4 20mA control current is recommended The control voltage methods may be less expensive but are the least stable If using a 0 1OVDC control signal a source current of 20mA is required If using a remote panel with a relay and a 4 20 ma transmitter for operation connect the 4 20ma transmitter output from the remote panel to the member boilers using the floating 250 ohm method type 4 The relay contacts on the remote panel will then be connected to the associated 4 20ma REMOTE ENABLE inputs on the associated boiler s The minimum setting of the boiler is calibrated so that the minimum PWM signal to control the Blower motor is 2096 The VFD to blower motor operates with a control signal from 2096 8096 Pulse Width Modulation This PVM signal to the VFD can be measured using a multimeter It is a 0 10volt square wave signal at 110 Hertz A 20 modulation signal will read 2 0 VDC and an 80 modulation signal will read 8 0 VDC on an RMS multimeter See Figure 42 page 47 Setpoint Control functionality can be implemented remotely using the 4 20mA input This function translates a 4 to 20ma control signal to a setpoint mapped from 50F to 220F The feature is enabled in the SETPOINTS menu as SETPT SOURCE 4 20ma ADVANCED SETUP 4 20ma INPUT Also when selecting SETUP SETPOINTS SETPOINT SOURCE and selecting 4 20ma the 4 20ma INPUT menu will be automatically entered You may now select the current at which the boiler will s

HeatNet Manual - IDC Associates, Inc

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