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ATH KN-10 Control Manual Download Page 64

 

HeatNet Control  V3 1.x

 

 

Failsafe: Low DHW 
Temperature

  

The boiler has entered Failsafe mode due to a low DHW temperature. 

Failsafe: Low 
Header 
Temperature

  

The boiler has entered Failsafe mode due to a low Header temperature. 

Failsafe: Low 
Return 
Temperature

  

The boiler has entered Failsafe mode due to a low Return temperature. 

Failsafe: Low 
Supply 
Temperature

  

The boiler has entered Failsafe mode due to a low supply temperature.. 

Fault

 

A problem has occurred with boiler – Interlocks or firmware detected. 

Fuel Change (Dual 
Fuel) is in Progress 

If the boiler is configured for dual fuel – displays during a changeover. 

Gas Pressure is 
too High or Low

 

If the GAS PR opens on J11A.7 & J11A.8 due to a gas pressure issue. 

Heating 

The system is in a heating mode, but none of the boilers are firing. 

High/Low ∆T 
limited

 

Algorithm that looks at High ∆T or Low ∆T to protect boiler from thermal shock/stress. When 
this is displayed firing rate is limited 

Ignition Control 
Alarm

 

Occurs when the Ignition Control closes it alarm relay – Input on J5 FLAME SAFE 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. 

Input Clamped at 
Modulation 
Maximum

 

This clamp ensures that until all boilers are running, the input is limited to minimize over 
firing the system when new boilers are added. It also limits the boiler’s input before 
servicing a request to go to high fire (preventing thermal shock). 

Input Clamped for 
Protection 
(Operating Limit)

 

This clamp is active when the supply water temperature is in the Operating Limit Band 
(Yellow part of the Heating bar). It is used to limit the input of the boiler in order to 
minimize cycling off the Operating Limit. 

Input is limited 
to ½ rate

 

The boiler is in a protection mode, High/Low Delta – firing rate 

limited

. 

64

Summary of Contents for KN-10

Page 1: ...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 injur e boiler can only be operated with a dust freeairsupply Followtheinstructionmanualprocedurestoductairtotheboilerairintake Iftheboilerhasbeencontaminatedbyo...

Page 2: ...ATUTORY OR OTHERWISE RELATED TO THE INFORMATION INCLUDING BUT NOT LIMITED TO ITS CONDITION QUALITY PERFORMANCE MERCHANTABILITY OR FITNESS FOR PURPOSE The Advanced Thermal Hydronics name and logo Mestek name and logo KN HeatNet and H Net name and logo are registered trademarks of Mestek Incorporated in the U S A and other countries BACnet is a registered trademark of ASHRAE LonWorks is a registered...

Page 3: ...D SYSTEM TYPE 1 HIGH SYSTEM TURNDOWN 15 MIXED SYSTEM TYPE 2 CONDENSING NON CONDENSING 18 BASE LOADING RELAY CONTROL 21 SETTING UP BASE LOADING 23 Heating Control Methods 24 HEATING METHOD 1 24 HEATING METHOD 2 24 HEATING METHOD 3 24 HEATING METHOD 4 24 HEATING METHOD 5 24 OPERATING LIMIT 24 INPUT PRIORITIES 24 HEATING METHOD 1 HEAT DEMAND 25 HEATING METHOD 2 STAGE CONTROL T1 T2 26 HEATING METHOD 3...

Page 4: ...ASTER BOILER AND MEMBER BOILER S 42 MASTER TYPE MIXED COMBINATION 42 DHW METHOD 3 DHW HEATING USING A HEADER SENSOR INPUT 45 DHW METHOD 4 SPACE HEATING WITH DHW OVERRIDE OF SETPOINT ON MASTER 45 DHW METHOD 5 DHW OF A LOCAL BOILER S TANK 46 DHW METHOD 6 DHW USING DIRECT CONTROL 48 Wiring Connections 49 Home Screen Navigation 60 Home Screen 61 Home Screen Messages 62 HEATING MODE MESSAGES 62 SETPOIN...

Page 5: ...er water temperature at the supply or the header sensor using a target setpoint This function is displayed in the Home Screen 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 IGNIT...

Page 6: ... Member boiler but are still visible 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...

Page 7: ...y types Vacuum Florescent and Color LCD using the same 20 pin ribbon cable 7 System Return sensor input 8 Enhanced bootloader and firmware storage One firmware storage location for user updates One firmware program that always remains resident so that a factory program can be restored Primary loading is with a flashdrive 9 Support for High Efficiency Ametek blowers 10 32 bit Microcontroller operat...

Page 8: ...d Lag True Rotation based on boiler runtime is default First On First Off FOFO Last On First Off LOFO and MIXED are optional 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 Whe...

Page 9: ... DHW Pump v2 x 8A 250 VAC resistive K8 on J4 2 6 for Base Loading version 2 x Control AC Interlocks 24 VAC 120 VAC input Control Inputs AA Heat Demand 4 20ma Enable OA override T1 T2 dry contact inputs 4 20mA 0 10 VDC Dimensions 9 wide 6 high 2 deep Temperature Sensors NTC thermistor 10K 77 F 335 67K 40 F 185 150 F 1 F USB 1 0 RS485 MODBUS Modbus RTU Boiler to Boiler HeatNet H Net Network Optional...

Page 10: ...281 ACI 10k CP S Strap on sensor ACI X 2 CP PO 4 4 probe with dual sensor ACI X 2 CP PO 6 6 probe with dual sensor 02 4280 ACI 10k CP O Outside Air Sensor with Housing 0040 1300 1k Platinum Stack sensor Installation 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...

Page 11: ...otation 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 RUNTIME setting in SETTINGS FIRING MODE 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...

Page 12: ... now lowers the modulation rate to the boilers 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...

Page 13: ... SETTINGS FIRING MODE MIXED BOILERS LAST example If the Stop condition for Priority 1 is met the Master or Member boiler that are 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 the remaining PRIORITY 1 set of boilers will stop based on runtime If the Stop condition changes and or is not met such as with O...

Page 14: ...eturn water temperature is below 140F and condensing occurs The Master s system return water would need to be used 3 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 brou...

Page 15: ... 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 Also non condensing boilers may be set to go offline when a return temperature is too low using the SETTINGS HEAT EXCHANGER TEMP DISAB menu Base load boilers can also be mixed in the sa...

Page 16: ... the system Number of boilers Turndown Ratio Effective System Turndown 5 5 1 25 1 Figure 5 Mixed Boiler System System MMBTU Effective Turndown MOD MAX Priority 1 5 1 Priority 2 4 1 4 2 35 1 60 KN6 KN6 KN10 KN10 KN10 3 8 42 1 70 KN4 KN4 KN10 KN10 KN10 2 2 55 1 81 KN2 KN2 KN6 KN6 KN6 3 6 90 1 72 KN2 KN2 KN2 KN10 KN10 KN10 With the mixed boiler system a lower minimum fire rate BTU can be delivered to...

Page 17: ...are set as Priority 1 and KN10 s set as Priority 2 With a MOD MAX of 60 each KN6 can run to 360M 720M total before a KN10 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 198M 330M 726M and operate a...

Page 18: ...tion charts and the MOD MAX value so that boilers are brought on and fired in their respective efficiency curve while maintaining continuity in BTUs Since selecting the 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 Mixed System Type 2 Condensing Non Conden...

Page 19: ... 1M 1 2M Mod Max 60 300 450 600 750 900 1 1M Mod Max 50 250 375 500 625 750 875M KN Boiler Btu Chart MBH KN2 KN4 KN6 KN10 KN20 KN30 Max Input 200 400 600 1MM 2M 3M Min Input 5 1 40 80 120 200M 400 600 Mod Max 80 160 320 480 800M 1 6M 2 4M Mod Max 70 140 280 420 700M 1 4M 2 1M Mod Max 60 120 240 360 600M 1 2M 1 8M Mod Max 50 100 200 300 500 1M 1 5M Using the boiler charts and the examples used in M...

Page 20: ...ystem Return temperature The Member s menu SETTINGS HEAT EXCHANGER TEMPERATURE DISABLE if set to RETURN or SYSTEM RET will force the boiler to become unavailable to HeatNet when the SETTINGS HEAT EXCHANGER TEMP 140F This value is adjustable to 135F if a forced air fan is used When the SYSTEM RETURN or RETURN temperature is 140F the boiler responds to a HeatNet Master s request as unavailable As so...

Page 21: ... Load Boiler 2 The SETTINGS BASE LOADING BOILERS to 1 Currently allows 1 base load boiler 3 The START WHEN STOP WHEN qualifier condition to the method discussed below 4 The DELAY 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 boil...

Page 22: ...o 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 Outside Air is above xxF may also be used if the system design temperature is known Then let the Base Load boiler cycle off of its limits wh...

Page 23: ...l open to disable the boiler when the OUTSIDE AIR read from the Outside Air Temperature sensor if equipped rises above this value SETTINGS BASE LOADING STOP WHEN OUTSIDE AIR IS ABOVE If the OUTSIDE AIR qualifier is used as the Start and Stop qualifier ensure that there is at least a few degrees difference for hysteresis 3 Return Water Temperature a START menu item The relay contact will close to e...

Page 24: ...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 H Net a software operating limit on the member boiler will be used to limit the maximum output of the member boiler This operat...

Page 25: ...ch 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...

Page 26: ...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 25 of output Any signal between 20 and 25 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 25 such as 33 a control signal ...

Page 27: ...time that allows any write to a MODBUS register to reset the setpoint timer as long as it occurs within that time This will reset the setpoint timer without writing the setpoint timer register So periodically writing the setpoint register will automatically reset the setpoint timer as long as the write occurs within that time window Protocessor option An optional BACnet or LonWorks bridge module c...

Page 28: ...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 the dip switch S6 is set to the 0 10 p...

Page 29: ...control current applied achieves this value of 4 10ma The boiler must drop 1ma below this to turn OFF 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 4ma SETPOINT and the upper setpoint is defined as 20ma SETPOINT The 4ma SETPOINT is linked to th...

Page 30: ...ow proving switch is implemented using SPARE 3 System Water Flow on J11A If a flow switch is connected to the WTR FLW interlock the HeatNet control will wait up to 10 seconds to prove flow 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 flo...

Page 31: ...ion of the 2 pumps can be controlled using two methods 3 Pumps are switched based on the system run time 4 Pumps are switched by the difference between each pump s runtime The HeatNet control keeps a running record of each pump s runtime in hours If a pump is taken offline or replaced The runtimes can then be adjusted until they become equal These features may be selected in the menu SETTINGS SYST...

Page 32: ...ting 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 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 ma...

Page 33: ...s the Winter Summer mode W arm W eather S hutdown With the WWS SETPOINT set to 72F and WARM WEATHER SHUTDOWN set to ON the boiler system will enter summer shutdown when the Outside 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...

Page 34: ...ys Once a file has been selected a STORAGE LOCATION needs to be selected There are 2 storage locations for the new file Location 1 is used for normal updates and Location 0 is for the factory stored backup file When the Storage location default is Location 1 is selected the file will be loaded into a permanent storage memory location Next the control will reboot and copy this new program into runn...

Page 35: ...from J13A 2 to the Ametek blower contactor s enable input This allows the HeatNet control firmware to control power to the blower by switching the contactor ON or OFF The reasons for this are as follows 1 The Stage 4 relay has been allocated to help bring the power up in steps These steps are used to minimize inrush currents by engaging the blower s contactor 7 seconds after the main power has bee...

Page 36: ...ion of this manual 3 Low Temperature Protection LOW TEMP OFF SUPPLY HEADER DHW or RETURN 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 tem...

Page 37: ... the largest boiler in the system The HIGHEST FLOW FLOW FACTOR are currently not used with this release Once flow meter manufacturers have been determined new firmware will become available f Write to address BMS GPM register 40019 with a valid flow 0 1500 GPM g If a new GPM value is not written within 10 minutes this feature will be deactivated until a new flow value is written Ensure periodic up...

Page 38: ...n 2 x and version 3 x HeatNet controls and is standard on V3 x The bridge module provides an RJ45 connector for access to the internet If an RJ45 hardline is not available a wireless modem can also be used Consult the factory or sales for available solutions The HeatNet Online site may be accessed at www heatnet net A login Account Password is required Once a user has registered a site the users e...

Page 39: ...gram as pictured below The date time picker can be used to mine the raw data stored on the HeatNet Online server Runtime graphs of each boiler ensure even runtimes are being observed by a properly operating system This is just an overview of HeatNet Online and a few of the screens that are available 39 ...

Page 40: ...oices are AUTO will handle normal heating only applications It may also be used when individual boilers have tanks connected and are controlled with the DHW BOILER set to LOCAL DHW is for DHW applications without space heating MIXED Combination Will allow combination Space and DHW heating control of boilers by the Master The OR OVR input now functions in many of the methods as a DHW Heat Demand in...

Page 41: ...call for heat ends A The pump will remain on during a post purge pump cycle until the post purge timer expires 2 Next enter the DOMESTIC HOT WATER menu on the Master boiler In the BOILER MODE selection enter OFF The Master uses this method as a DHW system much like a space heating system Member boilers may set the BOILER MODE to LOCAL and go offline to perform secondary DHW heating but the Master ...

Page 42: ...e DHW pump off within a few seconds The SPACE setting should only be used only for combination space and DHW heating 12 Set the HYB SENSOR OFF This sensor is selectable for Method 5A only Now in the SETTINGS DISTRIBUTED CONTROL MASTER TYPE select DHW NOTE JPS1 MUST be cut on all boilers providing DHW DHW METHOD 2 Combination DHW and Space Heating using a MASTER Boiler and Member boiler s Master Ty...

Page 43: ... It can also monitor system status through a central location Master boiler by a BMS or HeatNet Online This failsafe method can also be used in the Combination DHW Space Heating Simplified Drawing Set up the Master boiler first 1 Connect a 10k thermistor from the DHW tank s sensor well to J10B terminals on the MASTER and connect a Header Sensor to the SYSTEM HEADER input Wire any pump or valve fro...

Page 44: ...cal pump valve will remain running during DHW heating YES The local pump will shut off with a delay determined by LOCAL DELAY seconds This allows the DHW pump valve to prove before shutting off the local pump Piping of the system will determine which setting to use 13 Go to the PURGE TO menu After a DHW cycle completes the pump valve can be selected to either purge to the TANK or to the SPACE for ...

Page 45: ...d set the SHED BOILER DELAY time to 0 or other small value 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 POS...

Page 46: ...nt Once the tank temperature exceeds the Setpoint UPPER BAND temperature DHW heating will stop and the pump valve s post purge will start LOCAL DHWTANK MEMBER Tank Sensor LOCAL DHWTANK MASTER Tank Sensor Main Heating Loop LOCAL LOCAL DHW DHW LOCAL DHW Simplified Drawing When a tank s temperature sensor is connected directly to a boiler and the BOILER MODE is set to LOCAL The boiler will go offline...

Page 47: ...k or DHW loop temperature using the DHW sensor The upper and lower differential temperatures will also be loaded 31 Got to SHARING and set it to OFF or CYLE if the boiler is currently running in space heating and needs to be shut down before starting up in DHW If SHARING is set to NO CYCLE a hot swap will occur A hot swap is when the boiler is running in space heating mode and does not need to be ...

Page 48: ...r continuous demand or speed in heating the tank It is already available so no additional sensor is needed Return sensor will allow the boiler to run its supply temperature up quickly but may bounce off of the operating limit band This would heat the tank in the shortest time but may overheat the tank It is already available so no additional sensor is needed DHW sensor will allow the placement any...

Page 49: ...r J4 1 W J4 7 B and J4 5 135 Ohm mode JS1 4 20mA NOTE S5 6 must be set to J4 1 J4 5 0 10V for the above to work in 4 20mA mode If JS1 is set to 0 10VDC then this switch has no effect on J4 1 and J4 5 S5 2 NOT USED Factory S5 3 Set to NONE if there is no Stack Sensor or if a 1k Platinum stack sensor is used Set to 10k STACK if a 10k Thermistor stack sensor is connected to J10B S5 4 Set to NONE if t...

Page 50: ...ommunications HeatNet Termination Enable Switches DOWN Position Disable Switches UP position Switch shown disabled MEMBER Close to run at Local setpoint MASTER Close to control all boilers and run at System setpoint Close this contact to override the outdoor reset slope and run boiler at the Local setpoint The 2 LEDs on the RJ45 indicate GREEN Transmit Data YELLOW Received Data 50 ...

Page 51: ...Figure 29 Heating Methods 2 and 4 AA High Fire and High Low master or member boiler Heating Mode 2 Stage Control Inputs T1 or T2 Closed Lowfire T1 T2 closed Highfire T1 T2 Heating Mode 4 High Fire Close this contact to run boiler at Highfire 51 ...

Page 52: ...using a 0 10 VDC signal multiply any references to current in the manual by 5 Example 5ma 5 2 5 VDC 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 a 0 10 VDC signal mult...

Page 53: ...ay be damaged The pin headers are located on 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 Communication from the Protocessor bridge to the H Net control is also handled through the sockets Next connect the BACnet or LonWorks network cable to the Protocessor module or configur...

Page 54: ...6 7 8 Low Fire Hold Fires the boiler at the minimum rate while in Calibrate This functions exactly as the T1 input Calibrate Allows adjustment of the Minimum Fire Maximum Fire and Pilot Ignition settings Combustion proving switch from Combustion Air Damper Remote 120 VAC Operator USB and Flashdrive Ports Used by HeatNet Pro and updating firmware Local Pump or Power Open Power Close Valve DHW Pump ...

Page 55: ... well OPTIONAL Water Temperature Common System Supply Header REQUIRED Water Temperature OUT supply of Boiler REQUIRED Water Temperature INLET return of Boiler IF CONNECTED BOILER MASTER OPTIONAL Outside Air Temperature Sensor OPTIONAL DHW Temperature Domestic Hot Water Temperature TANK T OPTIONAL Stack Temperature T OPTIONAL System Return Temperature 55 ...

Page 56: ...ER YES a Heat Demand signal must be used to activate the system HEADER SENSOR Determines Master Boiler 4 RETURN SENSOR 3 SUPPLY SENSOR 2 LOCAL PUMP ENABLE 8 FLOW PROVE 10 SYSTEM PUMP ENABLE 14 FLOW PROVE 9 OUTDOOR SENSOR North Away From Exhaust 1 BOILER DHW TANK DHW PUMP ENABLE 12 DHW TANK SENSOR 5 DHW TANK AQUASTAT 13 DHW RETURN DHW SUPPLY COMBUSTION AIR DAMPER ENABLE 7 PROVE 11 56 ...

Page 57: ...rol signal must drop below 4 01 mA to stop Boiler MAX OUTPUT After Ignition 0 100 Control Signal to MAX Output Boiler Off Percent of Boilers INPUT 0ma Display input of control when running A control signal greater than 4 2mA adjustable will start boiler PWM Duty Cycle Blower Off 20 Blower Fully ON 80 100 0 20 the minimum speed the VFD will run 20 for 5 1 boilers 25 for 4 1 boilers 33 for 3 1 boile...

Page 58: ...24 VAC Transformer DAMPER Prove Switch DAMPER Enable 24 VAC Mains MASTER BOILER MEMBER BOILER 1 Connection if Member boiler is running as Failsafe MEMBER BOILER 2 Connect to 24 VAC Return on each Boiler NOTE Ensure that the Combustion Air Damper is enabled on all Boilers for use SETUP MENU AUX FUNCTIONS 58 ...

Page 59: ...system pump wiring System Pump Contactor System Pump Voltage Feed System Pump System Pump Voltage Return 120VAC Ph2 Ph3 120 Return 120 VAC Return DPST Relay System Flow Prove Switch 120VAC Add additional relays contacts for more boilers MASTER BOILER MEMBER BOILER 1 59 ...

Page 60: ...nd Binary Inputs Analog Motor Tach and Misc Outdoor Reset if Active Boiler Runtimes Home Screen This diagram depicts the Home screen and subsequent screens when the right arrow button is pressed Repeatedly pressing the right arrow button forms a ring of the different screens These screens are used during normal operation of a boiler or boiler system 60 ...

Page 61: ...ing Limit Band Beginning of Red is the Operate Limit Top Arrow is the Supply Temperature Bottom Arrow is the Return Temperature Boxed Boilers indicate Boilers that are recognized by HeatNet The green bar numeric indicates Modulation Small flame indicates pilot large flame main flame A Red Exclamation point indicates a problem exists with the boiler The lock symbol indicates the boiler is locally c...

Page 62: ...r in Failsafe mode No other Heating Demand may be present HeatNet Call for Space Heat is controlled by HeatNet HeatNet DHW Call for DHW Heat is controlled by HeatNet High Fire High Fire AA is active or T1 and T2 Inputs are active T1 T1 Input is active Low Fire rate T2 T2 Input is active Low Fire if T1 Input High Fire if T1 active Status Line 1 Setpoint Source Heating Mode Status Line 2 Running Sta...

Page 63: ...ay excessive speed this message will be displayed With this event the HeatNet control will lockout the boiler and the boiler will require a manual reset to restart Operation of the blower above the boiler s maximum blower rpm setting could over fire the boiler Blower Signal not Received Retrying The Boiler attempted to start by sending the J5 FLAME SAFE ALARM signal to the Ignition Control The con...

Page 64: ...shock stress When this is displayed firing rate is limited Ignition Control Alarm Occurs when the Ignition Control closes it alarm relay Input on J5 FLAME SAFE 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 ...

Page 65: ...e circulator pump relay will cycle ON for 10 seconds and then OFF for 10 seconds to try and establish flow No System Flow The SYSTEM WTR FLOW interlock is open J11A 1 J11A 2 Once the HeatNet series boiler receives a call for heat it closes the system circulator pump relay It then waits 10 seconds or more to prove flow If there is no flow the flow switch alarm will be set Every 10 seconds the circu...

Page 66: ... Limit When the supply water temperature exceeds the top of the Operating Limit Band and the Operating Limit This is the Yellow Band portion of the temperature bar on the Home Screen Supply Water Temperature has Exceeded the Stat Operating Limit The system is in a heating mode but none of the Displays when a mechanical thermostat input is used and connected to EXT OPER J11B 3 J11B 4 and opens User...

Page 67: ...s waiting for the handshaking events to begin with the ignition control and the HeatNet control Warm Weather Shutdown in effect The WWS temperature has been exceeded The boiler system is in a sleeping state but can be awoken with a DHW call Once the outside a ir temperature falls below the WWS temperature normal space heating will restart Warning This message unlike a Fault still allows the boiler...

Page 68: ...ll boilers running are modulated to maintain Setpoint Boilers are not added or shed while in the heating band Yellow except for when Predictive Start is set to YES If Predictive Start is used and when the temperature is falling fast through the band a boiler will be started when in the band The same use applies to the DHW Start Timer Add Boiler Delay and DHW Stop Timer Shed Boiler Delay for DHW he...

Page 69: ...on Pressing any of the Member buttons will bring up a Member s informational screen Limited information is available for a Member from the Master boiler including making Settings changes and the Log These need to be viewed on each Member boiler directly Next to it is the Log File button Pressing this button will allow viewing of the log file See Log Entry section 69 ...

Page 70: ... the MIN VFD as shown in the display press the Adjust button under the Minimum setting The percentage value will turn green 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 X key to throw out the setting or the check key to save To adjust th...

Page 71: ...ing the arrow keys The top line left corner indicates any condition that caused the event This may be a fault such as to indicate a sensor that has failed or general event as denoted by Event The top line right corner displays the time and date the event occurred In the bottom center of the command bar the event is displayed so that easy indexing can be done using the arrow keys The second line fr...

Page 72: ... Control V3 2 x SETTINGS To Enter the Settings menus the first boiler button must be selected The button is highlighted by the red box Next press the Settings box as also illustrated by the red box The Settings Menu Page 1 will then be displayed 72 ...

Page 73: ...er the numbers are the H Net address of each boiler from 2 16 LOCAL SETPT SYSTEM SETPOINT 160 F 40 220 F Local setpoint used to maintain temperature of SETPT SOURCE System Setpoint is used by the Master HEAT BAND 30 F 2 50 F Differential temp around setpoint used to stage boiler s OFF ON OPERATE LIMIT 215 F 45 230 F When running as a member boiler shuts off when supply temperature reached Boiler r...

Page 74: ...is set to SYS HRS ROTATE TIME is used to switch pumps when this time expires This time is measured against the actual time the system pump is enabled This would include a post purge time If ROTATION is set to PUMP HRS ROTATE TIME is used to switch pumps when the pump s time difference is greater than ROTATE TIME Whichever pump has the least time and is at least below the other pump s time ROTATE T...

Page 75: ...stops ALWAYS ENABLED OFF Pump never shuts off LOCAL PUMP VFD OFF ON OFF ON Outputs a 0 10VDC or 4 20mA signal from J4 pins 1 5 that is proportional to the fire rate of the boiler Connect to a VFD controlling a Local pump FLOW PROVE 10s 10 240 sec This is an adjustable flow proving time to allow slower valves to open before proving flow MASTER PUMP VALVE REMAINS ON OFF ON OFF ON The master boiler w...

Page 76: ...he 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 ...

Page 77: ... SYS RET the boiler will use the Return temperature sent from the MASTER boiler RETURN the boiler will use its own Return sensor If it is set to OFF then this feature will not be used If a sensor is selected then the Boiler will determine if the Return sensor s temperature is below the TEMP XXX setting in the following menu If the Return temperature is lower the boiler will take itself offline fro...

Page 78: ...e DHW relay remains on after the DHW call ends USE SENSOR NO If this entry is set to YES the DHW 10k Sensor is looked to for controlling DHW water temperature If set to NO A thermostat is used Sharing OFF OFF NO CYCLE CYCLE NO CYCLE allows the boiler to perform as a space or DHW heating boiler DHW always has priority and will override steal a space heating boiler that is running when none are avai...

Page 79: ...ilers heat into the tank SPACE will turn off the DHW pump after 5 seconds and enable the local pump valve when a DHW heating cycle completes This allows dumping some of the remaining heat from the boiler into the heating space dump zone and preventing the tank from overheating HYBRID SENSOR OFF OFF SUPPLY DHW RETURN Hybrid mode sensor for DHW method 5A OFF This sensor is selectable for DHW Method ...

Page 80: ... item selects how they are to be used The MASTER TYPE setting is used to determine if the MASTER control is to be used as a space heating control a combination DHW space heating control or just to perform DHW Heating When set to AUTO the boiler uses one PID control to provide space heating When set to MIXED Combination the control will use two independent PID controls to provide space heating and ...

Page 81: ... 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 in a system or when bumps in the temperature occur as boilers are added and subtracted this value may ...

Page 82: ... 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 within their Priority sets based on their runtime hours MINIMUM RUNTIME 10 1 750 When the firing rotation is based on runtime this value represents the interval in hours of runtime before rota...

Page 83: ...T MODULATION IS BELOW OUTSIDE AIR IS ABOVE RETURN IS BELOW MODULATION IS BELOW 20 20 100 20 20 100 The base load relay K8 will open when the Modulation is OUTSIDE AIR IS ABOVE 40 100 F The base load relay K8 will open when the OA temp is T RETURN IS BELOW 60 150 F The base load relay K8 will open when the Return temp is T DELAY TIME 0 0 60 minutes This setting allows a wait time before firing the ...

Page 84: ...e when a 20mA or a 10 VDC signal is applied BOILER START 4 11mA Or 2 04V 3 71 5 0mA Or 01 2 50 VDC This is the current value which will start the boiler There is a 1mA or 25 VDC hysteresis value So if the Boiler starts at 4 11mA it shuts off a 4 01mA PRIORITY NORMAL If the Priority is set to NORMAL the boiler responds to its HEAT DEMAND inputs in the Priority that is outlined in the Control Method...

Page 85: ... not need to be changed but is calculated to 65 GPM and that value is used by HeatNet INPUT TYPE VOLTS 2 CH2 V CH2 mA BMS This setting determines where the flow values are originating If set to Volts 2 then a Flow meter is providing a 0 10V signal on J10B 4 20mA 2 Ensure that S6 switch 2 is UP for 0 10VDC If the setting is mA 2 then a Flow meter is providing a 4 2omA signal on J10B 4 20mA 2 Ensure...

Page 86: ...5 1 This is the turndown of the boiler For the KN series the default is 5 1 and determines the minimum firing percentage 5 1 Min 20 4 1 Min 25 3 1 Min 33 NOTE The boiler must be set up for operation at this Turndown rate using the Calibrate settings This TURNDOWN setting only controls the displayed percentage ALTITUDE LESS THAN 2000FT LESS THAN 2000 FT GREATER THAN 2000 FT GREATER THAN 4000 FT Thi...

Page 87: ...celeration rate is automatically decreased as the rpm approaches low fire SOFT START 2 2 4 seconds In order to start the Ametek blower the control signal must be applied to start the blower at a low rpm If the low speed start time is too low the Ametek blower may not start and lock out with its current limit This may result in the need for the boiler to be recycled If this is to be avoided the Sta...

Page 88: ...irmware Check the http www knseries com website periodically for firmware updates USB DRIVE USB DRIVE SAVE FILE Selecting the USB DRIVE tab will read the FIRMWARE directory on a flash drive and display any hex files located in the FIRMWARE directory Follow the on screen prompts and then select a file using the arrow keys Once a file has been selected a STORAGE LOCATION needs to be selected There a...

Page 89: ...ts except the Calibration values HeatNet Modbus addresses and personality profiles for the boiler type CONFIG SAVE SAVE RESTORE Selecting SAVE will save all of the current settings in this table into a permanent memory location on the HeatNet control This should be done prior to upgrading new firmware or when a job has been commissioned Selecting RESTORE will restore all of the saved settings from...

Page 90: ... 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 This is a failsafe feature used to help safeguard the system in case of BMS failure If the set...

Page 91: ...DHW Setpoint 40 200 F 40019 BMSGPMRate 16 bit unsigned 1 0 GPM rate to be loaded by BMS for calculating how many boilers can run based on flow 0 1500 GPM 40020 BMSLimitBoilers 16 bit unsigned 1 0 Write the of boilers that the BMS allows to fire If x boilers are available x becomes less than or equal to LimitBoilers 0 16 Figure 39 MODBUS Input Variables Read Only Address Name Raw Data Type Scale De...

Page 92: ...s2 30024 Boiler05Status1 30025 Boiler05Status2 30026 Boiler06Status1 30027 Boiler06Status2 30028 Boiler07Status1 30029 Boiler07Status2 30030 Boiler08Status1 30031 Boiler08Status2 30032 Boiler09Status1 30033 Boiler09Status2 30034 Boiler10Status1 30035 Boiler10Status2 30036 Boiler11Status1 30037 Boiler11Status2 30038 Boiler12Status1 30039 Boiler12Status2 30040 Boiler13Status1 30041 Boiler13Status2 3...

Page 93: ...meHigh16 30067 Boiler10RuntimeLow16 30068 Boiler11RuntimeHigh16 30069 Boiler11RuntimeLow16 30070 Boiler12RuntimeHigh16 30071 Boiler12RuntimeLow16 30072 Boiler13RuntimeHigh16 30073 Boiler13RuntimeLow16 30074 Boiler14RuntimeHigh16 30075 Boiler14RuntimeLow16 30076 Boiler15RuntimeHigh16 30077 Boiler15RuntimeLow16 30078 Boiler16RuntimeHigh16 30079 Boiler16RuntimeLow16 30080 Boiler01Status3 16 bit unsig...

Page 94: ...0110 Boiler15SupplyTemp 30111 Boiler16SupplyTemp 30112 Boiler01ReturnTemp 16 bit signed 0 01 Boiler 1 16 return temperature if available See BoilerStatus2 to determine if the sensor is present Boiler01 Master Boiler02 Member01 Boiler16 Member15 32 250 F 30113 Boiler02ReturnTemp 30114 Boiler03ReturnTemp 30115 Boiler04ReturnTemp 30116 Boiler05ReturnTemp 30117 Boiler06ReturnTemp 30118 Boiler07ReturnT...

Page 95: ...Boiler10CyclesHigh16 30147 Boiler10CyclesLow16 30148 Boiler11CyclesHigh16 30149 Boiler11CyclesLow16 30150 Boiler12CyclesHigh16 30151 Boiler12CyclesLow16 30152 Boiler13CyclesHigh16 30153 Boiler13CyclesLow16 30154 Boiler14CyclesHigh16 30155 Boiler14CyclesLow16 30156 Boiler15CyclesHigh16 30157 Boiler15CyclesLow16 30158 Boiler16CyclesHigh16 30159 Boiler16CyclesLow16 30160 Boiler01Status4 16 bit unsign...

Page 96: ...16DHWTemp 30224 Boiler01Modulation 16 bit signed The running display modulation This is typically the actual running modulation except under special circumstances when the boiler is running in a self protection mode Op Limit Fire Rate etc Boiler01 Master or Connected Boiler Boiler02 Member01 Boiler16 Member15 0 100 30225 Boiler02Modulation 30226 Boiler03Modulation 30227 Boiler04Modulation 30228 Bo...

Page 97: ... combined concatenated into a single 32 bit counter as SystemFlowHigh16 SystemFlowLow16 Example SystemFlow SystemFlowHigh16 65536 SystemFlowLow16 0 01 This value is either the system flow meter reading or the value written to the BMSFlowRateGPM register by the BMS 0 1500 GPM 30266 SystemFlowLow16 30269 HeatingBoilersOn 8 bit unsigned The number of boilers currently running for heating 0 16 30270 D...

Page 98: ...ing condition has occurred An attempt s will automatically be made to recover and resume normal operation 0 ok 1 alarm 3 Failed A condition has occurred under which the boiler can no longer run 0 ok 1 failed 4 Member Error An Alarm or Failed condition has occurred on one or more of the member boilers 0 ok 1 error 5 Boiler Running Main Valve is open and Modulation Delay time has expired 0 off 1 run...

Page 99: ...verride 0 off 1 on 4 T1 0 off 1 on 5 T2 0 off 1 on 6 Obsolete 0 off 1 on 7 Obsolete 0 off 1 on 8 reserved for future use 9 reserved for future use 10 reserved for future use 11 reserved for future use 12 reserved for future use 13 reserved for future use 14 reserved for future use 15 reserved for future use This BoilerStatus3 Heat Demand Flag is Heat Demand input On member boilers this indicates a...

Page 100: ...ler 1 This control board has been designated a DHW boiler by cutting the DHW jumper JPS1 0 no 1 yes DHW jumper cut 11 Operating Limit Clamp 1 Boiler input is being limited clamped due to a high supply outlet temperature 0 off 1 clamped 12 Firing boilers limited by value in BMS Flow Rate Register 1 0 not limited 1 limited 13 Firing boilers limited by value in BMS Limit Boilers Register 1 0 not limi...

Page 101: ...OR 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 PUMP ROTATION ROTATION SYSTEM PUMPS ROTATE TIME MORE MENUS ZERO RUNTIME PUMP PUMP1 TIME PUMP2 TIME ALWAYS ENABLED SUMMER PUMP JOG OVR ENAB IN WWS LOCAL PUMP DELTA TEMP ENAB DELTA TEMP POST PRGE TIME s ALWAYS ENABLED 101 ...

Page 102: ...E END DAY TIME OPTIONS TEMP SCALE KEY CLICK SKIP PASSWORD BRIGHTNESS LOG RUNTIME RUN HOURS DATA LOG ENTRY SIZE BOILER CYCLES AUX FUNCTIONS COMBUST AIR DAMPER TYPE IN USE INPUT PROOF TIME ALARM SILENCE SWITCH IN USE INPUT FAILSAFE MODES H NET COMM LOST LOW TEMP TEMP HEAT EXCHANGER EXCHGR DELTA T LIMIT HALF RATE DOMESTIC HOT WATER DHW BOILER DHW SETPOINT LOWER DHW DIFF 102 ...

Page 103: ...ET ADDRESS MODBUS ADDRESS MODULAR BOILER SET SPACE HEATING ADD BOILER DELAY SHED BOILER DELAY MODULATE DELAY TIME MOD MAX LAST FIRE DHW HEATING ADD BOILER DELAY SHED BOILER DELAY MODULATE DELAY TIME MOD MAX LAST FIRE ADD BOILER DELAY SHED BOILER DELAY MODULATE DELAY TIME MOD MAX LAST FIRE ADAPTIVE MOD MOD MODE DROP DOWN DELAY RELEASE FIRING MODE MODE MIXED START PRIORITY 1 SET STOP PRIORITY 1 SET ...

Page 104: ...INPUT ANALOG IN CHANNEL CHANNEL MODE 4mA SETPOINT 20mA SETPOINT BOILER START PRIORITY PASSWORD COMMUNICATIONS BAUD DATA FORMAT SETPOINT TIMER SETPOINT TIME FLOWMETER FLOWMETER GLYCOL MIX INPUT TYPE LOWEST FLOW HIGHEST FLOW FULL SCALE FLOW FACTOR BLOWER SETTINGS AMETEK BLOWER ACCELERATE DECELERATE SOFT START SECS OFF BOILER BLOWR SYSTEM CONFIGURE INTERLKS INTRLK ASSIGNMENTS SYSTEM FLOW ON LOAD FIRM...

Page 105: ...WORKSHEET HeatNet Control V3 REV 2 x OPTION BOILER TYPE PRODUCT CONDENSING BTU IN BLOWER MASS TURNDOWN ALTITUDE CALIBRATION SETTINGS MIN VFD IGN VFD MAX VFD 105 ...

Page 106: ...0 4 97 072 80 176 1 255 15 5 72 951 85 185 1 070 10 14 55 326 90 194 915 4 5 23 43 326 95 203 786 6 0 32 32 650 100 212 678 6 5 41 25 391 105 221 587 6 10 50 19 899 110 230 510 6 15 59 15 711 115 239 445 2 20 68 12 492 120 248 389 6 25 77 10 000 125 257 341 9 30 86 8 057 130 266 301 0 35 95 6 531 135 275 265 8 40 104 5 326 140 284 235 4 45 113 4 368 145 293 209 0 50 122 3 602 150 302 186 1 55 131 ...

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Page 108: ...IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 7555 TRANMERE DRIVE MISSISSAUGA ONT L5S 1L4 905 670 5888 FAX 905 670 5782 www knseries com ...

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