HydroTherm HeaetNet V3 KN-10 User Information Download Page 20 | Manualshive

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SETUP & OPERATION

HeatNet Control V3 2.x

Page 20

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

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Summary of Contents for HeaetNet V3 KN-10

Page 1: ...ith 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 i...

Page 2: ...ED SYSTEM TYPE 1 HIGH SYSTEM TURNDOWN 14 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 HEATIN...

Page 3: ...HYDRONICS 92 KN HeatNet V3 Advanced Menu Tree ATH 93 Worksheet 94 Type II Thermistor Resistance Temperature Table 99 Status Information 100 STATUS INFORMATION SCREENS 100 Status Screen Fault Display 1...

Page 4: ...mit 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 li...

Page 5: ...oiler 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 signa...

Page 6: ...splay 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 On...

Page 7: ...Lead 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...

Page 8: ...arm 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 in...

Page 9: ...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 Inst...

Page 10: ...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 wat...

Page 11: ...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...

Page 12: ...he 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 MOD...

Page 13: ...y not applicable in most configurations since the local return temperature on the Master is used to provide a difference temperature across the heat exchanger A System Return sensor will be required H...

Page 14: ...h 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 maximu...

Page 15: ...M 240M 360M 600M 1 2MM 1 8MM Mod Max 50 100M 200M 300M 500M 1MM 1 5MM When selecting the Priority 1 boiler s for a high effective system turndown the BTU Min Input is selected first See KN Fusion Boil...

Page 16: ...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 run...

Page 17: ...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 18: ...00 500 500 Figure 13 Mixed Boilers Example Condensing Non Condensing Figure 14 FIII Boiler Btu Chart MBH MB MW 500 750 1000 1250 1500 1750 Max Input 500 750 1M 1 25M 1 5M 1 75M Min Input 3 1 166 250 3...

Page 19: ...TIONS HEAT EXCHNAGER TEMP 140F This value is adjustable to 135F if a forced air fan is used When the SYS RET or RETURN temperature is 140F the boiler responds to a HeatNet Master s request as unavaila...

Page 20: ...tu 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...

Page 21: ...urrently allows 1 base load boiler 3 The START STOP 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 t...

Page 22: ...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 xxF may also be used if the system design tem...

Page 23: ...ble the boiler when the OA T read from the Outside Air Temperature sensor if equipped rises above this value ADVANCE SETUP BASE LOADING STOP OA T If the OA T qualifier is used as the Start and Stop qu...

Page 24: ...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...

Page 25: ...Local setpoint MASTER Close to control all boilers and run at System setpoint Master boiler The MASTER boiler controls the system using a PID algorithm Once the boiler is started a PID algorithm is u...

Page 26: ...a 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...

Page 27: ...stem BMS This feature can be turned off in ADVANCED SETUP COMMUNICATIONS SETPOINT TIMER OFF If the setpoint timer feature is set to ON the ADVANCED SETUP COMMUNICATIONS SETPOINT TIME may be set to a t...

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 in...

Page 29: ...en the 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 setpoi...

Page 30: ...that can be selected when the system is in summer shutdown OUTDOOR RESET The jog allows the system circulator pump s and the local pump to run for the system pump purge time once a week It can be set...

Page 31: ...trol signal If 2 pumps are available pump rotation is available The rotation of the 2 pumps can be controlled using two methods 3 Pumps are switched based on the system run time 4 Pumps are switched b...

Page 32: ...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...

Page 33: ...1k ohm platinum type sensor Part 0040 1300 To configure the 1k PT Stack sensor Switch S5 3 should be set to the NONE position and S5 4 set to PLATINUM STACK The sensor will then be auto detected after...

Page 34: ...r 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...

Page 35: ...boiler system will run locally if communications 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...

Page 36: ...BTU load value When using the BMS GPM register the BTU values are only calculated to a whole GPM since the BMS GPM register currently does not support floating point numbers The Building Management Sy...

Page 37: ...INPUT TYPE to mA 2 or VOLTS 2 depending on whether a 4 20 milliamp or 0 10 volt signal is used The connection should be made from the Flow Meter to analog input 4 20 mA 2 d Select ADVANCED SETUP FLOW...

Page 38: ...s modulation and events To the right of the histogram is the Master Boiler s log Since the HeatNet bridge only transmits at 1 minute intervals the log can be used to precisely view the state of the bo...

Page 39: ...each of the 2 PIDs DHW METHOD 1 DHW Heating ONLY using a DHW MASTER and Member boiler s employing H Net This method requires a 10k thermistor connected to the DHW Sensor input of a DHW MASTER or a sta...

Page 40: ...eaves the system pump on 7 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 A...

Page 41: ...atus screens Press the DOWN arrow key when SYSTEM SET is displayed The space heating band will be displayed on the left and the DHW Heating band on the right The bands will operate in a split screen v...

Page 42: ...above which boilers are to be shed This setting is the maximum tank temperature Setting the SHED BOILER DELAY TIME correctly will limit the maximum tank temperature to the DHW SETPOINT UPPER DHW DIFF...

Page 43: ...ARING This can be set on any boiler and will how boilers will cycle on off when they are called to perform DHW Heating LOCAL PUMP OFF This can be set on any boiler to determine how the local pump valv...

Page 44: ...the DHW Pump relay normally open contact J13 terminals 9 10 to control flow of the heating water into the tank s coil 14 Enter the DOMESTIC HOT WATER MENU When prompted for DHW BOILER enter NO 15 DHW...

Page 45: ...led as long as the Heat Demand input is closed and the SETUP DOMESTIC HOT WATER DHW PRIORITY is set to NO The DHW pump will be enabled whenever there is a DHW call for heat A DHW call for heat is when...

Page 46: ...PURGE TO THE TANK If the PURGE TO THE is set to SPACE once the DHW cycle has completed the Master will shut the DHW pump off within a few seconds The SPACE setting is to be used only for mixed space a...

Page 47: ...Member boilers only The Master uses OR OVR already with DHW METHOD 4 When the thermostat contact closes across the input OR OVR J12A 7 8 on a Member boiler the control will sense this closure and disc...

Page 48: ...hm for 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...

Page 49: ...er Communications 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...

Page 50: ...50 Figure 30 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...

Page 51: ...If 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 c...

Page 52: ...ule may 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 the...

Page 53: ...4 5 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 s...

Page 54: ...re a 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 O...

Page 55: ...MASTER 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 FLO...

Page 56: ...control 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 cont...

Page 57: ...PER 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...

Page 58: ...mmon 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 ad...

Page 59: ...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 M...

Page 60: ...d the ignition condition Main 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 Bo...

Page 61: ...BAND SETPT SOURCE AUTO AUTO 4 20mA AUTO Local System WWS Setpoint is used 4 20mA input is mapped to a setpoint OUTDOOR AIR RESET OA RESET OFF Outdoor reset ratio boiler water temp outside air temp WA...

Page 62: ...on to work OVR ENAB IN WWS OFF ON OFF Priority mode for the system pump while in Warm Weather Shutdown ON The system pump is allowed to run in WWS when the OR OVR override input is closed When set to...

Page 63: ...Prove the damper is open INPUT J12B 7 DAMPER The damper prove input is dedicated to connect at J12B terminals 7 and 8 If using a common damper refer to the common damper wiring diagram PROOF TIME 2 0...

Page 64: ...will only fire at 40 The delta T needs to drop 10F below the maximum delta T to reset this limit The message INPUT will be displayed on a member boiler and a Master Boiler will display the Modulation...

Page 65: ...and DHW heating NO turns off the DHW PID but still allows control of the DHW pump and DHW setpoint for backwards compatibility Note If the System is configured to use the OR OVR input to override the...

Page 66: ...h valves the local valve may still have flow when the DHW valve begins to open This would cause a flow fault when the local valve closes and the DHW valve still has not opened The way it works is that...

Page 67: ...or just to perform DHW Heating When set to AUTO the boiler uses one PID control to provide space heating When set to MIXED the control will use two independent PID controls to provide space heating an...

Page 68: ...he maximum modulation the boiler can obtain when first starting is equal to the ADVANCED SETUP MODULAR BOILER SET MOD MAX LAST FIRE The timer value ADVANCED SETUP MODULAR BOILER SET ADD BOILER DELAY i...

Page 69: ...through the band The purpose of this is to ensure the temperature remains in the heating band It also minimizes temperature swings when the boiler is stopped and started at low inputs This algorithm l...

Page 70: ...etting SET PARAMETERS START SETPOINT 50 F 50 220 F When using 4 20mA setpoint control in SETPOINTS SETPOINT SOURCE This is the temperature when a BOILER START signal see BOILER START menu below The Se...

Page 71: ...r to get to setpoint DECELERATE 3 0 s 1 8 0 s If a signal is sent to decrease the blower rpm the blower s deceleration speed will change at this rate until it s rpm is equal to the signal sent per sec...

Page 72: ...USB DRIVE USB DRIVE USB CABLE SAVE FILE Selecting USB DRIVE will read the FIRMWARE directory on a flash drive and display any hex files located there Follow the on screen prompts and then select a fil...

Page 73: ...er as condensing or non condensing BTU IN 200 000 This is the BTU input rating of the boiler This value is not used with this released version and is displayed only for reference Future releases may i...

Page 74: ...etpoint 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 th...

Page 75: ...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...

Page 76: ...r06Status1 30027 Boiler06Status2 30028 Boiler07Status1 30029 Boiler07Status2 30030 Boiler08Status1 30031 Boiler08Status2 30032 Boiler09Status1 30033 Boiler09Status2 30034 Boiler10Status1 30035 Boiler1...

Page 77: ...Boiler11RuntimeHigh16 30069 Boiler11RuntimeLow16 30070 Boiler12RuntimeHigh16 30071 Boiler12RuntimeLow16 30072 Boiler13RuntimeHigh16 30073 Boiler13RuntimeLow16 30074 Boiler14RuntimeHigh16 30075 Boiler...

Page 78: ...Temp 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 M...

Page 79: ...30147 Boiler10CyclesLow16 30148 Boiler11CyclesHigh16 30149 Boiler11CyclesLow16 30150 Boiler12CyclesHigh16 30151 Boiler12CyclesLow16 30152 Boiler13CyclesHigh16 30153 Boiler13CyclesLow16 30154 Boiler14...

Page 80: ...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 protectio...

Page 81: ...o 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...

Page 82: ...red 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...

Page 83: ...set Override 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 futur...

Page 84: ...W Boiler 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 s...

Page 85: ...tuation 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 conne...

Page 86: ...type Shielding of the cable is required d Minimize the electrical interference by routing the communications cable away from electrical noise sources such as Motors ignition controls contactors etc Si...

Page 87: ...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 d...

Page 88: ...polarity to determine the proper connections A ground wire must always be used and a shielded twisted wire is STRONGLY suggested 5 The HeatNet LonWorks and BACnet bridges plug directly into Revision...

Page 89: ...oint 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 3 Newer firmware versions allow the SETPOINT TIMER...

Page 90: ...CALIBRATE RUN 100 CALIBRATE RUN 100 5853 TACH CALIBRATE RUN 100 LOCAL SET 158 F The SETPOINT can be adjusted by pressing and holding the SELECT button until the SETPOINT flashes Then use the UP and D...

Page 91: ...HeatNet Control Run Screen Continued DHW screens are available depending on the DHW mode of operation RUN 100 NA SYS FLOW RUN 100 NA SYS FLOW RUN 100 RUN 100 DHW CALIBRATE DHW STATUS START 0 STOP 0 RU...

Page 92: ...L E RS S E TP O I NT S OUTDOOR A I R RE S E T 2 4 6 0 3P 0 2 2 0 1 3 S E TUP ADVANCE D S ETUP V I EW LOG 2O 7 7 S E 16 0 F A NA MOD 4 0 M P S MPB RM O 1 H T F AT WAT E R T EMP 140 H I GH OA T EMP 70...

Page 93: ...20mA SETPOINT 20mA SETPOINT 68 F 68 F 200 F 200 F 4 11mA 4 11mA PRIORITY PRIORITY NORMAL NORMAL MODULAR BO ILER SET MODULAR BO ILER SET PASSWORD PASSWORD 10 HRs 10 HRs TRUE TRUE MODE MODE 0m 0m MIN RU...

Page 94: ...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 TIM...

Page 95: ...ME 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 U...

Page 96: ...S 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 LA...

Page 97: ...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...

Page 98: ...WORKSHEET HeatNet Control V3 REV 2 x Page 98 BOILER TYPE PRODUCT CONDENSING BTU IN BLOWER MASS TURNDOWN ALTITUDE CALIBRATION SETTINGS MIN VFD IGN VFD MAX VFD...

Page 99: ...167 1 479 20 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...

Page 100: ...ee the Default Settings Menu Item Descriptions SETUP starting on page 61 Status information screens This screen indicates that the boiler s SUPPLY Temperature has gone above the OPERATOR LIMIT This wi...

Page 101: ...see CALL SERVICE LOG entry This screen indicates that the boiler s has received a heat demand but it s MINIMUM OFF time has not expired This Screen indicates that the boiler s input is temporarily be...

Page 102: ...er exceeds the EXCHR DELTA T RANGE setting this message will be displayed LOW WATER CUTOFF If there is a low water condition reported by the low water cutoff switch this fault is displayed Check that...

Page 103: ...will not start and then display the fault A combustion damper fault on a boiler can only be cleared by power cycling OPEN SENSOR If the open sensor fault is displayed the sensor in the position report...

Page 104: ...eratures can result in damage to the boiler BLOWER RPM HIGH Ametek Blower If the signal from the HeatNet control board to the Ametek blower exceeds the factory limits or the blower runs away excessive...

Page 105: ...ches are wired to J11A and J11B COMBUSTION AIR FAIL If the combustion air damper is used and does not prove across J10B DAMPER or J12B DAMPER this message is displayed SYSTEM RESET O stack overflow U...

Page 106: ...he 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 instal...

Page 107: ...tries indicate that they became active for some reason and the boiler had entered Fail Safe mode BASE LOAD BOILER The Base load Boiler Relay K8 is Active if ON Inactive if OFF CALL SERVICE If the H Ne...

Page 108: ...Page 108 http www knseries com...

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