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Control menus and adjustments (continued)

1. D J12B A Combustion air damper proving D alternate location select AUX ID FUNCTIONS setup used only for Combustion air damper 8 D compatibility with existing boilers that proving for systems with a SOS O were wired for a previous firmware damper for each boiler default ses E D edition location For multiple boiler ul systems with a single damper nos use the wiring diagram below NOTE Apply the following wiring when connecting multiple boilers with a single combustion air damper Member boilers set up for Failsafe mode boiler starts if signal from master boiler is lost must be able to activate the combustion air damper when operating The following wiring will allow that All member boilers set up for Failsafe operation must be wired as shown NOTE You must install a separate 24 VAC transformer to power the combustion air damper in order for this wiring to work correctly Boiler 1 Boiler 2 Boiler3 e J13 J13 J13 Z DAMPER O Z DAMPER O Z DAMPER terminals 0 terminals terminals amp amp gt Ps ee s s S E 0 q J10B Ole 24VDCRET Q a 24VDCRET KO gt J12B J12B O J12B
2. 9 Setup worksheet record all parameters here continued SETBACK ENTRY AUX FUNCTIONS IN USE NO ON FF SETBACK ENTRY FAILSAFE MODES H NET COMM LOST START DAY TIME TEMP LESS THAN 40 F END DAY TIME SYSTEM CLOCK Verified updated _ ADVANCED SETUP MENU DISTRIBUTED CTRL LOG RUNTIME CONTROL H NET MASTER SIZE BOILER CYCLES P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 9 Setup worksheet record all parameters here continued MODULAR BOILER SET SENSOR ADD BOILER DELAY 10 MINUTES MINUTES TYPE sECONDS SECONDS CALIBRATED SHED BOILER DELAY MINUTES MODULATE DELAY TIME MINUTES MINUTES TYPE 10 sEcoNps SECONDS CALIBRATED MOD MAX LAST FIRE 50 SENSOR BOILER START TIME CALIBRATED MODULATION PID OO 4 20MA INPUT Factory set not adjustable FIRING MODE 20MA SETPOINT ROTATION BOILER START MASTER FIRST OFF PASSWORD OUTSIDE TUBE COMMUNICATIONS A 19200 SENSOR SUPPLY MODEM INSTALLE NO CALIBRATED LOAD DEFAULTS Defaults loaded NEN RETURN TYPE F TRUE P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 1 0 Control specifications Control Microprocessor based PID modulating control NOT a safety limit Environment 40 F to 140 F lt 90 RH non condensing Switched Line KN 6 KN 10 120 VAC single phase
3. The system must be equipped with a bypass pressure regulator or other means to prevent dead heading if system valves close when call for heat is completed SUMMER PUMP JOG PUMP OPTIONS This option is available to prevent the pump from seizing during long idle periods Enable SYSTEM PUMP the option to have the system pump operated once per week specify the day in setup The pump will cycle on at 12 00 AM on the day specified It will operate for a time equal to the time set for POST PRG TIME WARNING The system must be equipped with a bypass pressure regulator or other means to prevent dead heading if system valves close when call for heat is completed or during summer or outdoor air shutdown DELTA TEMP ENAB PUMP OPTIONS The boiler pump can be set to run after boiler shutdown to distribute residual heat to the LOCAL PUMP heating system Delta enable causes the boiler pump to run until the temperature difference between boiler inlet and outlet is less than DELTA TEMP see below The pump will continue to run an additional period after this for the amount of time specified in PURGE TIME below P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued DELTA TEMP PUMP OPTIONS When DELTA ENABLE above is set to ON the boiler pump will run until the temperature LOCAL PUMP diffe
4. CONTROL MANUAL 6 Control menus and adjustments continued Table8 ADVANCED SETUP menus see Table 9 page 30 for explanations To enter Setup From STANDBY hold o for 5 seconds If SKIP PASSWORD is set to OFF you will have to enter the password Then press with cursor on SETUP Make sure there is no call for heat at the boiler before attempting to perform setup adjustments To return to STANDBY press release o until the display returns to standby or turn boiler ON OFF switch off then on Level 1 Level 2 Level 3 Default Range OQ next item OQ next item OQ next item OQ to change value to select select 2 to select o back one level o back one level Typical line Display shows four lines at a time cursor indicates active line o to accept value and return to previous menu level MODBUS ADDRESS Default 1 Range 1 to 247 DISTRIBUTED CTRL CONTROL HNET H NET MASTER YES Display only not changeable here MEMBER boilers will show NO and CONTROL H NET addresses must be set from 2 to 16 H NET MASTER YES LOCAL ADDRESS 255 H NET ADDRESS Master default 255 not changeable Member default 2 Range 2 to 16 MODBUS ADDRESS 1 ADD DELAY TIME MODULAR BOILER SET ADD BOILER DELAY 10 minutes 0 to 15 minutes 10 MINUTES SECONDS SHED DELAY TIME SHED BOILER DELAY 2 minutes 0 to 15 minutes 2 MINUTES SECONDS MODULATE DELAY TIME MODULATE DELAY TIME 10 seconds 0 t
5. Press SELECT to change the value IGNITION rate must be between 20 and 40 The number will begin flashing Use the arrow keys to change Then press SELECT to save the set ting The value is saved when the number stops flashing Press SELECT to change the value Minimum must be at least 20 The number will begin flashing Use the arrow keys to change Then press SELECT to save the setting The value is saved when the number stops flashing d Additional screens follow and show information only for SUPPLY supply temperature value and HEADER header temperature value When a setting is blinking you have minutes to change the value with the arrow keys or the control will restore the original value and stop blinking 4 Slide the calibration to NORM to return the boiler to normal operation Reconnect wires as needed KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL Boiler operation and status display Starting the system Follow the Boiler manual Install the boilers according to the KN Series Gas Boiler Installation amp Operating Instructions manual before attempting to set up the control system Perform the start up and adjustment procedures in the manual before proceeding Failure to comply could result in severe personal injury death or substantial property damage FAULTS Clear any faults that appear on the display and make sure to correct the cause before
6. The control display will show the trim value setting The trim value must not exceed 200 ohms If it does verify that the resistor is correctly connected If so the sensor input is bad Contact Mestek for recommended action If the trim setting is acceptable press the SELECT key to accept The display will show TRIM VALUE SET After a slight delay the display will return to the sensors menu 4mA SETPOINT ADVANCED SETUP The 4mA SETPOINT and 20mA SETPOINT establish the temperature range when the boiler 20mA SETPOINT 4 20mA INPUT system is operated with a remote 4 20mA setpoint ADVANCED SETUP Set the 4mA SETPOINT to the starting temperature 4 20mA INPUT Set the 20mA SETPOINT to the maximum desired temperature at max signal of 20 mA Any signal between 4 and 20 mA will change the setpoint proportionally between the upper and lower temperature values Example 4mA SETPOINT 140 F 20mA SETPOINT 200 F If the signal is at 4 mA the setpoint temperature will be 140 F at 20 mA the setpoint temperate will be 200 F At 12 mA the setpoint temperature will be 140 200 140 x 12mA 4 mA 16mA 140 60 x 8 16 140 30 170 F At 15 mA the setpoint temperature will be 140 200 140 x 15mA 4 mA 16mA 140 60 x 11 16 140 41 181 F NOTE Under SETUP SETPOINTS the SETPT SOURCE must be set to 4 20mA The current must be above the BOILER STAR
7. lation amp Operating Instructions to start up the boiler and verify operation After setting up the boiler per the KN I amp OM Instructions you can set MIN MAX and IGNITION firing rates using the CALIBRATION procedure in this manual P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL I Stand alone boiler von Table1 Control parameters stand alone boiler BOILERS HEAT BAND SETPOINTS LOCAL SETPT Set if control will regulate boiler supply temp SYSTEM SETPT Set if control will regulate header or DHW tank temp requires header sensor OPERATE LIMIT Set OP LIMIT BAND Set SETPT SOURCE Specify AUTO or 4 20mA remote control AUTO uses the HeatNet control setup values for setpoint temperature 4 20mA uses a 4 20mA signal to determine setpoint temperature as described in the parameters tables OUTDOOR RESET IF USED Enable if used Enable if used WWS SETPOINT Set if used OA SETPTS Set if used requires outdoor sensor SYSTEM PUMP Applies ONLY if the control will cycle a system pump as well as the boiler pump POST PRG TIME Set or keep default ALWAYS ENABLE Enable if desired SUMMER PUMP JOG Enable if desired LOCAL PUMP Settings for boiler pump DELTA TEMP ENABLE Enable if desired requires installing a return water temp sensor DELTA TEMP Set value if enabled Set or keep default Enable if desired Enable if used connect flow switch AUX FUNCTIONS COMB
8. Canada Install a separate 120 volt 15 amp circuit for the boiler A properly rated shut off switch should be located at the boiler The boiler must be grounded in accordance with the authority having jurisdiction or if none the latest revision of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of 14awg Use appropriate wiring materials for units installed outdoors Control setup sequence CAUTION Install the boilers according to the KN Series Gas Boiler Installation amp Operating Instructions before attempting to set up the control system Close the external gas valve Wire the boiler following the guidelines in this manual Attach sensors as required including a HEADER sensor if needed for primary secondary circuits or DHW tank heating Set the boiler control parameters using its display keypad Wiring I 2 See page 16 for wiring information and wiring diagrams Note that the boiler can be wired for override operation The wiring section provides information on override pri orities and options The boiler can be activated by the HEAT DEMAND input and allowed to modulate based on the HeatNet control It can also be activated by either ON OFF full input operation by closing the AA terminals Operation via remote 4 20mA signal by closing the 4 20mA ENABLE terminals and providing the 4 20mA signal
9. 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 locally or by external inputs The HNet 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 RJAS jacks flash roughly twice a second The MASTER is the only one that should flash with no communications cables plugged in Ifthe control does not sense a closed circuit at input connection FLOW SWITCH 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 If there is no flow prove switch check to make sure that a jumper wire has been connected across the FLOW SWITCH terminals Turn the ON OFF switch off Then depress and hold the ESC key while turning it back on This will load the default password AAAAAA Ensure that the USB driver for your PC Laptop computer is properly installed P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL S Troubleshooting continued Table 11 Troubleshooting suggestions continued Suggested procedure H Net boilers are detected but then lost and then detected again Only the MASTER boiler Fires
10. OR 208 230 240 VAC 1 60 with neutral KN 20 208 230 240 VAC 1 60 with neutral AC Interlocks 24 VAC 120 VAC input Control Inputs AA Heat Demand 4 20ma Enable OA override T1 T2 dry contact inputs Temperature Sensors NTC thermistor 10K 77 F 335 67K 40 F 185 150 F 1 F Environment 40 F to 140 F lt 90 RH non condensing USB RS485 Console Modbus RTU 9600 baud 8 bits Even Parity 1 Stop Bit Boiler to Boiler Heat Net H Net Network Optional LonWorks BACnet available P N 42 9534 8 08 Copyright 2008 Hydrotherm 5 4 Hydro Therm A Product of Advanced Thermal Hydronics 4 A A MESTEK COMPANY 260 North Elm Street Westfield MA 01085 Tel 413 564 5515 Fax 413 568 9613 7555 Tranmere Drive Mississauga ONT L5S IL4 Canada Tel 905 672 2991 Fax 905 672 2883 www hydrotherm com
11. need for analog control signals Analog signal inputs are supported but a higher level of control precision repeatability and feedback is gained with digital communications The HeatNet control can be versatile providing for operation in multiple ways As a stand alone boiler either modulating two stage or ON OFF As a boiler in a boiler network using the on board HeatNet protocol Asa member boiler in a boiler management system either directly managed by BMS or managed by a MASTER HeatNet boiler that communicates with the BMS As a member ofa remotely controlled boiler network 4 20 milliamp regulation Setpoint can be determined by the HeatNet control or by a 4 20 milliamp input signal Network boilers can be operated by override commands for increased versatility This manual is arranged so the instructions for each of the methods above is self contained See the Table of contents for selection and location PID response The HeatNet control uses proportional integral derivative calculations to determine the response to boiler water temperature changes This means it not only looks at how far away the water temperature is from the setpoint temperature but how fast the temperature is changing and how it has responded over time This ensures the boiler won t make sudden unnecessary changes in firing rate External limit monitoring amp annunciation In addition to controlling the boiler the KN HeatNet control monitors e
12. using local setpoint outdoor reset or SYS DHW HEADER temperature setpoint 4 20mA If 4 20mA is selected the KN control determines setpoint based on the signal it receives at the 4 20ma terminals on the connection board There must be a contact closure across the 4 20mA ENABLE terminals J12A for the boiler to respond to the 4 20mA signal The temperature and boiler start settings are set in the ADVANCED SETUP 4 20mA INPUT menus The menu will automatically transfer to the 4 20mA INPUT menus if 4 20mA is selected for SETPOINT SOURCE If the HEAT DEMAND input is closed the H NET control will use the SYSTEM SETPT or LOCAL SETPT temperature to control the boiler s if the 4 20ma signal is below 5ma Once the current exceeds 5ma the setpoint is determined from the ma signal value This method may be thought of as a backup in the event the 4 20ma signal is lost If the HEAT DEMAND input is open the 4 20ma signal will start the H NET system once the current exceeds 5ma Temperature is controlled to the setpoint determined by the ma signal value OA RESET OUTDOOR AIR Set to ON to enable resetting the SUPPLY temperature or SYS DHW HEADER temperature based on outside air temperature This requires an outdoor sensor when enabled Set to OFF to disable outdoor reset WARM WEATHER SD OUTDOOR AIR When this setting is YES the boiler will Shut down when outdoor temperature is at or above WWS SETPOINT The outside temperature
13. 1 60 20 amp for KN 20 A properly rated shut off switch should be located at the boiler The boiler must be grounded in accordance with the authority having jurisdiction or if none the latest revision of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of 14 awg Use appropriate wiring materials for units installed outdoors Control setup sequence pe N A caution Follow the Boiler manual Install the boilers according to the KN Series Gas Boiler Installation amp Operating Instructions manual before attempting to set up the control system Close the external gas valve on every boiler Wire all boilers following the guidelines in this manual Attach a header sensor SYS DHW HEADER terminals to the master boiler ONLY The KN HeatNet control automatically configures the boiler with a header sensor as the master Set the master boiler control parameters using its display keypad Set the master boiler s termination DIP switches Set the termination DIP switches on the member boilers Set the member boilers control parameters using their display keypads Follow the instructions in the KN Series Gas Boiler Installation amp Operating Instructions to start up each boiler before proceeding further Finish by connecting cables between the communications boards of all of the boilers and verifying network operation W
14. A High Fire n staging Heat demand control field wiring Remote enable D Outdoor reset y D override o Min 25 In C Input T1 D Max 100 Input T2 Reserve TS S Alternate damper proving gt Sense location set up under lt Hot D AUX FUNCTIONS select J12B under INPUT a NORM CALg I Calibration switch USB to computer HeatNet termination switches Down ON RJ45 cable from boiler J12A Buzzer J12B J21 J23 NEU L2 L1 Power service input KN 6 amp KN 10 120 VAC single phase 60 hz T Sn as eos Use terminals L1 NEU GND JKN 20 208 230 240 VAC single phase 60 hz stake NUN RO Use terminals L1 L2 NEU GND USB A B G SSS H LINK RS485 XY System flow switch 3k AN Low water cut off Interlock 24VAC D Gas pressure interrlocks amp LOW factory wiring LN Spare 4 D Operator D Usej Boiler flow switch se Jumpers on Aw i these terminals if UV sensor air switch interlock is not p A installed r Outside air sensor gu Supply water sensor a Return water sensor Sensors SYSTEM DHW sensor and inputs D o Damp
15. DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations FIRMWARE VERSION VX XX All boilers in a multiple boiler application should preferably have the same firmware version to ensure consistency If versions are different all versions must be either version 2 0 or greater or version 1 x OF BOILERS BOILERS Display only shows the number of boilers detected on the network for a HeatNet network only displays the total number only on the Master boiler displays 1 for MEMBER boilers or for any boiler not on a HeatNet network The maximum number of boilers on a HeatNet network is 16 LEAD BOILER CU only always shows 1 HEAT BAND BOILERS Boilers stage OFF when The heat band is the height of the modulating g band When the water temperature is between 1 2 the heat band above or below the setpoint temperature boiler firing rate modulates zz BoilersMODULATE d Apot T MP Boilers are at minimum input at the upper end rm inheatband of the band and maximum input at the lower Lun y n yy end of the band Boilers come on only if the water temperature is below the band Boilers Boilers stage ON when watertempisbelow Stage off when the water temperature is above heat band J the band HEAT NET BOILERS BOILERS This line appears on the display only for a HeatNet Master boiler boiler with a sensor connected to the SYS DHW HEADER
16. Level 1 Level 2 Level 3 Default Range OQ next item OQ x NEI Dessen OO a 2187048 in select 2 to select to select o to accept value and return to previous menu level D line o back one level o back one level KN VX X Shows firmware version number KN SERIES V 2 45 Typical line Display shows four lines at a time cursor indicates active BOILERS OF BOILERS 1 to 16 display only gives the number of boilers on a HeatNet network Always shows 1 display only not adjustable OF BOILERS 1 LEAD BOILER 1 HEAT BAND 30 F HNT 12345678910111213141516 30 F 10 to 50 F HEAT NET BOILERS 123544 Display only on MASTER boiler only shows the H NET ADDRESS of each boiler detected on the HeatNet network from 1 to 16 NOTE that the MASTER address actually 255 is shown as 1 in this display SETPOINTS LOCAL SETPT or SYSTEM SETPT 180 F 40 to 180 F SYSTEM SETPT will appear if a sensor is connected to the SYS DHW HEADER terminals Otherwise the display will show LOCAL SETPT OPERATE LIMIT 205 F 145 to 205 F LOCAL SETPT 180 F OPERATE LIM 10 F OP LIM BAND DEREN 10 F 1 to 50 F OP LIM BAND 215 F SETPT SOURCE AUTO OUTDOOR AIR OA RESET WE OFF ON or OFF WARM WEATHER SD NO YES or NO OA RESET OFF WARMWEATHER SD NO OA SETPOINT 68 F WWS SETPOINT 68 F 40 to 100 F SET OA SETPOINTS If the OA OVR input is closed outdo
17. ON FIRST OFF maintains the same rotation sequence at all times Master FIRST ADVANCED SETUP Set this to ON to always start the master boiler first regardless of the rotation scheme FIRING MODE selected ADVANCED SETUP The HeatNet control can be connected to up to six sensors OUTSIDE SUPPLY RETURN SENSORS HEADER and two user selectable inputs number 5 or number 6 P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued TYPE ADVANCED SETUP For each sensor select either TYPE Z 10K ON OFF TE6000 1K or NONE ENSOR Type Z is a thermistors sensor as supplied by Hydrotherm Type Z sensors are NTC thermistors 10Kohms at 77 F 335 67 Kohms at 40 F 185 Kohms at 150 F 1 F 40 to 140 F ON OFF looks for an external dry contact closure TE6000 is a 1 Kohm wire wound sensor NONE means no sensor is connected to the terminals CALIBRATE ADVANCED SETUP Use this function only if the response to a sensor indicates the control calibration may be off OURS Calibrate Type Z sensors inputs by attaching a 10Kohm precision resistor across the sensor terminals Use a 1Kohm precision resistor for TE6000 elements Select YES after CALIBRATE The control will measure the resistance and establish a trim value in ohms for the sensor input
18. Troubleshooting suggestions page 45 HeatNet Electrical connection panel amp subpanel 9 Setup worksheet page 48 Use this section to enter setup information P N 42 9534 8 08 Copyright 2008 Hydrotherm 5 d I KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL Stand alone boiler Electrical shock hazard Disconnect all electrical power sources to the boiler before making any electrical connections Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Failure to comply with the above could result in severe personal injury death or substantial property damage Close the external manual gas valve on every boiler before proceeding DO NOT open any gas valve or attempt to fire the boiler until the boilers has been set up and verified following the instructions in the KN Series Gas Boiler Installation amp Operating Instructions Failure to comply could cause a boiler failure leading to possible severe personal injury death or substantial property damage NOTICE The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform to CSA C22 1 Canadian Electrical Code Part I if installed in
19. Two stage fired by using the T1 and T2 terminals Clos ing one of these brings the boiler on at MIN firing rate Closing the other brings the boiler to MAX input Set control parameters NOTICE Before turning boilers on to set parameters disconnect all call for heat wiring at the electrical connection boards This will prevent the boiler from attempting to cycle during the setup process See Table 1 for a list of parameters that should be set for a stand alone boiler See Control menus and adjustments beginning on page 24 for a complete list of control parameters and expla nations Table 7 page 25 and Table 8 page 28 Carefully read the parameter explanations in Table 9 page 30 When adjusting the limit band operating limit OP LIMIT local setpoint LOC SETPOINT system header SYS DHW HEADER setpoint make sure the operating temperature bands do not overlap or cause potential for nuisance cycling System clock Set the system clock to ensure the time stamps will be accurate in the data logs Turn on the power to the boiler and set the on off switch to ON as you set its parameters Use the boiler s keypad to enter the parameters as described on page 24 After setting a boilers parameters turn off the power to the boiler until you are ready to start the boiler up following the Boiler manual instructions Start up boiler I 2 Follow all instructions KN Series Gas Boiler Instal
20. WATER FLOW SWITCH or WAITING FOR FLOW You have forgotten the password Firmware update program starts to load but then stops Verify that the latest version of firmware is installed on all boilers All boilers in a system must have the same firmware revision version Verify the proper termination is set on the Master and the last Member boiler The H Net communications cable may be receiving interference from the blower ignition or other form of radiated electrical noise Termination of the jumpers may not be correct or there is more than one master 1 Ensure that the termination dip switchs are set on the MASTER boiler and only the LAST MEMBER boiler All of the other member boilers should have their termination dip switches OFF There may be two or more MASTER boilers Ensure that only one header sensor is present and connected to the SYS DHW HEADER input There should be no wires or sensors connected to the SYS DHW HEADER input if the boiler is operating as a member Verify that the HNet cables are of a shielded or twisted pair type Shielding of the cable is required Minimize possible electrical interference by routing the communications cables away from electrical noise sources such as motors ignition controls contactors etc 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
21. board is used to interface with the KN HeatNet control If each boiler is directly controlled by the BMS set the DIP switches for each boiler the same as for a master boiler both switches on P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 2 Multiple boilers HeatNet modulation von Close the external manual gas valve on every boiler before proceeding DO NOT open any gas valve or attempt to fire any boiler until the boilers have been set up and verified following the instructions in the KN Series Gas Boiler Installation amp Operating Instructions Failure to comply could cause a boiler failure leading to possible severe personal injury death or substantial property damage Set control parameters NOTICE Before turning boilers on to set parameters disconnect all call for heat wiring at the electrical connection boards This will prevent the boiler from attempting to cycle during the setup process 1 See Control menus and adjustments beginning on page 24 for a complete list of control parameters and explanations Table 7 page 25 and Table 8 page 28 Carefully read the parameter explanations in Table 9 page 30 When adjusting the limit band operating limit OP LIMIT local setpoint LOC SETPOINT and DHW setpoint make sure the operating temperature bands do not overlap or cause potential for nuisance cycling 4 System clock Set the system
22. but the system has many boilers and is using H Net You get the error message WATER FLOW SWITCH or WAITING FOR FLOW You have forgotten the password Firmware update program starts to load but then stops P N 42 9534 8 08 Copyright 2008 Hydrotherm d d The H Net communications cable may be receiving interference from the blower ignition or other forms of radiated electrical noise Termination of the jumpers may not be correct or there is more than one master 1 Ensure that the termination dip switches are set on the MASTER boiler and only the LAST MEMBER boiler All of the other member boilers should have their termination dip switches OFF There may be two or more MASTER boilers Ensure that only one header sensor is present and con nected to the HEADER input There should be no wires or sensors connected to the HEADER input if the boiler is operating as a member Verify that the HNet cables are of a shielded or twisted pair type Shielding of the cable is required Minimize possible electrical interference by routing the communications cables away from electrical noise sources such as motors ignition controls contactors etc 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 c
23. clock on the master boiler ONLY to ensure the time stamps will be accurate in the data logs 5 Turn on the power to each boiler and set the on off switch to ON as you set its parameters Use the boiler s keypad to enter the parameters as described on page 24 After setting a boilers parameters turn off the power to the boiler until you are ready to start the boiler following the Boiler manual instructions 8 Set the master boiler and each member boiler following the guidelines given in Table 3 Start up boilers per KN amp OM 1 Turn off power to all boilers 2 Follow all instructions in the KN Series Gas Boiler Installation amp Operating Instructions to start up each boiler and verify operation Connect network cables Electrical shock hazard Turn off power to each boiler before attempting to connect the network cables NOTICE Before turning boilers on to check network operation disconnect all call for heat wiring at the electrical connection boards This will prevent the boiler from attempting to cycle during the setup process Master boiler cable 1 Connect an RJ45 cable to the master boiler H Link OUT block item 2 Figure 2 page 12 or 3 wire shielded cable to the H Link terminal strip item 4 Figure 2 page 12 The other end of this cable will be attached to the first member boiler in following steps Turn on power to the master boiler and set its on off switch to ON You should hear at lea
24. disconnect wires if necessary to ensure there are not heat calls during the procedures 2 Disconnect the HeatNet cable from the boiler if necessary to ensure there is no call for heat from the MASTER boiler 3 Turn the boiler ON OFF switch to ON Open the boiler front door and locate the control board S Find the calibration switch located on the lower left corner of the control board It is labeled NORM and CAL Calibration switch on lower left corner of control board shown with reduced board component detail for clarity Figure 11 1 Slide the calibration switch to the right to CAL Calibration mode display 1 The KN HeatNet control is now in calibration mode and will show CALIBRATE on the display 2 first screen will show the following The value shown for temperature is the SYSTEM or LOCAL setpoint MEMBER boilers will show LOCAL SET in stead of SYSTEM SET 3 Press the DOWN key to navigate through the following displays P N 42 9534 8 08 Copyright 2008 Hydrotherm Control menus and adjustments continued This screen is for display only and shows the setting for DELTA TEMP see SETUP instructions on previous STANDBY This screen is for display only STANDBY Press SELECT to change the value The number will begin flash ing Use the arrow keys to change Then press SELECT to save the setting The value is saved when the number stops flashing
25. high outside air temperature The low water temperature is generally equal to room temper ature meaning no heat input to the space would occur below this outside air temperature HI WATER AT LOW OA TEMP in High outside emperature air temperature T mg 6 50 4 30 20 10 OUTSIDE AIR TEMPERATURE F ia POST PRG TIME PUMP OPTIONS SYSTEM PUMP settings apply to a system pump if it is to be cycled by the HeatNet control SYSTEM PUMP Connect a relay or starter for the system pump to the SYSTEM PUMP terminals J13 DO NOT directly connect the pump motor with these terminals They are for pilot duty only To prove system flow before boiler operation install a flow proving switch across SYSTEM WTR FLOW terminals J11A Place a jumper on these terminals if system flow proving is not used POST PRG TIME keeps the pump running for the specified time after call for heat is completed allowing distribution of residual heat to the system WARNING The system must be equipped with a bypass pressure regulator or other means to prevent dead heading if system valves close when call for heat is completed ALWAYS ENABLED PUMP OPTIONS If enabled the system pump remains on constantly If pump is constant DELTA TEMP and SYSTEM PUMP POST PRG TIME have not effect NOTE The system pump will shut down if outdoor air reset is enabled and the outside tem perature is above OA SETPOINT summer mode operation WARNING
26. in a multiple boiler application should preferably have the same firmware version to ensure consistency If versions are different all versions must be either version 2 0 or greater or version 1 x After the controls timer finishes the display will show STANDBY and SYSTEM This verifies that the master boiler is setup correctly as the master The same display will show on member boilers when there is a call for heat from the master boiler When there is no call for heat at a member boiler the display will show LOCAL instead If the master is functioning correctly the yellow LED s on the H Link jack ports will blink The blinking indicates that the master is trying to communicate with member boilers If FAULT message is displayed clear the faults until the STANDBY message is displayed Refer to troubleshooting suggestions in this manual if you cannot re solve the issue Member boiler cables Begin with the first member boiler Plug the other end of the master boilers communications cable to the member boiler input port Figure 2 page 12 item 2 for RJAS cable or item 4 for 3 wire cable Connect cables to all ofthe member boilers by cabling from one to the next Connect incoming cables to item 1 or 4 Figure 2 page 12 Connect outgoing cables to item 2 or 4 Note that shielded cable wires will share terminals when using item 4 Check the network pe de pe des SES o Turn the power on and the on off switch t
27. is on the circulator pump relay will be locked out and the heating boilers will not fire 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 Unable to change the of Boilers In H Net method the KN control auto detects the boilers in the system and adjusts the number of boilers in the BOILERS menu accordingly Using H NET ifthe number ofboilers is not being detected properly as the actual number of boilers in the system check each boiler There can only be 1 master boiler but there can be up to 15 member boilers Make sure only the master boiler has a Header Sensor SYS DHW HEADER connected Verify that each boilers HeatNet cable is in place Verify that each boiler has a unique address assigned ADVANCED SETUP DISTRIBUTED CTRI H NET ADDRESS P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 9 Troubleshooting continued Table 11 Troubleshooting suggestions continued Suggested procedure The BOILERS menu only indicates one boiler but there are member boilers connected The amber light blinks on all of the boilers communications jacks H Net boilers are detected but then lost and then detected again Only the MASTER boiler Fires but the system has many boilers and is using H Net You get the error message
28. sensor input terminals The line is blank on MEMBER boilers If the number of boilers shown is less than the number of boilers on the HeatNet network check the yellow light on the HeatNet connection port of each boiler The yellow light will be ON if the communications port is successfully connected to the Master The address of each recognized MEMBER boilers addresses 2 up to 16 and begins with 1 the address of the Master boiler LOCAL SETPT OR SETPOINTS Setpoint temperature controlled by the KN control SYSTEM SETPT Local setpoint refers to boiler supply temperature System setpoint appears if there is a sensor connected to the SYS DHW HEADER sensor terminals System setpoint refers to the header or DHW temperature NOTE If the boiler is operated by a Master control or by a remote control building management system 4 20ma control etc this setpoint temperature only comes into play when the KN control is in override mode such as by closing its Heat Demand AA or T1 T2 terminals or by the 4 20mA Enable if 4 20mA is set to Highest Priority OPERATE LIMIT SETPOINTS This is for boilers regulating header temperature instead of boiler supply temperature or boilers operated by an external source such as by a Master boiler on a HeatNet network or by external 4 20mA signal or closure on T1 T2 or AA OPERATE LIMIT is the temperature at the boiler outlet that will cause the boiler control to shut down on high temperatur
29. temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed FLOW SWITCH ERROR Occurs on failure to close of a flow switch connected to J11B FAULT SUPPLY Automatically corrects if J11B WTR FLW WTR FLW terminals The boiler will restart every 10 minutes WATER FLOW SWITCH flow is proven attempting to prove flow The display continues showing the SUPPLY HEADER other 1 6 8 F temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed GAS PRESSURE Occurs on opening of gas pressure switches connected to J11A FAULT SUPPLY Automatically resets J11A GAS PR GAS PR terminals The high and low gas pressure switches are GAS PRESSURE control after condition is wired in series Opening of either switch will cause this fault 168 The boiler is shut down until the fault is corrected The display continues showing the SUPPLY HEADER or other temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL S Troubleshooting continued Table 10 Status screen fault displays continued FAULT EVENT amp CAUSE Discussion INTERLOCK TERMINALS DISPLAY Act
30. 0000 c Optional cover plate to secure Optional BACnet LonWorks Protocessor 9 LonWorks Bridge 24 VAC Optional BACnet or LonWorks Network Terminal Block key From Boiler Boiler G B G USB to computer KN303 MODBUS P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments The Heat Net control display Starting the display I ME gt Check all wiring to make sure it is complete and all wires are securely connected Verify that the HEAT DEMAND and DHW DEMAND wires are removed Close the external gas valve on every boiler Turn on power to the boiler and then turn the boiler on off switch ON The control will beep at least twice and the display will show the first STANDBY display in Figure 10 Note that pushing the DOWN button on the keypad will change the right side of the display as shown providing information on various setpoints and parameters The display LOCAL SET means the setpoint temperature for a single boiler ap plication Figure 10 shows the factory default values Adjusting setpoint temperature while in Standby l The local setpoint temperature LOCAL SET or system setpoint temperature SYS DHW HEADER can be ad
31. 2 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL Hydrotherm KN Series boilers HeatNet control HeatNet Electrical enclosure Control overview The KN HeatNet control monitors boiler temperature and limit circuit inputs modulating boiler firing rate to meet demand The control uses microprocessor electronics watching time average response from the system to anticipate how much heat the system needs Coupled with the five to one turndown of the KN boiler this results in maximum possible condensing mode operation The KN boiler will provide unmatched seasonal efficiency The HeatNet platform HeatNet controls are designed to provide an integrated boiler management system on every boiler The platform provides multiple levels of selectivity HeatNet electronics can be operated as a simple single boiler control while still providing intelligent regulation of boiler firing rate to match system demand With a few key strokes on the key pad the HeatNet control can operate as a sophisticated multiple boiler controller using simple RJ45 cable interfacing between units The control can even accept external control commands from building managements systems Modbus standard with optional bridge for BACnet or LonWorks or 20 milliamp analog input from an external controller The control method used by the HeatNet control is based on digital communications which eliminates the
32. 6 30046 Below The lower 16 bits of each 32 bit register is stored at even numbered addresses 30017 30047 Unsigned Boilers 1 16 runtime 32 bit registers The 0 4294967295 upper 16 bits of each 32 bit register is stored at seconds Connect the BMS cable AT l DO NOT connect the building management system cable until the boiler network has been proven to operate inde pendently The system is designed to revert to local control by the master boiler should communications with the building management system be lost 30048 30079 2 Turn off power to the master boiler See Figure 2 page 12 Connect an RJAS cable to the BMS input port item 6 Or use shielded wire cable connected to odd numbered addresses 30048 30078 The lower 16 bits of each 32 bit register is stored at even numbered addresses 30049 30079 terminal block item 3 When the upper and lower registers com bined they form a 32 bit unsigned integer that is the number of seconds that the boiler has been running For instance Register 29 65536 Register 30 Boiler 1 runtime in seconds Boiler 1 is the master boiler Boilers 2 16 are member boilers Verify BMS HeatNet operation 1 Turn on power to the master boiler 2 Allow the master boiler to initialize 3 Verify operation with the building management system P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON B
33. BUSTION AIR DAMPER AUX FNCTIONS COMBUSTION AIR DAMPER AUX FNCTIONS COMBUSTION AIR DAMPER AUX FUNCTIONS COMBUSTION AIR DAMPER AUX FUNCTIONS FAILSAFE MODES AUX FUNCTIONS FAILSAFE MODES AUX FUNCTIONS FAILSAFE MODES AUX FUNCTIONS HEAT EXCHANGER This option allows selecting either a single master combustion air damper or an individual independent damper for each boiler Select LINKED COMMON if only one damper is present If the damper fails to prove all boilers in the system are disabled The control will re attempt to prove the damper every 10 minutes Select INDEPENDENT to operate an independent damper with each boiler If a boiler s damper fails to prove the control will shut down only that boiler and will retry proving every 10 minutes Enter YES to enable the combustion air damper interlock If not using the combustion air damper make sure the damper proving terminals on the HeatNet control board are jumpered NOTE If the damper is not proven the HeatHet control will retry proving every 10 minutes This indicates which terminals are connected to the combustion air damper proving switch Set proof time long enough to be sure the combustion air damper can open and activate its end switch When set to NO the boiler will only operate if activated by an override input AA 4 20mA enable or T1 T2 When set to YES the boiler will revert to LOCAL operation controlling its outlet water temperatur
34. DDRESS HeatNet address is automatic for MASTER 255 Set from 2 to 16 unique address for each boiler MODBUS ADDRESS Set only if using BMS operation Set only if using BMS operation MODULAR BOILER SET ADD DELAY TIME Adjust timings as needed to match control operation Not applicable to member boilers SHED DELAY TIME to system response MODULATE DELAY TIME MOD MAX LAST FIRE FIRING MODE Not applicable to member boilers FIRING MODE Select rotation method preferred MASTER FIRST Enable if desired Select type or accept defaults make sure installed ONLY return sensor would apply with member boiler sensors are listed and are the correct type make sure and ONLY if using DELTA TEMP or HEAT EXCHGER HEADER sensor is connected to MASTER boiler only parameters 4 20mA INPUT Set values for 4 20mA parameters if using either as Set values for 4 20mA parameters if using as an primary control source or as an override override PASSWORD Set if desired Set if desired Set if desired Set if desired LOAD DEFAULTS Restore defaults if desired Restore defaults if desired SYSTEM Load firmware if necessary to bring up to date Load firmware if necessary to bring up to date COMMUNICATIONS P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 2 Multiple boilers HeatNet modulation on The controls firmware version number will display Make sure the firmware of all boilers is compatible All boilers
35. ETPOINT SOURCE is set 4 20MA 220 F 50 to 220 F Not applied unless SETPOINT SOURCE is set to 4 20MA SETPOINT 50 F 4 11 MA 3 7 to 4 3 MA Applies to either 4 20ma setpoint or modulation 20MA SETPOINT 220 F BOILER START 4 11MA Default NORMAL NORMAL or HIGH PRIORITY NORMAL NOTE HIGH will cause the 4 20MA input to take control when a contact closes across the 4 20MA ENABLE terminals J12A To set to HIGH make sure SETUP SETPOINTS SETPOINT SOURCE is set to AUTO CHANGE PASSWORD OLD gt Enter current password CHANGE PASSWORD Press S enter old password using arrow keys and for each character OLD CHANGE PASSWORD NEW Enter new password CHANGE PASSWORD Press Ss enter new password using arrow keys and for each character OLD AAAAAA Onceall six places are filled the display changes as shown below NEW CHANGE PASSWORD Once new password is entered press to save press to cancel OLD AAAAAA NEW ACCEPT PASSWORD ACCEPT PASSWORD 19200 COMMUNICATIONS BAUD PARITY MODEM INSTALLED LOAD DEFAULTS FACTORY CAL NO YES or NO FACTORY CAL NO FACTORY RESET NO FACTORY RESET NO YES or NO SYSTEM FACTORY TEST a Press and the test will proceed LOAD FIRMWARE NO LOAD FIRMWARE NO YES or NO COMMUNICATIONS BAUD 19200 PARITY EVEN MODEM NO EVEN EVEN or ODD 0 YES or NO P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED
36. HH Modulation PWM Boilers running Boiler 1 on x Boiler 2 on Boiler 3 on NC No Call for Heat Boiler 4 on HD Heat Demand Boiler 5 on RM Remote Mod 4 20ma Boiler 6 on HF 1T 2T 3T T inputs Fire Rates Boiler on HT H NET Control P Circulator pump Note Only 7 boilers can be M Nain val displayed And this readout only Main valve open H Ignition Control Alarm shows on the Heat Net MASTER P Pilot valve open B Blower on P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL o Troubleshooting continued Fault indications The HeatNet control monitors both boiler and external interlocks and will shut down the boiler and display a fault code when a problem occurs See Table 10 for details Some faults will cause the control to shut down the boiler or system and display the message CALL FACTORY Should this message appear immediately contact Hydrotherm for assistance DO NOT attempt to correct the condition without discussing the issue with the factory Failure to comply could result in severe personal injury death or substantial property damage Table 10 Status screen fault displays when fault is tripped display will show fault message beep and close the alarm contact for remote alarm the fault displays for a second then is followed by the time the fault occurred The fault and time toggle once per second until the condition is co
37. KNCT2 808 Is Tirea direct vent ast Iron borers Viodels KIN 6 10 20 only MeatNet contro nrmwareeaition 2451 HydroTherm a L A Gontrol manual her o fH rero aajustment and a ET a Qperationi instructions KN Series Gas Boiler Installation amp Operation 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 boiler 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 Afhx these instructions near to the boiler Instruct the building owner to retain the instructions for future use by a qualified service CAUTION 2 technician and to follow all guidelines in the User s Information Manual P N 4
38. OILERS CONTROL MANUAL 1 External 4 20ma control Electrical shock hazard Disconnect all electrical power sources to the boiler before making any electrical connections Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Failure to comply with the above could result in severe personal injury death or substantial property damage NOTICE The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform to CSA C22 1 Canadian Electrical Code Part I if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler for KN 6 and KN 10 208 230 240 VAC 1 60 20 amp for KN 20 A properly rated shut off switch should be located at the boiler The boiler must be grounded in accordance with the authority having jurisdiction or if none the latest revision of the National Electrical Code ANSI NFPA 70 Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of 14 awg Use appropriate wiring materials for units installed outdoors caution Follow the Boiler manual Install the boilers according to the KN Series Gas Boiler Installation amp Operating Instructions manual before attempting to set up the control system I
39. R boiler unless boiler will operate in override mode Set Set if needed for override operation Not needed Set Set Set only if boiler will operate in override mode with 4 20mA input Not applicable to member boiler unless boiler is to operate in override mode Not applicable to member boiler Enable if desired requires installing a return water temp sensor Set value if enabled Set or keep default Enable if desired Enable constant pump if desired Enable if used connect flow switch Not applicable to member boiler Set P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 2 Multiple boilers HeatNet modulation von Table 3 Control parameters for HeatNet networks continued Requirement MASTER boiler Requirement MEMBER boiler AUX FUNCTIONS COMBUST AIR DAMPER Select IN USE YES to enable select proof time or Same as MASTER keep default connect wires to damper and end switch select COMMON or INDEPENDENT ALARM SILENCE Enable remote alarm silence if desired connect Enable remote alarm silence if desired connect terminals to remote switch terminals to remote switch FAILSAFE MODES Enable LOW TEMP if desired for freeze protection set Enable LOW TEMP if desired for freeze protection set temp as desired temp as desired SYSTEM CLOCK Set to ensure accuracy of time stamping NO set only on master boiler DISTRIBUTED CTRL H NET A
40. T CAST IRON BOILERS CONTROL MANUAL Wi ri n g continued Figure 8 Field wiring connections for on off and two stage firing options ON OFF firing Close this contact to run boiler at High Fire Stage firing Close these contacts to run boiler at MIN 25 stage 1 or MAX 100 stage 2 KN301 opoe I O Interlock Relay K3 Boiler start Relay K1 Boiler other Relay 4 Boiler 3 Relay K5 Circulator Relay K6 Alarm Relay K2 J12A Buzzer J12B c P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 5 Wi ri n g continued Figure 9 Installation of optional BACnet or LonWorks bridge protocessor for MODBUS operation sige Interlock Relay K3 J11A Boiler start Relay K1 X 16 Boiler other 8 zi Relay K4 1 js Boiler 3 Relay K5 J11B Circulator Relay K6 24 VAC OOO00
41. T PRG TIME 2M DELTA TEMP 10 F 0 to 50 F ALWAYS ENABLED OFF POST PRGE TIME 2 minutes 1 to 60 minutes ALWAYS ENABLED OFF ON or OFF PUMP VALVE OPTION MASTER PUMP VALVE MASTER PUMP VALVE REMAINS ON OFF ON or OFF REMAINS ON OFF FLOW PROVE Was 10 seconds 10 to 240 seconds FLOW PROVE NIGHT SETBACK SETBACK ENTRY 1 1 through 4 SETBACK ENTRY 1 ENTRY IS OFF ON of OFF ENTRIES OFF SETBACK 20 F SETBACK TIME SETBACK 20 F 0 to 50 F SETBACKTIME START DAY MON SUN MON TUE WED THU FRI SAT TIME 12 00 AM Time AM or PM START DAY MON TIME 10 00 PM END DAY FRI END DAY MON SUN MON TUE WED THU FRI SAT FUE 3700 M TIME 12 00 AM Time AM or PM F F or C ON ON or OFF fey Gace SKIP PASSW ON ON or OFF BRIGHTNESS 50 12 25 37 50 62 75 87 100 P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table7 SETUP menus continued see Table 9 page 30 for explanations Level 1 Level 2 Level 3 Default Range OQ next item OQ next item OQ next item OQ to change value to select to select to select o to accept value and return to previous menu level o back one level o back one level LOG RUNTIME RUN HOURS Cn DATA LOG ENTRY RUN HOURS 1240 DATA LOG ENTRY 327 f SIZE 1000 SIZE The size of the data log BOILER CYCLES 5021 T
42. T value the 4 20mA ENABLE contact must be closed for remote setpoint operation to function P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued BOILER START ADVANCEDSETUP This sets the signal current at which the boiler will start shut off The boiler will start when the 4 20mA INPUT current is approximately 0 10 mA above the setting The boiler will shut off if the current falls below the setting Example 4mA SETPOINT 3 8 mA the boiler will start at 3 9 mA and shut at or below 3 7 mA PRIORITY ADVANCEDSETUP When this is set to NORMAL the priority of a 4 20mA input when enabled by closure across 4 20mA INPUT the 4 20mA enable terminals is in the normal order AA high fire HEAT DEmAND HeatNet 4 20mA T1 T2 When set to HIGHEST the priority sequence is changed to give 4 20mA the highest priority above AA NOTE The SETPOINT SOURCE under SETUP SETPOINTS must be set to AUTO for HIGHEST priority to work The control cannot be placed in LOCAL mode if this PRIORITY is enabled and active CHANGE PASSWORD ADVANCED SETUP Use to set change a password G NOTE You can reset the password to the default value AAAAAA by turning the ON OFF switch to OFF Then hold down the BACK key as you turn the ON OFF switch to ON The password is only required if the contro
43. UST AIR DAMPER Select IN USE YES to enable select proof time or keep default connect wires to damper and end switch ALARM SILENCE Enable remote alarm silence if desired connect terminals to remote switch FAILSAFE MODES Enable LOW TEMP if desired for freeze protection set temp as desired SYSTEM CLOCK Set to ensure accuracy of time stamping Select type or accept defaults make sure installed sensors are listed and are the correct type 4 20mA INPUT Set values for 4 20mA parameters if using either as primary control source or as an override P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 2 We Electrical shock hazard Disconnect all electrical power sources to the boiler before making any electrical connections WARNI Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Failure to comply with the above could result in severe personal injury death or substantial property damage The electrical connections to this boiler must be made in accordance with all applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform to CSA C22 1 Canadian Electrical Code Part I if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler for KN 6 and KN 10 208 230 240 VAC
44. VENT CASI IRON BOILERS CONTROL MANUAL Contents 4 External4 20ma control page 15 4 20mA HeatNet combined operation The master boiler can receive the 4 20mA modulation signal and control the other boilers 4 20mA direct operation Up to 5 boilers can be controlled by an external control that provides a 4 20ma input signal The external controls must also activate each boiler by closing a contact across the boiler s 4 20ma Remote Enable contacts Member boilers can override external boiler control if they receive a contact closure on the Heat Demand or any terminal higher priority than the 4 20mA controls can be set up to make 4 20mA the highest priority if desired 5 Control menus and adjustments page 24 Operating parameters and control behaviors are set using the KN controls display keypad interface Refer to this section for the menu structure and explanations of the setup options Table SETUP MENU ie TTE page 25 Table 8 ADVANCED SETUP menus page 28 Table 9 Setup menus parameter explanations EUR page 30 6 Wiring o0 24 Wire the boilers as described in this section 7 Boiler operation and status display page24 his section describes control start up and operation 8 Troubleshooting page44 Table 10 Status screen fault displays page 42 Table 11
45. W operation in particular would raise the supply temperature from overriding boilers to the DHW Setpoint P N 42 9534 8 08 Copyright 2008 Hydrotherm NOTICE Override operation control setup MEMBER boilers must be set up with operating parameters necessary during their override local operation 1 HeatNet boiler will respond to overrides in the following order The modes listed will override any other activation function listed below it Figure 3 Boiler input priorities MASTER BOILER Priority 1 AA terminals ON OFF operation Master boiler operates in ON OFF and fires all member boilers ON OFF together based on system settings See Figure 8 page 22 for wiring connections Priority 2 HEAT DEMAND Master boiler operates in full modulation and fires modulates member boilers based on system settings Priority 3 4 20mA 0 10VDC input Requires closure across the 4 20mA ENABLE terminals Master boiler operates and controls member boilers based on 4 20m A signal received at master Priority 4 T1 T2 stage control Master boiler operates based on closure of T1 and T2 terminals on master firing member boilers at the same rate See Figure 8 page 22 for wiring connections MEMBER BOILER Priority 1 AA terminals ON OFF operation Member boiler switches to local control in ON OFF operation using the boilers settings See Figure 8 page 22 for wiring connections Priority 2 HEAT DEMAND Mem
46. apability and require only RJAS HeatNet cables or shielded wires to connect between them The header water temperature setpoint can be set by the master boiler or by a 4 20ma input from an external controller Member boilers can override master boiler control if they receive a contact closure on the HEAT DEMAND terminals or the AA high fire terminals In addition the controls can be set up to allow priority override by a remote 4 20mA source 3 Multiple boilers BMS operation page 13 Combined BMS HeatNet operation This method uses the KN controls built in communications capabilities to accept MODBUS protocol inputs from a building management system The master boiler control sequences and modulates the boiler network to accomplish the demands from the building management system Direct BMS control of all boilers Each boiler can be operated directly by the BMS each boiler will require an optional bridge ifusing BACnet or LONWORKS Boiler setup is essentially the same as for method 2 with the exception that each boiler must be assigned both a HeatNet network address and an address for the MODBUS interface HeatNet An additional bridge is required to interface with systems using BACnet or LON Co ntrol pa nel WORKS protocol The master boiler will take control and regulate the boiler network if signal from the BMS is lost or times out P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT
47. ber boiler switches to local control using the boilers settings for operation and modulation Priority 3 HeatNet input Member boiler receives operating commands from the master boiler through the cable or shielded wires between HeatNet boilers Priority 4 4 20mA 0 10VDC input Requires closure across the 4 20mA ENABLE terminals Member boiler operates on local control based on 4 20mA signal received at member Setting the 4 20mA parameter to HIGHEST in the ADVANCED SETUP menu will cause 4 20mA ENABLE to move to priority 1 Priority 4 T1 T2 stage control Member boiler operates on local control based on closure of T1 and T2 on member boiler See Figure 8 page 22 for wiring connections KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 5 Wi ri n g continued Figure 4 KN HeatNet control fleld wiring also see KN Gas Boiler Installation amp Operation Instructions Verify against wiring diagram supplied with boiler Power service switched NEU L2 L1 QU Interlock Relay K3 Boiler start Relay K1 Boiler other Relay K4 Boiler 3 Relay K5 Circulator Relay K6 Alarm Relay K2 J1 System circulator relay 1 Relay output Damper dry contacts field wiring Boiler circulator relay Alarm A
48. ble termi nals and any override wiring to Heat Demand or DHW Demand terminals to ensure there will be no call for heat while proceeding 7 Settheboilers control parameters using their display keypads 8 Followthe instructions in the Boiler manual to start up each boiler before proceeding further 9 Finish by reconnecting call for heat wiring then operating the complete system to verify operation in all modes Option 3 Remote setpoint operation 1 HeatNet system or an individual boiler can be operated using remote setpoint by providing a 4 20mA input and en able Set the 4 20mA parameters for compatible boiler start current and correct temperature range ps See Figure 7 page 21 for wiring from the 4 20mA controller Wiring l See page 16 for wiring information and wiring diagrams 2 Note that the boilers can be wired for override operation The wiring section provides information on override priorities KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL Wiring Power supply 120 VAC 1 Connect mininum 14awg copper wire to the power con nection See Figure 4 page 18 2 Install a fused service switch mounted and installed in ac cordance with all applicable codes Circulator wiring CAUTION All circulators operated by the HeatNet control require a motor starter or relay to handle the power load of the circulator Use the output terminals of the KN HeatNet control ONLY to operate
49. d 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 setpoint timer is not written a default timeout value of 60 seconds is assumed To write the system clock registers 40009 40015 must first be loaded with the cor rect date and time Then a 1 must be written to register 16to write the date and time to the system clock Table5 Boiler status flags Description Bit _ Description Disabled Pilot Valve 1 P Local Override 2 Alarm 3 4 5 Pump Running 22 XS Factory 7 8 10 11 ca SS Ss Water Prove Flow Interlock 29 Air Prove UV Sensor Interlock Present Boiler Detected KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 3 Multiple boilers BMS operation vont BACnet or LONWORKS protocols Table6 MODBUS input read only registers 1 Install the correct bridge to adapt to building management systems using BACnet or LONWORKS protocols Each boiler must have a bridge if the BMS is to operate with di rect control of each boiler option 2 page 13 2 The bridge translates the BACnet or LONWORKS input 30001 Data Description Valid Values Type Range Unsi
50. e address any value from 2 through 16 DISTRIBUTED CTRL The Master boiler H NET address is automatically set to 255 The master boiler is automatically recognized because it is the one with a sensor wired to its SYS DHW HEADER terminals MODBUS ADDRESS ADVANCED SETUP This is used only when the boilers are regulated by a building management system using DISTRIBUTED CTRL MODBUS BACNET or LONWORKS Assign each member boiler AND the Heat Net master boiler a unique address any value from 1 to 247 ADD BOILER DELAY ADVANCED SETUP This is the minimum wait time before an additional boiler can fire when called on by the MODULAR BOILER master boiler control MODULATE DELAY TIME The boiler will remain at minimum fire when first starting until this amount of time has elapsed MODULAR BOILER MOD MAX LAST FIRE ADVANCED SETUP This sets the maximum firing percentage for boilers during times that some boilers are not MODULAR BOILER firing It limits input of the boilers to keep them as efficient as possible Once all boilers are started during high heat demand periods this restriction is removed and all boilers can fire up to maximum input Once any boiler is dropped offline the restriction is applied again ROTATION ADVANCED SETUP Select the rotation method FIRING MORE TRUE ROTATION or TRUE RUNTIME ROTATION attempts to fire all boilers an equal amount of time FIRST ON FIRST OFF jogs between boilers to balance usage LAST
51. e limit It must be high enough above the upper end of the heat band to avoid nuisance cycling For boilers operating as stand alone and regulating boiler supply temperature this setting is not necessary because the boiler shuts off when the SUPPLY temperature exceeds the top of the HEAT BAND The maximum setting is 220 F Example If the boiler setpoint is 180 F and the heat band is 30 F the upper end of the heat band is 180 30 2 195 F The limit band see below must be set at 10 F so the OP LIMIT setting can be 195 10 205 F The OP LIMIT cannot be higher than 220 F The operating limit setting OPERATE LIMIT always limits boiler outlet water temperature regardless of how the boiler is controlled HeatNet member 4 20ma control stand alone or other The OP LIMIT BAND see below determines when the boiler begins to be forced to reduce input as the outlet temperature rises toward the limit setting P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued OP LIM BAND SETPOINTS Boiler firing rate is limited BoilerOFFabove If the boiler outlet water tem perature rises thelimitband OPHMITseing toward the OPERATE LIMIT setting the KN OP LIMIT SETTING 2096 control will begin to reduce the boiler s firing N 4 4 4 rate when the temperat
52. e shown is the value detected at the sensor listed INTERLOCK SPARE 4 Occurs on opening of an external device connected to J11B FAULT SUPPLY Automatically resets J11B SPARE 4 SPARE 4 terminals The boiler is shut down until the fault is INTERLOCK SPARE 4 control after condition is corrected corrected The display continues showing the SUPPLY HEADER or other 1 6 8 F temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed IRIALARM Occurs when the HeatNet control receives an alarm signal from FAULT SUPPLY Requires cycling the the gas valve The boiler is shut down If the condition isn t IRI ALARM boiler ON OFF switch to corrected within one minute CALL FACTORY appears on the reset after condition is display 168 F corrected Check the gas valve if this fault appears The display continues showing the SUPPLY HEADER or other temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed LOW WATER CUTOFF Occurs on opening of a low water cutoff switch connected to FAULT SUPPLY Automatically J1 LWCO J11 LWCO terminals The boiler is shut down until the fault is LOW WATER CUTOFF resets control after corrected temperature drops The display continues showing the SUPPLY HEADER or other 1 6 8 F temperature whichever had been selected for display The temperature shown is the value detected at the sensor l
53. e to the LOCAL SETPOINT setting NOTE The control will wait 10 minutes after losing communications with the HeatNet master before switching to local operation This function can automatically start the boiler or boilers via the Master if water temperature drops below the value set for TEMP LESS THAN This function can be used to provide automatic freeze protection Once the temperature TEMP LESS THAN value is reached the boiler or boilers will shut off Select which sensor to monitor SUPPLY RETURN or HEADER Set the minimum allowable temperature for the location selected in LOW TEMP above This feature is active if LIM gt HALF RATE is set to YES see following explanation When the temperature rise through the boiler SUPPLY minus RETURN temperatures rises higher than the value of EXCHGR DELTA the control immediately begins limiting the boiler firing rate to one half of the called for rate This quickly reduces the boiler output to avoid short cycling on limit The control will return to normal operation once the boiler temperature rise reduces to 10 F less than the value set for EXCHGR DELTA P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued LIM gt HALF RATE AUX FUNCTIONS HEAT EXCHANGER Set this feature to YES to cause the control to automatically r
54. ed locally It will not override 4 20ma control or building management control SETBACK This is the reduction in local or system setpoint temperature during the specified period SETBACK TIME Enter the start and end days and the times for start end TEMP SCALE Select Fahrenheit or Centigrade KEY CLICK If activated the control beeps when a key is pressed SKIP PASSWORD OPTIONS The control can be programmed such that a password is required to change settings Setting this to ON disables the password If SKIP PASSWORD is OFF then a password is required to enter the setup menus Default password AAAAAA Restore to default by pressing o while turning ON OFF switch to ON Password must be 6 characters long the control will not accept blank characters owes Depts the total tmethe bollergasvakehasbesnopen em n Dmsysinecunentnumbe ofentriesinthedatalog I BOILER CYCLES LOG RUNTIME Displays the number of times the boiler gas valve has been cycled on then off It does not include failed ignition attempts P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued Under Explanation TYPE INPUT PROOF TIME RUN IN LOCAL IF H NET COMM LOST RUN IN LOCAL IF LOW TEMP RUN IN LOCAL IF TEMP LESS THAN EXCHGR DELTA AUX FNCTIONS COM
55. educe the boiler firing rate to one half the called for value if the temperature rise through the boiler exceeds the maximum value desired This maximum temperature rise is EXCHGR DELTA NOTE This function can be used to prevent short cycling if the header temperature can drop quickly causing the boiler to try increasing boiler supply temperature to meet the apparent demand increase Quick header temperature drop can occur for example when boilers are equipped with slow opening valves the valve begin to allow flow as they open but the boiler can t fire until they are fully open and make their end switches NOTE DISPLAY When this feature is enabled the display will be different from normal In RUN mode the display will show 1 2 INPUT instead of RUN 96 The STATUS screen will show ADAPTIVE IN over the START and STOP times SYSTEM CLOCK Set the system clock time day of week month day and year on start up and after any power outage to ensure the data log time stamp information will be accurate CONTROL ADVANCED SETUP This is not adjustable It only displays that the control is a HeatNet H Net control DISTRIBUTED CTRL H NET Master ADVANCED SETUP This is not adjustable It will automatically say YES for the Master boiler and NO for a MEMBER DISTRIBUTED CTRL boiler The Master boiler is the boiler with a sensor connected to the SYS DHW HEADER terminals H NET ADDRESS ADVANCED SETUP Assign each MEMBER boiler a uniqu
56. emperature drops temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL S Troubleshooting continued Table 11 Troubleshooting suggestions Suggested procedure Nothing happens when the Check 120VAC power to connection board Verify power is connected per wiring diagrams power switch is turned on The Power switch light ON Position should illuminate if power is wired correctly If the Ignition Control is active but the front panel display is inactive check 1 Cable and cable polarity from the control board to the display 2 Check for 120vac 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 miswired The KN 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 minutes The display shows combustion If you are not using the combustion air damper then it needs to be disabled in the AUX FUNCTIONS air damper failure menu The prove switch for the combustion air damper is not closing Check to make sure the dampers are being control
57. er in the event communications is lost The MODBUS protocol allows writing and reading reg isters using MODBUS commands An optional BACNet or LONWorks bridge module can be used to connect the MODBUS network to a BACNet or LonWorks network This method allows enabling and disabling the boiler or HeatNet system changing setpoints and reading boiler status or temperatures remotely using digital commands from a Building Management System The master boiler assumes the role of MEMBER RTU 19 2Kb 8 bits Even Parity 1 stop bit when connected to a BMS The Member Boilers should not be connected to a BMS system other than to view read only addresses Option 2 Total MBS control 1 This option uses direct control of each boiler and requires a BACnet or LonWorks bridge on each boiler if not using MODBUS The MBS controls each boiler directly except when the boiler is wired and activated for override operation 2 Consult the website for address configuration information at info www hyrdothermkn com Click the HeatNet On Board icon MODBUS registers 1 See Table 4 page 13 Table 5 page 13 and Table 6 page 14 for register requirements 2 The system setpoint timer and system setpoint work in tan dem to externally control the operating setpoint 3 Thesetpoint countdown timer should be loaded with a time out value in seconds prior to writing the system setpoint 4 When the timer reaches zero the control assume
58. er proving switch only if field wiring D o J10B INPUT option is chosen a Alarm silence D 24VDC Ret 2 4 20 24VDC L H LINK shielded wire This terminal strip can be used with shielded wire if RJ45 cable ends are unavailable RJ45 cable to boiler ses RS485 Communication board b Mounts on stand offs on main board can be removed to simplify cable EN connections To computer or management system shielded wire only To computer or management system RJ45 cable 20500 P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 5 Wi ri n g continued Figure 5 KN HeatNet temperature sensors E 888 J1 Interlock Relay K3 Boiler start Relay K1 Boiler other J Relay K4 Boiler 3 Relay K5 Im Il Relay K6 99999999 S Alarm Relay K2 Circulator J12A Buzzer 8 J12B J11A J11B sessssessssssssessses E J10A n CN J10B 1 NORM L io P N 42 9534 8 08 Copyright 2008 Hydrotherm All Temperature Sensors are 10k Thermistors Immersion sensors require a well Outside air temperat
59. f using a 0 10 VDC signal multiply any references to current in the manual by 0 5 Example Sma 0 5 2 5 VDC Option 1 Modulation using HeatNet control l Set up the boilers following the instructions for a HeatNet modulated system be ginning on page 8 See Figure 7 page 21 for wiring from the 4 20mA external controller The controller must provide the 4 20mA signal and a contact for each boiler to enable its operation by closing across the Remote Enable contact Set parameters as for the HeatNet modulated system Closing the 4 20mA enable contact will cause the master boiler to modulate all boilers at a level proportional to the 4 20mA signal Make sure to set the 4 20mA parameters for compatible boiler start current P N 42 9534 8 08 Copyright 2008 Hydrotherm Option 2 Direct modulation up to 5 boilers 1 Set up parameters as for a stand alone boiler beginning on page 6 2 The 4 20mA input is daisy chained connected in series from boiler to boiler Connect the 4 20mA input signal with its input on boiler 1 and its input on the last boiler Then connect the 4 20mA input terminals from boiler to boiler in series i e the from boiler 1 goes to on boiler 2 etc 3 Closethe external gas valve on every boiler 4 Wire all boilers following the guidelines in this manual 5 DO NOT install a header SYS DHW HEADER sensor on any of the boilers 6 Disconnect the wires to the boilers Remote Ena
60. gned Boilers Running 0 16 to the MODBUS protocol for compatibility with the Heat 30002 Unsigned Modulation BTU Load 0 100 Net controls 30003 Signed Header System Temperature 32 250 F 30004 Signed Supply Temperature 32 250 F Wiring and set up Se ET 1 Wire and set up the master boiler and member boilers exactly 30006 Signed Outside Air Temperature 40 250 F as for HeatNet modulation local control applications See section beginning on page 8 30007 Signed Spare Input 1 32768 to 32767 2 ALL control parameters must be set up just as for the local 30008 Signed Spare Input 2 32768 to 32767 control method 30009 Unsigned Clock Month 3 The ONLY difference in setup is the termination DIP _ switch settings Use the settings for MODBUS communi ET ju cations given in Table 2 page 8 30011 Unsigned Clock Year 4 Connect communications cables RJ45 or shield wire 30012 Unsigned Clock Hours cables between the control communications boards as for thelocal control method 30013 S Verify network operation BEFORE connecting the building 30014 management system 30015 Unsigned Clock Minutes Unsigned Clock Seconds Clock Day of Week Unsigned 1 Monday 7 Sunday Unsigned Boilers 1 16 status flag 32 bit registers The See the Boiler upper 16 bits of each 32 bit registerisstored Status Flags Table at odd numbered addresses 3001
61. ies boilers HeatNet control Electrical components Electrical enclosure Control panel 4 line digital display and navigation buttons Electrical connection panel Electrical subpanel Power connection strip for KN 6 and KN 10 120v 1 60 Power connection strip for KN 20 208 230 240 VAC 1 60 Flame safeguard Honeywell VFD blower speed controller On off switch HeatNet Electrical enclosure P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL The Mestek KN boiler with HeatNet control 1 Stand alone boiler page6 Provide an external contact connected across J12A HEAT DEMAND terminals to start the boiler A MEMBER boiler in a network can also be activated by closing the circuit across HEAT DEMAND The boiler can operate based on its SUPPLY temperature or can be operated by remote control from a 4 20mA source And setpoint temperature can be controlled locally or by 4 20mA signal from a remote source The boilers T1 T2 terminals can be used to operate the boiler as two stage fired at minimum input or maximum input The AA terminals can be used to fire the boiler as ON OFF at maximum input 2 Multiple boilers HeatNet modulation page 8 The KN HeatNet control can control up to 16 KN boilers using built in software and hardware KN boilers come standard with HeatNet communications c
62. ion required to reset from fault HIGH LIMIT Occurs on opening of an external limit connected to J5 FAULT SUPPLY Automatically resets J5 HIGH LIMIT HIGH LIMIT terminals The boiler is shut down until the fault is HIGH LIMIT control after external corrected limit closes The display continues showing the SUPPLY HEADER or other 1 6 8 F temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed IGNITION CTRL ALARM Occurs when the HeatNet control receives an alarm signal from FAULT SUPPLY Automatically resets the ignition control This could occur on ignition failure air IGNITION CTRL ALARM control after external proving switch error or any other fault that triggers the ignition signal ends control s alarm circuit The boiler is shut down until the fault is 1 6 8 F corrected The display continues showing the SUPPLY HEADER or other temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed INTERLOCK SPARE 3 Occurs on opening of an external device connected to J11A FAULT SUPPLY Automatically resets J11A SPARE 3 SPARE 3 terminals The boiler is shut down until the fault is INTERLOCK SPARE 3 control after condition is corrected 168 The display continues showing the SUPPLY HEADER other temperature whichever had been selected for display The temperatur
63. iring 1 2 See page page 16 for wiring information and wiring diagrams Note that the boilers can be wired for override operation The wiring section pro vides information on override priorities Multiple boilers HeatNet modulation Set termination DIP switches 1 The HeatNet network needs to recognize the beginning and end of the network This requires setting the four DIP switches on each boiler s electrical connection board See Figure 1 for location of the switches See Table 2 for required settings The table gives settings for HeatNet modulation local control and for remote control from a building management system MODBUS protocol 4 DONOT connect the communications cables or shielded wires between boilers until all boilers have had parameters set and then been started up following all instructions in the KN Boiler manual Termination DIP switches located at lower left corner of control board component details are omitted for clarity Figure 1 Table 2 Termination DIP switch settings HeatNet switches are on left MODBUS switches are on right Other members MODBUS see note Switch 1 ON Switch 2 ON Switch 1 ON Switch 2 ON Switch 1 ON Switch 2 ON Switch 1 ON Switch 2 ON Switch 1 OFF Switch 2 OFF Switch 1 OFF Switch 2 OFF Note MODBUS setup is for applications controlled by a building management system For systems using BACnet or LONWORKS a bridge
64. isted P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL S Troubleshooting continued Table 10 Status screen fault displays continued FAULT EVENT amp CAUSE Discussion INTERLOCK TERMINALS DISPLAY Action required to reset from fault OPEN SENSOR Occurs when the HeatNet control detects an open circuit on SUPPLY Automatically resets ANY SENSOR any sensor that should be in operation The boiler will shut SENSOR control after external down on the failure of any sensor except the OUTDOOR sensor limit closes If the OUTDOOR circuit is open and the boiler is set for outdoor reset operation the control reverts to fixed setpoint operation name of the sensar controlling to either the LOCAL or SYSTEM setpoint until the appears where the condition is corrected is above The display continues showing the SUPPLY HEADER or other temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed SHORTED SENSOR Occurs when the HeatNet control detects a short circuit on any FAULT SUPPLY Automatically resets ANY SENSOR sensor that should be in operation The boiler will shut down SHORTED SENSOR control after external on the failure of any sensor except the OUTDOOR sensor If limit closes the OUTDOOR circuit is open and the boiler is set for outdoor reset o
65. justed using the SETUP menus or by pressing down the SELECT key for one second while in Standby The setpoint will begin to flash Use the arrow keys to increase or decrease the setpoint When satisfied press SELECT to keep the new number To cancel and return to Standby press the BACK button Accessing setup menus With the display in STANDBY press and hold the BACK key for 5 seconds The display will change to SETUP ADVANCED SETUP I 2 VIEW LOG Press the SELECT key to select setup Note that pressing the DOWN key would change the selection to ADVANCED SETUP or VIEW LOG The display will now show the first options in the setup menus KN SERIES V 2 1 BOILERS SETPOINTS OUTDOOR ATR RESET NOTICE All boilers on a network must have firmware revisions of 2 0 or above 5 or all can have revision 1 x Do not mix 2 x firmware boilers with 1 x firmware boilers Follow the procedure in this manual Table 9 page 30 to install a firmware update on each boiler as necessary To ensure consistent setup all boilers should preferably have the SAME firmware edition Press the DOWN key to access additional menu options Pressing the DOWN button once will change the display to TS OUTDOOR ATR RESET The cursor moves to the second line indicating this option could now be selected with the SELECT key Continuing to press the DOWN key will access the menu options listed on the following pages Table 7
66. l is setup with SKIP PASSWORD set to NO found under SETUP OPTIONS SKIP PASSWORD BAUD ADVANCED SETUP 9600 COMMUNICATIONS PARITY ADVANCED SETUP Select even or odd as required by communications port used COMMUNICATIONS ADVANCED SETUP Select YES only if a modem is installed COMMUNICATIONS LOAD DEFAULTS ADVANCED SETUP Load the factory defaults when you want to be sure nothing has been changed or after you have loaded new firmware Disconnect wires to the Heat Demand terminals and any other remote operation wiring There must be no call for heat during the process Navigate the control display to LOAD DEFAULTS To restore factory calibration settings or factory settings section either of the options and select YES for the prompt ARE YOUR SURE P N 42 9534 8 08 Copyright 2008 Hydrotherm 6 KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL Control menus and adjustments continued Table9 Setup menus parameter explanations continued FIRMWARE VERSION UPDATE CONTROL ADVANCED SETUP SYSTEM The firmware version in the control must match the version in this manual in order to ensure accuracy of the installation operation information The control displays the firmware version number when SETUP is accessed To update the control s firmware obtain a disk from Hydrotherm or download the current file from the Hydrotherm website For networked boilers all must have ver
67. led by the output relay you specified when programming for the damper Also check to make sure the prove switch is working properly If these steps have been done and you continue to get the error message check the sensor TYPE specified in the SENSORS menu If it is set to NONE the controller will not recognize the closed circuit Set the Sensor type to ON OFF The display is displaying random There may exist a grounding problem with the controller or one of the boilers pumps contactors or other characters or the control keeps devices connected to it resetting 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 contactors 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 being out of adjustment Attempt to identify the noise source 1 What is the boiler controller trying to do at the time of the failure Is the boiler on the same circuit as the noise source The boiler should have isolated power 2 3 Are shielded sensor wires used Ensure the shields are grounded only at the boiler control end 4 Are any sensors or sensor wires located near a transmitting antenna Move sensor There are no heating boilers on Check the settings for OA SETPOINT and OA RESET Ifthe outdoor air temperature is above the OA SETPOINT and OA RESET
68. load is interrupted or fails turn the boiler ON OFF switch OFF then ON Restart the firmware download program to start the download The boiler will appear unresponsive during this time because it is waiting for the download to take place When the download is complete the boiler will power cycle The display should show STANDBY If the firmware does not load correctly the display will remain blank Try running the firmware program again Check that the boiler performs properly P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Calibration of firing rates blower speeds This section describes use of the KN HeatNet control to set blower speeds for mini mum input MIN OUTPUT maximum input MAX OUTPUT and pilot ignition period IGNITION a TUN Follow all instructions in the KN Series Gas Boiler Installation and Operation Instructions manual to install and adjust the boiler before proceeding with any of the procedures below Failure to comply could result in severe personal injury death or substantial property damage Entering calibration mode WARNING Electrical shock hazard Use caution when working around electrical components in the boiler Exposed line voltage electrical connections could cause a severe shock Failure to comply could result in severe personal injury or death 1 Turn offall call for heat inputs or
69. mp Oper ating Instructions manual Consult the factory for applica tions not covered If using the SYS DHW HEADER sensor in the DHW tank the DHW circulator should be activated using the SYSTEM CIRCULATOR terminals on the electrical con nection board External interlocks CAUTION If used wire external limits and flow switch as shown in Fig ure 6 page 20 If wiring to and from a motorized combustion air damper or dampers follow the guidelines given in Figure 6 page 20 Connect only to the master boiler Make sure the AUX FUNCTION options are set correctly If any of the member boilers is to operate in override mode and the system is equipped with a single master combustion air damper you must provide special wiring in order to ensure the damper opens and proves when the boiler fires This must be done without compromising the wiring between the master boiler and the damper Overrides Control priorities I The KN HeatNet control can provide override operation for any or all boilers in a HeatNet network This requires the boilers be piped with appropriate isolation piping and controls as needed for isolation CAUTION Donotwire boilers for override operation unless the piping design provides automatic isolation of the overriding boilers The master boiler would be unable to properly control system water temperature if member boilers were to input heat to the system without control from the master DH
70. must drop at least 2 F below the WWS SETPOINT for the boiler to come on again Set to NO to disable P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table9 Setup menus parameter explanations continued WWS SETPOINT OUTDOOR AIR The boiler and its circulator shut down when the outside air temperature is above WWS SETPOINT if outdoor air reset is enabled ON This requires an outdoor sensor when enabled The differential is 2 F i e the boiler will shut off if the outdoor temperature is equal to or greater than OUTDOOR AIR setting The outdoor temperature must drop 2 F below OUTDOOR AIR setting for the boiler to turn back on If the OA OVR input is closed outdoor reset and warm weather shutdown are overridden The boiler will run at LOCAL SYSTEM SETPOINT This function can be used to operate the HeatNet system at a fixed temperature equal to the LOCAL SETPT or SYSTEM SETPT for applications such as DHW heating S WATER SETPOINT TEMPERATURE F LOW WATER OUTDOOR AIR AT SET OA SETPTS HIGH OA TEMP These temperatures determine the reset curve for supply water temperature High water at low outside air means the design water temperature for maximum load at ODT or outside design alow outside temperature for the installation The other end of the reset curve is the low water temperature at
71. nt the sensor such that it is shielded from direct sunlight if possible and not likely to be covered by snow drifts or debris Connect the outdoor sensor leads to the electrical con nection board terminals on J10 as shown in Figure 5 page 19 The sensor must be connected to the MASTER boiler for a HeatNet system member boiler could have its own outdoor sensor if it is to be activated in override mode by closing the Heat Demand terminals The outdoor sensor can also be connected to a stand alone boiler connection board Return water temperature sensor The return water temperature sensor is optional but is needed for some of the parameter options Parameters that require the return water temperature sensor are DELTA TEMP under PUMP OPTIONS and EXCHGR DELTA under AUX FUNCT IONS Install the sensor in a well in the boiler return piping Connect the sensor leads to the electrical connection board terminals J10 as shown in Figure 5 page 19 Each boiler requires a return water temperature sensor in order to use the DELTA functions P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL S Wi ri n g continued DHW wiring To operate the boiler for domestic water heating with a storage tank install and pipe the tank according to the tank manufacturers instructions and the recommended piping diagrams in the KN Series Gas Boiler Installation a
72. o 60 minutes MINUTES 10 SECONDS MOD MAX LAST FIRE 5096 25 to 10096 STOP MOD MAX Factory set not adjustable PID CFACTORY FIRING MODE FIRING MODE TRUE ROTATION TRUE ROTATION LAST ON FIRST OFF FIRST ON FIRST OFF FIRING MODE TRUE ROTATION MASTER FIRST OFF ON or OFF MASTER FIRST OFF OUTSIDE OUTSIDE SUPPLY RETURN HEADER 5 6 SENSOR ASSIGNMENTS SENSOR OUTSIDE TYPE 7 TYPE Z 10K ON OFF TE6000 1K NONE TYPE TYPEZ NO YES or NO CALIBRATE NO IFYES is selected PLACE A PRECISION 1K OR 10K RESISTOR ON CHANNEL Z 1 TRIM OHMS 120 See explanation Table 9 page 30 SENSORS SENSOR TYPE CALIBRATE CALIBRATE P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table8 ADVANCED SETUP menus continued see Table 9 page 30 for explanations Level 1 Level 2 Level 3 Default Range Typical line o Q next item Q next item OQ next item OQ to change value Display shows four lines at a 4 20MA INPUT 4MA SETPOINT 20MA SETPOINT BOILER START PASSWORD Default AAAAAA Restore to default by pressing o while turning ON OFF switch to ON Password must be 6 characters long the control will not accept blank characters z to select to accept value and return to previous menu level time cursor indicates active E line lt level 50 F 50 to 220 Not applied unless S
73. o ON for all ofthe member boilers Allow time for each boiler to initialize After about 30 seconds the master boiler should recognize the member boilers Navigate to the BOILERS menu then to HEAT NET BOILERS display The mas ter control will show the boilers it recognizes If the display shows a blank space such as 123 56789 the control does not de tect the missing boiler boiler 4 Check the yellow LED on the communication port of the missing boiler NORMAL connection LED should flash steadily about twice per second TERMINATION incorrect LED will flash rapidly and stay on OPEN connection LED does not flash at all If FAULT message is displayed clear the faults until the STANDBY message is displayed Refer to troubleshooting suggestions at the end of this manual if you cannot resolve the issue Start the system GA Cu D gt Turn off power to all boilers Connect all call for heat wiring to the boilers Turn on power to all boilers and turn the on off switches to ON he boilers should now operate normally as described in the Boiler manual The master boiler will sequence and modulate boilers as necessary to control the water temp erature The master boiler will show the number of boilers firing as well as the temperature and heat band display Use the UP DOWN keys to scroll through the displays to watch the process of starting and stopping boilers Figure 2 RS485 communications connec
74. onsidered a valid sensor The boiler will default to the MEMBER mode if the temperature is not in this range and can only be run locally or by external inputs The HNet 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 RJAS jacks flash roughly twice a second The MASTER is the only one that should flash with no communications cables plugged in Ifthe control does not sense a closed circuit at input connection FLOW SWITCH 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 If there is no flow prove switch check to make sure that a jumper wire has been connected across the FLOW SWITCH terminals Turn the ON OFF switch off Then depress and hold the ESC key while turning it back on This will load the default password AAAAAA Ensure that the USB driver for your PC Laptop computer is properly installed KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 9 Setup worksheet record allparameters here SETUP MENU mr WATER TEMP 140 F AT HIGH OA TEMP 70 F WATER TEMP 180 F AT LOW OA TEMP 10 F PUMP OPTIONS DELTA TEMP ENAB O FF LOCAL PUMP FF _ P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL
75. or reset and warm weather shutdown are overridden The boiler will run at LOCAL SYSTEM SETPOINT AUTO AUTO 4 20MA NOTE If 4 20MA is selected the control setup menu Will automatically open the ADVANCED SETUP 4 20MA INPUT menu to allow setting the operating levels to match the 4 20MA remote signal controller requirements SET OA SETPTOINS WATER TEMP 140 F 60 to 150 F WATER TEMP 40 F AT AT HIGH OA TEMP 70 F 50 to 90 F HIGH OA TEMP 70 F NEXT WATER TEMP 180 F 70 to 180 F WATER TEMP 1807F AT N f LOW OATEMP 10 F 35 to 40 F LOW OA TEMP 10 F BACK P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table7 SETUP menus continued see Table 9 page 30 for explanations Level 1 Level 2 Level 3 Default Range OQ next item OQ next item OQ next item OQ to change value to select to select 2 to select o to accept value and return to previous menu level o back one level o back one level PUMP OPTIONS SYSTEM PUMP POST PRG TIME ALWAYS ENABLED OFF ON or OFF Typical line Display shows four lines at a time cursor indicates active line POST PRG TIME 2M ALWAYS ENABLED OFF SUMMER PUMP JOG OFF 2 minutes 1 to 60 minutes SUMMER PUMP JOG OFF Day of week MON TUE etc LOCAL PUMP DELTA TEMP ENAB OFF ON or OFF DELTA TEMP ENAB OFF DELTA TEMP 10 POS
76. page 25 lists the sequence of menu items found under the SETUP menu Table 8 page 28 lists the sequence of menu items found under the ADVANCED SETUP menu For an explanation of the parameters see Table 9 page 30 Figure 10 Heat Net display during Standby no call for heat pressing the DOWN key on the keypad changes the display as shown LOCAL SET or SYS DHW HEADER can be adjusted while in Standby as described in this section The above display occurs on single boiler installations only no header sensor installed _ OR NOTICE The above display occurs when boilers are connected to a HeatNet network NOTICE The NA appears if a sensor is not connected to the SYS DHW HEADER sensor terminals The master boiler where the SYS DHW HEADER sensor is attached will show the SYS DHW HEADER temperature in lieu of NA P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 6 Control menus and adjustments continued Table7 SETUP menus see Table 9 page 30 for explanations To enter Setup From STANDBY hold o for 5 seconds If SKIP PASSWORD is set to OFF you will have to enter the password Then press with cursor on SETUP Make sure there is no call for heat at the boiler before attempting to perform setup adjustments To return to STANDBY press release o until the display returns to standby or turn boiler ON OFF switch off then on
77. peration the control reverts to fixed setpoint operation nome of the sensan controlling to either the LOCAL or SYSTEM setpoint until the appears where the condition is corrected is above The display continues showing the SUPPLY HEADER or other temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed UV AIR SWITCH Occurs on opening of the air proving switch connected to J11B FAULT SUPPLY Automatically resets J11B UV SENSOR AIR UV SENSOR AIR SWITCH terminals UV AIR SWITCH control after air flow is SWITCH The air switch detects air flow across the UV sensor The air flow 1 6 8 F restored can also be is intended to reduce condensation on the UV lens assembly reset by cycling the boiler ON OFF switch This fault will not shut down the system but does require attention to avoid nuisance problems This failure is latched causing the fault to display after the call for heat goes away The display continues showing the SUPPLY HEADER or other temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed VAR FREQ DRIVE Occurs when the variable frequency drive sends a fault signal to SUPPLY Automatically J11A VFD the HeatNet control VFD terminals on J11A VAR FREQ DRIVE resets control after The display continues showing the SUPPLY HEADER or other 1 6 9 t
78. proceeding You can silence the alarm by applying a jumper across J10B SPARE terminals Place the LOCAL REMOTE switch on the MASTER boiler or stand alone boiler to LOCAL Place MEMBER boiler LOCAL REMOTE switches to REMOTE Start the MASTER boiler first Turn the MASTER boiler ON OFF switch to ON The HeatNet control will initialize and show the standby screen unless there is a call for heat Start a call for heat As soon as the control receives a call for heat it will show the setpoint temperature bar as below 6 The graphic below explains the temperature bar You will see the header or supply temperature change as boilers add heat to the system or demand changes Measured temperature or header or supply n B Setpoint temperature Heat band 5 F per division on scale 7 10 11 The upper left of the display will show boiler condition prepurge etc as the boiler begins its cycle After the boiler begins firing the screen will show RUN as above After the ADD BOILER DELAY time has elapsed the next boiler will fire The MASTER boiler display will show the START and STOP times The START time counts down on the display When the next boiler starts a 2 will shown in the BLRS FIRING list If this doesn t happen the water temperature may have entered the HEAT BAND so no ad ditional heat is needed Watch the temperature response as boilers are added The HeatNet cont
79. rence across the boiler is less than DELTA TEMP The pump will run an additional time equal to the PURGE TIME An inlet temperature sensor is required POST PRGE TIME PUMP OPTIONS The boiler pump can run after boiler shutdown to distribute heat remaining in the boiler LOCAL PUMP water POST PRGE TIME sets how long the boiler pump will run Also see DELTA TEMP above NOTICE For systems that shut off flow valves such as zone valve systems when the call for heat is satisfied this option must be set to 0 to prevent dead heading the pump ALWAYS ENABLED PUMP OPTIONS If ALWAYS ENABLED is set to YES the boiler circulator never turns off LOCAL PUMP MASTER PUMP VALVE PUMP OPTIONS If set to ON the master control in the network will keep its pump contacts closed running REMAINS ON PUMP VALVE its pump and or control valve if no other boilers are operating This is used to prevent dead OPTION heading system flow FLOW PROVE PUMP OPTIONS This is the time allowed for flow to prove closure across the J11B WTR FLW terminals It can FLOW PROVE be increased to allow time for slow opening valves to open SETBACK ENTRY NIGHT SETBACK Setback entry is the designator for the setback operation Up to four 4 setback operations can be programmed ENTRY IS NIGHT SETBACK Select ON to enable a setback operation Then program the times days and setpoint The setpoint assigned will override the KN control s setpoint when setpoint is controll
80. rol will attempt to bring the controlled tem perature to the setpoint by modulating boilers to meet the demand If temperature tends to overshoot too much adjust the ADD BOILER DELAY STOP BOILER DELAY and MODULATE DELAY settings in the ADVANCED SET UP menu to adapt behavior to the system Member boiler displays will show RUN in the upper left of the display The AA terminals are the high fire override If closed on a MEMBER boiler the boiler runs independently of the MASTER because AA takes priority If AA is closed on the MASTER boiler the HeatNet network shuts down and only the master boiler fires at high fire If using a diverter valve for a DHW tank it is recommended that you use a MEMBER boiler activated with its AA terminals This way the HeatNet and heating loop will still be under control P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS CONTROL MANUAL Troubleshooting Accessing the data log The log stores major events that have occurred during the operationof 4 Notice the snapshot This is a log entry of which there are up to 1 000 the KN series boiler These events include As soon as you enter the view log screen it displays the last log entry Faults the KN series boiler recorded Boilers starting and stopping S To view previous entries press DOWN arrow key Pump activity 6 Ifyou pressed the UP arrow key instead you would have been taken
81. rrected NOTE Momentary closure across J10B terminals ALARM SILENCE will silence the alarm FAULT EVENT amp CAUSE Discussion INTERLOCK TERMINALS DISPLAY Action required to reset from fault AIR SWITCH BLOWER Occurs if the blower remains in prepurge longer than two FAULT SUPPLY Automatically resets minutes The boiler is shut down until the fault is corrected AIR SWITCH BLOWER control after external The display continues showing the SUPPLY HEADER or other 168 e F limit closes temperature whichever had been selected for display The temperature shown is the value detected at the sensor listed COMBUST AIR DAMPER Occurs if closure isn t detected across J12B terminals 7 and 8 FAULT SUPPLY MASTER boiler J12B terminals 7 amp 8 within the allowable time after the damper is activated via the ee Vio EY WM aca Automatically resets J13 BOILER3 DAMPER contact control after external LINKED COMMON damper operation single common damper 1 6 8 F limit closes MEMBER boiler or stand alone boiler The system is shut down until the fault is corrected but attempts a restart every 10 minutes Requires cycling of the boiler ON OFF switch INDEPENDENT damper operation a damper for each boiler The individual boiler is shut down until the fault is corrected and the ON OFF switch is cycled The display continues showing the SUPPLY HEADER or other
82. s that the BMS is no longer operating and the local setpoint saved on the master control is reloaded S This isa fail safe feature used to help safeguard the system in case of BMS failure 6 Ifthe setpoint timer is not written a default timeout value of 60 seconds is assumed 7 To write the system clock registers 40009 40015 must first be loaded with the correct date and time Then a 1 must be written to register 16 to write the date and time to the system clock P N 42 9534 8 08 Copyright 2008 Hydrotherm Multiple boilers BMS operation Table 4 MODBUS holding read write registers Data Description Address Type Boiler System Enable Disable 0 Disabled Off 1 Enabled On 40002 System Setpoint Timer 1 0 65535 seconds 40003 40 F 220 F Outdoor Air Reset Enable Disable 0 Disabled Off 1 Enabled On High Outside Air Temperature 35 F 40 F 0 11 Valid Values Range 40011 Unsigned Set Clock Day of Month 2 40012 Unsigned Set Clock Year 2 0 9 et Clock Minutes 2 et Clock Seconds 2 Unsigned Set Clock Day of Week 2 0 59 1 Monday 7 Sunda Set Clock After the Set Clock Registers listed above have been written a 1 must be written to this location The system setpoint timer and system setpoint work in tandem to externally control i e a BMS building management system the operating setpoint The System Setpoint countdown timer shoul
83. sion 1 x or all must have version 2 x It is preferable for all boilers to have the same version number for consistency If replacing a boiler control or adding a new boiler to a network update the firmware on all boilers particularly if any or all existing boilers have firmware 1 x not 2 x Disconnect wires to the Heat Demand terminals and any other remote operation wiring There must be no call for heat during the process Record all setup information for the application before proceeding use SETUP WORK SHEET page 48 Insert the Firmware Update Program disk or download executable file into the computer The program will auto start if on disk manually execute the program if working from a file on the computer Follow the instructions as the program progresses If a separate option is provided to install USB drivers do so before running the firmware update program Plug a USB cable into the control connection board with the other connected to the computer THE CABLE MUST BE CONNECTED BEFORE STARTING THE FIRMWARE UPDATE PROGRAM Follow the program instructions for selecting the correct com port and firmware file Navigate to the KN control ADVANCED SETUP menu to SYSTEM Move the cursor to LOAD FIRMWARE NOTICE The firmware must be downloaded now for the KN control to function again Return to the computer Follow the firmware program instructions to begin downloading the firmware to the KN control If the down
84. st 2 beeps P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 2 Multiple boilers HeatNet modulation von Table3 Control parameters for HeatNet networks Requirement MASTER boiler Requirement MEMBER boiler SETPOINTS HEAT BAND SETPOINTS LOCAL SETPT SYSTEM SETPT OPERATE LIMIT OP LIMIT BAND SETPT SOURCE OUTDOOR RESET IF USED WWS SETPOINT OA SETPTS SYSTEM PUMP POST PRG TIME ALWAYS ENABLE SUMMER PUMP JOG LOCAL PUMP DELTA TEMP ENABLE PUMP VALVE OPTION FLOW PROVE NIGHT SETBACK OPTIONS all Set if control will regulate boiler supply temp Set if control will regulate header or DHW tank temp requires header sensor Set Set Specify AUTO or 4 20mA remote control AUTO uses the HeatNet control setup values for setpoint temperature 4 20mA uses a 4 20mA signal to determine setpoint temperature as described in Table 9 page 30 Enable if used Enable if used Set if used Set if used requires outdoor sensor Applies ONLY if the control will cycle a system pump as well as the boiler pump Set or keep default Enable if desired Enable if desired Settings for boiler pump Enable if desired requires installing a return water temp sensor Set value if enabled Set or keep default Enable if desired Enable constant pump if desired Enable if used connect flow switch Set if desired Set Not applicable to MEMBE
85. the starter or relay coil Boiler circulator If the boiler circulator is to be controlled by the boiler s HeatNet control power the boiler circulator starter or relay coil through the terminals provided on J13 see Figure 4 page 18 System circulator If the system circulator is operated by one of the HeatNet controls by the MASTER boiler control for HeatNet multiple boiler systems power the boiler circulator starter or relay coil through the terminals provided on J13 see Figure 4 page 18 Sensor wiring e Factory installed sensors KN boilers are provided with a factory installed supply sensor boiler outlet water temperature connected to the terminals on J10 e Header SYS DHW HEADER sensor is required A header sensor SYS DHW HEADER must be installed in the system supply piping or DHW tank for HeatNet con trolled systems Connect the header sensor ONLY to the master boiler Install the header sensor in an immersion well Locate the sensor where it will accurately sense the sys tem water supply temp erature Connect the sensor leads to the MASTER boiler elec trical connection board terminals on J10 as shown in Figure 5 page 19 The header sensor can be used with a stand alone boil er to allow regulation of a primary secondary system or to control DHW tank temperature Outdoor reset application To operate with outdoor reset purchase and install an optional outdoor sensor Mou
86. to Valve activity main and pilot the very first entry The log entries form a continuous ring of entries You can verify this by observing the time stamp as you cycle through Input Type of call for heat H 8 posue 2 Additionalinformation recorded includes 7 Once the log is full 1 000 entries pressing the UP arrow key will show the oldest entry and no longer take you to the first entry The log The of the event in the log cannot be cleared and is a continuous record of 1000 entries Older entries are overwritten Time of event Time stamp The supply water temperature The setpoint 8 To exit the log press the o key he outside air temperature The actual PWM of modulation NOTICE Boiler N on display The display can only show up to 7 f f boilers and this information only appears on the MASTER All of the boilers that are firing Master boiler display To view boilers above number 7 you will 3 See Figure 12 for an explanation of the data on the screen need the Boiler Control Pro software Figure 12 Accessing and using the Log Enter Setup From STANDBY hold o for 5 seconds Then press Oo until the cursor points to VIEW LOG Press with the cursor on VIEW LOG The screen will now show the most recent entry in the log Use the arrow keys to scroll through the log entries Time Snapshot stamp number Water temperature out EE lt Water setpoint Outside air temperature
87. tors RJAS HeatNet cable IN from master or previous member RJAS HeatNet cable OUT to next member boiler Shielded wire 3 2ire option to RJAS cable HeatNet communications INPUT and connection for addi tional boilers on the network Shielded wire optionto RJ45 cable MODBUSINPUT from building management system USB cable port for USB cable connection to a PC required when updating control firmware RJAS cable from building management system when used Plug for insertion into KN control electrical connec tion panel see page 3 NOT SHOWN An optional plug in bridge is required to interface with building management sys tems that use BACnet or LONWORKS protocol The KN control supports MODBUS protocol with no additional components except the 5485 inter face board P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 3 Option 1 Combined BMS HeatNet 1 This method uses an RS485 digital communications cable with the MODBUS protocol to control a boiler or HeatNet network The boiler or boiler network will operate as in the HeatNet local control method Section 1 of this manual But in stead of the HEAT DEMAND input a software form of the HEAT DEMAND input is used address 40001 Boiler System Enable Disable The System Setpoint Timer needs to be loaded periodically to allow the HeatNet system to revert to local control from the master boil
88. ure gets within the limit ontrol limits boiler firing rate when in band degrees F below the operating limit X limit band setting At the lower end of the limit band the Bel 05 5 e e boiler fire to maximum input 100 ee oe up io the time the temperature reaches the upper P water temperature is end of the band the OP LIMIT setting the h ba below _ boiler is limited to minimum input 20 Example If OPERATE LIMIT is set to 220 F and OP LIM BAND is set to 30 F the boiler will begin to reduce firing rate when the SUPPLY temperature in the boiler exceeds 220 30 190 F The boiler firing rate will be reduced to minimum when SUPPLY temperature reaches 220 F The boiler will shut off if the SUPPLY temperature rises above 220 F Restart The boiler will not fire again until the SUPPLY temperature drops below the bottom of the OP LIM BAND For the example above the boiler will be allowed to come on again below 190 F The limit band reduces the likelihood of short cycling on boilers controlled by a master control or a remote control by reducing boiler maximum allowable firing rate as the temperature rises toward the limit setting Make sure the lower end of the limit band is above the upper end of the heat band SETPOINT SOURCE SETPOINTS Specifies where the space heating setpoint temperature comes from AUTO With AUTO selected the KN HeatNet control determines the setpoint
89. ure sensor optional l Outlet water temperature sensor required So Return water temperature sensor optional System DHW water temperature sensor optional connect only to Master boiler KN304 KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 5 Wi ri n g continued Figure 6 Field wiring relays interlocks and boiler status Low voltage The highest priority interlock interlocks that opens will be displayed QU QU QU QU QU QU 24 VAC as the fault JA Priority lt System flow prove 1 Interlock Relay K3 11 Low Water Cutoff 2 Boiler start i i System pump Relay Ki Variable Frequency Drive 3 J1 id ERN 2 Gas Pressure High amp Low 4 Combustion air gt lt Spare for user or Factory 5 damper activate oe mem Relay K5 J11B Operator 6 Boiler circulator or gt E lt Water Flow Switch T valve activate Relay K6 3 lt UV Sensor Air Switch 8 Alarm Alarm contacts close during a fault condition QUO 2 E NOTE Spare interlocks can be b J12A O used as REMOTE interlocks QD E 0 uzzer E J10A 10 QI
90. x D 8 0 8 7 D 8 0 l n T4 terminals 7 5 T4 terminals 7 x T4 terminals 7 o du QU eee 1 cues ce 4 End s D s switch EN eee an ae a ee eR Pe E l ea 24VAC Transformer for CAD motor by others V Earth ground the transformer secondary k aU P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL 5 Wi ri n g continued Figure 7 Field wiring connections for 4 20mA remote operation DOS Interlock Relay K3 Boiler start Relay K1 c of Boiler other Relay K4 Boiler 3 Relay K5 Circulator Relay K6 99999999 Alarm Relay K2 J12A a Buzzer J12B Closing Contact here enables the 4 20 ma O control input CA C2 ee O 24VDC Return 4 20ma 0 10vdc Modulating controlinput O 4 20ma 0 10vdc O 24VDC KN302 Jumper left to center for 0 20 mA Jumper right to center for 0 10 VDC P N 42 9534 8 08 Copyright 2008 Hydrotherm S KN SERIES GAS FIRED DIRECT VEN
91. xternal limits wired into the limit circuit connections The control shuts down the boiler if a limit opens and the digital display shows which limit failed Monitored limits include high limit aquastat low water cutoff flow ignition control fault gas valve alarm and other optional or user selectable limits Multiple boiler operation The HeatNet control easily interfaces with other HeatNet controls Multiple boiler operation using HeatNet protocol only requires RJ45 cables daisy chained from boiler to boiler and a few key strokes setting up control behavior The master boiler is automatically selected by connecting a sensor lead to its SYS DHW HEADER sensor terminals The HeatNet control recognizes the sensor and configures the boiler as the master Other boilers only need to have an address assigned Among the advanced design features of the HeatNet control is the MOD MAX setting This limits the firing rate of all boilers to a pre set maximum 70 by default This means all of the boilers will be run at a very efficient level until all boilers are on Only then can firing rate increase above this setting Boiler rotation can be first on first off first on last off or true rotation the HeatNet control monitors the total on time of all boilers and rotates their usage so the total on time is the same for all P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CAST IRON BOILERS CONTROL MANUAL Hydrotherm KN Ser
92. ypical line Display shows four lines at a time cursor indicates active line Total time gas valve has been open Current entry in the log see Table 9 page 30 Number of times gas valve has been cycled on off BOILER CYCLES AUX FUNCTIONS COMBUST AIR DAMPER TYPE LINKED COMMON LINKED COMMON or INDEPENDENT IN USE NO YES or NO TYPE LINKED COMMON f IN USE NO INPUT J10B DANNER a DER oe 7 inge i un required INPUT J12B DAMPER to maintain existing wiring on boilers with an older edition of the firmware that PROOF TIME 2 00 used J10 B instead of J12 for this interlock PROOF TIME 2 00 minutes 0 to 4 minutes ALARM SILENCE IN USE YES YES or NO ALARM SILENCE SWITCH IN USE YES INPUT J10B SPARE 2 see explanation Table 9 page 30 INPUT J10B SPARE 2 FAILSAFE MODES RUN IN LOCAL IF RUN IN LOCAL IF H NET COMM LOST ON ON or OFF H NET COMM LOST OFF LOW TEMP OFF SUPPLY SYS DHW HEADER RETURN N A or OFF LOW TEMP OFF TEMP LESS THAN 40 F 35 to 200 F TEMP 40 F HEAT EXCHANGER EXCHGR DELTA 100 F 1 to 120 F ADAPTIVE INPUT EXCHGR DELTA 120 F LIM gt HALF RATE LIM gt HALF RATE NO NO YES or NO See explanation Table 9 page 30 TIME 11 20AM SYSTEM CLOCK TIME DAY OF WEEK MON DAY OF WEEK MONTH JAN NEXT MONTH DAY FRI YEAR 2008 PRESS SEL TO SAVE YEAR P N 42 9534 8 08 Copyright 2008 Hydrotherm KN SERIES GAS FIRED DIRECT VENT CASI IRON BOILERS

Control menus and adjustments (continued)

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