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HeatNet® manual

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1. DHW PUMP PUMP OPTIONS If set to N A the boiler s local circulator will be energized for all heat demands including DHW KN4 ONLY If set to ENABLE the local circulator will be used on all heat demands EXCEPT DHW demands and the BYPASS contacts will be used to energize a DHW pump for DHW demands No Priority is given if there isa DHW demand AND a Heat Demand then both pumps would be active If set to PRIOR the local circulator will be used on all heat demands EXCEPT DHW demands and the BYPASS contacts will be used to energize a DHW pump for DHW demands Priority is given to DHW demands if there is a DHW demand AND a Heat Demand then only the BYPASS contacts would be enabled If set to MULTI the local circulator will be used on all heat demands EXCEPT DHW demands and the BYPASS contacts and the local circulator will be energized for DHW demands NOTE The Bypass contacts will have a 2 minute post purge time for the DHW pump SETBACK NIGHT SETBACK Setback number is the designator for the setback operation Up to four 4 setback operations can be programmed KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations continued Explanation NIGHT SETBACK Select ON to enable a setback operation Then program the times days and setpoint The ENTRY IS setpoint assigned will override the KN control s setpoint when setpoint is cont
2. 7 Input Variables Read Only continued KNSLM KN2 KN4 modbus registers continued 30221 Boiler14DHWTemp 30222 Boiler15DHWTemp 30237 Boiler14Modulation 30238 Boiler15Modulation 30239 Boiler16Modulation 30240 OperatingSetpoint 16 bit signed E Boiler 1 16 DHW temperature if available 32 250 F This value is taken from the return sensor if the DHW uses return sensor option is enabled See BoilerStatus4 to determine if the sensor is present BoilerO1 Master or Connected Boiler BoilerO2 Member01 Boiler16 Member15 The running display modulation This 0 100 is typically the actual running modulation except under special circumstances when the boiler is running in a self protection mode Op Limit 1 2 Fire Rate etc BoilerO1 Master or Connected Boiler BoilerO2 Member01 Boiler16 Member15 This is the current operating or active 40 220 F setpoint It may be 1 The normal heating setpoint 2 The DHW setpoint if running in DHW mode 3 A calculated setpoint if running in Outdoor Air Reset Mode 4 The 4 20ma 0 10V setpoint KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued BoilerStatus1 Flags a a a CE CA Ea es or DC oE Foo Boiler Detected not detected 1 detected A boiler was detected at this address 1 Available in Firmware Version 2 70 BoilerStatus2 Flags Disabled 0 enab
3. ADVANCED SETUP This is used only when the boilers are regulated by a building management system using DISTRIB CTRL MODBUS BACNET or LONWORKS Assign each member boiler AND the Heat Net master boiler a unique address an value from 1 to 247 S KN USER S CONTROL MANUAL Control menus and adjustments continued Table 8 Setup menus parameter explanations continued ADVANCED SETUP MODULAR BOILER ADD BOILER DLY ADVANCED SETUP MODULAR BOILER SHED BOILER DLY ADVANCED SETUP MODULAR BOILER MOD DELAY TIME ADVANCED SETUP MODULAR BOILER MOD MAX LAST ADVANCED SETUP MODULAR BOILER STOP BAND OFSET ADVANCED SETUP MODULAR BOILER BLR START TIME ADVANCED ADAPTIVE MODE ADAPTIVE ADVANCED ADAPTIVE MODE ADJUST ADVANCED ADAPTIVE MODE HOLD TIME ADVANCED SETUP FIRING MODE ROTATION ADVANCED SETUP FIRING MODE MASTER 1ST ADVANCED SETUP SENSORS ADVANCED SETUP SENSORS TYPE This is the minimum wait time before an additional boiler can fire when called on by the master boiler control This time is also used to limit the maximum modulation the boiler can obtain when first starting in response to a 4 20mA or High Fire Demand This is the minimum wait time before a boiler can shut down by the master boiler control The boiler will remain at minimum fire when first starting until this amount of time has elapsed This sets the maximum firing percentage for boilers during ti
4. 14 awg Use appropriate wiring materials for units installed outdoors Overview control setup sequence AV AND a caution Follow the Boiler manual Install the boilers according to the KN Boiler manual before attempting to set up the control system This method can be used for from 1 to 5 boilers Install all boilers per the Boiler manual Close the external gas valve on every boiler Wire all boilers following the guidelines in this section DO NOT install a header sensor on any of the boilers Disconnect the wires to the boilers Remote Enable terminals and any override wiring to Heat Demand or DHW Demand terminals to ensure there will be no call for heat while proceeding Set the boilers control parameters using their display keypads Follow the instructions in the Boiler manual to start up each boiler before proceeding further Finish by reconnecting call for heat wiring then operating the complete system to verify operation in all modes Connect 4 20mA wiring l See Figure 16 for wiring from the 4 20mA controller The control must provide the 4 20mA signal and a contact for each boiler to enable its operation by closing across the Remote Enable contact Power supply 120 VAC See Figure 11 and Figure 12 Connect minimum l4awg copper wire to the power connection as shown in Figure 12 Install a fused service switch mounted and installed in accordance with all applicable codes
5. 30065 BoilerO9Runtime Low16 30066 Boiler10Runtime High16 30067 Boiler10Runtime Low16 30068 Boiler1 1Runtime High16 30069 Boiler1 1Runtime Low16 KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued Input Variables Read Only continued Address a 2Runtime High16 30071 Boiler1 2Runtime Low16 30072 Boiler1 3Runtime High16 30073 Boiler1 3Runtime Low16 30074 Boiler14Runtime High16 30075 Boiler14Runtime Low16 30076 Boiler1 5Runtime High16 30077 Boiler1 5Runtime Low16 30078 Boiler16Runtime High16 30079 Boiler16Runtime Low16 Name RawData Type Data Raw DataType Scale Description Description Valid Valid Values Range 16 bit unsigned 16 bit signed Boiler 1 16 status3 flags These bits See the BoilerStatus3 Flags in indicate the state of various boiler statuses Appendix A Boiler01 Master or Connected Boilers Boiler02 Member01 Boiler16 Member15 Boiler 1 16 supply temperature if avail 32 250 F able See BoilerStatus2 to determine if the sensor is present Boiler01 Master or Connected Boilers Boiler02 Member01 Boiler16 Member15 KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued Input Variables Read Only continued Address Name Raw Data Type 30109 Boiler14SupplyTemp Boiler15SupplyTemp 30112 Boiler01ReturnTemp 16 bit signed 0 01 Boiler 1 16
6. Indoor Air Reset wiring apply ONLY if using space heating override mode IAR can only be used if one or more of the boilers is wired and piped for override operation Override would occur when a contact closed across the Heat Demand terminals While this contact is closed the boiler will operate based on local control including feedback for IAR if wired If override operation will be used and you want to operate with LAR when in override mode follow the instructions under Method 1 in this manual to wire for IAR wiring Header sensor cannot be used when the boilers are configured for remote operation by a 24 mA source Outdoor reset application can be done only in override mode To operate with outdoor reset purchase and install an outdoor sensor Mount 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 master boiler s electrical connection board as shown in Figure 8 Member boilers could have their own outdoor sensor if they will be operated in override mode by closing the Heat Demand terminals Return water temperature sensor The return water temperature sensor is optional only needed if you want to automatically control the boiler postpurge pump cycle time Install the sensor in a well in the boiler return piping Connect the sensor leads to the electrical connection board as shown in Figure 8 Ea
7. circulator or boiler system circulator to the terminal strip ofthe KN 2 electrical connection board M 120v DO NOT directly connect a circulator with a motor larger than 1 4 hp For larger motors install a circulator relay or 0 gt motor contactor Figure 13 and Figure 14 show the correct ways to install the boiler circulator using a relay or motor al starter O _ c 7 SS Sse E Figure 13 Wiring the boiler circulator using a circulator l i g g e g M Dry contact out to remote alarm relay required for motors over 1 4 hp e O Alarm contact closes on open or 4 E 120VAC 60HZ 1Ph Zo shorted sensor ignition lockout E g NO H i flow switch or user interlock ie combustion air damper failure Circulator relay j en i blocked flue or blocked air inlet with internal scr All boilers can be connected to 24VAC transformer p alarm by wiring in parallel gt a b E O D E Lo ro s i Boiler circulator 6 8 or S ad Eui DO NOT directly connect enn 120 VAC i lt 4 circulator if motor is over 1 4 HP 20209 son Use a motor contact or relay N j S n 120VAC Figure 14 Wiring the boiler circulator using a relay or pati starter required for motors over 1 4 hp oe NO j 4 a 120VAC 60HZ 1Ph Fused service switch by installer we N HQ 2 i D 120 VAC Relay or motor oo starter with 120VAC coil Y Boiler circulator lt lt A
8. ready to start the boiler up following the Boiler manual instructions Start up boilers per KN Boiler manual l 2 Turn off power to all boilers Follow all instructions in the KN Boiler manual to start up each boiler and verify operation Start the system l 2 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 The boilers should now operate normally as described in the Boiler manual The remote 4 20mA controller will sequence and modulate boilers as necessary to control the water temperature Table6 Control parameters Parameter When to set see notes HEAT BAND Set LOC SETPOINT AUX FUNCTIONS DO NOT use SYSTEM CLOCK LOCAL ADD DO NOT use MODULAR BOILER MODULATION PID PASSWORD COMMUNICATIONS Only as required LOAD DEFAULTS Only as required SYSTEM Only as required Notes 1 HD Only means to set the parameter for a member boiler only ifit is wired for Heat Demand override 2 DHW Only means to set the parameter for a member boiler only ifit is wired for DHW Demand override 3 HDOA Only means to set these parameters only ifthe member boiler will be operated with outdoor reset when put in override mode with closure across its Heat Demand terminals requires outdoor sensor connected to boiler KN USER S CONTROL MANUAL Failsafe Modes FAILSAFE MODES have been added to help protect
9. the boiler will only operate if activated by an override input HD DHW 4 20mA FAIL SAFE MODE LOW FIRE or HIGH FIRE When set to YES the boiler will revert to LOCAL operation controlling its Supply water temperature to the LOCAL SETPOINT setting The LOCAL PUMP relay will remain ON during failsafe operation NOTE Failsafe boilers can be used to attempt to prevent deadheading system pumps by opening their local valves in the event the master control goes down If the failsafe member boiler has its Master Pump setting to ON and it does not see communication from the master for 30 seconds it wil energize its local pump valve contacts NOTE If the Master Pump setting is not set to ON then the control will wait 10 minutes after losing communications with the HeatNet master before switching to local operation NOTE If a Combustion Air Damper is in use make sure the Fail Safe boiler is able to open and prove the damper LOW TEMP AUX FUNCTIONS This function can automatically start the boiler or boilers via the Master if water temperature FAIL SAFE MODE drops below the value set in TEMPSET lt This function can be used to provide automatic freeze protection The LOCAL PUMP relay will be set to always ON during failsafe operation Once the boiler setpoint temperature is reached the boiler or boilers will shut off Select which sensor to monitor SUPPLY RETURN or HEADER NOTE If a Combustion Air Damper is in use make sure the Fail
10. waits until the newly added boiler reaches its run state before lowering the modulation rate of running boilers ON CALL the Master boiler ADAPTIVE is ON drops the modulating rate of running boilers immediately when an additional boiler is called When ADAPTIVE is ON the Master boiler waits this amount of time before allowing the system to return to normal modulation This delay allows time for the newly added heat to impact the system Select the rotation method True rotation attempts to fire all boilers an equal amount of time First on first off jogs between boilers to balance usage Last on first off maintains the same rotation sequence at all times Set this to ON to always start the master boiler first regardless of the rotation scheme selected There are up to three sensors OUTSIDE HEADER and RETURN Type Z is for a thermistors sensor as supplied by HydroTherm None means do not use this sensor ON OFF looks for an external dry contact closure KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations continued CALIBRATE ADVANCED SETUP Use this function only if the response to a sensor indicates the control calibration may be off E Calibrate the control by attaching a 10k precision resistor across the sensor terminals Select YES after CALIBRATE The control will measure the resistance and establish a trim value in
11. wires to the Heat Demand 120VAC terminals on the electrical connection board 20205 KN USER S CONTROL MANUAL Method 1 HeatNet modulation local control on Figure 7 KN wiring summary wiring to electrical connection board Also see Figure 2 page 6 POWER SERVICE Factory wiring harness plugs LF LA A DIP SW alla aia 1234 15 amp fused service switch by installer Electrical connection board Located in center panel on boiler right side 120VAC 60HZ 1Ph Power to boiler Wire Harness 70 2043 r es i Factory Wiring Do Not Change IN m J9 Control Inputs 7 i a E z _ IEE EER REMOTE HEAT DHW LOW HIGH ENABLE DEMAND DEMAND _ FIRE FIRE U Use these terminals only during boiler setup as given in the Boiler manual Com Tank Aquastat The boiler is shipped with a jumper across the HEAT DEMAND terminals Remove this jumper when using a thermostat or other external control to start the boiler CS i Master boiler Room thermostats end switches or relay contacts Connect thermostat zone valve end switches or remote start relay contact here Test when done to ensure no stray voltage is present on any of the wires See the Boiler manual for procedure Master boiler Connect override contacts only Individual boilers if piped appropriately can be activated for override operation such as DHW heating or emergency space h
12. 1 65535 Every second this value will decremented If it reaches zero the local permanently As an example if it is decided that the BMS will write the control every 5 minutes you may decide to write 600 seconds 10 minutes to the setpoint timer If after 10 minutes 5 minutes longer than the normal write interval the BMS has not written the timer the saved setpoint values will be restored As a convenience the SETPOINT TIMER is automatically loaded with 60 seconds if it has fallen below 60 each time the setpoint is written If you decide to take advantage of this convenience you would need to write the setpoint periodically at less than 1 minute intervals Newer firmware versions allow the SETPOINT TIMER failsafe feature to be disabled by writing a zero 0 to the timer The feature will automatically revert back to the enabled state whenever the control is reset or power cycled The SETPOINT TIMER failsafe feature can permanently disabled or enabled in firmware versions 2 5 or greater This setting can be changed in the ADVANCED SETUP gt COMMUNICATIONS menu KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers Input Output Variables Read Write 40001 HeatDemand 1 bit unsigned Heat Demand Request Setting the state 0 no heat demand member of this variable will put the boiler in 1 heat demand heating mode 40002 SetpointTimer 16 bit unsigned System Setpoint Timer 0 65535 seconds The system setpoin
13. AN circulator s Postpurge Boiler circulator circu ator 5 or boiler system circulator 20210 KN USER S CONTROL MANUAL Method 3 External 4 20ma control continued ni 20mA operation A 4 02 mA current signal will start the boiler at low fire A 20mA signal will cause the boiler to go to full input 2 Between these input signal limits the boiler modulates The boiler firing rate percentage is equal to the percentage of the signal between 0 and 20 mA Example a signal of 12 mA is 60 of 20 mA so the boiler firing rate would be 60 of max 3 In addition to the 4 20mA signal the remote controller must also close a contact across each boiler s Remote Enable contact in order for the boiler to fire 4 See Figure 16 for wiring Notice that the boiler 4 20mA terminals are wired in series When using the 4 20 mA input for direct modula tion the maximum modulation the boiler can obtain when first starting is equal to the ADVANCED SETUP MODULAR BOILER MOD MAX LAST FIRE The timer value ADVANCED SETUP MODULAR BOILER ADD BOILER DELAY is used in conjunction to limit the modulation for this amount of time Once the boiler has fired and the ADD BOILER DELAY time expires the full modulation is available When the boiler is operating under these conditions a blinking is displayed This is a protective means for extending the life of the heat exchanger which may consistently be exposed to thermal stress IAR
14. Method 3 External 4 20ma control Electrical connection board see item 10 page 3 for location Also see the wiring summary illustrations on the next pages Figure 11 n Factory wiring harness plugs Ii ti Ta i F i mi F i i i J j did Iid anng Ff i in i es O O 20226 Figure 12 120VAC power service terminals on electrical connection board See Figure 15 for location of the power terminal strip POWER SERVICE 120VAC 15 amp fused service switch by installer Gnd NO H 120VAC 60HZ 1Ph Power to boiler KN USER S CONTROL MANUAL Method 3 External 4 20ma control continued Circulator wiring Figure 15 Circulator wiring terminal strip see Figure 11 for location Also see the wiring summary Postpurge circulator KN 2 only illustrations on the next pages The circulator shipped installed with the boiler can not be used for system circulation It must be used as supplied from the factory It circulates water after the boiler stops firing to prevent potential damage from heat pocketing in the top of the heat exchanger The postpurge circulator is factory piped and pre wired Do a not change the usage the wiring the location or the piping ryvyyyyy Boiler circulator See the Boiler manual for circulator piping l l l Figure 13 Figure 14 and Figure 15 show wiring of the Boiler BYPASS CIRC ALARM OPT
15. NO COMMUNICATIONS 19200 1200 or 2400 or 4800 or 9600 or 19200 or 38400 FORMAT 8 81 8M1 8N2 801 serie OOO S LOAD DEFAULTS FACTORYCAL NOTYESorNo _ www w e HOS NO NO Z TJ 4 2 1 2 l V Mmv 701 wn ARE YOU SURE gt YES or NO SYSTEM UPDATE CTRL ARE YOU SURE gt YES or NO PRIORITY SET LS 2 2or1 KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations FIRMWARE VERSION HEATNET BOILERS HEAT BAND LOC SETPT SOURCE DHW SETPT BOILERS BOILERS SETPOINTS SETPOINTS SETPOINTS lt 2s Explanation All boilers in a multiple boiler application should preferably have the same firmware version to ensure consistency If versions are different they must all have the same first digit in the version number i e 2 x This line appears on the display only for a HeatNet Master boiler boiler with a sensor connected to the SYSTEM HEADER 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 flashing indicating network traffic 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 M the address
16. Safe boiler is able to open and prove the damper TEMP SET lt AUX FUNCTIONS Set the minimum allowable temperature for the location selected in LOW TEMP above PAE SATE MDEE NOTE If a Combustion Air Damper is in use make sure the Fail Safe boiler is able to open and prove the damper AUX FUNCTIONS This is the amount of time that a HEAT DEMAND must be present before the boiler is allowed to fire The circulator pumps will come on normally only the boiler ignition will be delayed EXTENDED PURGE AUX FUNCTIONS This is the amount of time the fan post purge can be extended from the required 10 seconds A demand during the extended purge will end the purge cycle and allow the boiler to fire and IGN DELAY TIME handle the demand DELTA T AUX FUNCTIONS This is the maximum differential temperature the heat exchanger can see before the LIMIT RATE HEAT EXCHANGER feature is activated and a log entry is made 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 LOCAL ADD ADVANCED SETUP Assign each member boiler a unique address beginning with 2 or higher Enter any value from 2 DISTRIB CTRL to 16 The master boiler local address is automatically set to 255 The master boiler is automatically recognized because it is the one with a header sensor wired to its HEADER SENSOR terminals CONSOLE ADD
17. assumes that the BMS is no longer operating and the local setpoint saved on the control is reloaded If the setpoint timer is not written a default timeout value of 60 seconds is assumed The timer is automatically reloaded with the default value when a setpoint is written 2 HeatNet Communications Lost SETUP AUX FUNCTIONS FAILSAFE MODES H NET COMM LOST This mode allows a member boiler to run in LOCAL if the communications link via the H NET cable is lost This includes the MASTER boiler losing its Control board Communications board or the power on the MASTER is switched OFF When this MODE is set to ON and if the member boiler loses it s link heartbeat packet over the H NET cable to the MASTER Boiler this MEMBER will fire to the LOCAL setpoint NOTICE Failsafe boilers can be used to attempt to prevent deadheading system pumps by opening their local valves in the event the master control goes down Ifthe failsafe member boiler has its Master Pump setting set to ON and it does not see communication from the master for 30 seconds it will energize its local pump Vvalve contacts NOTICE If the Master Pump setting is not set to ON then the control will wait 10 minutes after losing communications with the HeatNet master before switching to local operation This MEMBER boiler will continue to run at the LOCAL setpoint until H NET communications from the MASTER boiler is re established Ensure that this Member boil
18. ee nvSetclc 0 59 Faoois setsecond shit unsigned Set realtime cock second ee Setclocd 0 59 Taoore ees Bit unsigned _ __ Set realtime dock weekdoy Gee Setlocl 1 Wonday 7 Sunda 40017 SetClock 1 bit unsigned Set write the real time clock 0 no action 1 set write the clock To write the real time clock the system vari ables SetMonth SetMonth SetDay SetYear SetHour SetMinute SetSecond SetWeekday must first be loaded with the correct date and time Then a 1 must be written to the state portion of this system variable to write the new date and time to the system clock The following registers are available starting if firmware version 2 70 40018 DHWSetpoint 16 bit signed DHW Setpoint 40 200 F 40003 8 bit unsigned 1 0 0 O KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued Input Variables Read Only 30001 Boilerson 8 bit unsigned eae The number of boilers currently running 30002 Modulation 8 bit unsigned Current system target modulation level This 0 100 is the modulation level that the system is trying to run at to meet the heating demand oo spre t6bitsigned gt RawA Dvaluefiomspare tinput 22768103277 C E E rane e E i a ieee ie Bona Hour ebrunsona Realtmeclockhous fpa o ons Minute abitunsigned Realtimeclockminute os oa second J abitunsigned _ Realtime clocksecon fos 2001s weekday ___ e
19. member boilers by cabling from one to the next Connect incoming cables to item 1 or 4 Figure 10 Connect outgoing cables to item 2 or 4 Note that shielded cable wires will share terminals when using item 4 Check the network 1 Turn the power on and the on off switch to ON for all of the member boilers 2 Allow time for each boiler to initialize 3 After about 30 seconds the master boiler should recognize the member boilers A Navigate to the BOILERS menu then to HEAT HEAT HET BOILERS NET BOILERS display The master control will show the boilers it recognizes iar ae aie oe Leo SSB Peo yt yetatyts 5 If the display shows a blank space such as 123 56789 the control does not detect 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 Ifa 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 D PON DN Start the system 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 The boilers should now operate normally as described in the Boiler manual ee Sf The ma
20. ohms for the sensor input 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 HydroTherm 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 20mA SETPOINT ADVANCED The 4mA SETPOINT and 20mA SETPOINT establish the temperature range when the boiler system 4 20mA INPUT is operated with a remote 4 20mA setpoint Set the 4mA SETPOINT to the starting temperature 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 START val
21. systems from loss of heat conditions When using one of these modes ensure that you connect any DAMPER control or system pump control to safely allow operation with the assumption that the MASTER boiler or BMS system is DOWN Failsafe requirements 1 Ifthe combustion air damper is used as a common system damper the Failsafe boiler should be wired to control the damper in parallel with the Master boiler See Figure 9A 2 The Failsafe boiler must have the LOCAL SETPOINT set to the same setpoint temperature as the Master boiler s SYSTEM SETPOINT Be aware that the boiler may start without a call for heat in the FAILSAFE MODES FAILSAFE MODES can be accessed through the SETUP AUX FUNCTIONS FAILSAFE MODES The following are types of Failsafe conditions 1 Building Management System Failure Master Boiler Only If a BMS system is controlling the setpoint and enabling the boiler system a timer is provided to allow operation of the system in the event that communications are lost with the BMS system The HeatNet boiler system will run locally if communications is lost and this timer expires due to the lack of being updated The system setpoint timer and system setpoint work in tandem to externally control i e a BMS building management system the operating setpoint The setpoint countdown timer should be loaded with a timeout value in seconds prior to writing the system setpoint When the timer reaches zero the control
22. 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 milliamp signal value This is the setpoint temperature for the boiler outlet water or header water temperature when the DHW Demand terminals see a closed contact DHW tank temperature control calls for heat for example KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations continued Explanation OP LIMIT SETPOINTS This is the temperature at the boiler outlet or header sensor that will cause the control to shut down on high temperature limit It must be high enough above the upper end of the heat band to avoid nuisance cycling The maximum setting is 205 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
23. the demands from the building management system Each boiler requires the RS485 interface board and cable above Boiler setup is essentially the same as for method 1 with the exception that each boiler must be assigned both a HeatNet network address and an address for the Modbus interface An additional bus is required to interface with systems using BACnet or LonWorks protocol The master boiler will take control and regulate the boiler network if signal from the BMS is lost or times out 3 Method 3 External 4 20ma control page 16 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 DHW Demand terminals 4 Failsafe modes ccesecececsesees Page 22 5 Control menus and adjustments page 23 Operating parameters and control behaviors are set using the KN control display keypad interface Refer to this section for the menu structure and explanations of the setting options 6 Troubleshooting 2 page 35 7 Communication Registers page 40 KN USER S CONTROL MANUAL l WARNING Electrical shock hazard Disconnect all electrical power sources to the boiler before making any electrical connecti
24. 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 5 minutes If you are not using the combustion air damper then it needs to be disabled in the AUX FUNCTIONS menu The prove switch for the combustion air damper is not closing Check to make sure the dampers are being controlled by the output relay you specified when programming for the damper Also check to make sure the prove switch is working properly If there is no proving switch you must put a jumper wire across input connection USER INTRLK 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 There may exist a grounding problem with the controller or one of the boilers pumps contactors or other devices connected to it If all grounding is correct there may be an issue with radiated or induced electrical noise interference This may be caused by arcing across a contactor s contacts when starting a pump motor or a large electrical loa
25. 0210 Figure 5 Circulator wiring terminal strip see Figure 1 for location Also see the wiring summary illustrations on the next pages ALARM OPT lt gt i RO To combustion air i damper motor power 5 supply and motor f S master boiler ONLY E ha see wiring summary OQ illustrations for m Z more information j Oo a n l Dry contact out to remote alarm Alarm contact closes on open or a T shorted sensor ignition lockout flow switch or user interlock OD combustion air damper failure o blocked flue or blocked air inlet ag All boilers can be connected to W alarm by wiring in parallel i U DO NOT directly connect lt circulator if motor is over 1 4 HP o Use a motor contact or relay N m 120VAC Power to circulator E O O H Fused service switch by installer m n Gnd 120 VAC g Postpurge circulator KN 2 only Boiler circulator or boiler system circulator KN USER S CONTROL MANUAL l Method 1 HeatNet modulation local control on IAR Indoor Air Reset wiring when used Heat Demand terminal connections The end switch leads from the zone valves must connect to the Heat Demand terminals on the electrical connection board as shown in Figure 7 See Figure 6 for typical wiring to the IAR inputs when using 4 wire zone valves without a zone controller For other applications such as circulator relays or zone controllers see A
26. 72 2883 www hydrothermkn com
27. 9 for location of the switches 3 See Table 1 for required settings The table gives settings for HeatNet modulation local control and for remote control from a building management system Modbus protocol 4 DO NOT 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 KN USER S CONTROL MANUAL I Method 1 HeatNet modulation local control con Figure9A KN2 KN4 multiple boilers with a single combustion air damper Boiler 1 Boiler 2 Boiler 3 J11 J11 OPT S ols Pa ALARM CIRC BYPASS S S 9 9 9 QOOVOOOD AEAEE USER FLOW HIGH LIMIT OOVOOY PS essed PS Besaet End Switch O i Bic oe 24VAC Q CAD Motor 24VAC Transformer for CAD motor by others KN USER S CONTROL MANUAL l Method 1 HeatNet modulation local control von Table2 Control parameters Close the external manual gas valve on every boiler before proceeding DO NOT open any gas valve or attempt to fire any Parameter Master Member boiler until the boilers have been set up and verified following boiler boiler the instructions in the KN Boiler manual see notes Failure to comply could cause a boiler failure leading to possible HEAT BAND Set on master boiler only severe personal injury death or substantial property damage LOC SETPOI NT o Set HD only SOURCE Set HD o
28. ARM 120V O External high limits low water cut offs or other limits if used HIGH FLOW USER LIMIT SWITCH INTRLK Water flow switch if used Remove factory jumper across FLOW SWITCH terminals when using a flow switch Factory wiring DO NOT change Dry contact out to remote alarm Alarm contact closes on open or shorted sensor ignition lockout flow switch or user interlock combustion air damper failure blocked flue or blocked air inlet 120 VAC ONO Om H ovac Fused service switch by installer Power to 120 VAC n circulator aoe m Gnd DO NOT directly connect circulator if motor is over 1 4 HP Use a motor contactor i Jj Postpurge circulator KN 2 only This circulator is factory pipe and wired It circulates water in the boiler after shutdown to prevent overtemperature in the top of the boiler DO NOT remove or use in any other manner It cannot be used for system circulation wired by the boiler installer See the suggested piping diagrams in the Boiler manual for circulator application and piping IMPORTANT If the circulator motor is larger than 1 4 hp connect the circulator using a motor contactor Outdoor sensor water if used sensor Override if used mode Supply sensor Boiler circulator ONLY factory or boiler system circulator installed to boiler This circulator must be supplied piped and outlet 20239 KN USER S CONTR
29. F VIEW IAR VALUES Display only not changeable here shows values for 8 zones OUTDOOR AIR OA SHUTDOWN rr ee OFF ON or OFF OA RESET S OFF ON or OFF SET OA SETPTS sae 140 F 60 to 190 F HIOA 70 F 50 to 90 F LOWOA 10 F 35 to 40 F PUMP OPTIONS FlowPROVE fd 10s 10 2405 Poamews OF nr Poamrewr _ 0 sr Peuncetme Pawson _ int Pwstenrun Yer DHW PUMP KN4 ONLY a eee N A NA or ENABLE or PRIOR or MULTI KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 7 Setup menus see Table 8 for explanations continued ENTRY IS OFF SETBACK fF 20 F 0 t0 50 F TOY SUN SUN MON TUE WED THU FRI SAT ENDDAY sf SUN SUN MON TUE WED THU FRI SAT wa S o o C a C a A or LOG RUNTIME PRUNHRS ff Total time gas valve has been open PuoGeNTRY ff Current entry in the log see Table 9 page 30 BOILER CYC nn Number of times gas valve has been cycled on off AUX FUNCTIONS COMBUST DAMPER CAD IN USE I YES YES or NO PROOF TIME oOo O 2 00 0 00 to 4 00min DHW PROTECTION SS OFF OFF 60 90 120min DHW CYCLE MAX IN USE NO YES or NO FAIL SAFE MODE BMS LOST Ea OFF OFF or ON H NET LOST a OFF OFF or ON LOW TEMP ee OFF OFF or SUPPLY or RETURN or HEADER TEMP SET lt P 40 F 35 to 180 F Peeves __ noone rsaonin oe OT Pwarecimce oat i room Poworwee S a wow o o o C S 0 E a A E T T R e yam in iN T 7 TI oN
30. KN 2 4 CM2 81 1 42 9452 Hydro Therm CERTIFIED ENERGY STAR WARNING 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 WARNING 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 CAUTION Afix these instructions near to the boiler water heater Instruct the building owner to retain the instructions for future use by a qualified service technician and to follow all guidelines in the User s Information Manual KN USER S CONTROL MANUAL The KN boiler HeatNet control Control overview The KN HeatNet control monitors boiler temperature and limit circuit inputs modulating boiler firing rate to meet demand The control uses micr
31. OL MANUAL 3 Method 3 External 4 20ma control continued 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 Boiler manual Failure to comply could cause a boiler failure leading to possible severe personal injury death or substantial property damage Set control parameters on keypads NOTICE Before turning boilers on to set parameters disconnect all call for heat wiring at the electrical connection boards including the wiring to the boilers Remote Enable terminals This will prevent the boiler for attempting to cycle during the setup process See Control menus and adjustments for a complete list of control parameters and explanations Carefully read the parameter explanations in Table 8 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 System clock Set the system clock on all boilers to ensure the time stamps will be accurate in the data logs 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 23 After setting a boiler s parameters turn the power off to the boiler until you are
32. Supply Sensor not Present Outside Air Sensor not Present 12 Reserved s J s SSCSC F Water Prove Flow Interlock Combination Air Damper Present Boiler Detected KN USER S CONTROL MANUAL pi Method 2 HeatNet modulation BMS control on BACnet or LonWorks protocols Table 5 Modbus input read only registers 1 Install the correct bridge to adapt to building management systems using BACnet or LonWorks protocols Data Description Valid Values Type Range 0001 Boilers Running U ion z S 1 2 The bridge translates the BACnet or LonWorks input to the Modbus protocol for compatibility with the HeatNet controls B Address 30003 Header System Temperature 32 250 Wiring and set up 30004 Supply Temperature 32 250 AF F 1 Wire and set up the master boiler and member boilers exactly 30005 32 250 F F 31 30002 Modulation BTU Load 0 100 for HeatNet modulation local control applications D et modulation local control applications 30006 NE PET 2 ALL control parameters must be set up just as for the local 30007 Spare Input 1 32768 to 32767 control method 30008 Spare Input 2 32768 to 32767 3 The ONLY difference in setup is the termination DIP switch 30009 Clock Month Unsigned Clock Month o f on a the settings for Modbus communications given 0 Clock Day 3 4 Connect communications cables RJ45 or shield wire 30011 Clock Year 0 9 cable
33. TUP 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 FIRMWARE VERSION UPDATE CONTROL ADVANCED SETUP The firmware version in the control must match the version in this manual in order to ensure SYSTEM 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 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 Insert the Firmware Update Program disk into the computer The program will start and show an option screen Select Install USB Drivers to install the program onto the computer After the USB driver installation is complete select Install Firmware Update 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 Start the Firmw
34. The display LOC SET means the setpoint temperature Figure 18 shows the fac tory default values Accessing setup menus L 2 With the display in STANDBY press and hold the BACK key for 5 seconds The display will change to gt SETUP IEW LOL Press the SELECT key to select setup Note that pressing the DOWN key would change the selection to VIEW LOG The display will now show the first options in the setup menus gt REH O MAS BOILERS Press the DOWN key to access additional menu options Pressing the DOWN button once will change the display to EN OW BOILERS 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 these menu options BOILERS SETPOINTS INDOOR AIR PUMP OPTIONS NIGHT SETBACK OPTIONS LOG RUNTIME AUX FUNCTIONS SYSTEM CLOCK ADVANCED SETUP Control menus and adjustments Figure 18 Heat Net display during Standby no call for heat pressing the DOWN key on the keypad changes the display as shown 3 TANDE Y LEL SET 186 F STANDBY DAW SET 138 F HEHLER 138 F SUPPLY 78 F OUTSIDE 46 F RE TURN TA F DELIH T SA F HOU Hk SHU 12 IHR MAS fii ST TEMP S THAME STHAUET STHAUET STAUB Y O O OOOO STHAUE Y STHAUET S THAME STHAUET O O 0 138 F KN USER S CONTROL MANUAL 5 Con
35. all RS485 devices not just the HeatNet control To help eliminate grounding prob lems nylon standoffs are required to isolate the bridge from the boiler chassis Please download com plete HeatNet bridge installation instructions from the product web site a When the ProtoCarrier is functional the small green surface mount TX and RX LEDs near the 6 pin connector power and communications should be flashing regularly Ifthe TX LED flashes very briefly about once per minute the ProtoCarrier has most likely been damaged please contact Tech Services If either LED is always on the ProtoCarrier has most likely been damaged please contact Tech Services We are using a Building When using a BMS the setpoint values work in conjunction with the SETPOINT TIMER The SET Management System BMS to POINT TIMER is a failsafe feature used to help detect that a BMS is no longer working or communi control the boilers We can write the setpoints but they keep changing back to their default values after approximately 60 saved values for the setpoints will be loaded The concept is that periodically or every time a setpoint seconds is written the BMS must write this value If the value reaches zero 0 the HeatNet control assumes that the BMS in no longer functional and safe operational values for the setpoints will be restored cating with the control The time must be regularly loaded with a predetermined number of seconds
36. are Update Program It will auto detect the KN 2 control The program dialog box will automatically show the control s comport number in the first box The second box will show the firmware file number Make sure this is the correct file If not use the box to the right of the file name to navigate to the correct file Navigate to the control Advanced menu System Select YES to update the control NOTICE The firmware must be downloaded now for the KN 2 control to function again Return to the computer Select UPDATE The computer program will ask to turn the boiler off then back on After the power is cycled on the boiler the download will start If the download 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 wating 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 PRIORITY SET ADVANCED SETUP This setting is only used if a KN6 KN10 or KN20 HeatNet Control is used as a MASTER in a MIXED SYSTEM Boiler System For more information on the operation of HeatNet Mixed Boiler Systems see the KN6 KN10 KN20 HeatNet Con
37. at 10 F so the OP LIMIT setting can be 195 10 205 F maximum allowable setting The operating limit setting OP LIMIT always limits boiler outlet water temperature regardless of how the boiler is controlled HeatNet member 4 20ma control or stand alone The limit band see below determines when the boiler begins to be forced to reduce input as the outlet temperature rises toward the limit setting LIMIT BAND SETPOINTS Boiler firing rate is limited Boiler OFF above If the boiler outlet water temperature rises toward i A the limit setting OP LIMIT above the KN control a ETE will begin to reduce the boiler s firing rate when the temperature gets within the LIMIT BAND a A when degrees F below the operating limit setting At limit badd the lower end of the limit band the boiler can E E a PEE O ey ar asa fire up to maximum input 100 By the time the RY Boiler can fireupto temperature reaches the upper end of the band a full input as long as R water temperatureis the OP LIMIT setting the boiler is limited to C wait below the limit band J minimum input 20 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 Control limits boiler IA RESET INDOOR AIR Enable I
38. bitunsignea Realtmeclockweekday r Monday 7 Sunday __ 16 bit unsigned Boiler 1 16 status 1 and status 2 flags See the BoilerStatus1 Flags eee indicate the state of various boiler pe Flags in ie j ie a Boiler Boiler16 Member15 KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued Input Variables Read Only continued Name RawData Type Data Raw DataType Scale Description Description Valid Valid Values Range 30048 Boiler01Runtime 16 bit unsigned Boiler 1 16 Runtime seconds High Upper 0 4294967295 seconds High16 and Low Lower 16 bit counters To get 30049 Boiler01Runtime the actual runtime for any given boiler lowt the high and low 16 bit counters must be combined concatenated into a single 32 bit High16 Boiler RuntimeHigh16 Boiler RuntimeLow16 30051 BoilerO2Runtime Low16 Example O EE Boiler01Runtime Am ie ey HIME BoilerO1RuntimeHigh 16 65536 9 Boiler01RuntimeLow16 30053 BoilerO3Runtime Low16 BoilerO1 Master or Connected Boiler 30054 Boiler04Runtime BSS Rusealetsn High16 as Boiler16 Member15 30055 BoilerO4Runtime Low16 30056 BoilerOS5Runtime High16 30057 BoilerOS5Runtime Low16 30058 BoilerO6Runtime High16 30059 BoilerO6Runtime Low16 30060 BoilerO7Runtime High16 30061 BoilerO7Runtime Low16 30062 BoilerO8Runtime High16 30063 BoilerO8Runtime Low16 30064 BoilerO9Runtime High16
39. ch boiler requires a return water temperature sensor Sensor wiring return water sensor Firmware Version 2 5 and greater monitors the temperature differential Delta T across the heat exchanger Ifthe Delta T exceeds the setting the input to the boiler can be optionally limited DHW wiring ONLY if using DHW override mode S The boiler or boilers must be piped with isolation valves and wired for override operation Override of the 4 20mA input will occur if a contact closes across the boilers DHW Demand terminals To operate the boiler for domestic water heating with a storage tank install and pipe the tank according to the tank manufacturer s instructions and the recommended piping diagrams in this manual Consult the factory for applications not covered The circulator used for DHW must be operated by a circulator relay or zone controller that is activated when the tank aquastat calls for heat Connect the tank aquastat terminals across the DHW DEMAND terminals on the master boiler s electrical connection board as shown in Figure 7 Member boilers could be connected to tank aquastats if they are piped appropriately and intended to operate in override mode External interlocks Wire external limits and flow switch when used as shown in Figure 17 Overrides Control priorities l The KN control can provide override operation for any or all member boilers This requires the boilers be piped with appro
40. d To combustion air damper proving switch required when controlling combustion air damper Indoor air reset inputs connect to up to 8 zone thermostats Optional 20 ma control signal input Remote enable to start when operating on 20 ma input Optional HeatNet communications board Boiler wiring socket to blower and gas valve Boiler wiring socket to pressure switches and ignition control Boiler wiring socket to control panel Boiler wiring socket to control panel Boiler wiring socket to power switch Boiler wiring socket to transformer Termination DIP switches KN components Contents KN HeatNet Control panel KN USER S CONTROL MANUAL 1 Method 1 HeatNet modulation control page 6 The KN HeatNet control can control up to 16 KN boilers using built in software and hardware Install a RS485 interface on each boiler and connect with RJ45 HeatNet cables or shielded wires 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 or DHW Demand terminals 2 Method 2 HeatNet modulation BMS page 14 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
41. d 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 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 Are shielded sensor wires used Ensure the shields are grounded only at the boiler control end Are any sensors or sensor wires located near a transmitting antenna Move sensor Check the settings for OA SETPOINT and OA RESET If the outdoor air temperature is above the OA SETPOINT and OA RESET is on the circulator pump relay will be locked out and the heating boilers will not fire If the 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 L In H Net method the KN control auto detects the boilers in the system and adjusts the number of boilers accordingly Using H NET if the numbere of boilers 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 connected Verify that each boiler s HeatNet cable is in place Verify that each boiler has a unique address assigned ADVANCED SETUP DISTRIB CTRL LOCAL AD Verify that
42. e member boiler will be or 3 wire shielded cable to the H Link terminal strip item 4 Figure 10 The other o aS EA A pues ea eee end of this cable will be attached to the first member boiler in following steps KN USER S CONTROL MANUAL l Method 1 HeatNet modulation local control on Turn on power to the master boiler and set its on off switch to ON You should hear at least 2 beeps The control s firmware version number will display oe o RN show STANDBY and SYS SET 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 LOC SET instead 6 Ifthe 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 7 Ifa 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 STONORY SYS SET After the control s timer finishes the display will BOF Member boiler cables 1 Begin with the first member boiler 2 Plug the other end of the master boilers communications cable to the member boiler s input port Figure 10 item 2 for RJ45 cable or item 4 for 3 wire cable 3 Connect cables to all of the
43. eating Supplied mounted and wired by installer 4 20mA input option for remote setpoint control ONLY Connect remote temperature control 4 20mA input wires here when remote setpoint is required The setpoint temperature will be set by the 4 20mA signal The corresonding setpoint values can be set in the 4 20mA INPUT menu KN USER S CONTROL MANUAL Figure 8 4 Also see Figure 5 page 7 External high limits low ai Oe Hod dod I BYPASS CIRC ALARM OPT 120V Power for combustion air damper motor Water flow switch if used Combustion a H air damper Proving motor if used switch Factory wiring DO NOT change Dry contact out to remote alarm Alarm contact closes on open or shorted sensor ignition lockout flow switch or user interlock combustion air damper failure blocked flue or blocked air inlet H 120VAC Fused service switch by installer Power to n Circulator 120 VAC 120 VAC Gnd DO NOT directly connect circulator if motor is over 1 4 HP Use a motor contactor Postpurge circulator KN 2 only This circulator is factory pipe and wired It circulates water in the boiler after shutdown to prevent overtemperature in the top of the boiler DO NOT remove or use in any other manner It cannot be used for system circulation Boiler circulator or boiler system circulator This circulator must be supplied piped and w
44. en 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 KN USER S CONTROL MANUAL WARNING 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 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 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 NEFPA 70 Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of
45. ent is using HeatNet Q At power up the header sensor is auto detected If the temperature of the header sensor at power up is greater than 25 F and less than 240 F it is considered a valid sensor The boiler will default to the MEMBER mode if the temperature is not in this range and can only be run locally or by external inputs Q 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 RJ45 jacks flash roughly twice a second The MASTER is the only one that should flash with no communications cables plugged in You get the error message L Ifthe control does not sense a closed circuit at input connection FLOW SWITCH check to make sure the WATER FLOW SWITCH or WAITING circuit for the circulator pump is correct that the pump is being energized and that the flow prove switch FOR FLOW is working properly L If there is no flow prove switch check to make sure that a jumper wire has been connected across the FLOW SWITCH terminals You have forgotten the password L 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 Firmware update program starts UL Check that the termination DIP switchs 3 and 4 are not in the termination setting If they are remove them to load but then stops or does temporarily while updating All of the other memb
46. er boilers should have their termination dip switches not load at all OFF L Ensure that the USB driver for your PC Laptop computer is properly installed LJ Disconnect BMS or Protocessor Module if connected All HeatNet Boilers fire at the L This is usually caused by the HeatNet addresses on the Member boilers not being set Ifthe address on each same time boiler is not set then all boilers will have address 2 by default When the Master boiler calls to fire boiler 2 all boilers with address 2 will fire Set each Member boiler to a unique address from 2 16 Q Check the ADD Boiler delay time to ensure it is at a reasonable value A setting of 0 will start all the boilers at the same time KN USER S CONTROL MANUAL 6 Troubleshooting continued Suggested procedure can hear the blower ramping The Boiler always shows it s called for firing modulation This is not an indication of what the boiler is up and down and the firing rate actually firing at In this case the boiler is trying to meet the called for modulation which is displayed but is changing but the display is unable to do so The boiler protects itself by looking at it s supply water temperature and the temperature indicates it is running at the same is probably in the Operating Limit Band While in the operating limit band the HeatNet control limits modulation rate the input of the boiler The boiler tries to deliver the most input it can in an attempt
47. ers Damper and The System pump controlare configured correctly with the assumption that the Master is not powered Also ensure that any other System settings related to outside air temperature sensing and system interlocks are set to provide safe operation 3 Low Temperature Protection LOW TEMP OFF SUPPLY HEADER or RETURN This mode may be used by the MASTER or MEMBER boiler and can be used as a type of freeze protection In this mode you may select which Sensor you wish to monitor or you may opt to turn this mode OFF If you select a sensor you may then associate it with a temperature at which the boiler will turn ON Once the temperature at this sensor falls below the LOW TEMP temperature the boiler will start and fire to its LOCAL setpoint Once the Boiler reaches it s setpoint it will turn OFF KN USER S CONTROL MANUAL S The Heat Net control display Starting the display l Verify that the HEAT DEMAND and DHW DEMAND wires are removed nn A w N Check all wiring to make sure it is complete and all wires are securely connected 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 18 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
48. es 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 DELTA TEMP PUMP OPTIONS When DELTA ENABLE above is set to ON the boiler pump will run until the temperature difference 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 PURGE TIME PUMP OPTIONS The boiler pump can run after boiler shutdown to distribute heat remaining in the boiler water PURGE 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 ON If ALWAYS ON is set to YES the boiler circulator never turns off MASTER PUMP PUMP OPTIONS If set to ON the master control in the network will keep its pump contacts closed running its pump and or control valve if no other boilers are operating This is used to prevent dead heading system flow NOTE See H NET LOST Failsafe description for MASTER PUMP failsafe on member boiler DHW PRIOR If set to ON the boiler s local circulator will be de energized on all DHW calls KN2 ONLY WATER SETPOINT TEMPERATURE F lt
49. for heat demand DH for o R will show P if boiler pump was i NOTICE The second line will show typical reading as shown unless an error code is displayed See codes at right L KN2ONLY B indicates the bypass pump was on Screen 3 Messages e NO FLOW SENSED e OPERATE HIGH LIMIT high limit tripped e SETPT LIMIT OP LIMIT reached e SETBACK IS ACT setback initiated shows 1 to 4 e SETBACK __ EXPIRED setback completed shows 1 to 4 e COMBUST AIR FAIL ae peels eee internal control processor D aay error detection Entry number from 1 to 1000 highest e OUTDOOR RESET number is most recent entry OPEN with SUPPLY HEADER OA or RETURN sensor is open e SHORT with SUPPLY HEADER OA or RETURN sensor is shorted e FOUND BOILER master boiler detecting member boiler e LOST BOILER master boiler losing signal from member boiler e IGN LOCKOUT e USER INTERLOCK e BLOCKED FLUE e BLOCKED INLET e IAR COMM FAILURE indicates problem with wiring between control and connection board e IGN LOCKOUT RETRY e BLOWER PROVE FAULT blower did not prove during pre purge time FAIL SAFE BMS HD FAIL SAFE H NET HD FAIL SAFE TEMP HD HIGH DELTA T TEMP Setpoint temperature Water temperature at time of entry from 20 to 100 Mod readings can often be an indicator of boiler status Examples 45 may indicate prepurge while 30 ma
50. indicated by a blinking boiler in the Boilers Firing screen Ensure the HeatNet is set up properly Amber lights blink on HeatNet Jacks Only one Master boiler If the Member boiler is in Local Mode then it also would not be called and report unavailable to the Master We are trying to use a 0 10VDC The HeatNet control was designed to use a 4 20mA control input If a 0 10 VDC control signal is to be control signal but when we send used it must supply at least 20mA 0 10 VDC control signals are not recommended due to line loss and it 10 VDC only 7 VDC is measured the ability of the control signal to reject noise So ifusing a 0 10 VDC control signal it must be able to sup at terminal J10B 6 amp 7 ply the 20mA KN USER S CONTROL MANUAL 6 Troubleshooting continued Suggested procedure We are using a BACnet or L This condition usually indicates that the bridge is not communicating with the HeatNet control When LonWorks bridge We can talk to operating properly the bridge continuously reads data from the boiler on the Modbus port into an internal the bridge but all of the data is buffer When a BACnet or LonWorks read request is received the buffered values are placed in a BACnet zero 0 or invalid or LonWorks packet and sent If the bridge has never been able to successfully read data from the control all data points will have their default value which is typically zero In this situation the control will also not respond
51. ing 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 con troller The control method used by the HeatNet control is based on digital communications which eliminates the 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 Operation as a stand alone boiler Operation as a boiler in a boiler network using the on board HeatNet protocol Operation as a member boiler in a boiler management sys tem Operation as a member ofa remotely controlled boiler net work 20 milliamp regulation Setpoint can be determined by the HeatNet control or bya 20 milliamp input signal Network boilers can be operated by override commands for increased versatility PID response The HeatNet control uses proportional integral derivative cal culations 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 Multiple boiler operat
52. ion 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 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 ofall boilers to a pre set maximum 50 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 Firmware Version 2 5 and greater is now compatible with HeatNet Mixed Boiler Systems For more information on the operation of HeatNet Mixed Boiler Systems see the KN6 KN10 KN20 HeatNet Control Manual V3 47 which is available at www HydroThermKN com External limit monitoring amp annunciation In addition to controlling the boiler the HeatNet control monitors external limits wired into the limit circuit connections The control shuts down the boiler ifa limi
53. ion local control on Circulator wiring Postpurge circulator KN 2 only The circulator shipped installed with the boiler cannot be used for system circulation It must be used as supplied from the factory It circulates water after the boiler stops firing to prevent potential damage from heat pocketing in the top of the heat exchanger The postpurge circulator is factory piped and pre wired Do not change the usage the wiring the location or the piping Boiler circulator See the Boiler manual for circulator piping Figure 3 Figure 4 and Figure 5 show wiring of the Boiler circulator or boiler system circulator to the terminal strip of the KN 2 electrical connection board DO NOT directly connect a circulator with a motor larger than 1 4 hp For larger motors install a circulator relay or motor contactor Figure 3 and Figure 4 show the correct ways to install the boiler circulator using a relay or motor starter Figure 3 Wiring the boiler circulator using a circula tor relay required for motors over 1 4 hp 4 120VAC 60HZ 1Ph wih Circulator relay with internal 24VAC transformer Boiler circulator or boiler system circulator 120 VAC 20209 Figure 4 Wiring the boiler circulator using a relay or starter required for motors over 1 4 hp D it 120VAC 60HZ 1Ph l Relay or motor starter with 120VAC coil Boiler circulator or boiler system circulator 120 VAC 2
54. ired by the boiler installer See the suggested piping diagrams in the Boiler manual for circulator application and piping IMPORTANT If the circulator motor is larger than 1 4 hp water cut offs or other limits if used connect the circulator using a motor contactor Method 1 HeatNet modulation local control on KN wiring summary wiring to electrical connection board continued see Figure 7 for terminal strip locations O 24VAC INTERLOCKS pme pamm met foan FLOW USER ITCH INTRLK lal HIGH LIMIT S i Remove factory jumper across FLOW SWITCH terminals when using a flow switch Connect combustion air damper ONLY to the master boiler Note For multiple boilers with a single combustion air damper see figure 9A WATER WATER HEADER OUT IN Outdoor Return sensor water if used sensor Supply fYS d Header sensor sensor factory REQUIRED installed to boiler Install a header outlet sensor in an immersion well Connect ONLY to the master boiler 20232 KN USER S CONTROL MANUAL I Method 1 HeatNet modulation local control on External interlocks 1 Wire external limits and flow switch when used as shown in Figure 8 Figure 9 Termination DIP switches see item 7 Figure 7 for location 2 If wiring to and from a motorized combustion air damper follow the guidelines DIP switches located at given in Figure 8 Connect only to the master boiler left
55. led 1 disabled The boiler is disabled Heat Demand 0 no demand 1 demand 1 A combination of the Heat Demand Input Local Override and the BMS Heat Demand Alarm 0 ok 1 alarm An alarm or warning condition has occurred An attempt s will automatically be made to recover and resume normal operation Failed 0 ok 1 failed A condition has occurred under which the boiler can no longer run Member Error 0 ok 1 error An Alarm or Failed condition has occurred on one or more of the member boilers Boiler Running 0 off 1 running Ea Pump Running 0 off 1 running Spare 4 User Interlock 0 open 1 closed Eo 13 Water Prove Flow Interlock 0 open 1 closed KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued BoilerStatus3 Flags a o em fee 1 Available in Firmware Version 2 70 Hydro Therm BoilerStatus4 Flags DHW Sensor Enabled 1 0 off 1 on menu DHW Sensor has been enabled in the menus Damper Prove 1 0 open 1 on Status of Damper Prove Input J12B E a o e e ee o Sa Operating Limit Clamp Boiler input is being limited clamped due to a high supply outlet temperautre amp s ys A MESTEK COMPANY IN UNITED STATES 260 NORTH ELM ST WESTFIELD MA 01085 413 564 5515 FAX 413 568 9613 IN CANADA 7555 TRANMERE DRIVE e MISSISSAUGA ONT L5S 1L4 905 672 2991 FAX 905 6
56. mes that some boilers are not 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 limit is remove and all boilers can fire up to maximum input Once any boiler is dropped offline the limit is applied again This value is also used as the maximum modulation the boiler can obtain when first starting in response to a 4 20mA or High Fire Demand This setting helps reduce short cycling when water temperature is within the heat band If the water temperature rises to the top of the heat band less the STOP BAND OFFSET before a boiler just added has completed its modulation delay time the boiler will shut down Example if the top of the heat band is 190 F and stop band offset is 15 F a newly added boiler will shut down if the temperature reaches 175 F 190 15 before its modulation delay time has ended DO NOT CHANGE This is the time from receiving a call for heat to when a boiler begins its modulation operation running at minimum fire ON the Master boiler lowers the modulation rate of all currently operating boilers before a newly added boiler enters run state After the new boiler starts the Master boiler waits the DELAY RELEASE time see below before allowing return to normal modulation OFF the Master boiler allows the HeatNet system to modulate normally as additional boilers Start ON IGN the Master boiler ADAPTIVE is ON
57. move this jumper when using a a thermostat or other external control to start the boiler ie y 120VAC 60HZ 1Ph Power to boiler r a o o 0 4 r s 3 E a a i a i ae CSa 7 T E 4 20mA REMOTE HEAT DHW LOW HIGH ENABLE IDEMANDIDEMAND FIRE FIRE LUJ Use these terminals only during boiler setup as given in the Boiler manual Use ONLY if wiring and piping for Override mode DHW tank aquastat when used A DHW circulator and circulator relay will be required Start the DHW circulator on call for heat To remote controller from the tank aquastat enable a E l contact Use ONLY if wiring and piping for Override mode Connect thermostat zone valve end switches or remote start relay contact here Test when done to ensure no stray voltage is present on any of the wires See the Boiler manual for procedure 1 per boiler 4 20mAinput Bird Blir2 Bir 3 Blr4 signal see right for wiring i 4 20mA REMG 4 20mA REMG 4 20mA REMG 4 20mA REMG 4 20mA REMG _ ENA ENA ENA ENA ENA The resistive load across the 24mA source is 250 ohms per boiler UO 4 20mA ryt Input KN USER S CONTROL MANUAL Method 3 External 4 20ma control continued Figure 17 KN wiring summary wiring to electrical connection board continued see Figure 7 for terminal strip locations a T a me s t R e BYPASS CIRC AL
58. ndoor Reset by setting this to one of the following possible modes NEEDITEST The boiler s maximum fire rate will be determined by the zone with the largest load AVERAGE The boiler s maximum fire rate will be determined by the average load of the ACTIVE ZONES SPECIFIC The boiler s maximum fire rate will be determined by the load of the SPECIFIC ZONE ACTIVE ZONES The number of zones to be used to determine the boiler s maximum fire rate when using Indoor Air Reset in AVERAGE Mode The zones in use always starts at 1 example an ACTIVE ZONES value of 5 will use zones 1 2 3 4 and 5 to determine the boiler s maximum input SPECIFIC ZONE The zone which will be used to determine the boiler s maximum firing rate when using Indoor Air Reset in SPECIFIC mode INDOOR AIR AVG TIME The averaging time AVG TIME is the time span over which the control averages the results of zone demands Leave this setting at the factory default unless directly otherwise by HydroTherm Technical Support SET IAR SETPTS INDOOR AIR Leave the delta temp settings at factory default settings unless directed otherwise by HydroTherm Technical Support The determine how much the control adjusts maximum allowable firing rate based on its monitoring of zone demand OA SHUTDOWN OUTDOOR AIR When outdoor air shutdown is enabled ON the boiler and its circulating pump shut down when the outside temperature is above the outdoor air setpoint OA SETPT This requi
59. nsor ONLY to the master boiler Install the header sensor in an immersion well Locate the sensor where it will accurately sense the system water supply temperature Connect the sensor leads to the electrical connection board as shown in Figure 8 Outdoor reset application To operate with outdoor reset purchase and install an outdoor sensor Mount 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 master boiler s electrical connection board as shown in Figure 8 Member boilers could have their own outdoor sensor if they will be operated in override mode by closing the Heat Demand terminals Return water temperature sensor The return water temperature sensor is optional only needed if you want to automatically control the boiler postpurge pump cycle time Install the sensor in a well in the boiler return piping Connect the sensor leads to the electrical connection board as shown in Figure 8 The Return water sensor can OPTIONALLY be used as a DHW sensor The control would then regulate to this sensor for DHW demands When used in this way the sensor must be moved to a position where it will sense the temperature of the water being supplied to the tank For more information see the DHW SENSOR description in Table 8 Sensor wiring return water temperature sensor Firmware Version 2 5 and greater monitors the temperature differen
60. o not wire 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 DHW operation in particular would raise the supply temperature from overriding boilers to the DHW Setpoint NOTICE Override operation control setup Boilers must be set up with operating parameters necessary during their override operation i e local setpoint DHW setpoint etc Summary priority sequence is Priority 1 DHW Demand Priority 2 Heat Demand Priority 3 HeatNet input Other members Switch 1 Switch 2 Switch 3 Switch 4 Switch 1 Switch 2 Switch 3 Switch 4 Switch 1 Switch 2 Switch 3 Switch 4 Switch 1 Switch 2 Switch 3 Switch 4 Switch 1 Switch 2 Switch 3 Switch 4 Switch 1 Switch 2 Switch 3 Switch 4 Note Modbus setup is for applications controlled by a building management system For systems using BACnet or LonWorks a bridge board is used to interface with the KN 2 control The switch is on when in the down position and off when in the up position 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 2 See Figure
61. of RS485 communications board on electrical connection board CAUTION fany of the member boilers is to operate in override mode and the system is equipped with a 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 m _ Overrides Control priorities 3 The KN control can provide override operation for any or all member boilers in a HeatNet network This requires the boilers be piped with appropriate isolation piping and controls z v op Nam Co m nom 4 Override is done by closing a contact across the Heat Demand or DHW Demand terminals of any boiler These priority inputs override all network controls or 4 20mA input controls to the boiler 5 DHW Demand The DHW Demand closure takes priority for ALL boilers including the master and all members When DHW Demand closes the boiler or boilers immediately switch to DHW operation including setting the water temperature to the DHW Setpoint 6 Space heating Heat Demand If any member boiler sees closure across its Heat Demand terminals it will begin operation in space heating mode indepen Table 1 dently of commands from the master boiler or 4 20mA input source Boiler Modbus see note Termination DIP switch settings CAUTION D
62. of the Master boiler Boilers stage OFF when The heat band is the height of the modulating linea ce alae g5 band When the water temperature is between 2 the heat band above or below the setpoint temperature boiler firing rate modulates Boilers a2 Boiler MODULATE EETPOINTITENE are at minimum input at the upper end of the band Ie jnheat band and maximum input at the lower end of the band Boilers come on only if the water temperature is below the band Boilers stage off when the water Boilers stage ON when water temp isbelow temperature is above the band heat band J Setpoint temperature controlled by the KN control NOTE If the control 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 2 control is in override mode such as by closing its Heat Demand or DHW Demand terminals Specifies where the space heating setpoint temperature comes from AUTO With AUTO selected the HeatNet control determines the setpoint using local setpoint outdoor reset or SYS DHW HEADER temperature setpoint 4 20mA If 4 20mA is selected the HeatNet 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 REMOTE ENABLE terminals J9 for the boiler to respond to the 4 20mA signal The temperature and boiler start settings are set in
63. ons 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 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 NEFPA 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 Overview control setup sequence CAUTION Follow the Boiler manual Install the boilers according to the KN de E D NAM Boiler manual before attempting to set up the control system Install all boilers per the Boiler manual Close the external gas valve on every boiler Wire all boilers following the guidelines in this section Attach a header sensor to the master boiler ONLY The KN 2 control automati cally configu
64. oprocessor electronics watching time average response from the system to anticipate how much heat the system needs Coupled with the frve to one turndown of the KN boiler this results in maximum possible condensing mode operation The KN boiler will provide unmatched seasonal efficiency Indoor air reset IAR HydroTherm s unique approach to boiler output regulation is its Indoor Air Reset function The control monitors the demand from up to 8 different zones Watching the demand duration and response to supply temperature averaging over time the Heat Net control anticipates system needs It sets boiler maximum firing rate and adjusts supply water temperature to fine tune boiler heat output All that is required to enable IAR is to con nect thermostat circuit wires to the IAR inputs The HeatNet control can also be configured for outdoor reset operation but IAR provides response based on system behavior rather than just looking at outdoor temperature 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 oper ated as a simple single boiler control while still providing intel ligent 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 sim ple RJ45 cable interfac
65. ppendix A in the Boiler manual CAUTION Polarity The connections to the IAR positive terminals IAR must be to the same location on the zone valve as the thermostat wire as shown in Figure Al The connections to the IAR negative terminals IAR must be from the zone valve terminal connected to the 24VAC common line as shown Connecting the wires incorrectly can cause the transformer to be shorted out and damaged Verify the wiring with a voltmeter CAUTION Always use a voltmeter to check the leads coming from the end switches of the zone valves With the thermostat calling for heat connect the voltmeter leads across the wires coming from the end switches If the meter shows a voltage reading the zone valve wires are incorrect Change the wiring and retest DO NOT connect the wires to the boiler until you have tested as described Incorrect wiring can damage the boiler control or other system components If there is only one transformer feeding all of the zone valves in the system you can omit the wires to the IAR negative terminals IAR on all but one of the zone valves This is because these terminals are jumpered internally on the electrical connection board If there is more than one transformer provide one wire from each transformer common side to one of the IAR negative terminals IAR Sensor wiring Header sensor is required A header sensor must be installed in the system supply piping Connect the header se
66. priate isolation piping and controls Override is done by closing a contact across the Heat Demand or DHW Demand terminals of any boiler These priority inputs override all 4 20m lt A input controls to the boiler DHW Demand The DHW Demand closure takes priority for ALL boilers including the master and all members When DHW Demand closes the boiler or boilers immediately switch to DHW operation including setting the water temperature to the DHW Setpoint Space heating Heat Demand If any member boiler sees closure across its Heat Demand terminals it will begin operation in space heating mode independently of commands from the 4 20mA input source CAUTION Donotwire boilers for override operation unless the piping design provides automatic isolation of the overriding boilers NOTICE Override operation control setup Boilers gt must be set up with operating parameters necessary during their override operation i e local setpoint DHW setpoint etc Summary priority sequence is Priority 1 DHW Demand Priority 2 Heat Demand Priority 3 4 20mA Input Enable KN USER S CONTROL MANUAL Method 3 External 4 20ma control continued Figure 16 KN wiring summary wiring to electrical connection board POWER SERVICE Electrical connection board Located in center panel on boiler right side 0 ee 15 amp 2 The boiler is shipped with a jumper across the HEAT fused DEMAND terminals Re
67. r Mo mn A L Cz lm m Zz co oa 5 pam co al mo rq KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 7 Setup menus see Table 8 for explanations continued ADVANCED SETUP DISTRIB CTRL CONTROL fT HNETMASTER f YES Display only not changeable here Goo Master default 255 not changeable Member default 2 Range 2 to 16 CONSOLEADD o Default 1 Range 1 to 247 MODULAR BOILER eee 10 minutes 0 to 15 minutes as i 2 minutes 0 to 15 minutes C 0 00 0 00 to 60 00min ADAPTIVE MODE ADAPTIVE ON OFForoN Adjustable on ADUST f ONIGN ON IGN or ON CALL FIRING MODE ROTATION ss fs TRUE True FOFO LOFO TYPE TTY EZ TYPEZ None ON OFF O a 4 20mA input ee 50 F 50 to 220 F Not applied unless SETPOINT SOURCE is set to 4 20MA m 180 F 50 to 200 F Not Applied unless SETPOINT SOURCE is set to 4 20mA Co 4 11mA 3 7 to 4 3mA Applies to either 4 20mA setpoint or modulation PRIORITY Default NORMAL NORMAL or HIGH NOTE HIGH will cause the 4 20mA input to take control when a contact closes across the 4 20mA ENABLE terminals To set to HIGH make sure SETUP SETPOINTS SETPOINT SOURCE is set to AUTO PASSWORD CHANGE PASSWORD Press S enter old password using arrow keys and OLD gt _ S for each character CHANGE PASSWORD Press S enter new password using arrow keys and NEW gt S for each character ACCEPT gt Po YES YES or
68. r DHW only S S be used S S et et Set control parameters on keypads OP LIMIT et et se se Before turning boilers on to set parameters disconnect all call for heat LIMIT BAND Se Set wiring at the electrical connection boards This will prevent the boiler IA RESET ON if IAR is used Do not set for attempting to cycle during the setup process orsetto OFF 1 See Control menus and adjustments for a complete list of control parameters OA SHUTDOWN Set ON if used HDOA only and explanations or set to OFF 3 2 Carefully read the parameter explanations in 8 l OA SETPOINT HDOA only 3 When adjusting the limit band operating limit OP LIMIT local setpoint LOC SETPOINT and DHW setpoint make sure the operating temperature bands do SAREL ZE LIEUREG HECRON not overlap or cause potential for nuisance cycling OA SETPTS HDOA only 4 Indoor air reset Use this option whenever possible The indoor air technology DELTA ENABLE monitors space heating demand to help the boiler operate at the highest possible efficiency throughout the season To operate with IAR you must wire to the IAR cee set if used set if used input terminals as described on page 18 PURGE TIME 5 System clock Set the system clock on all boilers to ensure the time stamps will ALWAYS ON 6 Turn on the power to each boiler and set the on off switch to ON as you set its parameters NIGHT SETBACK Set on master boiler only 7 Use the boiler s keypad to enter
69. res an outdoor sensor when enabled OA SETPT OUTDOOR AIR The boiler and its circulator shut down when the outside air temperature is above this setting if outdoor air shutdown is enabled ON This requires an outdoor sensor when enabled KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations continued OA RESET OUTDOOR AIR Set to ON to enable resetting the boiler outlet temperature or header temperature based on outside air temperature Set to OFF to disable outdoor reset This requires an outdoor sensor when enabled LOW WATER OUTDOOR AIR HIOA SET OA SETPTS x These temperatures determine the reset curve High water eloped for supply water temperature High water at low outside air means the design water temperature for maximum load at ODT or outside design 4 low outside temperature for the installation The other end of 3 the reset curve is the low water temperature at high outside air temperature The low water temperature HI WATER LOW OA air temperature re _ i High outside emperature a lt air temperature a airtemperatue is generally equal to room temperature meaning 70 ER ee 10 no heat input to the space would occur below this outside air temperature DELTA ENABLE PUMP OPTIONS The boiler pump can be set to run after boiler shutdown to distribute residual heat to the heating system Delta enable caus
70. res 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 Boiler manual 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 Add communications modules 1 Insert a RS485 communications module onto each ofthe boilers electrical connection panels as shown in Figure 1 Power supply 120 VAC L 2 3 See Figure 1 and Figure 2 Connect minimum l4awg copper wire to the power connection as shown in Figure 2 Install a fused service switch mounted and installed in accordance with all applicable codes Method 1 HeatNet modulation local control Electrical connection board see item 10 page 3 for location Also see the wiring summary illustrations on the next pages Figure 1 seed 2 bocce H ea Figure 2 O 120VAC power service terminals on electrical connection board See Figure 15 for location of the power terminal strip POWER SERVICE 15 amp fused service switch by installer Gnd NO H 120VAC 60HZ 1Ph Power to boiler KN USER S CONTROL MANUAL Method 1 HeatNet modulat
71. return temperature if avail 32 250 F 30113 BoilerO2Returntemp able see BoilerStatus2 to determine if the sensor is present 30114 BoilerO3ReturnTemp 30115 BoilerO4Returntemp BoilerO1 Master or Connected Boiler BoilerO2 Member01 30116 BoilerO5ReturnTemp 30117 BoilerO6ReturnTemp Boiler16 Member15 30118 BoilerO7ReturnTemp 30123 Boiler 2ReturnTemp 30124 Boiler13ReturnTemp 30119 BoilerO8ReturnTemp 30125 Boiler14ReturnTemp i Boiler 1 16 Cycles High Upper and Low 0 4294967295 Lower 16 bit counters To get the actual cycle count for any given boiler the high and low 16 bit counters must be combined concatenated into a single 32 bit counter as Boiler CyclesHigh16 Boiler CyclesLow16 Example BoilerO1Cycles BoilerO1CyclesHigh16 65536 BoilerO1CyclesLow16 BoilerO1 Master or Connected Boiler BoilerO2 Member01 Boiler16 Member15 30145 BoilerO9CyclesLow16 30146 Boiler10CyclesHigh16 KN USER S CONTROL MANUAL 7 KNSLM KN2 KN4 modbus registers continued Input Variables Read Only continued Name RawData Type Data Raw Data Type Scale Description Description Valid Values Range Valid Values Range 16 bit unsigned Boiler 1 16 status4 flags These bits See the BoilerStatus4 Flags in indicate the state of various boiler statuses Appendix A BoilerO1 Master or Connected Boiler BoilerO2 Member01 30176 RESERVED 30207 KN USER S CONTROL MANUAL
72. rolled locally It will not override 4 20ma control or building management control TEMP SCALE OPTIONS Select Fahrenheit or Centigrade OPTIONS If activated the control beeps when a key is pressed OPTIONS The control can be programmed such that a password is required to change settings Setting this to ON disables the password OPTIONS If set to OFF the audible alarm will not be used to annunciate faults LOG RUNTIME Displays the number of times the boiler gas valve has been cycled on then off It does not include failed ignition attempts AUX FUNCTIONS Select YES to connect a combustion air damper and its end switch to the electrical connection board AUX FUNCTIONS Set proof time long enough to be sure the combustion air damper can open and activate its end switch AUX FUNCTIONS Select YES to have the control maintain the DHW SETPOINT value at the RETURN water sensor location for all DHW Demands KEY CLICK BRIGHTNESS ALARM SOND LOG ENTRY BOILER CYC COMB AIR DMPR IN USE PROOF TIME This allows the HEADER sensor to be located in the Heating loop and a separate DHW sensor to be located in the DHW loop This is useful for a MASTER boiler to be able to use members for Heating or DHW when a HEADER sensor is located outside the DHW loop NOTE When this feature is enabled ALL Delta T features using RETURN sensor are DISABLED and the temperature is reported as DHW instead of RETURN on
73. s between the control communications boards as for 30012 nsigned Clock Hours the local control method D ae Unsi Unsi 5 Verify network operation BEFORE connecting the building 30014 Clock Seconds 0 59 management system 30015 nsigned Clock Day of Week 1 Monday 7 Sunday Connect the BMS cable 30016 Unsigned Boilers 1 16 status flag 32 bit registers The See the Boiler L DONO meie aene 30047 upper 16 bits of each 32 bit register is stored at Status Flags until the boiler network has been proven to operate inde odd numbered addresses 30016 30046 The Table Below lower 16 bits of each 32 bit register is stored at pendently The system is designed to revert to local control even numbered addresses 30017 30047 building management system be lost by the master boiler should communications with the 30048 Unsigned Boilers 1 16 runtime 32 bit registers The 0 4294967295 2 Turn off power to the master boiler 30079 upper 16 bits of each 32 bit register is stored at seconds 3 See Figure 10 Connect an RJ45 cable to the BMS input odd numbered addresses 30088 30078 The port item 6 Or use shielded wire cable connected to lower 16 bits of each 32 bit register is stored at terminal block item 3 even numbered addresses 30049 30079 When the upper and lower registers are combined they form a 32 bit unsigned integer that is the number of seconds that the boiler has be
74. saved on the master control is reloaded S This is a 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 Method 2 HeatNet modulation BMS control Basic For Full Register Set see page 40 Table 3 Modbus holding read write registers Valid Values Range lt 40001 Unsigned Boiler System Enable Disable 0 Disabled Off S tnt Pacem Spe 40004 Unsigned Outdoor Air Reset Enable Disable 0 Disabled Off 1 Enabled On 40005 Outdoor Air Setpoint 40 F 100 F Description 40006 Water Temperature at High Outside Air 60 F 150 F 40007 High Outside Air Temperature 40008 Water Temperature at Low Outside Air 50 F 90 F 70 F 220 F 35 F 40 F 40012 Unsigned SetClock Year 2 f 0 9 40016 Set Clock Day of Week 2 1 Monday 7 Sunday 40017 Unsigned Set Clock After the Set Clock Registers listed 1 above have been written a 1 must be written to this location to set the clock 2 Table 4 Boiler status flags Disabled Local Override Fal EA eit osain Oe 6 PumpRunning 22 Reserved o 8 Reserved 24 Header Sensor not Present 9 Reseved TS S
75. ster boiler will sequence and modulate boilers as necessary to control the water temp erature 6 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 10 RS485 communications board view 5485 Botton see item 20 page i 0 page 3 Rs485 T see item 2 RJ45 HeatNet cable IN from master or previous member RJ45 HeatNet cable OUT to next member boiler Shielded wire 3 2ire option to RJ45 cable Heat Net communications INPUT and connection for additional boilers on the network Shielded wire option to RJ45 cable Modbus INPUT from building management system USB cable port for USB cable connection to a PC required when updating control firmware RJ45 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 systems that use BACnet or LonWorks protocol The KN control supports Modbus protocol with no additional components except the RS485 interface board KN USER S CONTROL MANUAL 2 Overview 1 This method uses an RS485 digital communications cable with the Modbus protocol to control a boiler or HeatNet network 2 The boiler or boiler network
76. t opens and the digital display shows which limit failed Monitored limits include high limit aquastat flow ignition control fault inlet pressure flue pressure and other optional or user selectable limits KN USER S CONTROL MANUAL The KN boiler HeatNet control KN Control panel Located on boiler front shown with keypad cover removed Two line fluorescent display shows boiler status and setup menu navigation RUN 75 LOC SET cae ORS Keypad provides navigation and selection for readouts and boiler setup Electrical connection board Located in center panel on boiler right side All field and boiler wiring connects here 2D O p gt Ww N gt giatu N 2 NO oli pmf Mie SS co f i T 8 0 All boiler wiring is made with non interchangeable plug in harnesses connected to this board 22 23 2d 25 26 m Wiring connections Power wiring 120 vac Heat demand input DHW demand input Low fire terminals High fire terminals To boiler outlet water temperature sensor To optional outdoor temperature sensor To optional boiler return water temperature sensor To optional header temperature sensor To boiler postpurge pump factory piped and wired To boiler circulator Alarm output dry contacts To external high limit and or low water cutoff if desired To flow switch when used Used to activate combustion air damper if desire
77. t timer is a BMS failsafe feature This countdown timer should be periodically reloaded with a timeout value in seconds If 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 When any 1 Read Write variable is timer is written if the SetpointTimer is less than 60 it is automatically reloaded with 60 1 In Firmware Versions lt 2 70 the BMS has to write theSystemSetpoint to automatically reload the SetpointTimer System Setpoint see SetpointTimer 40 220 F Enables Disables outdoor air reset mode 0 disabled 1 enabled Outdoor air reset setpoint Temperature at 40 100 F which boiler shuts down Boiler water temperature setpoint when out 60 150 F 40004 OAResetEnable 1 bit unsigned 40005 OARSetpoint 8 bit unsigned 1 door air temperature is at the high outdoor air 40006 OARHighWaterTemp_ 8 bit unsigned 1 0 temperature setpoint OARHiAirlemp 40007 OARHighAirTemp 8 bit unsigned 1 0 High outdoor air temperature setpoint 50 90 F 40008 OARLowWaterTemp 8 bit unsigned Header Supply temperature setpoint when 70 220 F outdoor air temperature is at the low outdoor air temperature setpoint OARLoAirlemp oons semo shit unsigned Setrealtime ock rour se etl 0 23 soars Setwinute Bit unsigned E Set eat cock minute
78. the Home screen NOTE When used in this way the sensor must be moved to a position where it will sense the temperature of the water being supplied to the tank AUX FUNCTIONS If in use the control will alarm and disable the DHW demand input if a DHW demand lasts for more than the selected time AUX FUNCTIONS DHW PROTECTION DHW CYCLE MAX If set to ON when a DHW demand is satisfied and there is still a heat demand preset and the supply temperature is above the heating band the boiler will continue to fire a minimum input until the supply temperature drops back into the band or the heat demand is satisfied This is useful when running a lower temperature LCL Setpoint with a higher DHW setpoint KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations continued BMS LOST AUX FUNCTIONS When set to NO the boiler system will only operate if activated by an override input HD DHW MASTER BOILERS FAIL SAFE MODE 4 20mA LOW FIRE or HIGH FIRE ONLY When set to YES the Master boiler will revert to LOCAL operation controlling its Header water temperature to the LOCAL SETPOINT setting NOTE The control will wait 10 minutes after losing communications with the BMS before switching to local operation NOTE If a Combustion Air Damper is in use make sure the Fail Safe boiler is able to open and prove the damper H NET LOST AUX FUNCTIONS When set to NO
79. 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 KN USER S CONTROL MANUAL 6 Troubleshooting continued Suggested procedure HeatNet boilers are detected but Q The H Net communications cable may be receiving interference from the blower ignition or other form then lost and then detected again of radiated electrical noise LJ 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 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 Only the MASTER boiler Fires but In order for the MASTER boiler to act as a MASTER the header sensor must be set to TYPEZ and there the system has many boilers and must be a header sensor pres
80. the parameters as described on page 23 OPTIONS all Set 8 After setting a boiler s parameters turn the power off to the boiler until you are AUX FUNCTIONS Set on master boiler only ready to start the boiler up following the Boiler manual instructions SYSTEM CLOCK 9 Ja master boiler and each member boiler following the guidelines given in LOCAL ADD Set bedinnihg at 2 CONSOLE ADD Set beginning at 2 Start up boilers per KN Boiler manual PETT 1 Turn off power to all boilers Set on master boiler only TYPE HD HDOA only Connect network cables PASSWORD se m et Electrical shock hazard Turn off power to each boiler before COMMUNICATIONS attempting to connect the network cables LOAD DEFAULTS On any boiler if required Before turning boilers on to check network operation disconnect all SYSTEM On any boiler if required call for heat wiring at the electrical connection boards This will prevent e the boiler for attempting to cycle during the setup process 2 Follow all instructions in the KN Boiler manual to start up each boiler and verify operation 1 HD Only means to set the parameter for a member boiler only ifit is wired for Heat Demand override Ma ster boi l er ca b l e 2 DHW Only means to set the parameter for a member boiler only ifit is wired for DHW Demand override 1 Connectan RJ4S cable to the master boiler H Link OUT block item 2 Figur el 0 3 HDOA Only means to set these parameters only ifth
81. tial Delta T across the heat exchanger If the Delta T exceeds the setting the input to the boiler can be optionally limited DHW wiring To operate the boiler for domestic water heating with a storage tank install and pipe the tank according to the tank manufacturer s instructions and the recommended piping diagrams in this manual Consult the factory for applications not covered The circulator used for DHW must be operated by a circulator relay or zone controller that is activated when the tank aquastat calls for heat as shown in Figure 7 terminal 2 Connect the tank enable terminals across the DHW DEMAND terminals on the master boiler s electrical connection board as shown in Figure 7 Member boilers could be connected to tank aquastats if they are piped appropriately and intended to operate in override mode Figure 6 Indoor Air Reset wiring to IAR terminals with 4 wire zone valves and no zone controller see Figure 7 for terminal block 6 location 6 i e a a IAR1 IAR2 IAR3 IAR4 IAR5 IAR6 IAR7 IAR8 To other zone valves up to 8 zones total WARNING Rewire the zone 24VAC to other valves if necessary to zone valves ensure the hot leads are connected as shown zd 7 4 wire zone valves typical EENES ee EEEE SEERE NETER EEEE E EEE OEE Q 24VAC 9 V WV Connect all end switch Eee
82. to meet the called for modulation without tripping the operating limit If the boiler is constantly varying in blower speed and in the operating limit band there may be not enough flow through the boiler or the Operating Limit Operating Limit Band may be improperly set The Oper ating Limit Operating Limit Band should not overlap the heating band This may occur when a building management system is controlling the setpoint and is setting the setpoint in the operating limit band Example Setpoint set to 180F by Building Management and the Operating Limit is set to 200F with a 20F Operating Limit Band When the boiler is trying to deliver 180F to the load it s supply temperature would be a minimum of 180F The beginning of the Operating Limit Band looks at supply np would be 200F 20F 180F Now when the Master is trying to maintain setpoint at 180F the boiler is trying to reduce input beginning at 180F at its supply sensor and as a result fighting the setpoint The Operating Limit band needs to be reduced in this case while taking into account the Heat Band differential The Master boiler sees all of the If the Master modulates to 100 without firing a Member boiler and the Member boilers are seen by Member boilers in the system the Master in menu SETUP BOILERS then the Member boilers are sending back offline status to the but does not fire any of the Master Members The Member boilers may have an alarm or error condition which would be
83. to write commands for instance changing the setpoint 1 The controls MODBUS ADDRESS must be set to one 1 This is set in the ADVANCED SETUP gt DISTRIBUTED CONTROL menu On older legacy firmware this setting was also called the CONSOLE ADDRESS The control BAUD rate must be set to 19200 and the DATA FORMAT must be set to 8E1 8 data bits even parity 1 stop bit On older legacy versions of firmware the DATA FORMAT was called PARITY which must be set to EVEN These settings are set in the ADVANCED SETUP gt COMMUNICATIONS menu Check the termination on the BMS Modbus port If the control is the first or last device on the Mod bus RTU network it should be terminated For the short cable runs for instance when using a BAC net or LonWorks bridge on a Revision 1 x board the termination should be in but usually doesn t matter Check the wiring The Modbus RTU RS485 connections on the HeatNet control are A B and G ground Some systems use opposite polarity A B Always use the polarity to de termine the proper connections A ground wire must always be used and a shielded twisted wire is STRONGLY suggested A ProtoCarrier is required a to provide power and the RS485 signal conversion to the LonWorks and BACnet bridges The RS845 signal conversion chips are easily damaged by electrical noise ground loops and large differences in ground potential between devices on the network This is a common problem faced by
84. trol Manual V3 47 which is available at www HydrothermKN com Priority 2 is the default and lowest priority Priority 1 is the highest priority A priority may be assigned to a set of boilers which fires and rotates based on time and is independent of the other priority set KN USER S CONTROL MANUAL 6 Troubleshooting Table9 Accessing and using the Log Enter Setup From STANDBY hold for 5 seconds Then press O until the cursor points to VIEW LOG Press Ss 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 entry number and date are on the first line of the log screen Each log entry includes three screens as described below The top line remains the same in all three and contains the date stamp and entry number An entry is made each time a change in demand occurs or when demand changes from heating to DHW or back each prepurge and postpurge occurrence and each ignition sequence An entry is also made when any of the Screen 3 events below occurs These events may be errors faults or notification of setback activity Screen 1 Date stamp lass PM ele2o HD 175 F SETISG r Screen 2 Outside temp and mod percentage Shows the modulation percentage Screen 3 Status or messages see right lees PH Ble 29 68r Biga PHDBI Ho _ Displays HD
85. trol menus and adjustments continued Table 7 Setup menus see Table 8 for explanations To enter Setup From STANDBY hold ox for 5 seconds Then press S 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 until the display returns to standby or turn boiler ON OFF switch off then on Level 1 Level 2 Level 3 Level 4 Default Range Typical line OO nent OO tee OO Peary OO next item O Q to change value Display shows two item z z l Ss to select S to select Ss to select to accept value and return to lines at a time cursor Ss to select previous menu level indicates active line j back one level back one level back one level BOILERS BOILERS Pf 1 to 16 display only LEAD BOILER 1 display only the lead boiler is the boiler with a HEADER sensor connected HEAT BAND PY 30 F 2 t0 50 F HEAT NET BOILERS Display only on MASTER boiler only shows the 123456789101112131415 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 M in this display SETPOINTS ocsETPT fs 180 F 40 to 20 F Tren rr INDOOR AIR PF iaRESET fF OFF or NEEDIEST or AVERAGE or SPECIFIC Pacwemnes a A T PIARTIME f 60 MIN 30 to 120 minutes SET IAR SETPTS DELTA TEMP 10 F 10 to 20 F HI IAR 70 40 to 70 DELTA TEMP 20 F 10 to 20
86. ue the REMOTE ENABLE contact must be closed for remote setpoint operation to function START ADVANCED 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 ADVANCED When this is set to NORMAL the priority of a 4 20mA input when enabled by closure across the 4 20mA INPUT REMOTE ENABLE terminals is in the normal order HIGH FIRE DHW DEMAND HEAT DEMAND HeatNet 4 20mA LOW FIRE When set to HIGHEST the priority sequence is changed to give 4 20mA the highest priority above HIGH FIRE 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 PASSWORD BAUD ADVANCED SETUP This is the Baud rate for serial communication from the MODBUS port Selectable from 1200 2400 COMMUNICATIONS 4800 9600 19200 38400 FORMAT ADVANCED SETUP 8 bits Even Parity 1 stop bit Selectable from 8E1 8N1 8N2 801 COMMUNICATIONS KN USER S CONTROL MANUAL 5 Control menus and adjustments continued Table 8 Setup menus parameter explanations continued LOAD DEFAULTS ADVANCED SE
87. will operate as in the HeatNet local control method Section 1 of this manual But instead of the HEAT DEMAND input a software form of the HEAT DEMAND inputis used address 40001 Boiler System Enable Disable 3 The System Setpoint Timer needs to be loaded periodically to allow the HeatNet system to revert to local control from the master boiler in the event communications is lost 4 The Modbus protocol allows writing and reading registers using Modbus commands An optional BACnet or LonWorks bridge module can be used to connect the Modbus network to a BACnet or LonWorks network 5 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 6 The master boiler assumes the role of MEMBER RTU 192Kb 8 bits Even Parity 1 stop bit when connected to a BMS 7 The Member Boilers should not be connected to a BMS system other than to view read only addresses MODBUS registers 1 See Table 3 Table 4 and Table 5 for register requirements 2 The system setpoint timer and system setpoint work in tandem to externally control the operating setpoint 3 The setpoint countdown timer should be loaded with a timeout value in seconds prior to writing the system setpoint 4 When the timer reaches zero the control assumes that the BMS is no longer operating and the local setpoint
88. y indicate the boiler was in ignition sequence Outside air temperature if sensor connected otherwise display NA DHW demand NC is there is no call for heat or LK if boiler is called to heat by the master boiler n M if main valve was open D if Ae air damper was energized B if blower was on and l if ignition cycle was in process KN4 ONLY D indicates the DHW pump was on 100 or other value shows IAR MAX INPUT value if there was a heat demand at the time Shows which boilers were firing at the time the log entry was made 6 KN USER S CONTROL MANUAL Troubleshooting continued Suggested procedure Nothing happens when the power switch is turned on The display shows combustion air damper failure The display is displaying random characters or the control keeps resetting There are no heating boilers on Unable to change the of Boilers in the BOILERS menu The BOILERS menu only indicates one boiler but there are member boilers connected The amber light blinks on all of the boilers communication s jacks E E E Check 120VAC power to connection board Verify power is connected per wiring diagrams The Power switch light ON Position should illuminate if power is wired correctly Ifthe 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

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