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HydroTherm HeatNet KN-10 User Manual

HydroTherm HeatNet KN-10
108 pages
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Copyright 2014 Mestek, Inc.
This manual is intended only for use by a qualified heating installer/technician. Read and follow this manual, all
supplements and related instructional information provided with the boiler. Install, start and service the boiler only
in the sequence and methods given in these instructions. Failure to do so can result in severe personal injury,
death or substantial property damage.
Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause
contamination of the burner, resulting in possible severe personal injury, death or substantial property damage.
The boiler can only be operated with a dust-free air supply. Follow the instruction manual procedures to duct air to
the boiler air intake. If the boiler has been contaminated by operation with contaminated air, follow the instruction
manual guidelines to clean, repair or replace the boiler if necessary.
Affix these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a
qualified service technician, and to follow all guidelines in the User’s Information Manual.
KNV3-1020
HeatNet
®
V3
This instruction manual applies only to Advanced
Thermal Hydronics
firmware version 1.x on
version 3.x control boards. Current firmware is
backwards compatible with version 1.x & 2.x
boards, but some current features may not be
available. To replace firmware on an existing
boiler, contact the factory to obtain the original
firmware file or for assistance in applying current
firmware to an older version control board.
Control adjustment and operation instructions
for Advanced Thermal Hydronics firmware
version 1.8
Also read and follow:
KN-Series Gas Boiler Installation
and Operating Instructions
KN
Series
Gas-fired direct vent
Cast iron boilers
Models:
KN -6, -10, -16, -20, -26, -30

Table of Contents

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HydroTherm HeatNet KN-10 Specifications

General IconGeneral
BrandHydroTherm
ModelHeatNet KN-10
CategoryBoiler
LanguageEnglish

Summary

Introduction

The KN-Series V3 HeatNet Control

Overview of the third generation HeatNet control platform and its features.

Master Boiler Role

Defines the function and sensor requirements for a master boiler.

Member Boiler Role

Describes the operation and connectivity of member boilers in a system.

Features & Specifications

HeatNet Version 3.x Discontinued Features

Lists features removed or changed from previous HeatNet versions.

Hardware Version 3.x Additional Features

Details new hardware capabilities introduced in version 3.x.

Standard Features Overview

Summarizes the primary capabilities and flexibility of the control.

Specifications

Components & Accessories

SETUP & OPERATION

Basic Multi Boiler System Operation

Explains how to configure and operate multi-boiler systems.

Mixed Boiler Types Using Priority Sets

Details system configuration using priority sets for mixed boiler types.

Mixed Boiler System Operation

Describes the logic for starting and stopping boilers in mixed systems.

Start/Stop Priority Conditions

Explains how to define conditions for starting and stopping boilers.

Selecting Mixed Boilers

Factors to consider when choosing boilers for mixed systems.

Mixed System Type 1: High System Turndown

Example of designing systems for high turndown and fault tolerance.

Mixed System Type 2: Condensing / Non-Condensing

Example of mixing condensing and non-condensing boilers for cost control.

CONTROL METHODS

Base Loading, Relay Control

Details how to configure a base load boiler using relay control.

Setting up base loading

Configuration steps for enabling and controlling base loading.

Heating Control Methods

Heating Method 1

Stand-alone modulating control using PID and Heat Demand input.

Heating Method 2

Boiler operation using two-stage (T1/T2) inputs.

Heating Method 3

Boiler control using 4-20mA or 0-10VDC remote signals.

Heating Method 4

Boiler ON/OFF control at 100% modulation via AA terminal.

Heating Method 5

Boiler control via RS485 digital communications (MODBUS).

Operating Limit

Setting limits to prevent short cycling and protect boiler components.

Input Priorities

Defines the order of precedence for different control inputs.

Heating Method 1 HEAT DEMAND

Detailed explanation of using the Heat Demand input for control.

Heating Method 2 STAGE Control T1-T2

How to use T1 and T2 inputs for two-stage boiler operation.

Heating Method 3 4-20ma Control

Using 4-20mA signals for remote modulation control.

Heating Method 4 AA Input

Utilizing the AA input for high-fire control.

Heating Method 5 MODBUS communications

Controlling boilers via MODBUS protocol using digital commands.

OPTIONAL FEATURES

Using the 4-20ma input (OPTIONAL)

Details on utilizing the optional 4-20mA input for control.

Circulator Pump Options

Configuration options for system and local circulator pumps.

Auxiliary Function Options

Setup for additional functions like combustion air dampers.

Outdoor Reset

How outdoor temperature affects setpoint and system shutdown.

Security

Options for password protection of control and setup features.

Saving Configuration Settings

Procedure for backing up and restoring control settings.

USB Features

Using USB for firmware updates and desktop connectivity.

Blower Protection

Features and settings to protect the blower motor and prevent downtime.

Communications

Capabilities for communicating with building management systems.

Failsafe Modes

Modes to ensure system operation during communication or BMS failures.

Flow Options

Methods for limiting boilers based on system flow.

HeatNet Online

Web-based system for fault notification, monitoring, and tuning.

Domestic Hot Water Methods

DHW METHOD 1: DHW Heating ONLY using H-Net

Controls DHW heating using a DHW Master and member boilers via H-Net.

DHW METHOD 2: Combination DHW and Space Heating

Master boiler simultaneously manages DHW and space heating with dual PID.

DHW METHOD 3: DHW Heating using a Header Sensor Input

Controls tank temperature for extended periods with minimal cycling.

DHW METHOD 4: Space Heating with DHW Override of Setpoint on Master

Uses a tank thermostat to override space heating setpoint for DHW.

DHW METHOD 5: DHW of a Local Boiler’s Tank.

Provides DHW heating priority for individual boilers based on tank temperature.

DHW METHOD 6: DHW using Direct Control

Direct modulation of a boiler using a 4-20mA signal for DHW.

Wiring Connections

Calibration

LOG ENTRY

Default Settings & Menu Item Descriptions — SETUP

Default Settings & Menu Item Descriptions — ADVANCED SETUP

MODBUS COMMUNICATIONS

TROUBLESHOOTING

BoilerStatus4 Flags

Status flags related to DHW, sensors, and limits.

Situation: Nothing happens when the power switch is turned on.

Troubleshooting steps for a completely unresponsive boiler.

Situation: You get the error message for the Combustion Air Damper.

Diagnosing and resolving combustion air damper error messages.

Situation: H-Net boilers are detected but then lost and then detected again etc...

Troubleshooting intermittent H-Net communication issues.

Situation: We are using a Building Management System (BMS) to control the boilers...

Resolving issues with BMS setpoints reverting to default values.

OPERATION

KN HeatNet Control Run Screen

Navigating and understanding the main operational display screen.

KN HeatNet V3 Menu Tree — ADVANCED THERMAL HYDRONICS

KN HeatNet V3 Advanced Menu Tree – ATH

WORKSHEET

APPENDIX A

Status Screen Fault Display

Detailed descriptions of various fault messages and interlocks.

APPENDIX B

Line 4 Log Entries:

Explains system messages displayed on the fourth line of the log.

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