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RBI HEATNET 3.0 Torus Series - User Manual

RBI HEATNET 3.0 Torus Series
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05/2022 Copyright 2020 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.
TRSV3C-IOM-2
82-0962-001
Torus Series
Models:
WB/WW1250, WB/WW1500,
WB/WW2000, WB/WW2500,
WB/WW3000, WB/WW4000
C
ontrol Manual
Control Adjustment and
Operation Instructions
Control adjustment and operation
instructions for RBI firmware version 4.x
This instruction manual applies only to RBI
firmware version 4.x on version 3.x control boards.
Also read and follow:
Torus Series Gas Boiler Installation
and Operating Instruction Manual
H & HLW

Table of Contents

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RBI HEATNET 3.0 Torus Series Specifications

General IconGeneral
CategoryBoiler
BrandRBI
SeriesHEATNET 3.0 Torus Series
DimensionsVaries by model
WeightVaries by model
Fuel TypeNatural Gas, Propane
Vent DiameterVaries by model

Summary

Introduction

The Torus WB;WW Series V3 HeatNet Control

Overview of the integrated boiler management system for Torus Series boilers.

Home Screen

Displays boiler water temperature and monitors limits for orderly shutdown.

Master Boiler Role

A boiler that controls system temperature using a setpoint and PID algorithm.

Member Boiler Role

Boilers that respond to commands from a Master or external control.

Features & Specifications

Hardware Version 3.x Control Features

Lists specific features identified by circuit board color (BLACK) for version 3.x control.

Standard Features Overview

Provides a summary of key features and capabilities of the HeatNet control system.

Components & Accessories

Part Number Listing

Lists part numbers for various control boards, displays, sensors, and cables.

Setup & Operation

Basic Multi Boiler System Operation

Details the setup and operation of multi-boiler systems using HeatNet.

Mixed Boiler Types Using Priority Sets

Explains how to use priority sets to control different boiler types in a mixed system.

Mixed Boiler System Operation

Covers the starting and stopping procedures for mixed boiler systems.

CONTROL METHODS

Start;Stop Priority Conditions

Defines conditions for starting and stopping boiler sets based on priority.

Selecting Mixed Boilers

Discusses factors to consider when choosing boilers for mixed systems.

Mixed System Type 1: High System Turndown

Example of mixed systems with high turndown and fault tolerance.

Heating Control Methods

Heating Method 1: Standalone Modulating

Standalone modulating method using PID and HEAT DEMAND input.

Heating Method 2: Stage Control T1-T2

Operation as two separate boilers or HIGH/LOW using T1 & T2 inputs.

Heating Method 3: 4-20 mA Control

Remote 4-20mA or 0-10VDC signal control for firing rate modulation.

Heating Method 4: AA Input

ON/OFF control at 100% modulation using the AA terminal.

Heating Method 5: MODBUS Communications

RS485 digital communications via MODBUS protocol for boiler control.

Operating Limit

Software operating limit to limit maximum member boiler output to prevent short cycling.

Input Priorities

Priority 1: AA Terminal

AA terminal has absolute control, fires at 100% output.

Priority 2: HEAT DEMAND Input

HEAT DEMAND input for LOCAL mode or external control.

Priority 3: H-Net Network Control

H-Net network cable control between Master and Member boilers.

Priority 4: 4-20 mA;0-10 VDC Input

4-20mA/0-10VDC input with REMOTE ENABLE for boiler operation.

Priority 5: Stage Control T1;T2

Boiler operation using T1 and T2 inputs for HIGH/LOW stage control.

Domestic Hot Water Methods

DHW METHOD 1: DHW Heating Only

DHW heating only, using DHW MASTER and member boilers via H-Net.

DHW METHOD 2: Failsafe Combination DHW;Space Heating (Valves)

Combines DHW/space heating with failsafe mechanisms using valves.

DHW Method 2: Failsafe Combination DHW;Space Heating (Pumps)

Combines DHW/space heating with failsafe mechanisms using pumps.

DHW Method 3: DHW Heating Only (Header Sensor)

DHW heating only, maintaining setpoint at Master's System Header Sensor.

DHW Method 4 a: DHW Override with Aquastat

Space heating with DHW override of setpoint using an aquastat.

DHW Method 4 b: DHW Override with DHW Sensor

Space heating with DHW override using DHW sensor and reverse return.

DHW Method 5 a: Local DHW Tank Heating (10 k Sensor)

Local DHW tank heating using a 10k tank sensor, boiler managed by Master.

DHW Method 5 b: Local DHW Tank Heating (Thermostat;Hybrid Sensor)

Local DHW tank heating using thermostat and hybrid sensor for flexible placement.

DHW METHOD 6: DHW using Direct Control

DHW control using direct 4-20mA input for modulating the boiler.

OPTIONAL FEATURES

Base Loading, Relay Control

Controls a base load boiler using K8 Relay contacts and 4-20mA signal.

Using the 4-20 mA Input

Details operation with 4-20mA input for control and modulation.

Setpoint Priorities

Describes the hierarchy of setpoint controls that can be employed.

Circulator Pump Options

Explains features for system and local circulator pump control and rotation.

Local Pump Options

Details options for local circulator pump behavior, including preventing deadheading.

Combustion Air Damper

Covers control and setup of combustion air dampers, common or independent.

Outdoor Reset

Allows water setpoint to change dynamically with outside air temperature.

Sensors

Information on supported sensors, including thermistors and platinum sensors.

Security Settings

Information on using passwords to lock out control and setup features.

Save;Restore Configuration Settings

Allows saving and restoring system settings to onboard memory or USB.

USB Features

Covers USB updating system and desktop connectivity for firmware and software.

Diagnostics

Explains how to display and identify faults, interlocks, and system status.

Blower Protection

Details blower control functions like acceleration, deceleration, and soft start.

Failsafe Modes

Adds protection for loss of heat conditions, defining requirements and types.

Limited Flow Boiler Control Options

Methods to limit boiler operation based on system flow, including BMS integration.

WIRING CONNECTIONS

Dip Switches and Wiring

Details dip switch settings and wire strip lengths for terminal blocks.

Heating Method 1 H-Net Wiring

Wiring diagram and explanation for H-Net Master/Member communication.

Heating Method 2;4 Wiring

Wiring for AA-High Fire and High/Low stage control inputs.

Heating Method 3: 4-20 mA;0-10 VDC Wiring

Wiring for 4-20mA or 0-10VDC analog input for direct modulation.

Heating Method 5: MODBUS;BACnet;LonWorks Wiring

Wiring for MODBUS, BACnet, or LonWorks via Protocessor module.

Relays, Interlocks, and Boiler Status Wiring

Explains the function of various relays, interlocks, and status indicators.

Temperature Sensor Wiring

Details connections for temperature sensors like Header, Supply, Return, DHW.

Typical Single Boiler System Wiring

Wiring diagram illustrating a typical single boiler system setup.

Common System Damper Wiring

Wiring diagram for common system damper control.

Failsafe Common System Pump Wiring

Wiring diagram for failsafe common system pump operation.

SCREEN DESCRIPTIONS

Home Screen Navigation

Illustrates navigation through various screens during normal operation.

Home Screen Overview

Describes the main Home screen layout for temperatures and ancillary functions.

Home Screen Messages

Explains various messages displayed on the Home screen, categorized by mode.

Master Boiler Status Screen

Displays start/stop timers, boiler status, and modulation for the master boiler.

CALIBRATION

Boiler Calibration Procedure

Procedure for calibrating boiler settings like MINIMUM, MAXIMUM, and IGNITION percentages.

LOG ENTRY

Log Entry Overview

Records major boiler activities, events, faults, and status for troubleshooting.

DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS

Control Settings Menu Navigation

Guide to accessing and navigating the control settings menus.

Control Settings Menu - Page 1

Details settings for HeatNet Boilers, Setpoints, System Pumps, etc.

Control Settings Menu - Page 2

Details settings for Distributed Control, Firing Mode, Adaptive Modulation, etc.

Control Settings Menu - Page 3

Covers Load Factory Calibration, Factory Reset, Save/Restore Settings, Passwords.

Control Settings Menu - Page 4

Provides access to information, manuals, firmware loading, and HeatNet Online.

MODBUS COMMUNICATIONS

MODBUS Input;Output Variables (Read;Write)

Lists Modbus addresses, data types, and valid ranges for control and monitoring.

MODBUS Input Variables (Read Only)

Lists Modbus addresses for read-only variables like temperatures and boiler status.

WORKSHEET

Setup Worksheet

Blank tables for recording setup menu parameters and calibration settings.

Type II Thermistor Resistance;Temperature Table

Type II Thermistor Data

Provides resistance values for Type II thermistors at various temperatures.

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