RBI FUTERA XLF Series Control Manual

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Installation and operation instructions manual (44 pages)

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Installation and operation instructions manual (44 pages)

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Page 1 V3HN-I0M-3 82-0400 HeatNet ® Control Manual Control adjustment and operation instructions for firmware versions Version 3.x This instruction manual applies only to version 3.x firmware on version 3.x control boards. Current firmware is backwards compatible with version 2.x boards, but some current features may not be available.
Page 2 Information contained in this publication regarding device applications and the like The RBI name and logo, Mestek name and logo, Futera, HeatNet, and H- is provided only for your convenience and may be superseded by updates. It is your Net name and logo are registered trademarks of Mestek, Incorporated in the responsibility to ensure that your application meets with your specifications.
Page 3: Table Of Contents
TABLE OF CONTENTS Table of Contents TABLE OF CONTENTS ..........................3 Introduction ..............................5 III/F V3 H ........................5 UTERA USION ERIES ONTROL Features & Specifications ......................... 7 ................................ 7 TANDARD EATURES VERVIEW Specifications ............................9 Components & Accessories ........................10 Setup &...
Page 4 TABLE OF CONTENTS HeatNet Control V3 Auxiliary Function Options ........................59 Outdoor Reset ............................60 Sensors ..............................60 Stack Temperature ..........................60 Security ..............................61 Save/Restore Configuration Settings ..................... 61 USB Features ............................61 Saving/Restoring Settings ........................61 Diagnostics .............................. 61 Communications .............................
Page 5: Introduction
FEATURES & SPECIFICATIONS HeatNet Control V3 ® A boiler, in a Boiler Network, using the HeatNet ® Introduction (H-Net ) protocol. A Member boiler to a boiler management system with multiple input control methods. The Futera III/Fusion-Series V3 HeatNet Control The primary purpose of the control is to maintain the boiler water temperature at the supply or the header sensor using a The Futera III/Fusion-Series V3 boiler control is the third...
Page 6 FEATURES & SPECIFICATIONS HeatNet Control V3 Member Figure 1 Heat band If a “SYS/DHW HEADER” sensor is not connected to J10, a boiler always defaults to the role of Member. The control algorithm is based upon a Heat Band, at the The Member boiler can operate as part of a multi-boiler center of which is the setpoint.
Page 7: Features & Specifications
FEATURES & SPECIFICATIONS HeatNet Control V3 Enhanced boot loader and firmware storage. One Features & Specifications firmware storage location for user updates. One firmware program that always remains resident so that a factory program can be restored. Primary loading is HeatNet Version 3.x Discontinued with a flashdrive.
Page 8 FEATURES & SPECIFICATIONS HeatNet Control V3 Automatically detects the optional temperature sensors 22. Programmable password protection to secure the on power up (Outdoor Air Temp sensor is enabled in programmable settings. the settings menu). 23. Remote 4-20mA setpoint control using a mapped 10.
Page 9: Specifications
FEATURES & SPECIFICATIONS HeatNet Control V3 Specifications Control Microprocessor based PID modulating control (NOT a safety limit) Environment -40 °F to 140 °F, <90% RH non-condensing Input Power 24 VAC, 500 mA Relays 1 System Pump (Lite version), 2 System Pumps (Full Version), Damper, Circulator, Alarm, DHW Pump (v2.x), 8A 250 VAC resistive* - Refer to wiring diagram for application specific ratings K8 on J4.2 &.6 for Base Loading 24 VAC –...
Page 10: Components & Accessories
FEATURES & SPECIFICATIONS HeatNet Control V3 Components & Accessories Part Number Component Description 16-0046 Futera III/Fusion-Series Control Board Version 3.x Full- Optional 16-0047 Futera III/Fusion-Series Control Board Version 3.x Lite - Standard 40-0088 Graphics Display Board 40-0091 Graphics Display, Color Touchscreen (HeatNet Online Interface) 16-0026 Temperature probe (bullet type, 1x.250 inch) ACI/10K-CP-BP 14-0325...
Page 11: Setup & Operation
SETUP & OPERATION HeatNet Control V3 The Master now checks all of the runtimes to determine SETUP & OPERATION which boiler has the least runtime based on the MIN RUNTIME setting in ADVANCED SETUP: FIRING MODE:. The MIN RUNTIME setting is the minimum runtime interval in hours that is used to compare boiler to Basic Multi Boiler System Operation boiler runtimes.
Page 12: Mixed Boiler Types Using Priority Sets
SETUP & OPERATION HeatNet Control V3 10. If main-flame is detected the H-Net control holds the Mixed Boiler Types Using burner at the low-fire rate for the MODULATION Priority Sets DELAY time period. After this timer expires, the PID allows the boiler to modulate and places the boiler into Using the Basic Multi Boiler System Operation, a MIXED the running state.
Page 13 SETUP & OPERATION HeatNet Control V3 available. The Master boiler then looks at which boilers are Temp), the PRIORITY 2 set of boilers will stop first/next returning Priority firing status (set on a boiler in: based on their highest runtime. (ADVANCED SETUP:FIRING MODE: MODE: A boiler’s firing Priority can be designated as such in: MIXED: SET LAST (example) If the Stop condition for...
Page 14: Start/Stop Priority Conditions
SETUP & OPERATON HeatNet Control V3 temperature on the Master is used to provide a difference Start/Stop Priority Conditions temperature across the heat exchanger. A System Return sensor will be required. However, the return temperature The following is an example using mixed sensor may have been moved on the Master to provide condensing and non-condensing boilers: system return temperature on existing installations and is...
Page 15: Selecting Mixed Boilers
SETUP & OPERATON HeatNet Control V3 condensing boilers (Fusion-Series) when the return water MOD MAX CLAMP: This value determines the temperature is below 140F. maximum modulation % at which the boilers will fire to, until all available boilers are firing. The return water temperature sensor would Total System BTUs.
Page 16 SETUP & OPERATON HeatNet Control V3 With the traditional Non-Mixed boiler system, the effective The reason for this is to keep the continuity of BTUs linear turndown increases by the turndown ratio for every boiler without a BTU bump (discontinuity) when boilers are added added.
Page 17 SETUP & OPERATON HeatNet Control V3 Non-Condensing Boilers chart can help illustrate how the Fusion boilers from low to middle input rates. See: Typical MOD-MAX value can affect the efficiency by limiting the Efficiency of Condensing Boiler graph. input until all boilers have fired. Non-condensing boiler efficiency is relatively flat compared with condensing as Figure 9 Boiler System Response 1...
Page 18: Mixed System Type 2: Condensing / Non-Condensing
SETUP & OPERATON HeatNet Control V3 Figure 10 Boiler System Response 2 Figure 12 Boiler System Response 4 (1) MB/MW 500, (3) MB/MW 1250, 60% Mod- (2) MB/MW 500s, (3) MB/MW 2000s Blr 1+2 (1750 MBTU) Blr 1+2+3 (3000 MBTU) Blr 1+2+3 (4250 MBTU) 1.00 0.90...
Page 19 48:1 1500 The Member’s menu “SETUP: AUX FUNCTIONS: HEAT For the examples, the RBI FIII/Fusion series water heaters EXCHNAGER: TEMP DISAB:” if set to RETURN or SYS will be used. These boilers are non-Condensing, fully RET, will force the boiler to become unavailable to modulating, low mass, and HeatNet compatible.
Page 20 SETUP & OPERATON HeatNet Control V3 available” state, it can still be fired locally and failsafe is dashed lines). Once all boilers are firing, the modulation is still available. released allowing all boilers to fire to 100%. SETUP: AUX FUNCTIONS: HEAT EXCHANGER: Figure 15 Boiler System Response 5 SEND RETURN:...
Page 21 SETUP & OPERATION HeatNet Control V3 Figure 17 Mixed Boilers: Example: Condensing/Non-Condensing Page 21...
Page 22: Heating Control Methods
CONTROL METHODS HeatNet Control V3 Short cycling may occur when a firing rate is Heating Control Methods sent to a Member boiler that would cause the supply temperature to rise high enough to trip the operating limit (low flow rate). After the An overview of the (5) methods for controlling the Futera supply temperature falls, the boiler would III/Fusion series boiler are presented here.
Page 23: Heating Method 1 Heat Demand
CONTROL METHODS HeatNet Control V3 external control is not present, has failed, or needs to be Master boiler enabled or disabled. A Member can override the H-Net The MASTER boiler controls the system using a PID commands using this input. algorithm.
Page 24: Heating Method 4 Aa Input
CONTROL METHODS HeatNet Control V3 Closing the other contact will fire the boiler at MAXIMUM Heating Method 4 output (the same rate as closing the AA input). AA Input Figure 19 Stage control inputs HIGH FIRE input Control: The AA input will fire the boiler at HIGH fire (maximum output of the boiler).
Page 25: Base Loading, Relay Control
CONTROL METHODS HeatNet Control V3 The System Setpoint Timer also needs to be loaded Base Loading, Relay Control periodically to allow the H-Net system to fallback to Method 1 in the event communications is lost from the The H-Net control has the ability to control (1) base load Building Management System (BMS).
Page 26 CONTROL METHODS HeatNet Control V3 that is sized correctly to the H-Net boilers. Consider the Figure 24 Base loading with Dominator boiler Futera II or the Dominator series for the Base Load role. If the base load boiler is not of the modulating type, stopping the Base Load boiler will require that the size of the Base Load boiler in BTUs to be known relative to the HeatNet boilers.
Page 27 CONTROL METHODS HeatNet Control V3 Figure 25 Base loading relay Page 27...
Page 28: Setting Up Base Loading
CONTROL METHODS HeatNet Control V3 from the Return Water Temperature sensor (if Setting up base loading Equipped) rises above this temperature. ADVANCE SETUP:BASE LOADING: STOP< RET The base load boiler is controlled using a set of contacts to enable it (location J4). Enabling/Disabling this relay contact FIRST: can be done using any combination of (3) qualifiers to start STOP menu item: The relay contact will open to...
Page 29: Dhw Maximum Runtime
CONTROL METHODS HeatNet Control V3 down or loses communication with the Member, a Failsafe Figure 26 Jumper JPS1 mode is available to provide temporary heat. The DHW Failsafe mode is active when a Member boiler’s SETUP: AUX FUNTIONS: FAILSAFE MODES: H-NET COMM LOST: is set to ON.
Page 30: Dhw Method 1: Dhw Heating Only Using A Dhw Master And Member Boiler(S) Employing H-Net
DHW METHODS HeatNet Control V3 DHW Method 1: DHW Heating ONLY using a DHW MASTER and MEMBER Boiler(s) Employing H-Net Figure 27 Example DHW Only, Reverse Return Piping – Method 1. Domestic Domestic Supply Supply Tank Sensor Make Make Pressure Reducing Backflow Prevention...
Page 31 DHW METHODS HeatNet Control V3 Figure 28 DHW Method 1 Quick Start Settings DHW METHOD 1: DHW Heating ONLY Using a DHW MASTER and MEMBER Boiler(s). MASTER (DHW Only) Settings DHW Use Sensor HeatNet Address MASTER Type Combustion Air Damper Automatic DHW Only Inputs...
Page 32 DHW METHODS HeatNet Control V3 This method requires a 10k thermistor connected to the this method as a DHW system much like a space DHW Sensor input of a DHW MASTER, or a standalone heating system. boiler, and a DHW tank. This method does not use a HEADER sensor.
Page 33 DHW METHODS HeatNet Control V3 The MASTER’s DHW relay will remain on as long B. The System pump on the MASTER boiler as there are boiler’s firing and the DHW functions as a global pump and remains on as long as the heat demand is enabled. temperature is below the (DHW SETPOINT + UPPER BAND).
Page 34: (Master Type : Combination )
DHW METHODS HeatNet Control V3 DHW Method 2: Failsafe Combination DHW and Space Heating with a MASTER Boiler and MEMBER Boilers Utilizing Valves (MASTER Type: Combination) Figure 29 In this example the MASTER is not a DHW boiler. MIN 3X PIPE DIAMETERS MAX 10X PIPE DIAMETERS BETWEEN CENTERS System Supply...
Page 35 DHW METHODS HeatNet Control V3 Figure 30 DHW Method 2 W/Diverting Valves Quick Start Settings DHW METHOD 2: Combination DHW and Space Heating Using a MASTER Boiler and MEMBER Boiler(s) Employing Diverting Valves. MASTER (Space Heating Only W/Valves) Settings MASTER Type HeatNet Address DHW Use Sensor Combustion Air Damper...
Page 36: Dhw Method Ailsafe Ombination Dhw And Pace Eating With Amaster Boiler And Member Boilers Tilizing Umps (Master Type Ombination )
DHW METHODS HeatNet Control V3 DHW Method 2: Failsafe Combination DHW and Space Heating with a MASTER Boiler and MEMBER Boilers Utilizing Pumps (MASTER Type: Combination) Figure 31 In this example the MASTER is not a DHW boiler. MIN 3X PIPE DIAMETERS MAX 10X PIPE DIAMETERS BETWEEN CENTERS System Pump...
Page 37 DHW METHODS HeatNet Control V3 Figure 32 DHW Method 2 W/Pumps Quick Start Settings DHW METHOD 2: Combination DHW and Space Heating Using a MASTER Boiler and MEMBER Boiler(s) Utilizing DHW Pumps. MASTER (Space Heating Only W/Pumps) Settings MASTER Type HeatNet Address DHW Use Sensor Combustion Air Damper...
Page 38 DHW METHODS HeatNet Control V3 This Method highlights the flexibility of the HeatNet The DHW Method 2 examples uses (3) boilers. The system. It works much the same as DHW METHOD 1, but MASTER controls the Space and Domestic needs, though it also has the ability to provide space heating and failsafe is not a DHW boiler.
Page 39 DHW METHODS HeatNet Control V3 setting is the maximum tank temperature. Setting YES The local pump will shut off with a delay the SHED BOILER DELAY TIME correctly will determined by LOCAL DELAY: seconds. This limit the maximum tank temperature to the allows the DHW pump/valve to prove before (DHW SETPOINT + UPPER BAND).
Page 40: Dhw Method 3: Dhw Heating Only, Using A Header Sensor Input
DHW METHODS HeatNet Control V3 DHW Method 3: DHW Heating Only, Using a Header Sensor Input Example: DHW Only Using Header Sensor, Primary/Secondary – Method 3 Figure 33 Domestic Domestic Supply Supply Tank Sensor Make Make HeatNet HeatNet HeatNet HNET HNET MASTER MEMBER 2...
Page 41 DHW METHODS HeatNet Control V3 Figure 34 DHW Method 3 Quick Start Settings METHOD 3: DHW Heating ONLY Using a MASTER and MEMBER boiler(s) Employing H-Net Space Heating PID. Master Settings MASTER Type HeatNet Address Combustion Air Damper Automatic Automatic Inputs Local/Remote Header Sensor...
Page 42 DHW METHODS HeatNet Control V3 This method will control a tank temperature when the tank INTRODUCTION section on the MASTER in temperature setpoint needs to be maintained for extended the beginning of this manual. periods with minimal cycling. Multiple boilers can be used via the H-Net, as this method employs the same PID This differential has the added effect of heating the tank above the tank’s setpoint temperature.
Page 43: Dhw Method 4A: Space Heating With Dhw Override Of Setpoint On Master, Using An Aquastat
DHW METHODS HeatNet Control V3 DHW Method 4a: Space Heating with DHW Override of Setpoint on MASTER, using an Aquastat Figure 35 Example: DHW METHOD 4a Space Heating with DHW Override of Setpoint on MASTER, using an Aquastat, Primary Secondary, Reverse Return DHW METHOD 4a: Space Heating with DHW Override of Setpoint on MASTER, using an Aquastat, Primary Secondary, Reverse Return In DHW METHOD 4a, the MASTER’s Heat Demand input enables space heating by energizing the system pump and...
Page 44 DHW METHODS HeatNet Control V3 Figure 36 DHW Method 4a Quick Start Settings DHW METHOD 4a: Space Heating with DHW Override of Setpoint on MASTER Using an Aquastat. MASTER Settings Master Type HeatNet Address Combustion Air Damper Auto Automatic Inputs JPS1 Jumper must be cut to Local/Remote OR OVR...
Page 45 DHW METHODS HeatNet Control V3 This method is for controlling DHW utilizing a tank system pump on. This active period includes the post thermostat connected to a MASTER boiler. This method purge of the DHW/valve pump. requires a thermostat input to the OR OVR. When the Select the menu item POST PURGE.
Page 46: Dhw Method 4B: Space Heating With Dhw Override Of Setpoint On Master, Using A Dhw 10K Tank Sensor
DHW METHODS HeatNet Control V3 DHW Method 4b: Space Heating with DHW Override of Setpoint on MASTER, using a DHW 10K Tank Sensor Figure 37 Example: DHW Method 4b: Space Heating with DHW Override of Setpoint on MASTER, using a DHW Sensor, Primary Secondary, Reverse Return.
Page 47 DHW METHODS HeatNet Control V3 Figure 38 DHW Method 4b Quick Start Settings DHW METHOD 4b: Space Heating with DHW Override of Setpoint on the MASTER Using a 10K Tank Sensor. Master Settings MASTER Type HeatNet Address DHW Use Sensor Combustion Air Damper Auto Automatic...
Page 48 DHW METHODS HeatNet Control V3 This method is for controlling DHW utilizing a 10k sensor mode is active. Setting this value to NO leaves the in the tank connected to DHW TANK (J10A, 9 & 10) of a system pump on. This active period includes the post MASTER boiler.
Page 49: Dhw Method 5A: Local Dhw Tank Heating Using A 10K Tank Sensor
DHW METHODS HeatNet Control V3 DHW Method 5a: Local DHW Tank Heating using a 10k Tank Sensor. Example: DHW Heating to a Local Boiler’s Tank,– Method 5a Figure 39 Domestic Hot Domestic Hot Water Water System Supply Supply Supply Make Up Make Up Tank Sensor Tank Sensor...
Page 50 DHW METHODS HeatNet Control V3 Figure 40 DHW Method 5a Quick Start Settings DHW METHOD 5a: Local Tank Heating Using a DHW Tank Sensor MASTER Settings MASTER Type HeatNet Address Combustion Air Damper Automatic Automatic Inputs Local/Remote Header Sensor System Return Local Optional Outputs...
Page 51 DHW METHODS HeatNet Control V3 This method is used to provide combination space heating A. The pump/valve will remain enabled during a and DHW heating. The boiler may be standalone or in a post purge pump cycle until the post purge timer HeatNet configuration.
Page 52 DHW METHODS HeatNet Control V3 If SHARING is set to NO CYCLE, a hot swap 11. Set the PURGE TO value to TANK. This will will occur. A hot swap is when the boiler is purge the heat from the boiler into the tank or running in space heating mode and does not need system loop.
Page 53: Dhw Method 5B: Local Dhw Tank Heating Using A Thermostat & Hybrid Sensor
DHW METHODS HeatNet Control V3 DHW Method 5b: Local DHW Tank Heating using a Thermostat & Hybrid Sensor. Example: DHW Heating to a Local Boiler’s Tank, Movable Sensor Location – Method 5b Figure 41 Domestic Domestic Supply Supply System Supply Tank Thermostat Tank Thermostat Cold Water...
Page 54 DHW METHODS HeatNet Control V3 Figure 42 DHW Method 5b Quick Start Settings DHW METHOD 5b: Local Tank Heating using a Hybrid Sensor (DHW, Supply, or Return) MASTER Settings MASTER Type HeatNet Address Combustion Air Damper Automatic Automatic Inputs Local/Remote Header Sensor System Return Local...
Page 55: Dhw Method 6: Dhw Using Direct Control (Not Preferred)
DHW METHODS HeatNet Control V3 Method 5b can also be used in a Hybrid mode on the DHW call, post-purge the pump, and put itself back on MEMBER boilers with a thermostat connected to the OR line available for space heating. OVR input.
Page 56 OPTIONAL FEATURES HeatNet Control V3 functionality. To convert a 0-10VDC signal to mA, divide Figure 43 Example: 4–20 mA connections by 2510 (ohms). 24 VDC Return NOTE: Due to the inability of control voltage methods (1-5, 2-10 VDC) to reject noise and compensate for line loss, the Channel 2: Channel 1: use of the 4-20mA control current is recommended.
Page 57: Setpoint Priorities
OPTIONAL FEATURES HeatNet Control V3 setpoint is defined as 4mA SETPOINT and the upper setpoint normally open contacts at J16 SYSTEM PUMP 1 and is defined as 20mA SETPOINT. The 4mA SETPOINT is SYSTEM PUMP 2. linked to the BOILER START x.xxmA where this starting current is the lower setpoint.
Page 58 OPTIONAL FEATURES HeatNet Control V3 The system flow proving switch is implemented using pump relative to how many boilers are firing. The VFD SPARE 3/System Water Flow on J11A. If a flow switch is would need to be set appropriately to allow the correct flow connected to the WTR FLW interlock, the HeatNet control through each boiler.
Page 59: Local Pump Option
OPTIONAL FEATURES HeatNet Control V3 open, the system will not start. If the Master boiler’s system Local Pump Option damper fails, then no call for heat will be made to the Member boiler(s). LOCAL PUMP/VALVE OPTION: This is a special feature, when using valves, it prevents deadheading water Using the INDEPENDENT setting, each Member boiler can flow when all boilers are off.
Page 60: Outdoor Reset
OPTIONAL FEATURES HeatNet Control V3 value when a contact is closed across this input. This can be Outdoor Reset used as a Domestic Hot Water demand input. The Outdoor reset feature allows the water setpoint Another function of the OUTDOOR RESET is the temperature to change dynamically with the outside air Winter/Summer mode ((W)arm (W)eather (S)hutdown).
Page 61: Security
OPTIONAL FEATURES HeatNet Control V3 The Stack sensor should be a 1k ohm platinum type sensor. new file. Location 1 is used for normal updates and Location Part # 0040-1300. To configure the 1k PT Stack sensor, 0 is for the factory stored backup file. When the Storage Switch S5.3 should be set to the NONE position and S5.4 set location (default is Location 1) is selected the file will be to PLATINUM STACK.
Page 62: Communications
OPTIONAL FEATURES HeatNet Control V3 the data. If using Modbus, BACnet, or LonWorks, there are If the combustion air damper is used as a common software flag bits in registers available. system damper, the Failsafe boiler should be wired to control the damper in parallel with the Master boiler.
Page 63: Category 1 Venting
OPTIONAL FEATURES HeatNet Control V3 This MEMBER boiler will continue to run at the temperature the boiler will start and fire to its LOCAL LOCAL setpoint until H-NET communications from the setpoint. Once the Boiler reaches its setpoint it will turn MASTER boiler is re-established.
Page 64 OPTIONAL FEATURES HeatNet Control V3 When using the BMS GPM register the BTU values are only for the Master Boiler; if Status 4 bit (12) is set, it calculated to a whole GPM since the BMS GPM register indicates that the HeatNet control is running with currently does not support floating point numbers.
Page 65: Heatnet Online
OPTIONAL FEATURES HeatNet Control V3 d. TYPE to mA 2 or VOLTS 2 depending on whether Sample email message: a 4-20 milliamp or 0-10 volt signal is used. The connection should be made from the Flow Meter to analog input 4-20 mA (2). e.
Page 66: Wiring Connections
OPTIONAL FEATURES HeatNet Control V3 This screen is an excellent way to diagnose system Runtime graphs of each boiler ensure even runtimes are problems and tune systems for optimal performance. being observed by a properly operating system. Data Points can also be viewed in a manner other than a histogram as pictured below.
Page 67 WIRING CONNECTIONS HeatNet Control V3 Figure 49 Jumper & Dip Switch Locations Page 67...
Page 68 WIRING CONNECTIONS HeatNet Control V3 Figure 50 Heating Method 1 H-Net, Master/ Member Figure 51 Boiler Terminal Block Page 68...
Page 69 WIRING CONNECTIONS HeatNet Control V3 Figure 52 Heating Methods 2 and 4: AA-High Fire and High/Low, Master or Member boiler Heating Mode 4: High Fire Close this contact to run boiler at Highfire. Heating Mode 2: Stage Control Inputs. T1 or T2 Closed: Lowfire T1 &...
Page 70 WIRING CONNECTIONS HeatNet Control V3 Figure 53 Heating Method 3 4–20 mA / 0-10 VDC Figure 54 Boiler Terminal Block Page 70...
Page 71 WIRING CONNECTIONS HeatNet Control V3 Figure 55 Heating Method 5: MODBUS (Optional BACnet or LonWorks bridge — Protocessor) http://rbiwaterheaters.com/resource-center/technical-library/ Page 71...
Page 72 WIRING CONNECTIONS HeatNet Control V3 Figure 56 Relays, Interlocks and Boiler Status The Highest priority SYSTEM FLOW PROVE --------- Low Water Cutoff------------------- Variable Frequency Drive -------- Gas Pressure (High & Low) ----- Spare for user or Factory ------ Operator------------------------------ Water Flow Switch----------------- Factory ------------------------------ Low Voltage Interlocks, 24VAC...
Page 73 WIRING CONNECTIONS HeatNet Control V3 Figure 57 Temperature sensors Page 73...
Page 74 WIRING CONNECTIONS HeatNet Control V3 Figure 58 Typical Single Boiler System HEADER SENSOR (Determines Master Boiler) #4 SYSTEM PUMP LOCAL PUMP OUTDOOR ENABLE #14 ENABLE #8 DHW TANK SENSOR FLOW PROVE #9 FLOW PROVE AQUASTAT #13 North Away From Exhaust DHW TANK RETURN SUPPLY...
Page 75 WIRING CONNECTIONS HeatNet Control V3 Figure 59 Using a 4–20mA signal for direct modulation A control signal greater 20mA than 4.2mA (adjustable) will start boiler. Output Range From No Effect Control Control Signal Once boiler starts the control signal must Display input % of control when running drop below 4.01 mA to stop Boiler...
Page 76 WIRING CONNECTIONS HeatNet Control V3 Figure 60 Common system damper wiring MEMBER BOILER 2 MEMBER BOILER 1 Connection if Member boiler is running as Failsafe MASTER BOILER NOTE: Ensure that the Combustion Air Damper is enabled on all Boilers for use. SETUP MENU:AUX FUNCTIONS DAMPER Prove Switch...
Page 77 WIRING CONNECTIONS HeatNet Control V3 Figure 61 Failsafe common system pump wiring MEMBER BOILER 1 120 VAC Return DPST Relay Add additional relays/ contacts for more boilers System Flow Prove Switch 120VAC 120VAC 120 Return MASTER BOILER System Pump Voltage Return System Pump Voltage Feed System Pump System Pump...
Page 78: Status Information
WIRING CONNECTIONS HeatNet Control V3 * Status Information Whenever an * is displayed on the RUN screen it indicates that there is more information available about the current running conditions. This information can be viewed by going to the *STATUS screen as shown on the previous page. For more information on the parameters discussed here please see the Default Settings &...
Page 79 WIRING CONNECTIONS HeatNet Control V3 Status information screens This screen indicates the control is attempting to re- initiate the ignition control because the ignition control did not begin PRE-PURGE. For more information see CALL SERVICE LOG entry. This screen indicates that the boiler’s has received a heat demand, but its MINIMUM OFF time has not expired.
Page 80: Status Screen Fault Display
WIRING CONNECTIONS HeatNet Control V3 Status Screen Fault Display There are numerous interlock switches and software limits that are detected. Each of these, when tripped will produce a display message, an audible beeping, and an alarm relay closure. The fault is displayed first, then after a second, the time the fault occurred is displayed.
Page 81 WIRING CONNECTIONS HeatNet Control V3 SYSTEM WATER FLOW: IGNITION CTRL ALARM: Once the HeatNet series boiler receives a call for heat, it The ignition control alarm is displayed if the ignition closes the system circulator pump relay. It then waits 10 control detects a fault.
Page 82 WIRING CONNECTIONS HeatNet Control V3 OPEN ******* SENSOR: CALL SERVICE: If the open sensor fault is displayed, the sensor in the position reported was originally detected, but has since If the H-Net control closes the last interlock string entering opened. The boiler will shut down on any OPEN sensor the ignition control and the ignition control never closes its except the OUSTSIDE AIR sensor.
Page 83: Calibration
Calibration HeatNet Control V3 Calibration Press the arrow keys until MIN VFD is shown in the display, along with the minimum percentage value at which The calibration of the Futera III/Fusion- the boiler is to run at min fire. While in Standby (no call for Series boiler should only be performed heat on inputs), the minimum percent may be preset.
Page 84: Log Entry
LOG ENTRY HeatNet Control V3 The control state is defined as the Boiler(s) that is running, Log Entry the Circulator Pump state, and the ignition condition (Main Valve, Pilot Valve, Blower, and the Ignition alarm). The # of boilers that are displayed is limited to 7 if the boiler is the To access the Log Files, press and hold, the “Back”...
Page 85: Line 4 Log Entries
LOG ENTRY HeatNet Control V3 Line 4 Log Entries: To access the Log Files, press and hold, the “Back” button for 5 seconds, the control will beep once. There are three menu options, SETUP, ADVANCED SETUP, and VIEW LOG. Place the curser in front of the VIEW LOG menu item and press “Select”.
Page 86 LOG ENTRY HeatNet Control V3 Line # 4 Message Description OUTDOOR RESET This log entry indicates that Warm Weather Shutdown is in effect. This log entry occurs when the temperature across the heat exchanger has HIGH DELTA TEMP been greater than the EXCHR DELTA T RANGE degrees F. After 24 hours of continuous runtime the ignition control module needs to SHUTDOWN UV TEST check its UV detection circuit.
Page 87 LOG ENTRY HeatNet Control V3 Line # 4 Message Description SHORTED OUTSIDE SENSOR, SUPPLY SENSOR, If one of the 10k thermistor sensors was detected to be shorted this fault will RETURN SENSOR, be logged. HEADER SENSOR, DHW SENSOR If a call is made to the ignition control to start and the HeatNet control detects AIR SWITCH(BLOWER) a blower start, but no Pilot within two minutes, the boiler locks out.
Page 88: Default Settings & Menu Item Descriptions - Setup
DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 Default Settings & Menu Item Descriptions — SETUP To enter the Settings Menu, press and hold, the “Back” button for 5 seconds, the control will beep once. There are three menu options, SETUP, ADVANCED SETUP, and VIEW LOG.
Page 89 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 If ROTATION is set to SYS HRS, ROTATE TIME is used to switch pumps when this time expires. This time is measured against the actual time the system pump is enabled. This would include a post purge time.
Page 90 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 START DAY Day of the week to begin setback or a day range TIME 12:00AM Time to begin setback END DAY Day of the week to end the setback or a day range TIME 12:00AM Time of the day to end the setback...
Page 91 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 FAILSAFE MODES If this entry is set to ON and the Member boiler does not see any RUN IN LOCAL IF: communications coming from the Master boiler, this boiler will run H-NET COMM LOST in LOCAL.
Page 92 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 DOMESTIC HOT WATER Setting this value to LOCAL or COMBO enables the DHW PID. Setting this value to NO disables the DHW PID. LOCAL allows the boiler to run in DHW locally off of its own sensor or stat input.
Page 93 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 YES will shut off the local pump/valve when DHW heating is in effect. If the boiler is running in space heating mode, the LOCAL DELAY will be in effect before the local pump/valve shuts off. LOCAL PUMP OFF NO, YES NO both the local and the DHW pump/valve will be enabled during...
Page 94: Default Settings & Menu Item Descriptions - Advanced Setup
DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 Default Settings & Menu Item Descriptions — ADVANCED SETUP DISTRIBUTED CTRL CONTROL H-Net Displays method of operation: HeatNet (H-Net) Auto detected, based on the HEADER sensor. If the HEADER sensor is present and is set to TYPEZ, the Futera H-Net MASTER III/Fusion-Series control is run as a H-Net MASTER (YES).
Page 95 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 In mixed boiler size configurations, more than (2) boilers in a system, or when “bumps” in the temperature occur as boilers are added and subtracted, this value may need adjustment. The adjustments will help produce smooth temperature control when each boiler is started and stopped.
Page 96 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 This is the time in minutes that the boiler must remain OFF before it can be fired again. Very effective in dynamic systems to minimize MIN OFF TIME 0-10m short cycling of a boiler and force the call to the next boiler (with next shortest runtime if True Runtime is used) There are (2) Priority settings used by the MIXED boiler rotation algorithm.
Page 97 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 Placing a precision 10k (TYPEZ) precision resistor across the sensor input selected allows calibration of the sensor input. Do not select CALIBRATE calibrate with the temperature sensing thermistor/PT connected. Doing this will cause significant temperature errors. 4–20mA INPUT There are (2) channels that may be configured for 4-20mA inputs or 0-10VDC inputs.
Page 98 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 This time is used to automatically reset the SETPOINT TIMER when any Modbus value is written. If it is set to 1 minute, a periodic SETPT TIME 1 minute 1-240 minutes write to one of the registers must occur within 1 minute otherwise the BMS Setpoint will revert back to the System/Local setpoint.
Page 99 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 Currently not used. Flow Factor SYSTEM BOILER TYPE CONFIGURE INTERLKS The 24 VAC interlocks can be enabled or disabled for reporting. Enters the Load Firmware menu. Loading new firmware allows for LOAD FIRMWARE upgrades and bug fixes to the HeatNet control.
Page 100 DEFAULT SETTINGS & MENU ITEM DESCRIPTIONS HeatNet Control V3 This defines the mass of the boiler. This value is not used with this MASS MEDIUM LOW,MEDIUM, HIGH version and is displayed only for reference and future applications. This is the turndown of the boiler. For the Futera III/Fusion-Series the default is 5:1 and determines the minimum firing percentage.
Page 101: Modbus Communications
MODBUS COMMUNICATIONS HeatNet Control V3 MODBUS Communications The Futera III/Fusion-Series control can be controlled using Modbus commands to Enable/Disable the boiler/system. A connection to the Console Modbus Port on the Communications board is required. The Master Boiler assumes the role of MEMBER, RTU, 192Kb, 8 bits, Even Parity, 1 stop bit, when connected to a BMS (Building Management System).
Page 102 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 63 MODBUS Input/Output Variables (Read/Write) Address Name Raw Data Type Scale Description Valid Values/Range Set real time clock – year (see SetClock) 0 – 99 40012 SetYear 8 bit unsigned Set real time clock – hour (see SetClock) 0 –...
Page 103 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 64 MODBUS Input Variables (Read Only) Raw Data Address Name Scale Description Valid Values/Range Type 30016 Boiler01Status1 30017 Boiler01Status2 30018 Boiler02Status1 30019 Boiler02Status2 30020 Boiler03Status1 30021 Boiler03Status2 30022 Boiler04Status1 30023 Boiler04Status2 30024 Boiler05Status1 30025 Boiler05Status2 30026 Boiler06Status1...
Page 104 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 64 MODBUS Input Variables (Read Only) Raw Data Address Name Scale Description Valid Values/Range Type 30056 Boiler05RuntimeHigh16 Example Boiler01Runtime = 30057 Boiler05RuntimeLow16 (Boiler01RuntimeHigh16 * 65536) + 30058 Boiler06RuntimeHigh16 Boiler01RuntimeLow16 30059 Boiler06RuntimeLow16 Boiler01 = Master 30060 Boiler07RuntimeHigh16 Boiler02 = Member01...
Page 105 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 64 MODBUS Input Variables (Read Only) Raw Data Address Name Scale Description Valid Values/Range Type ----- The following registers are available starting in firmware version 2.0 ----- 30096 Boiler01SupplyTemp 30097 Boiler02SupplyTemp 30098 Boiler03SupplyTemp 30099 Boiler04SupplyTemp 30100 Boiler05SupplyTemp...
Page 106 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 64 MODBUS Input Variables (Read Only) Raw Data Address Name Scale Description Valid Values/Range Type 30135 Boiler04CyclesLow16 Example Boiler01Cycles = 30136 Boiler05CyclesHigh16 (Boiler01CyclesHigh16 * 65536) + 30137 Boiler05CyclesLow16 Boiler01CyclesLow16 30138 Boiler06CyclesHigh16 Boiler01 = Master Boiler02 = Member01 30139 Boiler06CyclesLow16...
Page 107 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 64 MODBUS Input Variables (Read Only) Raw Data Address Name Scale Description Valid Values/Range Type 30175 Boiler16Status4 30176 … RESERVED 30207 30208 Boiler01DHWTemp 30209 Boiler02DHWTemp 30210 Boiler03DHWTemp 30211 Boiler04DHWTemp 30212 Boiler05DHWTemp 30213 Boiler06DHWTemp 30214 Boiler07DHWTemp 30215 Boiler08DHWTemp...
Page 108 MODBUS COMMUNICATIONS HeatNet Control V3 Figure 64 MODBUS Input Variables (Read Only) Raw Data Address Name Scale Description Valid Values/Range Type 4) The 4-20mA (0-10V) setpoint. 16 bit signed 0 - 16 The maximum number of boilers available to 30241 AvailableBoilers fire.
Page 109 MODBUS COMMUNICATIONS HeatNet Control V3 MODBUS — BoilerStatus Flags Figure 65 Description Valid Values/Range System Pump 0 = off, 1 = on Combustion Air Damper 0 = off, 1 = on Master Boiler 0 = Member, 1 = Master Boiler Detected (at this address) 0 = not detected, 1 = detected MODBUS —...
Page 110 MODBUS COMMUNICATIONS HeatNet Control V3 MODBUS — BoilerStatus3 Flags Figure 67 0 = off, 1 = on 0 = off, 1 = on reserved for future use reserved for future use reserved for future use reserved for future use reserved for future use reserved for future use reserved for future use reserved for future use...
Page 111 MODBUS COMMUNICATIONS HeatNet Control V3 BoilerStatus4 Flags Description Valid Values/Range DHW Enabled (1) 0 = off, 1 = on (menu) DHW Mode had been enabled in the menus. Combustion Air Damper Prove (1) 0 = not proven, 1 = proven Status of Combustion Air Damper Prove Input J12B Call Service Fault 0 = off, 1 = on...
Page 112: Troubleshooting
TROUBLESHOOTING HeatNet Control V3 Situation: Troubleshooting The display is displaying random characters or the control keeps resetting. This section is included as an aide to help troubleshoot problems with the setup and operation of the boiler. There may exist a grounding problem with the controller or one of the boilers, pumps, contactors or other devices connected to it.
Page 113 TROUBLESHOOTING HeatNet Control V3 sources, such as: Motors, ignition controls, Situation: contactors etc… The boilers menu only indicates 1 boiler, but there are Member boilers connected and the amber light blinks on all of the boilers communication’s jacks. Situation: Ensure that the latest version of firmware is installed on Only the MASTER boiler Fires, but the system has all boilers.
Page 114 TROUBLESHOOTING HeatNet Control V3 While in the operating limit band, the HeatNet control Situation: limits the input of the boiler. The boiler tries to deliver Firmware update program starts to load, but then the most input it can in an attempt to meet the called for stops, or does not load at all.
Page 115 TROUBLESHOOTING HeatNet Control V3 HeatNet control to help eliminate electrical noise (VFD Situation: and spark pickup, power spikes, etc.) on the power We are using a BACnet or LonWorks bridge. We supply lines. Please download complete HeatNet can talk to the bridge, but all of the data is zero (0) bridge installation instructions from the product web or invalid.
Page 116 TROUBLESHOOTING HeatNet Control V3 Newer firmware versions allow the SETPOINT feature can permanently disabled (or enabled) or can be TIMER failsafe feature to be disabled by writing a zero adjusted up to 4 hours before a new value is written. (0) to the timer.
Page 117: Futera Iii/Fusion-Series Heatnet Control Run Screen
OPERATION HeatNet Control V3 Futera III/Fusion-Series HeatNet Control Run Screen Press the UP or DOWN Arrow Keys MASTER:SYSTEM SET to navigate the display screen. MEMBER: LOCAL SET SYSTEM SET Hold theBACK SYSTEM SET RUN %100 LOCAL SET RUN %100 If the Header Sensor is present the button down menu will display SYSTEM SET, for 5 seconds...
Page 118 OPERATION HeatNet Control V3 Futera III/Fusion-Series HeatNet Control Run Screen CALIBRATE SYS FLOW SYS FLOW RUN %100 RUN %100 DHW STATUS DHW STATUS RUN %100 RUN %100 START 0 START 0 STOP STOP DHW screens are available depending DHW: DHW: RUN %100 RUN %100 on the DHW mode of...
Page 119: Futera Iii/Fusion-Series Heatnet V3 Control Menu Tree
OPERATION HeatNet Control V3 Futera III/Fusion-Series HeatNet V3 Control Menu Tree HOME SCREEN Press and HOLD BACK SYSTEM SET RUN %100 button down for 5 seconds to enter the 140°F menu screen MAIN MENU SCREEN I L E R S L E A D B OI L E R # S E T UP H E A T B A N D...
Page 120: Futera Iii/Fusion Heatnet V3 Control Advanced Menu Tree
OPERATION HeatNet Control V3 Futera III/Fusion HeatNet V3 Control Advanced Menu Tree D I S T R I B U T E D H -NET MASTER C T R L D I S T R I B U T E D C T R L M O D U L A R B O I L E R S E T MASTER TYPE:...
Page 121: Worksheet
WORKSHEET HeatNet Control V3 Worksheet SETUP MENU BOILERS # of BOILERS LEAD STAGE HEAT BAND ° SETPOINTS SYSTEM/LOCAL SETPOINT ° OPERATE LIMIT ° OP LIM BAND ° SETPOINT SOURCE OUTDOOR AIR RESET ° OA RESET WARM WEATHER SD WWS SETPOINT °...
Page 122 WORKSHEET HeatNet Control V3 REMAINS ON: LOCAL PUMP VFD FLOW PROVE NIGHT SETBACK SETBACK ENTRY ENTRY IS SETBACK ° ° ° ° SETBACK TIME START DAY TIME END DAY TIME OPTIONS TEMP SCALE ° KEY CLICK SKIP PASSWORD BRIGHTNESS LOG/ RUNTIME RUN HOURS DATA LOG ENTRY SIZE...
Page 123 WORKSHEET HeatNet Control V3 DHW SETPOINT LOWER DHW DIFF UPPER DHW DIFF DHW PRIORITY? POST PURGE USE SENSOR? SHARING LOCAL PUMP OFF LOCAL DELAY PURGE TO THE HYB SENSOR: SYSTEM CLOCK ADVANCED SETUP DISTRIBUTED CTRL CONTROL MASTER TYPE H-NET ADDRESS MODBUS ADDRESS MODULAR BOILER SET SPACE HEATING...
Page 124 WORKSHEET HeatNet Control V3 FIRING PRIORITY PREDICT START BASE LOADING BASE LOAD BOILERS: START > MOD STOP DELAY TIME SENSORS SENSOR # TYPE OUTDSIDE SUPPLY R E T U R N H E A D E R DHW STACK 4-20mA INPUT ANALOG IN CHANNEL: CHANNEL MODE: 4mA SETPOINT...
Page 125 WORKSHEET HeatNet Control V3 TURNDOWN ALTITUDE CALIBRATION SETTINGS MIN VFD IGN VFD MAX VFD Page 125...
Page 126 APPENDIX A HeatNet Control V3 Type II Thermistor Resistance/Temperature Table Temp C Temp F Temp C Temp F Resistance Resistance 336,450 2,488 242,660 2,083 176,960 1,752 130,410 1,479 97,072 1,255 72,951 1,070 55,326 915.4 43,326 786.6 32,650 678.6 25,391 587.6 19,899 510.6 15,711...
Page 127 (413)-568-9571 Fax (413)-568-9613 Page 127...
Page 128 260 North Elm Street 7555 Tranmere Drive Westﬁ eld, MA 01085 Mississauga, Ontario L5S 1L4 Canada Phone: (413) 568-9571 Phone: (905) 670-5888 Fax: (413) 568-9613 Fax: (905) 670-5782 www.rbiwaterheaters.com...

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