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HydroTherm KN Series Manual
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HydroTherm KN Series Manual

Gas-fired direct vent cast iron boilers
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CLICK ANYWHERE on THIS PAGE to RETURN to HYDROTHERM BOILER INFORMATION at
InspectApedia.com
Th is manual is intended only for use by a qualifi ed 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.
the burner, resulting in possible severe personal injury, death or substantial property damage. Th e 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.
Affi x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualifi ed service
technician, and to follow all guidelines in the User' s Information Manual.
KN
Series
Series
Gas-fi red direct vent
Gas-fi red direct vent
Cast iron boilers
Cast iron boilers
Models KN-6, -10, -20 only
Models KN-6, -10, -20 only
(HeatNet control fi rmware edition 2.45 )
(HeatNet control fi rmware edition 2.45 )
Control manual
Control manual
Control adjustment and
Control adjustment and
Operation instructions
Operation instructions
Also read and follow:
Also read and follow:
KN Series Gas Boiler
KN Series Gas Boiler
Installation & Operation
Installation & Operation
Instructions
Instructions
Construction dust and particulate, particularly drywall dust, will cause contamination of
KNCT2-808
P/N 42-9534 8/08 Copyright 2008 Hydrotherm

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Summary of Contents for HydroTherm KN Series

  • Page 1 CLICK ANYWHERE on THIS PAGE to RETURN to HYDROTHERM BOILER INFORMATION at KNCT2-808 InspectApedia.com Series Series Gas-fi red direct vent Gas-fi red direct vent Cast iron boilers Cast iron boilers Models KN-6, -10, -20 only Models KN-6, -10, -20 only (HeatNet control fi rmware edition 2.45 )
  • Page 2 , fi rst-on/last-off , or true rotation (the HeatNet control monitors the total on time of all boilers, and rotates their usage so the total on time is the same for all). P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 3 Electrical connection panel Electrical subpanel Power connection strip for KN-6 and KN-10— (120v/1/60) Power connection strip for KN-20 — (208/230/240 VAC/1/60) Flame safeguard (Honeywell) VFD blower speed controller On/off switch HeatNet Electrical enclosure P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 4 An additional bridge is required to interface with systems using BACnet or LON- Control panel WORKS protocol. • Th e master boiler will take control and regulate the boiler network if signal from the BMS is lost or times out. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...

  • Page 5: Table Of Contents

    9 Setup worksheet ......page 48 panel & subpanel • Use this section to enter setup information. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 6 Start up boiler Close the external gas valve. Follow all instructions in the KN Series Gas Boiler Instal- Wire the boiler following the guidelines in this manual. lation & Operating Instructions to start up the boiler and verify operation.
  • Page 7 Set values for 4-20mA parameters if using either as primary control source or as an override PASSWORD Set if desired COMMUNICATIONS Set if desired LOAD DEFAULTS Restore defaults if desired SYSTEM Load fi rmware if necessary to bring up to date P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 8 Set the member boilers’ control parameters using their display/keypads. Switch 2: ON Switch 2: ON Follow the instructions in the KN Series Gas Boiler Installation & Operating Instructions to start up each boiler before proceeding further. Last member Switch 1: ON...
  • Page 9 Table 3. Start up boilers per KN I & OM Turn off power to all boilers. Follow all instructions in the KN Series Gas Boiler Installation & Operating Instructions to start up each boiler and verify operation. Connect network cables Turn off power to each boiler before Electrical shock hazard —...
  • Page 10 Enable constant pump if desired Enable constant pump if desired FLOW PROVE Enable if used Enable if used (connect fl ow switch) (connect fl ow switch) NIGHT SETBACK Set if desired Not applicable to member boiler OPTIONS (all) P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 11 Set if desired LOAD DEFAULTS Restore defaults if desired Restore defaults if desired SYSTEM Load fi rmware if necessary to bring up to date Load fi rmware if necessary to bring up to date P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 12 Th e master boiler will show the number of boilers fi ring as well as the temperature no additional components except the RS485 inter- and heat band display. Use the UP/DOWN keys to scroll through the displays to face board. watch the process of starting and stopping boilers. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 13 Th en, a 1 must be writt en to register 16 to write the date and time to Air Prove UV Sensor Interlock Master Boiler the system clock. Main Valve Present (Boiler Detected) P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 14 Turn on power to the master boiler. seconds. Allow the master boiler to initialize. Boiler 1 is the master boiler. Boilers 2 – 16 are Verify operation with the building management system. member boilers. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...

  • Page 15: External 4-20Ma Control

    4-20mA signal. Note that the boilers can be wired for override operation. Th e Make sure to set the 4-20mA parameters for compatible boiler start current. wiring section provides information on override priorities. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 16 Install the header sensor in an immersion well. • Locate the sensor where it will accurately sense the sys- • Each boiler requires a return water temperature sensor tem water supply temperature. in order to use the DELTA functions. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 17 A KN HeatNet boiler will respond to overrides in the following order. Th e modes manufacturer’ s instructions and the recommended piping listed will override any other activation function listed below it. diagrams in the KN Series Gas Boiler Installation & Oper- ating Instructions . Consult the factory for applica- manual tions not covered.
  • Page 18 KN-SERIES GAS-FIRED DIRECT VENT CAST IRON BOILERS – CONTROL MANUAL Wiring (continued) Figure 4 KN HeatNet control fi eld wiring (also see KN Gas Boiler Installation & Operation Instructions) — Verify against wiring diagram supplied with boiler P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 19 KN-SERIES GAS-FIRED DIRECT VENT CAST IRON BOILERS – CONTROL MANUAL Wiring (continued) Figure 5 KN HeatNet temperature sensors P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 20 KN-SERIES GAS-FIRED DIRECT VENT CAST IRON BOILERS – CONTROL MANUAL Wiring (continued) Figure 6 Field wiring — relays, interlocks and boiler status P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 21 KN-SERIES GAS-FIRED DIRECT VENT CAST IRON BOILERS – CONTROL MANUAL Wiring (continued) Figure 7 Field wiring connections for 4-20mA remote operation P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 22 KN-SERIES GAS-FIRED DIRECT VENT CAST IRON BOILERS – CONTROL MANUAL Wiring (continued) Figure 8 Field wiring connections for on/off and two-stage fi ring options P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 23 KN-SERIES GAS-FIRED DIRECT VENT CAST IRON BOILERS – CONTROL MANUAL Wiring (continued) Figure 9 Installation of optional BACnet or LonWorks bridge — protocessor (for MODBUS operation) P/N 42-9534 8/08 Copyright 2008 Hydrotherm...

  • Page 24: Control Menus And Adjustments

    S E T SETUP menu. Table 8, page 28 lists the sequence of menu items found under the ADVANCED SETUP menu. For an explanation of the parameters, see Table 9, 1 8 0 page 30. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 25 140°F {60 to 150°F} HIGH OA TEMP 70°F HIGH OA TEMP 70°F {50 to 90°F} NEXT WATER TEMP 180°F WATER TEMP 180°F {70 to 180°F} LOW OA TEMP 10°F LOW OA TEMP 10°F {-35 to +40°F} BACK P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 26 °F {°F or °C} TEMP SCALE °F KEY CLICK ON {ON or OFF} KEY CLICK SKIP PASSW SKIP PASSWORD ON {ON or OFF} BRIGHTNESS BRIGHTNESS 50% {12, 25, 37, 50, 62, 75, 87, 100%} P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 27 LIM->HALF RATE NO {YES or NO} LIM->HALF RATE SYSTEM CLOCK TIME See explanation, Table 9, page 30 TIME 11:20AM DAY OF WEEK DAY OF WEEK MONTH NEXT MONTH YEAR 2008 PRESS SEL TO SAVE YEAR P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 28 TYPE Z {TYPE Z (10K), ON/OFF, TE6000 (1K), NONE} CALIBRATE? CALIBRATE NO {YES or NO} PLACE A PRECISION CALIBRATE If YES is selected: 1K OR 10K RESISTOR (See explanation, Table 9, page 30) ON CHANNEL # 1 TRIM OHMS = P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 29 FACTORY CAL? NO {YES or NO} FACTORY CAL? FACTORY RESET? FACTORY RESET? NO {YES or NO} SYSTEM FACTORY TEST Press and the test will proceed. FACTORY TEST LOAD FIRMWARE LOAD FIRMWARE NO {YES or NO} P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 30 (HeatNet member, 4-20ma control, stand-alone or other). The OP LIMIT BAND (see below) determines when the boiler begins to be forced to reduce input as the outlet temperature rises toward the limit setting. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 31 When this setting is YES, the boiler will shut down when outdoor temperature is at or above WWS SETPOINT. The outside temperature must drop at least 2°F below the WWS SETPOINT for the boiler to come on again. Set to NO to disable. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 32 DELTA TEMP (see below). The pump will continue to run an additional period after this for the amount of time specifi ed in PURGE TIME (below). P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 33 Displays the current number of entries in the data log. BOILER CYCLES LOG/RUNTIME Displays the number of times the boiler gas valve has been cycled on, then off . It does not include failed ignition attempts. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 34 This quickly reduces the boiler output to avoid short cycling on limit. The control will return to normal operation once the boiler temperature rise reduces to 10°F less than the value set for EXCHGR DELTA. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 35 Set this to “ON” to always start the master boiler fi rst, regardless of the rotation scheme FIRING MODE selected. ADVANCED SETUP SENSOR# The HeatNet control can be connected to up to six sensors: OUTSIDE, SUPPLY, RETURN SENSORS HEADER, and two user-selectable inputs (number 5 or number 6). P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 36 For each sensor, select either TYPE Z (10K), ON/OFF, TE6000 (1K), or NONE. SENSORS Type Z is a thermistors sensor (as supplied by Hydrotherm). Type Z sensors are NTC thermistors, 10Kohms at 77 °F, 335.67 Kohms at -40 °F, 185 Kohms at 150 °F, +/- 1 °F, -40 to 140 °F.
  • Page 37 There must be no call for heat during the process. Navigate the control display to “LOAD DEFAULTS. ’ To restore factory calibration settings or factory settings, section either of the options and select “YES” for the prompt, “ARE YOUR SURE?” P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 38 SETUP is accessed. To update the control’s fi rmware, obtain a disk from Hydrotherm or download the current fi le from the Hydrotherm website. For networked boilers, all must have version 1.x, or all must have version 2.x. It is preferable for all boilers to have the same version number for consistency.
  • Page 39 Th is screen is for display only, and shows the sett ing for DELTA TEMP (see SETUP instructions on previous pages). Follow all instructions in the KN Series Gas Boiler Installation and Operation Instructions manual to install and adjust the boiler before proceeding with any of the procedures below.

  • Page 40: Boiler Operation And Status Display

    RUN % as above. — Install the boilers Follow the Boiler manual KN Series Gas Boiler Installation according to the Aft er the ADD BOILER DELAY time has elapsed, the next & Operating Instructions manual before boiler will fi re.
  • Page 41 Th e log stores major events that have occurred during the operation of As soon as you enter the view log screen, it displays the last log entry the KN series boiler. Th ese events include: the KN series boiler recorded.
  • Page 42 Some faults will cause the control to shut down the boiler or system and display the message. CALL FACTORY. Should this message appear, immediately contact Hydrotherm for assistance. DO NOT att empt to correct the condition without discussing the issue with the factory.
  • Page 43 LOW WATER CUTOFF corrected. 168°F temperature drops The display continues showing the SUPPLY, HEADER or other temperature, whichever had been selected for display. The temperature shown is the value detected at the sensor listed. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 44 (J11A, VFD) 168°F temperature drops The display continues showing the SUPPLY, HEADER or other temperature, whichever had been selected for display. The temperature shown is the value detected at the sensor listed. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 45 Make sure only the master boiler has a Header Sensor (SYS/DHW HEADER) connected. ❑ Verify that each boiler’ s HeatNet cable is in place. ❑ Verify that each boiler has a unique address assigned (ADVANCED SETUP | DISTRIBUTED CTRL | H-NET ADDRESS). P/N 42-9534 8/08 Copyright 2008 Hydrotherm...

  • Page 46: Troubleshooting

    Turn the ON/OFF switch off . Th en depress and hold the ESC key while turning it back on. Th is will load You have forgotten the password. the default password “AAAAAA”. ❑ Ensure that the USB driver for your PC/Laptop computer is properly installed. Firmware update program starts to load, but then stops. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 47 Turn the ON/OFF switch off . Th en depress and hold the ESC key while turning it back on. Th is will load You have forgotten the password. the default password “AAAAAA”. ❑ Ensure that the USB driver for your PC/Laptop computer is properly installed. Firmware update program starts to load, but then stops. P/N 42-9534 8/08 Copyright 2008 Hydrotherm...

  • Page 48: Setup Worksheet

    WATER TEMP ENTRY IS HIGH OA TEMP 70°F SETBACK 180°F WATER TEMP SETBACK TIME LOW OA TEMP 10°F START DAY TIME PUMP OPTIONS END DAY SYSTEM PUMP TIME POST PURGE TIME 2 minutes ALWAYS ENABLED P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 49 TEMP SCALE °F KEY CLICK ADVANCED SETUP MENU SKIP PASSWORD Menu item Default Value BRIGHTNESS DISTRIBUTED CTRL LOG/ RUNTIME CONTROL H-NET RUN HOURS H-NET MASTER DATA LOG ENTRY LOCAL ADDRESS SIZE CONSOLE ADDRESS BOILER CYCLES P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 50 TYPE TYPE Z BAUD 19200 CALIBRATED? PARITY EVEN SENSOR # SUPPLY MODEM INSTALLED TYPE TYPE Z LOAD DEFAULTS CALIBRATED? Defaults loaded? SENSOR # RETURN SYSTEM TYPE TYPE Z Factory test run? CALIBRATED? Firmware loaded? P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 51 -40 F, 185 @ 150 F ,+/- 1 F Environment –40 F to 140 F < 90% RH non-condensing RS485 Console Modbus RTU, 9600 baud, 8 bits, Even Parity, 1 Stop Bit Boiler-to-Boiler Heat Net (H-Net) Network Optional LonWorks, BACnet available P/N 42-9534 8/08 Copyright 2008 Hydrotherm...
  • Page 52 A Product of Advanced Thermal Hydronics 260 North Elm Street, Westfi eld, MA 01085 Tel: (413) 564-5515 • Fax: (413) 568-9613 7555 Tranmere Drive, Mississauga, ONT. L5S IL4 Canada Tel: (905) 672-2991 • Fax: (905) 672-2883 www.hydrotherm.com...

This manual is also suitable for:

Kn-6Kn-10Kn-20