ATH HeatNet KN-2 Manual
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ATH HeatNet KN-2 Manual

Cast iron condensing boilers
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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/water heater. 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.
Cast Iron Condensing
Boilers
Models K N-2 and K N-4
HeatNet® Manual
Control Adjustment and Operation Instructions
for Mestek Firmware Version 2.8
Also read and follow:
KN Boiler Manual
KN Vent/Air Manual
K N-2 only
Construction dust and particulate, particularly drywall dust, will cause contamination of
KN-2/4-CM2-0714
42-9452

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Summary of Contents for ATH HeatNet KN-2

  • Page 1 KN-2/4-CM2-0714 42-9452 Cast Iron Condensing Boilers Models K N-2 and K N-4 HeatNet® Manual Control Adjustment and Operation Instructions for Mestek Firmware Version 2.8 Also read and follow: KN Boiler Manual KN Vent/Air Manual K N-2 only 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.
  • Page 2 KN USER’S CONTROL MANUAL The KN boiler — HeatNet® control • Operation as a member of a remotely-controlled boiler Control overview network (20-milliamp regulation). Th e KN HeatNet control monitors boiler temperature and limit • Setpoint can be determined by the HeatNet control or by a circuit inputs, modulating boiler fi ring rate to meet demand.

  • Page 3: Wiring Connections

    KN USER’S CONTROL MANUAL The KN boiler — HeatNet® control Wiring connections Power wiring, 120 vac Heat demand input DHW demand input Low fi re terminals High fi re terminals To boiler outlet water temperature sensor To optional outdoor temperature sensor To optional boiler return water temperature sensor To optional header...

  • Page 4: Table Of Contents

    KN USER’S CONTROL MANUAL Contents 1 Method 1: HeatNet modulation – control..page 5 • Th e KN HeatNet control can control up to (16) KN boilers using built-in soft ware and hardware. • Install a RS485 interface on each boiler and connect with RJ45 HeatNet cables (or shielded wires).

  • Page 5: Method 1: Heatnet Modulation - Control

    KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control Figure 1 Electrical connection board (see item 10, page 3 for location — Also see the wiring Disconnect all electrical power Electrical shock hazard — summary illustrations on the next pages) sources to the boiler before making any electrical connections.

  • Page 6: Boiler Circulator

    KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) Circulator wiring Figure 5 Circulator wiring terminal strip (see Figure 1 for location) — Also see the wiring summary illustrations on the next pages) Postpurge circulator (KN-2 only) •...
  • Page 7 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) IAR (Indoor Air Reset) wiring, when used Figure 6 Indoor Air Reset wiring to IAR terminals with 4-wire zone valves and no zone controller • Heat Demand terminal connections — Th e end switch leads from the zone valves (see Figure 7 for terminal block 6 location) must connect to the Heat Demand terminals on the electrical connection board as shown in Figure 7.
  • Page 8 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) Figure 7 KN wiring summary — wiring to electrical connection board Also see Figure 2. Wire Harness 70-2043 Factory Wiring — Do Not Change J9 Control Inputs 120V 50VA 24VAC Tank...
  • Page 9 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) Figure 8 KN wiring summary — wiring to electrical connection board, continued (see Figure 7 for terminal strip locations) Also see Figure 5. Note: For multiple boilers with a single combustion air damper (KN-2 only)
  • Page 10 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) External interlocks Figure 9 Termination DIP switches (see item 7, Figure 7 for location) 1. Wire external limits and fl ow switch, when used, as shown in Figure 8. 2.
  • Page 11 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) Figure 9A KN2/KN4 multiple boilers with a single combustion air damper...
  • Page 12 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) Table 2 Control parameters before Close the external manual gas valve on every boiler proceeding. DO NOT open any gas valve, or att empt to fi re any Parameter Master Member...
  • Page 13 KN USER’S CONTROL MANUAL Method 1: HeatNet modulation – local control (cont.) 2. Turn on power to the master boiler and set its on/off switch to ON. Figure 10 RS485 communications board 3. You should hear at least 2 beeps. 4.

  • Page 14: Method 2: Heatnet Modulation - Bms

    KN USER’S CONTROL MANUAL Method 2: HeatNet modulation – BMS control (Basic) For Full Register Set see page 40 Overview Table 3 Modbus holding (read/write) registers 1. Th is method uses an RS485 digital communications cable Data Description Valid Values/ with the Modbus protocol to control a boiler or HeatNet Type Range...

  • Page 15: Building Management System

    KN USER’S CONTROL MANUAL Method 2: HeatNet modulation – BMS control (cont.) BACnet or LonWorks protocols Table 5 Modbus input (read-only) registers 1. Install the correct bridge to adapt to building management Data Description Valid Values/ systems using BACnet or LonWorks protocols. Type Range 2.

  • Page 16: Method 3: External 4-20Ma Control

    KN USER’S CONTROL MANUAL Method 3: External 4-20ma control Figure 11 Electrical connection board (see item 10, page 3 for location — Also see the wiring Disconnect all electrical power Electrical shock hazard — summary illustrations on the next pages) sources to the boiler before making any electrical connections.
  • Page 17 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 illustrations on the next pages) Postpurge circulator (KN-2 only) • The circulator shipped installed with the boiler can- It must be used as not be used for system circulation.
  • Page 18 KN USER’S CONTROL MANUAL Method 3: External 4-20ma control (continued) • — Firmware Sensor wiring, return water sensor 4-20mA operation Version 2.5 and greater monitors the temperature 1. A 4.02 mA current signal will start the boiler, at low fi re. A diff erential (Delta T) across the heat exchanger.
  • Page 19 KN USER’S CONTROL MANUAL Method 3: External 4-20ma control (continued) Figure 16 KN wiring summary — wiring to electrical connection board...
  • Page 20 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) (KN-2 only)
  • Page 21 KN USER’S CONTROL MANUAL Method 3: External 4-20ma control (continued) Table 6 Control parameters before Close the external manual gas valve on every boiler proceeding. DO NOT open any gas valve, or att empt to fi re any Parameter When to set boiler, until the boilers have been set up and verifi ed following (see notes) the instructions in the KN Boiler manual.

  • Page 22: Failsafe Modes

    KN USER’S CONTROL MANUAL Failsafe Modes FAILSAFE MODES have been added to help protect systems HeatNet Communications Lost from loss of heat conditions. When using one of these modes SETUP:AUX FUNCTIONS:FAILSAFE MODES: ensure that you connect any DAMPER control, or H-NET COMM LOST: system pump control to safely allow operation with the Th is mode allows a member boiler to run in LOCAL if...

  • Page 23: Control Menus And Adjustments

    KN USER’S CONTROL MANUAL Control menus and adjustments The Heat Net control display Figure 18 Heat Net display during Standby (no call for heat) — pressing the DOWN key on the keypad changes the display as shown Starting the display 1.
  • Page 24 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 7 Setup menus (see Table 8 for explanations) To enter Setup: From STANDBY, hold for 5 seconds. Then press with cursor on SETUP. Make sure there is no call for heat at the boiler before attempting to perform setup adjustments.
  • Page 25 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 7 Setup menus (see Table 8 for explanations) (continued) NIGHT SETBACK SETBACK # X 1 {1 through 4} SETBACK # ENTRY IS OFF SETBACK 20°F {0 to 50°F} ENTRY IS ST DAY SUN {SUN, MON, TUE, WED, THU, FRI, SAT} ST DAY...
  • Page 26 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 7 Setup menus (see Table 8 for explanations) (continued) ADVANCED SETUP DISTRIB CTRL CONTROL HNET CONTROL HNET HNET MASTER YES (Display only, not changeable here) HNET MASTER LOCAL ADD Master default = 255 (not changeable) LOCAL ADD Member default = 2 (Range = 2 to 16) CONSOLE ADD...
  • Page 27 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations Menu item Under . . . Explanation VX.X FIRMWARE All boilers in a multiple boiler application should preferably have the same fi rmware version to VERSION ensure consistency.
  • Page 28 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . 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.
  • Page 29 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation OA RESET OUTDOOR AIR Set to “ON” to enable resetting the boiler outlet temperature (or header temperature) based on outside air temperature.
  • Page 30 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation ENTRY IS NIGHT SETBACK Select “ON” to enable a setback operation. Then program the times, days and setpoint. The setpoint assigned will override the KN control’s setpoint when setpoint is controlled locally.
  • Page 31 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation 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)
  • Page 32 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation ADD BOILER DLY ADVANCED SETUP This is the minimum wait time before an additional boiler can fi re when called on by the master MODULAR BOILER boiler control.
  • Page 33 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation CALIBRATE ? ADVANCED SETUP Use this function only if the response to a sensor indicates the control calibration may be off . SENSORS Calibrate the control by attaching a 10k precision resistor across the sensor terminals.
  • Page 34 KN USER’S CONTROL MANUAL Control menus and adjustments (continued) Table 8 Setup menus — parameter explanations (continued) Menu item Under . . . Explanation LOAD DEFAULTS ADVANCED SETUP Load the factory defaults when you want to be sure nothing has been changed or after you have loaded new fi rmware.

  • Page 35: Troubleshooting

    KN USER’S CONTROL MANUAL Troubleshooting Screen 3 — Table 9 Accessing and using the Log Messages: Enter Setup: From STANDBY, hold for 5 seconds. Then press until the cursor points to VIEW LOG. NO FLOW SENSED • Press with the cursor on VIEW LOG. OPERATE HIGH LIMIT •...
  • Page 36 KN USER’S CONTROL MANUAL Troubleshooting (continued) Situtation Suggested procedure ❑ Check 120VAC power to connection board. Verify power is connected per wiring diagrams. Nothing happens when the power switch is turned on. ❑ Th e Power switch light (ON -Position) should illuminate if power is wired correctly. ❑...
  • Page 37 KN USER’S CONTROL MANUAL Troubleshooting (continued) Situtation Suggested procedure ❑ Th e H-Net communications cable may be receiving interference from the blower, ignition, or other form HeatNet boilers are detected but of radiated electrical noise. then lost and then detected again. ❑...
  • Page 38 KN USER’S CONTROL MANUAL Troubleshooting (continued) Situtation Suggested procedure ❑ Th e Boiler always shows it’ s called for fi ring modulation %. Th is is not an indication of what the boiler is I can hear the blower ramping actually fi ring at.
  • Page 39 KN USER’S CONTROL MANUAL Troubleshooting (continued) Situtation Suggested procedure ❑ Th is conditi on usually indicates that the bridge is not communicating with the HeatNet control. When We are using a BACnet or operating properly, the bridge continuously reads data from the boiler on the Modbus port into an internal LonWorks bridge.
  • Page 40 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers Input/Output Variables (Read/Write) Address Name Raw Data Type Scale Description Valid Values/Range 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.
  • Page 41 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) Input Variables (Read Only) Address Name Raw Data Type Scale Description Valid Values/Range 30001 BoilersOn 8 bit unsigned The number of boilers currently running. 0 – 16 30002 Modulation 8 bit unsigned 0.01 Current system (target) modulation level.
  • Page 42 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) Input Variables (Read Only) (continued) Address Name Raw Data Type Scale Description Valid Values/Range 30043 Boiler14Status2 30044 Boiler15Status1 30045 Boiler15Status2 30046 Boiler16Status1 30047 Boiler16Status2 30048 Boiler01Runtime- 16 bit unsigned Boiler (1 – 16) Runtime seconds High (Upper) 0 –...
  • Page 43 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) Input Variables (Read Only) (continued) Address Name Raw Data Type Scale Description Valid Values/Range 30070 Boiler12Runtime- High16 30071 Boiler12Runtime- Low16 30072 Boiler13Runtime- High16 30073 Boiler13Runtime- Low16 30074 Boiler14Runtime- High16 30075 Boiler14Runtime- Low16 30076 Boiler15Runtime-...
  • Page 44 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) Input Variables (Read Only) (continued) Address Name Raw Data Type Scale Description Valid Values/Range 30105 Boiler10SupplyTemp 30106 Boiler11SupplyTemp 30107 Boiler12SupplyTemp 30108 Boiler13SupplyTemp 30109 Boiler14SupplyTemp 30110 Boiler15SupplyTemp 30111 Boiler16SupplyTemp 30112 Boiler01ReturnTemp 16 bit signed 0.01 Boiler (1 –...
  • Page 45 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) Input Variables (Read Only) (continued) Address Name Raw Data Type Scale Description Valid Values/Range 30147 Boiler10CyclesLow16 30148 Boiler11CyclesHigh16 30149 Boiler11CyclesLow16 30150 Boiler12CyclesHigh16 30151 Boiler12CyclesLow16 30152 Boiler13CyclesHigh16 30153 Boiler13CyclesLow16 30154 Boiler14CyclesHigh16 30155 Boiler14CyclesLow16 30156 Boiler15CyclesHigh16...
  • Page 46 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) Input Variables (Read Only) (continued) Address Name Raw Data Type Scale Description Valid Values/Range 30208 Boiler01DHWTemp 16 bit signed Boiler (1-16) DHW temperature (if available) 32 – 250°F This value is taken from the return sensor 30209 Boiler02DHWTemp if the “DHW uses return sensor option”...
  • Page 47 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) BoilerStatus1 Flags BoilerStatus2 Flags Description Valid Values/Range Description Valid Values/Range Disabled 0 = enabled, 1 = disabled The boiler is disabled. Blower Running 0 = off , 1 = running Heat Demand 0 = no demand, 1 = demand (1) Ignition Alarm 0 = ok, 1 = alarm...
  • Page 48 KN USER’S CONTROL MANUAL KNSLM (KN2/KN4) modbus registers (continued) BoilerStatus3 Flags BoilerStatus4 Flags Description Valid Values/Range Description Valid Values/Range DHW Sensor Enabled (1) 0 = off , 1 = on (menu) AA High Fire 0 = off , 1 = on DHW Sensor has been enabled Heat Demand (Local Override) 0 = off , 1 = on (1)

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