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Bosch Heatronic 4000 Installation & Operating Instructions Manual
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Bosch Heatronic 4000 Installation & Operating Instructions Manual

4 boiler control, dhw, bacnet and modbus io heatronic 4000 2014/04 en-us
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Features
• Control and monitor up to 4 boilers, condensing,
non-condensing, or a mix
®
®
• BACnet
IP or Modbus
Compatible
• Programmable Scheduling
• DHW priority
• Outdoor Temperature Reset
• Compatible with modulating, singe stage, two stage
and dual fuel burners
• Compatible with NG, LPG & Oil Burners
• Programmed boiler default parameters
4 boiler control, DHW, BACnet and Modbus
Heatronic 4000
IO Heatronic 4000 2014/04 en-us
Installation/Operating instructions (IO)
To avoid serious personal injury or property damage:
• Read Manual and all product labels BEFORE using this product and follow all safety and
use information. Failure to do so could result in personal injury or property damage.
• Do not use unless you know the safe and proper operation of equipment required for
installation.
• It is the installers responsibility to ensure that this product is safely installed according
to all applicable codes and standards.
The Heatronic 4000 is designed to operate up to four boilers to
accurately maintain a target water temperature. The Heatronic
4000 operates both condensing & non-condensing boilers that
are either modulating, single stage two stage or dual fuel to
provide a flexible, cost effective mixed boiler plant solution
with better system performance.
The target water temperature is based on outdoor temperature
reset or a fixed setpoint for space or process heating applications.
Additional loads supplied by the Heatronic 4000 include
domestic hot water heating. Boiler equal run-time rotation,
stand-by primary pump operation & pump exercising all
increase boiler plant reliability.
The Heatronic 4000 communicates with a Building Automation
System (BAS) using BACnet
monitoring & adjustment capability.
®
®
IP or Modbus
for remote

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Summary of Contents for Bosch Heatronic 4000

  • Page 1 The Heatronic 4000 is designed to operate up to four boilers to accurately maintain a target water temperature. The Heatronic 4000 operates both condensing & non-condensing boilers that are either modulating, single stage two stage or dual fuel to provide a flexible, cost effective mixed boiler plant solution with better system performance.

  • Page 2: Table Of Contents

    ® ® EMS, Modbus & BACnet Connections ........28 Appendix: Bosch / Buderus Boiler Model Default Table ....58 Testing the Sensor Wiring ..............29 Testing the Control Wiring ..........30 Control Settings ..................31 Understanding Safety Information This symbol identifies hazards which, This is a safety-alert symbol.

  • Page 3: Sequence Of Operation

    Boiler (Source (#) Menu) Setup & Operation The Heatronic 4000 is able to operate up to four boilers as a Boiler Type -- -- --- -- -- -- -- -- -- -- -- -- - -- -- --- - -- -- --- -- -- -- -- -- -- -- - -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- heat source.
  • Page 4 100,000 = 100 MBtu/h Output Signal Signal Range 1,000 Range Minimum Boiler Output = 20,000 = 20 MBtu/h Boiler’s Minimum 1,000 1.8 V (dc) Minimum Modulation Input 0 V (dc) Signal BTC461503101C | 6720810369 (2018/03) Heatronic 4000 4 of 60...
  • Page 5 This setting is to be set to the appropriate output signal range of the Heatronic 4000. Use the MAX MOD temperature that is defined by the boiler’s ignition control. For...

  • Page 6: System Setup

    1/2 of the differential below the boiler target temperature. As the boiler supply water temperature reaches 1/2 of the differential above the boiler target temperature, the boiler is shut off. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 6 of 60...
  • Page 7 FLUE MAX, the boiler plant is shut down. The boiler plan will not be allowed to operate until the vent temperature drops 10°F (6°C) below the FLUE MAX. If OFF is selected, the common flue temperature is only monitored. BTC461503101C | 6720810369 (2018/03) 7 of 60 Heatronic 4000...

  • Page 8: Boiler Plant Operation

    Boiler Plant Operation The Heatronic 4000 is able to operate up to four boilers to Stage Delay -- --- --- --- --- - --- --- --- --- --- --- --- -- ---- --- -- --- --- --- --- --- --- --- --- --- --- -- -- --- --- --- maintain a boiler target temperature.
  • Page 9 (#) menu. To reset the running time, select the appropriate The Heatronic 4000 supports operation of a condensing & a BURNER item in the Monitor (#) menu & select CLEAR until non-condensing boiler group. A condensing boiler group is “0”...

  • Page 10: Dual Fuel Operation

    Dual Fuel Boiler Operation The Heatronic 4000 supports the operation of dual fuel if applicable, boiler outlet sensor, are to be connected to boilers. Dual fuel boiler functionality is only available with boiler 3. applicable Bosch / Buderus boiler models. The control allows...
  • Page 11 WWSD is only available when the Application Mode is set to RSET. While in WWSD, the control will still operate to provide Indirect Domestic Hot Water or Setpoint operation. BTC461503101C | 6720810369 (2018/03) 11 of 60 Heatronic 4000...

  • Page 12: Setpoint Operation

    *Requires 500  Resistor in Parallel temperature of 210°F (99°C). As the voltage varies between 1 V (dc) & 10 V (dc) the boiler target temperature varies linearly between 50°F (10°C) & 210°F (99°C). BTC461503101C | 6720810369 (2018/03) Heatronic 4000 12 of 60...

  • Page 13: Indirect Domestic Hot Water (Idhw) Operation

    When using a DHW Sensor, a DHW Call is registered when the temperature at the DHW sensor drops the IDHW DIFF setting below the IDHW Setpoint setting. The DHW Call is satisfied BTC461503101C | 6720810369 (2018/03) 13 of 60 Heatronic 4000...
  • Page 14 Primary Pump During IDHW -------------------------------------------------- -------------------------------------------------- The control has a Primary Pump during IDHW setting that selects whether or not the primary pump is required during indirect DHW operation. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 14 of 60...
  • Page 15 & continues to operate the IDHW pump while the primary pump is turned on. This allows some of the DHW return water to mix with the cool return water from the zones & temper the boiler return water. BTC461503101C | 6720810369 (2018/03) 15 of 60 Heatronic 4000...

  • Page 16: Dedicated Domestic Hot Water (Ddhw) Operation

    ® The control supports Modbus & BACnet IP communica- Refer to the Heatronic 4000 BAS Manual for more information tions. Selection is made through BAS TYPE item in the BAS including a listing of the read / write parameters. menu.

  • Page 17: Pump Operation

    If flow is not proven, the stand-by pump turns off. The period of time is set through the FLW PROOF item in the Setup menu & it is adjustable between 10 seconds & 3 minutes. BTC461503101C | 6720810369 (2018/03) 17 of 60 Heatronic 4000...
  • Page 18 The pump logic feature is only applicable for Bosch / Buderus boiler models that are non-condensing. The control uses the boiler outlet sensor of the respective boiler for the pump logic feature.

  • Page 19: Combustion Air Damper & Dhw Recirculation

    5-11 7 day Requirements Saturday • • • The Heatronic 4000 Setback /Off DIP Switch must be set Sunday • • to Setback to access the Schedule Menu. Monday • Schedule Types - - -- - - - - - ---- ---------- -------- ----------...

  • Page 20: Time Clock

    & year are entered. Use the Time menu to set the correct time, day, month, & year. Requirements : The Setback / Off DIP Switch must be set to Setback before the Time menu can be accessed. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 20 of 60...

  • Page 21: Installation

    • Do not attempt to service the control. There are no user serviceable parts inside the control. Attempting to do so voids warranty. • It is your responsibility to ensure that this control is safely installed according to all applicable codes and standards. Bosch is not responsible for damages resulting from improper installation and/or maintenance. Installation Location When choosing the location for the control, consider the •...

  • Page 22: Control Wiring

    Control Wiring This section explains how to wire individual devices to the Heatronic 4000. For step by step wiring refer to the terminal number on the right of the page. • Before wiring, ensure all power is turned off & take •...
  • Page 23 Terminals 1, 2 The Heatronic 4000 requires a closed switch or short for proof of flow. Up to 24 V (ac) can be passed through the switch. If a flow proof device is being used, ensure the Prim Pump Flow Proof / Off DIP switch on the front of the control is set to the Prim Pump Flow Proof position.
  • Page 24 • It is the installers responsibility to ensure that this product is safely installed according to all applicable codes and standards. Wiring a Central Heat (CH) Call Terminals 5, 6 The Heatronic 4000 requires a switched external heat call to operate the boiler plant unless calls for heat are ® ® ®...

  • Page 25: Sensor Installation & Wiring

    Boi l er 1 Sta g e 1 Sta g e 2 • Connect the Mod + terminals from boilers 1, 2, 3 and 4 to the Heatronic 4000 terminals 51, 57, 63 and 69, respectively. • Connect the Mod - terminals from boilers 1, 2, 3 and 4 to the Heatronic 4000 terminals 52, 58, 64 and 70, respectively.
  • Page 26 Wiring Boiler Outlet Sensors (7738003451) Terminals 26 to 31 Up to 4 boiler outlet sensors can be wired to the Heatronic 4000. These connections are not polarity sensitive. • Connect one wire from the outlet sensor for boiler 1 to the Boil 1 Out terminal 26.
  • Page 27 Wiring a Flow Sensor (provided by others) Terminals 11, 12 An analog flow sensor can be connected to the Heatronic 4000 to provide flow monitoring. The control supports an analog 4-20 mA type flow sensor. Using the primary supply sensor & the primary return sensor, energy output can be calculated &...

  • Page 28: Ems, Modbus & Bacnet Connections

    Wiring a Common Flue Sensor (provided by others) Terminals 23, 25 A common flue sensor can be connected to the Heatronic 4000 to provide monitoring of the common boiler plant flue temperature. The common flue sensor can also be used to provide a common flue temperature maximum limiting feature.

  • Page 29: Testing The Sensor Wiring

    ® • Connect the Ethernet RJ45 socket on the BACnet IP network to the Ethernet RJ45 socket on the Heatronic 4000, labeled BACnet, top center of control. Testing the Sensor Wiring A good quality test meter capable of measuring up to 5,000 kΩ...

  • Page 30: Testing The Control Wiring

    Remove all wires from the Fuel Switch terminals (9 & 10). Switch terminals. The control should now show a F SW. The control display should show no F SW. Reconnect wires. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 30 of 60...

  • Page 31: Control Settings

    Default Lock / Unlock & Access Levels Unlocked Use this DIP switch to lock & unlock the Access Level of the Heatronic 4000. For details, see above. • Once unlocked, the access level can be changed in the Toolbox menu.

  • Page 32: User Interface

    • Single stage: 100% (On) • Two stage: 50% (stage 1 On), 100% (stage 2 On) ® tekmarNet • Modulating: current modulation % The Heatronic 4000 is communicating • EMS = current setpoint temperature with other tekmarNet ® devices. BTC461503101C | 6720810369 (2018/03)

  • Page 33: Navigating The Display

    Navigating The Display The menu items of the Heatronic 4000 are described in detail in the following pages. The number of available items changes depend- ing on the control configuration. To find out what other settings affect the display of an item, refer to the menu descriptions.
  • Page 34 (-12.0 to 148.0°C) is connected. Access: ADV Requirements: This item is only available if boiler 1 outlet & boiler inlet sensors are connected. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 34 of 60...

  • Page 35: Setup Menu

    Selects the offset from the boiler target temperature interpreted from the EMS Default: 0°F (0.0°C) analog input signal. Requirements: This item is only available if the Application Mode is set to EMS. Access: ADV BTC461503101C | 6720810369 (2018/03) 35 of 60 Heatronic 4000...
  • Page 36 Default: 1:00 min relay turns on. Requirements: This item is only available if the Comb Air Proof / Off switch is Access: ADV set to Off & Auxiliary Relay is set to DMPR. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 36 of 60...
  • Page 37 If set to ON, boiler 4 is always the last to fire. Requirements: This item is only available if boiler 4 is enabled (Boiler Enable = Access: ADV AUTO) & all available boilers are either condensing or non-condensing. BTC461503101C | 6720810369 (2018/03) 37 of 60 Heatronic 4000...
  • Page 38 Selects whether indirect DHW priority is active or not. Default: OFF Requirements: This item is only available when Application Mode is set to RSET, Access: ADV SETP or EMS & Indirect DHW Mode is set to ON. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 38 of 60...
  • Page 39 BOILER ALERT Default: 20 min Alert signal if the boiler supply temperature does not increase in temperature, after all available boilers have been turned on, within the selected time. Access: ADV BTC461503101C | 6720810369 (2018/03) 39 of 60 Heatronic 4000...
  • Page 40 Selects the model of pressure sensor based on the pressure range in units of Default: 50 PSI. Requirements: This item is only available when Pressure Sensor is set to ON. Access: ADV BTC461503101C | 6720810369 (2018/03) Heatronic 4000 40 of 60...

  • Page 41: Source # Menu

    Source # Menu (1 of 3) There is a different Source Menu for each of the 4 boilers that the Heatronic 4000 can operate. Settings can vary for each boiler if desired. OFF or AUTO Default: BOILER ENABLE AUTO for Boil1 Selects whether the boiler is operational or not.
  • Page 42 Default: HI Requirements: This item is only available if Boiler Enable is set to AUTO & Copy Boiler 1 is set to OFF. This item is not available for adjustment if Bosch / Buderus Access: INST Model is set to YES.

  • Page 43: Bas Menu

    BACNET PORT Default: 0xBAC0 Sets the User Datagram Port (UDP) port on the BACnet ® network. (47808) Requirements: This item is only available when BAS Type is set to BACn. Access: ADV BTC461503101C | 6720810369 (2018/03) 43 of 60 Heatronic 4000...
  • Page 44 Sets the BBMD UDP port on the BACnet network. (47808) ® Requirements: This item is only available when BAS Type is set to BACn & BACnet BBMD Time is not set to OFF. Access: Adv BTC461503101C | 6720810369 (2018/03) Heatronic 4000 44 of 60...

  • Page 45: Monitor # Menu

    (-12.0 to 148.0°C) while viewing to reset. Access: ADV Requirements: This item is only available when Boiler Enable is set to AUTO & boiler outlet & boiler inlet sensors are connected. BTC461503101C | 6720810369 (2018/03) 45 of 60 Heatronic 4000...

  • Page 46: Monitor Menu

    Records the highest pressure since this item was last cleared. Press & hold the ‘CLEAR’ button while viewing to reset. Access: ADV Requirements: This item is only available when Pressure Sensor is set to ON. BTC461503101C | 6720810369 (2018/03) Heatronic 4000 46 of 60...
  • Page 47 Records the lowest common flue temperature since this item was last cleared. (-40.0 to 260.0°C) Press & hold the ‘CLEAR’ button while viewing to reset. Requirements: This item is only available when a common flue sensor is Access: ADV connected. BTC461503101C | 6720810369 (2018/03) 47 of 60 Heatronic 4000...

  • Page 48: Time Menu

    Time change is required. will be displayed in the View menu. Schedule Menu (1 of 2) Schedule Type The Heatronic 4000 can follow an internal schedule or an available schedule on a tekmarNet ® network. Four heating 24 Hour 5-11 7 day schedules can be present on one network.

  • Page 49: Schedule Menu

    Requirements: This item is only available when the Setback / Off switch is set Default = 8:00AM to Setback, Heat Schedule is set to CTRL or MST1 to MST4. Access: USER BTC461503101C | 6720810369 (2018/03) 49 of 60 Heatronic 4000...

  • Page 50: Toolbox Menu

    & C0 (32 & 33). BOILER BUS 1 DEVICES 1 to 24 Displays the number of tN4 devices connected to the Boiler Bus 1 terminals, tN4 Access: INST & C1 (34 & 35). BTC461503101C | 6720810369 (2018/03) Heatronic 4000 50 of 60...
  • Page 51 30 days. To manually clear, press ‘CLEAR’ while viewing screen the error until CLR is displayed. The last 5 history items will display if present. Access: INST BTC461503101C | 6720810369 (2018/03) 51 of 60 Heatronic 4000...

  • Page 52: Manual Override

    Hand Override (HAND) --- --- --- --- --- --- --- - --- --- --- --- --- --- --- --- --- --- --- -- -- --- --- --- Heatronic 4000 are accessed by holding the Manual Override In this mode, the control overrides the normal operating mode button for 3 seconds.
  • Page 53 99°C) Requirements: This item is only available if Manual Override is set to HAND & Boiler Enable is set to AUTO & Boiler Type is set to EMS. BTC461503101C | 6720810369 (2018/03) 53 of 60 Heatronic 4000...

  • Page 54: Troubleshooting

    Troubleshooting It is recommended to complete all wiring to ensure trouble free operation. Should an error occur, simply follow these steps: 1. Find: If the Heatronic 4000 flashes on the screen, it is indicating a problem on the system. 2. Identify: Press & hold the Home button for 3 seconds to view the available menus. Tap the NEXT ITEM button to locate the Toolbox Menu &...
  • Page 55 NO CHANGE IN SUPPLY TEMP alert time. The control operates normally while this Alert is WITHIN SPECIFIED PERIOD OF present. To reset the Alert, press the ‘CLEAR’ button while TIME viewing this warning message. BTC461503101C | 6720810369 (2018/03) 55 of 60 Heatronic 4000...
  • Page 56 DUPLICATE MASTER ERROR More than one tN4 system control has been detected on the tN4 Boiler Bus. The Heatronic 4000 is a “Master Device” & no DUPLICATE MASTER CONTROL other tekmarNet reset controls can be added to the tN4 Boiler DETECTED ON TN4 BUS Bus terminals.

  • Page 57: Technical Data

    & materials if the Product is installed & have not been authorized by Bosch; or if the Product was not installed in used in compliance with Bosch’s instructions, ordinary wear &...

  • Page 58: Appendix: Bosch / Buderus Boiler Model Default Table

    Appendix - Bosch / Buderus Boiler Model Default Table Boiler Fuel Dual Boil Condense Fire Boil Output Output Motor Start Pump Model Type Fuel Type* Type* Dly* Delay* Mass* High Purge SB625160 0-10 High 100 194 5:00 SB625220 0-10 High...
  • Page 59 3980 100 200 5:00 0-10 High 1610 3980 100 200 5:00 Dual 0-10 High 1330 3980 100 200 5:00 2 STG High 3980 N/A 200 5:00 Item not available for adjustment. BTC461503101C | 6720810369 (2018/03) 59 of 60 Heatronic 4000...
  • Page 60 Bosch Thermotechnology Corp. 65 Grove Street Watertown, MA 02472 Tel. 866-642-3198 Fax 603-965-7581 www.boschheatingandcooling.com U.S.A. Bosch Thermotechnology Corp. reserves the right to make changes without notice due to continuing engineering and technological advances. BTC 461503101C | 6720810369 (2018/03)

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