200i

ray 200i Control Manual

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Cast iron condensing boiler

200i

Control manual

Control adjustment and

operation instructions

M2i-CM-1

Also read and follow:

200i Boiler manual

200i Vent/air manual

 is manual is intended only for use by a quali 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. Construction dust and particulate, particularly drywall dust, will cause contamination of

the burner, resulting in possible severe personal injury, death or substantial property damage.  e boiler can only be operated with a dustfree 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.

A x these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a quali ed

service technician, and to follow all guidelines in the User’s Information Manual.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

The Mestek 200i boiler — SmartCycle

Control overview

 e 200i SmartCycle control monitors boiler temperature and limit circuit inputs, modulating boiler  ring rate to meet demand.  e control uses microprocessor electronics, watching time-average response from the system to anticipate how much heat the system needs. Coupled with the  ve-to-one turndown of the 200i boiler, this results in maximum possible condensing-mode operation.  e 200i boiler will provide unmatched seasonal e ciency.

Indoor air reset (IAR)

Mestek’s unique approach to boiler output regulation is its Indoor Air Reset function.  e control monitors the demand from up to 8 di erent zones. Watching the demand duration and response to supply temperature, averaging over time, the SmartCycle control anticipates system needs. It sets boiler maximum  ring rate and adjusts supply water temperature to  ne-tune boiler heat output. All that is required to enable IAR is to connect thermostat circuit wires to the IAR inputs.  e SmartCycle control can also be con gured for outdoor reset operation, but IAR provides response based on system behavior rather than just looking at outdoor temperature.

The SmartCycle platform

SmartCycle controls are designed to provide an integrated boiler management system on every boiler.  e platform provides multiple levels of selectivity. SmartCycle electronics can be operated as a simple single-boiler control, while still providing intelligent regulation of boiler  ring rate to match system demand. With a few key strokes on the key pad, the SmartCycle control can operate as a sophisticated multiple-boiler controller, using simple RJ45 cable interfacing between units.  e control can even accept external control commands from building managements systems (Modbus standard, with optional bridge for BACnet or LonWorks) or 20-milliamp analog input from an external controller.

 e control method used by the SmartCycle control is based on digital communications, which eliminates the need for analog control signals. Analog signal inputs are supported, but a higher level of control precision, repeatability and feedback is gained with digital communications.

 e SmartCycle control can be versatile, providing for operation in multiple ways:

Operation as a stand-alone boiler.

• Operation as a boiler in a boiler network, using the on-board SmartCycle protocol.

• Operation as a member boiler in a boiler management system.

• Operation as a member of a remotely-controlled boiler network (20-milliamp regulation).

• Setpoint can be determined by the SmartCycle control or by a 20-milliamp input signal.

•

control

PID response

 e SmartCycle control uses proportional-integral-derivative calculations to determine the response to boiler water temperature changes.  is means it not only looks at how far away the water temperature is from the setpoint temperature, but how fast the temperature is changing and how it has responded over time.  is ensures the boiler won’t make sudden unnecessary changes in  ring rate.

Multiple boiler operation

200i

SmartCycle

Control panel

 e SmartCycle control easily interfaces with other SmartCycle controls. Multiple boiler operation using SmartCycle protocol only requires RJ45 cables daisy-chained from boiler to boiler and a few key strokes se ing up control behavior.  e master boiler is automatically selected by connecting a sensor lead to its HEADER sensor terminals.  e SmartCycle control recognizes the sensor and con gures the boiler as the master. Other boilers only need to have an address assigned.

Among the advanced design features of the SmartCycle control is the MOD-MAX se ing.  is limits the  ring rate of all boilers to a pre-set maximum (50% by default).  is means all of the boilers will be run at a very e cient level until all boilers are on. Only then can  ring rate increase above this se ing. Boiler rotation can be  rst-on/ rst-o ,  rst-on/last-o , or true rotation (the SmartCycle control monitors the total on time of all boilers, and rotates their usage so the total on time is the same for all).

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

The Mestek 200i boiler — SmartCycle

control

Wiring connections

Power wiring, 120 vac

Heat demand input

DHW demand input

Low  re terminals

High  re terminals

To boiler outlet water

6. temperature sensor

To optional outdoor

7. temperature sensor

To optional boiler return

8. water temperature sensor

To optional header

9. temperature sensor

To boiler postpurge pump

10. (factory piped and wired)

To boiler circulator

11.

Alarm output dry contacts

12.

To external high limit and/or

13. low water cuto if desired

To  ow switch, when used

14.

Used to activate combustion

15. air damper if desired

To combustion air damper proving

16. switch, required when controlling combustion air damper

Indoor air reset inputs — connect

17. to up to 8 zone thermostats

Optional 20 ma control signal input

18.

Remote enable to start when

19. operating on 20 ma input

Optional SmartCycle

20. communications board

Boiler wiring socket to blower

21. and gas valve

Boiler wiring socket to pressure

22. switches and Fenwal control

Boiler wiring socket to

23. control panel

Boiler wiring socket to

24. control panel

Boiler wiring socket to

25. power switch

Boiler wiring socket to transformer

26.

Termination DIP switches

27.

200i

components

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

The Mestek 200i boiler — with SmartCycle

control

Contents

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

1 Method 1: SmartCycle modulation – control. . .page 6

 e 200i SmartCycle control can control up to (16) 200i boilers using built-in so ware

• and hardware.

Install a RS485 interface on each boiler and connect with RJ45 SmartCycle cables

• (or shielded wires).

•

 e header water temperature setpoint can be set by the master boiler or by a 4-20ma input from an external controller.

•

Member boilers can override master boiler control if they receive a contact closure on the Heat Demand or DHW Demand terminals.

2 Method 2: SmartCycle modulation – BMS . . page 14

•

 is method uses the 200i control’s built-in communications capabilities to accept Modbus protocol inputs from a building management system.  e master boiler control sequences and modulates the boiler network to accomplish the demands from the building management system.

•

Each boiler requires the RS485 interface board and cable.

•

Boiler setup is essentially the same as for method 1, with the exception that each boiler must be assigned both a SmartCycle network address and an address for the Modbus interface.

•

An additional bus is required to inter face w ith systems using BACnet or LonWorks protocol.

•

 e master boiler will take control and regulate the boiler network if signal from the BMS is lost or times out.

3 Method 3: External 4-20ma control . . . . . .page 16

•

Up to 5 boilers can be controlled by an external control that provides a 4-20ma input signal.  e external controls must also activate each boiler by closing a contact across the boiler’s 4-20ma Remote Enable contacts.

•

Member boilers can override external boiler control if they receive a contact closure on the Heat Demand or DHW Demand terminals.

200i

SmartCycle

Control panel

4 Control menus and adjustments . . . . . . . . .page 22

•

Operating parameters and control behaviors are set using the 200i control’s display/ keypad interface.

•

Refer to this section for the menu structure and explanations of the se ing options.

5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .page 31

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Label all wires prior to disconnection when servicing controls.

Failure to comply with the above could result in severe personal

Line voltage  eld wiring of any controls or other devices must

Method 1: SmartCycle modulation – local control

Electrical shock hazard — Disconnect all electrical power

sources to the boiler before making any electrical connections.

Wiring errors can cause improper and dangerous operation! Verif y proper operation a er servicing.

injury, death or substantial property damage.

 e electrical connections to this boiler must be made in

accordance with all applicable local codes and the latest revision of the National Electrical Code, ANSI /NFPA-70. Installation should also conform to CSA C22.1 Canadian Electrical Code Part I if installed in Canada. Install a separate 120 volt 15 amp circuit for the boiler. A properly rated shuto switch should be located at the boiler.  e boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/NFPA-70.

use copper conductors with a minimum size of #14 awg. Use appropriate wiring materials for units installed outdoors.

Figure 1 Electrical connection board (see item 10,

page 3 for location — Also see the wiring summary illustrations on the next pages)

Figure 2 120VAC power service terminals on electrical

connection board — See Figure 15 for location of the power terminal strip

Overview — control setup sequence

Follow the Boiler manual — Install the boilers according to the 200i

Boiler manual before a empting to set up the control system.

Install all boilers per the Boiler manual.

1. Close the external gas valve on every boiler.

2. Wire all boilers following the guidelines in this section.

3. A ach a header sensor to the master boiler ONLY.  e 200i control automatically

4. con gures the boiler with a header sensor as the master.

Set the master boiler control parameters using its display/keypad.

5. Set the master boiler’s termination DIP switches.

6. Set the termination DIP switches on the member boilers.

7. Set the member boilers’ control parameters using their display/keypads.

8. Follow the instructions in the Boiler manual to start up each boiler before proceeding

9. further.

Finish by connecting cables between the communications boards of all of the boilers

10. and verifying network operation.

Add communications modules

Insert a RS485 communications module onto each of the boilers’ electrical connection

1. panels, as shown in Figure 1.

Power supply (120 VAC)

See Figure 1 and Figure 2.

1. Connect minimum 14awg copper wire to the power connection as shown in Fig ure 2.

2. Install a fused service switch, mounted and installed in accordance with all appli-

3. cable codes.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 1: SmartCycle modulation – local control (cont.)

Circulator wiring

Postpurge circulator

The circulator shipped installed with the boiler can-

•

not be used for system circulation.

supplied from the factory. It circulates water a er the boiler stops  ring to prevent potential damage from heat pocketing in the top of the heat exchanger.

 e postpurge circulator is factory-piped and pre-wired. Do

• not change the usage, the wiring, the location or the piping.

Boiler circulator

See the Boiler manual for circulator piping.

• Figure 3, Figure 4, and Figure 5 show wiring of the Boiler

• circulator (or boiler/system circulator) to the terminal strip of the 200i electrical connection board.

DO NOT directly connect a circulator with a motor larger

• than 1/4 hp. For larger motors, install a circulator relay or motor contactor . Figure 3 and Figure 4 show the correct ways to install the boiler circulator using a relay or motor starter.

It must be used as

Figure 5 Circulator wiring terminal strip (see Figure 1,

page 6, for location) — Also see the wiring summary illustrations on the next pages)

Figure 3 Wiring the boiler circulator using a circula-

Figure 4 Wiring the boiler circulator using a relay or

tor relay (required for motors over 1/4 hp)

starter (required for motors over 1/4 hp)

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 1: SmartCycle modulation – local control (cont.)

IAR (Indoor Air Reset) wiring, when used

Heat Demand terminal connections —  e end switch leads from the zone valves

• must connect to the Heat Demand terminals on the electrical connection board as shown in Figure 7, page 9.

See Figure 6 for typical wiring to the IAR inputs when using 4-wire zone valves

• without a zone controller. For other applications, such as circulator relays or zone controllers, see Appendix A in the Boiler manual.

Polarity —  e connections to the IAR positive terminals (IAR +)

must be to the same location on the zone valve as the thermostat wire, as shown in Figure A1.  e connections to the IAR negative terminals (IAR –) must be from the zone valve terminal connected to the 24VAC common line, as shown. Connecting the wires incorrectly can cause the transformer to be shorted out and damaged. Verify the wiring with a voltmeter.

Always use a voltmeter to check the leads coming from the end switches

of the zone valves. With the thermostat calling for heat, connect the voltmeter leads across the wires coming from the end switches. If the meter shows a voltage reading, the zone valve wires are incorrect. Change the wiring and retest. DO NOT connect the wires to the boiler until you have tested as described. Incorrect wiring can damage the boiler control or other system components.

If there is only one transformer feeding all of the zone valves in the system, you can

• omit the wires to the IAR negative terminals (IAR –) on all but one of the zone valves.  is is because these terminals are jumpered internally on the electrical connection board. If there is more than one transformer, provide one wire from each transformer common side to one of the IAR negative terminals (IAR –).

Figure 6 Indoor Air Reset wiring to IAR terminals with

4-wire zone valves and no zone controller

(see Figure 7, page 9 for terminal block 6 location)

Sensor wiring

Header sensor is required — A header sensor must be installed in the system

• supply piping. Connect the header sensor ONLY to the master boiler. Install the header sensor in an immersion well. Locate the sensor where it will accurately sense the system water supply temperature. Connect the sensor leads to the electrical connection board as shown in Figure 8, page 10.

Outdoor reset application — To operate with outdoor reset, purchase and in-

• stall an outdoor sensor. Mount the sensor such that it is shielded from direct sunlight if possible and not likely to be covered by snow dri s or debris. Connect the outdoor sensor leads to the master boiler’s electrical connection board as shown in Figure 8, page 10. (Member boilers could have their own outdoor sensor if they will be operated in override mode by closing the Heat Demand terminals.)

Return water temperature sensor —  e return water temperature sensor

• is optional, only needed if you want to automatically control the boiler postpurge pump cycle time. Install the sensor in a well in the boiler return piping. Connect the sensor leads to the electrical connection board as shown in Figure 8, page 10. Each boiler requires a return water temperature sensor.

DHW wiring

To operate the boiler for domestic water heating with a storage tank, install and pipe

• the tank according to the tank manufacturer’s instructions and the recommended piping diagrams in this manual. Consult the factory for applications not covered.

 e circulator used for DHW must be operated by a circulator relay or zone con-

• troller that is activated when the tank aquastat calls for heat.

Connect the tank aquastat terminals across the DHW DEMAND terminals on the

• master boiler’s electrical connection board as shown in Figure 7, page 9. (Member boilers could be connected to tank aquastats if they are piped appropriately and intended to operate in override mode.)

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Figure 7 200i wiring summary — wiring to electrical connection board

Method 1: SmartCycle modulation – local control (cont.)

Also see Figure 2, page 6.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Figure 8 200i wiring summary — wiring to electrical connection board, continued (see Figure 7, page 9, for terminal strip locations)

Method 1: SmartCycle modulation – local control (cont.)

Also see Figure 5, page 7.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 1: SmartCycle modulation – local control (cont.)

External interlocks

Wire external limits and  ow switch, when used, as shown in Figure 8, page 10.

1. If wiring to and from a motorized combustion air damper, follow the guidelines

2. given in Figure 8, page 10. Connect only to the master boiler.

If any of the member boilers is to operate in override mode, and the

system is equipped with a combustion air damper, you must provide special wiring in order to ensure the damper opens and proves when the boiler  res.  is must be done without compromising the wiring between the master boiler and the damper.

Overrides — Control priorities

 e 200i control can provide override operation for any or all member boilers in a

3. SmartCycle network.  is requires the boilers be piped with appropriate isolation piping and controls.

Override is done by closing a contact across the Heat Demand or DHW Demand

4. terminals of any boiler.  ese priority inputs override all network controls or 420mA input controls to the boiler.

DHW Demand —  e DHW Demand closure takes priority for ALL boilers, in-

cluding the master and all members. When DHW Demand closes, the boiler or boilers immediately switch to DHW operation, including se ing the water temperature to the DHW Setpoint.

Space heating, Heat Demand — If any member boiler sees closure across its

Heat Demand terminals it will begin operation in space heating mode independently of commands from the master boiler or 4-20mA input source.

Do not wire boilers for override operation unless the piping design

provides automatic isolation of the overriding boilers.  e master boiler would be unable to properly control system water temperature if member boilers were to input heat to the system without control from the master. DHW operation, in particular, would raise the supply temperature from overriding boilers to the DHW Setpoint.

Override operation control setup — Boilers must be set up with

operating parameters necessary during their override operation; i.e., local setpoint, DHW setpoint, etc.

Summary — priority sequence is:

Priority 1 = DHW Demand

Priority 2 = Heat Demand

Priority 3 = SmartCycle input

Set termination DIP switches

 e SmartCycle network needs to recognize the beginning and end of the

1. network.  is requires se ing the four DIP switches on each boiler’s electrical connection board.

See Figure 9 for location of the switches.

2. See Table 1 for required se ings.  e table gives se ings for SmartCycle modula-

3. tion — local control and for remote control from a building management system (Modbus protocol).

DO NOT connect the communications cables (or shielded wires) between boilers

4. until all boilers have had parameters set and then been started up following all instructions in the 200i Boiler manual.

Figure 9 Termination DIP switches (see item 7, Figure 7,

Table 1 Termination DIP switch settings

Last member Switch 1: ON

Other members Switch 1: OFF

Note: Modbus setup is for applications controlled by a building management system. For systems using BACnet or LonWorks, a bridge board is used to interface with the 200i control.  e sw itch is “on” when in the down position and “o ” when in the up position.

page 9 for location)

Boiler SmartCycle Modbus

Master Switch 1: ON

Switch 2: ON

Switch 3: OFF

Switch 4: OFF

Switch 2: ON

Switch 3: OFF

Switch 4: OFF

Switch 2: OFF

Switch 3: OFF

Switch 4: OFF

(see note)

Switch 1: ON

Switch 2: ON

Switch 3: ON

Switch 4: ON

Switch 1: ON

Switch 2: ON

Switch 3: OFF

Switch 4: OFF

Switch 1: OFF

Switch 2: OFF

Switch 3: OFF

Switch 4: OFF

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 1: SmartCycle modulation – local control (cont.)

Close the external manual gas valve on every boiler before

proceeding. DO NOT open any gas valve, or a empt to  re any boiler, until the boilers have been set up and veri ed following the instructions in the 200i Boiler manual.

Failure to comply could cause a boiler failure, leading to possible

severe personal injury, death or substantial property damage.

Set control parameters on keypads

Before turning boilers on to set parameters, disconnect all call for heat

wiring at the electrical connection boards.  is will prevent the boiler for a empting to cycle during the setup process.

See “Control menus and adjustments,” beginning on page 22 for a complete list of control parameters and explanations.

Carefully read the parameter explanations in Table 8, page 25 through page 29.

When adjusting the limit band, operating limit (OP LIMIT), local setpoint (LOC SETPOINT) and DHW setpoint, make sure the operating temperature bands do not overlap or cause potential for nuisance cycling.

Indoor air reset — Use this option whenever possible.  e indoor air technology monitors space heating demand to help the boiler operate at the highest possible e ciency throughout the season. To operate with IAR, you must wire to the IAR input terminals as described on page 18.

System clock — Set the system clock on all boilers to ensure the time stamps will be accurate in the data logs.

Turn on the power to each boiler and set the on/o switch to ON as you set its parameters.

Use the boiler’s keypad to enter the parameters as described on page 22.

7. A er se ing a boiler’s parameters, turn the power o to the boiler until you are

8. ready to start the boiler up following the Boiler manual instructions.

Set the master boiler and each member boiler, following the guidelines given in

9. Table 2.

Start up boilers per 200i Boiler manual

Turn o power to all boilers.

1. Follow all instructions in the 200i Boiler manual to start up each boiler and verify

2. operation.

Connect network cables

Electrical shock hazard — Turn o power to each boiler before

a empting to connect the network cables.

Before turning boilers on to check network operation, disconnect all

call for heat wiring at the electrical connection boards.  is will prevent the boiler for a empting to cycle during the setup process.

Master boiler cable

Connect an RJ45 cable to the master boiler H-Link OUT block (item 2, Figure 10,

1. page 13) or 3-wire shielded cable to the H-Link terminal strip (item 4, Figure 10, page 13).  e other end of this cable will be a ached to the  rst member boiler in following steps.

Table 2 Control parameters

Parameter Master

boiler

HEAT BAND Set on master boiler only

LOC SETPOI NT Set HD only

SOURCE Set HD or DHW only

DHW SETPOINT Set if DHW will

OP LIMIT Set Set

LIMIT BAND Set Set

IA RESET ON if IAR is used,

OA SHUTDOWN Set ON if used

OA SETPOINT Set if used HDOA only

OA RESET Set if used HDOA only

OA SETPTS Set if used HDOA only

DELTA ENABLE Set if used Set if used

DELTA TEMP Set if used Set if used

PURGE TIME Set if used Set if used

ALWAYS ON Set if used Set if used

MASTER PUMP Set if used Do not set

NIGHT SETBACK Set on master boiler only

OPTIONS (all) Set Set

AUX FUNCTIONS Set on master boiler only

SYSTEM CLOCK Set Set

LOCAL ADD Automatic Set (beginning at 2)

CONSOLE ADD Automatic Set (beginning at 2)

MODULAR BOILER Set on master boiler only

MODULATION PID Set on master boiler only

FIRING MODE Set on master boiler only

SENSOR # Set HD/HDOA only

TYPE Set HD/HDOA only

CALIBRATE ? On any boiler if required

PASSWORD Set Set

COMMUNICATIONS Set Set

LOAD DEFAULTS On any boiler if required

SYSTEM On any boiler if required

Notes:

1 — HD Only means to set the parameter for a member boiler only if it is wired for Heat Demand override.

2 — DHW Only means to set the parameter for a member boiler only if it is wired for DHW Demand override.

3 — HDOA Only means to set these parameters only if the member boiler will be operated with outdoor reset when put in override mode with closure across its Heat Demand terminals (requires outdoor sensor connected to boiler).

be used

or set to OFF

Member

boiler

(see notes)

DHW only

Do not set

HDOA only

1,2

1,3

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Turn on power to the master boiler and set its on/o switch to ON.

2. You should hear at least 2 beeps.

3.  e control’s  rmware version number will display.

5. show STANDBY and SYS SET.  is veri es that the master boiler is setup correctly as the master.  e same display will show on member boilers when there is a call for heat from the master boiler. When there is no call for heat at a member boiler, the display wi ll show LOC SET instead.

If the master is functioning correctly, the yellow LED’s on the H-Link jack ports will blink.  e blinking indicates that the master is trying to communicate with member boilers.

If a FAULT message is displayed, clear the faults until the STANDBY message is displayed. Refer to troubleshooting suggestions at the end of this manual if you cannot resolve the issue.

Method 1: SmartCycle modulation – local control (cont.)

A er the control’s timer  nishes, the display will

Member boiler cables

Begin with the  rst member boiler.

Plug the other end of the master boiler’s communications cable to the member boiler’s input port (Figure 10, page 13, item 2 for RJ45 cable or item 4 for 3-wire cable).

Connect cables to all of the member boilers by cabling from one to the next. Connect incoming cables to item 1 or 4, Fig ure 10, page 13. Connect outgoing cables to item 2 or 4. (Note that shielded cable wires will share terminals when using item 4.)

Figure 10 RS485 communications board

Check the network

Turn the power on and the on/o switch to ON for all of the member boilers.

Allow time for each boiler to initialize.

A er about 30 seconds, the master boiler should recognize the member boilers.

4. NET BOILERS display.  e master control will show the boilers it recognizes. Values from 10 to 15 will display as le ers (10=A, 11=B, 12=C, 13=D, 14=E and 15=F).

If the display shows a blank space, such as “123_56789ABC,” the control does not detect the missing boiler (boiler 4). Check the yellow LED on the communication port of the missing boiler.

NORMAL connection — LED should  ash steadily, about twice per second.

TERMINATION incorrect — LED will  ash rapidly and stay on.

OPEN connection — LED does not  ash at all.

If a FAULT message is displayed, clear the faults until the STANDBY message is displayed. Refer to troubleshooting suggestions at the end of this manual if you cannot resolve the issue.

Nav igate to the BOILERS menu , then to HE AT

Start the system

Turn o power to all boilers.

Connect all call for heat wiring to the boilers.

Turn on power to all boilers and turn the on/o switches to ON.

 e boilers should now operate normally, as described in the Boiler manual.

 e master boiler will sequence and modulate boilers as necessary to control the water temperature.

 e master boiler will show the number of boilers  ring as well as the temperature and heat band display. Use the UP/DOWN keys to scroll through the displays to watch the process of starting and stopping boilers.

RJ45 SmartCycle cable IN from master or previous

1. member

RJ45 SmartCycle cable OUT to next member boiler

2. Shielded wire (3-2ire), option to RJ45 cable, Smart-

3. Cycle communications INPUT and connection for additional boilers on the network

Shielded wire (option to RJ45 cable) Modbus INPUT

4. from building management system

USB cable port (for USB cable connection to a PC —

5. required when updating control  rmware)

RJ45 cable from building management system, when

6. used

Plug for insertion into 200i control electrical connec-

7. tion panel (see page 3)

NOT SHOWN — An optional plug-in bridge is re-

8. quired to interface with building management systems that use BACnet or LonWorks protocol.  e 200i control supports Modbus protocol with no additional components except the RS485 interface board.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 2: SmartCycle modulation – BMS control

Overview

 is method uses an RS485 digital communications cable

1. with the Modbus protocol to control a boiler or SmartCycle network.

 e boiler or boiler network will operate as in the SmartCycle

2. local control method (Section 1 of this manual). But, instead of the HEAT DEMAND input, a so ware form of the HEAT DEMAND input is used (address 40001 — Boiler/ System Enable/Disable).

 e System Setpoint Timer needs to be loaded periodically

3. to allow the SmartCycle system to revert to local control from the master boiler in the event communications is lost.

 e Modbus protocol allows writing and reading registers

4. using Modbus commands. An optional BACnet or LonWorks bridge module can be used to connect the Modbus network to a BACnet or LonWorks network.

 is method allows enabling and disabling the boiler or

5. SmartCycle system; changing setpoints; and reading boiler status or temperatures remotely, using digital commands from a Building Management System.

 e master boiler assumes the role of MEMBER, RTU, 192K b, 8 bits, Even Parity, 1 stop bit, when connected to a BMS.

 e Member Boilers should not be connected to a BMS system other than to view read-only addresses.

Table 3 Modbus holding (read/write) registers

Data Type

Address

40001 Unsigned Boiler/System Enable/Disable 0 = Disabled/O

40002 Unsigned System Setpoint Timer (1) 0 – 65535 seconds

40003 Unsigned System Setpoint (1) 40°F – 220 °F 40004 Unsigned Outdoor Air Reset Enable/Disable 0 = Disabled/O

40005 Unsigned Outdoor Air Setpoint 40°F -100 °F 40006 Unsigned Water Temperature at High Outside Air 60°F -150 °F

40007 Unsigned High Outside Air Temperature 50°F -90 °F 40008 Unsigned Water Temperature at Low Outside Air 70°F -220 °F 40009 Signed Low Outside Air Temperature -35°F -40 °F 40010 Unsigned Set Clock – Month (2) 0 – 11 40011 Unsigned Set Clock – Day of Month (2) 1 – 31 40012 Unsigned Set Clock – Year (2) 0 – 99 40013 Unsigned Set Clock – Hours (2) 0 – 23 40014 Unsigned Set Clock – Minutes (2) 0 – 59 40015 Unsigned Set Clock – Seconds (2) 0 – 59 40016 Unsigned Set Clock – Day of Week (2) 1 – Monday 7

40017 Unsigned Set Clock – After the Set Clock Registers listed

Description Valid Values/

Range

1 = Enabled/On

– Sunday

1 above have been written, a 1 must be written to this location to set the clock. (2)

MODBUS registers

See Table 3, page 14; Table 4, page 14; and Table 5, page 15 for register requirements.

 e system setpoint timer and system setpoint work in tandem to externally control the operating setpoint.

 e setpoint (countdown) timer should be loaded with a timeout value (in seconds) prior to writing the system setpoint.

When the timer reaches zero, the control assumes that the BMS is no longer operating and the local setpoint (saved on the master control) is reloaded.

 is is a fail-safe feature used to help safeguard the system in case of BMS failure.

If the setpoint timer is not wri en, a default timeout value of 60 seconds is assumed.

To write the system clock, registers 40009 – 40015 must  rst be loaded with the correct date and time.  en, a 1 must be wri en to register 16 to write the date and time to the system clock.

Table 4 Boiler status  ags

Bit Description Bit Description

0 Disabled 16 Pilot Valve 1 Local Override 17 Blower 2 Alarm 18 Ignition Alarm 3 Failed 19 Valve Alarm 4 Member Error 20 High Limit 5 Boiler Running 21 Air Prove Switch 6 Pump Running 22 XS Factory 7 Spare 3 Interlock 23 Software Operator 8 LWCO Interlock 24 Header Sensor not Present

9 VFD Interlock 25 Supply Sensor not Present 10 Gas Prove 26 Return Sensor not Present 11 Spare 4 27 Outside Air Sensor not Present 12 Operator Interlock 28 — — 13 Water Prove (Flow) Interlock 29 — — 14 Air Prove UV Sensor Interlock 30 Master Boiler 15 Main Valve 31 Present (Boiler Detected)

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 2: SmartCycle modulation – BMS control (cont.)

BACnet or LonWorks protocols

Install the correct bridge to adapt to building management

1. systems using BACnet or LonWorks protocols.

 e bridge translates the BACnet or LonWorks input to the

2. Modbus protocol for compatibility with the SmartCycle controls.

Wiring and set-up

Wire and set up the master boiler and member boilers exactly

1. as for SmartCycle modulation — local control applications. See page 6 through page 13.

ALL control parameters must be set up just as for the local

2. control method.

 e ONLY di erence in setup is the termination DIP switch

3. se ings. Use the se ings for Modbus communications given in Table 1, page 11.

Connect communications cables (RJ45 or shield-wire

4. cables) between the control communications boards as for the local control method.

Verify network operation BEFORE connecting the building

5. management system.

Connect the BMS cable

DO NOT connect the building management system cable

1. until the boiler network has been proven to operate independently.  e system is designed to revert to local control by the master boiler should communications with the building management system be lost.

Turn o power to the master boiler.

See Figure 10, page 13. Connect an RJ45 cable to the BMS

3. input port, item 6. Or use shielded wire cable, connected to terminal block, item 3.

Verify BMS/SmartCycle operation

Turn on power to the master boiler.

Allow the master boiler to initialize.

Verif y operation with the building management system.

Table 5 Modbus input (read-only) registers

Data Type

Address

30001 Unsigned Boilers Running 0 – 16

30002 Unsigned Modulation (% BTU Load) 0 – 100

30003 Signed Header / System Temperature 32 – 250 °F

30004 Signed Supply Temperature 32 – 250 °F

30005 Signed Return Temperature 32 – 250 °F

30006 Signed Outside Air Temperature -40 – 250 °F

30007 Signed Spare Input 1 -32768 to 32767

30008 Signed Spare Input 2 -32768 to 32767

30009 Unsigned Clock – Month 0 – 11

30010 Unsigned Clock – Day 1 – 31

30011 Unsigned Clock – Year 0 – 99

30012 Unsigned Clock – Hours 0 – 23

30013 Unsigned Clock – Minutes 0 – 59

30014 Unsigned Clock – Seconds 0 – 59

30015 Unsigned Clock – Day of Week 1 – Monday 7 –

30016 –

30047

30048 –

30079

Unsigned Boilers 1 – 16 status  ag (32-bit) registers. The

Unsigned Boilers 1 – 16 runtime (32-bit) registers. The

Description Valid Values/

Range

Sunday

See the Boiler upper 16-bits of each 32-bit register is stored at odd numbered addresses 30016 –30046. The lower 16-bits of each 32-bit register is stored at even numbered addresses 30017 – 30047.

upper 16-bits of each 32-bit register is stored at odd numbered addresses 30048 – 30078. The lower 16-bits of each 32-bit register is stored at even numbered addresses 30049 – 30079. When the upper and lower registers are combined they form a 32-bit unsigned integer that is the number of seconds that the boiler has been running. For instance: (((Register 29) * 65536) + Register 30) = Boiler 1 runtime in seconds. Boiler 1 is the master boiler. Boilers 2 – 16 are member boilers.

Status Flags Table Below

0 – 4294967295

seconds

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Label all wires prior to disconnection when servicing controls.

Failure to comply with the above could result in severe personal

Line voltage  eld wiring of any controls or other devices must

Method 3: External 4-20ma control

Electrical shock hazard — Disconnect all electrical power

sources to the boiler before making any electrical connections.

Wiring errors can cause improper and dangerous operation! Verif y proper operation a er servicing.

injury, death or substantial property damage.

 e electrical connections to this boiler must be made in

use copper conductors with a minimum size of #14 awg. Use appropriate wiring materials for units installed outdoors.

Figure 11 Electrical connection board (see item 10,

page 3 for location — Also see the wiring summary illustrations on the next pages)

Figure 12 120VAC power service terminals on electrical

connection board — See Figure 15 for location of the power terminal strip

Overview — control setup sequence

Follow the Boiler manual — Install the boilers according to the 200i

Boiler manual before a empting to set up the control system.

 is method can be used for from 1 to 5 boilers.

1. Install all boilers per the Boiler manual.

2. Close the external gas valve on every boiler.

3. Wire all boilers following the guidelines in this section.

4. DO NOT install a header sensor on any of the boilers.

5. Disconnect the wires to the boilers’ Remote Enable terminals (and any override

6. wiring to Heat Demand or DHW Demand terminals) to ensure there will be no call for heat while proceeding.

Set the boilers’ control parameters using their display/keypads.

7. Follow the instructions in the Boiler manual to start up each boiler before proceed-

8. ing further.

Finish by reconnecting call for heat wiring, then operating the complete system to

9. verify operation in all modes.

Connect 4-20mA wiring

See Figure 16, page 19 for wiring from the 4-20mA controller.  e control must

1. provide the 4-20mA signal and a contact for each boiler to enable its operation by closing across the Remote Enable contact.

Power supply (120 VAC)

See Figure 11 and Figure 12.

1. Connect minimum 14awg copper wire to the power connection as shown in Fig-

2. ure 12.

Install a fused service switch, mounted and installed in accordance with all appli-

3. cable codes.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 3: External 4-20ma control (continued)

Circulator wiring

Postpurge circulator

The circulator shipped installed with the boiler can-

•

not be used for system circulation.

supplied from the factory. It circulates water a er the boiler stops  ring to prevent potential damage from heat pocketing in the top of the heat exchanger.

 e postpurge circulator is factory-piped and pre-wired. Do

• not change the usage, the wiring, the location or the piping.

Boiler circulator

See the Boiler manual for circulator piping.

• Figure 13, Figure 14, and Figure 15 show wiring of the Boiler

• circulator (or boiler/system circulator) to the terminal strip of the 200i electrical connection board.

DO NOT directly connect a circulator with a motor larger

• than 1/4 hp. For larger motors, install a circulator relay or motor contactor . Figure 13 and Figure 14 show the correct ways to install the boiler circulator using a relay or motor starter.

It must be used as

Figure 15 Circulator wiring terminal strip (see Figure 11,

page 16, for location) — Also see the wiring summary illustrations on the next pages)

Figure 13 Wiring the boiler circulator using a circulator

Figure 14 Wiring the boiler circulator using a relay or

relay (required for motors over 1/4 hp)

starter (required for motors over 1/4 hp)

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 3: External 4-20ma control (continued)

To operate the boiler for domestic water heating with a

4-20mA operation

A 4.02 mA current signal will start the boiler, at low  re. A

1. 20mA signal will cause the boiler to go to full input.

Between these input signal limits, the boiler modulates.  e

2. boiler  ring rate percentage is equal to the percentage of the signal between 0 and 20 mA. Example, a signal of 12 mA is 60% of 20 mA, so the boiler  ring rate would be 60% of max.

In addition to the 4-20mA signal, the remote controller

3. must also close a contact across each boiler’s Remote Enable contact in order for the boiler to  re.

See Figure 16, page 19 for wiring. Notice that the boiler 4-

4. 20mA terminals are wired in series.

IAR (Indoor Air Reset) wiring — apply ONLY if using space heating override mode

IAR can only be used if one or more of the boilers is wired

• and piped for override operation. Override would occur when a contact closed across the Heat Demand terminals. While this contact is closed, the boi ler will operate based on local control, including feedback for IAR if wired.

If override operation will be used, and you want to operate

• with IAR when in override mode, follow the instructions under Method 1 in this manual to wire for IAR.

Sensor wiring

Header sensor cannot be used when the boilers

•

are con gured for remote operation by a 24-mA source.

Outdoor reset application can be done only in over-

•

ride mode

install an outdoor sensor. Mount the sensor such that it is shielded from direct sunlight if possible and not likely to be covered by snow dri s or debris. Connect the outdoor sensor leads to the master boiler’s electrical connection board as shown in Figure 8, page 10. (Member boilers could have their own outdoor sensor if they will be operated in override mode by closing the Heat Demand terminals.)

Return water temperature sensor —  e return wa-

• ter temperature sensor is optional, only needed if you want to automatically control the boiler postpurge pump cycle time. Install the sensor in a well in the boiler return piping. Connect the sensor leads to the electrical connection board as shown in Figure 8, page 10. Each boiler requires a return water temperature sensor.

— To operate with outdoor reset, purchase and

• storage tank, install and pipe the tank according to the tank manufacturer’s instructions and the recommended piping diagrams in this manual. Consult the factory for applications not covered.

 e circulator used for DHW must be operated by a circula-

• tor relay or zone controller that is activated when the tank aquastat calls for heat.

Connect the tank aquastat terminals across the DHW

• DEMAND terminals on the master boiler’s electrical connection board as shown in Figure 7, page 9. (Member boilers could be connected to tank aquastats if they are piped appropriately and intended to operate in override mode.)External interlocks

Wire external limits and  ow switch, when used, as shown

5. in Figure 17, page 20.

 e combustion air interlocks cannot be used when operat-

6. ing with a 24-mA remote control. Combustion air damper control must be done by the remote control system.

Overrides — Control priorities

 e 200i control can provide override operation for any or

1. all member boilers.  is requires the boilers be piped with appropriate isolation piping and controls.

Override is done by closing a contact across the Heat De-

2. mand or DHW Demand terminals of any boiler.  ese priority inputs override all 4-20mA input controls to the boiler.

DHW Demand —  e DHW Demand closure takes prior-

3. ity for ALL boilers, including the master and all members. When DHW Demand closes, the boiler or boilers immediately switch to DHW operation, including se ing the water temperature to the DHW Setpoint.

Space heating, Heat Demand — If any member boiler

4. sees closure across its Heat Demand terminals it will begin operation in space heating mode independently of commands from the 4-20mA input source.

Do not wire boilers for override operation unless

the piping design provides automatic isolation of the overriding boilers.

Override operation control setup — Boilers

must be set up with operating parameters necessary during their override operation; i.e., local setpoint, DHW setpoint, etc.

Summary — priority sequence is:

DHW wiring — ONLY if using DHW override mode

The boiler (or boilers) must be piped with isolation

•

valves and wired for override operation

the 4-20mA input will occur if a contact closes across the boiler’s DHW Demand terminals.

. Override of

Priority 1 = DHW Demand

Priority 2 = Heat Demand

Priority 3 = 4-20mA Input/Enable

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Figure 16 200i wiring summary — wiring to electrical connection board

Method 3: External 4-20ma control (continued)

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Figure 17 200i wiring summary — wiring to electrical connection board, continued (see Figure 7, page 9, for terminal strip locations)

Method 3: External 4-20ma control (continued)

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Method 3: External 4-20ma control (continued)

Close the external manual gas valve on every boiler before

proceeding. DO NOT open any gas valve, or a empt to  re any boiler, until the boilers have been set up and veri ed following the instructions in the 200i Boiler manual.

Failure to comply could cause a boiler failure, leading to possible

severe personal injury, death or substantial property damage.

Set control parameters on keypads

Before turning boilers on to set parameters, disconnect all call for heat

wiring at the electrical connection boards, including the wiring to the boilers’ Remote Enable terminals.  is will prevent the boiler for a empting to cycle during the setup process.

See “Control menus and adjustments,” beginning on page 22 for a complete list of

1. control parameters and explanations.

Carefully read the parameter explanations in Table 8, page 25 through page 29.

When adjusting the limit band, operating limit (OP LIMIT), local setpoint (LOC

3. SETPOINT) and DHW setpoint, make sure the operating temperature bands do not overlap or cause potential for nuisance cycling.

System clock — Set the system clock on all boilers to ensure the time stamps will

4. be accurate in the data logs.

Turn on the power to each boiler and set the on/o switch to ON as you set its

5. parameters.

Use the boiler’s keypad to enter the parameters as described on page 22.

A er se ing a boiler’s parameters, turn the power o to the boiler until you are

7. ready to start the boiler up following the Boiler manual instructions.

Start up boilers per 200i Boiler manual

Turn o power to all boilers.

Follow all instructions in the 200i Boiler manual to start up each boiler and verify

2. operation.

Start the system

Turn o power to all boilers.

Connect all call for heat wiring to the boilers.

Turn on power to all boilers and turn the on/o switches to ON.

 e boilers should now operate normally, as described in the Boiler manual.

 e remote 4-20mA controller will sequence and modulate boilers as necessary to

5. control the water temperature.

Table 6 Control parameters

Parameter When to set

HEAT BAND Set

LOC SETPOINT HD only

SOURCE HD only

DHW SETPOINT DHW only

OP LIMIT Set

LIMIT BAND Set

IA RESET HD only

OA SHUTDOWN HD or HDOA only

OA SETPOINT HD or HDOA only

OA RESET HDOA only

OA SETPTS HDOA only

DELTA ENABLE Set if used

DELTA TEMP Set if used

PURGE TIME Set if used

ALWAYS ON Set if used

MASTER PUMP Set as required

NIGHT SETBACK HD only

OPTIONS (all) Set

AUX FUNCTIONS DO NOT use

SYSTEM CLOCK Set

LOCAL ADD DO NOT use

CONSOLE ADD DO NOT use

MODULAR BOILER DO NOT use

MODULATION PID DO NOT use

FIRING MODE DO NOT use

SENSOR # HD/HDOA only

TYPE HD/HDOA only

CALIBRATE ? Only as required

PASSWORD Set

COMMUNICATIONS Only as required

LOAD DEFAULTS Only as required

SYSTEM Only as required

Notes:

1 — HD Only means to set the parameter for a member boiler only if it is wired for Heat Demand override.

2 — DHW Only means to set the parameter for a member boiler only if it is wired for DHW Demand override.

(see notes)

1,3

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Control menus and adjustments

The Heat Net control display

Starting the display

Check all wiring to make sure it is complete and all wires are securely connected.

Verif y that the HEAT DEMAND and DHW DEMAND wires are removed.

Close the external gas valve on every boiler.

Turn on power to the boiler and then turn the boiler on/o switch ON.

 e control will beep at least twice and the display will show the  rst STANDBY display in Figure 18. Note that pushing the DOWN bu on on the keypad will change the right side of the display as shown, providing information on various setpoints and parameters.

 e display, LOC SET, means the setpoint temperature. Figure 18 shows the factory default values.

Accessing setup menus

With the display in STANDBY, press and hold the BACK key for 5 seconds.

 e display will change to:

Figure 18 Heat Net display during Standby (no call

for heat) — pressing the DOWN key on the keypad changes the display as shown

Press the SELECT key to select setup. (Note that pressing the DOWN key would change the selection to VIEW LOG.)

 e display will now show the  rst options in the setup menus:

Press the DOWN key to access additional menu options. Pressing the DOWN bu on once will change the display to:

 e cursor moves to the second line, indicating this option could now be selected with the SELECT key.

Continuing to press the DOWN key will access these menu options:

BOILERS

•

SETPOINTS

•

INDOOR AIR

•

PUMP OPTIONS

•

NIGHT SETBACK

OPTIONS

•

LOG/RUNTIME

•

AUX FUNCTIONS

•

SYSTEM CLOCK

•

ADVANCED SETUP

•

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Control menus and adjustments (continued)

Table 7 Setup menus (see Table 8, page 25 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.

To return to STANDBY, press/release

Level 1

item

to select

200i V X.X Shows  rmware version number

BOILERS # BOILERS 1 {1 to 16} — display only

SETPOINTS LOC SETPT 180°F {140 to 180°F}

INDOOR AIR IA RESET OFF {ON or OFF}

OUTDOOR AIR OA SHUTDOWN OFF {ON or OFF}

PUMP OPTIONS DELTA ENAB OFF {ON or OFF}

NIGHT SETBACK SETBACK # X 1 {1 through 4}

OPTIONS TEMP SCALE °F {°F or °C}

Level 2

Level 3

next item

to select

back one level

LEAD BOILER 1 — display only — the lead boiler is the boiler with

HEAT BAND 30 °F {10 to 50°F}

HEAT NET BOILERS 123456789ABCDEFG

SOURCE AUTO {AUTO, 4-20MA}

DHW SETPT 180°F {140 to 180°F}

OP LIMIT 205°F {145 to 205°F}

LIMIT BAND 10°F {1 to 50°F}

AVG TIME 60 MIN {30 to 120 minutes}

SET IAR SETPTS DELTA TEMP

@ HI IAR%

DELTA TEMP @ LO IAR%

VIEW IAR VALUES Display only, not changeable here — shows values

OA SETPT 68°F {40 to 100°F}

OA RESET OFF {ON or OFF}

SET OA SETPTS LOW WATER

@ HI OA

HI WATER @ LOW OA

DELTA TEMP 10°F {10 to 50°F}

PURGE TIME 0 seconds {0 to 255 seconds}

ALWAYS ON NO {YES or NO}

MASTER PUMP OFF {ON or OFF}

ENTRY IS OFF SETBACK 20°F {0 to 50°F}

ST DAY SUN {SUN, MON, TUE, WED, THU, FRI, SAT}

ST TIME 12:00AM

ENDDAY SUN {SUN, MON, TUE, WED, THU, FRI, SAT}

ENDTIME 12:00AM

KEY CLICK ON {ON or OFF}

SKIP PASSW ON {ON or OFF}

BRIGHTNESS 50% {12, 25, 37, 50, 62, 75, 87, 100%}

until the display returns to standby, or turn boiler ON/OFF switch o , then on.

next item

to select

back one level

Level 4

next item

to select

back one level

Default {Range}

to change value

to accept value and return to

previous menu level

a HEADER sensor connected

Display only — shows 1 through the number of boilers on the network

10°F {10 to 20°F} 70% {40 to 70%}

20°F {10 to 20°F} 40% {40 to 70%}

for 8 zones

140°F {60 to 150°F} 70°F {50 to 90°F}

180°F {70 to 180°F} 10°F {-35 to +40°F}

Typical line

(Display shows two lines at a time; cursor indicates active line)

200i V 1.0

# BOILERS 1

LEAD BOILER 1

HEAT BAND 30°F

HEAT NET BOILERS 123456

LOC SETPT 180°F

SOURCE AUTO

DHW SETPT 180°F

OP LIMIT 215°F

LIMIT BAND 20°F

IA RESET OFF

AVG TIME 60MIN

DELTA TEMP 10°F @ HI IAR% 70%

DELTA TEMP 20°F @ LO IAR% 40%

70 70 70 70 70 70 70 70

OA SHUTDOWN OFF

OA SETPT 68°F

OA RESET OFF

LOW WATER 140°F @ HI OA 70°F

HI WATER 180°F @ LOW OA 10°F

DELTA ENAB OFF

DELTA TEMP 10°F

PURGE TIME 120s

ALWAYS ON NO

MASTER PUMP OFF

SETBACK # 2

ENTRY IS OFF

ST DAY THU

ST TIME 3:00PM

ENDAY SAT

ENDTIME 10:00PM

TEMP SCALE °F

KEY CLICK ON

SKIP PASSW ON

BRIGHTNESS 50%

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Control menus and adjustments (continued)

Table 7 Setup menus (see Table 8, page 25 for explanations) (continued)

LOG/RUNTIME RUN HRS Total time gas valve has been open

LOG ENTRY Current entry in the log (see Table 9, page 30)

SIZE The size of the data log

BOILER CYC Number of times gas valve has been cycled on/o

AUX FUNCTIONS COMB AIR DAMPER

IN USE? USE RELAY # OPT PROOF TIME 2:00 (2 min, 0 sec) {0 to 4 minutes}

SYSTEM CLOCK TIME 12:00AM

DAY OF WEEK SUN MONTH SEP DAY 12 YEAR 2007

ADVANCED SETUP DISTRIB CTRL CONTROL HNET

HNET MASTER YES (Display only, not changeable here) LOCAL ADD Master default = 255 (not changeable)

CONSOLE ADD Default = 1; Range = 1 to 247

MODULAR BOILERı ADD BOILER DLY 10 minutes {0 to 15 minutes}

SHED BOILER DLY 2 minutes {0 to 15 minutes}

MOD DELAY TIME 10 seconds {0 to 60 minutes}

MOD MAX - LAST 50% {25 to 100%}

STOP BAND OFSET 5°F {0 to 50°F}

BLR START TIME 50 seconds {0 to 4 minutes}

MODULATION PID (P)ROPOR = 100 {0 to 100}

(I)NTEGRAL= 10 {0 to 100} (D)ERIVAT = 10 {0 to 100} BAND 100°F {40 to 18 0°F}

FIRING MODE ROTATION TRUE {True, FOFO, LOFO}

MASTER 1ST OFF

SENSORS SENSOR# OUTSIDE

TYPE TYPEZ {TYPEZ, None, ON/OFF} CALIBRATE ? NO {YES or NO}

PASSWORD CHANGE PASSWORD

OLD:>?______

CHANGE PASSWORD NEW:>?______

ACCEPT > YES / YES or NO

COMMUNICATIONS BAUD 19200

PARITY EVEN {EVEN or ODD} MODEM NO {YES or NO}

LOAD DEFAULTS FACTORY CAL? NO {YES or NO}

ARE YOU SURE> NO { YES or NO}

FACTORY SET? NO {YES or NO}

ARE YOU SURE> NO { YES or NO}

SYSTEM UPDATE CTRL? ARE YOU SURE> NO {YES or NO}

YES {YES or NO}

Member default = 2 (Range = 2 to 16)

Press , enter old password using arrow keys and

for each character

Press , enter new password using arrow keys and

for each character

RUN HRS 1240

LOG ENTRY 327

SI ZE 1000 BOILER CYC 5021

COMB AIR DAMPER IN USE? YES USE RELAY # OPT PROOF TIME 2:00 TIME 11:20AM DAY OF WEEK MON MONTH JAN DAY FRI YEAR 2007 CONTROL HNET HNET MASTER YES LOCAL ADD 255

CONSOLE ADD 255 10 MINUTES > 0 SECONDS 2 MINUTES > 0 SECONDS 0 MINUTES > 10 SECONDS STOP MOD MAX > % 50 EARLY STOP > 5° 0 MINUTES > 30 SECONDS (P)ROPOR = 100 (I)NTEGRAL = 10 (D)ERIVAT = 10 BAND 100°F ROTATION TRUE MASTER 1ST OFF SENSOR# SUPPLY TYPE TYPEZ CALIBRATE ? NO CHANGE PASSWORD OLD:>?_ _ _ _ _ _

CHANGE PASSWORD NEW:>?_ _ _ _ _ _

CHANGE PASSWORD ACCEPT >YES BAUD 19200 PARITY EVEN MODEM NO FACTORY CAL? NO ARE YOU SURE> NO FACTORY SET? NO ARE YOU SURE> NO UPDATE CTRL?

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Table 8 Setup menus — parameter explanations

Control menus and adjustments (continued)

Menu item Under . . . Explanation

HEAT BAND

LOC SETPT

SOURCE

BOILERS

SETPOINTS

Setpoint temperature controlled by the 200i control.

NOTE: If the control is operated by a Master control or by a remote control (building management system, 4-20ma control, etc.), this setpoint temperature only comes into play when the 200i control is in override mode (such as by closing its Heat Demand or DHW Demand terminals).

Speci es where the space heating setpoint temperature comes from:

AUTO means the 200i control determines the setpoint (using local setpoint, outdoor reset or header temperature setpoint).

The option is “4-20ma.” If 4-20 ma is selected, the 200i control determines setpoint based on the signal it receives at the 4-20ma terminals on the connection board. The setpoint temperature (°F) equals the signal current (ma) divided by 0.09; example, a signal of 10ma will cause a setpoint of 10/0.09 = 110°F.

The heat band is the height of the modulating band. When the water temperature is between ½ the heat band above or below the setpoint temperature, boiler  ring rate modulates. Boilers are at minimum input at the upper end of the band and maximum input at the lower end of the band. Boilers come on only if the water temperature is below the band. Boilers stage o when the water temperature is above the band.

DHW SETPT

OP LIMIT

LIMIT BAND

SETPOINTS

This is the setpoint temperature for the boiler outlet water (or header water temperature) when the DHW Demand terminals see a closed contact (DHW tank temperature control calls for heat, for example).

This is the temperature at the boiler outlet (or header sensor) that will cause the control to shut down on high temperature limit. It must be high enough above the upper end of the heat band to avoid nuisance cycling.

The maximum setting is 205°F.

Example: If the boiler setpoint is 180°F, and the heat band is 30°F, the upper end of the heat band is 180 + 30/2 = 195°F. The limit band (see below) must be set at 10°F so the OP LIMIT setting can be: 195 + 10 = 205°F (maximum allowable setting).

The operating limit setting (OP LIMIT) always limits boiler outlet water temperature, regardless of how the boiler is controlled (SmartCycle member, 4-20ma control or stand-alone). The limit band (see below) determines when the boiler begins to be forced to reduce input as the outlet temperature rises toward the limit setting.

If the boiler outlet water temperature rises toward the limit setting (OP LIMIT, above), the 200i control will begin to reduce the boiler’s  ring rate when the temperature gets within the LIMIT BAND degrees F below the operating limit setting. At the lower end of the limit band, the boiler can  re up to maximum input (100%). By the time the temperature reaches the upper end of the band (the OP LIMIT setting), the boiler is limited to minimum input (20%).

The limit band reduces the likelihood of short cycling on boilers controlled by a master control or a remote control by reducing boiler maximum allowable  ring rate as the temperature rises toward the limit setting. Make sure the lower end of the limit band is above the upper end of the heat band.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Control menus and adjustments (continued)

Table 8 Setup menus — parameter explanations (continued)

Menu item Under . . . Explanation

IA RESET

AVG TIME

SET IAR SETPTS

OA SHUTDOWN

OA SETPT

OA RESET

INDOOR AIR

OUTDOOR AIR

Activate indoor air reset by setting this to “ON.” Zone wiring must be made to the IAR input terminals for IAR to operate. See the Boiler manual for details on wiring to the IAR terminals.

The averaging time (AVG TIME) is the time span over which the control averages the results of zone demands. Leave this setting at the factory default unless directly otherwise by Mestek Technical Support.

Leave the delta temp settings at factory default settings unless directed otherwise by Mestek Technical Support. The determine how much the control adjusts maximum allowable  ring rate based on its monitoring of zone demand.

When outdoor air shutdown is enabled (ON), the boiler and its circulating pump shut down when the outside temperature is above the outdoor air setpoint (OA SETPT). This requires an outdoor sensor when enabled.

The boiler and its circulator shut down when the outside air temperature is above this setting if outdoor air shutdown is enabled (ON). This requires an outdoor sensor when enabled.

Set to “ON” to enable resetting the boiler outlet temperature (or header temperature) based on outside air temperature. Set to “OFF” to disable outdoor reset. This requires an outdoor sensor when enabled.

LOW WATER @ HI OA

HI WATER @ LOW OA

DELTA ENABLE

DELTA TEMP

PURGE TIME

ALWAYS ON

MASTER PUMP

OUTDOOR AIR SET OA SETPTS

PUMP OPTIONS

These temperatures determine the reset curve for supply water temperature. High water at low outside air means the design water temperature for maximum load (at ODT, or outside design temperature for the installation). The other end of the reset curve is the low water temperature at high outside air temperature. The low water temperature is generally equal to room temperature, meaning no heat input to the space would occur below this outside air temperature.

The boiler pump can be set to run after boiler shutdown to distribute residual heat to the heating system. Delta enable causes the boiler pump to run until the temperature di erence between boiler inlet and outlet is less than DELTA TEMP (see below). The pump will continue to run an additional period after this for the amount of time speci ed in PURGE TIME (below).

When DELTA ENABLE (above) is set to “ON,” the boiler pump will run until the temperature di erence across the boiler is less than DELTA TEMP. (The pump will run an additional time equal to the PURGE TIME.) An inlet temperature sensor is required.

The boiler pump can run after boiler shutdown to distribute heat remaining in the boiler water. PURGE TIME sets how long the boiler pump will run. (Also see DELTA TEMP, above.) NOTICE: For systems that shut o  ow valves (such as zone valve systems) when the call for heat is satis ed, this option must be set to “0” to prevent dead-heading the pump.

If ALWAYS ON is set to “YES,” the boiler circulator never turns o .

If set to “ON,” the master control in the network will keep its pump contacts closed (running its pump and/or control valve) if no other boilers are operating. This is used to prevent deadheading system  ow.

SETBACK#

NIGHT SETBACK

Setback number is the designator for the setback operation. Up to four (4) setback operations can be programmed.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Control menus and adjustments (continued)

Table 8 Setup menus — parameter explanations (continued)

Menu item Under . . . Explanation

ENTRY IS

TEMP SCALE

KEY CLICK

SKIP PASSW

BRIGHTNESS

RUN HRS

LOG ENTRY

SIZE

BOILER CYC

NIGHT SETBACK

OPTIONS

LOG/RUNTIME

Select “ON” to enable a setback operation. Then program the times, days and setpoint. The setpoint assigned will override the 200i control’s setpoint when setpoint is controlled locally. It will not override 4-20ma control or building management control.

Select Fahrenheit or Centigrade.

If activated, the control beeps when a key is pressed.

The control can be programmed such that a password is required to change settings. Setting this to “ON” disables the password.

Adjust the brightness of the display.

Displays the total time the boiler gas valve has been open.

Displays the current entry in the data log (see Table 9, page 30).

Displays the current number of entries in the data log.

Displays the number of times the boiler gas valve has been cycled on, then o . It does not include failed ignition attempts.

COMB AIR DMPR IN USE?

USE RELAY #

PROOF TIME

SYSTEM CLOCK

LOCAL ADD

CONSOLE ADD

ADD BOILER DLY

SHED BOILER DLY

AUX FNCTIONS

ADVANCED SETUP DISTRIB CTRL

ADVANCED SETUP MODULAR BOILER

Select “YES” to connect a combustion air damper and its end switch to the electrical connection board.

Only one relay is available.

Set proof time long enough to be sure the combustion air damper can open and activate its end switch.

Set the system clock (time, day of week, month, day and year) on start-up and after any power outage to ensure the data log time stamp information will be accurate.

Assign each member boiler a unique address, beginning with “2” or higher. Enter any value from 2 to 16.

NOTE: When the master boiler control displays the number of boilers on the network, it will show numbers above 9 as letters: 10=A; 11=B; 12=C; 13=D; 14=E, and 15=F. For example, if there are 12 boilers on the network, then the master control will show: “SmartCycle BOILERS 123456789ABC” when displayed in the BOILERS menu.

The master boiler local address is automatically set to 255. (The master boiler is automatically recognized because it is the one with a header sensor wired to its HEADER SENSOR terminals.)

This is used only when the boilers are regulated by a building management system, using MODBUS, BACNET or LONWORKS. Assign each member boiler AND the Heat Net master boiler a unique address, an value from 1 to 247.

This is the minimum wait time before an additional boiler can  re when called on by the master boiler control.

This is the minimum wait time before a boiler can shut down by the master boiler control.

MOD DELAY TIME

ADVANCED SETUP MODULAR BOILER

The boiler will remain at minimum  re when  rst starting until this amount of time has elapsed.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Control menus and adjustments (continued)

Table 8 Setup menus — parameter explanations (continued)

Menu item Under . . . Explanation

MOD MAX-LAST

STOP BAND OFSET

BLR START TIME

(P)ROPOR =

(I)NTEGRAL =

ADVANCED SETUP MODULAR BOILER

ADVANCED SETUP MODULATION PID

This sets the maximum  ring percentage for boilers during times that some boilers are not  ring. It limits input of the boilers to keep them as e cient as possible. Once all boilers are started (during high heat demand periods), this limit is remove, and all boilers can  re up to maximum input. Once any boiler is dropped o ine, the limit is applied again.

This setting helps reduce short-cycling when water temperature is within the heat band. If the water temperature rises to the top of the heat band less the STOP BAND OFFSET before a boiler just added has completed its modulation delay time, the boiler will shut down. Example, if the top of the heat band is 190°F and stop band o set is 15°F, a newly-added boiler will shut down if the temperature reaches 175°F (190 - 15) before its modulation delay time has ended.

DO NOT CHANGE — This is the time from receiving a call for heat to when a boiler begins its modulation operation (running at minimum  re).

This parameter should generally be left at factory default.

(D)ERIVAT =

BAND

ROTATION

MASTER 1ST

SENSOR#

TYPE

CALIBRATE ?

ADVANCED SETUP MODULATION PID

ADVANCED SETUP FIRING MODE

ADVANCED SETUP SENSORS

This parameter should generally be left at factory default.

Select the rotation method. True rotation attempts to  re all boilers an equal amount of time. First on/ rst o jogs between boilers to balance usage. Last on/ rst o maintains the same rotation sequence at all times.

Set this to “ON” to always start the master boiler  rst, regardless of the rotation scheme selected.

There are up to three sensors: OUTSIDE, HEADER and RETURN.

Type Z is for a thermistors sensor (as supplied by Mestek).

“None” means do not use this sensor.

ON/OFF looks for an external dry contact closure.

Use this function only if the response to a sensor indicates the control calibration may be o .

Calibrate the control by attaching a 10k precision resistor across the sensor terminals.

Select “YES” after “CALIBRATE ?.”

The control will measure the resistance and establish a trim value (in ohms) for the sensor input.

The control display will show the trim value setting.

The trim value must not exceed +/- 200 ohms. If it does, verify that the resistor is correctly connected. If so, the sensor input is bad. Contact Mestek for recommended action.

If the trim setting is acceptable, press the SELECT key to accept.

The display will show, “TRIM VALUE SET!”

After a slight delay, the display will return to the sensors menu.

CHANGE PASSWORD

ADVANCED SETUP PASSWORD

Use to set/change a password.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Table 8 Setup menus — parameter explanations (continued)

Control menus and adjustments (continued)

Menu item Under . . . Explanation

BAUD

PARITY

MODEM

LOAD DEFAULTS

FIRMWARE VERSION (UPDATE CONTROL?)

ADVANCED SETUP COMMUNICATIONS

ADVANCED SETUP

ADVANCED SETUP SYSTEM

Not changeable. Always 19200.

Select even or odd as required by communications port used.

Select “YES” only if a modem is installed.

Load the factory defaults when you want to be sure nothing has been changed or after you have loaded new  rmware.

Disconnect wires to the Heat Demand terminals and any other remote operation wiring. 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

3. select “YES” for the prompt, “ARE YOUR SURE?”

The  rmware version in the control must match the version in this manual in order to ensure accuracy of the installation/operation information. The control displays the  rmware version number when Setup is accessed. To update the control’s  rmware, obtain a disk from Mestek.

Disconnect wires to the Heat Demand terminals and any other remote operation wiring. There must be no call for heat during the process.

Record all setup information for the application before proceeding.

Insert the Firmware Update Program disk into the computer. The program will start and show an option screen.

Select “Install USB Drivers” to install the program onto the computer.

After the USB driver installation is complete, select “Install Firmware Update.”

Plug a USB cable into the control connection board, with the other connected to the computer. THE CABLE MUST BE CONNECTED BEFORE STARTING THE FIRMWARE UPDATE PROGRAM.

Start the Firmware Update Program. It will auto detect the 200i control. The program dialog box will automatically show the control’s comport number in the  rst box.

The second box will show the  rmware  le number. Make sure this is the correct  le. If not, use the “. . .” box to the right of the  le name to navigate to the correct  le.

Navigate to the control Advanced menu, “System.”

10.

Select “YES” to update the control.

11.

NOTICE: The  rmware must be downloaded now for the 200i control to function again.

12.

Return to the computer. Select “UPDATE.” The computer program will ask to turn the boiler o , then back on.

13.

After the power is cycled on the boiler, the download will start.

14.

If the download is interrupted or fails, turn the boiler ON/OFF switch OFF, then ON. Restart the  rmware download program to start the download. (The boiler will appear unresponsive during this time because it is wating for the download to take place.)

15.

When the download is complete, the boiler will power cycle. The display should show STANDBY.

16.

If the  rmware does not load correctly, the display will remain blank. Try running the  rmware program again.

Check that the boiler performs properly.

17.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Table 9 Accessing and using the Log

Enter Setup: From STANDBY, hold

Press

The screen will now show the most recent entry in the log.

Use the arrow keys to scroll through the log entries (entry number and date are on the  rst line of the log screen).

Each log entry includes three screens as described below. The top line remains the same in all three, and contains the date stamp

and entry number.

An entry is made each time a change in demand occurs, or when demand changes from heating to DHW or back, each prepurge

and postpurge occurrence, and each ignition sequence. An entry is also made when any of the Screen 3 events (below) occurs.

These events may be errors, faults or noti cation of setback activity.

Troubleshooting

with the cursor on VIEW LOG.

for 5 seconds. Then press until the cursor points to VIEW LOG.

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Situtation Suggested procedure

Nothing happens when the power switch is turned on.

The display shows combustion air damper failure.

The display is displaying random characters or the control keeps resetting.

There are no heating boilers on.

Unable to change the # of Boilers in the BOILERS menu.

The BOILERS menu only indicates one boiler, but there are member boilers connected. The amber light blinks on all of the boilers communication’s jacks.

Troubleshooting (continued)

Check 120VAC power to connection board. Verify power is connected per wiring diagrams.

❑

 e Power switch light (ON -Position) should illuminate if power is wired correctly.

❑

If the Ignition Control is active, but the front panel display is inactive check:

❑

Cable and cable polarity from the control board to the display.

1. Check for 120vac on the primary of the transformer and 24vac on the secondary. If one of the 24vac

2. interlocks has been shorted to ground or the 24vac output is low, the transformer may be damaged or a 24vac circuit may be miswired.

 e 200i control is equipped with rese able fuses on the power input circuit. Wiring power incorrectly

❑

to the unit will cause these fuses to open. Once the incorrect wiring is corrected, the fuses should reset themselves in less than 5 minutes.

If you are not using the combustion air damper then it needs to be disabled in the AUX FUNCTIONS menu.

❑

 e prove switch for the combustion air damper is not closing. Check to make sure the dampers are being

❑

controlled by the output relay you speci ed when programming for the damper. Also check to make sure the prove switch is working properly.

If there is no proving switch, you must put a jumper wire across input connection (USER INTRLK).

❑

If these steps have been done and you continue to get the error message, check the sensor TYPE speci ed

❑

in the SENSORS menu. If it is set to NONE, the controller will not recognize the closed circuit. Set the Sensor type to ON/OFF.

 ere may exist a grounding problem with the controller or one of the boilers, pumps, contactors or other

❑

devices connected to it. If all grounding is correct, there may be an issue with radiated or induced electrical noise (interference).

❑

 is may be caused by arcing across a contactor’s contacts when starting a pump motor or a large electrical load. It may also be caused by the ignition transformer being improperly grounded or the spark gap being out of adjustment.

A empt to identify the noise source:

❑

What is the boiler/controller trying to do at the time of the failure?

1. Is the boiler on the same circuit as the noise source? ( e boiler should have isolated power.)

2. Are shielded sensor wires used? (Ensure the shields are grounded only at the boiler control end.)

3. Are any sensors or sensor wires located near a transmi ing antenna? (Move sensor)

Check the se ings for OA SETPOINT and OA RESET.

❑

If the outdoor air temperature is above the OA SETPOINT and OA RESET is on, the circulator pump

1. relay will be locked out and the heating boilers will not  re.

If the water temperature is within the heating band around the setpoint, boilers will not come on.

2.  e water temperature must fall below the lower band limit to begin  ring boilers.

In H-Net method, the 200i control auto-detects the boilers in the system and adjusts the number of boilers

❑

accordingly. Using H-NET, if the numbere of boilers is not being detected properly as the actual number of boilers in

❑

the system, check each boiler.  ere can only be (1) master boiler, but there can be up to 15 member boilers. Make sure only the master boiler has a Header Sensor connected.

❑

Verif y that each boiler’s SmartCycle cable is in place.

❑

Verif y that each boiler has a unique address assigned (ADVANCED SETUP, DISTRIB CTRL, LOCAL AD).

❑

Verif y that the latest version of  rmware is installed on all boilers.

❑

All boilers in a system must have the same  rmware revision (version).

❑

Verif y the proper termination is set on the Master and the last Member boiler.

❑

Cast iron condensing boiler — Control manual

Cast iron condensing boiler

Situtation Suggested procedure

SmartCycle boilers are detected but then lost and then detected again.

Only the MASTER boiler Fires, but the system has many boilers and is using SmartCycle.

You get the error message – WATER FLOW SWITCH or WAITING FOR FLOW.

You have forgotten the password.

Firmware update program starts to load, but then stops.

Troubleshooting (continued)

 e H-Net communications cable may be receiving interference from the blower, ignition, or other form

❑

of radiated electrical noise. Termination of the jumpers may not be correct or there is more than one master.

❑

Ensure that the termination dip switchs are set on the MASTER boiler and only the LAST MEMBER

1. boiler. All of the other member boilers should have their termination dip switches OFF.

 ere may be two or more MASTER boilers. Ensure that only one header sensor is present and con-

2. nected to the HEADER input.  ere should be no wires or sensors connected to the HEADER input if the boiler is operating as a member.

Verif y that the HNet cables are of a shielded or twisted pair type. Shielding of the cable is required.

3. Minimize possible electrical interference by routing the communications cables away from electrical

4. noise sources, such as motors, ignition controls, contactors, etc.

In order for the MASTER boiler to act as a MASTER, the header sensor must be set to TYPEZ, and there

❑

must be a header sensor present. At power-up, the header sensor is auto detected. If the temperature of the header sensor at power-up is

❑

greater than –25 °F and less than 240 °F it is considered a valid sensor.  e boiler will default to the MEMBER mode if the temperature is not in this range, and can only be run locally or by external inputs.

 e HNet needs a communications cable daisy-chained between boilers. Ensure that a good connection

❑

is made on the communications board and that the lights on the dual RJ45 jacks  ash (roughly twice a second).  e MASTER is the only one that should  ash with no communications cables plugged in.

If the control does not sense a closed circuit at input connection, FLOW SWITCH, check to make sure the

❑

circuit for the circulator pump is correct, that the pump is being energized, and that the  ow prove switch is working properly.

If there is no  ow prove switch, check to make sure that a jumper wire has been connected across the

❑

FLOW SWITCH terminals. Turn the ON/OFF switch o .  en depress and hold the ESC key while turning it back on.  is will load

❑

the default password “AAAAAA”. Ensure that the USB driver for your PC/Laptop computer is properly installed.❑

ray 200i Control Manual

Specifications and Main Features

Frequently Asked Questions

User Manual