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Ray
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200i
Control manual

Ray 200i Control manual - The Mestek

Other manuals for 200i: Installation And Operation Instructions Manual, User's Information Manual

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Cast iron condensing boiler

— Control manual

The Mestek

200 boiler — SmartCycle

control

Control overview

Th e 200i SmartCycle control monitors boiler temperature and limit circuit inputs, modulating boiler fi r-

ing rate to meet demand. Th e control uses microprocessor electronics, watching time-average response

from the system to anticipate how much heat the system needs. Coupled with the fi ve-to-one turndown

of the 200i boiler, this results in maximum possible condensing-mode operation. Th e 200i boiler will

provide unmatched seasonal effi ciency.

Indoor air reset (IAR)

Mestek’s unique approach to boiler output regulation is its Indoor Air Reset function. Th e control moni-

tors the demand from up to 8 diff erent zones. Watching the demand duration and response to supply

temperature, averaging over time, the SmartCycle control anticipates system needs. It sets boiler maxi-

mum fi ring rate and adjusts supply water temperature to fi ne-tune boiler heat output. All that is required

to enable IAR is to connect thermostat circuit wires to the IAR inputs. Th e SmartCycle control can also

be confi 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.

Th 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 fi ring rate to match system de-

mand. 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. Th e control can even ac-

cept 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.

Th e control method used by the SmartCycle control is based on digital communications, which elimi-

nates 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.

Th 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.

PID response

Th e SmartCycle control uses proportional-integral-derivative calculations to determine the response to

boiler water temperature changes. Th 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. Th is ensures the boiler won’t make sudden unnecessary changes in fi ring rate.

Multiple boiler operation

Th 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

sett ing up control behavior. Th e master boiler is automatically selected by connecting a sensor lead to its

HEADER sensor terminals. Th e SmartCycle control recognizes the sensor and confi 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 sett ing. Th is limits the

fi ring rate of all boilers to a pre-set maximum (50% by default). Th

is means all of the boilers will be run

at a very effi cient level until all boilers are on. Only then can fi ring rate increase above this sett ing. Boiler

rotation can be fi rst-on/fi rst-off , fi rst-on/last-off , 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).

•

200

SmartCycle

Control panel

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Summary of 200i

Page 1
Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions. Failure...
Page 2: The Mestek
2 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual the mestek 200 i boiler — smartcycle tm control control overview th e 200i smartcycle control monitors boiler temperature and limit circuit inputs, modulating boiler fi r- ing rate to m...
Page 3: The Mestek
3 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual the mestek 200 i boiler — smartcycle tm control 200 i components wiring connections power wiring, 120 vac heat demand input dhw demand input low fi re terminals high fi re terminals to ...
Page 4: The Mestek
4 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual the mestek 200 i boiler — with smartcycle tm control.
Page 5: Contents
5 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual 1 method 1: smartcycle modulation – control. . .Page 6 th e 200i smartcycle control can control up to (16) 200i boilers using built-in soft ware and hardware. Install a rs485 interface ...
Page 6
6 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 1: smartcycle modulation – local control 1 overview — control setup sequence follow the boiler manual — install the boilers according to the 200i boiler manual before att empting...
Page 7
7 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 1: smartcycle modulation – local control (cont.) 1 figure 3 wiring the boiler circulator using a circula- tor relay (required for motors over 1/4 hp) figure 4 wiring the boiler c...
Page 8
8 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual 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) method 1: smartcycle modulation – l...
Page 9
9 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual figure 7 200i wiring summary — wiring to electrical connection board method 1: smartcycle modulation – local control (cont.) 1 also see figure 2, page 6..
Page 10
10 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual figure 8 200i wiring summary — wiring to electrical connection board, continued (see figure 7, page 9, for terminal strip locations) also see figure 5, page 7. Method 1: smartcycle mod...
Page 11
11 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual external interlocks wire external limits and fl ow switch, when used, as shown in figure 8, page 10. If wiring to and from a motorized combustion air damper, follow the guidelines give...
Page 12
12 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual table 2 control parameters parameter master boiler member boiler (see notes) heat band set on master boiler only loc setpoi nt set hd only 1 source set hd or dhw only 1,2 dhw setpoint ...
Page 13
13 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual figure 10 rs485 communications board turn on power to the master boiler and set its on/off switch to on. You should hear at least 2 beeps. Th e control’s fi rmware version number will ...
Page 14
14 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 2: smartcycle modulation – bms control 2 table 3 modbus holding (read/write) registers address data type description valid values/ range 40001 unsigned boiler/system enable/disa...
Page 15
15 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 2: smartcycle modulation – bms control (cont.) 2 table 5 modbus input (read-only) registers address data type description valid values/ range 30001 unsigned boilers running 0 – ...
Page 16
16 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 3: external 4-20ma control 3 overview — control setup sequence follow the boiler manual — install the boilers according to the 200i boiler manual before att empting to set up th...
Page 17
17 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 3: external 4-20ma control (continued) 3 figure 13 wiring the boiler circulator using a circulator relay (required for motors over 1/4 hp) figure 14 wiring the boiler circulator...
Page 18
18 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 3: external 4-20ma control (continued) 3 4-20ma operation a 4.02 ma current signal will start the boiler, at low fi re. A 20ma signal will cause the boiler to go to full input. ...
Page 19
19 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 3: external 4-20ma control (continued) 3 figure 16 200i wiring summary — wiring to electrical connection board.
Page 20
20 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 3: external 4-20ma control (continued) 3 figure 17 200i wiring summary — wiring to electrical connection board, continued (see figure 7, page 9, for terminal strip locations).
Page 21
21 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual method 3: external 4-20ma control (continued) 3 table 6 control parameters parameter when to set (see notes) heat band set loc setpoint hd only 1 source hd only 1 dhw setpoint dhw only...
Page 22
22 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual figure 18 heat net display during standby (no call for heat) — pressing the down key on the keypad changes the display as shown the heat net control display starting the display check ...
Page 23
23 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual level 1 next item to select level 2 next item to select back one level level 3 next item to select back one level level 4 next item to select back one level default {range} to change v...
Page 24
24 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual table 7 setup menus (see table 8, page 25 for explanations) (continued) log/runtime run hrs total time gas valve has been open run hrs 1240 log entry current entry in the log (see tabl...
Page 25
25 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual control menus and adjustments (continued) 4 menu item under . . . Explanation heat band boilers the heat band is the height of the modulating band. When the water temperature is betwee...
Page 26
26 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual control menus and adjustments (continued) 4 table 8 setup menus — parameter explanations (continued) menu item under . . . Explanation ia reset indoor air activate indoor air reset by ...
Page 27
27 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual menu item under . . . Explanation entry is night setback select “on” to enable a setback operation. Then program the times, days and setpoint. The setpoint assigned will override the 2...
Page 28
28 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual menu item under . . . Explanation mod max-last advanced setup modular boiler this sets the maximum fi ring percentage for boilers during times that some boilers are not fi ring. It lim...
Page 29
29 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual menu item under . . . Explanation baud advanced setup communications not changeable. Always 19200. Parity advanced setup communications select even or odd as required by communications...
Page 30: Troubleshooting
30 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual troubleshooting 5 table 9 accessing and using the log enter setup: from standby, hold for 5 seconds. Then press until the cursor points to view log. Press with the cursor on view log. ...
Page 31: Troubleshooting
31 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual troubleshooting (continued) 5 situtation suggested procedure nothing happens when the power switch is turned on. Check 120vac power to connection board. Verify power is connected per w...
Page 32: Troubleshooting
32 p/n 42-9472 copyright 2008 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — control manual troubleshooting (continued) 5 situtation suggested procedure smartcycle boilers are detected but then lost and then detected again. Th e h-net communications cable may be receiving int...