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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.

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Summary of Contents for 200i

Page 1: ...ed with a dust freeairsupply Followtheinstructionmanualprocedurestoductairtotheboilerairintake Iftheboilerhasbeencontaminatedbyoperation with contaminated air follow the instruction manual guidelines...

Page 2: ...nput from an external controller The control method used by the SmartCycle control is based on digital communications which elimi nates the need for analog control signals Analog signalinputs are supp...

Page 3: ...ernal high limit and or low water cutoff if desired To flow switch when used Used to activate combustion air damper if desired To combustion air damper proving switch required when controlling combust...

Page 4: ...4 P N 42 9472 Copyright 2008 Mestek Inc Cast iron condensing boiler Cast iron condensing boiler Control manual The Mestek 200iboiler with SmartCycleTM control...

Page 5: ...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...

Page 6: ...inFigure2 Install a fused service switch mounted and installed in accordance with all appli cable codes 1 2 3 4 5 6 7 8 9 10 1 1 2 3 Figure 1 Electrical connection board see item 10 page 3 for locatio...

Page 7: ...potential damage from heat pocket ing in the top of the heat exchanger Thepostpurgecirculatorisfactory pipedandpre wired Do not change the usage the wiring the location or the piping Boiler circulato...

Page 8: ...ard If there is more than one transformer provide one wire from each transformer common side to one of the IAR negative terminals IAR Sensor wiring Header sensor is required A header sensor must be in...

Page 9: ...8 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...

Page 10: ...sing 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 p...

Page 11: ...trol 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...

Page 12: ...s 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 operati...

Page 13: ...C 13 D 14 E and 15 F If the display shows a blank space such as 123_56789ABC the control does not detectthemissingboiler boiler4 ChecktheyellowLEDonthecommunication port of the missing boiler NORMAL c...

Page 14: ...r 15 MainValve 31 Present Boiler Detected Overview This method uses an RS485 digital communications cable with the Modbus protocol to control a boiler or SmartCycle network Theboilerorboilernetworkwil...

Page 15: ...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 0 4294967295 seconds BA...

Page 16: ...connection as shown in Fig ure 12 Install a fused service switch mounted and installed in accordance with all appli cable codes 1 2 3 4 5 6 7 8 9 1 1 2 3 Figure 11 Electrical connection board see item...

Page 17: ...ntial damage from heat pocketing in the top of the heat exchanger Thepostpurgecirculatorisfactory pipedandpre wired Do not change the usage the wiring the location or the piping Boiler circulator See...

Page 18: ...ach boiler requires a return water temperature sensor DHW wiring ONLY if using DHW override mode The boiler or boilers must be piped with isolation valves and wired for override operation Override of...

Page 19: ...72 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 conn...

Page 20: ...ast 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 Fig...

Page 21: ...erminals This will prevent the boiler for attempting to cycle during the setup process See Control menus and adjustments beginning on page 22 for a complete list of control parameters and explanations...

Page 22: ...e of the display as shown providing information on various setpoints and parameters The display LOC SET means the setpoint temperature Figure 18 shows the fac tory default values Accessing setup menus...

Page 23: ...P 20 F LO IAR 40 VIEW IARVALUES Display only not changeable here shows values for 8 zones 70 70 70 70 70 70 70 70 OUTDOOR AIR OA SHUTDOWN OFF ON or OFF OA SHUTDOWN OFF OA SETPT 68 F 40 to 100 F OA SET...

Page 24: ...inutes 0 to 15 minutes 2 MINUTES 0 SECONDS MOD DELAYTIME 10 seconds 0 to 60 minutes 0 MINUTES 10 SECONDS MOD MAX LAST 50 25 to 100 STOP MOD MAX 50 STOP BAND OFSET 5 F 0 to 50 F EARLY STOP 5 BLR STARTT...

Page 25: ...r temperature when the DHW Demand terminals see a closed contact DHW tank temperature control calls for heat for example OP LIMIT SETPOINTS This is the temperature at the boiler outlet or header senso...

Page 26: ...ly 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...

Page 27: ...ivate its end switch SYSTEM CLOCK 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 LOCAL A...

Page 28: ...should generally be left at factory default BAND ADVANCED SETUP MODULATION PID This parameter should generally be left at factory default ROTATION ADVANCED SETUP FIRING MODE Select the rotation method...

Page 29: ...ogram 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 c...

Page 30: ...rrow keys to scroll through the log entries entry number and date are on the first line of the log screen Each log entry includes three screens as described below The top line remains the same in all...

Page 31: ...ntactors or other devices connected to it If all grounding is correct there may be an issue with radiated or induced electrical noise interference Thismaybecausedbyarcingacrossacontactor scontactswhen...

Page 32: ...TER 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...

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