ray 200i Control Manual
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ray 200i Control Manual

Cast iron condensing boiler
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See also: User's Information Manual
Th is manual is intended only for use by a qualifi ed heating installer/technician. Read and follow this manual, all supplements and related
instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these
instructions. Failure to do so can result in severe personal injury, death or substantial property damage.
Do not use the boiler during construction.
the burner, resulting in possible severe personal injury, death or substantial property damage. Th e boiler can only be operated with a dust-
free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation
with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.
Affi x these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a qualifi ed
service technician, and to follow all guidelines in the User' s Information Manual.
Cast iron condensing boiler
Cast iron condensing boiler
Control manual
Control manual
Control adjustment and
Control adjustment and

operation instructions

operation instructions
Also read and follow:
Also read and follow:
200
200
200
200
Construction dust and particulate, particularly drywall dust, will cause contamination of
200i
200i
i
i
Boiler manual
Boiler manual
i
i
Vent/air manual
Vent/air manual
P/N 42-9472 Copyright 2008 Mestek, Inc.
M2i-CM-1

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Summary of Contents for ray 200i

  • Page 1: Operation Instructions

    M2i-CM-1 Cast iron condensing boiler Cast iron condensing boiler 200i 200i Control manual Control manual Control adjustment and Control adjustment and operation instructions operation instructions Also read and follow: Also read and follow: Boiler manual Boiler manual Vent/air manual Vent/air manual Th is manual is intended only for use by a qualifi ed heating installer/technician.
  • Page 2 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.

  • Page 3: Wiring Connections

    Cast iron condensing boiler — Control manual Cast iron condensing boiler The Mestek boiler — SmartCycle control Wiring connections Power wiring, 120 vac Heat demand input DHW demand input Low fi re terminals High fi re terminals To boiler outlet water temperature sensor To optional outdoor temperature sensor...
  • Page 4 Cast iron condensing boiler — Control manual Cast iron condensing boiler The Mestek boiler — with SmartCycle control P/N 42-9472 Copyright 2008 Mestek, Inc.

  • Page 5: Table Of Contents

    Contents 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 on each boiler and connect with RJ45 SmartCycle cables (or shielded wires).

  • Page 6: Method 1: Smartcycle Modulation - Control

    Close the external gas valve on every boiler. Wire all boilers following the guidelines in this section. Att ach a header sensor to the master boiler ONLY. Th e 200i control automatically confi gures the boiler with a header sensor as the master.

  • Page 7: Boiler Circulator

    • 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 .
  • Page 8 Cast iron condensing boiler — Control manual Cast iron condensing boiler Method 1: SmartCycle modulation – local control (cont.) IAR (Indoor Air Reset) wiring, when used Figure 6 Indoor Air Reset wiring to IAR terminals with 4-wire zone valves and no zone controller •...
  • Page 9 Cast iron condensing boiler — Control manual Cast iron condensing boiler Method 1: SmartCycle modulation – local control (cont.) Figure 7 200i wiring summary — wiring to electrical connection board Also see Figure 2, page 6. P/N 42-9472 Copyright 2008 Mestek, Inc.
  • Page 10 Method 1: SmartCycle modulation – local control (cont.) 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. P/N 42-9472 Copyright 2008 Mestek, Inc.
  • Page 11 Overrides — Control priorities Th e 200i control can provide override operation for any or all member boilers in a SmartCycle network. Th is requires the boilers be piped with appropriate isolation piping and controls.
  • Page 12 MODULATION PID Set on master boiler only Turn off power to all boilers. FIRING MODE Set on master boiler only Follow all instructions in the 200i Boiler manual to start up each boiler and verify operation. SENSOR # HD/HDOA only TYPE...
  • Page 13 NOT SHOWN — An optional plug-in bridge is re- quired to interface with building management systems Th e master boiler will sequence and modulate boilers as necessary to control the that use BACnet or LonWorks protocol. Th e 200i water temperature. control supports Modbus protocol with no additional Th e master boiler will show the number of boilers fi ring as well as the temperature components except the RS485 interface board.

  • Page 14: Method 2: Smartcycle Modulation - Bms

    Cast iron condensing boiler — Control manual Cast iron condensing boiler Method 2: SmartCycle modulation – BMS control Overview Table 3 Modbus holding (read/write) registers Th is method uses an RS485 digital communications cable Data Description Valid Values/ with the Modbus protocol to control a boiler or SmartCycle Type Range network.

  • Page 15: Building Management System

    Cast iron condensing boiler — Control manual Cast iron condensing boiler Method 2: SmartCycle modulation – BMS control (cont.) BACnet or LonWorks protocols Table 5 Modbus input (read-only) registers Install the correct bridge to adapt to building management Data Description Valid Values/ systems using BACnet or LonWorks protocols.

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

    — See Figure 15 for loca- tion of the power terminal strip Overview — control setup sequence — Install the boilers according to the 200i Follow the Boiler manual Boiler manual before att empting to set up the control system.
  • Page 17 • 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 .
  • Page 18 While this contact is closed, the boiler will operate based on local control, including feedback for IAR if wired. Th e 200i control can provide override operation for any or all member boilers. Th is requires the boilers be piped with •...
  • Page 19 Cast iron condensing boiler — Control manual Cast iron condensing boiler Method 3: External 4-20ma control (continued) Figure 16 200i wiring summary — wiring to electrical connection board P/N 42-9472 Copyright 2008 Mestek, Inc.
  • Page 20 — Control manual Cast iron condensing boiler Method 3: External 4-20ma control (continued) Figure 17 200i wiring summary — wiring to electrical connection board, continued (see Figure 7, page 9, for terminal strip locations) P/N 42-9472 Copyright 2008 Mestek, Inc.
  • Page 21 Start up boilers per 200i Boiler manual SENSOR # HD/HDOA only Turn off power to all boilers. TYPE HD/HDOA only Follow all instructions in the 200i Boiler manual to start up each boiler and verify CALIBRATE ? Only as required operation. PASSWORD COMMUNICATIONS...

  • Page 22: Control Menus And Adjustments

    Cast iron condensing boiler — Control manual Cast iron condensing boiler Control menus and adjustments The Heat Net control display Figure 18 Heat Net display during Standby (no call for heat) — pressing the DOWN key on the keypad changes the display as shown Starting the display Check all wiring to make sure it is complete and all wires are securely connected.
  • Page 23 200i V X.X Shows fi rmware version number 200i V 1.0 BOILERS # BOILERS 1 {1 to 16} — display only...
  • Page 24 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 RUN HRS 1240 LOG ENTRY Current entry in the log (see Table 9, page 30)
  • Page 25 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;...
  • Page 26 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 INDOOR AIR Activate indoor air reset by setting this to “ON. ” Zone wiring must be made to the IAR input terminals for IAR to operate.
  • Page 27 NIGHT SETBACK 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.
  • Page 28 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 ADVANCED SETUP This sets the maximum fi ring percentage for boilers during times that some boilers are not fi ring. MODULAR BOILER It limits input of the boilers to keep them as effi cient as possible.
  • Page 29 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 fi rst box.

  • Page 30: Troubleshooting

    Cast iron condensing boiler — Control manual Cast iron condensing boiler Troubleshooting 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. The screen will now show the most recent entry in the log.
  • Page 31 24vac circuit may be miswired. ❑ Th e 200i control is equipped with resett 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.
  • Page 32 Cast iron condensing boiler — Control manual Cast iron condensing boiler Troubleshooting (continued) Situtation Suggested procedure ❑ Th e H-Net communications cable may be receiving interference from the blower, ignition, or other form SmartCycle boilers are detected of radiated electrical noise. but then lost and then detected again.

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