mascot® ft
Cascade Instructions
Document 1349
Cascading the
MASCOT ® FT
Wall-Mounted, Modulating
Gas, Condensing,
Heating Only, Boiler
Model MFTHW
80,000 BTU/hr
100,000 BTU/hr
120,000 BTU/hr
140,000 BTU/hr
199,000 BTU/hr
•N
atural Gas (NG)
Factory Configuration
•P
ropane Gas (LP)
Field-Convertible
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation
could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or
death. Improper installation and/or operation will void the warranty.
WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
nearby phone. Follow the gas supplier's
instructions.
• If you cannot reach your gas supplier, call
the fire department.
H2384200-
Installation and service must be performed
by a qualified installer, service agency, or gas
supplier.
AVERTISSEMENT
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d’incendie ou d’explosion
ou pour éviter tout dommage matériel, toute
blessure ou la mort.
Ne pas entreposer ni utiliser d’essence ou ni
d’autres vapeurs ou liquides inflammables dans
le à proximité de cet appareil ou de tout autre
appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE
GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous servir
des téléphones dans le bâtiment où vous vous
trovez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions
du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés par
un installateur ou un service d’entretien qualifié
ou par le fournisseur de gaz.
Page 2
LAARS Heating Systems
Table of Contents
SECTION 1
Piping
A. General Plumbing Connection Guidelines.... 3
B. Install a Backflow Preventer.......................... 3
C. Piping Diagrams for Cascading Systems... 3-7
SECTION 2
Electrical
A. Wiring Connections for Cascade...................... 8
B. Terminal Blocks............................................. 9
SECTION 3
The Control Display
A. The Control Display..................................... 10
B. The LCD...................................................... 10
C. Start-Up Sequence...................................... 11
SECTION 4
Cascade Programming
A.
B. C. D.
Programming a Cascade System............... 12
The Cascade CH Function..................... 13-14
Domestic Hot Water ‘Storage Mode’
for Cascade System.................................... 14
Cascade System Error Codes..................... 15
Page 3
Cascading the MASCOT FT, Heating Only Boiler
SECTION 1
Piping
Multiple Mascot FT boilers can be connected via a cascade communication cable to create a
bank of boilers that work in tandem. Up to 20 boilers can be controlled by a “Leader” Mascot FT
boiler with the others acting as “Followers”.
WARNING
Do not use Mascot FT units on common vents. Each unit must have its own supply and exhaust vents.
A. General Plumbing Connection Guidelines
•
•
•
•
•
•
Pipe material must be suitable to meet local codes and industry standards.
The pipe must be cleaned and without blemish before any connections are made.
Do not apply a torch within 12˝ of the bottom connections of the Heating Only Boiler. Doing so could
damage the Heating Only Boiler. Such damages ARE NOT covered by product warranty.
The size of the CH supply pipe should be 1¼˝ diameter.
Isolation (shutoff valves) should be used to ease future servicing.
All piping should be insulated.
B. Install a Backflow Preventer
It may be recommended to use a back flow preventer – check local codes. If a back flow preventer or a
no return valve is used, a thermal expansion tank must be installed on the cold water supply between
the Heating Only Boiler and valve.
WARNING
To control thermal expansion, a thermal expansion tank should be installed in systems with an
installed backflow preventer. DO NOT use a closed type expansion tank. Follow expansion tank
manufacturer’s specifications to properly size an expansion tank to the installation. Failure to properly
accommodate thermal expansion could result in property damage, severe personal injury, or death.
C. Piping Diagrams for Cascading Systems
The next four pages give examples of typical cascading hydronic piping diagrams.
CAUTION
Use at least the MINIMUM pipe size for all Heating Only Boiler loop piping. This is to avoid the
possibility of inadequate flow through the Heating Only Boiler. Using less than the required minimum
pipe size and piping could result in system problems, property damage, and premature Heating
Only Boiler failure. Such problems ARE NOT covered by product warranty.
Use both thread tape and pipe dope to connect to the 1¼˝ CH supply and return. Isolation valves
between the city water supply and inlet are recommended for ease of service.
Cascade Manifold Pipe Sizing (inches)
SIZE
80
100
120
140
199
2
1 1/4
1 1/2
1 1/2
2
2
Number of Cascaded Mascot FT Units
3
4
5
6
1 1/2
2
2
2
2
2
2
2 1/2
2 1/2
2
2 1/2
2 1/2
3
2
2 1/2
2 1/2
3
2 1/2
3
3
4
7
1/2
3
3
3
4
8
3
3
3
4
4
Note: Based on copper pipe and a 20°F Delta T with maximum water velocities of 4-1/2 ft per second
Page 4
LAARS Heating Systems
C. Piping Diagrams for Cascading Systems (continued)
Gate valve
Check valve
Indirect DHW Tank
Expansion tank
(Closed type)
Circulation pump
Pressure relief valve
Air separator
Isolation valve
Air Separator
Mixing Valve
2-way valve
Pressure Reducing
Valve
Expansion tank
(Diaphragm type)
Piping Symbol Legend
Cascade System - Diaphragm type Expansion tank
Gate valve
Expansion tank
(Diaphragm type)
Air separator
Circulation pump
Check valve
Isolation valve
Pressure relief valve
CH SUPPLY
CH SUPPLY
PRIMARY LOOP
(SPACE HEATING)
CH RETURN
PRIMARY/SECONDARY
CONNECTION
CH RETURN
Do not exceed 12" apart
SECONDARY LOOP (SPACE HEATING)
NOTE: These drawings are meant to show system piping concept only. Installer is responsible for
all equipment and detailing required by local codes.
Page 5
Cascading the MASCOT FT, Heating Only Boiler
Cascade System - Zoning with circulation pump
Gate valve
Expansion tank
(Diaphragm type)
Air separator
Circulation pump
Check valve
Isolation valve
Pressure relief valve
CH SUPPLY
CH SUPPLY
PRIMARY LOOP
(SPACE HEATING)
CH RETURN
PRIMARY/SECONDARY
CONNECTION
Do not exceed 12" apart
SECONDARY LOOP (SPACE HEATING)
ZONE 1
ZONE 2
ZONE 3
FLOOR HEATING
CH RETURN
Page 6
LAARS Heating Systems
C. Piping Diagrams for Cascading Systems (continued)
Gate valve
2-way valve
Expansion tank
(Diaphragm type)
Indirect DHW Tank
Air separator
Mixing Valve
Circulation pump
DHW Pump
Check valve
Isolation Valve
Isolation valve
Pressure relief valve
Pressure relief valve
CH SUPPLY
CH SUPPLY
CH SUPPLY
CH RETURN
PRIMARY LOOP
(SPACE HEATING)
CH RETURN
Do not exceed 12" apart
ZONE 1
ZONE 2
ZONE 3
FLOOR HEATING
Cascade System - Zoning with zone valve
SECONDARY LOOP (SPACE HEATING)
Cascade System - Indirect Water Heating
2-way valve
Indirect DHW Tank
Mixing Valve
DHW Pump
Isolation Valve
Pressure relief valve
CH SUPPLY
CH RETURN
CH SUPPLY
CH RETURN
DHW Pump
Indirect DHW Tank
CH System Pump
Leader
Cascade System sensor
Closely spaced tees
Make up water
Space heating zone
circuit
Follower
Indirect DHW Tank
DHW TEMP
SENSOR
DHW System Pump
Cold water
Purging valves
Zone circulators
Cascading the MASCOT FT, Heating Only Boiler
Page 7
C. Piping Diagrams for Cascading Systems (continued)
Cascade System - System Application & DHW Tank
Page 8
SECTION 2
LAARS Heating Systems
Electrical
A. Wiring Connections for Cascade
A system sensor must be connected to the master boiler in order to provide feedback for set point
temperature reference and therefore properly control the bank of cascaded boilers.
In order for the system to work properly, the thermostat, 0-10V signal, and/or outdoor sensor must be
connected to the Leader boiler only. Following boilers will run based on the Leader boiler’s controls.
Reference the Mascot FT Heating Only Installation and Operation manual (1342-NH) to set the Leader
boiler’s temperature set point based on an outdoor sensor, 0-10V signal or a fixed temperature set point.
Components Needed :
FT1868 : Mascot System Sensor (need only 1).
FT1861 : M
ascot FT/ST Cascade Communication Cable (1 per unit) with Ending Resistor.
Example. If you are cascading 6 Mascot ST’s, you will need 6 X FT1861’s and you will
throw away 5 of the resistors.
(CN1 RS-485)
(CN1 RS-485)
Primary
Connector.
Last Male
Connector.
Wrap it up neatly and wire-tie it.
It does not need a cap or an end.
Primary
Connector.
Ending
Resistor
Last Female
Connector.
Plug the included
‘Ending Resistor’ into it.
1. Turn off the power.
2. Remove the front covers of the units (4 screws on each unit).
3. Connect the ‘Cascade Communication Cables’ to every unit (add the Resistor to the
end of the last follower. Use the wiring throughway at the bottom of each unit.
4. Plug the primary connector on the cable (as shown) to the receptacle inside the unit.
5. Replace the front covers.
6. Turn on the power.
Page 9
Cascading the MASCOT FT, Heating Only Boiler
B.
Terminal Blocks
CH
PUMP
DHW
PUMP
DHW
TEMP
SENSOR
LOW
WATER
CUTOFF
CASCADE
SYSTEM
SENSOR
Thermostat
Connection
0-10V
Connection
Outdoor
Sensor
Connection
Page 10
SECTION 3
LAARS Heating Systems
The Control Display
Status Light
(constant green
when operating
normally)
E
The Control Display has a Control Dial (E), 4 buttons (A, B, C, D), and a Liquid Crystal Display
(with 72 back-lit segments). Section 3 will show you only a few of the functions of the Mascot FT.
For all functions, please review the Mascot FT Install and Instruction Manual. Doc 1342.
Buttons
A
Display Power
B
Modes
Functionality
PRESS (Tap)
Turns Control Display
PRESS and HOLD (5 seconds)
ON / OFF
Tap to return to menu
C
Heating
Water
CH set-point change mode
(Maxium 82°C(180°F))
D
Time / Date
Set
No Change
E
Scroll / Select
Menu select or value
up(+)/down(-) or setting dial.
(If Display Power was On ) Status Display Mode
(If Display Power was Off ) Installer Mode
To SET: Year/Month/Week/Day/Time/Min
•Temperature Specifications
Operating ambient Temperature Range : -10 to 60°C.
Operating Relative Humidity up to: 90% at 40°C.
Shipping & Storage Temperature Range of : -20 to 80°C.
B. The LCD
The LCD features a backlit
lamp that will illuminate when
a user presses a button.
The display will time out after
approximately 2 minutes.
Cascading the MASCOT FT, Heating Only Boiler
Page 11
B. The LCD (continued)
Symbol
Name
Description
Service Reminder mode
Service Reminder mode indication
Outside Temperature Mode
Outside Temp setting indication
Anti-freeze mode
Anti-freeze mode indication
Storage mode
Storage mode indication
Information mode
Information mode indication
Communication state
Communication state indication
Time setting mode
Time /Dispaly/Install mode indication
Fan operating mode
Fan operating mode indication
Flame signal
Flame Signal indication
CH pump mode
CH pump mode indication
Storage pump mode
Storage pump mode indication
Internal recirculation mode
Internal recirculation mode indication
Celsius mode
Indicated as Celsius temperature
Fahrenheit mode
Indicated as Fahrenheit temperature
Heat demand mode
Heat demand mode indication
DAY mode
Current day mode indication
Cascade System connecting
mode
Cascade System connecting mode
indication
Cascade System operating mode
Cascade System operating mode
indication
C. Start-Up Sequence
After the appliance is powered ON, the LCD display shows a sequence of information. The icons will flash,
followed by various indicators that describe the appliance controller and software versions.
After start-up, the display appears as follows.
The Control Display can operate through user and service modes that have specific LCD outputs and
dedicated controls, including:
•
Changing the Set-Point Temperature
•
Error Mode
•
Status Display Mode
•
Installer Mode
Page 12
SECTION 4
LAARS Heating Systems
Cascade Programming
A. Programming a Cascade System
AUTODESK � � � � � � � � � �
Once all of the 'Connection Wires' are made and all units are powered on, there are 2 items that need to
be programmed on all units. Start with the Lead Unit and then Repeat on all Following Units.
28: cP – (PARAMETER) The TOTAL NUMBER of units cascaded. Range: 01 - 20, The Default is 01 so
the Leader must be set to 01. Follower 1 set to 02, follower 2 set to 03, etc. THEN
27: cn– (NUMBER) This is each units ASSIGNED NUMBER. Default 00. Range: 00 - 19 with 00 as the
Leader, 01 (follower 1), 02 (follower 2), etc.
1. START by turning OFF the Power
to the Display Control.
5. Then turn the dial to 27:Cn – Set the Number to
00. The Leader unit should always be addressed to
00. The Following units will then start at 01 and go
sequencially from there.
3. R
otate the Dial until you get to 28cP. Tap Dial E to
enter into that Parameter.
button.
7. R
EPEAT steps 1 thru 6 with all following units in
sequence.
NOTE: D
o NOT change 29:Eh (Common Vent). This
Installer Parameter must always be set to 'Off'.
AUTODESK � � � � � � � � � �
4. A
djust to the Total Number of Units in the Cascaded
System. Range is Default at 01 and goes up to 20 units.
then press (tap) the Dial to save and to Exit.
6. Finish by pressing the
AUTODESK � � � � � � � � � �
�� ���
AUTODESK � � � � � � � � � �
2. Then, with the power OFF, Press and HOLD (5 seconds) the
button to get into the Installer Mode.
Page 13
Cascading the MASCOT FT, Heating Only Boiler
B. The Cascade CH Function
Changing the CHW Set-Point,
press the C
button. The CH Icon and current
CH Setpoint will flash. Turn the E dial clockwise
to increase, and counterclockwise to decrease CH
setpoint, until desired temperature is reached.
Press E dial to save changes and to Exit.
NOTE: W
hen you set the temperature set point
on the Leader Heating Only Boiler, it will
automatically be applied to the followers.
Indicate
B
A
C
E
D
Indicator
Current CH Temperature Set-Point
Celsius or Fahrenheit
or
If Communication state is activated
If flame is detected
Date and Time indicator
If CH pump is operating
If there currently a Demand for Central Heat (CH)
Default CH set-point is 180°F (82°C)
CH set-point range is 86°F ~180°F (30.0°C ~ 82.0°C)
1. The Leader unit controls all follower units' operation and combustion. All follower units follow what Leader
unit outputs. (Operating temperature and clock will only be controlled on Leader unit , but displayed on
Follower unit )
2. When Cascade is set for auto, the Leader boiler arranges which unit operates and for how long, when there
is a call for heat (CH), the Leader boiler controls the follower units either to increase or reduce firing rate.
* Installer mode 30: Cr -> Cr:at(Default)
3. When Cascade is set for cascade rotation time, the Leader boiler rotates the boilers based on a fixed
operating time limit. Each boiler is run (when there is a call for heat) until it reaches the operating time
limit, at which point the Leader boiler turns that boiler off and replaces it in the firing sequence with a boiler
that has been off. In this way, the first boiler on will be the first boiler off, and that first boiler will not turn on
again until the remaining boilers have each run for the operating time limit, as needed to meet demand.
*Installer mode 30: Cr -> Cr:Ct
4. Cascade mode operates via system sensor. Units shut off when system sensor reaches system target
temperature.
5. When each corresponding unit is operating the built in boiler pump operates. Also if a single unit is
operating the external CH pump operates
6. Only the Leader unit needs to be wired to the boiler pump.
Page 14
LAARS Heating Systems
B. Cascade CH Function (continued)
Index Numbers
Parameter
Description
Cr:at
Automatic rotation (default)
The first unit to operate when there is a T/T call is the unit
that ran the least amount of time during the prior heat calls
(burner ON time). Default auto
Cr:Ct
Cascade Rotation time
Cascade Rotation time, Range: 0-240 Hours,
Default 48Hours
31: Ct
Cascade System temperature
Cascade System temperature:
Range: 95°F – 180°F, Default 180°F
32: Cd
Cascade System Temperature
Differential (burner ON)
Cascade System Temperature Differential (burner ON)
Range: 5-30 °F, Default 10 °F
30:Cr
Cascade Operation Sequence: The first boiler in the rotation sequence will fire to satisfy a call for heat. Once
this boiler reaches 80% of full fire the first boiler will modulate down and a second boiler will be brought on to
split the load between boilers. If the heat demand is not satisfied a third boiler will be brought on in the same
manner, splitting the heat between the three boilers. This mode of operation will continue until enough boilers
are brought on to satisfy the demand.
As the heating demand is met the boilers will be shut down in reverse order, shutting down each boiler as it
reaches 40% of fire, until all boilers are shut down.
C. Domestic Hot Water ‘Storage Mode’ for Cascade System.
The boiler cascade system can be set up for Domestic Hot Water by using either a DHW Sensor or DHW
Aquastats with a tank. Note that they are setup differently.
The default DHW priority time is 30 minutes and can be adjusted from 0 to 60 minutes using parameter 24: dP,
see below parameter table.
Using a DHW Sensor
If a DHW sensor is used, the DHW Sensor leads must be connected to the Leader Boiler on the terminal strip
labeled “DHW TEMP SENSOR” (page 9) and sensor installed in the tank.
In this mode the tank sensor will control demand and modulation based on the DHW setpoint (21:dh). In the
case of indirect heaters the boiler will also modulate on the outlet water temperature sensor (25:st).
The DHW System Pump must be connected to the Leader Boiler (same boiler that the DHW sensor is connected
to) on the terminal strip labeled “DHW Pump” (page 9).
Using Aquastats
If a DHW aquastat is used, the maximum DHW load needs to be calculated to determine the number of boilers
required to meet max DHW load. The aquastat must be installed in the tank and wired to each boilers’ terminal
strip “DHW TEMP SENSOR” connection (page 9). Wire the boilers in series with the aquastat: aquastat to first
boiler and then from boiler to boiler.
The DHW System Pump must be connected to the first boiler among those selected to handle the domestic
water load on the terminal strip labeled “DHW Pump” (page 9).
required to meet max DHW load. The aquastat must be installed in the tank and wired to each boilers’ terminal
strip “DHW TEMP SENSOR” connection (page 10). They can be wired either in parallel (straight from the
Page 15
aquastat to each
boiler)
or in series
to first
boiler
and then from boiler to boiler).
Cascading
the
MASCOT
FT, (aquastat
Heating
Only
Boiler
The DHW System Pump must be connected to the first boiler among those selected to handle the domestic
water load on the terminal strip labeled “DHW Pump” (page 10).
C. Domestic Hot Water ‘Storage Mode’ for Cascade System (continued)
Domestic
Hot Water
Parameters
Domestic
Hot Water
Parameters
For a complete list of parameters, reference the Mascot FT Installation and Operation Manual 1342.
For a complete list of error codes reference the Mascot FT Installation and Operation Manual 1342
Index
Numbers
21: dH
Parameter
Description
Indirect Storage Tank
Temperature Set Point
Sets Maximum Indirect storage tank
Temperature Range: 95 - 180°F , Default 120 °F
22: dd
Indirect Storage Tank
Differential Set Point
DHW Differential Set Point Range: 5°F-30°F,
Default 7 °F
23: Pr
DHW Pump Post Run Time
24: dP
DHW Priority Timer
25: St
Boiler Supply Indirect Storage
Tank Temperature
DHW Pump Post Run Time Range: 0-10 Min,
Default 1 Min
DHW Priority Timer Range: 0 – 60 Min , Default
30 Min
Boiler Supply Indirect Tank Temperature Range:
120 °F– 180 °F , Default 180 °F
System Error Codes
ADDD.
NEWCascade
ERROR SECTION
For a complete list of error codes, reference the Mascot FT Installation and Operation Manual 1342.
D. Typical Cascade Error Codes
System
Sensor
This
will only
appear if the
boiler
is usedManual
in a cascaded
For a Er:30
complete list
of error
codes NOTE:
reference
theerror
Mascot
FT Installation
and
Operation
1342
Short
system.
This Error
will will
go only
away
when
system
sensor
or
NOTE:Code
This error
appear
if the
boiler is
used inisa repaired
cascaded system.
This Error Code will go away when system sensor is repaired or replaced.
replaced.
1. Check
system
temperature sensor.
sensor. Ensure
connections
are secure.
1. Check
system
temperature
Ensure
connections
are secure.
2. Check system sensor resistance. If resistance is zero, replace the sensor.
2.
C
heck
system
sensor
resistance.
If
resistance
is
zero,
replace
the
System Sensor Short 3. If the problem persists, replace the main control.
Er:30
sensor.
NOTE: During the error state the units will continue to operate. Boiler setpoint
will problem
be the same
as the system
sensor
until the issue is remedied.
3. If the
persists,
replace
the setpoint
main control.
During normal operation boiler setpoint is defaulted to 20°F higher than the
NOTE:
During the error state the units will continue to operate. Boiler
system setpoint to a maximum of 180°F setting
setpoint
willThis
be the
asappear
the system
sensor
setpoint until the issue is
NOTE:
errorsame
will only
in a cascaded
system.
1. TurnDuring
power OFF
and ON
at the boiler
display
panel.is defaulted to 20°F
remedied.
normal
operation
boiler
setpoint
If error
reappears,
all cascaded
boilers are
ON.
higher2.than
the
systemensure
setpoint
to a maximum
of powered
180°F setting
Er:78
Er:78
3. If error reappears, check Installer Mode parameter 28 at the Leader boiler.
Ensure the number of cascaded units chosen in this parameter matches the
number of cascaded units in the system.
Cascade
NOTE:
This error will only appear in a cascaded system.
Cascade
4. If error reappears, check Installer Mode parameter 27 at all cascaded
Communication
1. Turn
power
OFFthe
and
ON at
the boiler
display
boilers.
Ensure
address
number
matches
that ofpanel.
the connected boiler (00
Communication Error
for Leader,
01 for Follower
etc.)
and that no
numbers
skipped or
Error
2. If error
reappears,
ensure1,all
cascaded
boilers
arearepowered
ON.
repeated.
3. If error
reappears, check Installer Mode parameter 28 at the Leader
5. Ensure every unit in the cascade system is connected properly. Inspect the
boiler.
Ensure
the
number
ofare
cascaded
chosen
inorthis
parameter
cascade
cables
and
ensure all
connectedunits
without
damage
defect.
matches
the
number
of cascaded
units in the system.
Repair or
replace
any damaged
cables.
6. If the
problem persists,
the Mode
main control.
4. If error
reappears,
checkreplace
Installer
parameter 27 at all cascaded
boilers. Ensure the address number matches that of the connected
boiler (00 for Leader, 01 for Follower 1, etc.) and that no numbers are
skipped or repeated.
5. Ensure every unit in the cascade system is connected properly.
Inspect the cascade cables and ensure all are connected without
damage or defect.
Repair or replace any damaged cables.
6. If the problem persists, replace the main control.
H2384200-
Notes:
Customer Service and Product Support: 800.900.9276 • Fax 800.559.1583
Headquarters: 20 Industrial Way, Rochester, NH, USA 03867 • 603.335.6300 • Fax 603.335.3355
1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 • 905.238.0100 • Fax 905.366.0130
www.Laars.com
Printed in U.S.A. © Laars Heating Systems 1703 Document 1349
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