Mestek 200i Installation And Operation Instructions Manual

Cast iron condensing boiler

Installation instructions manual (29 pages)

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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

Boiler manual

Installation and operation

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Summary of Contents for Mestek 200i

Page 1 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. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 2 Cast iron heat exchanger Th e 200 cast iron heat exchanger uses Mestek’ s graphite port seals and ground joint fi t-up between sections for maximum fl exibility and resistance to thermal expansion. Th e heat exchanger provides maximum heat transfer with its counterfl ow design and fl ow-controlling baffl e assembly.
Page 3 20. Postpurge circulator, factory-installed and piped 21. Vent connection sleeve (with fl ue gas sampling port) 22. Condensate tubing connection 23. Upper section cover and premix burner 24. Gas connection, ½” NPT components P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 4: Table Of Contents
Customer service and technical support Please direct all questions to your Mestek distributor or contact the Mestek Customer Service Department at: 260 North Elm Street Westfi eld, MA 01085...
Page 5: Read Before Beginning The Installation
Th e 200i has been design certifi ed by CSA for • Before installing the 200i boiler, check the rating plate to ensure that the unit has been sized use with natural and propane gas under the latest properly for the job.
Page 6: Boiler Ratings And Specifi Cations
For additional information, refer to the 200i Control manual. Th ermostat anticipator sett ing is for a single thermostat connected to a single 200i boiler. Also jumper from the Heat Demand terminals to the IAR1 terminals on the connection board. See the 200i Control manual for details.
Page 7: Installation Site Preparation
Adjacent construction Mestek. Where cleaning is not possible, the boiler may have to be replaced. • Locate the boiler in an area that will prevent water damage to adjacent construction should a leak occur or during rou- •...
Page 8: Clearance Requirements
See Figure 1. Size the openings with a free area no less than 1 square inch per BTUH input of all 200i boilers in the room. EXCEPTION: Ventilation openings are not required if the boiler room provides at least the minimum SERVICE/OPERA TION clearances given in Table 2.
Page 9: Combustion Air Requirements
Each opening must be sized for a free area of at least 1 square inch per 1,000 BTUH input of the 200i boilers in the room. One opening must be within 12 inches of the ceiling, the other within 12 inches of the fl oor.
Page 10: Prepare The Boiler
Install a shut-off valve in the boiler supply and return connections to allow isolation of the boiler for servicing when necessary. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 11: Water Piping
— All piping and components must be supported such that no loads water cut-off s, fl ow switches, and high limit controls. Refer to the 200i Control manual for electrical connections for auxiliary controls. or stresses are applied to the boiler. Allow for thermal expansion in the piping design and passageways.
Page 12 Also consider installing a water meter on the cold water make-up line. Th e water Th is will lead to section failure due to oxygen meter will show if excessive make-up water is entering the system. corrosion and lime deposits. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 13: Zoning With Zone Valves
Purge valve — Suggested locations allow for improved 12 Extra high limit (when required) DHW circulator system fi lling and draining and initial air elimination. 13 Zone valve Flow/check valve Cold water fi ll line 14 Zone circulator Temperature gauge P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 14 Indirect-fi red DHW tank systems.) (when used) Temperature gauge 11 Low water cut-off (when required) DHW circulator 12 Extra high limit (when required) Flow/check valve Cold water fi ll line 14 Zone circulator P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 15 10 Air separator with automatic air vent (Replace air vent Indirect-fi red DHW tank with piping to the tank fi tt ing on closed-type expansion (when used) systems.) DHW circulator 11 Low water cut-off (when required) P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 16 10 Air separator with automatic air vent (Replace air vent Indirect-fi red DHW tank with piping to the tank fi tt ing on closed-type expansion Isolation valve (when used) systems.) DHW circulator 11 Low water cut-off (when required) Temperature gauge P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 17: Chilled Water Systems
Figure 13 Suggested piping — boilers connected to chilled water systems P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 18: Gas Piping
Check the gas type independently from the boiler gas connection. Th e 200i comes from the factory ready to be piped to the gas supply. If for any reason the boiler is not for the type of gas avail- Item 4 — Install a ground-joint union in the gas line for ease of installation and servicing.
Page 19 Undersized gas supply piping can cause the gas line pressure to become negative during operation of the 200i boiler. Th is can cause pilot Aft er testing the system gas piping, remove the outages and operation failures of other appliances...
Page 20: Wiring A Single Boiler
Th e wiring and control information in the Boiler manual is targeted at single-boiler, stand-alone installations. For multiple boilers and advanced options, see the 200i Control manual. • See Figures 20 and 21 for a wiring summary. See the Control manual for content not covered in this manual.
Page 21: Boiler Circulator
See section 5 of this manual for circulator piping. • Figure 19 shows 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.
Page 22 Th 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 electrical connection board as shown in Figure 21. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 23 — Installation and operation manual Cast iron condensing boiler Wiring and control setup (continued) Figure 21a 200i wiring summary (see Boiler manual and Control manual text for additional information) Also see page 20 P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 24 Cast iron condensing boiler Wiring and control setup (continued) Figure 21b 200i wiring summary (see Figure 21 for locations) (see Boiler manual and Control manual text for additional information) Also see page 21 Also see page 22 P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 25: Control Setup
7. 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 P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 26 3. With the cursor on DHW SETPT, press the SELECT key to change the value, using the same procedure as with the 3. For other sett ings and a complete menu tree, consult the 200i Control manual for LOC SETPT adjustment.
Page 27 5. If outdoor reset is enabled, set the reset temperatures as follows: switch. Reconnect HEAT DEMAND and 6. Use the arrow keys until the cursor points at SET OA SETPTS. DHW DEMAND wires. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 28: Vent Piping (And Air Piping When Used)
When a 200i boiler replaces a boiler that shared a common vent system, follow the guidelines below to check operation of the remaining appliance(s).
Page 29: Condensate Drain Line
Th e pump must have an overfl ow switch to prevent damage from overfl owing condensate. Wire the switch into the boiler limit circuit. See the 200i Control manual for details. Neutralization When required by codes or preference, install an appropriate condensate neutralization system.
Page 30: Fill And Test The System
Open the manual valve (or quick-fi ll valve) on the make-up • Do not apply the 200i boiler on open systems, such as direct heating of domestic water line. (When fi lling the system with glycol, connect water, swimming pool heating or process applications that use system water. For from the glycol pump to one of the purge valves with a hose.)
Page 31: System Pressure
Watch the boiler pressure/temperature gauge throughout substantial property damage. the start-up process. Make sure the pressure never drops below 12 psig and never goes higher than 80% of the boiler relief valve sett ing pressure. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 32: Starting The Boiler
Install boiler per manuals • Read and familiarize yourself with all three manuals before proceeding with start-up. Read and follow all boiler instructions, including this Boiler manual, the 200i Vent/air manual and the 200i Control manual. ❑ Check the boiler area •...
Page 33: Operating Instructions
Reatt ach the condensate line to the boiler condensate hose barb. ❑ Controls • Follow the instructions in the 200i Control manual to set the operating temperatures and parameters required for the installation (if not already done). • Set limit controls to their lowest sett ings.
Page 34 ON at purge RPM for postpurge Normal display unless ignition is unsuccessful three times after Boiler restarts a normal sequence restart For more information: See the 200i Control manual for additional information and troubleshooting. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 35 3. Tu rn manual gas valv e handle clock wise CL OSE DO NO T FORCE THE HANDLE . 2. Tu rn off all electric po wer to the boiler if ser vice is to be per fo rmed . 42-5230 P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 36 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Starting the boiler (continued) Illustration 26 En francaise . . . P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 37: Turn The Boiler Off
(see page 38). 6. Check the analyzer. A rapid increase in CO is an indicator of bad combustion. Turn the boiler and reduce fuel input as explained on page 38. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 38 7. If the computed rate exceeds the desired input rate or 200,000 Btuh, reduce the gas adjustment must be changed using the procedure input with the gas thrott le adjustment. on page 39. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 39 4. Pull the air fi lter clamp back. Replace the fi lter, gasket and access cover. Secure with the three thumbscrews. Replace the gas valve cover plate if removed. 5. Remove the low-fi re jumper from the connection board. Replace the electrical panel cover. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 40 1. Complete the checklist and installation certifi cate on the back page of this manual. 1. Allow the boiler to fi re until the supply temperature reaches the upper end of the control band. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 41: Annual Start-Up
Follow all procedures damage. specifi ed in the 200i manuals. Failure to inspect, test and maintain the boiler and system ❑ Verify boiler water treatment could result in severe personal injury, death or substantial property damage.
Page 42: Maintenance
NIOSH First aid procedures: If problems can’t be resolved • Eye exposure — irrigate immediately If following the procedures in the 200i manuals do not resolve problems, contact Mestek for technical support to resolve the issues. • Breathing — fresh air.
Page 43: Personal Injury, Death Or Substantial
Th e combustion chamber operates with a positive pressure. Failure to comply could result in severe personal injury, death or substantial property damage. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 44 RTV .) 12. Look down into the section assembly to verify it is clean. If the heat exchanger is blocked with sediment or shows damage, contact Mestek immediately for correc- Figure 37 Burner and chamber tive action.
Page 45 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Maintenance (continued) Notes P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 46: Replacement Parts
70-1244 Drain Assembly 03-1756 Ignition Cover 70-1232 Condensate Drain Extension 02-3928 High Limit Switch 70-1660 Drain Pan Assembly 02-3927 Operator - Supply Sensor 42-2999 Rating Label 03-1776 Ignition Box Cover 60-4257 Air Vent P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 47 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Replacement parts (continued) P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 48: Appendix A - Suggested Wiring
Th 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 negative terminals ( IAR – P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 49 Before connecting Verify 24VAC switched lead from thermostat: the wires to the IAR terminals, use a voltmeter to verify the 24VAC hot lead is NOT powered when the thermostat is not calling for heat. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 50 DHW tank aquastat and circulator. Th e priority switch will turn off space heating when there is a DHW call. Read the controller manufacturer’ s instructions to determine which zone is set up for priority operation. P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 51 Figure A3 Indoor Air Reset wiring to IAR terminals, Heat Demand and DHW Demand using typical zone controller for either circulators or zone valves (see Figure 21a for terminal block 2 and 6 locations) P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.
Page 52 Service company/address Describe service performed ___________________________________ ___________________________________ ___________________________________ Service date Technician Service company/address Describe service performed ___________________________________ ___________________________________ ___________________________________ Mestek, Inc • 260 North Elm St. • Westfi eld, MA 01085 • 413-568-9571 P/N 42-9470 1/12 Copyright 2012 Mestek, Inc.