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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
Cast iron condensing boiler
Boiler manual
Boiler manual
Installation and operation
Installation and operation
instructions
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
Control manual
Control manual
i
i
Vent/Air manual
Vent/Air manual
P/N 42-9470 3/08 Copyright 2007 Mestek, Inc.
M2i-IOM-2
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Table of Contents
Related Manuals for ray 200i
Summary of Contents for ray 200i
- Page 1 M2i-IOM-2 Cast iron condensing boiler Cast iron condensing boiler 200i 200i Boiler manual Boiler manual Installation and operation Installation and operation instructions instructions Also read and follow: Also read and follow: Control manual Control manual Vent/Air manual Vent/Air 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.
- Page 2 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler The Mestek condensing cast iron boiler Operation Overview Th e 200 is a cast iron boiler designed and constructed to allow full condensing operation. Th e illustra- tion at left shows how the boiler is heated with a down-fi red premix gas burner mounted above the heat exchanger.
- Page 3 Components Gas valve Pressure/temperature gauge Jacket Cast iron section assembly Inlet air fi lter access panel Blower 200i SmartCycle control with keypad and display Venturi assembly Pressure switches (blocked fl ue and blocked air inlet) Control connection board Electrical box (power and...
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Page 4: Table Of Contents
Maintenance ....42 You must read and follow this Replacement parts ....46 200i manual, the Vent/Air... -
Page 5: Read Before Beginning The Installation
Th e 200i has been design certifi ed by CSA for use with natural and propane gas under the latest revision of ANSI-Z21.13/CSA Should overheating occur 4.9, Gas-Fired Low Pressure Steam and Hot Water Boilers and... -
Page 6: Boiler Model
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
• Ensure that boiler components can be accessed for openings are not required unless other appliances share the operation/start-up/maintenance as required in the same room. 200i manuals. P/N 42-9470 11/07 Copyright 2007 Mestek, Inc. -
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
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Prepare the boiler Remove the boiler from the crate Piping guidelines: • All installations must be installed by a qualifi ed technician — Th e boiler jacket Cold weather handling in accordance with the latest revision of the ANSI/ASME includes plastic parts. -
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 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Water piping (continued) Expansion tank and air separation Figure 6 Diaphragm or bladder-type expansion tank suggested piping Th e system must include an expansion tank to control thermal expansion. Install the tank as close as possible to the boiler, and locate on the suction side of the system circu- lator.
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Page 13: Zoning With Zone Valves
Expansion tank (shown with diaphragm-type — problems when only a few zone valves are open. 200i boiler see page 12 for piping a closed-type tank) Boiler circulator 16 Boiler postpurge circulator (see page 11) - Page 14 EGEND page 12 for piping a closed-type tank) Expansion tank 17 Header sensor, required where shown (shown with diaphragm-type — see page 12 for piping 200i boiler a closed-type tank) Isolation valve Boiler circulator 10 Air separator with automatic air vent (Replace air vent Boiler/system circulator Purge valve —...
- Page 15 • • • • • • • EGEND Cold water fi ll line 16 Boiler postpurge circulator (see page 11) 200i boiler Expansion tank (shown with diaphragm-type — see 17 Header sensor, required page 12 for piping a closed-type tank) Expansion tank Boiler circulator (shown with diaphragm-type —...
- Page 16 Expansion tank (shown with diaphragm-type — see 16 Boiler postpurge circulator (see page 11) page 12 for piping a closed-type tank) Expansion tank 200i boiler (shown with diaphragm-type — see page 12 for piping a closed-type tank) 17 Header sensor, required...
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Page 17: Chilled Water Systems
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Water piping (continued) Th e boiler loop can be any of the designs in this manual, or per Chilled water systems standard engineering practices. Use the balancing valve to adjust the boiler loop fl ow. General Expansion tank/air control Provide the piping components shown in Figure 13 when... -
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...
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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 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Wiring single boiler (continued) Sensor wiring Figure 20 Indoor Air Reset wiring to IAR terminals with 4-wire zone valves and no zone controller No sensor wiring is necessary unless (see Figure 21a for terminal block 6 location) —...
- 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 11/07 Copyright 2007 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 11/07 Copyright 2007 Mestek, Inc.
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Page 25: Control Setup
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Control setup Before control setup Figure 22 Heat Net display during Standby (no call for heat) — pressing the DOWN key on the Before beginning the Heat Net control setup, remove the wires keypad changes the display as shown connected to the HEAT DEMAND and DHW DEMAND terminals... - Page 26 3. With the cursor on DHW SETPT, press the SELECT key to change the value, using the same procedure as with the For other sett ings and a complete menu tree, consult the 200i Control manual for LOC SETPT adjustment.
- Page 27 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Control setup (continued) 5. Th e factory default sett ing is ON, or IAR enabled. If the boiler is wired for IAR, Press SELECT and the display will show: then leave the sett ing at ON.
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Page 28: Common Vent Systems
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
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Fill and test the system (continued) ❑ ❑ Antifreeze System pressure • Once the system is cleaned, fi lled, purged and treated as • Antifreeze for hydronic systems contains propylene glycol and an inhibitor. With- required, set the make-up water pressure reducing valve out the inhibitor the glycol is actually corrosive. -
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). Hose barb •... - 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 11/07 Copyright 2007 Mestek, Inc.
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Page 35: For Your Safety Read Before Operating
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Starting the boiler (continued) Figure 25 Operating instructions (for starting boiler only — follow manual instructions to check boiler operation and adjust as needed) FOR YOUR SAFETY READ BEFORE OPERATING If you do not follow these instructions exactly, a fire or explosion may result, causing WARNING WARNING... - 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 11/07 Copyright 2007 Mestek, Inc.
- Page 37 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Starting the boiler (continued) Turn the boiler OFF Figure 27 Flue gas sampling hole Turn the boiler on/off switch and allow the boiler to cycle off . the manual gas valve.
- Page 38 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Starting the boiler (continued) Adjust gas valve throttle setting Figure 29 Throttle adjustment and fl ame window Allow combustion to stabilize • Allow the boiler to operate 15 minutes, or as needed to obtain a steady reading on the analyzer.
- Page 39 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Starting the boiler (continued) When is low fi re adjustment required? Figure 30 Removing boiler jacket top Adjust the gas valve low-fi re sett ing if the fl ame is unacceptable, ONLY the CO2, O2 or CO are out of acceptable range or you are changing fuels.
- Page 40 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Starting the boiler (continued) Measure fl ame current Figure 32 Throttle adjustment and fl ame window — Th e electrical box contains line-voltage Electrical shock hazard wiring and contacts. Use caution when working in the electrical box to avoid contact with line-voltage elements.
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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 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Maintenance (continued) Cleaning the air fi lter Figure 33 Accessing the air fi lter Turn the boiler on/off switch Remove the three thumb screws that secure the fi lter access plate (see Figure 33).
- Page 44 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Maintenance (continued) Accessing the burner Figure 35 Preparing to remove upper section cover If the fi lter enclosure and blower inlet show signs of drywall dust, construction debris or other deposits, you may need to inspect the burner.
- Page 45 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Maintenance (continued) Notes P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
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Page 46: Replacement Parts
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Replacement parts ITEM PART No. DESCRIPTION ITEM PART No. DESCRIPTION 20-1022 TRIDICATOR 70-6689 GAS TRAIN SUPPORT BRACKET 03-1752 RIGHT JACKET PANEL 02-1580 DUNGS GAS VALVE 60-5625 ABS SIDE MEDALLION 02-1582 INLET SHROUD - GAS VALVE 42-5238... - Page 47 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Replacement parts (continued) P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
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Page 48: Appendix A - Suggested Wiring
Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Appendix A — suggested wiring IAR (Indoor Air Reset) wiring, when used Figure A1 Indoor Air Reset wiring to IAR terminals with 3-wire zone valves and no zone controller Wiring for 3-wire zone valves without a zone (see Figure 21a for terminal block 6 location) controller... - Page 49 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Appendix A — suggested wiring (continued) IAR (Indoor Air Reset) wiring, when used Figure A2 Indoor Air Reset wiring to IAR terminals with 3-wire zone valves and no zone controller Wiring for circulator relays (relays must have (see Figure 21a for terminal block 6 location) 24VAC common terminals)
- Page 50 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Appendix A — suggested wiring (continued) IAR (Indoor Air Reset) wiring, when used Wiring for typical zone controller • Heat Demand terminal connections — Th e end switch leads from the controller must connect to the Heat Demand terminals on the electrical connection board as shown in Figure A3.
- Page 51 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Appendix A — suggested wiring (continued) 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 11/07 Copyright 2007 Mestek, Inc.
- Page 52 Cast iron condensing boiler — Installation and operation manual Cast iron condensing boiler Start-up & service history Installation and start-up (complete before leaving installation site) Start-up date Boiler model Serial number Installer/start-up company name and address: _____________________________________________________ Fuel (natural or LP) High fi re CO High fi re CO _____________________________________________________...