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- 200i
- Installation And Operation Instructions Manual
Ray 200i Installation And Operation Instructions Manual - Wiring Single Boiler
21
P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler
— Installation and operation manual
Wiring single boiler
(continued)
7
Figure 19
Circulator wiring terminal strip (see Figure 15
for location) — Also see the wiring summary
illustrations on the next pages)
Figure 17
Wiring the boiler circulator using a circulator
relay (required for motors over 1/4 hp)
Figure 18
Wiring the boiler circulator using a relay or
starter (required for motors over 1/4 hp)
Circulator wiring
Postpurge circulator
The circulator shipped installed with the boiler
cannot be used for system circulation.
It must be used
as supplied from the factory. It circulates water aft er the boiler
stops fi ring to prevent potential damage from heat pocketing
in the top of the heat exchanger.
Th e postpurge circulator is factory-piped and pre-wired. Do
not change the usage, the wiring, the location or the piping.
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. For larger motors, install a circulator relay or
motor contactor . Figures 17 and 18 show the correct ways
to install the boiler circulator using a relay or motor starter.
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Summary of 200i
Page 1
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...
Page 2: The Mestek
2 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual the mestek 200 i condensing cast iron boiler operation overview th e 200 i is a cast iron boiler designed and constructed to allow full condensing operation. Th...
Page 3: The Mestek
3 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual the mestek 200 i condensing cast iron boiler 200 i components components gas valve pressure/temperature gauge jacket cast iron section assembly inlet air fi lte...
Page 4: Contents
4 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual hazard icons you will fi nd the following icons throughout this manual. (english/french) the warning icon indicates a hazard that can cause severe personal inju...
Page 5
5 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual read before beginning the installation codes and standards boiler compliances th e 200i has been design certifi ed by csa for use with natural and propane gas u...
Page 6
6 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual boiler ratings and specifi cations 2 boiler model units 200i notes afue (doe seasonal effi ciency) % 92.7 1 csa input (max) btuh kw 200,000 58.6 2 csa input (mi...
Page 7
7 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual installation site preparation boiler location requirements do not install the boiler unless the location meets all of the requirements in this box. Failure to c...
Page 8
8 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual installation site preparation (continued) clearance requirements clearances to combustible surfaces all installations must provide the minimum clearances to com...
Page 9
9 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 3 air opening options for combustion air drawn from boiler room installation site preparation (continued) combustion air requirements air ducted to boile...
Page 10: Prepare The Boiler
10 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 4 relief valve piping prepare the boiler remove the boiler from the crate cold weather handling — th e boiler jacket includes plastic parts. If the boil...
Page 11: Water Piping
11 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping th e 200i boiler requires a continuous minimum water fl ow for proper operation. Th e circulator for the boiler must be sized to overcome the head...
Page 12: Water Piping
12 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping (continued) figure 6 diaphragm or bladder-type expansion tank suggested piping figure 7 closed-type expansion tank suggested piping expansion tank...
Page 13: Water Piping
13 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping (continued) figure 8 suggested piping — single boiler — zone valve zoning — two-pipe or series loop (left), or primary/secondary piping (right) l ...
Page 14: Water Piping
14 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping (continued) figure 9 suggested piping — single boiler — circulator zoning — two-pipe or series loop (left), or primary/secondary piping (right) zo...
Page 15: Water Piping
15 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping (continued) figure 11 suggested piping — multiple boilers — primary/secondary piping, reverse-return boiler headers multiple boilers, primary/seco...
Page 16: Water Piping
16 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping (continued) figure 12 suggested piping — multiple boilers — parallel-fl ow piping, reverse-return headers multiple boilers, parallel fl ow sizing ...
Page 17: Water Piping
17 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual water piping (continued) figure 13 suggested piping — boilers connected to chilled water systems chilled water systems general provide the piping components sh...
Page 18: Gas Piping
18 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual gas piping figure 14 connecting gas supply line failure to adhere to the following could result in severe personal in- jury, death or substantial property dama...
Page 19: Gas Piping
19 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual gas piping (continued) table 3 gas fl ow capacity for black iron pipe iron pipe size (inches) pipe length, equivalent feet (length plus allowance for fi ttings...
Page 20: Wiring A Single Boiler
20 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual wiring a single boiler 7 figure 15 electrical connection board (see item 10, page 3 for location — also see the wiring summary illustrations on the next pages)...
Page 21: Wiring Single Boiler
21 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual wiring single boiler (continued) 7 figure 19 circulator wiring terminal strip (see figure 15 for location) — also see the wiring summary illustrations on the n...
Page 22: Wiring Single Boiler
22 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual wiring single boiler (continued) 7 figure 20 indoor air reset wiring to iar terminals with 4-wire zone valves and no zone controller (see figure 21a for termin...
Page 23: Wiring and Control Setup
23 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 21a 200i wiring summary (see boiler manual and control manual text for additional information) wiring and control setup (continued) 7 also see page 20
Page 24: Wiring and Control Setup
24 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 21b 200i wiring summary (see figure 21 for locations) (see boiler manual and control manual text for additional information) wiring and control setup (c...
Page 25: Control Setup
25 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 22 heat net display during standby (no call for heat) — pressing the down key on the keypad changes the display as shown control setup 8 before control ...
Page 26: Control Setup
26 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual control setup (continued) 8 recommended settings th e following recommendations should cover most single-boiler applications. Th e sett ings covered in this ma...
Page 27: Control Setup
27 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual control setup (continued) 8 5. Th e factory default sett ing is on, or iar enabled. If the boiler is wired for iar, then leave the sett ing at on. 6. To change...
Page 28
28 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual vent piping (and air piping when used) all 200i boilers must be vented using only the materials listed in the 200i vent/air manual. Th e vent installation must...
Page 29: Condensate Drain Line
29 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual condensate drain line figure 23 connecting a condensate drain line fill the condensate trap before installing the condensate line, you must fi ll the condensat...
Page 30: Fill and Test The System
30 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual fill and test the system failure to adhere to the following could result in boiler section failure, resulting in potential for severe personal injury, death or...
Page 31: Fill and Test The System
31 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual fill and test the system (continued) antifreeze antifreeze for hydronic systems contains propylene glycol and an inhibitor. With- out the inhibitor the glycol ...
Page 32: Starting The Boiler
32 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual starting the boiler failure to adhere to the following could result in severe personal injury, death or substantial property damage. Accessibility th e boiler ...
Page 33: Starting The Boiler
33 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual measure the air piping length and note the number of fi tt ings. Make sure the air piping complies with the 200i vent/air manual. Verify ventilation openings t...
Page 34: Starting The Boiler
34 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 24b boiler sequence of operation, fault states and smartcycle control display information figure 24a smartcycle control display during operation startin...
Page 35: Starting The Boiler
35 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 25 operating instructions (for starting boiler only — follow manual instructions to check boiler operation and adjust as needed) starting the boiler (co...
Page 36: Starting The Boiler
36 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual illustration 26 en francaise . . . Starting the boiler (continued) 12.
Page 37: Starting The Boiler
37 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 27 flue gas sampling hole figure 28 electrical panel starting the boiler (continued) turn the boiler off turn off the boiler on/off switch and allow the...
Page 38: Starting The Boiler
38 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 29 throttle adjustment and fl ame window adjust gas valve throttle setting allow combustion to stabilize allow the boiler to operate 15 minutes, or as n...
Page 39: Starting The Boiler
39 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual figure 30 removing boiler jacket top figure 31 gas valve adjustments starting the boiler (continued) when is low fi re adjustment required? Adjust the gas valv...
Page 40: Starting The Boiler
40 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual starting the boiler (continued) figure 32 throttle adjustment and fl ame window measure fl ame current electrical shock hazard — th e electrical box contains l...
Page 41: Annual Start-Up
41 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual annual start-up th e boiler and system must be inspected, started and serviced at least annually by a qualifi ed service technician. Follow all procedures spec...
Page 42: Maintenance
42 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual maintenance 13 handling ceramic fi ber and fi berglass materials the 200i boiler contains some ceramic fi ber and fi berglass materials. Ceramic fi ber materia...
Page 43: Maintenance
43 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual cleaning the air fi lter turn the boiler on/off switch off . Remove the three thumb screws that secure the fi lter access plate (see figure 33). Remove the fi ...
Page 44: Maintenance
44 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual accessing the burner if the fi lter enclosure and blower inlet show signs of drywall dust, construction debris or other deposits, you may need to inspect the b...
Page 45: Maintenance
45 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual maintenance (continued) 14 notes.
Page 46: Replacement Parts
46 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual replacement parts 15 item part no. Description qty 1 20-1022 tridicator 1 2 03-1752 right jacket panel 1 3 60-5625 abs side medallion 1 4 42-5238 off label 1 5...
Page 47: Replacement Parts
47 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual replacement parts (continued) 15.
Page 48
48 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual appendix a — suggested wiring 16 figure a1 indoor air reset wiring to iar terminals with 3-wire zone valves and no zone controller (see figure 21a for terminal...
Page 49
49 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual appendix a — suggested wiring (continued) 16 figure a2 indoor air reset wiring to iar terminals with 3-wire zone valves and no zone controller (see figure 21a ...
Page 50
50 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual 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 c...
Page 51
51 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual 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 ...
Page 52: Start-Up & Service History
52 p/n 42-9470 11/07 copyright 2007 mestek, inc. Cast iron condensing boiler cast iron condensing boiler — installation and operation manual start-up & service history installation and start-up (complete before leaving installation site) start-up date boiler model serial number installer/start-up co...