Ray 200i Installation And Operation Instructions Manual - Annual Start-Up
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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
specifi ed in the
200i
manuals. Failure to
inspect, test and maintain the boiler and system
could result in severe personal injury, death or
substantial property damage.
Electrical shock hazard
— Use caution
when working on the boiler where electrical
components are exposed. Turn off power to the
boiler if necessary to avoid potential for electrical
shock.
Annual start-up overview
Perform start-up, pages 32 – 40
Perform the complete start-up, testing and inspection proce-
dures given on pages 32 through 40 to ensure the boiler and
system comply with the requirements in this manual.
In addition, perform the additional follow-up procedures given
below.
Perform follow-up procedures
Operating conditions or abuse can damage the boiler or sys-
tem components. Th e start-up checklist that follows includes
inspections and testing intended to verify that the boiler and
system are still fully functional.
Annual start-up checklist
Discuss system performance with the
homeowner or boiler operator
Ask the homeowner or boiler operator to rate the perfor-
mance of the heating system over the last season.
If the homeowner or boiler operator identifi es boiler or
system problems,, identify the cause and adjust or repair as
necessary.
Inspect the air fi lter
Remove, inspect (and clean if needed) the air fi lter. (See
instructions in the Maintenance section.)
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.
Follow the procedure in the Maintenance
section. Accumulation of debris in the burner can
result in burner damage and potential for severe
personal injury, death or substantial property
damage.
If the burner is removed for inspection, also
inspect the boiler heat exchanger. If the heat
exchanger is damaged or blocked with debris,
consult the factory for corrective action.
Operating the boiler with a damaged or
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obstructed heat exchanger could result in severe
personal injury, death or substantial property
damage.
Verify boiler water treatment
If the system requires water treatment, make sure the treat-
ment is being performed as required. Ensure that the water
soft ener, if used, is operational and is being maintained.
If the system uses antifreeze, check the antifreeze concen-
tration and inhibitor level. If the levels are low, check for
leaks or other causes. Adjust the antifreeze level or refi ll the
system as indicated.
Check expansion tank & air vents
Inspect the relief valve and piping to be sure there are no
signs of relief valve leakage.
If the relief valve has been weeping, make sure the expan-
sion tank is not waterlogged or undersized.
When performing the boiler start-up, watch the pressure
gauge as the boiler and system heat up. If the pressure rises
too fast or too high, the relief valve is not working properly.
Correct the problem as required.
Make sure all air vents are operating correctly.
Inspect and test the relief valve
Follow the instructions on the relief valve label to inspect
and test the boiler relief valve.
When discharging the relief valve, make sure there
is not risk of spraying water to you or others.
Condensate line maintenance
Make sure the condensate line, condensate pump and neu-
tralization system, if used, are operational.
Remove the condensate line at the boiler hose barb connection.
Pour water into the line and make sure the water drains
freely. Flush or replace the line if necessary.
Fill the condensate trap by att aching a 3/8-inch clear plastic
tube to the hose barb. Pour water into the tubing until the
trap is full.
Remove the clear tubing and reatt ach the condensate line to
the boiler hose barb.
Perform a complete start-up
Inspect, adjust and start-up the boiler and system compo-
nents as instructed on pages 32 through 40. Perform all
procedures to ensure the boiler and system are operating
properly.
Review with homeowner/operator
Review the User’s information manual with the homeown-
er or operator.
Make sure that all maintenance procedures are being fol-
lowed and that all instructions are clear and understood.
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