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1. IS Replacement parts 16 Appendix suggested wiring 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 Westfield MA 01085 Phone 413 568 9571 Always include the model and serial numbers from the rating plate of the boiler in question Claims for damage or missing components must be filed imme diately against the transportation company by the consignee Hazard icons You will find the following icons throughout this manual English French The WARNING icon indicates a hazard that can cause severe personal injury death or substantial property damage CAUTION AVERTISSEMENT The CAUTION icon indicates a hazard that will or can cause minor personal or property damage The NOTICE icon calls out special instructions that are important but are not related to hazards Other manuals You must read and follow this manual the 2001 Vent Air manual the 2001 Control manual and all additional materials supplied with the boiler Failure to do so can result in severe personal injury death or substantial property damage Start up service history Before leaving the installation site after start or service fill out the Start up service history information on the back page P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boil
2. manufacturer s instructions DHW aquastat if used Z _2ANAC NOTE Measure voltage on the n ON COMMON thermostat terminals before making Her OFF any connections The terminal connected to the IAR inputs must be the 0 volt side of each thermostat NOTE The DHW priority zone will vary between controllers Refer to controller manufacturer s instructions OUTPUTS TO CIRCULATORS OR ZONE VALVES Wire to circulators or zone valves per zone controller manufacturer s instructions 120VAC POWER IN DTE HEAT DHW LOW HIGH E DEMAND DEMAND FIRE FIRE P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler In and operation manu lt gt Start up amp 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 fire CO O High fire CO Low fire CO O Low fire CO Metered input Btuh ee Phone Flame current Gas supply pressure Check off each item listed below to indicate the work was performed and all installation aspects agree with boiler manuals L System and boiler filled with water Q Ignition control tested for ignition failure L Additional comments below L System flushed before filling QI SmartCycle control adjusted per Control manual 1 Water chemistry tested regime
3. Installation and operation manual S Recommended settings Control setup continued 1 The following recommendations should cover most single boiler applications 2 The settings covered in this manual are SETPOINTS INDOORAIR OUTDOOR AIR and SYSTEM CLOCK 3 For other settings and a complete menu tree consult the 200i Control manual for information Adjust SETPOINTS Setpoint menus 1 Use the arrow keys until the cursor points at SETPOINTS 2 Press the SELECT button to enter the SETPOINTS menus The menu selections available as you use the arrow keys will be LOC SETPOINT means the local setpoint or the target temperature of the boiler supply water this is sensed by the SUPPLY sensor SOURCE means whether the setpoint temperature is to be controlled at the boiler or by a remote device leave the default setting of AUTO unless you plan to use a remote controller with a 4 20ma output DHW SETPOINT means the supply temperature the boiler will target when operating on a call for DHW heating this uses the same sensor as the local setpoint OP LIMIT means the operating limit temperature of the boiler LIMIT BAND this is the differential for the limit function Set the local setpoint LOC SETPT 1 Use the arrow keys until the cursor points at LOC SETPT The display will show gt LOC SETPT 188 F JULRLE HOTO 2 The cursor must be pointing at LOC SETPT The value shown may vary if the con trol h
4. The display will show gt IH RESET HW TIME 6HMIK P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S S The factory default setting is ON or IAR enabled If the boiler is wired for IAR then leave the setting at ON 6 To change the setting to off press SELECT with the cursor pointing at IA RESET Press either arrow key and the value will change to OFF 8 Press SELECT to save and BACK to return to the main menus INDOOR RESET again Control setup continued Return to main menus When you have finished with LAR return to the main menus by using the BACK key OUTDOOR AIR when used General NOTICE Skip this procedure if there is no outdoor sensor present When possible use Indoor Air Reset instead of outdoor reset LAR provides much better feedback on system needs OUTDOOR AIR menu 1 Use the arrow keys until the cursor points at OUTDOOR AIR Then press SELECT 2 The display will show the beginning of the OUTDOOR AIR menus gt UH SAUTOUWH OM WH SETFT Bio F 3 OUTDOOR AIR menus are OA SHUTDOWN shuts the boiler down when outside temperature is above OA SETPT OA SETPOINT outside temperature at which no heat is needed used to shut down boiler above this temperature OA RESET enables or disables outdoor reset function SET OA SETPTS when outdoor reset is enabled this leads to setpoint selections Outdoo
5. boiler section failure resulting in potential for severe personal injury death or substantial property damage Q Flush and clean the system before filling Q Provide clean water to fill the system Q Water quality must be as prescribed in this manual Follow the system water checklist Follow the guidelines in this section to fill and test the system The system wa ter quality must meet the conditions given and you and the owner must make sure the conditions will be maintained throughout the life of the boiler Q Closed systems only Do not apply the 2001 boiler on open systems such as direct heating of domestic water swimming pool heating or process applications that use system water For these applications you must install a heat exchanger Hard water conditions If water hardness exceeds 7 grains use a water softener in the fill line to soften the water before it enters the system On multiple boiler commercial installations the large volume of water in the sys tem can contain substantial mineral salts even if the fill water hardness is less than 7 grains These salts can deposit in the boiler heat exchanger as limestone causing possible section damage Commercial installations should usually be filled with soft water to avoid this problem Prevent oxygen corrosion Make sure the system is provided with adequate automatic air elimination includin an in line air separator and automatic air vents diaphragm or bladder
6. for electrical connections for auxiliary controls Follow the guidelines below to install typical controls in the piping Low water cut off When the boiler is installed above terminal units or when required by applicable codes install a low water cut off in the piping above the boiler See suggested piping in the diagrams in this section Use a probe type control when possible Flow switch When a flow switch is required install the switch in a section of the piping that will ensure enough flow to operate the switch Additional high limit controls For ASME CSD 1 or Canadian applications or when required by applicable codes install an additional high limit control in the supply piping above the boiler Make sure the limit control is set at least 20 F above the highest operating temperature of the 200i boiler Cast iron condensing boiler Installation and operation manual Water pi pi n g continued Expansion tank and air separation The 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 Make sure the tank is sized large enough to handle the system volume Figure 5 Expansion tank comparison Diaphragm or bladder type expansion tank Tank can be mounted up or down shown with system tapping up Closed type expansion tank Tank can only be mounted on its side as shown
7. All installations must provide the minimum clearances to combustible materials and surfaces given in Table 1 Failure to comply could result in a fire hazard causing severe personal injury death or substantial property damage Table 1 Minimum clearances to combustible materials surfaces for ALL installations Figure 1 Left side 053 Rightside BB Front BB Rear 6 B System water piping 1 254 WARNING Ifthe boiler is located in a closed room the room must be provided with ventilation openings even if air is ducted to the boiler See Figure 1 Size the openings with a free area no less than 1 square inch per BTUH input of all 2001 boilers in the room EXCEPTION Ventilation openings are not required if the boiler room provides at least the minimum SERVICE OPERATION clearances given in Table 2 Failure to provide adequate ventilation could result in overheating of the boiler components or the room potentially causing severe personal injury death or substantial property damage Clearances for service and operation WARNING The installation must provide reasonable access and clearance for service and operation of the boiler Table 2 gives recommended minimum clearances for service and operation The boiler may be installed in a space that does not provide these recommended clearances provided it is accessible for the service and operation procedures required in the 200i manuals Flame observation port The flame ob
8. Coupez tout courant lectrique la chaudi re Appuyez sur le commutateur ON OFF MARCHE ARRET de la chaudi re pour le mettre OFF ARRET NE TENTEZ PAS D ALLUMER LE BR LEUR MANUELLEMENT Tournez la manette de soupape gaz dans le sens des aiguilles d une montre MN pour FERMER la soupape gaz La soupape gaz peut avoir un levier L emplacement de la soupape variera d une installation l autre Attendez cinq 5 minutes pour que tout gaz se dissipe Sentez alors pour d tecter la pr sence de gaz y compris pr s du plancher Si vous sentez du gaz ARRETEZ Suivez B dans les informations de s curit ci dessus Si vous ne sentez pas de gaz passez la prochaine tape Tournez la manette de soupape gaz dans le sens contraire des aiguilles d une montre pour OUVRIR la soupape gaz Allumez tout courant lectrique la chaudi re R glez le thermostat son niveau le plus lev Appuyez sur le commutateur ON OFF MARCHE ARRET pour le mettre ON MARCHE L AFFICHEUR fera une manoeuvre de s quence d allumage et affichera RUN EN FONCTION lorsque la chaudi re fonctionnera Si la chaudi re ne fonctionne pas suivez les instructions ci dessous pour ARR TER LE FLUX DE GAZ VERS LA CHAUDI RE Appelez votre technicien d entretien ou votre fournisseur de gaz BR COMMENT COUPER L ADMISSION DE GAZ DE L APPAREIL HER 1 R glez le thermostat la temp rature la plus basse 3 Tournez
9. For conditions not shown in Table 3 other pressure drops or natural gas with other than 0 6 specific gravity refer to the ap propriate code guidelines for sizing Equivalent length Do not neglect the pressure drop due to pipe fittings Equivalent length is the sum of the actual length of piping plus the total equivalent lengths of all fittings in the line from the main regulator to the boiler connection See Table 4 for equiva lent lengths of common fittings and components Multiple appliances If more than one appliance is supplied by the same supply pipe the piping must be sized based on the maximum possible demand TEV hve Undersized gas supply piping can cause the gas line pressure to become negative during operation of the 200i boiler This can cause pilot outages and operation failures of other appliances connected to the line including gas ranges water heaters etc Failure to properly size the gas lines can result in potential for severe personal injury death or substantial property damage P N 42 9470 1 12 Copyright 2012 Mestek Inc Gas pipi ng continued Table 3 Gas flow capacity for black iron pipe Iron Pipe length equivalent feet length plus allowance for fittings size 10 20 30 40 50 60 80 100 150 Natural gas pipe flow capacity cubic feet per hour notes 1 2 3 w ame 10 152 130 nsis 79 e Oum meoo moo 850760 670 oro sao 460 380 Propane gas pipe flo
10. NOT piping diagrams in the Boiler manual for system may be remove or use in any circulator application and piping IMPORTANT at a different other manner It cannot be If the circulator motor is larger than 1 4 hp temperature than used for system circulation connect the circulator using a motor contactor 20204 the boiler supply P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S Control setup Before control setup CAUTION Before beginning the HeatNet control setup remove the wires connected to the HEAT DEMAND and DHW DEMAND terminals on the electrical connection board see Figure 21 These must be removed to prevent a call for heat during the setup process Close the manual gas valve before proceeding to prevent any possibility of the boiler firing during setup The HeatNet control display Starting the display l 2 3 4 3 Check all wiring to make sure it is complete and all wires are securely connected Verify that the HEAT DEMAND and DHW DEMAND wires are removed Turn on power to the boiler and then turn the boiler on off switch ON The control will beep at least twice and the display will show the first STANDBY display in Figure 22 Note that pushing the DOWN button on the keypad will change the right side of the display as shown providing information on various setpoints and parameters The display LOC SET means the setpoint temperature Fi
11. Open the manual valve or quick fill valve on the make up water line When filling the system with glycol connect from the glycol pump to one of the purge valves with a hose Purge each zone separately by opening the isolation valves for that zone allowing water to push the air through and fill the zone After filling the zone close the isolation valves and move to the next zone Fill and purge the boiler loop in the same manner After the boiler is operated for a while air entrained in the fill water will bubble out of the water as it heats and will have to be removed by using air vents in the system Q Add a chemical inhibitor After purging and filling the system add a chemical inhibi tor sold for use in hydronic systems to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion Q Water pH The boiler water must be slightly basic never acidic Use lit mus paper to check pH which should range from 7 0 mini mum to 8 5 maximum If pH does not comply provide water chemistry correction from a qualified water treatment specialist If required make sure that the owner is aware and that the regimen will be continued P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual 11 Q Antifreeze Antifreeze for hydronic systems contains propylene glycol and an inhibitor With out the inhibitor the glycol is actual
12. Provide required combustion air openings to the boiler room and the building when required when using air from the boiler room for combustion see page 8 If air is piped to the boiler air intake connection combustion air openings are not required unless other appliances share the same room P N 42 9470 1 12 Copyright 2012 Mestek Inc Buildings will require the installation of a fresh air duct or other means of providing make up air if the intake air op tion isnt used Any building utilizing other gas burning ap pliances a fireplace wood stove or any type of exhaust fan must be checked for adequate combustion air when all of these devices are in operation at one time Sizing of an out side air duct must be done to meet the requirements of all such devices The boiler must be supplied with combustion air in ac cordance with Section 5 3 Air for Combustion and Ven tilation of the latest revision of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and all applicable local building codes Canadian installations must comply with CSA B149 1 or 2 Installation Code for Gas Burning Appli ances and Equipment or applicable provisions of the local building codes Negative room pressure Never operate the boiler in an environment subjected to a negative pressure unless it is Direct Vented Failure to com ply with this warning can result in excessive levels of carbon monoxide Combustion air contamination Combustion air contami
13. The flame must be blue and steady as discussed on page 37 CO must be no higher than 100 ppm Table 5 Acceptable CO and O values Natural gas High fire CO O Natural gas Low fire Minimum Maximum CO O CO O 84 62 9 5 4 2 Maximum Propane Low fire Minimum Maximum Propane High fire CO O Adjusting gas input with throttle screw max input 1 Adjust gas input with the throttle screw adjustment using a long shank common bit screwdriver inserted through the hole in the jacket top Figure 29 Maximum 2 When adjusting the throttle setting make changes in half turn increments Allow the flame to stabilize before adjusting each time Reduce gas input if the flame or burner appears red 3 IfCO is too HIGH O too low REDUCE gas by turning the adjustment CLOCKWISE one half turn at a time Recheck the analyzer and flame after each half turn 4 CO is too LOW O too high INCREASE gas by turning the adjustment COUNTERCLOCKWISE one half turn at a time Recheck the analyzer and flame after each half turn Verify gas inlet pressure 1 With the boiler operating at high fire check the gas pressure at the manual gas valve Gas pressure should never fall off by more than 2 inches WC 50 mm To meter gas input natural gas only Meter gas input with the high fire jumper in place Turn off all other gas appliances that use the same gas meter as the boiler Call
14. The flame should be blue and well defined with white traces If the flame is too lean too much air it will be light blue and unsteady If the flame appears reddish or there are red areas on the burner surface turn the boiler OFF and reduce fuel with the gas valve throttle see page 38 6 Check the analyzer A rapid increase in CO is an indicator of bad combustion Turn the boiler OFF and reduce fuel input as explained on page 38 P N 42 9470 1 12 Copyright 2012 Mestek Inc Figure 27 Flue gas sampling hole Fluejgas samplinglhole u nderband WARNING Seal test hole with high temperature silicone after each combustion test and annual inspection to prevent gases and condensation from leaking during appliance operation Figure 28 Electrical panel Low fire terminals High fire terminals Cast iron condensing boiler Installation and operation manual 12 Adjust gas valve throttle setting Starting the boiler continued Allow combustion to stabilize Allow the boiler to operate 15 minutes or as needed to obtain a steady reading on the analyzer WARNING If the flame or burner surface appear red NO NOT allow the boiler to run without adjusting the gas valve throttle to reduce fuel input as described below Proceed with final throttle setting only if the flame is visually acceptable blue and steady Acceptable CO O values The CO O values must be within the limits given in Table S
15. additional information External high limits low 4 5 water cut offs or other limits if used oe 24VAC INTERLOCKS Also see page 21 I gt HIGH FLOW USER LIMIT SWITCH INTRLK M Hi 11 11 11 11 11 BYPASS CIRC ALARM OPT Power for combustion air damper motor Water flow switch if used S Remove factory jumper across FLOW SWITCH terminals when using a flow switch Combustion LE air damper Proving motor if switch used Factory wiring DO NOT change Alarm contact closes on open or shorted sensor ignition lockout flow switch or user interlock combustion air damper failure blocked flue or blocked air inlet 120 VAC ONO OO HD OVAC 120 VAC Fused service switch by installer Power to n Circulator gs oe Gnd DO NOT directly connect Sue HEADER circulator if motor is over 1 4 HP Use a motor contactor or relay l Dry contact out to remote alarm rs Outdoor Return sensor water Post u rge if used sensor circulator Supply 4Sed Header This circulator is factor sensor sensor Boiler circulator factory if used pipe and wired It circulates or boiler system circulator installed water in the boiler after to boiler Install a header shutdown to prevent This circulator must be supplied piped and outlet sensor when overtemperature in the wired by the boiler installer See the suggested the water to the top of the boiler DO
16. any type of valve between the boiler and the relief valve or in the relief discharge piping An explosion could occur causing severe personal injury death or substantial property damage General piping requirements Boiler piping general WARNING Improper piping of the boiler will void the manufacturer s warranty and can cause boiler failure resulting in possible severe personal injury death or substantial property damage Install a shut off valve in the boiler supply and return connections to allow isolation of the boiler for servicing when necessary Piping guidelines All installations must be installed by a qualified technician in accordance with the latest revision of the ANSI ASME Boiler and Pressure Vessel Code Section IV Where required the installation must comply with ANSI ASME CSD 1 Standard for Controls and Safety Devices for Automatically Fired Boilers All applicable local codes and ordinances must also be fol lowed A minimum clearance of 1 inch 25 mm must be main tained between heating system pipes and all combustible construction All heating system piping must be supported by suitable hangers not by the boiler The thermal expansion of the system must be considered when supporting the system A minimum system pressure of 12 psig 84kPa must be maintained Figure 4 Relief valve piping Install relief valve piping 34 NPT Support piping to prevent bending load on r
17. control display during operation The UPPER LEFT display shows boiler status p Default readout shows local During start sequence this area will indicate what is happening and then i Mon AT m OL Li SE T setpoint or header setpoint switch to RUN __ The RUN is the of full input use arrow keys to change to m If there is a call for heat and the supply or header temperature is within the 1 i H F rel el Heat band the display will show HEATING until the call for heat stops or h d h for th to start the boil ji temperature and other t e temperature rops IOow enoug or the control to star e Doller g Setpoint j lies oe fhe DOWN ey i see other values such as DHW setpoint and supply temp The LOWER LEFT display shows the heat band temp range from min to max input and setpoint on the bottom and the actual temperature along the e top This tells you where the temperature is within the control range Heat band Actual temperature Figure 24b Boiler sequence of operation fault states and SmartCycle control display information Normal condition Blower status Time Ignition Gas valve Display status status upper left Standby not heat call not heat call ae ae STANDBY Start call for heat OFF Es switch and other interlocks in 10 seconds FLOW WAIT the flow switch circuit must prove OFF Demand OFF OFF HEATING if supply temperature is above the bottom of the heat band circulator runs but boiler does not fi
18. ifnot already done Q Verify boiler system water piping Inspect all water piping Make sure it complies with this manual Check the boiler relief valve Verify the relief valve setting is correct for the application Make sure the boiler and system are full of water and that the system has been purged and is ready for operation System pump Activate the system pump if it is not con trolled by the 200i SmartCycle Control Q Verify gas piping and connections Before starting the boiler smell around the area for presence of gas odorant Immediately locate and correct any leak Connect a manometer to the manual gas valve outlet test port Open the valve and measure the gas pressure It must not be above 12 psig 3 5 kPa a Open the main manual gas valve and check the gas piping and joints in the boiler Check for leaks if not already done following the instructions on page 19 P N 42 9470 1 12 Copyright 2012 Mestek Inc Q Prepare the condensate system Verify the condensate line is connected to the boiler cor rectly installed and terminated Turn on power to the condensate pump ifused Make sure the condensate neutralization system ifused is functional Slide the condensate hose off of the boiler condensate hose barb Connect a clear plastic tube 3 16 inch diameter to the hose barb Pour water into the tube until water backs into the tube at the hose barb indicating the trap is ful
19. in accordance with all location of the power terminal strip applicable local codes and the latest revision of the National Electrical Code ANSI NFPA 70 Installation should also conform to CSA C22 1 Canadian Electrical Code Part I if installed in Canada Install a separate 120 volt 15 amp circuit for the boiler A properl ihe shut off switch should be ee A POWER SERVICE the boiler The boiler must be grounded in accordance with the authority having jurisdiction or ifnone the latest revision of the National Electrical Code ANSI NEPA 70 Line voltage field wiring of any controls or other devices must use copper conductors with a minimum size of 14 awg Use appropriate wiring materials for units installed outdoors General The 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 15 amp fused service Power supply 120 VAC switch by installer See Figures 15 and 16 Gnd NO H Connect minimum 14 awg copper wire to the power connection as shown in Figure 16 Install a fused service switch mounted and installed in 120VAC 60HZ 1Ph accordance with all applicable codes Power to boiler P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and
20. la manette de soupape gaz dans le sens des ae oe ee Tee aiguilles d une montre x pour la FERMER 2 Coupez l alimentation lectrique le l appareil s il faut proc der l entretien NE FORCEZ PAS LA MANETTE 42 5230 P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Starting the boiler continued Turn the boiler OFF Turn OFF the boiler on off switch and allow the boiler to cycle off CLOSE the manual gas valve Multiple boiler SmartCycle applications Disconnect the communications cable or 3 wire connection to the boiler connection board Replace when done Check ignition With the manual gas valve CLOSED start the boiler with the on off switch Look into the flame window left side of the boiler Figure 29 page 38 When ignition starts the spark should jump between the electrodes not to other surfaces 4 The spark should be strong and steady If the spark is acceptable turn the boiler on off switch OFF Then proceed with the start up adjustment procedure 5 Ifthe sparkjumps to ground or is unsteady turn the boiler OFF See the Maintenance section of this manual for the procedure to remove and inspect the electrode as sembly Replace the electrode assembly if it is damaged or not within specifications Insert combustion analyzer probe WARNING The boiler must be checked and adjusted using combustion test instruments Failure t
21. of antifreeze is necessary an anti freeze specifically formulated for hydronic heating systems must be used or damage to the boiler may occur voiding the warranty On applications that use antifreeze or other low conductivity fluid in the water provide for increased water flow or ensure proper temperature rise Train the user Before leaving review the Users Information Manual with the boiler user homeowner including the required maintenance to be performed by the user the need for annual start up maintenance by a qualified technician the avoidance of combustion air blockage or contamination and never bringing or storing flammable products into the boiler area Cast iron condensing boiler Installation and operation manual AFUE DOE seasonal efficiency 92 7 Btuh 200 000 CSA Input Max Kw 58 6 Btuh 40 000 Kw 11 7 PSIG 100 kPa 700 Water supply and return connections Inches NPT 1 Gallons 4 75 Liters 18 0 ne Pounds 540 lt p Shipping weight Kg 245 CSA Input Min Maximum allowable working pressure Boiler water volume CERTIFIED Pounds 510 Kg 231 Fuels Natural gas or propane Operating weight Gas connection size Inches NPT Gas supply pressure minimum Inches WC mm WC fe Gas supply pressure maximum Inches WC 14 pply p wi re onci Inches 3 Ventconnectionse LE Vent options Direct Vent or Category IV pressurized vent condensing Combustion air options Air from boiler
22. operation manual 7 Wiring single boiler continued Circulator wiring Figure 19 Circulator wiring terminal strip see Figure 15 for location Also see the wiring summary Postpurge circulator illustrations on the next pages 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 after the boiler stops firing to prevent potential damage from heat pocketing in the top of the heat exchanger 4 The 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 HN Hi Il Il 11 Figure 19 shows wiring of the Boiler circulator or boiler a I system circulator to the terminal strip ofthe 200i electrical CIRC ALARM OPT Relay or motor starter with 120VAC coil connection board 120V DO NOT directly connect a circulator with a motor larger _ U than 1 4 hp For larger motors install a circulator relay or motor contactor Figures 17 and 18 show the correct ways L to install the boiler circulator using a relay or motor starter i N To combustion air damper motor power J if supply and motor Figure 17 Wiring the boiler circulator using a circulator E see UN AE relay required for motors over 1 4 hp Ee i illu
23. operation manual Gas Valve Venturi Gas Gas Air Mixture Premix Burner lt Ignition Electrodes Supply Flue gases Cast Iron Heat Exchanger ET Ly L L An v n D u LL Return d d d p p d d d d B os Condensate 2001 schematic flow diagram Operation Overview The 2001 is a cast iron boiler designed and constructed to allow full condensing operation The illustra tion at left shows how the boiler is heated with a down fired premix gas burner mounted above the heat exchanger The 2001 blower pulls gas and air through a venturi assembly and pushes the mixture into the burner The power of the blower forces the flue products through the heat exchanger and out the vent Boiler operation is controlled with the 2001 electronic control The control modulates boiler firing rate based on system demand allowing input as low as 20 of maximum 5 1 turndown Combined with the indoor or outdoor reset option of the 2001 control this allows maximum possible condensing mode operation with combustion efficiency up to 98 Cast iron heat exchanger The 2001 cast iron heat exchanger uses Mestek s graphite port seals and ground joint fit up between sections for maximum flexibility and resistance to thermal expansion The heat exchanger provides maximum heat transfer with its counterflow design and flow contr
24. room or i ducted to boiler from outside Electrical requirements AO CERTIFIED www ahridirectory org Thermostat anticipator setting Amperes S Operating control Mestek SmartCycle control Stand alone Control operation options SmartCycle BMS boiler management system Heat demand SmartCycle or stand alone On Off Control methods BMS 4 20 ma input Staging RS485 digital communication Notes DOE Heating capacity is based on standard tests specified by the United States Department of Energy All capacity ratings above are based on sea level Input adjustments allow setting the high fire input and may compensate for moderate altitudes For higher altitudes the maximum boiler input will be derated slightly The gas valve is capable of operating with natural gas or LP See instructions in this manual to adjust for the specific fuel used For additional information refer to the 200i Control manual Thermostat anticipator setting is fora single thermostat connected to a single 200i boiler Also jumper from the Heat Demand terminals to the IARI terminals on the connection board See the 200i Control manual for details 6 P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler 3 Installation site preparation Boiler location requirements Donotinstall the boiler unless the location meets all of the requirements in this box Failure to comply could result in severe personal injury d
25. tank sa or piping to the expansion tank closed type expansion tank systems Do not connect the 200i boiler to a system that contains non barrier radiant tubing Non barrier tubing can allow oxygen to enter the system causing oxygen corrosion of the boiler heat exchanger Flush and clean the system Flush the system to remove sediment flux filings and other foreign matter Use cleaning chemicals sold for use in hydronic systems Replacement boiler installations often have large amounts of accumulated sediment and corrosion that must be removed to ensure boiler life and reliable operation Flush each zone of multi zone systems individually using the purge valves and iso lation valves in the system Flush until the water runs clean After flushing the system thoroughly use trisodium phos phate or other chemical sold for cleaning hydronic systems to remove sediment and sludge Use caution when working with chemicals following all guidelines specified by the chemical supplier and the applicable codes Purge air from the system The system should be installed with purge valves such as those shown in the suggested piping in this manual Purging is the most efficient way to fill the system and remove most of the air Connect a hose to a purge valve and run the hose to an ap propriate draining area When filling with antifreeze solution run the hose back to the solution tank Close all isolation valves in the system
26. the boiler attempts ignition no flame will occur Within 4 seconds of igni tion start the control will close the boiler gas valve and attempt another start 7 After three failed ignition attempts the Fenwal control will lockout 8 The boiler will shut off and the SmartCycle control display will show LOCKOUT 9 Open the manual gas valve 10 Reset the controls by turning the boiler on off switch off then on again 11 The boiler should restart and operate normally Test control amp interlock operation Test SmartCycle operating limit function 1 Allow the boiler to fire until the supply temperature reaches the upper end of the control band Figure 32 Throttle adjustment and flame window Microammeter vb x Ww Ca ma Fenwal B Module amp i a h LS 2 The boiler should gradually cycle to minimum input firing rate 20 then turn off Test external controls 1 Lower the setting of external limit controls below the sup ply water temperature Verify that the controls shut down as required 2 Test operation of low water cut offs flow switches and other external devices 3 Test external gas pressure interlocks if used Test verify operation of combustion air dampers and end switches if used DHW applications 1 ForDHWapplications verify that the boiler operates on demand from the indirect water heater and shuts off as required Fill out the installation certificate 1 Complet
27. unsafe condition 3 Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remain ing connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhaust so they will operate at maximum speed Do not operate a summer exhaust fan for a boiler installation Close fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously S Test for spillage at the draft hood relief opening after 5 min utes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe 6 After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous condition of use Ts Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI Z223 1 NFPA 54 When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the
28. 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 Q 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 LJ 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 attaching a 3 s inch clear plastic tube to the hose barb Pour water into the tubing until the trap is full Remove the clear tubing and reattach the condensate line to the boiler hose barb Q 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 LJ Revie
29. with diaphragm type see 16 Boiler postpurge circulator see page 11 page 12 for piping a closed type tank Expansion tank shown with diaphragm type see page 12 for piping Ul Hatier sense sep onets duos 200i boiler 1 a closed type tank 2 Boiler circulator Re ge ee TE t Repl f Isolation valve r separator with automatic air vent Replace air ven l 4 Boiler system circulator i Sane to the tank fitting on close vee e expansion JF Purge valve Suggested locations allow for improved 5 Jndirect fired DHW tank systems system filling and draining and initial air elimination oo 11 L ter cut off wh ired O Temperature gauge 6 DHW circulator ow water cut off when require p gaug A eae 12 Extra high limit when required 8 Cold water fill line 14 Zone circulator P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S Water piping continued Multiple boilers primary secondary DHW operation when required The piping shown throughout this manual allows for domestic water heating without flow through the heating loop s This is important for sammer time operation of DHW tanks Sizing and flow control Size circulators to provide the flow needed for the individual zones Provide flow check valves where shown to prevent gravity circulation or Make sure to incorporate flow check valves as shown These prevent forced forced flow in idle zones flow in idle zon
30. your gas supplier and ask for the heating value of the gas Btu per cubic foot Start the boiler and let it run for 15 minutes high fire jumper in place With the boiler operating clock the time in SECONDS that it takes to burn 10 cubic feet of gas at high fire A ge Go te 6 Insert the heating value and the time in seconds into the formula below Input Gas Btu per cubic foot x 3600 x 10 seconds 7 Ifthe computed rate exceeds the desired input rate or 200 000 Btuh reduce the gas input with the gas throttle adjustment Figure 29 Throttle adjustment and flame window INCREASE DECREASE GAS ay GAS Screwdriver access Gas valve hole for gas valve throttle adjustment throttle adjustment gt WARNING Never operate the boiler at an input higher than its rating Excess input can result in overheating and damage to the heat exchanger and boiler components Check low fire operation 1 Turn the boiler on off switch OFF 2 Remove the high fire contact jumper Connect the jumper wire across the low fire terminals of the connector board Figure 28 page 37 These terminals are located on the lower row as shown Turn the boiler on off switch ON 4 The boiler will start at about 30 of input and then move to the low fire condition 5 Make sure the flame is blue and steady NOT red or light blue and unsteady 6 Ifthe flame or burner appears red or if the CO or O are outside the ranges o
31. Air from boiler room When the boiler draws combustion air from the boiler room If the room volume is at least 50 cubic feet per BTUH of the combined input of all appliances in the room no special openings are needed UNLESS the building is of tight construction see definition If the building is of tight construction provide openings to the building in accordance with all applicable codes If the boiler is in a space smaller than 50 cubic feet volume per BTUH input provide air openings using one of the methods in Figure 3 Definitions Free area Louvers or grilles reduce the area of an opening Free area is the area remaining with the louver or grille in place If the free area of a louver is unknown use the following Metal louver Multiply required free area of the opening times 1 7 to determine actual area of the required opening Wood louver Multiply required free area of the opening times 5 to de termine actual area of the required opening Tight construction When a building is extensively sealed to prevent air infiltration it cannot provide enough air for combustion unless openings are provided to the outside The National Fuel Gas Code defines such buildings as having all of the following Walls and ceilings exposed to the outside atmosphere have a continuous water vapor retarder with a rating of 1 perm or less with openings gasketed Weather stripping has been added on openable windows and do
32. CAUTION CAUTION CAUTION Polarity The connections to the IAR positive terminals IAR must be to the same location on the zone valve as the thermostat wire as shown in Figure Al The connections to the IAR negative terminals IAR must be from the zone valve terminal connected to the 24VAC common line as shown Connecting the wires incorrectly can cause the transformer to be shorted out and damaged 3 wire zone valves You will have to rewire existing 3 wire zone valves to meet the requirements shown in Figure Al Move the thermostat lead and the 24VAC hot lead to the CENTER terminal of the valve Move the 24VAC common lead to the outer terminal of the valve Discard existing wires connected to the end switch terminals Install a new wire single wire from each end switch to the Heat Demand LEFT SIDE terminal as shown in Figure A1 3 wire zone valves Always use a voltmeter to verify the wiring is correct The center terminal of the valve must be 24VAC to ground when the thermostat is calling for heat The motor common terminal outer post must not have voltage Change the wiring and retest DO NOT connect the wires to the boiler until you have tested as described Incorrect wiring can damage the boiler control or other system components If there is only one transformer feeding all of the zone valves in the system you can omit the wires to the IAR negative terminals IAR on all but one of the zone valves This is becaus
33. CAUTION M2i lOM 6 2001 Cast iron condensing boiler Boiler manual Installation and operation Tier tle ele pl Nye reaa andHolIoWw 2001Controlmanual 2007 Vent Air manual aaa CERTIFIED D CERTIFIED This manual is intended only for use by a qualified 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 Construction dust and particulate particularly drywall dust will cause contamination of the burner resulting in possible severe personal injury death or substantial property damage The 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 Affix these instructions near to the boiler water heater Instruct the building owner to retain the instructions for future use by a qualified service technician and to follow all guidelines in the User s Information Manual P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and
34. IAR positive terminals IAR must be to the same location on the zone valve as the thermostat wire as shown in Figure A3 The connections to the IAR negative terminals IAR must be from the zone controller s 24VAC common terminal as shown Connecting the wires incorrectly can cause the transformer to be shorted out and damaged NOTICE Thermostat terminal connections Use a voltmeter to verify the wiring is correct Measure the voltage on the thermostat terminals with the zone controller powered BEFORE connecting any wires The IAR positive terminal connections IAR must be to the side of the thermostat connections that have zero voltage DHW priority zone Most zone controllers will provide a priority zone for connection toa DHW tank aquastat and circulator The 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 Cast iron condensing boiler Installation and operation manual 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 NOTE The DHW priority zone will vary between controllers Refer IAR1 IAR2 IAR3 IAR4 IAR5 IAR6 IAR7 IAR8 to controller
35. Manual gas valve with test port use tee handle valve for Massachusetts installations eA 3 Piping must be clean and burr free at i black iron pipe 4 Ground joint union 5 Drip leg with cap 4 Gas cock pressure test port P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual 6 Gas piping joints WARNING Always use a pipe sealant that is suitable for use with LP gas Failure to comply could result in an explosion causing possible severe personal injury death or substantial property damage Onlyuse pipe dope listed for use with propane gas Even natural gas may contain some amount of propane Use pipe dope sparingly Excessive pipe dope can block pipe flow or foul gas train components Gas pipe sizing Required supply pressure at boiler Minimum gas supply pressure natural gas or propane both for flowing and static conditions 4 inches 102 mm water column Maximum gas supply pressure natural gas or propane both for flowing and static conditions 14 inches 356 mm water column Sizing guidelines The sizing recommendations of Table 3 are taken from the National Fuel Gas Code ANSI Z223 1 NFPA 54 Propane values are based on adjustment from propane specific gravity and pressure Table 3 allows for a pressure drop from the main supply regulator to the boiler of 0 3 inches 7 6 mm water column for natural gas or propane
36. National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CSA B149 Installation Codes Syst mes d vacuation d communs Au moment du retrait d une chaudi re existante les mesures sui vantes doivent tre prises pour chaque appareil toujours raccord au syst me d vacuation commun et qui fonctionne alors que d autres appareils toujours raccord s au syst me d vacuation ne fonction nent pas syst me d vacuation 1 Sceller toutes les ouvertures non utilis es du sys t me d vacuation 2 Inspecter de fa on visuelle le syst me d vacu ation pour d terminer la grosser et l inclinaison horizontale qui con viennentet s assurer quelesyst meestexemptdobstruction d tranglement de fruite de corrosion et autres d faillances qui pourraient pr senter des risques 3 Dans la mesure du possible fermer toutes les portes et les fen tres du b timent et toutes les portes entre l espace o les appareils toujours raccord s du syst me d vacuation sont install s et les autres espaces du b timent Mettre en marche les s cheuses tous les appareils non raccord s au syst me d vacuation commun et tous les ventilateurs d extraction comme les hottes de cuisin re et les ventilateurs des salles de bain S assurer que ces ventilateurs fonctionnent la vitesse maximale Ne pas faire fonctionner les ventilateurs d t Fermer les registres des chemin es 4 Mettre l appareil inspect en marche Suivre les instructions d allumage
37. R gler le thermostat de fa on que l appareil fonctionne de facon continue S Faire fonctionner le br leur principal pendant 5 min ensuite d terminer si le coupe tirage d borde louverture de d charge Utiliser la flamme d une allunette ou d une chan delle ou la fum e d une cigarette d un cigare ou d une pipe 6 Une fois qu il a t d termin selon la m tode indiqu e ci dessus que chaque appareil raccord au syst me d vacuation est mis l air libre de fa or ad quate Remettre les portes et les fen tres les ventilateurs les registres de chemin es et les ap pareils au gaz leur position originale 7 Tout mauvais fonctionnement du syst me d vacu tion commun devrait tr corrig de fa or que l instal lation soit conforme au National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou aux codes d installation CSA B149 Sila grosseur d une section du syst me d vacuation doit tr modifi e le syst me devrait tr modifi pour respecter les valeurs minimales des tableaux pertinents de l appendice F du Na tional Fuel Gas Code ANSI Z223 1 NFPA 54 et ou des codes d installation CSA B149 P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual l 0 Condensate drain line Fill the condensate trap Before installing the condensate line you must fill the condensate trap with water This will prevent flue products from escaping into
38. S possible and not likely to be covered by snow drifts or debris Connect the outdoor 6 i bi bi bi br vi sensor leads to the electrical connection board as shown in Figure 21b page 24 Header sensor application As shown in the piping diagrams in this manual a header sensor is needed if the boiler supply temperature may be different from the header temperature If required purchase and install a header sensor in an im T r 7 T mersion well Locate the sensor where it will accurately sense the system water IAR1 IAR2 IAR3 IAR4 IAR5 IAR6 IAR7 IAR8 supply temperature Connect the sensor leads to the electrical connection board poo jh gt as shown in Figure 21b page 24 om Return water temperature sensor The return water temperature sensor is optional only needed if you want to automatically control the boiler postpurge pump cycle time To use the return water temperature sensor purchase and install the sensor in a well in the boiler return piping Connect the sensor leads to the electrical connection board as shown in Figure 21b page 24 To other zone valves up to 8 zones total WARNING Rewire the zone 24VAC to other valves if necessary to zone valves ensure the hot leads are connected as shown ea Fa IAR Indoor Air Reset wiring when used Heat Demand terminal connections The end switch leads from the zone valves must connect to the Heat Dem
39. To system Water Diaphragm or bladder EN gt Charge tapping 20009 Diaphragm bladder type expansion tank Diaphragm or bladder type expansion tanks have a membrane that separates the water from the air in the tank See Figure S left side See Figure 6 for suggested piping Guidelines for diaphragm bladder type expansion tanks Always remove the tank from the system before charging This ensures the air pressure will be accurate Make sure the charge pressure equals the required system cold fill pressure usually 12 psig Install an automatic air vent on top of the air separator to remove air from the system Closed type expansion tank Closed type tanks are those that have air above the water in direct contact with the water See Figure S right side See Figure 7 for suggested piping Guidelines for closed type expansion tanks NEVER use automatic air vents in systems with closed type tanks The air must be kept in the system and returned to the tank in order to keep the tank operating correctly Automatic air vents will bleed air out of the system resulting in water logging of the tank causing the boiler relief valve to weep Air separation is done by connecting from an in line air separator to the bottom of the expansion tank Figure 7 The tank must be mounted above the air separator Install a tank fitting in the bottom of the tank It allows captured air to flow into the upper portion of the tank faci
40. ae O ane sopsiretefiae O 721002 Tsp O RO ooparalenate O a oes Spas O oes Grounds O ome Famesensor O MS sonne ignition BlockGasket a E RES Dr 08778 ignition Boxcover a PARTNO DESCRIPTION Jar eis maco mes WanemsiFiow check 1 ane ieee Lassa savtansiomer un eaten Lao oupinytowrt jet seme O Harness J2 Ctrl Ey Harness J3 Ctrl ER Harness J4 Ignition Flue Switch ES ro rene ROCCO E3 a E CICCTONES EN OOO ii pre T ie inaen EI ete eee T CIE ECC T ECC E He n EI 3 Las r T ECC E Pedee E P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual OQO OOA 9 6 amp P N 42 9470 1 12 Copyright 2012 Mestek Inc 47 Ob OOOOOOHOOOOH 16 Cast iron condensing boiler Installation and operation manual Appendix suggested wiring IAR Indoor Air Reset wiring when used Wiring for 3 wire zone valves without a zone controller Heat Demand terminal connections using 3 wire zone valves The end switch leads from the zone valves must connect to the Heat Demand LEFT SIDE terminal on the electrical connection board as shown in Figure Al IAR connections See Figure A1 for typical wiring to the IAR inputs when using 3 wire zone valves without a zone controller For other applications see the Con trol manual and Section 7 of this manual
41. alve handle clockwise VX to CLOSE the gas valve Gas valve may have lever handle Valve location will vary by installations Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above If you don t smell gas go to the next step Turn manual gas valve handle counterclockwise 6 to OPEN the gas valve Turn ON all electrical power to the boiler Set the thermostat to its highest setting Press the ON OFF switch to ON The DISPLAY will cycle through the ignition sequence and show RUN when the boiler is operating If the boiler does not operate follow the instructions below to TURN OFF GAS TO BOILER Call your service technician or gas supplier T TO TURN OFF GAS TO BOILER 1 Set the thermostat to its lowest setting 3 Turn manual gas valve handle clockwise y to CLOSE 2 Turn off all electric power to the boiler if service is to be DO NOT FORCE THE HANDLE performed 42 5230 P N 42 9470 1 12 Copyright 2012 Mestek Inc _ Cast iron condensing boiler Installation and operation manual l 2 Starting the boiler continued Illustration 26 En francaise BE POUR VOTRE S CURIT LISEZ ANANT DE METTRE EN MARCHE a Cet appareil ne comporte pas de veilleuse Il est muni d un Ne poussez ou tournez la manette d admission du gaz qu la main ne jamais utiliser dispositif d allumage qui allume automatiqu
42. and terminals on the electrical connection board as shown in Figure 20 and Figure 2 la See Figure 20 for typical wiring to the IAR inputs when using 4 wire zone valves without a zone controller For other applications such as circulator relays or zone controllers see Appendix A in this manual Also see the Controlmanual 1 r 40 O O_Os T 4 wire zone valves typical CAUTION Polarity The connections to the IAR positive terminals IAR must be to the same location on the zone valve as the thermostat wire as shown in Figure Al The connections to the IAR negative terminals IAR must be from the zone valve terminal connected to the 24VAC common line as shown Connecting the wires incorrectly can cause the transformer to be shorted out and damaged Verify the wiring with a voltmeter CAUTION Always use a voltmeter to check the leads coming from the end switches of the zone valves With the thermostat calling for heat connect the voltmeter leads across the wires coming from the end switches If the meter shows a voltage reading the zone valve wires are incorrect Change the wiring and retest DO NOT connect the wires to the boiler until you have tested as described Incorrect wiring can damage the boiler control or other system components QR Tfthere is only one transformer feeding all of the zone valves in the system you can omit the wires to the IAR negative te
43. aned effectively ob tain a replacement filter from your boiler distributor 8 To replace the air filter pull the filter clamp back insert the filter and allow the clamp to secure the filter in place 9 Replace the filter access cover gasket and access cover 10 Replace the three thumbscrews and finger tighten securely 11 Turn the boiler on off switch ON Accessing the electrode assembly 1 Turn the boiler on off switch OFF 2 If the boiler ignition electrodes or flame rod appear to be operating incorrectly remove and inspect the assembly as follows Do not remove the electrode assembly while the boileris operating Allow the boiler and electrode assembly to cool before attempting removal to avoid possible burns Failure to comply could result in severe personal injury 3 With the boiler and manual gas valve closed remove the upper electrical box cover right side of boiler Remove the two 1 4 inch bolts that secure the electrode flame rode assembly to the boiler Figure 34 The electrode spacing must be 1 8 inch 3 2 mm as shown in Figure 26 4 Ifthe electrodes or flame rod are damaged or the tip spacing is incorrect replace the assembly The electrodes are NOT adjustable 5 Re install the assembly in the boiler WARNING Make sure the electrode plate gasket is in good condition and that the assembly is securely bolted to the boiler The combustion chamber operates with a positive pressure Failure
44. as been adjusted before 3 Press the SELECT button to change the local setpoint value 4 The cursor will move to the temperature number 5 Use the arrow keys to increase or decrease the temperature to the desired setting If you hold down the arrow key the numbers will change faster after a brief waiting period 6 When the setting is correct press the SELECT key to accept Then press the BACK key to leave the local setpoint adjustment 7 The local setpoint should be set at the design water temperature for the heating units typically 1 80 F for finned tube baseboard for example The setpoint must never be higher than the OP LIMIT setting minus the LIMIT BAND minus half of the HEAT BAND setting This would cause the boiler to hit limit while trying to modulate Example If LIMIT BAND is 20 F OP LIMIT is 21S F and HEAT BAND is 30 F the local setpoint must never be higher than 215 20 30 2 180 F Set the DHW setpoint DHW SETPT 1 Skip this procedure if the boiler is not used for DHW heating 2 Use the arrow keys until the cursor is at DHW SETPT The display will be a M SN SOURCE HOTO DHU SETPT 184 F 3 With the cursor on DHW SETPT press the SELECT key to change the value using the same procedure as with the LOC SETPT adjustment 4 The DHW setpoint should usually be 190 F To obtain this setpoint you will also have to increase the OP LIMIT set ting to 225 or 230 F so the boil
45. e factory ready to be piped to the gas supply If for any reason the boiler is not for the type of gas avail able at the installation site call your Mestek representative to resolve the problem See WARNING below Gas supply components Figure 14 depicts the proper way to connect the boiler to the gas supply piping The gas connection at the boiler is 72 NPT Item 1 Install the gas line piping from the gas meter or branch in accordance with all applicable codes See the next page for suggested sizing or refer to the National Fuel Gas Code or Ca nadian Gas Code for recommendations Item 2 The manual shut off valve must be installed in the supply piping Install 5 feet above the floor where required by applicable codes WARNING Failure to adhere to the following could result in severe personal in jury death or substantial property damage Verify the gas type Check the boiler rating plate to make sure that the boiler is for the type of gas that will be used fit is not do not connect the boiler to the gas supply Support the gas line Support the gas line with hangers DO NOT allow gas train weight to rest on or cause bending ofthe boiler gas connection fitting Protect the gas connection fitting Use a 5 16 inch open end wrench to hold the boiler gas connection fitting when tightening gas connection piping to the boiler Never leak test with flame Never use an open flame to test for gas leaks A
46. e following The boiler must be installed by a licensed plumber or gas fitter When antifreeze is used in the system install an approved pressure back flow preventer Per DOE mandate the 200i operator control incorporates an automatic means outdoor indoor air reset of adjusting the boiler water temperature for hot water heating The boiler must not operate without the automatic means enabled IMPORTANT In accordance with Section 325 f 3 of the Energy Policy and Conservation Act this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless coil P N 42 9470 1 12 Copyright 2012 Mestek Inc Before placing the boiler Verify boiler rating and gas supply Before installing the 200i boiler check the rating plate to ensure that the unit has been sized properly for the job Ensure that the b
47. e seal is restored when servicing is complete Gas kets must be in good position and placed as originally installed Read the instructions Do not attempt the procedures in this manual without thoroughly reading the instructions given Follow all instructions If problems can t be resolved If following the procedures in the 200i manuals do not resolve problems contact Mestek for technical support to resolve the issues Handling ceramic fiber and fiberglass materials The 200i boiler contains some ceramic fiber and fiberglass materials Ceramic fiber materials such as the burner gas ket may contain carcinogenic particles chrystobalites after exposure to heat Airborne particles from fiberglass or ceramic fiber components have been listed as potentially carcinogenic by the State of California Take the following precautions when removing replacing and handling these items Protective measures Avoid breathing dust and avoid contact with skin or eyes Wear long sleeved loose fitting cloth ing gloves and eye protection Use a NIOSH N95 certified respirator This respirator meets requirements for protection from chrystobalites The actual job requirements or NIOSH regula tions may require other or additional protection For information refer to the NIOSH website http www cde gov niosh homepage html Ceramic fiber removal Ceramic fiber removal To prevent airborne dust thoroughly wet ceramic fiber with wate
48. e the checklist and installation certificate on the back page of this manual P N 42 9470 1 12 Copyright 2012 Mestek Inc 13 Cast iron condensing boiler Installation and operation manual Annual start up 3 The boiler and system must be inspected started and serviced at least annually by a qualified service technician Follow all procedures specified 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 ifnecessary 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 The 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 LI Discuss system performance with the homeowner or boiler operator Ask the homeowner or boiler operator to rate the perfor mance of the heating
49. e 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 IAR negative terminals IAR Figure A1 Indoor Air Reset wiring to IAR terminals with 3 wire zone valves and no zone controller see Figure 21a for terminal block 6 location Or W a e IAR2 IAR3 IAR4 IAR5 IAR6 IAR7 IAR8 I l 4 l IAR1 To other zone valves up to 8 zones total 24VAC to other zone valves 3 wire zone valves typical WARNING You MUST I rewire the zone valves with the hot leads to the center terminal Move I the neutral lead to the outer terminal as shown WARNING You MUST rewire the zone valves I with the hot leads to the center terminal Move the neutral lead to the outer terminal as l shown Q 24VAC 9 l A V NOTICE Connect a single wire from the outer terminal of each zone valve end switch to the LEFT SIDE of the Heat Demand terminals 225 H EEE EEEE EEE E E E E Transformer 120VAC N P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual l 6 Appendix A suggested wiring continued IAR Indoor Air Reset wiring when used Figure A2 Indoor Air Reset wiring to IAR
50. eath or substantial property damage Indoor installation only Do not install the boiler outside or in an area that would ex pose the boiler or its gas or electrical components to rain or dripping or spraying water Do not install the boiler in a location that would subject the boiler to freezing Where freeze protection is needed follow the guidelines in this manual Flooring The boiler can be installed on combustible flooring but must not be installed on carpeting The floor must be structurally sound and capable of sup porting the weight of the boiler The boiler must be leveled front to back and side to side Use metal shims if necessary Accessibility Jacket parts will have to be removed for some service proce dures Ensure that the location provides a reasonable means for service and operation of the boiler System piping fuel and electrical supply The boiler must be located such that piping for water gas vent and air can reasonable be connected There must be a reasonable means of providing electrical supply to the boiler Adjacent construction Locate the boiler in an area that will prevent water damage to adjacent construction should a leak occur or during rou tine maintenance Combustion air Do not place the boiler in a location that would restrict the flow of combustion air into the air intake or subject the boiler to a negative air pressure in the space when using air from the boiler room
51. elief valve Supplytojsystem Boiler postpurge circulator with integral check valve Returnifrom Wa he Discharge so as to prevent injury due to hot liquid or vapor Slope downward to ensure complete auoe drainage of relief valve and piping P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S Boiler piping connections Water piping The boiler supply and return connections are shown in Figure 4 Both connections are 1 4 inch NPT Size piping for the flow required Piping connections to the 200i boiler should generally be 1 inch NPT System design Design options The 200i boiler works well in a single or multiple boiler application for any type of system The following pages include suggested piping diagrams for the following system options Single boiler zoning with zone valves page 13 Single boiler zoning with circulators page 14 Multiple boilers primary secondary piping page 15 Multiple boilers parallel piping reverse return page 16 Guidelines for chilled water systems page 17 All of the piping diagrams show the suggested piping for optional indirect fired DHW tanks Follow the DHW tank manufacturer s instructions for installation and piping Make sure to size the DHW circulator and piping to provide the flow needed for the required recovery capacity Pipe sizing Generally install 14 inch piping in the boiler ci
52. ement le br leur d outil Si la manette reste conc e ne pas tenter de la r parer appelez un technicien Ne tentez pas d allumer le br leur manuellement qualifi Le fait de forcer la manette ou de la r parer peut d clencher une explosion ou un AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil CENAE pur d celer une odeur de gaz Reniflez pr s du plancher car N utilisez pa cet appareil s il a t plong lan l eau m me partiellement Faites inspecter certains gaz sont plus lourds que l air et peuvent s accumuler au l appareil par un technicien qualifi et remplacez toute partie du syst me de contr le et niveau du sol Voir ci dessous toute commande qui ont t plong s dan l eau QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ e _ Nepastenterd allumerd appareil e Appelezimm diatement votre fournisseur de gaz depuis un voisin Suivez les instructions du fournisseur e Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Sivous ne pouvezrejoindrele fournisseur appelez le service des incendies INSTRUCTIONS DE MISE EN MARCHE CM N essayez pas de faire fonctionner cette chaudi re moins qu elle ait t d marr e AVERTISSEMENT ajust e et entretenue au moins annuellement par un technicien d entretien de chauffage qualifi ARR TEZ Lisez les informations de s curit ci dessus sur cette tiquette R glez le thermostat au niveau le plus bas
53. er Installation and operation manual l Read before beginning the installation Codes and standards Boiler compliances The 200i has been design certified by CSA for use with natural and propane gas under the latest revision of ANSI Z21 13 CSA 4 9 Gas Fired Low Pressure Steam and Hot Water Boilers and CAN1 3 1 Industrial and Commercial Gas Fired Packaged Boilers Each unit has been constructed and hydrostatically tested for a maximum working pressure of 100 psi 700 kPa in accordance with Section IV of the A S M E Boiler and Pressure Vessel Code Code compliances All aspects of the boiler installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest revision Where required by the authority having jurisdiction the installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 In Canada the installation must be in accordance with the requirements of CSA B149 1 or 2 Installation Code for Gas Burning Appliances and Equipment Commonwealth of Massachusetts If installing a 200i boiler in the Commonwealth of Massachusetts you MUST FOLLOW the additional instructions contained in Mestek s instruction sheet MA CODE Ifyou don t have a copy call your Mestek dealer or Mestek When installed in the Commonwealth of Massachusetts ensure th
54. er won t prematurely cycle on the limit function 5 When the DHW setting is complete press SELECT and BACK to return to the setpoint menus Set OP LIMIT operating limit 1 Use the same procedure as on the previous settings to change the operating limit temperature Use the arrow keys to select OP LIMIT then press SELECT 3 If the boiler setpoint is to be higher than 180 F you will need to increase OP LIMIT The maximum setting for OP LIMIT is 230 E So the maximum allowable boiler setpoint is generally 190 F 4 Once the setting is correct press SELECT then BACK to return to the setp oint menus The LIMIT BAND 1 Do not change the LIMIT BAND setting unless specific application demands require a change or when directed by the factory Return to main menus When the setpoints have all been adjusted as desired press the BACK key until you return to SETPOINTS INDOOR AIR General Use the indoor air reset option whenever possible The indoor air technology monitors space heating demand to help the boiler operate at the highest possible efhciency throughout the season To apply indoor reset you must wire the AR inputs and the HEAT DEMAND terminals as described in Section 7 Enable or disable IAR 1 The only setting for indoor air reset that you will need to make is to enable the function Use the arrow keys until the cursor points to INDOOR AIR 3 Press SELECT to enter the indoor air menus UM
55. es Figure 11 Suggested piping multiple boilers primary secondary piping reverse return boiler headers 41 Return 12 10 j 17 305 mm O from system lt Supply to system lt EN gt DHW tappings l 7 ji i7 4 PRE FRET 5 4 4 1 20010 LEGEND ee cececee 7 Flow check valve 12 Extra high limit when required Cold water fill line 16 Boiler postpurge circulator see page 11 1 200 boiler 9 Expansion tank shown with diaphragm type see 17 Header sensor required Ck page 12 for piping a closed type tank Expansion tank 2 Boiler circulator shown with diaphragm type see page 12 for piping Isolation valve a closed type tank 3 System circulator 10 Air separator with automatic air vent Replace air vent Temperature gauge 5 Indirect fired DHW tank with piping to the tank fitting on closed type expansion when used systems 6 DHW circulator 11 Low water cut off when required P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S f Water piping continued Multiple boilers parallel flow Sizing and flow control Size the boiler system circulator to handle the flow needs of all zones If using variable speed control ofthe boiler system circulator ensure that the flow never drops below the total minimum for all boilers connected Do not exceed the maximu
56. f Table 5 turn the boiler on off switch OFF 7 See the next page for instructions to adjust the gas valve low fire setting 8 If flame and CO O CO are acceptable proceed with set up page 40 No further gas valve adjustments are needed Replace the gas valve cover plate Remove the low fire jumper and replace the electrical panel cover 9 gt Changing from propane to natural gas or natural gas to propane When adjusting the boiler for a different gas the low fire gas adjustment must be changed using the procedure on page 39 P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual 12 When is low fire adjustment required NOTICE Adjust the gas valve low fire setting ONLY if the flame is unacceptable the CO2 O2 or CO are out of acceptable range or you are changing fuels You will need to remove the boiler jacket top and adjust the gas valve low fire setting as described below Starting the boiler continued The boiler jacket top must be removed when it is necessary to access the gas valve low fire adjustment screw or other interior components such as the blower mo tor Use the procedure below Removing the boiler jacket top 1 See Figure 30 2 Remove the three thumb screws securing the filter access plate 3 Remove and set aside the filter access cover and gasket 4 Pull back on the filter clamp and remove the filter 5 Hold the f
57. gure 22 shows the fac tory default values Accessing setup menus l 2 With the display in STANDBY press and hold the BACK key for 5 seconds The display will change to gt SETUP LIEU LOL Press the SELECT key to select oa Note that pressing the DOWN key would change the selection to VIEW LOG The display will now show the first options in the setup menus gt cogl U AA BOILERS Press the DOWN key to access additional menu options Pressing the DOWN button once will change the display to CHE U AA gt BOILERS The cursor moves to the second line indicating this option could now be selected with the SELECT key 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 NAS Y Figure 22 HeatNet display during Standby no call for heat pressing the DOWN key on the keypad changes the display as shown LOC SET O 180 Q DHI SET O STANUEY STANLEY 184 F HEHUER 184 F SUPPLY 70 F OUTSIDE 46 F RETURN 70 F HOO OLY bHE SHU ULY 12H IHR MHA Hi sl TEMP 188 F SAU ULY 145 F STANLEY STANLEY STANLEY O O O STANLEY STANLEY STANLEY O O O THMDE THMDE STANDBY Cast iron condensing boiler
58. h by installer 120VAC 60HZ 1Ph Power to boiler The boiler is shipped with a jumper across the HEAT z DEMAND terminals Remove l this jumper when using a thermostat or other external 4 20mA REMOTE HEAT DHW LOW HIGH control to start the boiler ENABLE IDEMANDIDEMAND FIRE FIRE Uon Use these terminals only during boiler setup as given in the Boiler manual eg a 4 lt te WE de EN i r f h m T t r k a TW i F gr hoy P i nl a M ES l an L i ra L Vent Det nt a a e er ine f p J L 2 ee we j t DHW tank aquastat when used A DHW circulator and circulator relay will be required Start the DHW circulator on call for heat from the tank aquastat Room thermostat end switches or relay contacts Connect thermostat zone valve end switches or remote start relay contact here Test when done to ensure no stray voltage is present on any of the wires See the Boiler manual for procedure 24 mA optional input for sequencing boilers or providing remote setpoint See details in the 200i Control manual 20202 P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Wiring and control setup continued Figure 21b 200i wiring summary see Figure 21 for locations see Boiler manual and Control manual text for
59. he transformer to be shorted out and damaged Verify 24VAC switched lead from thermostat Before connecting 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 24VAC hot lead to IAR terminal must come from switched side of thermostat Use voltmeter to verify that lead is unpowered when thermostat is open switch O10 Circulator relay typical 120VAC to circulator Circulator relay typical 120VAC to circulator l ia ama A ea aaa a ea l l l l l l l l l l l l l L VW Connect all end switch wires to the Heat Demand terminals on the electrical connection board 20206 P N 42 9470 1 12 Copyright 2012 Mestek Inc 49 d Cast iron condensing boiler Installation and operation manual l 6 Appendix A suggested wiring continued IAR Indoor Air Reset wiring when used Wiring for typical zone controller Heat Demand terminal connections The end switch leads from the controller must connect to the Heat Demand terminals on the electrical connection board as shown in Figure A3 IAR connections See Figure A3 for typical wiring to the IAR inputs when using a zone controller For other applications see the Control manual and Section 7 of this manual CAUTION Polarity The connections to the
60. hroughout this manual allows for domestic water heating without flow through the heating loop s This is important for sammer time operation of DHW tanks Flow balancing and control On large systems or when using a high head circulator install a differential pressure by pass valve to limit the head applied to the zone valves Make sure to incorporate flow check valves as shown These prevent forced Some systems may require balancing valves to control flow in the loops flow in idle zones Figure 8 Suggested piping single boiler zone valve zoning two pipe or series loop left or primary secondary piping right Additional zones Additional zones Zone2 13 a _ Er Le is O 117 10 lt r i ir O rT p i q 11 re Te P 8 Un TA 9 i 162 i Aa eS 20012 LEGEND ececceee 9 Expansion tank shown with diaphragm type 15 Differential pressure by pass valve Use when high see page 12 for piping a closed type tank head circulator may cause noise erosion or valve lifting 1 200i boiler Expansion tank shown with diaphragm type problems when only a few zone valves are open 2 Boiler circulator see page L2 fr pin e dosed type taili 16 Boiler postpurge circulator see page 11 el 10 Air separator with automatic air vent Replace air 4 eae Re vent with piping to the tank fitting on cl
61. ilter clamp back as in Figure 30 6 Squeeze the conical grommet sides and maneuver the grommet out of the opening in the jacket top 7 Ifthere is no air pipe attached to the air inlet leave the air inlet plate in place 8 Ifair is piped to the air inlet plate remove the air inlet plate and gasket by removing the four screws that secure it to the jacket top Make sure the air piping is properly supported 9 Remove the seven Phillips head screws securing the jacket top to the jacket sides 10 Lift off the jacket top Leave the wire harnesses connected 11 Move the insulation aside if necessary Adjusting the low fire setting DO NOT adjust the low fire setting unless low fire flame or combustion are unacceptable 1 See Figure 31 for the location of the gas valve low fire adjustment Use a 2 mm hex wrench 2 When adjusting the low fire setting make changes in half turn increments Allow the flame to stabilize before adjusting each time Reduce gas input if the flame or burner appears red 3 IfCO is too HIGH O too low REDUCE gas by turning the adjustment COUNTERCLOCKWISE one half turn at a time Recheck the analyzer and flame after each half turn 4 ICO is too LOW O too high INCREASE gas by turning the adjustment CLOCKWISE one half turn at a time Recheck the analyzer and flame after each half turn Replace the boiler jacket top 1 To replace the jacket top reverse this order above Make sure insulat
62. ion is in place 2 Slide the conical grommet over the blower inlet Then seat the grommet ring into the hole in the jacket top 3 Reattach the air inlet plate if it was removed Inspect the air piping to make sure it was not displaced 4 Pull the air filter clamp back Replace the filter gasket and access cover Secure with the three thumbscrews Replace the gas valve cover plate if removed 5 Remove the low fire jumper from the connection board Replace the electrical panel cover P N 42 9470 1 12 Copyright 2012 Mestek Inc Figure 30 Removing boiler jacket top 3 thumb screws gt a T Filter access plate gt Gasket Filter Air inlet plate Filter clamp 4 screws Conical grommet Filter clamp Figure 31 Blower 7 Gas valve adjustments Low fire setting 2 mm hex socket AN Gas valve SS Throttle adjustment high fire setting Cast iron condensing boiler Installation and operation manual S S WS gt NS I 2 Starting the boiler continued Measure flame current Electrical shock hazard The electrical box contains line voltage wiring and contacts Use caution when working in the electrical box to avoid contact with line voltage elements Power must be on to measure flame current 1 With the boiler operating at low fire low fire jumper in place measure the flame current 2 Remove the upper electrical panel cover u
63. ks Use either a soap suds mixture a gas leak detector or other suitable means After testing the system gas piping remove the gas valve cover plate on the left side of the boiler see illustration at right Inspect and leak test around the interior gas line and gas valve Replace the cover after completing the gas connection inspection and testing Cast iron condensing boiler Installation and operation manual Wiring a single boiler Figure 15 Electrical connection board see item 10 TENTS Electrical shock hazard Disconnect page 3 for location Also see the wiring Hell power sources to the summary illustrations on the next pages boiler before making any electrical connections Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing AVERTISSEMENT Au moment de l entretien des com mandes tiquetez tous les fils avant de les d brancher Des erreurs de c blage peuvent entra ner un fonctionnement inad quat et dangereux S assurer que l appareil fonctionne ad quatement une fois l entretirn termin Failure to comply with the above could result in severe personal injury death or substantial property damage Figure 16 120VAC power service terminals on electri NOTICE The electrical connections to this boiler cal connection board See Figure 15 for must be made
64. l After filling the condensate trap remove the fill hose Reattach the condensate line to the boiler condensate hose barb 4D ae hose barb w Q Turn on power and gas Turn on power to the boiler Open the manual gas valve Operating instructions Adjust system controls or thermostats to call for heat Read about the SmartCycle control display on page 34 Then start the boiler following the Operating instructions on page 35 page 36 for French version The boiler must be checked and adjusted if necessary after starting Once the boiler has started follow the instructions beginning on page 37 to check boiler operation and adjust as needed using instruments If the boiler doesn t start Check external limit controls low water cut offs etc to be sure they are closed Check the 200i SmartCycle control display for indications of faults Are SmartCycle control settings correct for the application Is the gas supply on and is gas pressure within acceptable range Are room thermostats or building controls calling for heat Are all electrical connections intact Ifnone of the above resolve the problem follow the trouble shooting guide in the 200i Control manual Cast iron condensing boiler Installation and operation manual I 2 Starting the boiler continued To reset the SmartCycle control from lockout Turn the boiler on off switch OFF then back ON Figure 24a SmartCycle
65. litates filling and reduces recirculation in the expansion tank piping Cold water fill Follow all applicable codes when connecting the cold water fill to the piping Use a backflow preventer where required See suggested piping on this and the following pages Also consider installing a water meter on the cold water make up line The water meter will show if excessive make up water is entering the system Figure 6 Diaphragm or bladder type expansion tank suggested piping Diaphragm type expansion tank Automatic air vent Cold water fill line Pressure reducing valve Backflow preventer Gate valve 1 Air separator Isolation valves woonawh W NN System circulator 10 System supply Expansion tank 11 System return charge tapping Figure 7 Closed type expansion tank suggested piping Closed type expansion tank Tank fitting Cold water fill line Pressure reducing valve Backflow preventer Gate valve Air separator Isolation valves on OO 4 RE wn System circulator 10 System supply 11 System return Undersized or waterlogged expansion tanks will cause excessive make up water to enter the system This will lead to section failure due to oxygen corrosion and lime deposits CAUTION P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S d Water piping continued Zoning with zone valves DHW operation when required The piping shown t
66. lways use an approved leak detection method Protect the boiler gas valve from excessive pressure When pressure testing system gas piping disconnect the gas piping from the boiler or isolate the boiler with the manual shut off valve if test pressure will be higher than 4 psig 3 5 kPa Item 3 For all gas supply piping use only clean burr free black iron pipe supported independently from the boiler gas connection Item 4 Install a ground joint union in the gas line for ease of installation and servicing Item 5 Provide a sediment trap at the bottom of the vertical section of the gas supply pipe upstream of the gas controls Item 6 The gas cock must be equipped with a pressure test port This test port is used to measure the gas supply pressure at the boiler The gas line components in Figure 14 are not supplied with the boiler They must be supplied by the boiler installer WARNING Always use a wrench on the gas grain components when making gas connections Never over tighten the piping components or a failure could result causing possible severe personal injury death or substantial property damage Figure 14 Connecting gas supply line Ca Use a 15 16 open end wrench Pai to secure the gas connection fitting when tightening gas line components to prevent damage to the 200i gas connection and internal gas line ON sy 1 Piping from gas supply 2
67. ly corrosive So the system water must be checked at least annually to ensure that the inhibitor is at the correct level Never use galvanized piping in a system that contains antifreeze Never use chromate water treatment Either of these will react with the inhibitor in the antifreeze mix Antifreeze concentration If not using a pre mixed antifreeze solution de termine the amount of antifreeze to add based on the total volume of the system piping the boiler and the expansion tank Follow the antifreeze manufacturer s instructions for the ratio of glycol required for the lowest expected exposure tem perature NEVER use a glycol mix greater than 50 Prevent leaks Glycol will escape more easily than water through any leak in the system So the glycol concentration will reduce if a leak is allowed to continue Eliminate all leaks in the system and have the owner frequently inspect the visible portions of the system for leaks periodically Do not use circulators or valves with packing glands the packing glands can weep Install a water meter Because the system must be installed with automatic water make up to ensure pressure will always be at least 12 psig you should install a water meter with one half gallon resolution on the make up water line This will allow monitoring to see if excessive make up water is entering the system Circulator sizing Glycol water mixtures do not move heat as well as water only The circulator si
68. m flow of 50 GPM through any boiler DHW operation when required When heating system boilers are piped in parallel as in Figure 12 connect the DHW tank as a zone off of the main header or install boilers dedicated to the DHW application Figure 12 Suggested piping multiple boilers parallel flow piping reverse return headers Supply to system Return from system El t t t 4 t 4 t f f oug j 1 1 1 1 1642 16 CZ 1642 164 f TT YT 1 j 20011 LEGEND 0 8 Cold water fill line 12 Extra high limit when required 9 Expansion tank shown with diaphragm type see 1 200i boiler page 12 for piping a closed type tank Expansion tank 16 Boiler postpurge circulator see page 11 shown with diaphragm type see page 12 for piping a closed type tank 4 Boiler system circulator 17 Header sensor required 10 Air separator with automatic air vent Replace air vent 5 Indirect fired DHW tank with piping to the tank fitting on closed type expansion Isolation valve when used systems 6 DHW circulator 11 Low water cut off when required Temperature gauge P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Chilled water systems General Provide the piping components shown in Figure 13 when connecting a boiler to a chilled water system The check valve item 4 prevents chilled wa
69. mic fiber materials poe must have the following equipment Electric multimeter Ammeter Surface temperature gauge Metric Allen wrenches Pressure differential gauge or included DP manometer 3 Gas pressure meters Two 0 14inches WC One 0 S psi Combustion analyzer You must use a Sebastien analyzer and follow all instructions in this manual to correctly start up the boiler As prescribed in this manual the O levels must be between 5 and 7 Throughout all firing rate conditions the burner surface must never show red areas Follow manual procedures to correct this condition zol ler water You must thoroughly flush the system with the boiler isolated from the system to remove sediment Existing systems in particular often contain large amounts of iron sediment Excess suspended solids in the water can lead to premature boiler failure High efficiency equipment requires suitable water for reliable operation Follow the ASME recommendation for water treatment on hydronic applications that have dissolved solids greater than 200 parts per million Fill water must be softened if the solids concentration is higher than this See additional guidelines in this manual Do not allow the boiler to operate with frequent introduction of make up water Correct all problems causing leaks relief valve weeping or other factors that could cause fresh water to be added Do not use automotive anti freeze in the boiler waterways If the use
70. n established Q Vent air piping installed correctly L Air purged from water system L Boiler operated through several cycles L Air vents checked and opened as needed D Limits and interlocks tested o L Water piping correct and operational Q Metered gas input natural gas L Gas supply pressure tested verified _ DHW system tested if applicable Q Gas supply piping correct L Explained User s manual to owner Q Flame observed and combustion tested Q Instruction manual will be kept at site Service history complete before leaving boiler site after service Service date Technician Service company address E Describe service performed Service date Technician Service company address Describe service performed Service date Technician Service company address o Describe service performed Service date Technician Service company address Describe service performed Mestek Inc 260 North Elm St Westfield MA 01085 413 568 9571 P N 42 9470 1 12 Copyright 2012 Mestek Inc
71. n the 200i Vent Air manual The vent installation must meet requirements for direct vent when air is ducted to the boiler air intake or ANSI Category IV venting when air is taken from the boiler room DO NOT install a 200i boiler on a common vent system All 200i boilers must be individually vented Failure to comply could result in improper operation of any of the appliances on the vent system resulting in possible severe personal injury death or substantial property damage 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 BEFORE PROCEEDING FURTHER Install the vent and air piping according to the 200i Vent Air manual Common vent systems If an existing boiler is removed from a common venting system the common venting system may then be too large for the proper venting of the remaining appliances connected to it At the time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation 1 Seal any unused openings in the common venting system 2 Visually inspect the venting system for proper size and hori zontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an
72. nated with fluorocarbons or other halogenated compounds such as cleaning solvents and re frigerants will result in the formation of acids in the com bustion chamber These acids will cause premature failure of the boiler Construction dust If the boiler is operated while the building is under construction it must be protected from wood concrete sheet rock and other types of dust Failure to properly protect the boiler from construction dust will damage the boiler If the boiler has been operated with contaminated air it must be thoroughly inspected Where possible boiler com ponents must be cleaned following instructions provided in this manual and or supplementary instructions from Mestek Where cleaning is not possible the boiler may have to be replaced Never store combustible materials gasoline or any product containing flammable vapors or liquids in the vicinity of the boiler Clearances All installation must provide the minimum clearances to combustible materials given on page 8 The installation should provide the minimum service clear ances given on page 8 when possible If these clearances cannot be met then Ensure that boiler components can be accessed for operation start up maintenance as required in the 200i manuals Cast iron condensing boiler Installation and operation manual 3 Installation site preparation continued Clearance requirements Clearances to combustible surfaces WARNING
73. ndensate pump termination If no gravity drain is available install a condensate pump Use only a pump designed for use with condensing furnaces and boilers The pump must have an overflow switch to prevent damage from overflowing 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 P N 42 9470 1 12 Copyright 2012 Mestek Inc Condensate line requirements WARNING Failure to adhere to the following could result in condensate line leakage resulting in potential for severe personal injury death or substantial property damage Q Use only silicone rubber tubing 3 s inch 9 5 mm diameter Q Protect the condensate line from damage and secure it in position LJ Terminate the condensate line at an appropriate drain Q Do not install the condensate drain line such that it could be exposed to freezing temperatures Q Install a condensate pump if no appropriate drain is available Q Install a condensate neutralizing system when required Figure 23 Connecting a condensate drain line Y2 inch condensate drain tubing is factory installed connected at boiler condensate connection and J trap hose barb Cast iron condensing boiler Installation and operation manual 11 Fill and test the system _ Failure to adhere to the following could result in
74. o accurately measure flue gas analysis and adjust the boiler as needed could result in severe personal injury death or substantial property damage 1 After the boiler has cycled off loosen the hose clamp covering the flue gas sam pling hole Figure 27 CAUTION The flue gas vent pipe may be hot Touching the pipe with unprotected skin could result in a severe burns Slide the hose clamp off of the sample opening Insert the combustion analyzer probe into the sample opening If using an electronic analyzer zero and calibrate it before proceeding a de i IS If using a chemical analyzer make sure that the fluid is fresh and is at room tem perature Have a monoxer and test tubes available to test carbon monoxide levels Check high fire operation 1 Remove the electrical panel cover on the right side of the boiler see item 11 page 3 asin Figure 28 Electrical shock hazard The electrical box contains line voltage wiring and contacts Use caution when working in the electrical box to avoid contact with line voltage elements Turn off power to the boiler panel if necessary 2 Connect a jumper wire across the high fire terminals of the connector board Figure 28 These terminals are located on the lower row as shown 3 Turn the boiler on off switch ON The boiler will start at about 30 of maximum input and immediately go to high fire S Observe the flame through the flame window left side of boiler see Figure 29
75. o warm to room temperature before handling CAUTION Do not drop the boiler or allow the jacket to bump against the floor or wall when handling CAUTION 1 Remove the crate from the skid But leave the boiler on the skid to move the boiler near its location 2 Inspect the boiler thoroughly for any possible damage that may have occurred in shipping or handling 3 Slide the boiler off of the skid into position Use a spirit level to check whether the boiler sides and front are vertically plumb If not slide metal shims under the base until the boiler is level Install the relief valve Check relief valve pressure setting Inspect the boiler relief valve before installing to ensure it is set at the pressure required for the system You should also verify that all water system components are rated for at least the pres sure setting of the relief valve to avoid component damage due to excess pressure WARNING The boiler maximum allowable working pressure is 100 psig 700 kPa The relief valve must never have a setting greater than 100 psig Usinga higher pressure relief valve could result in an explosion causing possible severe personal injury death or substantial property damage Connecting the relief valve Connect 34 inch NPT black iron pipe and fitting so the relief valve as shown in Figure 4 Follow all instructions provided in the relief valve manufacturer s instructions and labeling WARNING Never install
76. oiler is set up for the type of gas available at the installation site Verify location is suitable Ensure the availability of an adequate electrical supply uncontaminated air for combustion and that vent and air piping can be correctly installed Ensure the boiler can be connected to system water piping and gas supply The boiler must not be exposed to dripping or spraying water or to rain If replacing an existing boiler find out what caused the boiler to fail before installing a new boiler Correct the problems that led to failure or the failure may happen to the new boiler Do not install or operate the boiler or leave an installation without complying with all of the following and with all information supplied in the boiler manuals Should overheating occur Do not shut off power to the circulators if the boiler should overheat or the gas supply fail to shut off Instead shut off gas supply to the boiler with a manual valve in the gas supply line NE servicing or operating the boiler Disconnect electrical power when servicing the boiler to avoid potential for electrical shock Allow the boiler components and water to cool before attempting to remove or handle boiler parts Do not add cold water to the boiler if it is hot Allow the boiler to cool completely before introducing cold water Do not operate the boiler if any part has been under water Follow the guidelines in the Maintenance section for dealing with fiberglass and cera
77. olling baftle assembly Premix burner Premix means the air and gas are mixed before they enter the burner The mixing of gas and air in the blower and piping ahead of the burner causes a uniform gas air mix in the burner providing reliable op eration with low excess air The result is exceptional combustion efficiency The burner consists of a high temperature stainless mesh secured to a stainless steel distributor plate The design causes uniform flame across the entire surface of the burner and the ability to operate at very low firing rates The flame is ignited with direct spark electrodes and an electronic ignition control Flame is proven using a flame rod flame rectification sensing Because of its low excess air operation and controlled combustion the burner also provides low NO emissions and quiet operation Gas valve blower and venturi Most gas valves regulate at a positive pressure downstream of the valve typically 312 inches water col umn But the 2001 gas valve regulates to ZERO pressure downstream This is called a zero governor valve The advantage is that gas will only flow if something lowers the pressure downstream of the valve below zero That is just what happens when the blower pulls air through the venturi As the air speeds up to pass through the narrow throat of the venturi a vacuum forms in the throat The more air that flows through the throat the greater the vacuum The gas valve raises the negative
78. om your distributor In stall the new burner If the burner is fouled with debris attempt to clean by using a shop vacuum Be careful not to damage the burner surface If the burner cannot be cleaned obtain a replacement from your distributor Inspect the ceramic fiber chamber item 3 Figure 37 and fiber gasket item 2 Figure 37 Make sure they are in good condition or replace Replace the burner or install a new one Replace all components in the reverse order from above WARNING Use extreme care when replacing the upper section cover The seal must be secure to avoid potential of carbon monoxide leakage or heat damage caused by flue gas spillage Inspect all components to ensure they are in good condition and correctly installed Soap suds leak test the gas line particularly the ground joint union to ensure the gas line is intact after servicing Follow servicing by a complete start up test procedure of the boiler Figure 35 Preparing to remove upper section cover Figure 36 Upper cover bolt locations Figure 37 Burner and chamber P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Ma i nte nance continued P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual l 5 Replacement parts DECO 2 ns Jacket Panelassemby O 1 ART O 7 can Sema O 2 soo combustion ASit 1 ems cas
79. only your hand to turn the gas valve handle Never use tools If with an ignition device which automatically the handle will not turn by hand don t try to repair it Call a lights the burner DO NOT TRY TO LIGHT THE qualified service technician Force or attempted repair may result BURNER BY HAND inafire or explosion B BEFORE OPERATING smell all around the boiler Do not use this boiler if any part has been under water area for gas Be sure to smell next to the floor Immediately call a qualified service technician to inspect the because some gas is heavier than air and will boiler and to replace any part of the control system and any gas settle on the floor See below control that has been under water WHAT TO DO IF YOU SMELL GAS e Donottrytolight any appliance e Immediately call your gas supplier from a phone outside of Donottouch any electric switch do not use any the building Follow the gas supplier s instructions phone in your building e Ifyou cannotreach your gas supplier call the fire department PE OPERATING INSTRUCTIONS P Do not attempt to operate this boiler unless it has been started adjusted and main WARNING tained at least annually by a qualified heating service technician STOP Read the safety information above on this label Set the thermostat to lowest setting Turn off all electrical power to the boiler Press the boiler ON OFF switch to OFF DO NOT TRY TO LIGHT THE BURNER BY HAND Turn manual gas v
80. ors Caulking or sealants are applied to areas such as joints around windows and door frames between sole plates and floors between wall ceiling joints between wall panels at penetrations for plumbing electrical and gas lines and in other openings Conversion factors In 1 000 BTUH to cm kw Multiply In 1 000 BTUH times 22 In2 2 000 BTUH to cm2 kw Multiply In2 2 000 BTUH times 11 In2 3 000 BTUH to cm2 kw Multiply In2 3 000 BTUH times 7 4 In 4 000 BTUH to cm kw Multiply In 4 000 BTUH times 5 5 P N 42 9470 1 12 Copyright 2012 Mestek Inc Figure 3 Air opening options for combustion air drawn from boiler room PU Ifother appliances are located in the same room as the boiler increase the size of air openings to provide the free area required for the other J appliances in addition to the air required for the 200i boiler s ventilated attic _ LEE Interior Wall ne Boiler room Upper openings U must be within 12 inches of the ceiling Lower openings L must be within 12 inches of the floor Option 1 air openings through interior wall When air is supplied to the boiler room through openings in an interior wall air supply from inside the building size each opening to provide minimum free area of 1 in per 1 000 BTUH of all 200i boilers in the room Option 2 air openings through outside wall When air is supplied to the boiler room through openings in an ou
81. osed type 17 Header sensor required where shown 5 Indirect fired DHW tank eua Isolation valve when used 11 Low water cut off when required 6 DHW circulator 12 Extra high limit when required JF Purge valve Suggested locations allow for improved 7 Flow check val 13 Zone valve system filling and draining and initial air elimination ow check valve 8 Cold water fill line 14 Zone circulator Temperature gauge 13 P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual S f Water piping continued Zoning with circulators DHW operation when required The piping shown throughout this manual allows for domestic water heating without flow through the heating loop s This is important for sammer time operation of DHW tanks Sizing and flow control Size circulators to provide the flow needed for the individual zones Provide flow check valves where shown to prevent gravity circulation or Make sure to incorporate flow check valves as shown These prevent forced forced flow in idle zones flow in idle zones Figure 9 Suggested piping single boiler circulator zoning two pipe or series loop left or primary secondary piping right Additional zones Additional zones ares Fa j a i L EL LJ e a pne oo p _ __ S p ro 20013 LEGEND e oss 9 Expansion tank shown
82. perature gauge Jacket Inlet air filter access panel Blower 2 3 4 Cast iron section assembly 5 6 7 200i SmartCycle control with keypad and display Venturi assembly Pressure switches blocked flue and blocked air inlet Control connection board Electrical box power and control entrances Water return connection Air inlet sleeve Relief valve Relief valve piping by installer Water supply connection Fenwalignition module Ignition electrodes flame rod assembly Control transformer 120 24 VAC Postpurge circulator factory installed and piped Vent connection sleeve with flue gas sampling port Condensate tubing connection Upper section cover and premix burner Gas connection 2 NPT 2001 components P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Contents Read before beginning the installation 2 Boiler ratings and specifications 3 Installation site preparation 4 Preparetheboiler S Water DIDING ss ewe ee ee 6 Gas DIDING svs heh awe he ee 7 Wiringasingleboiler 8 Controlsetup Q Vent piping and air piping when used 10 Condensate drainline 11 Fillandtestthe system 12 Startingtheboiler 13 Annualstart up 14 Maintenance
83. pper right side of boiler 3 Attach microammeter leads to the flame current test pins of the Fenwal ignition module as in Figure 32 4 The flame current should be approximately 6 microamps and never less than 1 mi croamp Record the flame current value on the back page of this manual S Ifflame current is acceptable continue with setup If flame current is too low check the ignition electrode flame rod assembly following the instructions in the Main tenance section of this manual Check boiler modulation 1 Remove the low fire jumper from the electrical connection panel see Figure 28 2 The boiler firing rate should change to meet demand The SmartCycle control dis play will show the percentage of maximum firing rate between 20 and 100 Test flame failure modes Flame loss 1 With the boiler running in normal operation close the manual gas valve on the incoming gas line 2 Within 0 8 second after the flame goes out the boiler gas valve should shut off 3 The SmartCycle control will restart operation with prepurge then continue through a normal start cycle 4 With the manual gas valve closed the boiler should attempt ignition three times then lockout as described below Ignition failure Make sure there is a call for heat Turn the boiler on off switch OFF Close the manual gas valve on the gas supply line Turn the boiler on off switch ON The boiler should start a regular cycle Se D o When
84. pressure in the venturi to zero by letting gas flow The lower the pressure in the venturi throat the more gas will that will flow So gas flow automatically adapts to air flow ensuring consistent gas air mix throughout the boiler s modulating range Thus the 2001 SmartCycle electronic control regulates the blower speed to control boiler firing rate 2001 SmartCycle control The 2001 SmartCycle electronic control consists of a microprocessor based module and a keypad display unit for user interface The control regulates boiler water temperature by adjusting boiler firing rate by varying the blower speed The control considers how fast the temperature changes and how the temperature varies over time to establish the best firing rate to meet demand Options include an outdoor sensor for outdoor reset operation and an indoor reset option Indoor reset monitors up to 8 zone ther mostats and determines a maximum firing rate needed to meet the demand This keeps the boiler at the highest possible efficiency In addition the control can be set for multiple boiler operation either stand alone or utilizing Mestek s on board SmartCycle technology The control also automatically cycles the factory installed postpurge circulator to equalize residual heat in the boiler after firing P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual 5 Components 1 Gas valve Pressure tem
85. r before handling Place ceramic fiber materials in a plastic bag and seal to dispose Avoid blowing tearing sawing or spraying fiber glass or ceramic fiber materials If such operations are necessary wear extra protection to prevent breathing dust Wash work clothes separately from other laundry Rinse clothes washer thoroughly afterwards to pre vent contamination of other clothing NIOSH First aid procedures Eye exposure irrigate immediately Breathing fresh air P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Ma i nten ance continued Cleaning the air filter 1 Turn the boiler on off switch OFF Remove the three thumb screws that secure the filter access plate see Figure 33 Remove the filter access plate and gasket Pull the filter clamp back and remove the air filter Inspect the filter and the filter enclosure area for dust or debris So ee D Clean the filter ifnecessary by washing under running water Shake off excess water and towel dry WARNING If the filter 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 this section Accumulation of debris in the burner can result in burner damage and potential for severe personal injury death or substantial property damage 7 Ifthe filter is damaged or cannot be cle
86. r shutdown 1 Enable or disable outdoor shutdown by pressing the SELECT button with the cursor on OA SHUTDOWN Use the arrow keys to change from ON to OFF Press SELECT to save then BACK to return 4 Then arrow key to OA SETPT to set the desired outdoor air shutdown tempera ture 5 Press SELECT and the cursor will move to the temperature Use the arrow keys to change the setting Press SELECT then BACK to accept and return Outdoor reset when desired 1 To set outdoor reset operation use the arrow keys until the cursor points at OA RESET The default setting is ON To change the setting press SELECT and use the arrow keys to change from ON to OFE Press SELECT then BACK 5 Ifoutdoor reset is enabled set the reset temperatures as follows 6 Use the arrow keys until the cursor points at SET OA SETPTS P N 42 9470 1 12 Copyright 2012 Mestek Inc 10 11 12 13 14 Press SELECT and the display will show gt LOW WATER 144 F a Hl UH 7A F Dont use the arrow keys yet but if you use the DOWN arrow twice the display will show HI WATER i188 F a LOW OH With the cursor on the setting you want to change press the SELECT key then use the arrow keys to change the temperature as you did for SETPOINTS 18 F LOW WATER HI OA Set for the supply water tem perature desired when the outside air is at the temperature when no heat is needed HI OA This should generally be
87. rcuit Size system and other circuit piping based on a 20 F temperature drop through the zones For water source heat pump systems the primary circuit flow rate will usually be based on a S F temperature drop Such high flow systems must be piped with the boiler on a separate loop Piping guidelines Support the piping All piping and a components must be supported such that no loads or stresses are applied to the boiler Allow for thermal expansion in the piping design and passageways The piping diagrams in this manual omit piping components such as unions Always install unions where needed to simplify piping and improve serviceability Circulator requirements Boiler cine circulator The postpurge circulator supplied with the 200i Figure 4 factory piped between the boiler Mme 20 and return connections is NOT intended for use in the system It must remain connected as supplied The postpurge circulator is only used by the 200i for postpurge flow to remove residual heat in the combustion zone The postpurge circulator includes an integral check valve to prevent by pass flow during operation P N 42 9470 1 12 Copyright 2012 Mestek Inc The 200i boiler requires a continuous minimum water flow for proper operation The circulator for the boiler must be sized to overcome the head loss of the boiler and the heating system in order to achieve the required temperature rise If the system contains hydronic antifreeze thi
88. re yet ON at purge RPM 55 of maximum 10 seconds PRE PURGE when supply temperature drops below the bottom of the heat band Flame is sensed ON at ignition RPM 30 of maximum 6 seconds CES 30 Stabilization period Operate on demand ON at RPM based on demand control Demand RUN XXX determines firing rate based on demand and rate of change etc End call for heat ON at purge RPM 55 of maximum OFF OFF POSTPRGE o POST PRGE Ignition failure ON at purge RPM Normal display unless three attempts fail then shows Boiler restarts a normal sequence IGN LOCKOUT alternating to Control will try 3 times then lockout Date amp Time of lockout Flame failure 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 Cast iron condensing boiler Installation and operation manual l 2 Starting the boiler continued Figure 25 Operating instructions for starting boiler only follow manual instructions to check boiler operation and adjust as needed BE FOR YOUR SAFETY READ BEFORE OPERATING Wa WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This boiler does not have a pilot It is equipped C Use
89. rminals IAR on all but one of the zone valves This 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 IAR negative terminals IAR DHW wiring To operate the boiler for domestic water heating with a storage tank install and pipe the tank according to the tank manufacturer s instructions and the recom mended piping diagrams in this manual Consult the factory for applications not Capen oneenaae Q 24VAC 9 covered The circulator used for DHW must be operated by a circulator relay or zone con V WV troller that is activated when the tank aquastat calls for heat Connect all end switch Mie Ere wires to the Heat Demand Connect the tank aquastat terminals across the DHW DEMAND terminals on terminals on the electrical 120VAC the electrical connection board as shown in Figure 21 connection board 20205 H N P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual Wiring and control setup continued Figure 21a 200i wiring summary see Boiler manual and Control manual text for additional information Also see page 20 POWER SERVICE J H sh le i EIEI Eri rs Electrical connection board Located in center panel on boiler right side 15 amp fused service switc
90. rsonal injury death or substantial property damage Accessibility The boiler must be accessible from both the right and left sides in order to do a correct start up adjustment Make sure the flame window on the left side and the gas valve throttle adjustment opening in the jacket top are accessible See Figure 29 page 38 Follow the start up checklist Perform the start up check list procedures before starting the boiler Turn off power and fuel supply Turn offelectrical power to boiler ifnot already off Close the main manual gas valve at the boiler Verify the gas type Check the boiler rating plate to make sure that the boiler is for the type of gas that will be used If it is not do not the boiler will have to be adjusted for the correct gas for both high fire and low fire Install boiler per manuals Read and follow all boiler instructions including this Boiler manual the 200i Vent air manual and the 200i Control manual All water piping gas piping vent piping and air piping must be complete before starting the boiler Check gas piping for leaks Check all gas piping for leaks including the boiler interior gas piping and connections per page 19 of this manual Never leak test with flame Never use an open flame to test for gas leaks Always use an approved leak detection method Propane gas applications The odorant in propane gas can fade over time reducing or eliminating the gas odor This makes the gas
91. s must be considered when sizing the pump The temperature rise across the boiler must never exceed 100 F 55 6 C CAUTION Boiler pressure drop Assume a pressure drop of 1 9 feet WC 0 7 meter for a flow rate of up to 18 GPM 68 LPM 7 5 feet WC 2 3 meters for a flow rate of up to 36 GPM 136 LPM Maintain boiler flow rate between 2 GPM and 36 GPM 7 6 to 136 LPM Boiler and system circulators See the following pages for suggested piping for 200i boilers All circulators are sup plied by the installer except the factory installed postpurge circulator Boiler circulator the circulator that flows water through the boiler System circulator the circulator that flows water through the system but not through the boiler Boiler system circulator a circulator that flows water through the boiler and the system Circulator activation See section 7 of this manual and the 200i Control manual for instructions on wiring boiler and system circulators The 200i SmartCycle Control provides an isolated contact to operate the boiler circulator or boiler system circulator The system circulator must be activated by a relay supplied by the installer This relay is usually activated by the system control or thermostat Additional controls Local codes or job specifications may require the use of additional controls such as low water cut offs flow switches and high limit controls Refer to the 200i Control manual
92. servation port on the LEFT side of the boiler must be accessible to view the combustion chamber during boiler start up Make sure that the installation allows serviceman access to the left side for this purpose Table 2 Recommended minimum clearances for service operation Figure 2 Figure 1 Clearance to combustibles references Figure 2 Service operation clearance references P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual 3 Installation site preparation continued Combustion air requirements Air ducted to boiler air intake If air is ducted from outside to the boiler air intake follow instructions in the 200i Vent Air manual to size and install the air piping If the boiler is located in a small room clearances less than the recommended SERVICE OPERATION clearances given in Figure 2 No other appliances in the room Provide two ventilation openings through one of the enclosure walls 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 floor Other appliances in the same room The room must have combustion air openings sized for the other appliances Increase the free area of the air openings by one square inch per 1 000 BTUH of the 200i boilers located in the room
93. set equal to room temperature or 70 F unless the applica tion calls for another setting HI OA Set this to the outside temperature at which no heat is needed usually 68 F or lower HI WATER LO OA Thisis the required supply water temperature at design heating conditions i e when outside air temperature is at ODT the outdoor design temperature or maximum heating conditions This temperature would typically be 180 for finned tube baseboard systems LO OA This is the ODT or design outdoor temperature for maximum heating requirements from the system Use the arrow keys to navigate to each of the above Then adjust as required Return to main menus NOTICE When you have finished with outdoor reset return to the main menus by using the BACK key Set the system clock Use the arrow keys in the main menus to navigate to SYSTEM CLOCK Use the procedures used for SETPOINTS and other adjustments to select and modify TIME DAY OF WEEK MONTH DAY and YEAR Because the events log gives time of occurrence it is best for the system clock to be correct After completing setup press the BACK key until the display returns to STANDBY Then turn off power and the boiler on off switch Reconnect HEAT DEMAND and DHW DEMAND wires 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 i
94. strations and O Control manual for 4 EE pe 120VAC 60HZ 1Ph fe more information 7 i l oO NO A A a Dry contact out to remote alarm Se a i Alarm contact closes on open or 24VAC transformer ie shorted sensor ignition lockout E i flow switch or user interlock gt combustion air damper failure blocked flue or blocked air inlet U LL Boiler circulator S or RUN ad Jul DO NOT directly connect circulator e 120 VAC g circulator if motor is over 1 4 HP ane son Use a motor contact or relay N nl 120VAC Figure 18 Wiring the boiler circulator using a relay or pita ie starter required for motors over 1 4 hp no 4 120VAC 60HZ 1Ph Fused service switch by installer i N O H k N Gnd 120 VAC i Boiler circulator or boiler system circulator Postpurge Boiler circulator on ci rcu lator or boiler system circulator P N 42 9470 1 12 Copyright 2012 Mestek Inc 120 VAC Cast iron condensing boiler Installation and operation manual 7 Wiring single boiler continued Sensor wiring Figure 20 Indoor Air Reset wiring to IAR terminals with bat 4 wire zone valves and no zone controller No sensor wiring is necessary unless see Figure 21a for terminal block 6 location Outdoor reset application To operate with outdoor reset purchase and install an outdoor sensor Mount the sensor such that it is shielded from direct sunlight if aoe I ee TU i
95. sure If it cannot hold pressure the membrane may be damaged If the system pressure is allowed to rise too high the boiler relief valve will open allowing water to escape from the system The resultant addition of make up water will cause mineral deposits and oxygen corrosion in the boiler Final checks After the system is cleaned filled and purged and the system pressure is correctly set make sure the water chemistry is correct The pH and chemistry must be as required and specified by the chemical treatment specialist when required Make sure all valves are correctly set Isolation and fill valves should be open before start up Purge valves must be closed Open the valve on each automatic vent in the system about one quarter turn to allow venting Thoroughly inspect the system for leaks or weeping valves Eliminate all system leaks to prevent excessive make up water which introduces oxygen as well as lime forming minerals This can lead to heat exchanger damage resulting in possible severe personal injury death or substantial property damage Watch the boiler pressure temperature gauge throughout the start up process Make sure the pressure never drops below 12 psig and never goes higher than 80 of the boiler relief valve setting pressure IN M Cast iron condensing boiler Installation and operation manual 12 Starting the boiler Failure to adhere to the following could result in severe pe
96. system over the last season If the homeowner or boiler operator identifies boiler or system problems identify the cause and adjust or repair as necessary Q Inspect the air filter Remove inspect and clean if needed the air filter See instructions in the Maintenance section Ifthe filter 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 P N 42 9470 1 12 Copyright 2012 Mestek Inc obstructed heat exchanger could result in severe personal injury death or substantial property damage Q Verify boiler water treatment If the system requires water treatment make sure the treat ment is being performed as required Ensure that the water softener 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 refill the system as indicated LI Check expansion tank amp air
97. ter from entering the boiler loop Sizing and flow control Size the system circulator to handle the flow needs of all zones If using variable speed control of the system circulator ensure that the flow never drops below the total minimum for all boil ers connected Figure 13 Closed type expansion tank Tank fitting Cold water fill line Check valve Strainer Balancing valve Air separator Isolation valves oon OO Un E WN System circulator 10 System supply 11 System return 10 Water pi pi n g continued The boiler loop can be any of the designs in this manual or per standard engineering practices Use the balancing valve to adjust the boiler loop flow Expansion tank air control Chilled water systems generally use closed type expansion tanks DO NOT use automatic air vents in these systems All air must be return to the expansion tank for the system to operate reliably If the boiler loop is connected to air handling units that use chilled water install flow control devices to prevent gravity circulation in the boiler loop during the cooling cycle in the air handling units CAUTION Suggested piping boilers connected to chilled water systems APM Chiller loop P N 42 9470 1 12 Copyright 2012 Mestek Inc Boiler loop 20014 Cast iron condensing boiler Installation and operation manual 6 Gas piping Check the gas type The 200i comes from th
98. terminals with 3 wire zone valves and no zone controller see Figure 21a for terminal block 6 location Onr et be wi Gi bi Wiring for circulator relays relays must have 24VAC common terminals Relays must have a 24VAC common terminal The IAR inputs require a connection to the 24VAC common of the circulator relay to operate If the circulator relays do not have a 24VAC common terminal you cannot connect to the IAR inputs To operate with indoor reset T you will have to remove the existing relays and replace with a circulator zoning controller or install relays that provide a 24VAC common I I i l l l terminal IAR1 IAR2 IAR3 IAR4 IAR5 IAR6 IAR7 IAR8 T AN PE e Heat Demand terminal connections using circulator relays The end switch leads from the relays must connect to the Heat Demand terminals on the electrical connection board as shown in Figure A2 To other circulator relays up to 8 zones total IAR connections See Figure A1 for typical wiring to the IAR inputs when using circulator relays For other applications see the Control manual and Section 7 of this manual CAUTION Polarity The connections to the IAR positive terminals IAR must be as shown in Figure A2 The connections to the IAR negative terminals IAR must be from the 24VAC common terminals of the circulator relays as shown Connecting the wires incorrectly can cause t
99. the room To fill the trap Temporarily attach a 3 s inch clear plastic hose to the con densate hose barb see Figure 23 Attach a funnel to the othe end of the hose and hold the funnel so it is higher than the hose barb Pour water into the funnel until water backs up into the tube Remove the temporary plastic hose WARNING The condensate trap must be filled when firing the boiler to prevent flue gases from escaping into the room Condensate line installation Condensate tubing material The condensate tubing must be silicone rubber 3 s inch 9 5 mm diameter Attachment Feed the silicone rubber tubing through the condensate line exit opening and slide the tubing end onto the condensate line hose barb as shown in Figure 23 Securing protecting the condensate line Secure the tubing Secure the condensate line to the floor with clips or other means to prevent movement Protect tubing from damage If foot traffic poses a risk to the tubing install a cover over the tubing or some other means to protect it from damage or movement Prevent freezing Do not route the line through or termi nate the line in any area that could expose the condensate to freezing temperatures Floor drain termination If the condensate line can be routed to a floor drain and ap plicable codes do not prohibit draining untreated condensate terminate the condensate line so condensate can reliably flow to the drain Co
100. tion must be replace after completing this work to 6 10 11 12 13 14 15 16 17 prevent overheating of the gas valve blower and jacket top To access the bolts and nuts that secure the upper section cover Remove the sheet metal cover plate at the flame observation window item 1 Figure 35 Remove the plastic plug from the jacket rear item 2 Figure 35 Remove the upper electrical panel cover plate item 3 Figure 35 Removing these items provides open end wrench access to the inch bolts and nuts Remove the seven 4 inch bolts nuts and washers that secure the upper section cover item 2 Figure 36 Note for reinstallation that there is a flat washer on both sides of the assembly and a lock washer on top Disconnect the three wire harnesses at the gas valve and blower items 2 and 3 Figure 36 In this illustration the wires are not shown Lift the upper cover plate blower gas valve assembly off of the section assembly The upper section cover gasket is adhered to the bottom the cover with silicone RTV The burner is now exposed Lift the burner up as in Figure 37 and inspect both sides The burner gasket is adhered to the bottom the cover with silicone RTV 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 tive action If the burner is damaged obtain a replacement burner fr
101. to comply could result in severe personal injury death or substantial property damage P N 42 9470 1 12 Copyright 2012 Mestek Inc Figure 33 Accessing the air filter 3 thumb screws gt a T Filter access plate Gasket Filter Filter clamp Figure 34 Electrode flame rod assembly inspection Electrode flamelrod assembly 5 Tip spacing must be 1 8 inch 3 2 mm Electrodes Flame rod Cast iron condensing boiler Installation and operation manual Z NAS NO 14 j Maintenance continued Accessing the burner WARNING If the filter enclosure and blower inlet show signs of drywall dust construction debris or other deposits you may need to inspect the burner Follow the procedure below Accumulation of debris in the burner can result in burner damage and potential for severe personal injury death or substantial property damage NOTICE Perform this procedure only if evidence indicates the burner may be l 2 3 4 fouled or damaged Turn the boiler on off switch OFF Close the manual gas valve Remove the boiler jacket top following the procedure given on page 39 Disconnect the gas supply piping at the ground joint union installed adjacent to the boiler Carefully remove the upper insulation item 4 Figure 35 that covers the upper section cover See Figure 35 Set the insulation aside for reuse WARNING The upper insula
102. tside wall air supply from outside the building size each opening to provide minimum free area of 1 in per 4 000 BTUH of all 200i boilers in the room Option 3 horizontal ducts to outside wall When air is supplied to the boiler room through horizontal ducts to an outside wall air supply from outside the building size each opening to provide minimum free area of 1 in per 3 000 BTUH of all 200i boilers in the room Option 4 openings to attic crawl space Air openings can be connected to a ventilated attic or crawl space The upper opening must be to the attic The lower opening can be a vertical duct from the attic or an opening in the floor from the crawl space Size each opening to provide minimum free area of 1 in per 3 000 BTUH of all 200i boilers in the room Option 5 single opening not shown A single opening directly connected to the outdoors through a wall or a vertical or horizontal duct can be used if the installation provides the clearances of Figure 2 and the top of the opening is within 12 inches of the ceiling Size the opening to provide minimum free area of 1 in per 3 000 BTUH of all 200i boilers in the room Cast iron condensing boiler Installation and operation manual Prepare the boiler Remove the boiler from the crate Cold weather handling The boiler jacket includes plastic parts If the boiler has been in a cold environment below 0 F allow the boiler t
103. undetectable by smell Before start up and periodi cally afterwards have the propane supplier check verify the odorant level Never attempt to measure gas valve outlet pressure Do not attempt to measure the boiler gas valve outlet pressure The high negative pressure in the venturi can suck fluid out of a manometer pulling it into the gas valve This would destroy the gas valve rendering it unusable Should overheating occur or gas supply fail to shut off Do not interrupt water flow to the boiler Instead shut off gas supply to the boiler with the manual valve in the gas supply line En cas de surchauffe ou si soupape en gaz ne s arr te pas Ninterrompez pas l coulement deau par la chaudi re Fermez manuellement le robinet d arr t de l admission de gaz Start up checklist Q Read all boiler manuals The 200i is supplied with three manuals Boiler manual Vent air manual Control manual Read and familiarize yourself with all three manuals before proceeding with start up Q Check the boiler area Make sure there are no combustible materials or chemicals that could cause air contamination in the boiler room Q Verify vent piping Inspect vent piping to be sure all joints are secure and prop erly sealed Verify vent piping supports are correctly placed and secure Check vent termination to be sure it is correct and not ob structed Measure total vent pipe length and note the number of fittings Make s
104. ure the vent complies with the 200i Vent air manual Q Verify combustion air and ventilation If combustion air is supplied from the boiler room make sure air openings agree with the requirements given in this manual If combustion air is piped to the boiler Inspect air piping to be sure all joints are secure and properly sealed Verify air piping supports are correctly placed and se cure Check air inlet termination to be sure it is correct and not obstructed P N 42 9470 1 12 Copyright 2012 Mestek Inc Cast iron condensing boiler Installation and operation manual l 2 Starting the boiler continued Measure the air piping length and note the number of fittings Make sure the air piping complies with the 200i Vent air manual Verify ventilation openings to the boiler room Even if air is piped to the boiler the boiler room must have ventilation openings as specified in this manual Q Verify electrical connections Before turning power on to the boiler Remove the electrical box covers on the right side of the boiler Inspect all wiring and connections Make sure there are no loose connections or wires LI Controls Follow the instructions in the 200i Control manual to set the operating temperatures and parameters required for the installation ifnot already done Set limit controls to their lowest settings Verify thermostat circuits following the procedure given in the 200i Control manual
105. w capacity cubic feet per hour notes 2 3 Que 650 ass 65 s10 27s 20 220 190 iss Notes Table 3 Natural gas flow capacity is based on 0 60 specific gravity Refer to the National Fuel Gas Code ANSI Z223 1 NFPA 54 for other pressure drops and other specific gravity gases The flow rates above allow for a pressure drop of Natural gas 0 30 inches water column with gas pressure 14 inches water column or less Propane 0 30 inches water column with gas pressure 14 inches water column or less To determine required flow rate in cubic feet per hour for all appliances connected to the gas line Natural gas Divide total Btuh by the gas Btu per cubic foot rating typically 1 000 Btu ft nominal Propane Divide total Btuh by 2 500 Table 4 Equivalent feet of pipe for common gas line components lron pipe size Equivalent feet of pipe for each fitting 90 Elbow Tee Gate valve note 1 note 2 Gas cock note 2 Notes Table 4 1 Allows for flow through the branch of the tee 2 Assumes valve is full open Test all gas piping for leaks All gas piping components and connections must be leak tested before putting the boiler in operation Isolate the boiler from the gas supply piping if testing with pressure greater than 14 inches 12 7 mm pressure Failure to do so could result in severe personal injury death or substantial property damage Check all gas piping components and joints for lea
106. w 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 13 Cast iron condensing boiler Installation and o Maintenance Read before proceeding Failure to adhere to the following could result in severe personal injury death or substantial property damage Licensed technician only The procedures in this manual must only be done by a qualified service technician Some details of service procedures are left to the expected good practices of a qualified technician Electrical shock hazard Except when the boiler must be tested or adjusted with the power on always turn power OFF before sevicing the boiler Burn or scald risk Always allow the boiler and parts to cool before attempting to service or remove Some parts may be very hot Do not open water piping components unless the wa ter has been allowed to cool to avoid scald hazard from spraying hot water Test verify the boiler after servicing Following service of any kind verify that the boiler controls and system devices are fully functional by performing the appropriate start up testing procedures given in this manual Seals If any pressure tight seal is broken for servicing such as combustion chamber burner seals air or vent piping joints or seals or gas piping joints or seals make sure th
107. ystem pressure Once the system is cleaned filled purged and treated as required set the make up water pressure reducing valve to the correct cold fill pressure This is usually 12 psig for systems using 30 psig relief valves For higher pressure sys tems set the cold fill pressure such that the system pressure will never exceed about 80 of the boiler relief valve setting when system water temperature reaches the maximum op erating temperature that the system and boiler temperature controls will allow The pressure in the boiler must never be below 12 psig Lower pressure could allow localized boiling in the boiler heat exchanger causing possible damage and section failure At cold fill the water level in closed type expansion tanks should not be above center Use the tank fitting to verify tank water level is correct As the system heats up the water will expand causing the system pressure to increase Ifthe expansion tank is properly sized and installed the system pressure will never exceed about 80 of the relief valve set pressure 24 psig for typical residential systems If the system operating pressure becomes too high check the expansion tank to ensure it is large enough For closed type expansion tanks make sure there are no leaks in the piping or the tank and the tank fitting is correctly installed For dia phragm or bladder type tanks you may have to remove the tank from the system and verify that it can hold pres
108. ze must be increased to account for this As a rule of thumb increase the flow rate by 15 Assume a 10 reduction in pressure drop compared to water only at a give flow rate Constant circulation For areas of the system that will be exposed to low tem peratures use continuous circulation to keep the water moving in the pipes Expansion tank sizing Increase the expansion tank size about 20 to account for the effects of the antifreeze Indirect heat exchangers Output from indirect heat exchangers including indirect water heaters can drop substantially when using antifreeze water Make sure the exchanger is sized correctly for the application Use only antifreeze sold for use in hydronic systems Never use automotive antifreeze Automotive antifreeze and ethylene glycol are toxic to humans and animals and will damage rubber components in the system Make sure the owner is aware that the antifreeze must be checked periodically by a qualified technician to ensure the concentration is correct and that the inhibitor level is adequate Obtain the MSDS for the antifreeze and leave a copy with the owner Follow antifreeze manufacturers guidelines for application and maintenance Failure to follow these guidelines could result in system or boiler failure causing possible severe personal injury death or substantial property damage P N 42 9470 1 12 Copyright 2012 Mestek Inc Fill and test the system continued Q S

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