Mestek 200i Installation And Operation Instructions Manual

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Page 1

M2i-IOM-6

200i

Cast iron condensing boiler

Boiler manual

Installation and operation

instructions

Also read and follow:

200i Control manual

200i Vent/Air manual

 is manual is intended only for use by a quali ed heating installer/technician. Read and follow this manual, all supplements and related

instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions. Failure to do so can result in severe personal injury, death or substantial property damage.

Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination of

the burner, resulting in possible severe personal injury, death or substantial property damage.  e boiler can only be operated with a dustfree 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.

A x these instructions near to the boiler/water heater. Instruct the building owner to retain the instructions for future use by a quali ed

service technician, and to follow all guidelines in the User’s Information Manual.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

The Mestek 200i condensing cast iron boiler

Operation

Overview

 e 200i is a cast iron boiler designed and constructed to allow full condensing operation.  e illustra- tion at le shows how the boiler is heated with a down- red premix gas burner mounted above the heat exchanger.  e 200i blower pulls gas and air through a venturi assembly and pushes the mixture into the burner.  e power of the blower forces the  ue products through the heat exchanger and out the vent.

Boiler operation is controlled with the 200i electronic control.  e control modulates boiler  ring 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 200i control, this allows maximum possible condensing mode operation, with combustion e ciency up to 98%.

Cast iron heat exchanger

 e 200i cast iron heat exchanger uses Mestek’s graphite port seals and ground joint  t-up between sections for maximum  exibility and resistance to thermal expansion.  e heat exchanger provides maximum heat transfer with its counter ow design and  ow-controlling ba e assembly.

Premix burner

Premix means the air and gas are mixed before they enter the burner.  e 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 operation with low excess air.  e result is exceptional combustion e ciency.

 e burner consists of a high-temperature stainless mesh secured to a stainless steel distributor plate.  e design causes uniform  ame across the entire surface of the burner and the ability to operate at very low  ring rates.  e  ame is ignited with direct-spark electrodes and an electronic ignition control. Flame is proven using a  ame rod ( ame recti cation 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 3½ inches water column). But the 200i gas valve regulates to ZERO pressure downstream.  is is called a “zero governor” valve.  e advantage is that gas will only  ow if something lowers the pressure downstream of the valve below zero.  at 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.  e more air that  ows through the throat, the greater the vacuum.

 e gas valve raises the negative pressure in the venturi to zero by le ing gas  ow.  e lower the pressure in the venturi throat, the more gas will that will  ow. So gas  ow automatically adapts to air  ow, ensuring consistent gas/air mix throughout the boiler’s modulating range.  us, the 200i SmartCycleTM electronic control regulates the blower speed to control boiler  ring rate.

200i

schematic

 ow diagram

200i SmartCycleTM control

 e 200i SmartCycleTM electronic control consists of a microprocessor-based module and a keypad/ display unit for user interface.  e control regulates boiler water temperature by adjusting boiler  ring rate (by varying the blower speed).  e control considers how fast the temperature changes and how the temperature varies over time to establish the best  ring 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 thermostats and determines a maximum  ring rate needed to meet the demand.  is keeps the boiler at the highest possible e ciency.) In addition, the control can be set for multiple boiler operation, either standalone or utilizing Mestek’s on-board SmartCycleTM technology.  e control also automatically cycles the factory-installed postpurge circulator to equalize residual heat in the boiler a er  ring.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

The Mestek 200i condensing cast iron boiler

Components

1. Gas valve

2. Pressure/temperature gauge

3. Jacket

4. Cast iron section assembly

5. Inlet air  lter access panel

6. Blower

7. 200i SmartCycleTM control

8. Venturi assembly

9. Pressure switches (blocked

10. Control connection board

11. Electrical box (power and

12. Water return connection

13. Air inlet sleeve

14. Relief valve

15. Relief valve piping

16. Water supply connection

17. Fenwal ignition module

18. Ignition electrodes/ ame

19. Control transformer

20. Postpurge circulator,

21. Vent connection sleeve

22. Condensate tubing connection

23. Upper section cover and

24. Gas connection, ½” NPT

with keypad and display

 ue and blocked air inlet)

control entrances)

(by installer)

rod assembly

(120/24 VAC)

factory-installed and piped

(with  ue gas sampling port)

premix burner

200i

components

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Contents

1 Read before beginning the installation . . . . 5

2 Boiler ratings and speci cations . . . . . . . . . 6

3 Installation site preparation . . . . . . . . . . . 7

4 Prepare the boiler . . . . . . . . . . . . . . . . . 10

5 Water piping . . . . . . . . . . . . . . . . . . . . 11

6 Gas piping . . . . . . . . . . . . . . . . . . . . . . 18

7 Wiring a single boiler . . . . . . . . . . . . . . . 20

8 Control setup . . . . . . . . . . . . . . . . . . . . 25

9 Vent piping (and air piping when used) . . . 28

10 Condensate drain line . . . . . . . . . . . . . . 29

11 Fill and test the system . . . . . . . . . . . . . . 30

12 Starting the boiler . . . . . . . . . . . . . . . . . 32

Hazard icons

You will  nd 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.

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.

13 Annual start-up . . . . . . . . . . . . . . . . . . 41

14 Maintenance . . . . . . . . . . . . . . . . . . . . 42

15 Replacement parts . . . . . . . . . . . . . . . . 46

16 Appendix A — suggested wiring . . . . . . . 48

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 West eld, 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  led immediately against the transportation company by the consignee.

Other manuals

You must read and follow this manual, the 200i Vent/Air manual, the 200i 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,  ll out the Start-up/service history information on the back page.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Read before beginning the installation

Codes and standards

Boiler compliances

 e 200i has been design certi ed 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 Massachuse s, you MUST FOLLOW the additional instructions contained in Mestek’s instruction sheet, MA CODE. If you don’t have a copy, call your Mestek dealer or Mestek.

When installed in the Commonwealth of Massachuse s, ensure the following:

•  e boiler must be installed by a licensed plumber or gas   er.

• W hen antifreeze is used in the system, install an approved pressure back- ow 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.  e boiler must not operate without the automatic means enabled.

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.  is 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.

•  is boiler is not used for any space heating .

•  is boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

•  is boiler is equipped with a tankless coil.

IMPORTANT

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 boiler 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.

•  e boiler must not be exposed to dripping or spraying water or to rain.

• If replacing an existing boiler,  nd 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 o power to the circulators if the boiler should overheat or the gas supply fail

to shut o . Instead, shut o gas supply to the boiler with a manual valve in the gas supply line.

When 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 a empting 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  berglass and ceramic

 ber materials.

You must have the following equipment

• Electric multimeter • Ammeter

• Surface temperature gauge • Metric Allen wrenches

• Pressure di erential gauge or included DP manometer

• (3) Gas pressure meters: Two @ 0 – 14 inches WC; One @ 0 – 5 psi

• Combustion analyzer  You must use a combustion analyzer and follow all instructions

in this manual to correctly start-up the boiler. As prescribed in this manual, the O2 levels must be between 5% and 7%.  roughout all  ring rate conditions, the burner surface must never show red areas. Follow manual procedures to correct this condition.

Boiler water

• You must thoroughly  ush the system, with the boiler isolated from the system, to remove

sediment. Existing systems, in particular, o en contain large amounts of iron sediment. Excess suspended solids in the water can lead to premature boiler failure.

• High e ciency 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 so ened 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 of antifreeze is

necessary, an anti-freeze speci cally 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  uid in the water, provide

for increased water  ow or ensure proper temperature rise.

Train the user

• Before leaving, review the User’s Information Manual with the boiler user/homeowner,

including the required maintenance to be performed by the user, the need for annual startup/maintenance by a quali ed technician, the avoidance of combustion air blockage or contamination, and never bringing or storing  ammable products into the boiler area.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Boiler ratings and speci cations

Boiler model Units

AFUE (DOE seasonal e ciency) % 92.7 1

CSA Input (Max)

CSA Input (Min)

Maximum allowable working pressure

Water supply and return connections Inches, NPT 1¼

Boiler water volume

Shipping weight

Operating weight

Fuels Natural gas or propane 3

Gas connection size Inches, NPT ½

Gas supply pressure, minimum

Gas supply pressure, maximum

Vent connection size

Vent options

Combustion air options

Combustion air adapter size

Electrical requirements

Voltage 120 vac/60 hz/1-phase

Current draw (120-volt power line) Amperes 2.75

Thermostat anticipator setting Amperes 0 5

Operating control Mestek SmartCycle

Control operation options

Control methods

Btuh

PSIG

kPa

Gallons

Liters

Pounds

Inches WC

mm WC

Inches WC

mm WC

Inches

Direct Vent or Category IV only (pressurized vent, condensing)

ducted to boiler from outside

Inches

Stand-alone SmartCycle BMS (boiler management system)

Heat demand (SmartCycle or stand-alone) On/O BMS (4-20 ma input) Staging RS485 digital communication

200i

200,000

58.6

40,000

11.7

100 700

4.75

18.0

540 245

510 231

102

356

76.2

Air from boiler room or

76.2

control 4

Notes

1 2

3 4 5

Notes

DOE Heating capacity is based on standard tests speci ed by the United States Department of Energy. All capacity ratings above are based on sea level. Input adjustments allow se ing the high  re input and may compensate for moderate altitudes.

For higher altitudes the maximum boiler input will be derated slightly.  e gas valve is capable of operating with natural gas or LP. See instructions in this manual to adjust for the speci c fuel used. For additional information, refer to the 200i Control manual.  ermostat anticipator se ing is for a single thermostat connected to a single 200i boiler. Also jumper from the Heat Demand terminals to the

IAR1 terminals on the connection board. See the 200i Control manual for details.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Installation site preparation

Boiler location requirements

Do not install the boiler unless the location meets all of the requirements in this box.

Failure to comply could result in severe personal injury, death or substantial property damage.

Indoor installation only

• Do not install the boiler outside or in an area that would expose 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

•  e boiler can be installed on combustible  ooring, but must not be installed on carpeting.

•  e  oor must be structurally sound and capable of supporting the weight of the boiler.

•  e 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 procedures. Ensure that the location provides a reasonable means for service and operation of the boiler.

System piping, fuel and electrical supply

•  e boiler must be located such that piping for water, gas, vent and air can reasonable be connected.

•  ere 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 routine maintenance.

Combustion air

• Do not place the boiler in a location that would restrict the  ow 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.

• 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.

• Buildings will require the installation of a fresh air duct or other means of providing make-up air if the intake air option isn’t used. Any building utilizing other gas burning appliances, a  replace, 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 outside air duct must be done to meet the requirements of all such devices.

•  e boiler must be supplied with combustion air in accordance with Section 5.3, “Air for Combustion and Ventilation,” 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 Appliances 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 comply with this warning can result in excessive levels of carbon monoxide.

Combustion air contamination

• Combustion air contaminated with  uorocarbons or other halogenated compounds such as cleaning solvents and refrigerants will result in the formation of acids in the combustion chamber.  ese 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 components 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  ammable vapors or liquids in the vicinity of the boiler.

Clearances

• All installation must provide the minimum clearances to combustible materials given on page 8.

•  e installation should provide the minimum service clearances 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.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Installation site preparation (continued)

Clearance requirements

Clearances to combustible surfaces

All installations must provide the minimum clearances to combustible materials and surfaces given in Table 1. Failure to comply could result in a  re hazard, causing severe personal injury, death or substantial property damage.

Table 1 Minimum clearances to combustible materials/surfaces for ALL

From: Inches Millimeters

Top 6 153 Back 6 153 Left side 6 153 Right side 6 153 Front 6 153 Rear 6 153 Vent piping 2 51 System water piping 1 25.4

EXCEPTION: Ventilation openings are not required if the boiler room

installations (Figure 1)

If the 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 200i boilers in the room.

provides at least the minimum SERVICE/OPE TION 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.

Figure 1 Clearance to combustibles references

Clearances for service and operation

 e installation must provide reasonable access and clearance for service

and operation of the boiler. Table 2 gives recommended minimum clearances for service and operation.  e 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.

Table 2 Recommended minimum clearances for service/operation

From: Inches Millimeters

Top 24 610 Back 24 610 Left side 24 610 Right side 24 610 Front 36 914

Rear 18 457

Flame observation port   e  ame observation 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 le side for this purpose.

(Figure 2)

Figure 2 Service/operation clearance references

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

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/OPE TION 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  oor.

• Other appliances in the same room   e 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.

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 de nition). 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.

De nitions

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 determine actual area of the required opening.

Tight construction  When a building is extensively sealed to prevent air

in ltration, it cannot provide enough air for combustion unless openings are provided to the outside.  e National Fuel Gas Code de nes 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 doors.

• Caulking or sealants are applied to areas such as joints around windows and door frames, between sole plates and  oors, between wall-ceiling joints, between wall panels, at penetrations for plumbing, electrical, and gas lines, and in other openings.

Conversion factors

In2/1,000 BTUH to cm2/kw  Multiply In2/1,000 BTUH times 22

/2,000 BTUH to cm2/kw  Multiply In2/2,000 BTUH times 11

/3,000 BTUH to cm2/kw  Multiply In2/3,000 BTUH times 7.4

/4,000 BTUH to cm2/kw  Multiply In2/4,000 BTUH times 5.5

Figure 3 Air opening options for combustion air

Upper openings (U) must be within 12 inches of the ceiling. Lower openings (

Option 1 —

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 in2 per 1,000 BTUH of all 200i boilers in the room.

Option 2 —

When air is supplied to the boiler room through openings in an outside wall (air supply from outside the building), size each opening to provide minimum free area of:

1 in2 per 4,000 BTUH of all 200i boilers in the room.

drawn from boiler room

If other 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 appliances in addition to the air required for the 200i boiler(s).

L) must be within 12 inches of the  oor.

air openings through interior wall

air openings through outside wall

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 in2 per 3,000 BTUH of all 200i boilers in the room.

Option 4 —

Air openings can be connected to a ventilated a ic or crawl space.  e upper opening must be to the a ic.  e lower opening can be a vertical duct from the a ic or an opening in the  oor from the craw l space. Size each opening to provide minimum free area of:

1 in2 per 3,000 BTUH of all 200i boilers in the room.

Option 5 —

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 in2 per 3,000 BTUH of all 200i boilers in the room.

openings to attic/crawl space

single opening (not shown)

Page 10

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Prepare the boiler

Remove the boiler from the crate

Cold weather handling   e boiler jacket

includes plastic parts. If the boiler has been in a cold environment (below 0 °F), allow the boiler to warm to room temperature before handling.

Do not drop the boiler or allow the jacket to bump

against the  oor or wall when handling.

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 o of the skid into position.

4. 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 pressure se ing of the relief valve to avoid component damage due to excess pressure.

Piping guidelines:

• All installations must be installed by a quali ed 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 followed.

• A minimum clearance of 1 inch (25 mm) must be maintained between heating system pipes and all combustible construction.

• All heating system piping must be supported by suitable hangers  not by the boiler.

•  e thermal expansion of the system must be considered when supporting the system.

• A minimum system pressure of 12 psig (84 kPa) must be maintained.

Figure 4 Relief valve piping

 e boiler maximum allowable working pressure

is 100 psig (700 kPa).  e relief valve must never have a se ing greater than 100 psig. Using a higher pressure relief valve could result in an explosion, causing possible severe personal injury, death or substantial property damage.

Connecting the relief valve

Connect ¾-inch NPT black iron pipe and   ing so the relief valve as shown in Figure 4. Follow all instructions provided in the relief valve manufacturer’s instructions and labeling.

Never install 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

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-o valve in the boiler supply and

return connections to allow isolation of the boiler for servicing when necessary.

Page 11

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Water piping

Boiler piping connections

 e boiler supply and return connections are shown in Figure 4. Both connections are 1¼-inch NPT.

Size piping for the  ow required. Piping connections to the 200i boiler should generally be 1¼-inch NPT.

System design

Design options

 e 200i boiler works well in a single or multiple-boiler application for any type of system.  e 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- red 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  ow needed for the required recovery capacity.

Pipe sizing

Generally install 1¼-inch piping in the boiler circuit. 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  ow rate will usually be based on a 5°F temperature drop. Such high  ow systems must be piped with the boiler on a separate loop.

 e 200i boiler requires a continuous minimum water  ow for proper

operation.  e 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 this must be considered when sizing the pump.  e temperature rise across the boiler must never exceed 100°F (55.6°C).

Boiler pressure drop

Assume a pressure drop of:

• 1.9 feet WC (0.7 meter) for a  ow rate of up to 18 GPM (68 LPM).

• 7.5 feet WC (2.3 meters) for a  ow rate of up to 36 GPM (136 LPM). Maintain boiler  ow 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 supplied by the installer, except the factory-installed postpurge circulator.

Boiler circulator  the circulator that  ows water through the boiler.

System circulator  the circulator that  ows water through the system, but not

through the boiler.

Boiler/system circulator  a circulator that  ows 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.

 e 200i SmartCycle Control provides an isolated contact to operate the boiler circulator (or boiler/system circulator).

 e system circulator must be activated by a relay supplied by the installer.  is relay is usually activated by the system control or thermostat.

Piping guidelines

Support the piping  All piping and

components must be supported such that no loads or stresses are applied to the boiler. Al low for thermal expansion in the piping design and passageways.

 e 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 postpurge circulator

 e postpurge circulator supplied with the

200i (Figure 4), factory piped between the boiler supply and return connections, is for use in the system. It must remain connected as supplied.  e postpurge circulator is only used by the 200i for postpurge  ow to remove residual heat in the combustion zone.  e postpurge circulator includes an integral check valve to prevent by-pass  ow during operation.

Additional controls

Local codes or job speci cations may require the use of additional controls, such as low water cut-o s,  ow switches, and high limit controls. Refer to the 200i Control manual for electrical connections for auxiliary controls.

Follow the guidelines below to install typical controls in the piping.

Low water cut-o

When the boiler is installed above terminal units, or when required by applicable codes, install a low water cut-o 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  ow switch is required, install the switch in a section of the piping that will ensure enough  ow to operate the switch.

NOT intended

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.

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Cast iron condensing boiler

Water piping (continued)

Expansion tank and air separation

 e system must include an expansion tank to control thermal expansion. Install the tank as close as possible to the boiler, and locate on the suction side of the system circulator. Make sure the tank is sized large enough to handle the system volume.

Figure 5 Expansion tank comparison

Figure 6 Diaphragm or bladder-type expansion tank

suggested piping

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 5, le side. See Figure 6 for suggested piping.

Guidelines for diaphragm/bladder-type expansion tanks

• Always remove the tank from the system before charging.  is ensures the air pressure will be accurate. Make sure the charge pressure equals the required system cold- ll 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 5, 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.  e 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 waterlogging of the tank, causing the boiler relief valve to weep.

• Air separation is done by connecting from an in-line air separator to the bo om of the expansion tank (Figure 7).  e tank must be mounted above the air separator.

• Install a tank   ing in the bo om of the tank. It allows captured air to  ow into the upper portion of the tank, facilitates  lling, and reduces recirculation in the expansion tank piping.

Cold water  ll

Follow all applicable codes when connecting the cold water  ll to the piping. Use a back ow 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.  e water meter will show if excessive make-up water is entering the system.

Figure 7 Closed-type expansion tank suggested piping

Undersized or waterlogged expansion tanks will

cause excessive make-up water to enter the system.  is will lead to section failure due to oxygen corrosion and lime deposits.

Page 13

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Zoning with zone valves

Flow balancing and control

On large systems, or when using a high-head circulator, install a di erential pressure by-pass valve to limit the head applied to the zone valves.

Some systems may require balancing valves to control  ow in the loops.

Figure 8 Suggested piping — single boiler — zone valve zoning — two-pipe or series loop (left), or primary/secondary piping (right)

Water piping (continued)

DHW operation, when required

 e piping shown throughout this manual allows for domestic water heating without  ow through the heating loop(s).  is is important for summertime operation of DHW tanks.

Make sure to incorporate  ow/check valves as shown.  ese prevent forced  ow in idle zones.

LEGEND • • • • • • •

1 200i boiler 2 Boiler circulator 3 System circulator 4 Boiler/system circulator 5 Indirect- red DHW tank

(when used)

6 DHW circulator 7 Flow/check valve 8 Cold water  ll line

9 Expansion tank (shown with diaphragm-type —

see page 12 for piping a closed-type tank) Expansion tank (shown with diaphragm-type — see page 12 for piping a closed-type tank)

10 Air separator with automatic air vent (Replace air

vent with piping to the tank   ing on closed-type expansion systems.)

11 Low water cut-o (when required) 12 Extra high limit (when required) 13 Zone valve 14 Zone circulator

15 Di erential pressure by-pass valve — Use when high-

head circulator may cause noise, erosion or valve li ing problems when only a few zone valves are open.

16 Boiler postpurge circulator (see page 11)

17 Header sensor, required where shown

Isolation valve

Purge valve — Suggested locations allow for improved

system  lling and draining and initial air elimination.

Temperature gauge

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Zoning with circulators

Sizing and  ow control

Size circulators to provide the  ow needed for the individual zones.

Provide  ow/check valves where shown to prevent gravity circulation or forced  ow in idle zones.

Figure 9 Suggested piping — single boiler — circulator zoning — two-pipe or series loop (left), or primary/secondary piping (right)

Water piping (continued)

DHW operation, when required

 e piping shown throughout this manual allows for domestic water heating without  ow through the heating loop(s).  is is important for summertime operation of DHW tanks.

Make sure to incorporate  ow/check valves as shown.  ese prevent forced  ow in idle zones.

LEGEND • • • • • • •

1 200i boiler 2 Boiler circulator 4 Boiler/system circulator 5 Indirect- red DHW tank

(when used)

6 DHW circulator 7 Flow/check valve 8 Cold water  ll line

9 Expansion tank (shown with diaphragm-type — see

page 12 for piping a closed-type tank) Expansion tank (shown with diaphragm-type — see page 12 for piping a closed-type tank)

10 Air separator with automatic air vent (Replace air vent

with piping to the tank   ing on closed-type expansion systems.)

11 Low water cut-o (when required)

12 Extra high limit (when required)

14 Zone circulator

16 Boiler postpurge circulator (see page 11)

17 Header sensor, required where shown

Isolation valve

Purge valve — Suggested locations allow for improved

system  lling and draining and initial air elimination.

Temperature gauge

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Multiple boilers, primary/secondary

Sizing and  ow control

Size circulators to provide the  ow needed for the individual zones.

Provide  ow/check valves where shown to prevent gravity circulation or forced  ow in idle zones.

Figure 11 Suggested piping — multiple boilers — primary/secondary piping, reverse-return boiler headers

Supply to system

Water piping (continued)

DHW operation, when required

 e piping shown throughout this manual allows for domestic water heating without  ow through the heating loop(s).  is is important for summertime operation of DHW tanks.

Make sure to incorporate  ow/check valves as shown.  ese prevent forced  ow in idle zones.

12" max (305 mm)

Return

from system

7777

222

1111

16 16 16 16

LEGEND • • • • • • •

1 200i boiler

2 Boiler circulator

3 System circulator

5 Indirect- red DHW tank

(when used)

6 DHW circulator

7 Flow/check valve

8 Cold water  ll line

9 Expansion tank (shown with diaphragm-type — see

page 12 for piping a closed-type tank) Expansion tank (shown with diaphragm-type — see page 12 for piping a closed-type tank)

10 Air separator with automatic air vent (Replace air vent

with piping to the tank   ing on closed-type expansion systems.)

11 Low water cut-o (when required)

12 Extra high limit (when required)

16 Boiler postpurge circulator (see page 11)

17 Header sensor, required

Isolation valve

Temperature gauge

DHW tappings

20010

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Multiple boilers, parallel  ow

Sizing and  ow control

Size the boiler/system circulator to handle the  ow needs of all zones. If using variable speed control of the boiler/system circulator, ensure that the  ow never drops below the total minimum for all boilers connected. Do not exceed the maximum  ow of 50 GPM through any boiler.

Figure 12 Suggested piping — multiple boilers — parallel- ow piping, reverse-return headers

Water piping (continued)

DHW operation, when required

When heating system boilers are piped in parallel as in Figure 12, connect the DHW tank as a zone o of the main header or install boilers dedicated to the DHW application.

LEGEND • • • • • • •

1 200i boiler

4 Boiler/system circulator

5 Indirect- red DHW tank

(when used)

6 DHW circulator

8 Cold water  ll line

9 Expansion tank (shown with diaphragm-type — see

page 12 for piping a closed-type tank) Expansion tank (shown with diaphragm-type — see page 12 for piping a closed-type tank)

10 Air separator with automatic air vent (Replace air vent

with piping to the tank   ing on closed-type expansion systems.)

11 Low water cut-o (when required)

12 Extra high limit (when required)

16 Boiler postpurge circulator (see page 11)

17 Header sensor, required

Isolation valve

Temperature gauge

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Chilled water systems

General

Provide the piping components shown in Figure 13 when connecting a boiler to a chilled water system.  e check valve (item 4) prevents chilled water from entering the boiler loop.

Sizing and  ow control

Size the system circulator to handle the  ow needs of all zones. If using variable speed control of the system circulator, ensure that the  ow never drops below the total minimum for all boilers connected.

Figure 13 Suggested piping — boilers connected to chilled water systems

Water piping (continued)

 e 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  ow.

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  ow control devices to prevent gravity circulation in the boiler loop during the cooling cycle in the air handling units.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Gas piping

Check the gas type

 e 200i comes from the factory ready to be piped to the gas supply. If for any reason the boiler is not for the type of gas available 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.  e gas connection at the boiler is ½” 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 Canadian Gas Code for recommendations.

Item 2   e manual shut-o valve must be installed in the supply piping. Install 5 feet above the  oor where required by applicable codes.

Failure to adhere to the following

could result in severe personal injury, death or substantial property damage.

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 bo om of the vertical section of the gas supply pipe upstream of the gas controls.

Item 6   e gas cock must be equipped with a pressure test port.  is test port is used to measure the gas supply pressure at the boiler.

 e gas line components in Figure 14 are not supplied with the boiler.  ey must be supplied by the boiler installer.

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

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 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 of the boiler gas connection   ing.

Protect the gas connection  tting

Use a  – inch open-end wrench to hold the boiler gas connection   ing when tightening gas connection piping to the boiler.

Never leak test with  ame

Never use an open  ame to test for gas leaks. Always 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-o valve if test pressure will be higher than ½ psig (3.5 kPa).

1 Piping from gas supply

2 Manual gas valve with test port

(use tee-handle valve for Massachuse s installations)

3 Piping must be clean and burr-free

black iron pipe

4 Ground-joint union

5 Drip leg with cap

6 Gas cock pressure test port

Page 19

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Gas piping (continued)

Gas piping joints

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.

Only use 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  ow or foul gas train components.

Gas pipe sizing

Required supply pressure at boiler

Minimum gas supply pressure (natural gas or propane), both for  owing and static conditions:

4 inches (102 mm) water column.

Maximum gas supply pressure (natural gas or propane), both for  owing and static conditions:

Table 3 Gas  ow capacity for black iron pipe

Iron

pipe

size

¾” 278 190 152 130 115 105 90 79 64

1 ” 520 350 285 245 215 195 170 150 120

1 ¼” 1050 730 590 500 440 400 350 305 250

1 ½” 1600 1100 890 760 670 610 530 460 380

¾” 172 118 94 81 71 65 56 49 40

1” 320 220 175 150 135 120 105 95 75

1 ¼” 650 455 365 310 275 250 220 190 155

Pipe length, equivalent feet (length plus allowance for  ttings)

10 20 30 40 50 60 80 100 150

Natural gas pipe  ow capacity

Propane gas pipe  ow capacity (cubic feet per hour) (notes 2, 3)

Notes, Table 3

Natural gas  ow capacity is based on 0.60 speci c gravity. Refer to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, for other pressure drops and other speci c gravity gases.

 e  ow 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  ow 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/ Propane — Divide total Btuh by 2,500.

(cubic feet per hour) (notes 1, 2, 3)

nominal).

14 inches (356 mm) water column.

Sizing guidelines

 e 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 speci c 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.

For conditions not shown in Table 3, other pressure drops, or natural gas with other than 0.6 speci c gravity, refer to the appropriate code guidelines for sizing.

Equivalent length

Do not neglect the pressure drop due to pipe   ings.

Equivalent length is the sum of the actual length of piping plus the total equivalent lengths of all   ings in the line from the main regulator to the boiler connection. See Table 4 for equivalent lengths of common   ings 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.

Undersized gas supply piping can cause the

gas line pressure to become negative during operation of the 200i boiler.  is 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.

Table 4 Equivalent feet of pipe for common gas line components

Iron

pipe

size

1” 2.6 5.2 0.6 1.5

1 1/4” 3.5 6.9 0.8 1.9

1 1/2” 4.0 8.0 0.9 2.3

2” 5.2 10.3 1.2 3.0

12Allows for  ow through the branch of the tee.

90° Elbow Tee

Assumes valve is full open.

Equivalent feet of pipe for each  tting

(note 1)

Notes, Table 4

Gate valve

(note 2)

Gas cock

Test all gas piping for leaks

All gas piping, components and connections must be leak tested

before pu ing 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 leaks. Use either a soap suds mixture, a gas leak detector or other suitable means.

A er testing the system gas piping, remove the gas valve cover plate on the le side of the boiler (see illustration at right). Inspect and leak test around the interior gas line and gas valve. Replace the cover a er completing the gas connection inspection and testing.

(note 2)

Page 20

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Wiring a single boiler

Electrical shock hazard — Disconnect

all electrical power sources to the 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 a er servicing.

Au moment de l’entretien des com-

mandes, étiquetez tous les  ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé.

Failure to comply with the above could

result in severe personal injury, death or substantial property damage.

 e electrical connections to this boiler

must be made in accordance with all 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 properly rated shut-o sw itch should be located at the boiler.  e boiler must be grounded in accordance with the authority having jurisdiction, or if none, the latest revision of the National Electrical Code, ANSI/ NFPA-70.

Figure 15 Electrical connection board (see item 10,

page 3 for location — Also see the wiring summary illustrations on the next pages)

Figure 16 120VAC power service terminals on electri-

cal connection board — See Figure 15 for location of the power terminal strip

Line voltage  eld 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

•  e wiring and control information in the Boiler manual is targeted at single-boiler, stand-alone installations. For multiple boilers and advanced options, see the 200i Control manual.

• See Figures 20 and 21 for a wiring summary. See the Control manual for content not covered in this manual.

Power supply (120 VAC)

• See Figures 15 and 16.

• Connect minimum 14 awg copper wire to the power connection as shown in Fig ure 16.

• Install a fused service switch, mounted and installed in accordance with all applicable codes.

Page 21

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Wiring single boiler (continued)

Circulator wiring

Postpurge circulator

• The circulator shipped installed with the boiler

cannot be used for system circulation.

as supplied from the factory. It circulates water a er the boiler stops  ring to prevent potential damage from heat pocketing in the top of the heat exchanger.

•  e postpurge circulator is factory-piped and pre-wired. Do not change the usage, the wiring, the location or the piping.

Boiler circulator

• See section 5 of this manual for circulator piping.

• Figure 19 shows wiring of the Boiler circulator (or boiler/ system circulator) to the terminal strip of the 200i electrical connection board.

• DO NOT directly connect a circulator with a motor larger than 1/4 hp. For larger motors, install a circulator relay or motor contactor . Figures 17 and 18 show the correct ways to install the boiler circulator using a relay or motor starter.

It mu st be used

Figure 19 Circulator wiring terminal strip (see Figure 15

for location) — Also see the wiring summary illustrations on the next pages)

Figure 17 Wiring the boiler circulator using a circulator

Figure 18 Wiring the boiler circulator using a relay or

relay (required for motors over 1/4 hp)

starter (required for motors over 1/4 hp)

Page 22

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Wiring single boiler (continued)

Sensor wiring

No sensor wiring is necessary unless:

• 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 possible and not likely to be covered by snow dri s or debris. Connect the outdoor sensor leads to the electrical connection board as shown in Figure 21b, page 24.

• Header sensor application  As show n in the piping diagrams in this manual, a header sensor is needed if the boiler supply temperature may be di erent from the header temperature. If required, purchase and install a header sensor in an immersion well. Locate the sensor where it will accurately sense the system water supply temperature. Connect the sensor leads to the electrical connection board as shown in Figure 21b, page 24.

• Return water temperature sensor   e 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.

IAR (Indoor Air Reset) wiring, when used

• Heat Demand terminal connections   e end switch leads from the zone valves must connect to the Heat Demand terminals on the electrical connection board as shown in Figure 20 and Figure 21a.

• 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 Control manual.

Polarity   e 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 A1.  e 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.

Figure 20 Indoor Air Reset wiring to IAR terminals with

4-wire zone valves and no zone controller

(see Figure 21a for terminal block 6 location).

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.

• 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.  is is because these terminals are jumpered internally on the electrical connection board. If there is more than one transformer, provide one wire from each transformer common side to one of the 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 recommended piping diagrams in this manual. Consult the factory for applications not covered.

•  e circulator used for DHW must be operated by a circulator relay or zone controller that is activated when the tank aquastat calls for heat.

• Connect the tank aquastat terminals across the DHW DEMAND terminals on the electrical connection board as shown in Figure 21.

Page 23

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Figure 21a 200i wiring summary (see Boiler manual and Control manual text for additional information)

Wiring and control setup (continued)

Also see page 20

Page 24

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Figure 21b 200i wiring summary (see Figure 21 for locations) (see Boiler manual and Control manual text for additional information)

Wiring and control setup (continued)

Also see page 21

Also see page 22

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Control setup

Before control setup

Before beginning the HeatNet control setup, remove the wires

connected to the HEAT DEMAND and DHW DEMAND terminals

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  ring during setup.

on the electrical connection board (see Figure 21).  ese

The HeatNet control display

Starting the display

1. Check all wiring to make sure it is complete and all wires are securely connected.

2. Verify that the HEAT DEMAND and DHW DEMAND wires are removed.

3. Turn on power to the boiler and then turn the boiler on/o switch ON.

4.  e control will beep at least twice and the display will show the  rst STANDBY display in Figure 22. Note that pushing the DOWN bu on on the keypad will change the right side of the display as shown, providing information on various setpoints and parameters.

5.  e display, LOC SET, means the setpoint temperature. Figure 22 shows the factory default values.

Figure 22 HeatNet display during Standby (no call

for heat) — pressing the DOWN key on the keypad changes the display as shown

Accessing setup menus

1. With the display in STANDBY, press and hold the BACK key for 5 seconds.

2.  e display will change to:

3. Press the SELECT key to select setup. (Note that pressing the DOWN key would change the selection to VIEW LOG.)

4.  e display will now show the  rst options in the setup menus:

5. Press the DOWN key to access additional menu options. Pressing the DOWN bu on once will change the display to:

6.  e cursor moves to the second line, indicating this option could now be selected with the SELECT key.

7. Continuing to press the DOWN key will access these menu options:

• BOILERS

• SETPOINTS

• INDOOR AIR

• PUMP OPTIONS

• NIGHT SETBACK

• OPTIONS

• LOG/RUNTIME

• AUX FUNCTIONS

• SYSTEM CLOCK

• ADVANCED SETUP

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Control setup (continued)

Recommended settings

1.  e following recommendations should cover most single-boiler applications.

2.  e se ings covered in this manual are SETPOINTS, INDOOR AIR, OUTDO OR AIR and SYSTEM CLOCK.

3. For other se ings 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 bu on to enter the SETPOINTS menus.  e 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 se ing 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 di erential for the limit function).

Set the local setpoint (LOC SETPT)

1. Use the arrow keys until the cursor points at LOC SETPT.  e display will show:

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.  e DHW setpoint should usually be 190°F. To obtain this setpoint, you will also have to increase the OP LIMIT setting to 225 or 230°F so the boiler won’t prematurely cycle on the limit function.

5. When the DHW se ing 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 se ings to change the operating limit temperature.

2. 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.  e maximum se ing for OP LIMIT is 230°F. So the maximum allowable boiler setpoint is generally 190°F.

4. Once the se ing is correct, press SELECT, then BACK to return to the setpoint menus.

The LIMIT BAND

1. Do not change the LIMIT BAND se ing unless speci c application demands require a change or when directed by the factory.

2.  e cursor must be pointing at LOC SETPT.  e value shown may vary if the control has been adjusted before.

3. Press the SELECT bu on to change the local setpoint value.

4.  e cursor will move to the temperature number.

5. Use the arrow keys to increase or decrease the temperature to the desired se ing.

If you hold down the arrow key the numbers will change faster a er a

brief waiting period.

6. W hen the se ing is correct, press the SELECT key to accept.  en press the BACK key to leave the local setpoint adjustment.

7.  e local setpoint should be set at the design water temperature for the heating units (typically 180°F for  nned-tube baseboard, for example).

 e setpoint must never be higher than the OP LIMIT se ing minus

the LIMIT BAND minus half of the HEAT BAND se ing.  is would cause the boiler to hit limit while trying to modulate.

Example: If LIMIT BAND is 20°F, OP LIMIT is 215°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.  e display will be:

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.  e indoor air technology monitors space heating demand to help the boiler operate at the highest possible e ciency throughout the season.

• To apply indoor reset you must wire the IAR inputs and the HEAT DEMAND terminals as described in Section 7.

Enable or disable IAR

1.  e only se ing for indoor air reset that you will need to make is to enable the function.

2. Use the arrow keys until the cursor points to INDOOR AIR.

3. Press SELECT to enter the indoor air menus.

4.  e display will show:

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Cast iron condensing boiler

5.  e factory default se ing is ON, or IAR enabled. If the boiler is wired for IAR, then leave the se ing at ON.

6. To change the se ing to o , press SELECT with the cursor pointing at IA RESET.

7. 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  nished with IAR, return to the main menus by using

the BACK key.

OUTDOOR AIR, when used

General

Skip this procedure if there is no outdoor sensor present.

• W hen possible, use Indoor Air Reset instead of outdoor reset. IAR provides much be er feedback on system needs.

OUTDOOR AIR menu

1. Use the arrow keys until the cursor points at OUTDOOR AIR .  en press SELECT.

2.  e display will show the beginning of the OUTDOOR AIR menus:

7. Press SELECT and the display will show:

8. Don’t use the arrow keys yet, but if you use the DOWN arrow twice, the display will show:

9. With the cursor on the se ing you want to change, press the SELECT key, then use the arrow keys to change the temperature as you did for SETPOINTS.

10. LOW WATER (@ HI OA)  Set for the supply water temperature desired when the outside air is at the temperature when no heat is needed (HI OA).  is should generally be set equal to room temperature, or 70°F unless the application calls for another se ing.

11. HI OA  Set this to the outside temperature at which no heat is needed, usually 68°F or lower.

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).

Outdoor shutdown

1. Enable or disable outdoor shutdown by pressing the SELECT bu on with the cursor on OA SHUTDOWN.

2. Use the arrow keys to change from ON to OFF.

3. Press SELECT to save, then BACK to return.

4.  en arrow key to OA SETPT to set the desired outdoor air shutdown temperature.

5. Press SELECT and the cursor will move to the temperature.

6. Use the arrow keys to change the se ing.

7. 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.

2.  e default se ing is ON.

3. To change the se ing, press SELECT and use the arrow keys to change from ON to OFF.

4. Press SELECT, then BACK.

5. If outdoor reset is enabled, set the reset temperatures as follows:

6. Use the arrow keys until the cursor points at SET OA SETPTS.

12. HI WATER (@LO OA)   is is 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.  is temperature would typically be 180° for  nned-tube baseboard systems.

13. LO OA   is is the ODT, or design outdoor temperature for maximum heating requirements from the system.

14. Use the arrow keys to navigate to each of the above.  en adjust as required.

Return to main menus

When you have  nished 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 o power and the boiler on/o switch. Reconnect HEAT DEMAND and DHW DEMAND wires.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Vent piping (and air piping when used)

All 200i boilers must be vented using only the materials listed in the 200i Vent/Air manual.  e 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 horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other de ciencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and w indows and all doors between the space in which the appliances remaining 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  replace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

5. Test for spillage at the dra hood relief opening a er 5 minutes of main burner operation. Use the  ame of a match or candle, or smoke from a cigare e, cigar or pipe.

6. A er 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,  replace dampers and any other gas-burning appliance to their previous condition of use.

7. 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 National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and or CSA B149 Installation Codes.

Systèmes d’évacuation d’communs

Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’évacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonction-nent pas: système d’évacuation

1. Sceller toutes les ouvertures non utilisées du sys-tème d’évacuation.

2. Inspecter de façon visuelle le système d’évacu-ation pour déterminer la grosser et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstr uction, d’étranglement de fruite, de corrosion et autres défaillances qui pourraient présenter des risques.

3. Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés du système d’évacuation sont installés et les autres espaces du bâtiment. Me re en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les ho es de cuisinère et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

4. Me re l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.

5. Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge. Utiliser la  amme d’une allune e ou d’une chandelle ou la fumée d’une cigare e, d’un cigare ou d’une pipe.

6. Une fois qu’il a été d éterminé, selon la métode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façor adéquate. Reme re les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

7. Tout mauvais fonctionnement du systéme d’évacu-tion commun devrait étré corrigé de façor que l’instal-lation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) au x codes d’installation CSA-B149. Si la grosseur d’une section du système d’ évacuation doit étré modi ée, le système devrait étré modi é pour respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d’installation CSA-B149.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Condensate drain line

Fill the condensate trap

Before installing the condensate line, you must  ll the condensate trap with water.  is will prevent  ue products from escaping into the room. To  ll the trap:

• Temporarily a ach a –inch clear plastic hose to the condensate hose barb (see Figure 23).

• A ach 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.

 e condensate trap must be  lled when  ring the

boiler to prevent  ue gases from escaping into the room.

Condensate line installation

Condensate tubing material

 e condensate tubing must be silicone rubber, –inch (9.5 mm) diameter.

Condensate line requirements

Failure to adhere to the following could result in

condensate line leakage, resulting in potential for severe personal injury, death or substantial property damage.

❑ Use only silicone rubber tubing, -inch (9.5 mm)

diameter.

❑ Protect the condensate line from damage and

secure it in position.

❑ Terminate the condensate line at an appropriate

drain.

❑ Do not install the condensate drain line such that it

could be exposed to freezing temperatures.

❑ Install a condensate pump if no appropriate drain is

available.

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  oor

with clips or other means to prevent movement.

Protect tubing from damage  If foot tra c 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  oor drain, and applicable codes do not prohibit draining untreated condensate, terminate the condensate line so condensate can reliably  ow to the drain.

Condensate pump termination

If no gravity drain is available, install a condensate pump. Use only a pump designed for use with condensing furnaces and boilers.  e pump must have an over ow switch to prevent damage from over owing condensate. Wire the switch into the boiler limit circuit. See the 200i Control manual for details.

❑ Install a condensate neutralizing system when

required.

Figure 23 Connecting a condensate drain line

Neutralization

When required by codes or preference, install an appropriate condensate neutralization system.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Fill and test the system

Failure to adhere to the following could result in

boiler section failure, resulting in potential for severe personal injury, death or substantial property damage.

❑ Flush and clean the system before  lling.

❑ Provide clean water to  ll the system

❑ Water quality must be as prescribed in this manual.

Follow the system water checklist

Follow the guidelines in this section to  ll and test the system.  e system water 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.

❑ Closed systems only

• A er  ushing the system thoroughly, use trisodium phosphate or other chemical sold for cleaning hydronic systems to remove sediment and sludge.

Use caution when working with chemicals,

following all guidelines speci ed by the chemical supplier and the applicable codes.

❑ Purge air from the system

•  e system should be installed with purge valves such as those shown in the suggested piping in this manual. Purging is the most e cient way to  ll the system and remove most of the air.

• Connect a hose to a purge valve and run the hose to an appropriate draining area. (When  lling with antifreeze solution, run the hose back to the solution tank.)

• Close all isolation valves in the system.

• Do not apply the 200i 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 so ener in the  ll line to so en the water before it enters the system.

• On multiple boiler commercial installations, the large volume of water in the system can contain substantial mineral salts, even if the  ll water hardness is less than 7 grains.  ese salts can deposit in the boiler heat exchanger as limestone, causing possible section damage. Commercial installations should usually be  lled with so water to avoid this problem.

❑ Prevent oxygen corrosion

• Make sure the system is provided with adequate automatic air elimination, including an in-line air separator and automatic air vents (diaphragm or bladder tank systems) 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

• Open the manual valve (or quick- ll valve) on the make-up water line. (When  lling 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  ll the zone. A er  lling the zone, close the isolation valves and move to the next zone.

• Fill and purge the boiler loop in the same manner.

• A er the boiler is operated for a while, air entrained in the  ll water will bubble out of the water as it heats, and will have to be removed by using air vents in the system.

❑ Add a chemical inhibitor

• A er purging and  lling the system, add a chemical inhibitor sold for use in hydronic systems to prevent limestone and magnetite deposits from forming, and to protect the boiler from galvanic corrosion.

❑ Water pH

• Flush the system to remove sediment,  ux,  lings and other foreign ma er. Use cleaning chemicals sold for use in hydronic systems.

• Replacement boiler installations o en 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 isolation valves in the system.

• Flush until the water runs clean.

•  e boiler water must be slightly basic, never acidic. Use litmus paper to check pH, which should range from 7.0 minimum to 8.5 maximum.

• If pH does not comply, provide water chemistry correction from a quali ed water treatment specialist. If required, make sure that the owner is aware and that the regimen will be continued.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Fill and test the system (continued)

❑ Antifreeze

• Antifreeze for hydronic systems contains propylene glycol and an inhibitor. Without the inhibitor the glycol is actually 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, determine 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 temperature. 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.  is 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.  e circulator size must be increased to account for this. As a rule of thumb, increase the  ow rate by 15%. Assume a 10% reduction in pressure drop compared to water only at a give  ow rate.

• Constant circulation  For areas of the system that will be exposed to low temperatures, 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 e ects of the antifreeze.

❑ System pressure

• Once the system is cleaned,  lled, purged and treated as required, set the make-up water pressure reducing valve to the correct cold- ll pressure.  is is usually 12 psig for systems using 30 psig relief valves. For higher pressure systems, set the cold- ll pressure such that the system pressure will never exceed about 80% of the boiler relief valve se ing when system water temperature reaches the maximum operating temperature that the system and boiler temperature controls will allow.

 e 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  ll, the water level in closed-type expansion tanks should not be above center. Use the tank   ing to verify tank water level is correct.

• As the system heats up, the water will expand, causing the system pressure to increase. If the 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   ing is correctly installed. For diaphragm or bladder-type tanks, you may have to remove the tank from the system and verify that it can hold pressure. 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.  e resultant addition of make-up water will cause mineral deposits and oxygen corrosion in the boiler.

• 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 quali ed 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 manufacturer’s 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.

❑ Final checks

• A er the system is cleaned,  lled and purged, and the system pressure is correctly set, make sure the water chemistry is correct.  e pH and chemistry must be as required (and speci ed by the chemical treatment specialist when required).

• Make sure all valves are correctly set. Isolation and  ll 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.

•  oroughly 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.  is 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 se ing pressure.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Starting the boiler

Failure to adhere to the following could result in severe personal

injury, death or substantial property damage.

Accessibility

 e boiler must be accessible from both the right and le sides in order to do a correct start-up/adjustment. Make sure the  ame window on the le side and the gas valve thro le 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 o power and fuel supply

Turn o electrical power to boiler if not already o . 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  re and low  re.

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.

Should overheating occur or

gas supply fail to shut o :

Do not interrupt water  ow to the boiler.

Instead, shut o gas supply to the boiler with the manual valve in the gas supply line.

En cas de surchau e ou si

soupape en gaz ne s’arrête pas :

N’interrompez pas l’écoulement d’eau

par la chaudière. Fermez manuellement le robinet d’arrêt de l’admission de gaz.

Start-up checklist

❑ Read all boiler manuals

•  e 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.

❑ Check the boiler area

• Make sure there are no combustible materials or chemicals that could cause air contamination in the boiler room.

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  ame

Never use an open  ame to test for gas leaks. Always use an approved leak detection method.

Propane gas applications

 e odorant in propane gas can fade over time, reducing or eliminating the gas odor.  is makes the gas undetectable by smell. Before start-up, and periodically a erwards, have the propane supplier check/verify the odorant level.

Never attempt to measure gas valve outlet pressure

Do not a empt to measure the boiler gas valve outlet pressure.  e high negative pressure in the venturi can suck  uid out of a manometer, pulling it into the gas valve.  is would destroy the gas valve, rendering it unusable.

❑ Verify vent piping

• Inspect vent piping to be sure all joints are secure and properly sealed.

• Verify vent piping supports are correctly placed and secure.

• Check vent termination to be sure it is correct and not obstructed.

• Measure total vent pipe length and note the number of   ings. Make sure the vent complies with the 200i Ve nt / air manual.

❑ 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.

Page 33

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

• Measure the air piping length and note the number of   ings. 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 speci ed in this manual.

Starting the boiler (continued)

❑ 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.

❑ Controls

• Follow the instructions in the 200i Control manual to set the operating temperatures and parameters required for the installation (if not already done).

• Set limit controls to their lowest se ings.

• Verify thermostat circuits following the procedure given in the 200i Control manual (if not already done).

❑ Prepare the condensate system

• Verify the condensate line is connected to the boiler, correctly installed and terminated.

• Turn on power to the condensate pump (if used).

• Make sure the condensate neutralization system (if used) is functional.

• Slide the condensate hose o 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 full.

• A er  lling the condensate trap, remove the  ll hose.

• Rea ach the condensate line to the boiler condensate hose barb.

❑ 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 se ing 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 controlled by the 200i SmartCycle Control.

❑ 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 ½ psig (3.5 kPa).

Manual gas valve

• 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.

❑ 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.  en start the boiler following the Operating instructions on page 35 (page 36 for French version).

•  e boiler must be checked and adjusted, if necessary, a er 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-o s, etc. to be sure they are closed.

• Check the 200i SmartCycle control display for indications of faults.

• Are SmartCycle control se ings 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?

• If none of the above resolve the problem, follow the troubleshooting guide in the 200i Control manual.

Page 34

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Starting the boiler (continued)

To reset the SmartCycle control from lockout: Turn the boiler on/o switch OFF, then back ON.

Figure 24a SmartCycle control display during operation

Figure 24b Boiler sequence of operation, fault states and SmartCycle control display information

Normal condition Blower status Time Ignition

Standby (not heat call) OFF

Start (call for heat) OFF (Flow switch and other interlocks in

the  ow switch circuit must prove)

OFF if supply temperature is above the bottom of the heat band; circulator runs, but boiler does not  re yet

ON at purge RPM (55% of maximum) when supply temperature drops below the bottom of the heat band

Ignition trial ON at ignition RPM (30% of maximum)

Flame is sensed (Stabilization period)

Operate on demand ON at RPM based on demand (control

End call for heat ON at purge RPM (55% of maximum)

Ignition failure ON at purge RPM

Flame failure ON at purge RPM for postpurge

ON at ignition RPM (30% of maximum)

determines  ring rate % based on demand and rate of change, etc.)

Boiler restarts a normal sequence Control will try 3 times, then lockout

Boiler restarts a normal sequence

10 seconds OFF OFF

Demand OFF OFF

10 seconds

4 seconds ON ON

6 seconds OFF ON

Demand OFF ON

Normal display unless three attempts fail, then shows:

Normal display unless ignition is unsuccessful three times after restart

status

OFF OFF

Gas valve

status

IGN LOCKOUT

Date & Time of lockout

Display

(upper left)

STANDBY

FLOW WAIT

HEATING

PRE PURGE

IGN 30%

RUN %XXX

POST PRGE

(alternating to:)

For more information: See the 200i Control manual for additional information and troubleshooting.

Page 35

Cast iron condensing boiler — Installation and operation manual

WARNIN G

Cast iron condensing boiler

Figure 25 Operating instructions (for starting boiler only — follow manual instructions to check boiler operation and adjust as needed)

Starting the boiler (continued)

FOR Y OUR SAFETY READ BEFORE OPERA TING

WARNIN G

A. This boiler does not hav e a p ilot. It is equipped

with an ignition device which automatically light s t he burner .

BURNER BY HAND

B. BEFORE OPER AT ING, smel l a ll around the boile r

area fo r gas . B e sur e t o smel l n ex t t ot he oor because some gas is heavier than air and will settle on the oor .S ee below .

•D o not tr y t o light an y applianc e.

•D o not touch an y e le c t ric switch; do not use an y phone in your buildin g.

If yo u d o not f ollow these instruc tions e xac tly ,a r eo re xplosion ma y r esult, causing proper ty damage , personal injur y o r loss of lif e.

C. Use onl y y our hand to turn the gas valve handl e. Never us e t ool s. If

DO NOT TR Y T OL IGHT THE

the handl e w ill not turn by hand, don 't tr y t or epai r i t. Call a qualied ser vice technician. Fo rc e o ra ttempted repai r m ay resul t in a r e o re xplosion.

D. Do not use this boile r i fa ny par t has been under water .

Immediately cal l a qualied ser vice technician to inspec t t he boiler and to replac e a ny par t o ft he contro l s ystem and an y gas contro l t hat has been under water .

WH AT TO DO IF YO U SMELL GAS

•I mmediately cal l y our gas supplie r f ro m a phone outside of the building.

•I fy ou cannot reach your gas supplie r, cal l t he re depar tment.

Followthe gassupplier's instructions.

WARNIN G

STOP!

2. Set the thermostat to lowest setting. Pr ess the boiler ON/OFF switch to .

DO NO T T RY TO LIGHT THE BURNER BY HAND

Tu rn manual gas valv e handle clock wise to the gas valv e. (G as

4. valve may have lever handle. Va lve location will va ry by installations .)

5. Wa it ve ( ) minutes to clear out an y gas . T hen smell fo r gas , including near the oor . If you smell gas , F ollo w “ B” in the saf ety in fo rmation abo ve. If you don 't smell gas , go to the ne xt step .

6. Tu rn manual gas valv e handle counterclock wise to the gas valv e.

7. Tu rn ON all electrical po wer to the boile r.

8. Set the thermostat to its highest setting. Press the ON/OFF switch to

9. The DISPLA Y will cy cle through the ignition sequenc e, and show "RUN" when the boiler is operatin g.

10. If the boiler does not oper ate, follow the instruc tions below to " TURN OFF GAS TO BOILER. " Call your ser vice technician or gas supplie r.

OPERA TING INSTR UCTIONS

Do not attempt to operate this boiler unless it has been star ted, adjusted and maintained at least annually b y a qualied heating ser vic e t echnician.

Read the saf ety in fo rmation abo ve on this label .

Tu rn o all electrical po wer to the boile r.

OFF

CL OSE

ST OP!

OPEN

ON.

CL OSE

DISPL AY

ON/OFF SWIT CH

OPEN

M ANU AL GA S VA LV E

TO TURN OFF GAS TO BOILER

1. Set the thermostat to its lowest setting.

2. Tu rn o all electric po wer to the boiler if ser vice is to be per fo rmed .

3. Tu rn manual gas valv e handle clock wise to . DO NO T FORCE THE HANDLE .

CL OSE

42-5230

Page 36

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Illustration 26 En francaise . . .

Starting the boiler (continued)

Page 37

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Starting the boiler (continued)

Turn the boiler OFF

1. Turn OFF the boiler on/o switch and allow the boiler to cycle o .

2. CLOSE the manual gas valve.

3. Multiple boiler SmartCycle applications  Disconnect the communications cable or 3-wire connection to the boiler connection board. (Replace when done.)

Check ignition

1. With the manual gas valve CLOSED, start the boiler with the on/o switch.

2. Look into the  ame window, le side of the boiler (Figure 29, page 38).

3. When ignition starts, the spark should jump between the electrodes, not to other surfaces.

4.  e spark should be strong and steady. If the spark is acceptable, turn the boiler on/o switch

5. If the spark jumps 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 assembly. Replace the electrode assembly if it is damaged or not within speci cations.

OFF.  en proceed with the start-up adjustment procedure.

Insert combustion analyzer probe

 e boiler must be checked and adjusted using combustion test

instruments. Failure to accurately measure  ue gas analysis and adjust the boiler as needed could result in severe personal injury, death or substantial property damage.

1. A er the boiler has cycled o , loosen the hose clamp covering the  ue gas sampling hole (Figure 27).

 e  ue gas vent pipe may be hot. Touching the pipe with unprotected

skin could result in a severe burns.

2. Slide the hose clamp o of the sample opening.

3. Insert the combustion analyzer probe into the sample opening.

4. If using an electronic analyzer, zero and calibrate it before proceeding.

5. If using a chemical analyzer, make sure that the  uid is fresh and is at room temperature. Have a monoxer and test tubes available to test carbon monoxide levels.

Figure 27 Flue gas sampling hole

Seal test hole with high temperature silicone a er

each combustion test and annual inspection to prevent gases and condensation from leaking during appliance operation.

Figure 28 Electrical panel

Check high  re operation

1. Remove the electrical panel cover on the right side of the boiler (see item 11, page 3) as in Figure 28.

Electrical shock hazard   e electrical box contains line-voltage

wiring and contacts. Use caution when working in the electrical box to avoid contact with line-voltage elements. Turn o power to the boiler panel if necessary.

2. Connect a jumper wire across the high- re terminals of the connector board (Figure 28).  ese terminals are located on the lower row as shown.

3. Turn the boiler on/o switch ON.

4.  e boiler will start at about 30% of maximum input and immediately go to high  re.

5. Obser ve the  ame through the  ame window (le side of boiler; see Figure 29).

•  e  ame should be blue and well-de ned, with white traces.

• If the  ame is too lean (too much air), it will be light blue and unsteady.

• If the  ame appears reddish, or there are red areas on the burner surface, turn

the boiler

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.

OFF and reduce fuel with the gas valve thro le (see page 38).

Page 38

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Starting the boiler (continued)

Adjust gas valve throttle setting

Allow combustion to stabilize

• Allow the boiler to operate 15 minutes, or as needed to obtain a steady reading on the analyzer.

If the  ame or burner surface appear red, NO NOT allow the boiler

to run without adjusting the gas valve thro le to reduce fuel input as described below. Proceed with  nal thro le se ing only if the  ame is visually acceptable (blue and steady).

Acceptable CO2/O2 values

•  e CO2/O2 values must be within the limits given in Table 5.  e  ame must be blue and steady as discussed on page 37. CO must be no higher than 100 ppm.

Table 5 Acceptable CO2 and O2 values

Natural gas – High  re CO2 / O

Minimum % 8.4 / 6.2 Minimum % 7.5 / 7.8 Maximum % 9.5 / 4.2 Maximum % 8.2 / 6.5

Propane – High  re CO2 / O

Minimum % 9.3 / 6.2 Minimum % 8.2 / 7.8 Maximum % 10.7 / 4.2 Maximum % 9.1 / 6.5

Natural gas – Low  re CO2 / O

Propane – Low  re CO2 / O

Figure 29 Throttle adjustment and  ame window

Adjusting gas input with throttle screw - max input

1. Adjust gas input with the thro le screw adjustment using a long-shank common bit screwdriver inserted through the hole in the jacket top. (Figure 29)

2. When adjusting the thro le se ing, make changes in half-turn increments. Allow the  ame to stabilize before adjusting each time. (Reduce gas input if the  ame or burner appears red.)

3. If CO2 is too HIGH (O2 too low):

• REDUCE gas by turning the adjustment CLOCKWISE (one half turn at a

time). Recheck the analyzer and  ame a er each half turn.

4. If CO2 is too LOW (O2 too high):

• INCREASE gas by turning the adjustment COUNTERCLOCKWISE (one

half turn at a time). Recheck the analyzer and  ame a er each half turn.

Verify gas inlet pressure

1. With the boiler operating at high  re, check the gas pressure at the manual gas valve. Gas pressure should never fall o by more than 2 inches WC (50 mm).

To meter gas input (natural gas only):

1. Meter gas input with the high- re jumper in place.

2. Turn o all other gas appliances that use the same gas meter as the boiler.

3. Call your gas supplier and ask for the heating value of the gas (Btu per cubic foot).

4. Start the boiler and let it run for 15 minutes (high- re jumper in place).

5. With the boiler operating, clock the time in

10 cubic feet of gas at high  re.

6. Insert the heating value and the time, in seconds, into the formula below.

Input = [

7. If the computed rate exceeds the desired input rate or 200,000 Btuh, reduce the gas input with the gas thro le adjustment.

Gas Btu per cubic foot] x [3600] x [10] ÷ [seconds]

SECONDS that it takes to burn

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  re operation.

1. Turn the boiler on/o switch OFF.

2. Remove the high- re contact jumper. Connect the jumper wire across the low- re terminals of the connector board (Figure 28, page 37).  ese terminals are located on the lower row as shown.

3. Turn the boiler on/o switch ON.

4.  e boiler will start at about 30% of input and then move to the low  re condition.

5. Make sure the  ame is blue and steady, NOT red or light blue and unsteady.

6. If the  ame or burner appears red, or if the CO2 or O2 are outside the ranges of Table 5, turn the boiler on/o switch

OFF.

7. See the next page for instructions to adjust the gas valve low- re se ing.

8. If  ame and CO2/O2/CO are acceptable, proceed with setup (page 40)  No further gas valve adjustments

are needed

low- re jumper and replace the electrical panel cover.

. Replace the gas valve cover plate. Remove the

Changing from propane to natural gas or

natural gas to propane

the boiler for a di erent gas, the low- re gas adjustment must be changed using the procedure on page 39.

 When adjusting

Page 39

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Starting the boiler (continued)

When is low  re adjustment required?

Adjust the gas valve low- re se ing ONLY if the  ame 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- re se ing as described below.

The boiler jacket top must be removed when it is necessary to access the gas

valve low- re adjustment screw or other interior components, such as the blower motor. Use the procedure below.

Removing the boiler jacket top

1. See Figure 30.

2. Remove the three thumb screws securing the  lter access plate.

3. Remove and set aside the  lter access cover and gasket.

4. Pull back on the  lter clamp and remove the  lter.

5. Hold the  lter 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. If there is no air pipe a ached to the air inlet, leave the air inlet plate in place.

8. If air 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. Li o the jacket top. (Leave the wire harnesses connected.)

11. Move the insulation aside if necessary.

Figure 30 Removing boiler jacket top

Adjusting the low- re setting

DO NOT adjust the low- re se ing unless low- re  ame or combustion

are unacceptable.

1. See Figure 31 for the location of the gas valve low- re adjustment. Use a 2-mm hex wrench.

2. When adjusting the low- re se ing, make changes in half-turn increments. Allow the  ame to stabilize before adjusting each time. (Reduce gas input if the  ame or burner appears red.)

3. If CO

4. If CO

is too HIGH (O2 too low):

• REDUCE gas by turning the adjustment COUNTERCLOCKWISE (one

half turn at a time). Recheck the analyzer and  ame a er each half turn.

is too LOW (O2 too high):

• INCREASE gas by turning the adjustment CLOCKWISE (one half turn at a

time). Recheck the analyzer and  ame a er each half turn.

Replace the boiler jacket top

1. To replace the jacket top, reverse this order above. Make sure insulation is in place.

2. Slide the conical grommet over the blower inlet  en seat the grommet ring into the hole in the jacket top.

3. Rea ach the air inlet plate if it was removed. Inspect the air piping to make sure it was not displaced.

4. Pull the air  lter clamp back. Replace the  lter, gasket and access cover. Secure with the three thumbscrews. Replace the gas valve cover plate if removed.

5. Remove the low- re jumper from the connection board. Replace the electrical panel cover.

Figure 31 Gas valve adjustments

Page 40

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Starting the boiler (continued)

Measure  ame current

Electrical shock hazard   e 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  ame current.

1. With the boiler operating at low  re (low- re jumper in place), measure the  ame current.

2. Remove the upper electrical panel cover (upper right side of boiler).

3. A ach microammeter leads to the  ame current test pins of the Fenwal ignition module as in Figure 32.

4.  e  ame current should be approximately 6 microamps, and never less than 1 microamp. Record the  ame current value on the back page of this manual.

5. If  ame current is acceptable, continue with setup. If  ame current is too low, check the ignition electrode/ ame rod assembly following the instructions in the Maintenance section of this manual.

Check boiler modulation

1. Remove the low- re jumper from the electrical connection panel (see Figure 28).

2.  e boiler  ring rate should change to meet demand.  e SmartCycle control display will show the percentage of maximum  ring rate (between 20% and 100%).

Figure 32 Throttle adjustment and  ame window

Test  ame 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 a er the  ame goes out, the boiler gas valve should shut o .

3.  e SmartCycle control will restart operation with prepurge, then continue through a normal start cycle.

4. With the manual gas valve closed, the boiler should a empt ignition three times, then lockout, as described below.

Ignition failure

1. Make sure there is a call for heat.

2. Turn the boiler on/o switch OFF.

3. Close the manual gas valve on the gas supply line.

4. Turn the boiler on/o switch ON.

5.  e boiler should start a regular cycle.

6. When the boiler a empts ignition, no  ame will occur. Within 4 seconds of ignition start, the control will close the boiler gas valve and a empt another start.

7. A er three failed ignition a empts, the Fenwal control will lockout.

8.  e boiler will shut o and the SmartCycle control display will show “LOCKOUT.”

9. Open the manual gas valve.

10. Reset the controls by turning the boiler on/o switch o , then on again.

11.  e boiler should restart and operate normally.

2.  e boiler should gradually cycle to minimum input ( ring rate = 20%), then turn o .

Test external controls

1. Lower the se ing of external limit controls below the supply water temperature. Verify that the controls shut down as required.

2. Test operation of low water cut-o s,  ow switches and other external devices.

3. Test external gas pressure interlocks, if used.

4. Test/verify operation of combustion air dampers and end switches, if used.

DHW applications

1. For DHW applications, verify that the boiler operates on demand from the indirect water heater and shuts o as required.

Test control & interlock operation

Test SmartCycle operating limit function

1. Allow the boiler to  re until the supply temperature reaches the upper end of the control band.

Fill out the installation certi cate

1. Complete the checklist and installation certi cate on the back page of this manual.

Page 41

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Annual start-up

 e boiler and system must be inspected, started

and serviced at least annually by a quali ed service technician. Follow all procedures speci ed in the 200i manuals. Failure to inspect, test and maintain the boiler and system could result in severe personal injury, death or substantial property damage.

Electrical shock hazard  Use caution

when working on the boiler where electrical components are exposed. Turn o power to the boiler if necessary to avoid potential for electrical shock.

Annual start-up overview

Perform start-up, pages 32 – 40

Perform the complete start-up, testing and inspection procedures 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 system components.  e start-up checklist that follows includes inspections and testing intended to verify that the boiler and system are still fully functional.

Annual start-up checklist

obstructed heat exchanger could result in severe personal injury, death or substantial property damage.

❑ Verify boiler water treatment

• If the system requires water treatment, make sure the treatment is being performed as required. Ensure that the water so ener, if used, is operational and is being maintained.

• If the system uses antifreeze, check the antifreeze concentration and inhibitor level. If the levels are low, check for leaks or other causes. Adjust the antifreeze level or re ll the system as indicated.

❑ Check expansion tank & air vents

• Inspect the relief valve and piping to be sure there are no signs of relief valve leakage.

• If the relief valve has been weeping, make sure the expansion tank is not waterlogged or undersized.

• When performing the boiler start-up, watch the pressure gauge as the boiler and system heat up. If the pressure rises too fast or too high, the relief valve is not working properly. Correct the problem as required.

• Make sure all air vents are operating correctly.

❑ Inspect and test the relief valve

• Follow the instructions on the relief valve label to inspect and test the boiler relief valve.

When discharging the relief valve, make sure there

is not risk of spraying water to you or others.

❑ Discuss system performance with the

homeowner or boiler operator

• Ask the homeowner or boiler operator to rate the performance of the heating system over the last season.

• If the homeowner or boiler operator identi es boiler or system problems,, identify the cause and adjust or repair as necessary.

❑ Inspect the air  lter

• Remove, inspect (and clean if needed) the air  lter. (See instructions in the Maintenance section.)

If the  lter enclosure and blower inlet show signs

of drywall dust, construction debris or other deposits, you may need to inspect the burner. Follow the procedure in the Maintenance section. Accumulation of debris in the burner can result in burner damage and potential for severe personal injury, death or substantial property damage.

If the burner is removed for inspection, also

inspect the boiler heat exchanger. If the heat exchanger is damaged or blocked with debris, consult the factory for corrective action. Operating the boiler with a damaged or

❑ Condensate line maintenance

• Make sure the condensate line, condensate pump and neutralization 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 a aching a -inch clear plastic tube to the hose barb. Pour water into the tubing until the trap is full.

• Remove the clear tubing and rea ach the condensate line to the boiler hose barb.

❑ Perform a complete start-up

• Inspect, adjust and start-up the boiler and system components as instructed on pages 32 through 40. Perform all procedures to ensure the boiler and system are operating properly.

❑ Review with homeowner/operator

• Review the User’s information manual with the homeowner or operator.

• Make sure that all maintenance procedures are being followed and that all instructions are clear and understood.

Page 42

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Maintenance

Read before proceeding

Failure to adhere to the following

could result in severe personal injury, death or substantial property damage.

Licensed technician only

 e procedures in this manual must only be done by a quali ed service technician. Some details of service procedures are le to the expected good practices of a quali ed 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 a empting to service or remove. Some parts may be very hot.

Do not open water piping components unless the water 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 the seal is restored when servicing is complete. Gaskets must be in good position and placed as originally installed.

Handling ceramic  ber and  berglass materials

The 200i boiler contains some ceramic

ﬁ ber and ﬁ berglass materials. Ceramic ﬁ ber materials, such as the burner gasket, may contain carcinogenic particles (chrystobalites) after exposure to heat. Airborne particles from ﬁ berglass or ceramic ﬁ ber 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-  ing clothing, gloves and eye protection. Use a NIOSH N95 certi ed respirator.  is respirator meets requirements for protection from chrystobalites.  e actual job requirements or NIOSH regulations may require other or additional protection. For information, refer to the NIOSH website, h p://www.cdc.gov/niosh/homepage.html.

Ceramic  ber removal

• Ceramic  ber removal: To prevent airborne dust, thoroughly wet ceramic  ber with water before handling. Place ceramic  ber materials in a plastic bag and seal to dispose.

• Avoid blowing, tearing, sawing or spraying  berglass or ceramic  ber materials. If such operations are necessary, wear extra protection to prevent breathing dust.

Read the instructions

Do not a empt 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.

• Wash work clothes separately from other laundry. Rinse clothes washer thoroughly a erwards to prevent contamination of other clothing.

NIOSH First aid procedures:

• Eye exposure  irrigate immediately

• Breathing  fresh air.

Page 43

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Maintenance (continued)

Cleaning the air  lter

1. Turn the boiler on/o switch OFF.

2. Remove the three thumb screws that secure the  lter access plate (see Figure 33).

3. Remove the  lter access plate and gasket.

4. Pull the  lter clamp back and remove the air  lter.

5. Inspect the  lter and the  lter enclosure area for dust or debris.

6. Clean the  lter, if necessary, by washing under running water. Shake o excess water and towel dry.

If the  lter enclosure and blower inlet show

signs of drywall dust, construction debris or other deposits, you may need to inspect the burner. Follow the procedure in 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. If the  lter is damaged or cannot be cleaned e ectively, obtain a replacement  lter from your boiler distributor.

8. To replace the air  lter, pull the  lter clamp back, insert the  lter, and allow the clamp to secure the  lter in place.

9. Replace the  lter access cover gasket and access cover.

10. Replace the three thumbscrews and  nger tighten securely.

11. Turn the boiler on/o switch

ON.

Figure 33 Accessing the air  lter

Figure 34 Electrode/ ame rod assembly inspection

Accessing the electrode assembly

1. Turn the boiler on/o switch OFF.

2. If the boiler ignition electrodes or  ame rod appear to be operating incorrectly, remove and inspect the assembly as follows.

Do not remove the electrode assembly while the

boiler is operating. Allow the boiler and electrode assembly to cool before a empting 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 ¼ inch bolts that secure the electrode/  ame rode assembly to the boiler (Figure 34).

•  e electrode spacing must be 1/8 inch (3.2 mm) as shown in Figure 26.

4. If the electrodes or  ame rod are damaged or the tip spacing is incorrect, replace the assembly.  e electrodes are NOT adjustable.

5. Re-install the assembly in the boiler.

Make sure the electrode plate gasket is in good

condition and that the assembly is securely bolted to the boiler.  e combustion chamber operates with a positive pressure. Failure to comply could result in severe personal injury, death or substantial property damage.

Page 44

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Maintenance (continued)

Accessing the burner

If the  lter enclosure and blower inlet show signs of drywall dust,

construction debris or other deposits, you may need to inspect the burner. Follow the procedure below. Accumulation of debris in the burner can result in burner damage and potential for severe personal injury, death or substantial property damage.

Perform this procedure only if evidence indicates the burner may be

fouled or damaged.

1. Turn the boiler on/o switch OFF.

2. Close the manual gas valve.

3. Remove the boiler jacket top following the procedure given on page 39.

4. Disconnect the gas supply piping at the ground joint union installed adjacent to the boiler.

5. Carefully remove the upper insulation (item 4, Figure 35)that covers the upper section cover. See Figure 35. Set the insulation aside for reuse.

 e upper insulation must be replace a er completing this work to

prevent overheating of the gas valve, blower and jacket top.

6. To access the bolts and nuts that secure the upper section cover:

• Remove the sheet metal cover plate at the  ame 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 ¼ inch bolts

and nuts.

7. Remove the seven ¼ inch bolts, nuts and washers that secure the upper section cover (item 2, Figure 36). Note for reinstallation that there is a  at washer on both sides of the assembly and a lock washer on top.

8. 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.

9. Li the upper cover plate/blower/gas valve assembly o of the section assembly. ( e upper section cover gasket is adhered to the bo om the cover with silicone RTV.)

10.  e burner is now exposed.

11. Li the burner up as in Figure 37 and inspect both sides. ( e burner gasket is adhered to the bo om the cover with silicone RT V .)

12. Look down into the section assembly to verify it is clean. If the heat exchanger is blocked with sediment or shows damage, contact Mestek immediately for corrective action.

13. If the burner is damaged, obtain a replacement burner from your distributor. Install the new burner.

14. If the burner is fouled with debris, a empt 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.

15. Inspect the ceramic  ber chamber (item 3, Figure 37) and  ber gasket (item 2, Figure 37). Make sure they are in good condition, or replace.

16. Replace the burner or install a new one.

17. Replace all components in the reverse order from above.

Use extreme care when replacing the upper section cover.  e seal must

be secure to avoid potential of carbon monoxide leakage or heat damage caused by  ue 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 a er 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

Page 45

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Notes

Maintenance (continued)

Page 46

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Replacement parts

ITEM PART No. DESCRIPTION QTY

1 20-1022

2 70-1655

5 58-1555

7 70-1223

11 70-1421

17 60-4280

19 57-3657

22 59-1089

24 59-1091

29 02-1580

31 70-1657

T&P Gauge

Jacket Panel Assembly

Illuminated Rocker Switch

Base Assembly

Blank Box Assembly

Sight Glass

Filter Box Thumb Screw

Combustion Air Filter

Filter Box Adapter Gasket

Gas Valve

Burner

ITEM PART No. DESCRIPTION QTY

41 09-1520

42 56-3346

45 26-3211

46 02-4288

NS 02-4290

NS 58-1831

NS 70-2074

NS 70-2075

NS 70-2076

NS 70-2077

47 02-5210

TACO 005 W/Internal Flow Check

3" Flue Adpater

50V Transformer

Breakout Board w/Wire Connectors

Display Board

5K Resistor

Harness (J2) Ctrl

Harness (J3) Ctrl

Harness (J4) Ignition/Flue Switch

Harness (J5) Blower/Gas Valve

Blocked Flue Switch

NS 59-1086

33 22-1203

22-1200

22-1803

22-1201

35 70-6700

04-1344

04-1345

04-1346

36 02-4296

NS 59-1112

37 03-1756

38 02-3928

Lower Chamber Gasket

30 psi Relief Valve

50 psi Relief Valve

75 psi Relief Valve

100 psi Relief Valve

Ignitor Assembly

Spark Rod

Ground Rod

Flame Sensor

Ignition Control

Ignition Block Gasket

Ignition Cover

High Limit Switch

48 45-1274

50 01-1640

51 58-1837

NS 70-1651

NS 02-1584

NS 02-1585

52 57-3413

54 02-4287

NS 60-5616

NS 60-5628

NS 70-1244

NS 70-1232

NS 70-1660

Ceramic Fiber Chamber

Upper Casting Cover

Blower

Blower Assembly

Intake Adapter Flat

Intake Adapter Hose

#6 X 1/2" Blk Screw

Control Board w/Display

Control Overlay

Display Label

Drain Assembly

Condensate Drain Extension

Drain Pan Assembly

39 02-3927

40 03-1776

Operator - Supply Sensor

Ignition Box Cover

NS 42-2999

NS 60-4257

Rating Label

Air Vent

Page 47

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Replacement parts (continued)

Page 48

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Appendix A — 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   e 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 A1.

• I AR connections  See Figure A1 for typical wir ing to the IAR inputs when using 3-wire zone valves without a zone controller. For other applications, see the Control manual and Section 7 of this manual.

Polarity   e connections to the IAR positive terminals (IAR +)

3-wire zone valves: You will have to rewire existing 3-wire zone valves

to meet the requirements shown in Figure A1. 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.

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)

3-wire zone valves: Always use a voltmeter to verify the wiring is

correct.  e center terminal of the valve must be 24VAC to ground when the thermostat is calling for heat.  e 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.

Page 49

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Appendix A — suggested wiring (continued)

IAR (Indoor Air Reset) wiring, when used Wiring for circulator relays (relays must have 24VAC common terminals)

Relays must have a 24VAC common terminal:  e 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, you will have to remove the existing relays and replace with a circulator zoning controller or install relays that provide a 24VAC common terminal.

• Heat Demand terminal connections using circulator relays   e end switch leads from the relays must connect to the Heat Demand terminals on the electrical connection board as shown in Figure A2.

• I AR connections  See Figure A1 for typical wir ing to the IAR inputs when using circulator relays. For other applications, see the Control manual and Section 7 of this manual.

Polarity   e connections to the IAR positive terminals (IAR +)

must be as shown in Figure A2.  e 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 the transformer to be shorted out and damaged.

Figure A2 Indoor Air Reset wiring to IAR terminals with

3-wire zone valves and no zone controller

(see Figure 21a for terminal block 6 location)

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.

Page 50

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Appendix A — suggested wiring (continued)

IAR (Indoor Air Reset) wiring, when used Wiring for typical zone controller

• Heat Demand terminal connections   e end switch leads from the controller must connect to the Heat Demand terminals on the electrical connection board as shown in Figure A3.

• I AR connections  See Figure A3 for typical wir ing to the IAR inputs when using a zone controller. For other applications, see the Control manual and Section 7 of this manual.

Polarity   e 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 A3.  e 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.

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.  e 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 to a DHW tank aquastat and circulator.  e priority switch will turn o space heating when there is a DHW call. Read the controller manufacturer’s instructions to determine which zone is set up for priority operation.

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Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Figure A3 Indoor Air Reset wiring to IAR terminals, Heat Demand and DHW Demand using typical zone controller for

Appendix A — suggested wiring (continued)

either circulators or zone valves

(see Figure 21a for terminal block 2 and 6 locations)

Page 52

Cast iron condensing boiler — Installation and operation manual

Cast iron condensing boiler

Start-up & service history

Installation and start-up (complete before leaving installation site)

Start-up date Boiler model Serial number Installer/start-up company name and address:

_____________________________________________________

Fuel (natural or LP) High  re CO

Low  re CO

Flame current Gas supply pressure

Check o each item listed below to indicate the work was performed and all installation aspects agree with boiler manuals

❑ System and boiler  lled with water ❑ Ignition control tested for ignition failure ❑ Additional comments below:

❑ System  ushed before  lling ❑ SmartCycle control adjusted per Control manual

❑ Water chemistry tested/regimen established ❑ Vent/air piping installed correctly

❑ Air purged from water system ❑ Boiler operated through several cycles

❑ Air vents checked and opened as needed ❑ Limits and interlocks tested

❑ Water piping correct and operational ❑ Metered gas input (natural gas)

❑ Gas supply pressure tested/veri ed ❑ DHW system tested, if applicable

❑ Gas supply piping correct ❑ Explained User’s manual to owner

❑ Flame observed and combustion tested ❑ Instruction manual will be kept at site

(O2)Low  re CO Metered input, Btuh

(O2) High  re CO

_____________________________________________________

Technician ___________________________________________

Phone ______________________________________________

Service history (complete before leaving boiler site after service)

Service date Technician Service company/address

Mestek, Inc • 260 North Elm St. • West eld, MA 01085 • 413-568-9571

Describe service performed

___________________________________

Describe service performed

___________________________________

Describe service performed

___________________________________

Describe service performed

___________________________________

Mestek 200i Installation And Operation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual