Rayco 200i Guide

WARNING: If the information in this
manual is not followed exactly, a re or
explosion may result, causing property
damage, personal injury or loss of life.
Do not store or use gasoline or other
ammable vapors and liquids in the
vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS . . .
Do not try to light any appliance.
Do not touch any electrical switch; do
not use any phone in your building.
Immediately call your gas supplier
from a neighbor’s phone. Follow the
gas supplier’s instructions.
If you cannot reach your gas supplier,
call the re department.
Installation and service must be performed
by a qualied installer, service agency or
the gas supplier.
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P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler
User’s information
manual
User’s information
manual
Read all instructions thoroughly,
and perform regular maintenance
and service as directed. Keep this
manual on or near the boiler.
M2i-UM-1
200i
200i

2P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Please read before proceeding . . .
AVERTISSMENT: Assurez-
vous de bien suivre les instructions
données dans cette notice pour
réduire au minimum le risque
d’incendie ou d’explosion ou pour
éviter tout dommage matériel,
toute blessure ou la mort.
Ne pas entreposer ni utiliser d’essence
ou ni d’autres vapeurs ou liquides in-
ammables à proximité de cet appareil
ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ
UNE ODEUR DE GAZ:
Ne pas tenter d’allumer d’appareil.
Ne touchez à aucun interrupteur; ne
pas vous servir des téléphones se
trouvant dans le bâtiment.
Appelez immédiatement votre
fournisseur de gas depuis un voisin.
Suivez les intructions du fournisseur.
Si vous ne purvez rejoindre le
fournisseur, appelez le service des
incendies.
L’installation et l’entretien doivent être
assurés par un installateur ou un service
d’entretien qualié ou par le fournisseur
de gaz.
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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.

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P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Please read before proceeding . . .
SHOULD OVERHEATING OCCUR OR GAS FAIL TO SHUT OFF:
DO NOT turn o power to the boiler or circulating pump.
DO shut o the gas supply at the external shut-o valve or other gas shut-o.
En cas de surchaue ou si l’alimentation de gaz ne peut être coupée, ne pas
couper ni débrancher l’alimentation électrique de la ponpe. Fermer plutôt le
robinet d’admission de gaz à l’extérieur de l’appareil
IF ANY PART OF THIS BOILER HAS BEEN UNDER WATER
DO NOT use this boiler if any part has been under water. Immediately call a
qualied service technician to inspect the boiler and to replace any part of
the control system and any gas control which has been under water.
N’utilisez pas cet appareil s’il a été plongé dans l’eau, même partiellement.
Faites inspecter l’appareil par un tecnicien qualié et remplacez toute partie
du système de contrôle et toute commande qui ont été plongés dans l’eau.
READ AND FOLLOW ALL INSTRUCTIONS
Installation and service must be performed by a qualied installer, service
agency or the gas supplier, following guidelines given in the Boiler manual
and other documents provided with the boiler.
Improper installation, adjustment, alteration, service or maintenance can
cause property damage, personal injury (exposure to hazardous materials)*
or loss of life.
*(This boiler contains crystalline silica materials that have been identied as
carcinogenic or possibly carcinogenic to humans when inhaled).
Une installation, un réglage, une modication, une réparation ou un
entretien non comforme aux normes peut entraîner des dommages
matériels, des blessures (exposition à des matières dangereuses) ou la mort.
L’installation et l’entretien doivent être eectués par un installateur ou un
service d’entretien qualié ou le fournisseur de gaz (qui doivent avoir lu les
instructions fournies avant de faire l’installation, l’entretien ou l’enlèvement
de la chaudière et les respecter, Cette chaudière contient des matériaux qui
ont été identiés comme étant cancérogènes ou pouvant l’ être).
YOU MUST MAINTAIN THE BOILER ACCORDING TO THIS MANUAL
Read and follow the care and maintenance procedures in this manual. As
with any piece of equipment, the life and reliability of the boiler and system
depend on regular and thorough maintenance.
Failure to properly inspect and maintain the boiler and it’s vent, air, and
condensate systems can result in excessive levels of carbon monoxide,
which can cause severe personal injury or death.
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Read and follow all
instructions on this
page and throughout
the User’s information
manual. Failure to
comply could result in
severe personal injury,
death or substantial
property damage.

4P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Notes

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P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Contents
The Mestek 200i cast iron boiler . . . . . . . . . . . . 6
Caring for the 200i boiler and system . . . . . . . . . 7
Operating instructions . . . . . . . . . . . . . . . . . . 8
Care and maintenance instructions . . . . . . . . . 10
Customer service
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 [phone]
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.

6P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
The Mestek 200icondensing cast iron boiler
200i
components
On/O switch
Display
Vent outlet
Air inlet
Air lter access
cover
Gas shut-o valve
Condensate drain
line
1.
2.
3.
4.
5.
6.
7.
1
2
3
7
6
4
5

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P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Caring for the 200i boiler and system
OPERATION SEE PAGES 6 & 7 FOR OPERATING INSTRUCTIONS
FREQUENTLY
Inspect and protect:
• Air intake system
• Vent piping
• Condensate system
INSPECT & PROTECT THE INTAKE AIR (see page10 for procedures)
NO gasoline or ammable liquids or vapors in the boiler area.
NO laundry products, paints, pool chemicals, acids, cements or
glues in the boiler area if the boiler uses inside air or near the air
intake tting if air is piped to the boiler.
DON’T block the boiler air intake or air piping intake tting.
INSPECT & PROTECT THE VENT PIPING (see page10 for procedures)
Check the vent piping to make sure it is intact and that the vent
termination is not obstructed.
INSPECT & PROTECT THE CONDENSATE DRAIN SYSTEM
See item 7, page 6.
Make sure the condensate line is intact and not obstructed.
Make sure the condensate pump and neutralization lter
are operating correctly and that you are maintaining per the
manufacturer’s instructions.
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MONTHLY
Clean the air lter
REMOVE AND INSPECT THE AIR FILTER (see page11 for procedure)
The boiler includes an air lter to remove particulate from entering
air. Remove and clean the lter following the instructions in this
manual.
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EVERY 6 MONTHS
Check water components
INSPECT/CHECK/TEST WATER SYSTEM COMPONENTS (see page10 for
procedures)
Check the boiler and system piping, the relief valve, and low water
cut-o (if one is installed) as directed in this manual.
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EVERY YEAR
Arrange for annual
service and start-up
by a qualied service
technician
Have the boiler and heating system serviced and started up at the
beginning of every heating season.
A qualied technician can ensure the boiler and system are
operating correctly. Without an annual service call, your boiler and
system can develop problems.
Have the boiler/system water checked by your water treatment
specialist.
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8P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Operating instructions
FOR YOUR SAFETY READ BEFORE OPERATING
A. This boiler does not have a pilot. It is equipped
with an ignition device which automatically
lights the burner.
.
B. BEFORE OPERATING, smell all around the boiler
area for gas. Be sure to smell next to the oor
because some gas is heavier than air and will
settle on the oor. See below.
DO NOT TRY TO LIGHT THE
BURNERBYHAND
C. Use only your hand to turn the gas valve handle. Never use tools. If
the handle will not turn by hand, don't try to repair it. Call a
qualied service technician. Force or attempted repair may result
in a re or explosion.
D. Do not use this boiler if any part has been under water.
Immediately call a qualied service technician to inspect the
boiler and to replace any part of the control system and any gas
control that has been under water.
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
• Immediately call your gas supplier from a neighbor's phone.
Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the re department.
1.
2. Set the thermostat to lowest setting.
3.
4.
5. Wait ve ( ) minutes to clear out any gas. Then smell for gas, including near
the oor. If you smell gas, Follow “B” in the safety information above. If
you don't smell gas, go to the next step.
6. Turn manual gas valve handle counterclockwise to the gas valve.
7. Turn ON all electrical power to the boiler.
8. Set the thermostat to its highest setting. Press the ON/OFF switch to
9. The DISPLAY will cycle through the ignition sequence, and show "RUN" when
the boiler is operating.
10. If the boiler does not operate, follow the instructions below to "TURN OFF
GAS TO BOILER." Call your service technician or gas supplier.
STOP!
OFF
DO NOT TRY TO LIGHT THE BURNER BY HAND
CLOSE
Read the safety information above on this label.
Turn o all electrical power to the boiler.
Press the boiler ON/OFF switch to .
.
Turn manual gas valve handle clockwise to the gas valve. (Gas
valve may have lever handle. Valve location will vary by installations.)
5
STOP!
OPEN
ON.
1. Set the thermostat to its lowest setting.
2. Turn o all electric power to the boiler if service is to be
performed.
3. Turn manual gas valve handle clockwise to .
DO NOT FORCE THE HANDLE.
CLOSE
42-5230
If you do not follow these instructions exactly, a re or explosion may result, causing
property damage, personal injury or loss of life.
WARNING
WARNING
WHAT TO DO IF YOU SMELL GAS
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO BOILER
Do not attempt to operate this boiler unless it has been started, adjusted and main-
tained at least annually by a qualied heating service technician.
WARNING
WARNING
DISPLAY
ON/OFF
SWITCH
MANUAL
GAS VALVE
OPEN
CLOSE

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P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Instructions de mise en marche

10 P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Air inlet inspection
procedure
(see item 4, page 6)
Air from the boiler room: If the boiler air inlet takes air from the
boiler room (no air piping connected to the air inlet, item 4, page 6
— the room must have air openings into the room as described in
the Boiler manual. Make sure the air openings are not obstructed.
Air piped to boiler: If boiler air is provided with air piping from
outside, make sure the air piping is fully supported with no sags.
All joints must be intact. And the air intake tting outside must be
unobstructed and in good condition.
Make sure that snow, leaves or other debris are not blocking the air
inlet.
Make sure there are no contaminants or ammable materials
around the boiler or the air intake.
If you nd any problems with the air inlet system, immediately turn
the boiler o and contact your qualied service technician.
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Vent system inspection
procedure
(see item 3, page 6)
Check the entire run of the vent system where possible.
The vent pipe should be fully supported with no sags.
All joints should be intact and secure.
Make sure the vent outlet is unobstructed and in good condition.
There should be no signs of corrosion of the vent pipe or
indications of dripping water.
Make sure that snow, leaves or other debris are not blocking the
vent outlet.
If you nd any problems with the vent system, immediately turn the
boiler o and contact your qualied service technician.
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Checking water system
components
Pressure/temperature gauge (on top rear of boiler) — The pressure
gauge should never read above about 24 PSIG. Higher pressure
probably indicates a problem with the system expansion tank.
Relief valve (on top rear of boiler) — Observe the relief valve and
discharge piping. Make sure there are no signs of dripping water.
The piping discharge must be unobstructed an located where hot
water from the discharge would not pose a hazard to anyone.
Also inspect any other components if recommended by your
qualied service technician.
Contact your qualied service technician immediately if you see
any problems.
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Report problems
immediately
If you observe any problems with the boiler or system, immediately
consult your qualied service technician.
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Care and maintenance instructions

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P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Care and maintenance instructions
Cleaning the air lter
(see item 5, page 6)
Turn the boiler on/o switch OFF.
Remove the three thumb screws that secure the lter access plate
(see the illustration below).
Remove the lter access plate and gasket.
Pull the lter clamp back and remove the air lter.
Inspect the lter and the lter enclosure area for dust or debris.
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, contact
your qualied service technician to inspect the boiler.
Operating the boiler under these conditions could result
in potential serious personal injury, death or substantial
property damage.
If the lter is damaged or cannot be cleaned eectively, obtain a
replacement lter from your qualied service technician.
To replace the air lter, pull the lter clamp back, insert the lter,
and allow the clamp to secure the lter in place.
Replace the lter access cover gasket and access cover.
Replace the three thumbscrews and nger tighten securely.
Turn the boiler on/o switch ON.
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12 P/N 42-9473 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — User’s information manual
Mestek, Inc.
260 N Elm Street Westeld, MA 01085
Ph [phone] Fx [phone]