Rayco 200i User 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 dust-
freeairsupply.Follow the instructionmanualprocedurestoductairtotheboilerairintake. Iftheboiler has been contaminatedbyoperation
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.
P/N 42-9470 3/08 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler
Boiler manual
Installation and operation
instructions
Boiler manual
Installation and operation
instructions
Also read and follow:
200iControl manual
200iVent/Air manual
Also read and follow:
200iControl manual
200iVent/Air manual
M2i-IOM-2
200i
200i

2P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
The Mestek 200icondensing cast iron boiler
Operation
Overview
e 200iis 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 200iblower 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 200ielectronic 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 200icontrol, this allows maximum possible condensing mode
operation, with combustion eciency up to 98%.
Cast iron heat exchanger
e200icastironheatexchangeruses Mestek’sgraphiteport 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 op-
eration 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 NOX
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 col-
umn). 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
consistentgas/airmix throughout the boiler’s modulatingrange.us,the200i SmartCycleTM electronic
control regulates the blower speed to control boiler ring rate.
200iSmartCycleTM 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 ther-
mostats 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 stand-
alone 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.
200i
schematic
ow diagram

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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
The Mestek 200icondensing cast iron boiler
200i
components
Components
Gas valve
Pressure/temperature gauge
Jacket
Cast iron section assembly
Inlet air lter access panel
Blower
200i SmartCycleTM control
with keypad and display
Venturi assembly
Pressure switches (blocked
ue and blocked air inlet)
Control connection board
Electrical box (power and
control entrances)
Water return connection
Air inlet sleeve
Relief valve
Relief valve piping
(by installer)
Water supply connection
Fenwal ignition module
Ignition electrodes/ame
rod assembly
Control transformer
(120/24 VAC)
Postpurge circulator,
factory-installed and piped
Vent connection sleeve
(with ue gas sampling port)
Condensate tubing connection
Upper section cover and
premix burner
Gas connection, ½” NPT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
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14.
15.
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17.
18.
19.
20.
21.
22.
23.
24.

4P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Hazard icons
You will 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.
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.
Contents
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 [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 imme-
diately against the transportation company by the consignee.
1Read before beginning the installation . . . . 5
2Boiler ratings and specications. . . . . . . . . 6
3Installation site preparation . . . . . . . . . . . 7
4Prepare the boiler . . . . . . . . . . . . . . . . . 10
5Water piping . . . . . . . . . . . . . . . . . . . . 11
6Gas piping. . . . . . . . . . . . . . . . . . . . . . 18
7Wiring a single boiler . . . . . . . . . . . . . . . 20
8Control setup . . . . . . . . . . . . . . . . . . . . 25
9Vent piping (and air piping when used) . . . 28
10 Condensate drain line . . . . . . . . . . . . . . 29
11 Fill and test the system. . . . . . . . . . . . . . 30
12 Starting the boiler. . . . . . . . . . . . . . . . . 32
13 Annual start-up . . . . . . . . . . . . . . . . . . 41
14 Maintenance . . . . . . . . . . . . . . . . . . . . 42
15 Replacement parts . . . . . . . . . . . . . . . . 46
16 Appendix A — suggested wiring . . . . . . . 48

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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
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 re-
quirements 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 au-
thority 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 re-
quirements 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 Massachu-
se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.
When antifreeze is used in the system, install an approved
pressure back-ow preventer.
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, un-
contaminated 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 wa-
ter or to rain.
If replacing an existing boiler, nd out what caused the boiler
tofailbeforeinstallinganewboiler.Correcttheproblemsthat
led to failure, or the failure may happen to the new boiler.
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Donot install or operatetheboiler,orleavean 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 re-
move 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 ber-
glass 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 w.c.; One @ 0 – 5 psi
Combustion analyzer  You must use a combustion analyzer and follow
allinstructionsinthismanualtocorrectlystart-uptheboiler.Asprescribed
in this manual, the O2levels must be between 5% and 7%. roughout all
ring rate conditions, the burner surface must never show red areas. Fol-
low 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 ap-
plications 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 start-up/maintenance by a qualied tech-
nician, the avoidance of combustion air blockage or contamination, and
never bringing or storing ammable products into the boiler area.
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1

6P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Boiler ratings and specications
2
Boiler model Units 200i Notes
AFUE (DOE seasonal eciency) % 92.7 1
CSA Input (Max) Btuh
Kw
200,000
58.6 2
CSA Input (Min) Btuh
Kw
40,000
11.7 2
Maximum allowable working pressure PSIG
kPa
100
700
Water supply and return connections Inches, NPT 1¼
Boiler water volume Gallons
Liters
4.75
18.0
Shipping weight Pounds
Kg
540
245
Operating weight Pounds
Kg
510
231
Fuels Natural gas or propane 3
Gas connection size Inches, NPT ½
Gas supply pressure, minimum Inches w.c.
mm w.c.
3
102
Gas supply pressure, maximum Inches w.c.
mm w.c.
14
356
Vent connection size Inches
mm
3
76.2
Vent options Direct Vent or Category IV only
(pressurized vent, condensing)
Combustion air options Air from boiler room or
ducted to boiler from outside
Combustion air adapter size Inches
mm
3
76.2
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 SmartCycleTM control 4
Control operation options
Stand-alone
SmartCycleTM
BMS (boiler management system)
4
Control methods
Heat demand (SmartCycle or stand-alone)
On/O
BMS (4-20 ma input)
Staging
RS485 digital communication
4
Notes
1
2
3
4
5
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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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Installation site preparation
Boiler location requirements
Donotinstall the boilerunlessthe 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 ex-
pose the boiler or its gas or electrical components to rain or
dripping or spraying water.
Do not install the boiler in a location that would subject the
boiler to freezing. Wherefreeze protectionisneeded, 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 sup-
porting 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 proce-
dures. 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 rou-
tine 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.
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Buildings will require the installation of a fresh air duct or
other means of providing make-up air if the intake air op-
tion isn’t used. Any building utilizing other gas burning ap-
pliances, 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 out-
side air duct must be done to meet the requirements of all
such devices.
e boiler must be supplied with combustion air in ac-
cordance with Section 5.3, “Air for Combustion and Ven-
tilation,” of the latest revision of the National Fuel Gas
Code, ANSI Z223.1/NFPA 54 and all applicable local
building codes. Canadian installations must comply with
CSA B149.1 or .2 Installation Code for Gas Burning Appli-
ances and Equipment, or applicable provisions of the local
building codes.
Negative room pressure
Never operate the boiler in an environment subjected to a
negative pressure unless it is Direct Vented. Failure to com-
ply with this warning can result in excessive levels of carbon
monoxide.
Combustion air contamination
Combustion air contaminated with uorocarbons or other
halogenated compounds such as cleaning solvents and re-
frigerants will result in the formation of acids in the com-
bustion 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 com-
ponents must be cleaned, following instructions provided
in this manual and/or supplementary instructions from
Mestek. Where cleaning is not possible, the boiler may have
to be replaced.
Never store combustible materials, gasoline or any product
containing ammable vapors or liquids in the vicinity of the
boiler.
Clearances
All installation must provide the minimum clearances to
combustible materials given on page 7.
e installation should provide the minimum service clear-
ances given on page 7 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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3

8P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Installation site preparation (continued)
Clearance requirements
Clearances to combustible surfaces
All installations must provide the minimum clearances to 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
installations (Figure 1)
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
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.
EXCEPTION: Ventilation openings are not required if the boiler 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.
Clearances for service and operation
einstallationmustprovidereasonableaccessandclearanceforservice
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.
Flame observation port eameobservationport on theLEFT
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.
Table 2 Recommended minimum clearances for service/operation
(Figure 2)
From: Inches Millimeters
Top 24 610
Back 24 610
Left side 24 610
Right side 24 610
Front 36 914
Rear 18 457
Figure 1 Clearance to combustibles references
Figure 2 Service/operation clearance references
3

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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Figure 3 Air opening options for combustion air
drawn from boiler room
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, page 7):
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 de-
termine 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
In2/2,000 BTUH to cm2/kw  Multiply In2/2,000 BTUH times 11
In2/3,000 BTUH to cm2/kw  Multiply In2/3,000 BTUH times 7.4
In2/4,000 BTUH to cm2/kw  Multiply In2/4,000 BTUH times 5.5
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Upper openings (U) must be within 12 inches of the ceiling. Lower
openings (L) must be within 12 inches of the oor.
Option 1 — air openings through interior wall
When air is supplied to the boiler room through openings in an interior
wall (air supply from inside the building), size each opening to provide
minimum free area of:
1 in2per 1,000 BTUH of all 200i boilers in the room.
Option 2 — air openings through outside wall
When air is supplied to the boiler room through openings in an outside
wall (air supply from outside the building), size each opening to provide
minimum free area of:
1 in2per 4,000 BTUH of all 200i boilers in the room.
Option 3 — horizontal ducts to outside wall
When air is supplied to the boiler room through horizontal ducts to an
outside wall (air supply from outside the building), size each opening
to provide minimum free area of:
1 in2per 3,000 BTUH of all 200i boilers in the room.
Option 4 — openings to attic/crawl space
Air openings can be connected to a ventilated 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 crawl space. Size
each opening to provide minimum free area of:
1 in2per 3,000 BTUH of all 200i boilers in the room.
Option 5 — single opening (not shown)
A single opening directly connected to the outdoors through a wall or
a vertical or horizontal duct can be used if the installation provides the
clearances of Figure 2, and the top of the opening is within 12 inches of
the ceiling. Size the opening to provide minimum free area of:
1 in2per 3,000 BTUH of all 200i boilers in the 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).
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Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Figure 4 Relief valve piping
Prepare the boiler
Remove the boiler from the crate
Cold weather handling  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.
Remove the crate from the skid. But leave the boiler on the
skid to move the boiler near its location.
Inspect the boiler thoroughly for any possible damage that
may have occurred in shipping or handling.
Slide the boiler o of the skid into position.
Use a spirit level to check whether the boiler sides and front
are vertically plumb. If not, slide metal shims under the base
until the boiler is level.
Install the relief valve
Check relief valve pressure setting
Inspect the boiler relief valve before installing to ensure it is set
at the pressure required for the system. You should also verify
that all water system components are rated for at least the pres-
sure seing of the relief valve to avoid component damage due
to excess pressure.
e boiler maximum allowable working pressure
is 100 psig (700 kPa). e relief valve must never
haveaseinggreaterthan100psig.Usingahigher
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.
1.
2.
3.
4.
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 fol-
lowed.
A minimum clearance of 1 inch (25 mm) must be main-
tained between heating system pipes and all combustible
construction.
All heating system piping must be supported by suitable
hangers  not by the boiler.
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.
•
•
•
•
•
•
•
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Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping
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 w.c. (0.7 meter) for a ow rate of up to 18 GPM (68 LPM).
7.5 feet w.c. (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 sup-
plied 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.
Additional controls
Localcodes orjob specicationsmayrequirethe use of additional controls, such aslow
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.
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.
•
•
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
e200i boiler works well ina singleor 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.
Piping guidelines
Support the piping  All piping and
components must be supported such that no loads
orstressesareappliedtotheboiler.Allowforthermal
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 NOT intended
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.
•
•
•
•
•
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12 P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping (continued)
Figure 6 Diaphragm or bladder-type expansion tank
suggested piping
Figure 7 Closed-type expansion tank suggested piping
Expansion tank 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 circu-
lator. Make sure the tank is sized large enough to handle the system volume.
Figure 5 Expansion tank comparison
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 water-
logging of the tank, causing the boiler relief valve to weep.
Air separation is done by connecting from an in-line air separator to the 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.
•
•
•
•
•
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.
5

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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping (continued)
Figure 8 Suggested piping — single boiler — zone valve zoning — two-pipe or series loop (left), or primary/secondary piping (right)
LEGEND • • • • • • •
1200i boiler
2Boiler circulator
3System circulator
4Boiler/system circulator
5Indirect-red DHW tank
(when used)
6DHW circulator
7Flow/check valve
8Cold water ll line
9Expansion 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
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.
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 summer-
time operation of DHW tanks.
Make sure to incorporate ow/check valves as shown. esepreventforced
ow in idle zones.
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14 P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping (continued)
Figure 9 Suggested piping — single boiler — circulator zoning — two-pipe or series loop (left), or primary/secondary piping (right)
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.
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 summer-
time operation of DHW tanks.
Make sure to incorporate ow/check valves as shown. esepreventforced
ow in idle zones.
LEGEND • • • • • • •
1200i boiler
2Boiler circulator
4Boiler/system circulator
5Indirect-red DHW tank
(when used)
6DHW circulator
7Flow/check valve
8Cold water ll line
9Expansion 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
5

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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping (continued)
Figure 11 Suggested piping — multiple boilers — primary/secondary piping, reverse-return boiler headers
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.
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 summer-
time operation of DHW tanks.
Make sure to incorporate ow/check valves as shown. esepreventforced
ow in idle zones.
LEGEND • • • • • • •
1200i boiler
2Boiler circulator
3System circulator
5Indirect-red DHW tank
(when used)
6DHW circulator
7Flow/check valve
8Cold water ll line
9Expansion 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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16 P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping (continued)
Figure 12 Suggested piping — multiple boilers — parallel-ow piping, reverse-return headers
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.
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 • • • • • • •
1200i boiler
4Boiler/system circulator
5Indirect-red DHW tank
(when used)
6DHW circulator
8Cold water ll line
9Expansion 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
5

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Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Water piping (continued)
Figure 13 Suggested piping — boilers connected to chilled water systems
Chilled water systems
General
Provide the piping components 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 boil-
ers connected.
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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18 P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Gas piping
Figure 14 Connecting gas supply line
Failure to adhere to the following
could result in severe personal in-
jury, death or substantial property
damage.
Verify the gas type
Check the boiler rating plate to make sure that the boiler
is for the type of gas that will be used. 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).
1Piping from gas supply
2Manual gas valve with test port
(use tee-handle valve for
Massachuses installations)
3Piping must be clean and burr-free
black iron pipe
4Ground-joint union
5Drip leg with cap
6Gas cock pressure test port
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 avail-
able at the installation site, call your Mestek representative to
resolve the problem. (See WARNING below.)
Gas supply components
Figure 14 depicts the proper way to connect the boiler to the gas
supply piping. e gas connection at the boiler is ½” NPT.
Item 1  Installthe gas line pipingfromthe gas meteror branch
in accordance with all applicable codes. See the next page for
suggested sizing, or refer to the National Fuel Gas Code or Ca-
nadian Gas Code for recommendations.
Item 2  e manual shut-o valve must be installed in the
supply piping. Install 5 feet above the oor where required by
applicable codes.
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
couldresult,causingpossible severepersonalinjury, deathorsubstantial
property damage.
6

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P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Gas piping (continued)
Table 3 Gas ow capacity for black iron pipe
Iron
pipe
size
(inches)
Pipe length, equivalent feet (length plus allowance for ttings)
10 20 30 40 50 60 80 100 150
Natural gas pipe ow capacity (cubic feet per hour) (notes 1, 2, 3)
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
Propane gas pipe ow capacity (cubic feet per hour) (notes 2, 3)
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
Notes, Table 3
1
2
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/3 nominal).
Propane — Divide total Btuh by 2,500.
Table 4 Equivalent feet of pipe for common gas line components
Iron
pipe
size
(inches)
Equivalent feet of pipe for each tting
90° Elbow Tee
(note 1)
Gate valve
(note 2)
Gas cock
(note 2)
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
Notes, Table 4
1
2
Allows for ow through the branch of the tee.
Assumes valve is full open.
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
Minimumgassupplypressure (naturalgas 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:
14 inches (356 mm) water column.
Sizing guidelines
esizing recommendations ofTable 3 aretakenfrom theNational
FuelGasCode,ANSIZ223.1/NFPA54.Propanevaluesarebased
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 ap-
propriate 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 equiva-
lent 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
outagesandoperationfailuresofotherappliances
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.
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.
6

20 P/N 42-9470 11/07 Copyright 2007 Mestek, Inc.
Cast iron condensing boiler
Cast iron condensing boiler — Installation and operation manual
Wiring a single boiler
7
Figure 15 Electrical connection board (see item 10,
page 3 for location — Also see the wiring
summary illustrations on the next pages)
Figure 16 120VAC power service terminals on electri-
cal connection board — See Figure 15 for
location of the power terminal strip
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
ratedshut-o switchshouldbelocatedat
the boiler. e boiler must be grounded
in accordance with the authority having
jurisdiction, or if none, thelatestrevision
of the National Electrical Code, ANSI/
NFPA-70.
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.
Connectminimum 14awgcopper wiretothe powerconnection
as shown in Figure 16.
Install a fused service switch, mounted and installed in accor-
dance with all applicable codes.
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