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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
Measure the air piping length and note the number
of fi tt 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 specifi ed in this manual.
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 sett ings.
Verify thermostat circuits following the procedure given in
the
200i
Control manual (if not already done).
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 sett 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 con-
trolled 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 18.
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Starting the boiler
(continued)
Prepare the condensate system
Verify the condensate line is connected to the boiler, cor-
rectly installed and terminated.
Turn on power to the condensate pump (if used).
Make sure the condensate neutralization system (if used) is
functional.
Slide the condensate hose off of the boiler condensate hose
barb. Connect a clear plastic tube (3/16 inch diameter) to
the hose barb. Pour water into the tube until water backs
into the tube at the hose barb, indicating the trap is full.
Aft er fi lling the condensate trap, remove the fi ll hose.
Reatt ach the condensate line to the boiler condensate hose
barb.
Hose barb
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.
Th en start the boiler following the Operating instructions
on page 35 (page 36 for French version).
Th e boiler must be checked and adjusted, if necessary, aft 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-off s, etc. to be
sure they are closed.
Check the
200i
SmartCycle control display for indications
of faults.
Are SmartCycle control sett 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 trouble-
shooting guide in the
200i
Control manual.
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