Raypak 0090B 0135B installation instructions START-UP Procedures, Filling the System

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START-UP PROCEDURES

SECTION 1. Filling the System

Fill system with water. Purge all air from the system using purge valve sequence. After system is purged of air, lower system pressure. Open valves for normal system operation, fill system through feed pressure regulator to minimum 12 PSI. Manually open air vent on the compression tank until water appears, then close vent.

On multiple zone systems, purge each zone sepa- rately. Isolate the other zones while one zone is being purged of air.

Flush system before putting into operation to as- sure that foreign material does not damage pump seals.

SECTION 2. Checking the Circulator

Before lighting the boiler and after system is filled, make sure that circulator is operating properly. Manual gas valve should be off. By adjusting the wall thermo- stat to the maximum setting, circulator should run immediately and allow water to flow through the boiler and the entire system.

NOTE: Circulator motor supplied with the boiler does not require lubrication.

CAUTION: In case of a prolonged power failure during freezing weather conditions, boiler and piping system must be drained completely to avoid possible damage to the heating system.

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Contents For Your Safety Operating Installation InstructionsContents Receiving Equipment General SpecificationsSpecifications and Dimensions Clearance Requirements Installation ProceduresCode Requirements Mounting BaseVenting Connections Model Sq. In. of Free Area 0030, 0042 100Fig.# Common VentsLocation Vent Damper InstallationMounting Installing the Vent Damper in Horizontal & Vertical VentsD80D General Wiring Diagram Flair Damper Vent DamperWater Connections & System Piping GAS PRESSURE-SPECIFICATIONSGAS Supply Connections Single Zone Piping Typical PipingZone Heating with Indirect Domestic HOT Water Supply Multiple Zones with Zone Valves Multiple Zones with CirculatorsFig.# Electrical WiringFig. # 2223e Wiring Diagram Standing Pilot 24 V 2 StageWiring Diagramintermittent Ignition Device IID Models 30, 42 Fig. #2358 Wiring Diagram Intermittent Ignition Device IIDWiring Diagram Single Zone Taco Valve Wiring Diagram System with 3 Zone Pumps Fig. #2223.2e Wiring Diagram Standing Pilot With Low Water Cut Off Device Sequence of Operation Intermittent Ignition Device IID Servicing ProceduresGeneral Location of Controls Control BOX Component Locations Models 135Filling the System START-UP ProceduresWhat to do if YOU Smell GAS Lighting the BoilerFor Automatic Ignition Models Honeywell Pilot Robertshaw PilotTo Turn OFF GAS to Boiler System Shut Down ProcedureFor Automatic Ignition Systems Main Burner Flame Inspection Procedures BurnersSafe Shutdown Tests Limit Action Flame FailureRepair Section Raypak Tube Cleaning KITBurner Drawer Removal Main Burner and Orifice RemovalCombustion Chamber Removal Heat Exchanger RE-ASSEMBLYImportant Notice Trouble Shooting GuidePiping ADJUSTMENTS/REPLACEMENTS of Components RAYPAK, INC Replacement Parts ListBypass valve supplied on sizes H-0135 and H-0180 only Page Venting