Raypak 992B-1262B manual Post Start-Up Check, Leak Test

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1.Manually close the downstream leak test valve.

2.Open test point A and connect a manometer to it. Verify that there is gas pressure and that it is with- in the proper range (NOTE: must not exceed 14.0 in. WC).

3.Open test point B and connect a rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure. Increasing pressure indicates a leaking gas valve.

4.Next, close the upstream manual gas valve and remove the manometer from test point A and from test point B. Connect a rubber tube from test point A to test point B and open the upstream manual gas valve. Make sure that test points A & B have been opened so as to allow gas to flow. This will bring pressure to the second valve seat.

5.Open test point C and connect a second rubber tube to it. Connect the other end of the tube to a manometer and look for a build-up of pressure. In- creasing pressure indicates a leaking gas valve.

6.Remove rubber tube and manometers. Close each test point valve as the tubes are removed.

7.Connect a manometer to each test point (one at a time) and look for a build-up of pressure. If a build- up of pressure is detected, check each test point valve to see if it is tightly closed. If leak persists, replace test point valve(s).

8.After no leakage has been verified at all valve seats and test valves, open downstream leak tests valve and restore electrical power to heater.

Fig. 45: Leak Test

This completes leak testing for a single Hi Delta mani- fold riser. Repeat steps 1-8 for each riser.

Post Start-Up Check

Check off steps as completed:

1.Verify that the heater and heat distribution units or storage tank are filled with water.

2.Confirm that the automatic air vent (if used) was opened two full turns during the venting proce- dure.

3.Verify that air has been purged from the system.

4.Verify that air has been purged from the gas pip- ing, and that the piping has been checked for leaks.

5.Confirm that the proper start-up procedures were followed.

6.Inspect burner to verify flame.

7.Test safety controls: If heater is equipped with a low water cut-off or additional safety controls, test for operation as outlined by manufacturer. Burner should be operating and should go off when con- trols are tested. When safety devices are restored, burners should re-ignite after pre-purge time delay.

8.Test limit control: While burner is operating, move indicator on high limit control below actual water temperature. Burner should go off while blower and circulator continue to operate. Raise setting on limit control above water temperature and burn- er should re-ignite after pre-purge time delay.

9.Test ignition system safety device:

a.Turn on manual gas valve. Turn power on.

b.Set thermostat to call for heat.

c.When the heater is in operation, pull cap off of tee in air switch hose. The burner should go off immediately.

d.Wait 5 minutes.

e.Reattach cap on tee. Burner should re-ignite after pre-purge time delay.

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Contents Installation & Operating Instructions Page Contents Pay Attention to These Terms Model Identification Before InstallationInstallations at Elevation Product ReceiptComponent Locations Back Component LocationsModel Burners per Valve Stages Fire at Stage General InformationModel Quantity Vent Size Gas Burners Blowers ValvesTime/Temperature Relationships in Scalds General SafetyWater Time to Produce Serious Temp Burn Stacking InstallationInstallation Codes Equipment BaseTable D Vent/Air Inlet Termination Clearances Outdoor Installations Indoor InstallationsClearances Direct Vent Combustion and Ventilation AirIndoor Units Reversing Air FilterAll Air from Inside the Building InstallationsConventional Combustion Air Supply TruSeal Combustion AirReversing Water Connections Canadian InstallationsWater Piping GeneralCold Water Operation Relief Valve Piping Hydrostatic TestHydronic Heating Temperature & Pressure GaugePump Selection Three-Way Valves Pressure Drop in Feet of Head Feedwater RegulatorPiping Air-Separation/Expansion TankPool Heating Potable Water and Space HeatingWinterizing Your Heater Automatic Chlorinators and Chemical FeedersTotal Dissolved Solids Gas SupplyPool/Spa Water Chemistry Water Hardness PH of WaterTable I Maximum Equivalent Pipe Length Gas Supply ConnectionReversing Gas Supply Connection ModelField-Connected Controllers Electrical Power ConnectionsCheck the Power Source Gas Supply PressureMaking the Electrical Connections Field Wiring ConnectionOn-Off Wiring Connections Appliance Categories VentingFlue Exhaust Tee Model Diameter Order NumberCertified Combustion Air Support of Vent StackVent Terminal Location Combustion ExhaustCanadian Installations InstallationsChanging the Flue Outlet Natural Draft Vertical Venting Category Venting Installation TipsVenting Configurations InstallationHeight TerminationCommon Venting System Certified Vertical Venting Combustion Air Air Inlet ModelHorizontal Through-the-Wall Venting Category Horizontal Through-the-Wall Venting CategoryEquivalent Material Vent Length Intake Pipe Direct Vent Horizontal Through- the-WallModel Certified Maximum Combustion Air Inlet VentingDirect Vent Vertical Direct Vent VerticalControls Outdoor InstallationFreeze Protection Models 992B-1262B Heater Sequence of OperationExternal Lights Color Indication Models 1532B 1802B Page Page Models 2002B 2342B Page Page Operating Control High Limit Manual ResetFlow Switch Ignition ModuleLow Water Cut-Off Optional High and Low Gas Pressure SwitchesUDB Fault History UDB Diagnostic BoardWater Piping 87%-Efficiency Boilers Special InstructionsVenting Appliance Categories Vent Terminal Location Vertical Venting CategoryCondensate Management Equivalent Certified Maximum Combustion Air Air Inlet Model VentingMax. Length Material Vent Length Direct Vent Horizontal Through- the-Wall 992BE 75’ 100’ 1262BE Galvanized Steel 1532BE Category 25’ Wiring Diagram Models 992B-1262B Wiring Diagram Models 1532B-2342B Pre Start-up START-UPMain Burner Adjustment Blower AdjustmentStart-Up Pilot Turn-Down Test Safety InspectionLeak Test Procedure Dual-Seat Gas Valves Follow-UpLeak Test Post Start-Up CheckLighting Instructions OperationTo Turn Off Gas To Appliance Step TroubleshootingSuggested Minimum Maintenance Schedule MaintenancePreventive Maintenance Schedule As Required WeeklySemi-Annually AnnuallyInside Air Contamination AppendixLimited Parts Warranty HI Delta Types H and WH Limited Parts Warranty HI Delta Type P START-UP Checklist for FAN-ASSISTED Raypak Products Page
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