Raypak 902B, 302B manual Safety Inspection, Follow-Up, Pilot Turn-Down Test

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Safety Inspection

1.Check all thermostats and high limit settings.

2.During the following safety checks leave manome- ters hooked up, check and record.

3.If other gas-fired appliances in the room are on the same gas main, check all pressures on the Hi Delta with all other equipment running.

4.Check thermostats for ON-OFF operation.

5.Check high limits for ON-OFF operation.

6.While in operation, check flow switch operation.

7.Check the low gas pressure switch. (For proper adjustment, use the attached manometers, if available, to set pressure. The scales on the switch are approximate only.) Low gas pressure switch must be set at 5.0 in. WC for natural gas and 10.0 in. WC for propane gas.

8.Make sure that the high gas pressure switch (op- tional) is set to 1.0 in. WC above manifold pressure.

Follow-Up

Safety checks must be recorded as performed.

Turn heater on. After main burner ignition:

1.Check manometer for proper reading.

2.Cycle heater several times and re-check readings.

3.Remove all manometers and replace caps and screws.

4.Replace all gas pressure caps.

5.Check for gas leaks one more time.

Pilot Turn-Down Test

The Hi Delta heaters, depending on their size, have one to three burner sections. Each burner section is supplied gas by gas valves incorporated into a single valve body. A maximum of three burner sections may be controlled by a single hot surface ignition system. The middle of the three burner sections is ignited directly with a hot surface ignition system.

The burner section that is ignited directly by the hot surface ignition system serves as a supervised pilot to light the burner sections on either side of it. The burn- er sections on either side of the supervised section (pilot) are electrically interlocked with the supervised ignition system so as they are not energized unless flame is proven on the center section which is acting as a pilot to light the right and left-hand sections.

The pilot turn-down test is conducted as follows:

1.Turn off manual valves on non-supervised burner sections.

2.Turn on electrical power and adjust thermostat to call for heat.

3.Wait for completion of ignition sequence to light burner section being utilized as a pilot for those turned off in step 1 above.

4.Gradually reduce manifold pressure (flame) on supervised burner section by slowly closing man- ual gas valve. Watch for shut-down due to loss of supervised flame signal as pressure is being re- duced. Flame signal should be lost before manifold pressure goes below 2.0 in. WC for nat- ural gas and 6.0 in. WC for propane gas.

Leak Test Procedure: Dual-Seat Gas Valves

Proper leak testing requires three pressure test points in the gas train.

Test point A is upstream of the automatic gas valve. On the first automatic valve, this is a bleedle valve. On the other valves, this is a plugged port. The bleedle valve on the first valve may be used for all the other valves as well.

Test point B is a bleedle valve located between the two automatic gas valve seats.

Test point C is located downstream of both automatic gas valve seats and upstream of the manual valve. On the manual valve, this is a bleedle valve. Identical readings will be found at the plugged port labeled as Alternate C.

Refer to Fig. 42. The numbers on the diagram refer to the steps below:

These tests are to be conducted with the electrical power to the heater turned off.

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Contents Installation & Operating Instructions Deletions None Contents Pay Attention to These Terms Before Installation Installations at ElevationProduct Receipt Model IdentificationComponent Locations Component Locations BackGeneral Information General Safety Time/Temperature Relationships in ScaldsWater Time to Produce Serious Temp Burn Installation Installation CodesEquipment Base StackingIndoor Installations Outdoor InstallationsClearances Ft 91 cm within a Combustion and Ventilation Air Indoor UnitsReversing Air Filter Direct VentInstallations Conventional Combustion Air SupplyTruSeal Combustion Air All Air from Inside the BuildingCanadian Installations Water PipingGeneral Reversing Water ConnectionsRelief Valve Piping Hydrostatic Test Cold Water OperationTemperature & Pressure Gauge Hydronic HeatingPump Selection Cold Water StartsPressure Drop in Feet of Head Feedwater Regulator PipingAir-Separation/Expansion Tank Three-Way ValvesPotable Water and Space Heating Pool HeatingAutomatic Chlorinators and Chemical Feeders Winterizing Your HeaterPool/Spa Water Chemistry Water HardnessPH of Water Total Dissolved SolidsGas Supply Gas Supply ConnectionModel Table K Maximum Equivalent Pipe LengthElectrical Power Connections Gas Supply PressureField-Connected Controllers Field Wiring Connection Check the Power SourceMaking the Electrical Connections Stage Tankstat Venting Flue Exhaust TeeModel Diameter Order Number Appliance CategoriesSupport of Vent Stack Vent Terminal LocationInstallations Canadian InstallationsChanging the Flue Outlet Venting Installation Tips Venting ConfigurationsInstallation Natural Draft Vertical Venting CategoryTermination Common Venting SystemCertified Vertical Venting Combustion Air Air Inlet HeightHorizontal Through-the-Wall Venting Category Horizontal Through-the-Wall Venting CategoryDirect Vent Horizontal Through- the-Wall Model Certified Maximum Combustion Air InletVenting EquivalentDirect Vent Vertical Direct Vent VerticalOutdoor Installation ControlsFreeze Protection Heater Sequence of Operation Models 302B-902BExternal Lights Color Indication Ignition Module Code ConditionHigh Limit Manual Reset Flow SwitchHigh and Low Gas Pressure Switches Low Water Cut-Off OptionalUDB Diagnostic Board UDB Fault HistoryPump Time Delay Table R UDB Fault Messages 87%-Efficiency Boilers Special Instructions Water PipingVenting Appliance Categories Model 10F 20F 30F Min. Flow Max Flow GpmVertical Venting Category Vent Terminal LocationCondensate Management Certified Maximum Combustion Air Air Inlet Model Venting 752BE Combustion Air 902BE 30’ 80’Direct Vent Horizontal Through- the-Wall ABS Cpvc Wiring Diagram START-UP Pre Start-upBlower Adjustment Main Burner AdjustmentStart-Up Safety Inspection Leak Test Procedure Dual-Seat Gas ValvesFollow-Up Pilot Turn-Down TestPost Start-Up Check Leak TestOperation Lighting InstructionsTo Turn Off Gas To Appliance Troubleshooting StepMaintenance Suggested Minimum Maintenance SchedulePreventive Maintenance Schedule Weekly Semi-AnnuallyAnnually As RequiredAppendix Inside Air ContaminationLimited Parts Warranty HI Delta Types H and WH Limited Parts Warranty HI Delta Type P START-UP Checklist for FAN-ASSISTED Raypak Products Important Instructions for the Commonwealth of Massachusetts
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302B, 902B specifications

Raypak is a prominent name in the heating industry, particularly known for its advanced technology and robust design in residential and commercial heating solutions. Two of their notable models, the Raypak 302B and 402B, exemplify innovation and efficiency in hydronic heating systems, designed to meet diverse needs while ensuring optimal performance.

The Raypak 302B and 402B are high-efficiency boilers that utilize gas-fueled systems. The 302B model has a heating capacity of 302,000 BTU/h, while the 402B boasts a maximum capacity of 402,000 BTU/h. This range of heating output makes these models suitable for a variety of applications, from residential heating needs to larger commercial spaces that require a reliable heat source.

One of the standout features of the Raypak 302B and 402B is their use of fire-tube heat exchanger technology. This design promotes efficient heat transfer and allows for lower emissions, thus minimizing the environmental impact. The fire-tube design also contributes to a longer lifespan and reduced maintenance costs, making these boilers a cost-effective solution over time.

Equipped with advanced control systems, the Raypak 302B and 402B ensure precise temperature regulation and improved energy usage. The digital display provides real-time feedback and diagnostics, enhancing user experience and simplifying troubleshooting. These models are also compatible with various building management systems, providing users with versatility in integration to optimize building performance.

In addition to their technological advancements, these boilers are designed with user safety and convenience in mind. They include features such as built-in safety controls, easy access for service and maintenance, and a compact footprint to fit into tight spaces. Their robust construction ensures durability, which is crucial for systems that operate under high demand.

Moreover, both models have been engineered to succeed in various climates, making them reliable choices for users in diverse geographical locations. With their energy-efficient operation, reliable performance, and advanced features, the Raypak 302B and 402B embody quality and innovation in the heating market, ensuring comfortable environments while lowering energy costs and environmental footprints.
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