Raypak 302B, 902B manual Post Start-Up Check, Leak Test

Page 49

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. 42: 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 Deletions None Contents Pay Attention to These Terms Installations at Elevation Before InstallationProduct Receipt Model IdentificationComponent Locations Back Component LocationsGeneral Information Time/Temperature Relationships in Scalds General SafetyWater Time to Produce Serious Temp Burn Installation Codes InstallationEquipment Base StackingOutdoor Installations Indoor InstallationsClearances Ft 91 cm within a Indoor Units Combustion and Ventilation AirReversing Air Filter Direct VentConventional Combustion Air Supply InstallationsTruSeal Combustion Air All Air from Inside the BuildingWater Piping Canadian InstallationsGeneral Reversing Water ConnectionsCold Water Operation Relief Valve Piping Hydrostatic TestHydronic Heating Temperature & Pressure GaugePump Selection Cold Water StartsPiping Pressure Drop in Feet of Head Feedwater RegulatorAir-Separation/Expansion Tank Three-Way ValvesPool Heating Potable Water and Space HeatingWinterizing Your Heater Automatic Chlorinators and Chemical FeedersPool/Spa Water Chemistry Water HardnessTotal Dissolved Solids PH of WaterGas Supply Connection Gas SupplyModel Table K Maximum Equivalent Pipe LengthGas Supply Pressure Electrical Power ConnectionsField-Connected Controllers Check the Power Source Field Wiring ConnectionMaking the Electrical Connections Stage Tankstat Flue Exhaust Tee VentingModel Diameter Order Number Appliance CategoriesVent Terminal Location Support of Vent StackCanadian Installations InstallationsChanging the Flue Outlet Venting Configurations Venting Installation TipsInstallation Natural Draft Vertical Venting CategoryCommon Venting System TerminationCertified Vertical Venting Combustion Air Air Inlet HeightHorizontal Through-the-Wall Venting Category Horizontal Through-the-Wall Venting CategoryModel Certified Maximum Combustion Air Inlet Direct Vent Horizontal Through- the-WallVenting EquivalentDirect Vent Vertical Direct Vent VerticalControls Outdoor InstallationFreeze Protection Models 302B-902B Heater Sequence of OperationExternal Lights Color Indication Code Condition Ignition ModuleFlow Switch High Limit Manual ResetHigh and Low Gas Pressure Switches Low Water Cut-Off OptionalUDB Fault History UDB Diagnostic BoardPump Time Delay Table R UDB Fault Messages Water Piping 87%-Efficiency Boilers Special InstructionsVenting Appliance Categories Model 10F 20F 30F Min. Flow Max Flow GpmVent Terminal Location Vertical Venting CategoryCondensate Management 752BE Combustion Air 902BE 30’ 80’ Certified Maximum Combustion Air Air Inlet Model VentingDirect Vent Horizontal Through- the-Wall ABS Cpvc Wiring Diagram Pre Start-up START-UPMain Burner Adjustment Blower AdjustmentStart-Up Leak Test Procedure Dual-Seat Gas Valves Safety InspectionFollow-Up Pilot Turn-Down TestLeak Test Post Start-Up CheckLighting Instructions OperationTo Turn Off Gas To Appliance Step TroubleshootingSuggested Minimum Maintenance Schedule MaintenancePreventive Maintenance Schedule Semi-Annually WeeklyAnnually As RequiredInside 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 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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