Raypak 302-902 manual Pilot Turn Down Test for Raypak HI Delta Boilers

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PILOT TURN DOWN TEST FOR RAYPAK HI DELTA BOILERS

The Hi Delta boilers, depending on their size, have from two to five burner sections. Each burner section is supplied gas by dual gas valves incorporated in 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 lighted 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 burner sections on either side of the supervised section (pilot) are electrically interlocked with the supervised ignition system so as to not be 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 (1) above.

4)Gradually reduce manifold pressure (flame) on supervised burner section by closing manual gas valve. Watch for shut down due to loss of supervised flame signal as pressure is being reduced. Flame signal should be lost before manifold pressure goes below 2 inches water column.

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 attached diagrams. Numbers on the diagram refer to the steps below:

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

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 within the proper range (note: must not exceed 14 inches water column).

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 u of pressure. Increasing pressure indicates a leaking gas valve.

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Contents Installation Operating Instructions Table of Contents Page Section a Before Installing the Boiler Model Identification High Delta Component Location General Information Stacking Equipment BaseBoiler Side 302-902 Boiler SizeOutdoor Installation Minimum Clearances OutdoorinstallationsDirect VENT-INSTALLATON Section C Combustion and Ventilation AIRCombustion and Ventilation AIR Indoor Units Page Temperature & Pressure Gauge LOW Temperature SystemSection D Water Piping General Reliefvalve PipingSection E Hydronic Heating Piping Fig. #9223 DUALBOILERPRIMARY/SECONDARYPIPINGSection F Domestic HOT Water Piping Potable Water and Space HeatingapplicationSingle Domestic HOT Water Heater with ONE Storage Tank Bypass Section G Pool HeatingAutomatic Chlorinators and Chemicalfeeders Winterizingyour HeaterSpawater Chemistry Singlepoolheaterapplication Section H GAS Supply Connections GAS Supply ConnectionGAS Supply Pressure GAS Pressure Regulator Check the Power Source Section I Electrical Power ConnectionsCheck Power Source FIELD-CONNECTEDCONTROLLERSMaking the Electrical Connections Field Wiring ConnectionShockhazard Electrical Connections Domestic HOT WaterDefinition ofAppliance Categories Section J Venting ConnectionsTable J-1 Vent Terminal Location General Support of Vent StackVenting Configurations Venting Installation TipsNatural Draft Verticalvent Section J-1 Natural Draft Vertical Venting CategoryNatural Draft Vertical Vent Termination Natural Draft Vertical Venting System InstallationPage HORIZONTALTHRU-WALLVENTING Category III Table Section J-2Fig. #9436 HI Delta Sleeve Flue ConversionHorizontal Thru-wall Direct Vent Termination HORIZONTALTHRU-WALLVENTING Table Section J-3 Direct VentHorizontal Thru-wall Direct Vent Termination Verticalventing Table Direct VentVertical Direct Vent Termination Vertical Direct Vent System InstallationHideltaoutdoorventkitandinstructions Section J-5Heater as shipped HI Delta Outdoor Vent InstructionsFinished assembly HI Delta Filter BOX KIT Thiskitincludes Model PartnumberHI Delta Filter BOX Instructions Filter Section K Controls HI-DELTAModel Boiler Sequence of OperationsHI-DELTAModel HI-DELTAModel902 Flow Switch High Limit Manual ResetIgnition Control Module Operating ControlLOW Water Cutoff High and LOW GAS Pressure Switches GAS Pressure SwitchLOW Water CUT OFF Optional Wire Diagram Model Reference Drawing Number M152470-Rev. J H3/W3 Reference Drawing Number M152464-Rev R H3/HW3 Reference Drawing Number M152465 Rev-P H3/W3 TIME/TEMPERATURE Relationships in Scalds Section L General Safety PrecautionsSection M PRE-START-UP Tools Needed Section N HI-DELTA Initial START-UPPreparation for START-UP Turn Off Main Gas ValveYour Hi-Delta is tuned START-UPPilot Turn Down Test for Raypak HI Delta Boilers Leak Test Procedure DUAL-SEAT GAS ValvesPage Section O Post START-UP Check Toturn Offgastoappliance Section P OperationSuggested Minimum Maintenance Schedule Section Q MaintenanceWeekly Preventive Maintenance ScheduleSemi-Annually AnnuallyInsidecombustionaircontamination Appendix aCorporate Headquarters

302-902 specifications

The Raypak 302-902 is a highly efficient, reliable, and versatile heating solution commonly used in residential and commercial pool heating applications. Known for its exceptional performance and advanced technology, the Raypak 302-902 has become a favored choice among pool owners looking to extend their swimming season and enhance comfort.

One of the main features of the Raypak 302-902 is its robust construction. Built with a copper heat exchanger, it is designed to withstand the rigors of continuous use while offering superior heat transfer capabilities. The heat exchanger is also designed for easy maintenance, enabling pool owners to keep their systems running efficiently for years.

The Raypak 302-902 employs advanced digital controls, which provide precise temperature regulation. This modern control system allows users to set their desired water temperature with accuracy and maintain it consistently, ensuring a pleasant swimming experience. Additionally, these digital controls feature self-diagnostic capabilities, alerting users to potential issues, which aids in quick troubleshooting and maintenance.

In terms of energy efficiency, the Raypak 302-902 stands out with its ability to harness energy effectively, leading to significant savings in operational costs. It is equipped with an efficient gas burner, which optimizes fuel consumption while delivering rapid heating performance. This efficiency is complemented by its ability to operate with natural gas or propane, making it adaptable to various setups and preferences.

The unit also prides itself on its environmentally friendly operation. It meets stringent regulations for emissions, ensuring that pool owners can enjoy a pool heating solution that is both effective and reduces its ecological footprint. This focus on sustainability has made it a popular choice among environmentally conscious consumers.

Moreover, the Raypak 302-902 is designed for versatility. It can be easily integrated with existing pool systems and is compatible with both in-ground and above-ground pools. This flexibility allows it to cater to a wide range of pool sizes and configurations, making it suitable for both residential and commercial applications.

In conclusion, the Raypak 302-902 offers an array of features, technologies, and characteristics that make it a top contender in the pool heating market. With its durable construction, advanced digital controls, energy efficiency, and environmentally friendly operation, it remains a reliable choice for those seeking comfort and convenience in their swimming experience. Whether for a backyard oasis or a commercial facility, the Raypak 302-902 delivers consistent performance and accessibility.
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