Raypak 302A-902A 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 pres- sure.

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 mani- fold pressure goes below 2.0 in. WC for natural 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. 41. 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 and Operating Instructions Page Contents Pay Attention to These Terms Ratings and Certifications Before InstallationProduct Receipt Model IdentificationComponent Locations Back Component LocationsModel # Burners Valve Firing Per Valve Staging General InformationModel # Burners per Stages Fire at Valve Water Time to Produce Serious Temp Burn General SafetyTime/Temperature Relationships in Scalds Stacking InstallationInstallation Codes Equipment BaseClearances Indoor InstallationsOutdoor Installations Installations1 Canadian Installations2 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 TestMin. Flow Max Flow Gpm Temperature & Pressure GaugeHydronic Heating Pump SelectionThree-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 J Maximum Equivalent Pipe Length Gas Supply ConnectionReversing Gas Supply Connection Field-Connected Controllers Electrical Power ConnectionsCheck the Power Source Gas Supply PressureMaking the Electrical Connections Field Wiring ConnectionWiring Connections Appliance Categories VentingStainless Steel Support of Vent StackVent Terminal Location Direct Venting Horizontal ThroughChanging the Flue Outlet InstallationsCanadian Installations Natural Draft Vertical Venting Category Venting Installation TipsVenting Configurations InstallationMin Max TerminationCommon Venting System Model Venting Vent Size Height Intake Pipe Max. LengthHorizontal Through-the-Wall Venting Category Horizontal Through-the-Wall Venting CategoryMaterial Direct Vent Horizontal Through- the-WallMax. Length Venting Vent Size Equivalent Intake Pipe Direct Vent Vertical Freeze Protection Outdoor InstallationControls Models 302A, 402A, 502A, 652A, 752A and 902A Heater Sequence of OperationInternal Lights Color Indication Auto Reset High Limit Red Auto reset optionExternal Lights Color Indication Code Condition Ignition ModuleOperating Control High Limit Manual ResetFlow Switch High and Low Gas Pressure SwitchesHigh/Low Gas Pressure Switch Direct Venting Horizontal Through AL29-4C 87%-Efficiency Boilers Special Instructions Water PipingVenting Appliance Categories Model 10F 20F 30F Min. Flow Max Flow GpmCondensate Management Vertical Venting CategoryVent Terminal Location 40’ 752AE Combustion Air 902AE 30’ 80’ Certified Maximum Combustion Air Air Inlet Model VentingMaterial Vent Length 100’ DuctedDirect Vent Horizontal Through- the-Wall 100’ 40’ 752A 902A Direct Vent VerticalCertified Vertical Venting Combustion Air Air Inlet 302A 100’ 402A Galvanized Steel 502A 75’ Category 25’Wiring Diagram Pre Start-up START-UPStart-Up Blower AdjustmentMain Burner Adjustment Pilot Turn-Down Test Safety InspectionLeak Test Procedure Dual-Seat Gas Valves Follow-UpLeak Test Post Start-Up CheckTo Turn Off Gas To Appliance OperationLighting Instructions Step TroubleshootingPreventive Maintenance Schedule MaintenanceSuggested Minimum 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

302A-902A specifications

The Raypak 302A-902A is a highly regarded pool and spa heater, known for its efficiency and reliability in delivering warmth to residential and commercial aquatic applications. This heater stands out due to its robust design, advanced technology, and user-friendly features.

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