Raypak 302A-902A 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. 41: 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 and Operating Instructions Page Contents Pay Attention to These Terms Before Installation Product ReceiptModel Identification Ratings and CertificationsComponent Locations Component Locations BackGeneral Information Model # Burners per Stages Fire at ValveModel # Burners Valve Firing Per Valve Staging General Safety Time/Temperature Relationships in ScaldsWater Time to Produce Serious Temp Burn Installation Installation CodesEquipment Base StackingIndoor Installations Outdoor InstallationsClearances Installations1 Canadian Installations2 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 Min. Flow Max Flow GpmPressure 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 HeaterGas Supply Pool/Spa Water Chemistry Water HardnessPH of Water Total Dissolved SolidsGas Supply Connection Reversing Gas Supply ConnectionTable J Maximum Equivalent Pipe Length Electrical Power Connections Check the Power SourceGas Supply Pressure Field-Connected ControllersField Wiring Connection Making the Electrical ConnectionsWiring Connections Venting Appliance CategoriesSupport of Vent Stack Vent Terminal LocationDirect Venting Horizontal Through Stainless SteelInstallations Canadian InstallationsChanging the Flue Outlet Venting Installation Tips Venting ConfigurationsInstallation Natural Draft Vertical Venting CategoryTermination Common Venting SystemModel Venting Vent Size Height Intake Pipe Max. Length Min MaxHorizontal Through-the-Wall Venting Category Horizontal Through-the-Wall Venting CategoryDirect Vent Horizontal Through- the-Wall Max. Length Venting Vent Size Equivalent Intake PipeMaterial Direct Vent Vertical Outdoor Installation ControlsFreeze Protection Heater Sequence of Operation Models 302A, 402A, 502A, 652A, 752A and 902AAuto Reset High Limit Red Auto reset option External Lights Color IndicationInternal Lights Color Indication Ignition Module Code ConditionHigh Limit Manual Reset Flow SwitchHigh and Low Gas Pressure Switches Operating ControlHigh/Low Gas Pressure Switch 87%-Efficiency Boilers Special Instructions Water Piping Venting Appliance CategoriesModel 10F 20F 30F Min. Flow Max Flow Gpm Direct Venting Horizontal Through AL29-4CVertical Venting Category Vent Terminal LocationCondensate Management Certified Maximum Combustion Air Air Inlet Model Venting Material Vent Length100’ Ducted 40’ 752AE Combustion Air 902AE 30’ 80’Direct Vent Horizontal Through- the-Wall Direct Vent Vertical Certified Vertical Venting Combustion Air Air Inlet302A 100’ 402A Galvanized Steel 502A 75’ Category 25’ 100’ 40’ 752A 902AWiring 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

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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