Raypak 302-902 manual Preventive Maintenance Schedule, Daily, Weekly, Monthly, Semi-Annually

PREVENTIVE MAINTENANCE SCHEDULE

Required procedure in CSD-1 States and good practice for all Hi-Delta installations.

Daily

1.Check gages, monitors and indicators. (See page 6 of the Operating and Installation Instructions Manual).

2.Check instrument and equipment settings. (See page 49-50 of the Operating and Installation Instructions Manual).

3.Check burner flame. (Should see light blue flame).

Weekly

1.For low-pressure boilers, test low-water fuel cutoff device. (With at least one stage of the appliance on, depress the low water cut-off test button, appliance should shut-off and ignition fault light should come on. Depress reset button to reset).

2.Check igniter. (Resistance reading should be 30- 70 ohms).

3.Check flame signal strength. (Flame signal should be greater than 1 microamp).

4.Check flame failure detection system. (See attached Turn Down Test Procedure).

5.Check firing rate control. (Check manifold pressure, see page 50 of the Operating and Installation Instructions Manual).

6.Make aural and visual check of pilot and main fuel valves.

Monthly

1.Check flue, vent, stack, or outlet dampers.

2.Test fan air pressure. (See page 50 of the Operating and Installation Instructions Manual).

3.Test high and low gas pressure interlocks. (See page 50 of the Operating and Installation Instructions Manual).

Semi-Annually

1.Recalibrate all indicating and recording gages.

2.Check flame failure detection system components. (See Turn Down Test Procedure).

3.Check firing rate control. (Check manifold pressure, see page 50 of the Operating and Installation Instructions Manual).

4.Check piping and wiring of all interlocks and shutoff valves.

5.Inspect burner components.

Annually

1.Flame failure detection system, pilot turndown test.

2.Test high limit and operating temperature. (See page 48 of the Operating and Installation Instructions Manual).

3.Check flame sensors, (Flame signal should be greater than 1 microamp).

4.Conduct a combustion test. (Carbon Dioxide 7-9 %; Carbon monoxide < 200 ppm).

5.Check all coils and diaphragms; test other operating parts of all safety shutoff and control valves. Coils- check for 60 cycle hum or buzz; diaphragms- using soapy water solution check for leaks on the vent outlets and all fittings on the valves; on other safety devices increase or decrease settings (depending on the type of control) until the safety circuit opens. Reset to original setting after each device is tested.

6.Perform leakage test on pilot and main gas valves. (See Leak Test Procedure).

7.Test purge air switch in accordance with manufacturer’s instructions. (Turn panel switch to the on position until blower is proven, then turn the switch to off. Blower should stay on for approximately 30 seconds).

8.	Test burner position interlock in accordance with manufacturer’s instructions. (Remove front panel and visually
	check burner orientation, all three screws holding the burner must be in place and flat portion of the flange must be
	on top in the horizontal position).

As Required

1.Recondition or replace low water fuel cutoff device.

2.For gas fired burners, check drip leg and gas strainers.

3.Flame failure detection system, pilot turndown test.

4.Test safety/safety relief valves in accordance with ASME Boiler and Pressure Vessel Code Sections VI and VII.

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