Raypak 503-2003 Preventive Maintenance Schedule, Periodically, Weekly, Semi-Annually, As Required

SECTION G: Maintenance

11.Check for piping leaks around pumps, relief valves and other fittings. Repair, if found. DO NOT use pe- troleum-based stop-leak.

Periodically

1.Check relief valve. Refer to manufacturer’s instruc- tions on valve.

2.Test low water cut-off (if equipped). Refer to manu- facturer’s instructions.

Preventive Maintenance

Schedule

The following is required procedure in all jurisdictions which require CSD-1 and good practice for all MVB instal- lations.

Daily

1.Check gauges, monitors and indicators.

2.Check instrument and equipment settings. (See “Post Start-Up Check” on page 45.)

3.Check burner flame. (Should see light blue flame at full input rate).

Weekly

For low-pressure heaters, test low-water cut-off device. (With heater in pre-purge, depress the low water cut-off test button. Appliance should shut-off and ignition fault light should come on. Depress reset button on front of heater control panel to reset).

1.Check igniter. (Resistance reading should be 42-70 ohms at ambient temperature.)

2.Check flame signal strength. (Flame signal should be greater than 1 microamp as measured at the 2 pins on the upper left corner of the ignition control).

3.Check flame failure detection system. (See “Post Start- Up Check” on page 45.)

4.Check firing rate control by checking the manifold pressure. (See “Manifold Adjustment” on page 43.)

5.Make auditory and visual check of main fuel valve.

Monthly

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

2.Test blower air pressure. (See “Blower Adjustment” on page 42.)

3.Test high and low gas pressure interlocks (if equipped). (See “Safety Inspection” on page 44.)

Semi-Annually

1.Recalibrate all indicating and recording gauges.

2.Check flame failure detection system components.

3.Check firing rate control by checking the manifold pressure. (See “Manifold Adjustment” on page 43.)

4.Check piping and wiring of all interlocks and shut-off valves.

Annually

1.Test flame failure detection system and pilot turndown.

2.Test high limit and operating temperature. (See “Post Start-Up Check,” page 45.)

3.Check flame sensors.

4.Conduct a combustion test at full fire. Carbon dioxide should be 8.0 to 9.0% at full fire for natural gas, and between 9.0 to 10.0% for propane gas. Carbon monox- ide should be < 100 ppm.

5.Check valve coil for 60 cycle hum or buzz. Check for leaks at all valve fittings using a soapy water solution (while heater is operating). Test other operating parts of all safety shut-off and control valves and 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 gas valves. (See Fig. 40.)

7.Test 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.”

8.Inspect burner.

As Required

1.Recondition or replace low water cut-off device (if equipped).

2.Check drip leg and gas strainers.

3.Perform flame failure detection tests.

4.Test safety/safety relief valves in accordance with ASME Heater and Pressure Vessel Code Section IV.

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