PART 2 - SECTION I - INSTALLATION INSTRUCTIONS
COMMISSIONING
WARNING: COMMISSIONING MUST ONLY BE UNDERTAKEN BY A PROPERLY AUTHORISED AND IN SOME CASES APPROPRIATELY LICENSED PERSON WHO IS FAMILIAR WITH SAFE COMMISSIONING PROCEDURES. THE COMMISSIONING MAY REQUIRE INSPECTION BY THE GAS SUPPLY AUTHORITY, CHECK IF THIS IS APPLICABLE.
RECOMMENDED COMMISSIONING PROCEDURE.
1.Check that all necessary approvals and appropriate documents have been obtained.
2.Ensure that the heater is clean and the
surrounding area is clear of all combustible and flammable materials.
3.Remove all liquids and chemicals from the plant room and check that combustion air openings are not obstructed. Chemicals must not be stored in the plant room - this is extremely dangerous and may damage the heater.
4.Fill the system with water and expel any air as required.
5.Purge all air from gas supply piping.
CAUTION: Liquid Propane Gas is heavier than air and sinks to the ground, exercise extreme care in lighting boiler in confined areas.
6.Test ALL gas connections for leaks, using soapy water and a manometer.
(NOT A NAKED FLAME)
7.Conduct a visual inspection of the heater and equipment for any damage or installation problems and report as necessary.
8.Check that the correct power supply is available and the circulation pump is electrically interlocked with the heater.
9.Check that the ventilation to the plant room complies with Raypak requirements, AG601 and local authority regulations.
If mechanical ventilation is provided, check its operation and any interlocks.
10.Check that the flue complies with the appropriate regulations and is fitted with an approved termination cowl.
11.Check that the gas supply is isolated and with the main gas valve isolation switch turned off, check the boiler gas train and components for gas escapes.
12.Start the circulation pump and verify the pressure switch operation, then test the operation of the heater with no gas flow to confirm its operation up to the lockout status. Pressure switch adjustment is required if the unit won’t fire and after faultfinding it is verified that the pressure switch has not closed. Adjust the pressure setting at the thumbwheel to a lower setting, then re start the heater.
If the heater fires up but won’t shutdown when the water is reduced then it will require adjustment to the thumbwheel to a
higher setting and the heater restarted.
(In some cases the electrical interlock between the pump and heater may require a temporary disconnection to carry out tests.)
13.Open the gas supply valve, switch on the main valve isolation switch and reset the ignition control to fire the heater.
14.When the unit fires and reaches high fire, set the burner gas pressure to that shown on the data plate which is located on
the front of the heater.
15.Verify that the high limit and any other safety devices are operating correctly.
16.Check the water temperature rise of the heater and adjust the water flow as necessary. For models
The difference should be approximately 5 - 10 Deg. C.
If it is lower than recommended, decrease the water flow through the heater.
If it is higher than recommended it indicates that the water flow rate is too low.
For models 1362 to 4224, the temperature gauges which are fitted to the heater can be used as a guide.
The objective is to maintain a temperature of approximately 50 Deg C at the outlet side of the heater, 30 Deg C at the inlet side, with the unit at full fire.
The digital display on the electronic thermostat will indicate the pool water temperature.
17.Check that the flue is operating correctly or if there is evidence of Down draft etc report as necessary.
18.Check operation of any water pressure relief valves etc and set up the controls to desired settings.
19.Ensure that the customer is supplied with this manual and you have demonstrated the operation of the unit etc.
It is quite normal for the heater to produce some smoke and possible condensation for the first thirty (30) minutes of firing from new.
WARNING - Should overheating occur or the gas fail to shut off, turn off the gas isolation valve adjacent to the heater and then examine the unit or call for assistance.
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