Operating instructions

10
PART 2 - SECTION I - INSTALLATION INSTRUCTIONS
ELECTRICAL WIRING
The electrical power consumption of the heater is:
240 Volts AC,50/60 Hz, of less than 1 Amp.
A normal 10 or 15 Amp, single phase power
circuit should be suitable.
Access to the electricals is achieved by
removing the cover of the control panel. (See
Location of Controls for different models.)
The heater must be properly earthed and
Raypak highly recommends the installation of
an RCD (Residual Current Device) for added
electrical safety. If the site is "electrically
noisy", a mains filter can be supplied at extra
cost, to eliminate Microzone failures.
THE HEATER MUST NOT BE ABLE TO
OPERATE WITHOUT THE CIRCULATING
WATER PUMP RUNNING.
The heater (240 Volts) power supply must be
"interlocked" via the auxiliary contacts of the
pump contactor (relay) etc or alternatively the
power supply for the pump and the heater
must operate off the same circuit and isolation
switch. (Parallel connection)
A Flow Switch is not regarded as an interlock
and must not be used as one.
If a Microzone control is fitted and the pump
control is used, this is recognised as being
interlocked with the heater.
Any other form of interlocking must
be approved by Raypak.
A pump run on timer is fitted so that at any
time that the heater is no longer required, the
heater shuts off and the pump continues for at
least ten (10) minutes.
If a Microzone is installed and the pump control
is used, this run on is included in the program.
A Raypak "Economaster" fitted as - standard
on all other heaters.
For servicing purposes we suggest that the
isolation switch be installed as near as
practical to the heater.
If there is any control wiring etc which is not
isolated by this switch then a suitable warning
label must be affixed to the heater which will also
direct the service person to the isolation switch
for that particular wiring.
E.G. More than one isolation switch is required to
turn off the power supply,Extra switch(es) on
switchboard etc.
CAUTION: Do not locate cables in front of
or underneath the burner, please consult
Raypak for advice if unsure.
Where cables or conduit, trunking etc are to be
mounted on the heater casing, please keep at
least 10mm air gap from the heater casing to
eliminate possible overheating.
Do not locate cables etc where they will restrict
access covers, doors etc.
Where the clearance from the right hand side
of the heater (models 538 to 1922) is
restrictive, please notify Raypak at the time of
manufacture and we may be able to relocate
the control panel for a minimal extra cost, if
this is not possible then a field retrofit may be
the best solution. (At extra cost)
If a Microzone or any other PLC device is
installed as part of the heater control etc,
please observe the requirements for suitably
screened data cable when utilising the
communication areas of these devices. Failure
to do so will result in malfunctions and /or
damage to the device, which will cause
inconvenience to the user.
Failure of, or damage caused to the Microzone
or any other heater component due to incorrect
wiring is NOT covered by our warranty and any
repairs will be at extra cost.
There are many variations to the types of
controls available and also RUN & FAIL indication
can be supplied.Advice on remote location of
reset button and failure indication is available
from your local representative or from Raypak.
COMMISSIONING
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 heater in
confined areas.
6. Test ALL gas connections for leaks, using
soapy water and a manometer.
( DO NOT USE 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,AS
5601/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 heater gas train and components
for gas escapes.
12. Start the circulation pump and verify the
flow switch operation (if fitted), then test the
operation of the heater with no gas flow to
confirm its operation up to the lockout status.
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.Set the low fire if necessary also.
15. Verify that the high limit and any other
safety devices are operating correctly and set
low fire for safe, reliable ignition if required.
16. Check that the flue is operating correctly
or if there is evidence of down draft etc report
as necessary.
17. Check operation of any water pressure
relief valves etc and set up the controls to
desired settings.
18. 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:
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.
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.