Service Procedures - Raypak B0507 Owner's Manual And Installation Instructions

ONLY AN AUTHORISED PERSON MAY REPAIR OR SERVICE A GAS APPLIANCE
Warning: Ceramic fire tile refractories are used in Raypak water heaters. Refractories must be treated with
care because they can be harmful by inhalation and irritating to the skin, eyes and respiratory system.
Refer to "Safety Precautions" on page
SIX MONTHLY SERVICE PROCEDURE
1. Isolate power to the water heater.
2. Operate the pressure relief valve (PRV) manually to check that the drain is clear and the valve reseals.
3. Remove burner access door(s) and header access panels.
4. Visually inspect combustion chamber area for build up of debris and clean if necessary.
5. Check the water heater thoroughly for any damage.
6. Check the heat exchanger and water seal areas for leaks and signs of sooting.
7. Check air vents and louvers, clean as required.
8. Restore power and check operation of the ignition system and all safety devices.
9. Check operation and calibration of all temperature control devices.
10. Perform a leak test on all gas unions using a soapy water solution.
11. Check and monitor the operation of the water heater for at least ten (10) minutes.
 With the burner lit, make a visual check of the main burner and pilot flame. Yellow flames indicate some
restriction of the combustion air openings or incorrect burner gas pressure setting.
 A bright orange, luminous flame is not normal and can cause sooting under prolonged operation.
12. Clean and remove any dust and debris from the water heater and its immediate area.
13. Refit burner access door(s) and header access panels.
ANNUAL SERVICE PROCEDURE
1. Conduct the Six Monthly Service Procedure detailed above PLUS;
2. Isolate gas, electricity and water supplies.
3. Disconnect and remove the burner tray.
4. Check igniter electrode and flame rod(s) - clean and re-align if required. Inspect and clean the earth terminal.
5. Check burner sheet metal and refractory tiles (replace if corroded or damaged)
Check main burner injectors – clean if required.
6.
7. Clean burner bars.
8. Inspect external area of heat exchanger, clean fins and baffles.
9. Refit the burner tray and reconnect the gas train.
10. Restore gas, electricity and water supplies.
11. Perform a leak test on the gas train using soapy water solution.
12. Check burner pressure - adjust if required. Refer to
13. Refit all panels and the burner access door(s).
14. Inspect flue for corrosion, obstruction and flue gas leakage.
5 YEARLY SERVICE PROCEDURE
1 Conduct the Annual Service procedure above PLUS;
2 Replace all relief valves.
A Service Report, including any damaged or faulty components, should be given to the responsible officer and
arrangements made to effect immediate repairs. Use only genuine replacement parts on this water heater.
Warning: DO NOT return the water heater to service where an unsafe condition exists. Operation of the
water heater when faulty or incorrectly adjusted will result in rapid and severe damage which is not covered
by warranty.

SERVICE PROCEDURES

35 for the precautions to be taken when servicing the water heater.
"Gas Pressure
50
Adjustment" on page 40.