Raypak XTherm 1005A Installation And Operation Manual page 51

Test point B is a bleedle valve located between the two
automatic gas valve seats.
Test point C is a bleedle valve located downstream of both
automatic gas valve seats and upstream of the manual
valve.
These tests are to be conducted with the electrical power
to the heater turned OFF.
1. Manually close the downstream leak test valve.
2. Open the bleedle valve at test point A and connect
a manometer to it. Verify that there is gas pressure
and that it is within the proper range (NOTE: must
not exceed 14.0" WC).
3. Open test point B and connect a rubber tube to it.
Connect the other end of the tube to a manometer
and look for a build-up of pressure. Increasing
pressure indicates a leaking gas valve which must
be replaced.
4. Next, close the upstream manual gas valve (field
supplied) and remove the manometers from the
bleedle valves in test point A and test point B.
Connect a rubber tube from the test point A bleedle
valve to the test point B bleedle valve and open the
upstream manual gas valve. Make sure that test
point A and B bleedle valves have been opened so
as to allow gas to flow. This will bring gas pressure
to the second valve seat.
A
GAS
B
Figure 56. Leak Test Procedure
A
1ST SEAT
FIRING
VALVE
B
2ND SEAT
C
MANUAL
VALVE
TO BURNER
TO BURNER
C
5. Open the bleedle valve at test point C and connect
a second rubber tube to it. Connect the other end
of the tube to a manometer and look for a build-up
of pressure. Increasing pressure indicates a leaking
gas valve which must be replaced.
6. Remove rubber tube and manometers. Close each
bleedle valve as the tubes are removed.
7. After no leakage has been verified at all valve seats
and test valve, open downstream leak test valve and
restore electrical power to the heater.
6.5.8. Post Start-Up Check
Check off steps as completed:
1. Verify that the heater and heat distribution units are
filled with water.
2. Verify that air has been purged from the system.
3. Verify that air has been purged from the gas piping,
and that the piping has been checked for leaks.
4. Confirm that the proper start-up procedures were
followed.
5. Inspect burner to verify flame.
6. Test safety controls: test low water cut-off or
additional safety controls for operation as outlined
by manufacturer. Burner should be operating and
should go off when controls are tested. When safety
devices are restored, burners should re-ignite after
pre-purge time delay.
7. To test the fixed manual reset high limit built into
the PIM, first set DIP switch #8 on the PIM to the
ON position. This will activate a Commission
Test Mode which will turn on the amber Alarm/
Test LED on the PIM. The fixed high limit setting
is temporarily overridden to match the setpoint
potentiometer position on the PIM. The high limit
can now be adjusted by the potentiometer to assist
in commission testing and verification of high limit
functionality. The VERSA IC will allow one-time
operation of the limit and then must be returned to
normal operation by turning DIP switch #8 back to
the OFF position. Power to the unit must then be
cycled off, then on to return to normal operation.
8. Test ignition system safety device:
a. Close manual gas valve. Turn power on.
b. Close Enable/Disable circuit to call for heat.
c. The burner should attempt three trials for
ignition for the standard model and then lock
out. Single-try ignition modules will try only once
and then lock out.
d. Open manual gas valve. Reset the ignition
control by pressing for one second and then
releasing the reset button adjacent the user
interface or at the PIM to clear the ignition fault.
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