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31
COMMISSIONING
COMMISSIONING MUST ONLY BE UNDERTAKEN BY AN APPROPRIATELY LICENSED PERSON WHO IS
FAMILIAR WITH SAFE COMMISSIONING PROCEDURES.
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 30 for the precautions to be taken when the water heater is first operated.
PRE-START CHECKS
• Ensure all packaging materials have been removed from the water heater.
• Conduct a visual inspection of the water heater and equipment for any damage or installation problems and
report as necessary.
• Ensure that the water heater is clean and the surrounding area is clear of all combustible and flammable
materials.
• Remove all liquids and chemicals from the plant room and check that combustion air openings are not
obstructed.
• Test ALL gas connections for leaks, using soapy water. NOT A NAKED FLAME
• Ensure the water heater is filled with water (refer to “To Fill the Water Heater
” on page 32).
• Check that the correct power supply is available and the circulation pump is supplied from the same electrical
circuit as the water heater.
• Check that the ventilation to the plant room complies with the requirements, of AS 5601 and local authority
regulations.
• If mechanical ventilation or power fluing is provided, check the operation of the fan(s) and interlocks.
• Check that the flue complies with the appropriate regulations and is fitted with an approved cowl.
• Ensure that the main gas isolation valve is closed.
OPERATIONAL CHECKS
• Turn on the water heater and circulation pump and verify the flow switch operation - if fitted (refer to “To Turn
on the Water Heater” on page 32).
• Test the operation of the water heater with no gas flow to confirm its operation up to lockout stage, then turn off
the power.
• Open the gas isolation valve and switch on power to the water heater.
• With the main burner lit and at high fire, check the inlet gas pressure (refer to “Gas Inlet Pressure
” on page 33).
• Check the water heater gas train and components for gas leaks using soapy water. NOT A NAKED FLAME
• Set the burner gas pressure to that shown on the rating label (refer to “Gas Pressure Adjustment
” on page 33).
• Make a visual check of the burners. The flame should be blue with a well-defined pattern. A yellow or floating
flame indicates restricted air openings or incorrect burner pressure setting.
• Verify that the high limit is operating and set correctly (refer to “High Limit Adjustment
” on page 37).
• Check that the flue on an indoor installation is drawing correctly.
• Check operation of the water pressure relief valve.
• It is normal for the water heater to produce some smoke and possibly condensation for the first thirty (30)
minutes of operation from new (refer to “Safety Precautions
” on page 30).
WARNING: Upon completion of the installation and commissioning of the water heater, leave this guide with the
householder or a responsible officer. DO NOT
leave this guide inside of the cover of the water heater, as it may
interfere with the safe operation of the water heater or ignite when the water heater is turned on.
Explain to the householder or a responsible officer the functions and operation of the water heater.