Burner Drawer Removal

1.Shut off power and gas supply to the pool heater. Dis- connect union(s) and pilot tubing, then loosen and remove burner-hold down screws.

2.Disconnect wires at gas valve and slide burner drawer out.

GAS VALVE REMOVAL

1.Shut off gas supply to the pool heater. Remove gas piping to gas valve inlet.

2.Disconnect wires, pilot tubing and bleed line, if required.

3.Turn vertical gas pipe from manifold slightly and unscrew gas valve.

4.Reverse above procedure to re-install.

MAIN BURNER AND ORIFICE REMOVAL

1. Remove screws and burner hold down bracket.

NOTE: If the heat exchanger is sooted badly, the burner hold-down bracket and spacer can become distorted from direct flame impingement and this usually necessi- tates replacement of these parts.

2.Lift burners from slotted spacer and slide from orifices. Clean with a wire brush.

3.Orifices usually do not need to be replaced. To clean, run either copper wire or wood through orifice. Do not enlarge hole. To remove orifice, use a socket wrench and remove the manifold. DO NOT overtighten when reinstalling.

PILOT REMOVAL AND CLEANING

1.Disconnect pilot tubing at pilot and sensor/igniter wire. Remove screws holding pilot bracket to burner drawer.

2.Remove pilot and bracket, clean pilot of debris, small bugs, etc., with wire or small brush.

3.Replace pilot, pilot tubing, sensor ignition wires and check for leaks.

HEAT EXCHANGER REMOVAL

1.Shut water, gas and electricity off, close valves, relieve pressure and remove relief valve. Remove side inspection panels.

2.Remove top holding screws.

3.Remove draft diverter, lift and remove top and flue collector on stack type models. Remove inspection panels.

4.Loosen bolts and disconnect flange nuts on inlet- outlet header, loosen union(s) at gas pipe, and slide boiler away from piping until studs clear the heater.

5.Remove heat exchanger corner brackets.

6.Remove combustion chamber clips at the four corners of the heat exchanger.

7.Lift heat exchanger straight up using caution not to damage refractory.

HEAT EXCHANGER REASSEMBLY

1.Heat exchanger header O-rings should be replaced with new ones.

2.Install inlet-outlet and return water headers and install header retainer nuts and torque nuts evenly.

3.Install the four (4) corner clips between tube sheets and refractory. Replace "V" baffles.

4.Install thermostat sensing bulbs in header wells and replace bulb retaining clips.

5.Install inlet and return pipes in water headers using pipe thread sealant.

6.Install water pressure relief valve, flow switch, and low water cutoff devices if so equipped.

7.Open water supply and return shutoff valves. Fill heater and water piping system with water. Check heater and piping system for leaks at full line pressure. Run system circulating pump for a minimum of 1/2 hour with heater shutoff.

8.Shut down entire system and vent all radiation units and high points in system piping. Check all strainers for debris.

9.Install fuel collector, jacket top and inspection panels. Install top holding screws. Install draft diverter and vent piping if so equipped.

10.If gas piping was disconnected, reconnect gas piping system and check for leakage using a soap solution.

11.Double check electrical circuits, grounding con- nections and pump with wiring diagram supplied with heater.

12.Check for correct water pressure and water level in the system. Make sure that system pump operates immediately on the call for heat.

The system is ready for operation.

COMBUSTION CHAMBER REMOVAL

To remove the combustion chamber you must first haveremovedtheheatexchanger. Unboltmetalcombus- tion chamber retainer from top and remove combustion chamber panels individually.

REFRACTORY PANELS TOP VIEW

Raypak 1287-1758, 2100-4001 Burner Drawer Removal, GAS Valve Removal, Pilot Removal and Cleaning