Raypak 85 Servicing Instructions, General, Routine Annual Servicing, Replacement of Components

12 - SERVICING INSTRUCTIONS

1. GENERAL

To ensure the continued safe and efficient operation of the boiler, it is recommended that it is checked and serviced at regular intervals. It is essential that any worn or failed component be replaced only with a genuine XPak spare parts. It should be remembered that although certain generic components may look similar, they will be specific to an individual appliance or product range. Use of non-genuine XPak spare parts could invalidate your warranty and may pose a potential safety hazard. The frequency of servicing will depend upon the particular installation conditions, but in general, once per year should be sufficient. It is the law that any servicing work is carried out by competent person such as a Raypak Technician, an approved service agent, or other suitably qualified personnel. The following instructions apply to the appliance and its controls, but it should be remembered that the central heating and the domestic hot water systems would also require attention from time to time.

2. ROUTINE ANNUAL SERVICING

-Check the operation of the boiler and ensure it functions as described in Section “11. Checks, adjustments and fault finding”.

-Thoroughly inspect the boiler for signs of damage or deterioration especially the flue system and the electrical apparatus.

-Check and adjust – if necessary – the system design pressure (see pg. 63 ref. 10).

-Carry out an analysis of the flue gases (pg. 73), and visually check the condition of the entire flue assembly.

-Check that the burner and main heat exchanger are clean and free from any debris or obstruction.

-Check and clean – if necessary – the condense trap to ensure correct operation.

-Compare the performance of the appliance with its design specification. The cause of any noticeable deterioration should be identified and fixed without delay.

-The combustion blower motor does not require lubrication for proper operation. DO NOT attempt to oil the motor or damage may occur.

3. REPLACEMENT OF COMPONENTS

Although it is anticipated that this appliance will give years of reliable, trouble free service, the life span of components will be determined by factors such as operating conditions and usage. Should the appliance develop a fault, the troubleshooting section will assist in determining which component is malfunctioning.

4. COMPONENT REMOVAL PROCEDURE

To remove a component, access to the interior of the boiler is essential. Isolate the appliance from the electrical supply. And when necessary, close all service valves on the boiler, remove the casing and drain the water content from the boiler via the drain valve. Ensure some water absorbent cloths are available to catch any residual water that may drip from the boiler or removed component. Undertake a complete commissioning check, after replacing any component.

ALWAYSTEST FOR GASTIGHTNESS IF ANY GAS CARRYING COMPONENTS HAVE BEEN REMOVED OR DISTURBED.

AIR BOX FRONT COVER REMOVAL (Fig. 68)

Locate the two clips and remove air box front cover. If it’s necessary to remove the air box side cover, locate and remove the 4 securing screws.

clips

Fig. 68

52

PUMP ASSEMBLY (Fig. 69)

Locate and remove the 2 securing screws (A) at the rear of the pump assembly. Disconnect the flow pipe (B, only for XPak 120) from the combustion chamber connection, slacken the pipe at the hydraulic assembly and swing/rotate clear of the pump assembly. Disconnect and remove the pump outlet pipe (C) from the pump assembly/combustion chamber connection. Locate and remove the pressure gauge securing pin (D) and disconnect the pressure gauge from the pump assembly.

Disconnect the electrical wiring from the pump’s electrical connection point (E). Remove locking pin (F) from pump base and lift pump assembly clear of the hydraulic manifold. The pump assembly can now be removed from the appliance. Replace carefully in the reverse order.

PRESSURE RELIEF VALVE (Fig. 69)

Disconnect the outlet pipe (L) and the flow pipe (M) from the safety valve, remove pressure release valve. Replace in the reverse order.

LOWER AUTOMATIC AIR RELEASE VALVE (Fig. 69)

Locate and remove the AAV locking pin (G) from the pump assembly and remove the AAV assembly (H). Replace in the reverse order.

TOP AUTOMATIC AIR RELEASE VALVE (Fig. 70)

Remove the drain pipe (A). Unscrew the top AAV (B). Replace in the reverse order. Loctite or similar should be used as a thread sealant for the AAV.

XPak 85

H

G

A C L

D

E

M

F

XPak 120 I

H

G

A C L

D

E

B

F

I

Fig. 69