Raypak Tube Cleaning Kit, Repairprocedures

LOW WATER CUT-OFF (WHEN INSTALLED)

The low water cut-off automatically shuts down burner whenever water level drops below probe. 90 second time delay prevents premature lockout due to temporary conditions such as power failure or air pock- ets. Flush float type devices at beginning of each heating season.

PROCEDURE FOR CLEANING FLUE GAS PASSAGEWAYS

Soot will clog areas behind fins and eventually cause tube failure. Any sign of soot at base of burners or around outer jacket indicates a need for cleaning.

1.Lift off drafthood and flue collector by removing bolts and screws.

2.Remove "V" baffles from heat exchanger.

3.Remove burner tray, see Burner Tray Removal.

4.Take garden hose and wash heat exchanger, mak- ing sure soot is removed from between fins. (Avoid excessive water against refractory).

5.Reassemble; when boiler is fired, some steam will form from wet refractory. This is normal.

NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The sim- plest method is steam cleaning at a local car wash. DO NOT WIRE BRUSH!

CAUTION:

Soot is combustible, so exercise extreme care.

BURNER TRAY REMOVAL

1.Shut-off power and gas supply to the boiler. Dis- connect union(s) and pilot tubing when present; then loosen and remove burner hold-down screws.

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

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.

	RAYPAK TUBE CLEANING KIT
Extension Pieces (5)		Auger with Carbide Tip			Wire Brush	Fig. #8154


5/8" - PN 052871F				7/8" - PN 052870F
REPAIRPROCEDURES			Another method is to remove the heat exchanger,
TUBE CLEANING PROCEDURE (TYPICAL)		ream tubes and immerse heat exchanger in non-inhibited
		de-scale solvent.
Establish a regular inspection schedule, the fre-		HEAT EXCHANGER REMOVAL
quency of which depends on the local water condition and
severity of service. Do not let the tubes clog up solidly.		1.	Shut water, gas and electricity off, close valves,
Clean out deposits over 1/16" in thickness.			relievepressureandremovereliefvalve. Removeside
The boiler may be cleaned from the side opposite the			inspection panels.
water connections as shown, without breaking pipe		2.	Remove top holding screws.
connections. It is preferable, however, to remove both		3.	Remove draft diverter, lift and remove top and flue
headers for better visibility through the tubes and to be			collector on stack type models. Remove inspection
sure the residue does not get into the system.			panels.
Note that you do not typically remove the top pan or		4.	Loosen bolts and disconnect flange nuts on inlet-
the heat exchanger.			outlet header, loosen union(s) at gas pipe, and slide
After reaming with the auger, mount the wire brush			boiler away from piping until studs clear the heater.
and clean out the debris remaining in the tubes.		5.	Remove heat exchanger corner brackets.

RAYPAK TUBE CLEANING KIT

REPAIRPROCEDURES