Raypak 0066B, 0180B, 0042B manual Heat Exchanger Re-assembly, Combustion Chamber Removal

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Heat Exchanger Re-assembly

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

2.Install in/out and return water headers and install header retainer nuts and torque nuts evenly.

3.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 cut-off devices if so equipped.

7.Open water supply and return shut-off valves. Fill boiler and water piping system with water. Check boiler and piping system for leaks at full line pres- sure. Run system circulating pump for a minimum of 1/2 hour with boiler shut off.

8.Shut down entire system and vent all radiation units and high points in system piping. Check all strainers for debris. Expansion tank water level should be at the 1/4 mark and the balance of the tank filled with air (when using Air-X-Tank).

9.Install flue collector, jacket top and inspection pan- els. Install top holding screws. Install draft diverter and vent piping if so equipped.

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

11.Check for correct water pressure and water level in the system. Make sure that system pump oper- ates immediately on the call for heat. The system is ready for operation.

12.Within two (2) days of start-up, recheck all air vents and expansion tank levels.

Combustion Chamber Removal

To remove combustion chamber panels, you must first remove the heat exchanger. Remove combustion chamber panels individually.

Fig. 36: Combustion Chamber Panels—Top View

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Contents Raytherm Residential Boilers Page Contents Proposition Pay Attention to These TermsReceiving Equipment General SpecificationsCapacity Input Heating Net Piping ConnectionsGas NPT RatingCode Requirements InstallationMounting Base Clearance RequirementsCombustion/Ventilation Air Model No Sq. in. of Free AreaModel No Venting Connections Model No Vent Max Connector Horizontal Diameter Length ftRoof Pitch X/12 Min. ft Common VentsVent Damper Location Vent Damper Installation LocationVent Damper Operation MountingAbbreviationDescription Flair DamperVent Damper Gas Supply Connections Gas PressureWater Connections & System Piping Model No System Flow Max. System Gpm Head ft/WC Single-Zone Piping Piping DiagramsElectrical Wiring Wiring Diagrams Page Page Single-Zone Taco Valve System with Three 3 Zone Pumps Primary/Secondary Pumping System Honeywell Zone Valve IID Units with Low Water Cut-off Device Sequence Operation Servicing ProceduresGeneral Location of Controls Intermittent Ignition Device IIDLighting the Boiler START-UP ProceduresFor Standing Pilot Models Filling the SystemFor Automatic Ignition Models To Turn Off Gas to the Boiler Models 90, 135To Turn Off Gas to the Boiler Shut-down ProcedureFor Honeywell valve Turn gas control knob For Honeywell valveSafe Shut-down Tests Testing the Ignition Safety Shut-offLow Water Cut-Off When Installed Inspection ProceduresProcedure for Cleaning Flue Gas Passageways BurnersTube Cleaning Procedure Typical Repair ProceduresHeat Exchanger Removal Burner Tray RemovalCombustion Chamber Removal Heat Exchanger Re-assemblyProblem Causes Solutions TroubleshootingPiping Adjustment & Replacement of Components Fast-Response Temperature Sensor Module Replacement Replacement Parts ListFast-Response Temperature Sensor Probe Replacement Circulator ReplacementLimited Parts Warranty
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