Raypak 0090B 0135B Heat Exchanger RE-ASSEMBLY, Combustion Chamber Removal

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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.

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 strain- ers 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 piping 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 operates immediately on the call for heat. The system is ready for operation.

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

HEAT EXCHANGER RE-ASSEMBLY

1.Heat exchanger water 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.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 shut-off valves. Fill boiler and water piping system with water. Check

COMBUSTION CHAMBER REMOVAL

To remove combustion chamber you must first have removed the heat exchanger. Unbolt metal com- bustion chamber retainer from top and remove com- bustion chamber panels individually.

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Contents Operating Installation Instructions For Your SafetyContents General Specifications Specifications and DimensionsReceiving Equipment Mounting Base Installation ProceduresCode Requirements Clearance RequirementsModel Sq. In. of Free Area 0030, 0042 100 Venting ConnectionsCommon Vents Fig.#Vent Damper Installation LocationInstalling the Vent Damper in Horizontal & Vertical Vents D80D General Wiring DiagramMounting Vent Damper Flair DamperGAS PRESSURE-SPECIFICATIONS GAS Supply ConnectionsWater Connections & System Piping Typical Piping Single Zone PipingZone Heating with Indirect Domestic HOT Water Supply Multiple Zones with Circulators Multiple Zones with Zone ValvesElectrical Wiring Fig.#Wiring Diagram Standing Pilot 24 V 2 Stage Fig. # 2223eWiring Diagramintermittent Ignition Device IID Models 30, 42 Wiring Diagram Intermittent Ignition Device IID Fig. #2358Wiring Diagram Single Zone Taco Valve Wiring Diagram System with 3 Zone Pumps Fig. #2223.2e Wiring Diagram Standing Pilot With Low Water Cut Off Device Control BOX Component Locations Models 135 Servicing ProceduresGeneral Location of Controls Sequence of Operation Intermittent Ignition Device IIDSTART-UP Procedures Filling the SystemLighting the Boiler What to do if YOU Smell GASHoneywell Pilot Robertshaw Pilot For Automatic Ignition ModelsSystem Shut Down Procedure To Turn OFF GAS to BoilerFor Automatic Ignition Systems Flame Failure Inspection Procedures BurnersSafe Shutdown Tests Limit Action Main Burner FlameMain Burner and Orifice Removal Raypak Tube Cleaning KITBurner Drawer Removal Repair SectionHeat Exchanger RE-ASSEMBLY Combustion Chamber RemovalTrouble Shooting Guide Important NoticePiping ADJUSTMENTS/REPLACEMENTS of Components Replacement Parts List RAYPAK, INCBypass valve supplied on sizes H-0135 and H-0180 only Page Venting
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