RAYPAK TUBE CLEANING KIT

Extension Pieces (5)

Auger with Carbide Tip

Wire Brush

Fig. 18: Raypak Tube Cleaning Kit

Repair Section

Tube Cleaning Procedure (Typical)

Establish a regular inspection schedule, the frequency depending on the local water condition and severity of service. Do not let the tubes clog up solidly. Clean out deposits over 1/16" in thickness.

The heater may be cleaned from the side opposite the water connections, without breaking pipe connections. It is preferable, however, to remove both headers for better visibility through the tubes and to be sure the residue does not get into the system. Generally, you do not remove the top pan or the heat exchanger .

After reaming with the auger, mount the wire brush and clean out the debris remaining in the tubes. Another method is to remove the heat exchanger, ream tubes and immerse heat exchanger in non-inhib- ited de-scale solvent.

Heat Exchanger Removal

1.Shut water, gas and electricity off, close valves and relieve pressure, 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 inspec- tion panels.

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

5.Remove heat exchanger corner brackets.

6.Remove combustion chamber clips at the four cor- ners of the heat exchanger.

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

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 even- ly.

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, sensor probe, and low water cutoff devices if so equipped.

7.Open water supply and return shut-off valves. Fill heater and water piping system with water. Check heater and piping system for leaks at full line pres- sure. Run system circulating pump for a minimum of 1/2 hour with heater 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 you must first have removed the heat exchanger. Unbolt metal combus- tion chamber retainer from top and remove combustion chamber panels individually.

Fig. 19: Refractory Panels—Top View

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Raypak 0135A, 0195A Repair Section, Tube Cleaning Procedure Typical, Heat Exchanger Removal, Heat Exchanger Re-Assembly
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0090A, 0135A, 0195A specifications

Raypak is a leading manufacturer in the pool and spa industry, known for its reliable and innovative heating solutions. Among its product line, the Raypak 0090A, 0135A, and 0195A are notable models that stand out for their efficiency, durability, and advanced technology.

The Raypak 0090A is ideal for residential pools, offering a heat output of 90,000 BTU per hour. It utilizes a copper heat exchanger, which provides efficient heat transfer and is resistant to corrosion, making it perfect for chlorinated pools. This model features a digital thermostat that enhances user control, allowing for precise temperature settings. Additionally, the 0090A is compatible with both natural gas and propane, providing flexibility depending on user preference.

The Raypak 0135A, with its 135,000 BTU output, is designed for larger residential pools or smaller commercial applications. This model employs advanced energy-efficient technology, helping to reduce operational costs while maintaining optimal heating performance. One of the key features of the 0135A is its built-in electronic ignition system, which improves reliability and eliminates the need for a standing pilot, enhancing safety and efficiency. The unit's compact design allows it to fit in tight spaces while still providing robust heating capabilities.

The Raypak 0195A is the most powerful of the trio, delivering 195,000 BTU, making it suitable for larger pool setups and high-demand environments. It also uses a copper heat exchanger, ensuring excellent heat retention and durability against corrosion. The 0195A is equipped with an easy-to-use digital display, offering intuitive controls for temperature adjustments and operational monitoring. This model also incorporates a high-tech air intake design, which maximizes airflow and reduces energy consumption.

All three models are designed for outdoor installation and possess weather-resistant features, ensuring longevity and reliability through various environmental conditions. Additionally, they are equipped with easy access service panels for maintenance, ensuring that servicing is efficient and straightforward.

In summary, Raypak's 0090A, 0135A, and 0195A models are designed to meet diverse heating needs with advanced technology, energy efficiency, and robust construction, making them excellent choices for anyone looking to enhance their pool experience.
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