Raypak 133-4001 Combustion Chamber Removal, Heat Exchanger Re-Assembly, Control Well Replacement

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.

Fig. 54: Heat Exchanger

10.If gas piping was disconnected, reconnect gas pip- ing system and check for leakage using a soapy 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 remove the heat exchanger. Unbolt metal combustion cham- ber retainer from top and remove combustion chamber panels individually.

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.Install the four (4) corner clips between tube sheets and refractory. 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 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.

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

Fig. 55: Refractory Panels—Top View

Control Well Replacement

Remove top, sensing bulb and clip. Collapse well tube at the opening with a chisel, push through into header and remove the well through header. Insert a new well and roll into place. If a roller is not available, solder the well in place with silver solder.

Tube Replacement Procedure

1.Remove heat exchanger from boiler following instructions outlined under HEAT EXCHANGER REMOVAL above.

2.Remove in/out and return headers. Remove "V" baffle from damaged tube.

3.Remove damaged tube by cutting with a hack saw or shearing with a chisel adjacent to each tube sheet.

4.Collapse stub ends in tube sheets using a chisel or screwdriver. DO NOT cut into tube sheet or mar surface in tube hole in any way.

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