5.Insert replacement tube by inserting the end with the most fins removed in the opening of one tube sheet. Slide tube until the opposite end clears the other tube sheet and fit the tube into the hole.
6.Insert the tube roller into tube opening up to stop, making certain that 1/8" of tube projects beyond the tube sheet.
7.Attach drill to tube roller, holding it straight and level.
NOTE: Use a 3/8" heavy duty, reversible, electric drill or larger. Proceed to expand tube until tool starts to grab. Approximately 1/2 to 1" of the tool shank will be visible.
8.Reverse drill motor and withdraw tube roller. If necessary wrench out by hand.
9.DO NOT apply excessive torque during rolling operation and avoid thinning any wall of the tube beyond 0.015".
10.Use same procedure on opposite end.
11.Apply line pressure test.
12.Reinstall as outlined under HEAT EXCHANGER
Cleaning Flue Gas Passageways
Soot will clog areas behind fins and cause eventual 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.
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.
6.Correct reason for soot formation.
NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The simplest method is steam cleaning at a local car wash. DO NOT WIRE BRUSH!
CAUTION: Soot is combustible, so exercise extreme care.
REPLACEMENT PARTS
See separate parts sheet in instruction envelope.
NOTE: To supply the correct part it is important that you supply the model number, serial number and type of gas when applicable.
Any part returned for replacement under standard company warranties must be properly tagged with Raypak return parts tag, completely filled in with the heater serial number, model number, etc., and shipped to Raypak freight prepaid. If determined defective by Raypak and within warranty, the part will be returned in kind or equal substitution, freight collect. Credit will not be issued.
RAYPAK, INC.
2151 Eastman Avenue
Oxnard, CA 93030
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