Raypak 135A, 195A, 090A manual Heat Exchanger Re-Assembly

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, 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 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.

COMBUSTION CHAMBER REMOVAL

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

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