CONTROL WELL REPLACEMENT
Remove top, sensing bulb and clip. Collapse well tube at the open end 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 heater following in- structions outlined under HEAT EXCHANGER REMOVAL.
2.Remove inlet/outlet 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.
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 fits 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 REASSEMBLY.
PROCEDURE FOR CLEANING FLUE GAS PAS-
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 draft hood and flue collector by removing bolts and screws.
2.Remove "V" baffles from heat exchanger.
3.Remove burner tray, see Burner Drawer Removal.
4.Take garden hose and wash heat exchanger, mak- ing sure soot is removed form between fins. (Avoid excessive water against refractory).
5.Reassemble; when heater is fired, some steam will form from wet refractory. This is normal.
NOTE: In extreme cases it may be necessary to remove the heat exchanger completely for cleaning. The sim- plest method is steam cleaning at a local car wash.
CAUTION: Soot is combustible. Exercise extreme care. Do not wire brush.
REPLACEMENT PARTS LIST
NOTE: To supply the correct part it is important that you state 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 the Company freight prepaid.
If determined defective by the Company 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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