Circulator Replacement
1.Shut off electrical power to the heater.
2.Shut off water supply and open drain valve to remove water in the piping at the pump level.
CAUTION: To avoid damage to electrical compo- nents keep water from getting into the control compartments and gas valve.
3.Disconnect wiring and conduit connections to the pump.
4.Remove the nuts and bolts at the inlet and outlet flanges. Remove old gaskets.
5.Remove the pump.
6.Reverse the above procedure to
Control Well Replacement
Remove top, sensing bulb and clip. Collapse well tube at the open end with a chisel, push through into head- er and remove the well through header. Insert a new well and roll into place. If a roller is not available, sol- der the well in place with silver solder.
Tube Replacement Procedure
1.Remove heat exchanger from heater following instructions 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 in. heavy duty, reversible, electric drill or larger. Proceed to expand tube until tool starts to grab. Approximately 1/2 to 1 in. 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 Passage Ways
Soot will clog areas behind fins and eventually cause 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 from between fins. (Avoid excessive water against refractory).
5.Reassemble; when heater is fired, some steam will form from wet refractory, which is normal.
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.
CAUTION: Soot is combustible. Exercise extreme care. Do not wire brush.
Replacement Parts
Any part returned for replacement under standard manufacturer warranties must be properly tagged with a return parts tag, completely filled in with the heater serial number, model number etc., and shipped to the manufacturer freight prepaid.
If the manufacturer determines the part is defective 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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