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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
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.
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.
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.
40
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