Control Well Replacement; Tube Replacement Procedure; Cleaning Flue Gas Passageways; Replacement Parts - Raypak RAYTHERM 0133-4001 Installation And Operating Instructions Manual

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.
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. Re-roll if necessary.
12. Reinstall as outlined under HEAT EXCHANGER
RE-ASSEMBLY.

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,
making 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 re-
move 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 war-
ranty, the part will be returned in kind or equal substi-
tution, freight collect. Credit will not be issued.
RAYPAK, INC.
2151 Eastman Avenue
Oxnard, CA 93030
39