Adjustments/Replacements Of Components - Raypak 260-401 Installation And Operating Instructions Manual

ADJUSTMENTS/REPLACEMENTS OF
COMPONENTS
CAUTION: Label all wires prior to disconnection when
servicing controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after ser-
vicing.
DANGER - SHOCK HAZARD
Make sure electrical power to the heater is disconnect-ed
to avoid potential serious injury or damage to com-
ponents.
GAS VALVE REMOVAL
1. Shut off gas supply to the heater. Remove gas
piping to gas valve inlet.
2. Disconnect wires, pilot tubing and bleed line, if
required.
3. Turn vertical gas pipe from manifold slightly and
unscrew gas valve.
4. Reverse above procedure to re-install.
PILOT REMOVAL AND CLEANING
1. Disconnect pilot tubing at pilot and sensor/ignitor
wire. Remove screws holding pilot bracket to
burner drawer.
2. Remove pilot and bracket, clean pilot of debris,
small bugs, etc., with wire or small brush.
3. Replace pilot, pilot tubing, sensor ignition wires
and check for leaks.
BURNER DRAWER REMOVAL
1. Shut off power and gas supply to the heater.
Disconnect union(s) and pilot tubing, then
loosen and remove burner hold down screws.
2. Disconnect wires at gas valve and slide burner
drawer out.
MAIN BURNER AND ORIFICE REMOVAL
1. Remove screws and burner hold down bracket.
NOTE: If the heat exchanger is sooted badly, the burner
hold down bracket and spacer can become distorted
from direct flame impingement and this usually necessi-
tates replacement of these parts.
2. Lift burners from slotted spacer and slide from
orifices. Clean with a wire brush.
3. Orifices usually do not need to be replaced.
To clean, run either copper wire or wood
through orifice. Do not enlarge hole. To remove
orifice, use a socket wrench and remove the
manifold. DO NOT overtighten when reinstall-
ing.
HIGH LIMIT OR TANKSTAT REMOVAL
1. Turn off electrical power.
2. Remove front inspection panel.
3. Remove wires to high limit and loosen screws
holding high limit to cabinet.
4. Remove wedge clip holding sensing bulb in
control well.
5. Remove high limit and install a new one.
6. Check control operation before leaving job.
FLAME ROLL-OUT SWITCH REPLACEMENT
1. Shut off electrical power to the heater.
2. Remove wiring connections to switch.
3. Remove screws (2) holding the switch.
4. Reverse above procedure to re-install.
VENT THERMAL SWITCH REPLACEMENT
1. Shut off electrical power to the heater.
2. Remove wiring connections to switch.
3. Remove the screws (2).
4. Reverse above procedure to re-install.
IGNITION MODULE REPLACEMENT
1. Shut off electrical power to the heater.
2. Remove control cover screws and open
control compartment.
3. Disconnect wiring connections to module.
4. Remove screws (2) holding module.
5. Reverse above procedure to re-install.
TRANSFORMER REPLACEMENT
1. Shut off electrical power to the heater.
2. Remove control cover screws and open control
compartment.
3. Disconnect wiring connections from
transformer leads.
4. Remove screws (2) holding transformer.
5. Reverse above procedure to re-install.
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 components
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 re-install.
Use new gaskets and make sure they are
seated properly when tightening the nuts
and bolts.
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