Raypak 133 Installation & Operating Instructions Manual

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Contents

Raypak 133 Installation & Operating Instructions Manual Manual pdf 47 page image

47Main burner and OrificeRemoval1. Remove screws and burner hold-down bracket.NOTE: If the heat exchanger is sooted badly, theburner hold-down bracket and spacer can becomedistorted from direct flame impingement and thisusually necessitates replacement of these parts.2. Lift burners from slotted spacer and slide from ori-fices. Clean with a wire brush.3. Orifices usually do not need to be replaced. Toclean, run either copper wire or wood through ori-fice. Do not enlarge hole. To remove orifice, use asocket wrench and remove the manifold. DO NOTovertighten when reinstalling.Pilot Removal and Cleaning1. Disconnect pilot tubing at pilot and sensor/igniterwire. Remove screws holding pilot bracket to burn-er tray.2. Remove pilot and bracket, clean pilot of debris,small bugs, etc., with wire or small brush.3. Replace pilot, pilot tubing, sensor ignition wiresand check for leaks.High Limit or TankstatRemoval1. Turn off electrical power.2. Remove front inspection panel.3. Remove wires to high limit and loosen screwsholding high limit to cabinet.4. Remove wedge clip holding sensing bulb in con-trol well.5. Remove high limit and install a new one.6. Check control operation before leaving job.Heat Exchanger Removal1. Shut water, gas and electricity off, close valvesand relieve pressure, remove relief valve.2. Remove side inspection panels.3. Remove top holding screws.4. Remove draft diverter, lift and remove top and fluecollector on stack type models. Remove inspec-tion panels.5. Loosen bolts and disconnect flange nuts on in/outheader, loosen union(s) at gas pipe, and slideheater away from piping until studs clear theheater.6. Remove heat exchanger corner brackets.7. Remove combustion chamber clips at the four cor-ners of the heat exchanger.Fig. 40: Typical Heat Exchanger Configuration8. Lift heat exchanger straight up using caution not todamage refractory.Heat Exchanger Re-Assembly1. Heat exchanger water header O-rings must bereplaced with new ones.2. Install in/out and return water headers and installheader retainer nuts and torque nuts evenly.3. Install the four (4) corner clips between tubesheets and refractory. Replace "V" baffles.4. Install thermostat sensing bulbs in header wellsand replace bulb retaining clips.5. Install inlet and return pipes in water headersusing pipe thread sealant.6. Install water pressure relief valve, flow switch, andlow water cut-off devices (if so equipped).7. Open water supply and return shut-off valves. Fillheater and water piping system with water. Checkheater and piping system for leaks at full line pres-sure. Run system circulating pump for a minimumof 1/2 hour with heater shut-off.8. Shut down entire system and vent all radiationunits and high points in system piping. Check allstrainers for debris. Expansion tank water levelshould be at the 1/4 mark and the balance of thetank filled with air.9. Install flue collector, jacket top and inspection pan-els. Install top holding screws. Install draft diverterand vent piping if so equipped.10. If gas piping was disconnected, reconnect gas pip-ing system and check for leakage using a soapsolution.11. Check for correct water pressure and water levelin the system. Make sure that system pump oper-ates immediately on the call for heat. The systemis ready for operation.12. Within two (2) days of start-up, recheck all airvents and expansion tank levels.