Raypak 260-401 Installation And Operating Instructions Manual

Contents

HEAT EXCHANGER RE-ASSEMBLY1. Heat exchanger water header O-rings should bereplaced with new ones.2. Install inlet-outlet and return water headers andinstall header retainer nuts and torque nuts evenly.3. Install the four (4) corner clips between tube sheetsand refractory. Replace "V" baffles.4. Install thermostat sensing bulbs in header wellsand replace bulb retaining clips.5. Install inlet and return pipes in water headers usingpipe thread sealant.6. Install water pressure relief valve, flow switch,and low water cutoff 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 radiation unitsand high points in system piping. Check all strain-ers for debris. Expansion tank water level shouldbe at the 1/4 mark and the balance of the tank filledwith 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 gaspiping system and check for leakage using a soapsolution.11. Check for correct water pressure and water level inthe system. Make sure that system pump operatesimmediately on the call for heat. The system isready for operation.12. Within two (2) days of start-up, recheck all air ventsand expansion tank levels.COMBUSTION CHAMBER REMOVALTo remove combustion chamber you must first haveremoved the heat exchanger. Unbolt metal combustionchamber retainer from top and remove combustion cham-ber panels individually.REFRACTORY PANELS TOP VIEWREPAIR SECTIONTUBE CLEANING PROCEDURE (TYPICAL)Establish a regular inspection schedule, the fre-quency depending on the local water condition andseverity of service. Do not let the tubes clog up solidly.Clean out deposits over 1/16" in thickness.The heater may be cleaned from the side oppositethe water connections, without breaking pipe connec-tions. It is preferable, however, to remove both headersfor better visibility through the tubes and to be sure theresidue does not get into the system.Note that you do not remove the top pan or the heatexchanger generally.After reaming with the auger, mount the wire brushand clean out the debris remaining in the tubes.Another method is to remove the heat exchanger,ream tubes and immerse heat exchanger in non-inhibitedde-scale solvent.HEAT EXCHANGER REMOVAL1. Shut water, gas and electricity off, close valves andrelieve pressure, remove relief valve. Remove sideinspection panels.2. Remove top holding screws.3. Remove draft diverter, lift and remove top and fluecollector on stack type models. Remove inspectionpanels.4. Loosen bolts and disconnect flange nuts on inlet-outlet header, loosen union(s) at gas pipe, and slideheater away from piping until studs clear the heater.5. Remove heat exchanger corner brackets.6. Remove combustion chamber clips at the fourcorners of the heat exchanger.7. Lift heat exchanger straight up using caution not todamage refractory.25