Raypak 2600401 Installation & Operating Instructions Manual

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29The heater may be cleaned from the side opposite thewater connections, without breaking pipe connections.It is preferable, however, to remove both headers forbetter visibility through the tubes and to be sure theresidue does not get into the system. Generally, youdo not remove the top pan or the heat exchanger .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-inhib-ited de-scale solvent.Heat Exchanger Removal1. Shut water, gas and electricity off, close valvesand relieve pressure, remove relief valve. Removeside inspection panels.2. Remove top holding screws.3. Remove draft diverter, lift and remove top and fluecollector on stack type models. Remove inspec-tion panels.4. Loosen bolts and disconnect flange nuts on inlet-outlet header, loosen union(s) at gas pipe, andslide heater away from piping until studs clear theheater.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 todamage refractory.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 even-ly.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 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 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.Combustion Chamber RemovalTo remove combustion chamber you must first haveremoved the heat exchanger. Unbolt metal combus-tion chamber retainer from top and removecombustion chamber panels individually.Fig. 33: Refractory Panels—Top View