Raypak RAYTHERM 0133-4001 - Manual (Page 38)

5. Remove heat exchanger corner brackets.
6. Remove combustion chamber clips at the four
corners of the heat exchanger.
7. Lift heat exchanger straight up using caution not to
damage refractory.
IN/OUT
HEADER
HIGH LIMIT
ELECTRICAL
JUNCTION BOX
REDUNDANT
SAFETY
SHUT-OFF
VALVE
MANUAL GAS VALVE
MAIN GAS VALVE
SEDIMENT TRAP
Fig. # 8184
REFRACTORY PANELS TOP VIEW
8. Shut down entire system and vent all radiation
units and high points in system piping. Check all
strainers for debris. Expansion tank water level
should be at the 1/4 mark and the balance of
the tank filled with air.
9. Install flue collector, jacket top and inspection
panels. Install top holding screws. Install draft
diverter and vent piping if so equipped.
10. If gas piping was disconnected, reconnect gas
piping system and check for leakage using a
soapy solution.
12. Check for correct water pressure and water level in
the system. Make sure that system pump operates
immediately on the call for heat. The system is
ready for operation.
13. Within two (2) days of start-up, recheck all air vents
and expansion tank levels.
COMBUSTION CHAMBER REMOVAL
To remove combustion chamber you must first
remove the heat exchanger. Unbolt metal combustion
chamber retainer from top and remove combustion
chamber panels individually.
HEAT EXCHANGER RE-ASSEMBLY
1. Heat exchanger water header O-rings should be
replaced with new ones.
2. Install in/out and return water headers and install
header retainer nuts and torque nuts evenly.
3. Install the four (4) corner clips between tube
sheets and refractory. Replace "V" baffles.
4. Install thermostat sensing bulbs in header wells
and replace bulb retaining clips.
5. Install inlet and return pipes in water headers
using pipe thread sealant.
6. Install water pressure relief valve, flow switch, and
low water cut-off devices if so equipped.
7. Open water supply and return shut-off valves. Fill
boiler and water piping system with water. Check
boiler and piping system for leaks at full line pres-
sure. Run system circulating pump for a minimum
of 1/2 hour with boiler off.
MODEL 2100-4001 BOILER ILLUSTRATED
38