Raytherm WH-0133, Installation & Operating Instructions Manual, Page: 46 / 52

46
heater away from piping until studs clear the
heater.
6. Remove heat exchanger corner brackets.
7. Remove combustion chamber clips at the four cor-
ners of the heat exchanger.
8. Lift heat exchanger straight up using caution not to
damage refractory.
Heat Exchanger Re-Assembly
1. Heat exchanger water header O-rings must 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
heater and water piping system with water. Check
heater and piping system for leaks at full line pres-
sure. Run system circulating pump for a minimum
of 1/2 hour with heater shut-off.
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 pan-
els. Install top holding screws. Install draft diverter
and vent piping if so equipped.
10. If gas piping was disconnected, reconnect gas pip-
ing system and check for leakage using a soap
solution.
11. Check for correct water pressure and water level
in the system. Make sure that system pump oper-
ates immediately on the call for heat. The system
is ready for operation.
12. Within two (2) days of start-up, recheck all air
vents and expansion tank levels.
Fig. 39: Typical Heat Exchanger Configuration
Combustion Chamber Removal
To remove combustion chamber refractory you must
first have removed the heat exchanger. Unbolt metal
combustion chamber retainer from top and remove
refractory panels individually.
Control Well Replacement
Remove top, sensing bulb and clip. Collapse well tube
at the open and with a chisel, push through into head-
er and remove the well through header. Insert a new
well and roll into place. If a roller is not available, sol-
der the well in place with silver solder.
Tube Replacement
1. Remove heat exchanger from heater following
instructions outlined under HEAT EXCHANGER
REMOVAL on page 45.
2. Remove in/out and return headers. Remove "V"
baffle from damaged tube.
3. Remove damaged tube by cutting with a hack saw
or shearing with a chisel adjacent to each tube
sheet.
4. Collapse stub ends in tube sheets using a chisel or
screwdriver. DO NOT cut into tube sheet or mar
surface in tube hole in any way.
5. Insert replacement tube by inserting the end with
the most fins removed in the opening of one tube
sheet. Slide tube until the opposite end clears the
other tube sheet and fit the tube into the hole.
6. Insert the tube roller into tube opening up to stop,
making certain that 1/8" of tube projects beyond
the tube sheet.
7. Attach drill to tube roller, holding it straight and
level. Note: Use a 3/8" heavy duty, reversible,
electric drill or larger. Proceed to expand tube until
tool starts to grab. Approximately 1/2 to 1" of the
tool shank will be visible.
8. Reverse drill motor and withdraw tube roller, If
necessary wrench out by hand.
Fig. 40: Refractory Panels—Top View