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CONTROL WELL REPLACEMENT
Remove top, sensing bulb and clip. Collapse well
tube at the open end with a chisel, push through into
header and remove the well through header. Insert a new
well and roll into place. If a roller is not available, solder
the well in place with silver solder.
TUBE REPLACEMENT PROCEDURE
1. Remove heat exchanger from heater following in-
structions outlined under HEAT EXCHANGER
REMOVAL.
2. Remove inlet/outlet 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 fits 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.
9. DO NOT apply excessive torque during rolling
operation and avoid thinning any wall of the tube
beyond 0.015".
10. Use same procedure on opposite end.
11. Apply line pressure test. Re-roll if necessary.
12. Reinstall as outlined under HEAT EXCHANGER
REASSEMBLY.
PROCEDURE FOR CLEANING FLUE GAS PAS-
SAGE-WAYS
Soot will clog areas behind fins and cause eventual
tube failure. Any sign of soot at base of burners or around
outer jacket indicates a need for cleaning.
1. Lift off draft hood and flue collector by removing
bolts and screws.
2. Remove "V" baffles from heat exchanger.
3. Remove burner tray, see Burner Drawer Removal.
4. Take garden hose and wash heat exchanger, mak-
ing sure soot is removed form between fins. (Avoid
excessive water against refractory).
5. Reassemble; when heater is fired, some steam will
form from wet refractory. This is normal.
NOTE: In extreme cases it may be necessary to remove
the heat exchanger completely for cleaning. The sim-
plest method is steam cleaning at a local car wash.
CAUTION: Soot is combustible. Exercise extreme care.
Do not wire brush.
REPLACEMENT PARTS LIST
NOTE: To supply the correct part it is important that you
state the model number, serial number and type of gas
when applicable.
Any part returned for replacement under standard
company warranties must be properly tagged with
RAYPAK return parts tag, completely filled in with the
heater serial number, model number etc., and shipped to
the Company freight prepaid.
If determined defective by the Company and within
warranty, the part will be returned in kind or equal
substitution, freight collect. Credit will not be issued.
RAYPAK, INC.
2151 Eastman Avenue
Oxnard, CA 93030
31