Raypak 131 Service Instructions Manual Download Page 15

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TM018 Raypak 131 Type A Pool & Spa Heaters REV: A
D.O.I: 8/04/2009

This document is stored and maintained electronically by

Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Operational Flow Chart 2

Flame signal

lost? (< 0.2µA)

YES

Water temp = Set

temp + 0.5ºC?

Ignition

& flame

proving
(15 sec

max)

Burner

operation

45º high limit

contacts open?

External switch or

time switch

contacts open?

Water pressure
switch contacts

open?

55º high limit

contacts

open?

YES

Flame signal >

0.2µA detected?

Internal check

ok?

YES

System

check

(3 sec)

Approx

5 sec

Flame signal >

0.2µA detected?

Flame signal >

0.2µA detected?

YES

Ignitor current

draw > 1.4A?

YES

Has 15 sec

‟s

expired since

igniter on?

YES

Igniter on

Gas valve energised

Gas valve opens

Igniter off

Relay 1 de-energised

Gas valve

de-energised

Gas valve

de-energised

Gas valve closes

Ignition module

de-energised

Ignition module

de-energised

Gas valve

de-energised

Ignition module

de-energised

Control board ends

call for heat

Ignition module 3

flash indication

Ignition module

3 flash indication

Ignition module

4 flash indication

Ignition module

energised

LOCKOUT

Gas valve closes

Gas valve de-

energised

Turn controller on

Turn controller off

Igniter off

False Flame

Flame Failure

Relay 2

de-energised

Gas valve closes

5 sec
delay

Summary of Contents for 131

Page 1: ...stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled SERVICE INSTRUCTIONS Raypak 131 Pool Heater TM020 Revision A Published April 09 Spartan P0131 ...

Page 2: ...ards 11 Sequence of Operation 12 Components and Their Function 16 Fault Indication 18 Fault Finding 19 General Fault Finding Chart 20 Fault Finding Chart 1 21 Fault Finding Chart 1 1 22 Fault Finding Chart 1 2 22 Fault Finding Chart 1 3 23 Fault Finding Chart 1 4 24 Fault Finding Chart 1 5 25 Fault Finding Chart 1 6 1 7 26 Fault Finding Chart 1 8 27 Fault Finding Chart 2 28 Fault Finding Chart 3 2...

Page 3: ...n bold italics and or a warning symbol see below Take care to observe the recommended procedure Live testing to be conducted Personal Protective Clothing PPE shall be worn and an RCD shall be installed between the power point and 3 pin cord of the pool heater to reduce the risk of electric shock Isolate power before conducting the indicated test Hot surface or liquid Personal Protective Clothing P...

Page 4: ... 62 2 ohms Secondary winding 24 Volts AC 50Hz 1 3 ohms Pressure switch Barksdale MSPS EE05 Q71 or Tecmark MSPS EE05 Adjustable 3 5 34 5kPa max pressure 55kPa Flow switch Adjustable max pressure 1000kPa 40ºC temperature probe Refer to table on page 40 Control circuit fuse 3A Relay 1 Omron LY2N DPDT 24VAC coil resist 186 ohms Relay 2 Omron LY2N DPDT 24VAC coil resist 186 ohms Reset illuminated push ...

Page 5: ... C high limit located on the inlet header the burner should extinguish Reconnect the wire the reset button lamp should illuminate however the burner must not light Press the reset button the lamp should extinguish and the burner should light 11 With the burner operating disconnect one wire from the 55 C high limit located on the outlet header the burner should extinguish Reconnect the wire the res...

Page 6: ...hether a black or grey board is fitted Refer to page 9 for grey board wiring diagram and pages 10 11 for black board wiring diagrams Black control board Grey control board Addition of Reset Button Safety Lock Out Circuit Weather Shielding All Raypak pool and spa heaters manufactured after 14 04 2008 have been fitted with an additional safety feature and weather shielding The additional safety feat...

Page 7: ...rs manufactured from the 14 4 09 have an additional auto reset PCB fitted This control automatically resets the safety lockout circuit when power is applied for the first time or from a power outage overcoming nuisance lock outs The auto reset PCB also incorporates the safety circuit functionality noted above including relays relay 1 and relay 2 A manual reset by pressing the red reset button is s...

Page 8: ...as STOP if you smell gas and follow the safety instructions in the installation and operating instructions If you do not smell any gas go to the next step 6 Turn the gas isolation valve to the ON position 7 Turn on electrical power to the pool spa heater 8 Press and release the red reset button the reset light should go out NOTE For models manufactured from 14 04 09 onwards the reset button should...

Page 9: ...Spa Heaters REV A D O I 8 04 2009 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 9 Wiring Diagrams 131 Wiring Diagram Grey Control Board ...

Page 10: ...a Heaters REV A D O I 8 04 2009 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 10 131 Wiring Diagram Black Control Board prior to 14 4 09 ...

Page 11: ...pa Heaters REV A D O I 8 04 2009 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 11 131 Wiring Diagram Black Control Board 14 4 09 onwards ...

Page 12: ... high limit for grey boards also via the water pressure switch contacts 4 When power is supplied to the RAM ignition module the ignition module will perform an internal check to ensure that it is functioning correctly If the internal check fails the ignition module will lock out and require resetting by turning the controller off for 5 seconds and then turning the controller back on again If the i...

Page 13: ...igh limit contacts are open at the start of a call for heat step 3 relay 1 will be de energised and no further operation will take place until the 45ºC inlet high limit contacts close cool below 35ºC at which time the reset indicator lamp will illuminate The heater will then require resetting by pressing the red reset button Also refer to point d below b If the 45ºC inlet high limit contacts open ...

Page 14: ...o reset safety circuit board resets D Reset button pushed released YES NO NO 1 YES E I B OPERATION Control board set to Manual Start NO Is time within auto set time period NO Aux 2 enabled Aux 3 enabled Aux 4 enabled Aux 5 enabled Aux 6 enabled YES YES A B YES NO A B YES NO A B YES NO A B YES NO A B YES NO A B YES NO A B Dotted line denotes optional electronic interface box E I B Disabled Aux rela...

Page 15: ...eck 3 sec Approx 5 sec Flame signal 0 2µA detected NO Flame signal 0 2µA detected YES D D Ignitor current draw 1 4A YES YES Has 15 sec s expired since igniter on NO YES E E NO Igniter on Gas valve energised Gas valve opens Igniter off Igniter off Relay 1 de energised Gas valve de energised Gas valve de energised Gas valve closes Gas valve closes Ignition module de energised Ignition module de ener...

Page 16: ... flame area of the burner and when in contact with the flame produces a DC current µA which is detected by the ignition module Burner Manifold A pipe fitted with a series of injectors which deliver gas from the gas valve to the burner Burner A series of bars connected to the burner manifold and held in place by a sheet metal surround Each bar contains a series of holes from which air gas mixture f...

Page 17: ...is present the flow switch contacts will close enabling operation of the gas valve ignition system refer to page 42 for flow switch adjustment procedure Water Temperature Probe A thermistor located on the inlet header manifold which is utilised to detect the water temperature entering the heater pool spa water temperature The temperature probes resistance value will change according to the detecte...

Page 18: ...ler is set to On or AUTO and the water pressure switch contacts are open a small o will be shown to the left of the temperature display No Mains Power Indication Power Backup black boards only The controller and remote controller if fitted has a super capacitor power backup to keep the time of day clock operating maintain any programmed time periods and remember the last operating mode if mains po...

Page 19: ...cting diagnostic procedures is provided below This equipment is available from Rheem Service Spare Parts Department Fine probe adapter kit WH0020082 Probe to alligator clip kit WH0020084 Fault Fault finding chart Page Heater not operating 1 21 1 1 22 1 2 22 1 3 23 1 4 24 1 5 25 1 6 1 7 26 1 8 27 Water not hot enough 2 28 Water too hot 3 29 High Limits Tripping 4 30 No or low water flow 5 31 Auxili...

Page 20: ...int for water not hot enough Is the complaint for heater not operating Is the complaint for water too hot Is the complaint for 45º and or 55º high limits tripping NO NO NO YES 2 3 4 8 YES YES NO Is the complaint for auxiliary switching not working NO Is the complaint for no or low water flow NO 5 6 YES YES Is the complaint for remote controller not working NO 7 YES Is the complaint for leaking 9 Y...

Page 21: ...ty fuse replaced check appliance operation YES Household wiring or power point faulty Advise customer to call an electrician NO Test 1 YES YES Are relay 2 contacts 5 1 closed Test 2 Are relay 1 contacts 5 1 closed YES Test 3 Replace relay 2 NO Replace relay 1 NO Replace reset button YES Does the red reset light extinguish Is the reset button contact block ok NO Test 4 YES Replace reset button NO R...

Page 22: ...megger between cord set active and earth pins then cord set neutral and earth pins Replace fuse Is reading less than 1 mega ohm for either reading Disconnect transformer at line terminal block and measure between each transformer wire and earth Fault Finding Chart 1 2 1 2 Is 24 volts present at control board terminal marked 24VAC Is 240 volts present at line terminal block YES NO NO NO Replace hea...

Page 23: ...be adjusted YES Fault rectified Water pressure or flow switch adjusted YES Replace water pressure or flow switch NO Is 24 volts present at control board terminal marked VALVE Replace control board NO YES Test 10A for black boards Test 10B for grey boards Min flow rate 1 3 l sec Max flow rate 6 9 l sec Refer to section on adjusting pressure switch or adjusting flow switch Does controller show flame...

Page 24: ...ater temp probe wiring ok Repair solar water temperature probe wiring NO YES Is Error code PO displayed YES 1 2 Is Error code o displayed NO Is the pump operating YES NO YES Water temperature probe open circuit Water temperature probe short circuit No power at control board Pressure switch open during call for heat Black boards only Is the water pressure or flow switch closed 5 Is there sufficient...

Page 25: ...ts 6 4 closed YES Replace relay 1 NO 4 NO Is there 24 volts at relay 1 coil Repair O C wiring NO Are 55ºC outlet high limit contacts closed YES 4 Is 24 volts present at the ignition module NO YES Repair O C wiring NO Test 12 Test 13 Test 14 Test 15 Test 16 Test 17 Test 18 55ºC outlet high limit has tripped Is the ignition module giving 4 flash indication 45ºC inlet high limit has tripped NO Replac...

Page 26: ...asing the power button wait 5 seconds then turn controller on again by pressing and releasing the power button 1 Is gas available YES NO Advise customer NO YES Refer to specification table NO YES Are burner injectors blocked Does burner ignite NO YES Is a false flame present YES Is flame sensor clean NO NO Replace gas valve Clean or replace burner injectors YES NO 1 Faulty hot surface igniter Repl...

Page 27: ...arsh noisy blue flame Refer to specification table YES Refer to specification table Does 45º inlet or 55º outlet high limit trip 4 YES Is flame wind affected NO YES Is inlet gas pressure within specification Advise customer NO Heater operating correctly NO 4 1 Refer to section on adjusting burner gas pressure Burner gas pressure adjusted Check appliance operation Can burner gas pressure be adjuste...

Page 28: ...ame should not be a harsh noisy blue flame NO Are burner injectors correct size and gas type Refer to Gas Valve section YES Can burner gas pressure be correctly adjusted Replace burner injectors with injectors of correct size and gas type NO NO Burner gas pressure correctly adjusted YES NO YES Advise customer NO Replace gas valve Advise customer that supply gas is of a bad quality and is unsuitabl...

Page 29: ...ched NO YES Is 24 volts present at the ignition module after flame icon is extinguished YES YES Test 18 Heater operating normally NO Does burner extinguish after flame icon extinguishes Replace gas valve NO YES What was original complaint Water too hot 45ºC and or 55ºC high limits NOT tripping Free or replace in out header bypass valve YES Is in out header bypass valve stuck in closed position Cle...

Page 30: ...finding to determine why water flow is too low then check heater operation to determine if high limit s trip YES Clean or replace tube bundle Are heat exchanger fins blocked YES NO Are heat exchanger fins blocked with soot NO Is burner flame satisfactory YES YES Is inlet gas pressure within specification Advise customer NO Clean or replace tube bundle NO 4 1 YES Chart 4 1 is part of and located wi...

Page 31: ...g Chart 5 Are plumbing valves open or in correct position 5 Is heater plumbed correctly YES NO Remake plumbing to comply with installation instructions NO YES Ensure plumbing valves are open or in correct postion Is skimmer box blocked Unblock skimmer box YES Blockage in pipe work Is pump blocked or seized NO Unblock free or replace seized pump YES NO Is pool spa filter blocked NO Advise customer ...

Page 32: ...uxiliary s turned on YES YES Set controller clock to correct time NO Correctly program auto mode time periods Auxiliary s must be programmed to turn on during auto mode time periods NO NO For information on programming auxiliary operation in auto mode refer to TM055 Raypak Pool Heater Controller Guide For information on selecting auxiliary s whilst in manual mode refer to TM055 Raypak Pool Heater ...

Page 33: ...rly retaining probe and that o ring is present Replace o ring if required Use silicone grease on o ring YES Is leak at water pressure switch NO YES Is leak at in out header to heat exchanger union s NO YES NO Replace leaking heat exchanger Is leak from rain or splashed water pooling at heater Is leak from external plumbing Advise customer YES YES NO Is leak Due to condensate forming NO NO Normal o...

Page 34: ...m nearby equipment i e pool pump NO YES Look for loose component or screws Screaming or whining noises are associated with low water flow NO Flow Chart 4 1 is part of flow chart 1 8 Test Procedures Fault Finding Tests 1 2 Test 1 Test 2 Ensure power point is switched on and using a multimeter on the AC voltage scale measure between the 3 pin sockets on the power point Normal reading should be Activ...

Page 35: ...AC voltage scale measure between the two terminals on the reset button LED block yellow and blue wires Normal reading should be 24 Volts AC Test 5 Test 6 Disconnect red wire from the reset button contact block and using a multimeter on the ohms scale measure between the two terminals on the reset button contact block grey and red wires The following result should be obtained while the reset button...

Page 36: ...wing result should be obtained 240 Volts AC Using a multimeter on the AC voltage scale measure between terminal marked 24VAC and terminal marked GND on the control board The following result should be obtained 24 Volts AC Test 8B Test 9 Using a multimeter on the AC voltage scale measure between terminal marked 24VAC and terminal marked GND on the control board The following result should be obtain...

Page 37: ... disconnect wiring at pressure or flow switch Restore power and using a multimeter on the ohms scale measure between the two terminals on the pressure or flow switch The following result should be obtained whilst the pump is operating 0 ohms pressure or flow switch closed Test 11A Test 11B Using a multimeter on the AC voltage scale measure between terminal marked VALVE and terminal marked GND on t...

Page 38: ...e obtained 24 Volts AC Using a multimeter on the AC voltage scale measure between the brown wire terminal and blue wire terminal on relay 2 The following result should be obtained 24 Volts AC Test 14 Test 15 Disconnect wiring at 45ºC inlet high limit and using a multimeter on the ohms scale measure between the two terminals on the 45ºC inlet high limit The following result should be obtained 0 ohm...

Page 39: ...outlet high limit and using a multimeter on the ohms scale measure between the two terminals on the 55ºC outlet high limit The following result should be obtained 0 ohms high limit contact closed Test 18 Test 19 Using a multimeter on the AC voltage scale measure between each purple wire and the blue wire on the RAM ignition module terminal strip The following results should be obtained 1st purple ...

Page 40: ...r probe tip next to tip of water temperature probe so both probes measure the ambient air temperature at the same location 3 Disconnect the water temperature probe from the control board connect a multimeter to the probe plug and select the ohms scale on the multimeter 4 Compare the ohms reading to the thermometer temperature and check against the water table shown below allowing for a tolerance o...

Page 41: ...ting the gas valve burner pressure regulator Adjust the burner gas pressure to match the appliance rating plate as follows 1 Remove the Lower In Out Header Panel Gas Valve Cover and Gas Valve Enclosure 2 Remove the Gas Valve burner pressure adjustment screw cap by unscrewing in an anticlockwise direction 3 Using a screwdriver turn the inner adjustment screw clockwise to increase or counter clockwi...

Page 42: ...with the pressure switch or pool heater and fault finding will need to be performed to locate the fault 9 If the heater did go out in step 8 the pump should be cycled on and off several times to ensure that the adjustment is correct Flow Switch Adjustment 1 Check that all valves are correctly positioned to allow water flow through the heater 2 Start system pump and ensure that the correct water fl...

Page 43: ...l Refer to Front Access Panel procedure above 2 Cut cable tie retaining the water temperature probe cable to wiring loom 3 Remove four screws retaining the Display Panel and place on ground Note Support the Display Panel whilst removing screws otherwise the Display Panel will fall when the last screw is removed 4 Remove the PCB Cover Panel by pressing down on the top side and pulling away from the...

Page 44: ...per Grille 5 Gently pull the Side Panel away from the Upper Grille to disengage the locating tab 6 Gently slide the Upper Grille locating tab out of the opposite side panel and remove 7 Reassemble in reverse order of above Upper In Out Header Panel 1 Turn Controller off 2 Isolate power supply to the pool heater and pool pump 3 Remove four screws retaining the Upper In Out Header Panel 4 Remove the...

Page 45: ...emove four hex head screws retaining the Flue Collector to the front and rear Refractory Supports and lift out the Flue Collector Jacket Assembly Complete 1 Turn controller off 2 Isolate the power supply to the pool heater and pool pump 3 Isolate the pool water from the pool heater 4 Disconnect the pool plumbing from the pool header at the In Out Header unions 5 Isolate the gas supply to the pool ...

Page 46: ...d side panel 10 Remove the 3 screws along the bottom edge of the right hand side panel 11 Remove the side Panel NOTE Each Upper Grille has a tab which slots into the side panel To disengage the tab slide the panel off the tabs while keeping the panel upright 12 Reassemble in reverse order of above 13 Test for gas leaks using soapy water solution Left Hand Side Panel 1 Remove the Display Panel Foll...

Page 47: ...e Probe 1 Isolate the pool water from the pool heater 2 Remove the In Out Header Access Cover Refer to In Out Header Access Cover procedure on page 44 3 Remove the clip retaining the Water Temperature Probe and withdraw the Water Temperature Probe from the Adaptor NOTE Ensure the o ring is also removed from the Adapter 4 Remove the Display Panel Follow steps 1 4 of the Display Panel Removal proced...

Page 48: ... NOTE Some P0131 models are fitted with two 55 C Outlet High Limits one on the In Out Header and one on the Heat Exchanger Outlet A number of changes have been made to the weather shielding covers fitted to the In Out Header this procedure details the method for current assembly methods For P0131 models fitted with the rework kit it will be necessary to remove the Top Panel Flue Diverter Assembly ...

Page 49: ...rews retaining the In Out Header weather shield s to the Refractory Support and remove the weather shield Note On pool heaters that have the rework kit fitted the silicone seal between the weather shield and the Flue Collector will need to be broken 11 Disconnect the pool pipe work from the pool heater at the In Out Header Unions 12 Disconnect the In Out Header from the Heat Exchanger at the union...

Page 50: ...ing and Bypass Valve Cap spindle 8 Restore the pool water supply start the pool pump and check for water leaks 9 Complete reassembly in reverse order of above Heat Exchanger 1 Remove the In Out Header Follow steps 1 12 of the In Out Header procedure on page 49 2 Remove the 2 screws retaining the 55ºC Outlet High Limit to the Heat Exchanger and remove 3 Remove the remaining screws securing the Flue...

Page 51: ... reverse order of above Do not fit the Lower In Out Header Panel at this stage 7 Restore the gas and power supplies and operate the pool heater and adjust the burner pressure to that indicated on the rating label refer to Burner Pressure Adjustment procedure on page 41 8 Test for gas leaks using soapy water solution 9 Complete reassembly Burner Manifold Injectors 1 Remove the Burner Assembly Refer...

Page 52: ...reverse order of above Note Do not refit the Gas Valve Enclosure Gas Valve Cover or Lower In Out Header Panel as this stage 11 Restore the gas supply 12 Operate the pool heater test for gas leaks using soapy water solution and adjust the burner pressure to that indicated on the rating label refer to Burner Pressure Adjustment procedure on page 41 13 Complete reassembly Refractories Top Refractory ...

Page 53: ...he Display Panel procedure on page 43 10 Remove the Burner Assembly if not already removed in step 4 above Follow steps 4 5 of the Burner Assembly procedure on page 51 11 Remove the Electrical Control Box from the Front Refractory Support Note On some models this will require the removal of all the components within the Electrical Control Box Refer to the various replacement procedures for each co...

Page 54: ...ton and pull to separate Type 2 Pivot the locking tab across the switch and LED assembly to release the switch and LED assembly from the push button and pull to separate 3 Undo the lock nut to remove the push button from the Display Panel Note the orientation of the push button to ensure the switch and LED assembly will be re installed in the same orientation 4 Mark and disconnect the wiring at th...

Page 55: ...ew the Cord Set cable gland compression nut in an anticlockwise direction and remove the Cord Set by withdrawing through the compression gland 5 Reassemble in reverse order of above Relay 1 Relay 2 1 Remove the Electrical Control Box Cover Refer to Electrical Control Box Cover procedure on page 43 2 Pull the relevant Relay out of the Relay Base 3 Reassemble in reverse order of above Relay Base 1 R...

Page 56: ...mer secondary winding active at the quick connect to the main wiring loom 6 Pull the Relays 1 2 out of the Relay Bases 7 Remove the Relay Bases from the din rail Follow step 4 of the Relay Base procedure on page 55 8 Disconnect the wiring at the flame rod spade terminal 9 Disconnect the wiring at igniter electrode spade terminals 10 Remove the In Out Header Access Cover Refer to In Out Header Acce...

Page 57: ...ak 131 Type A Pool Spa Heaters REV A D O I 8 04 2009 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 57 Exploded View ...

Page 58: ...20410 39 Panel Heat Shield Header Cover 56144824 12 Controller Grey Board 56659197 40 Panel Header Cover Wrapper 56144814 Controller Black Board 56PE5001 41 Panel Header Cover Lid 56144813 13 Panel PCB Control Cover 56144826 42 Panel Access In Out Header 56144832 14 Cover Igniter 56144825 43 Panel Access Lower Rear 56320420 15 Igniter HSI Norton 56659144 44 Panel Access Upper Rear 56320432 16 Pane...

Page 59: ...e assemble and fit the Burner Assembly to the pool heater 4 Remove the Gas Valve Cover and Gas Valve Enclosure Refer to steps 5 6 of the Gas Valve procedure on page 52 5 Natural Gas Propane Gas Conversion Remove the regulator cover screw plastic adjustment screw and gas type spring from the gas valve and replace with the grey white powder coated spring suitable for propane refer to diagram opposit...

Page 60: ...l damage to the heater or any component including a Acts of God b Failure due to misuse c Incorrect installation d Attempts to repair carried out by other than Rheem or an accredited Agent 2 Where it is found that there is nothing wrong with the heater 3 Where the complaint is related to excessive discharge from the pressure relief valve if fitted due to excessive water pressure 4 Where there is n...

Page 61: ...ned electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 61 Document Revision History Title Raypak 131Pool Heater Service Instructions Document Nº TM020 Revision Details of change D O I A Type A Raypak pool spa heater service instructions issued 4 09 ...

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