Zodiac Aerospace 1010099-6 Maintenance Manual Download Page 39 | Manualshive

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Zodiac Aerospace 1010099-6 Maintenance Manual Download Page 39

25-30-31

Nov. 16, 2012

CMM & IPL

1010099 SERIES

Page 9002

SPECIAL TOOLS, FIXTURES AND EQUIPMENT

3 CONSUMABLES

NOTE: Equivalent alternatives can be used for listed items.

PART No.

APPLICATION

ARTICLE

PACKAGE

TOOLING

P0000320

N.A.

N.A.

N.A.

L9-970-AA

9-097-40

9-921-46

Nut locking
compound

Pipe thread sealing
compound

Pipe thread sealing
compound

Liquid sealant

Seal-lack yellow

Cable loom & thread
sealant

Cable binder

Loctite 243 blue
Not permanent

Loctite 586

Loctite 648

OmniFit seal 50H*
OmniTECHNIC GmbH

Bäder GmbH
Sicherheitslack

Teflon tape

TY-rap

250 ml flask

250 ml flask

250 ml flask

200 g flask

20 ml tube

Roll

N.A.

None

None

None

None

None

None

None

N.A. – Not applicable

* Alternative sealant is Loctite 243 blue, Nut locking compound.

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Summary of Contents for 1010099-6

Page 1: ...Revision AA COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST RAPID WATER HEATER P N L13471 Type 1010099 6 L13471 11 Type 1010099 6 1 L13471 19 Type 1010099 6 2 L13471 32 Type 1010099 6 3 L134...

Page 2: ......

Page 3: ...30 31 Jan 18 2010 CMM IPL 1010099 SERIES SERVICE BULLETIN LIST SERVICE BULLETIN LIST Bulletin Number Subject Revision Number Incorporation Date Connect 127 01 Electrical connector replacement Jan 05 2...

Page 4: ...Jan 18 2010 Jan 18 2010 Jan 18 2010 Jan 18 2010 Jan 18 2010 Jan 18 2010 Jan 18 2010 DISASSEMBLY 3001 3002 Jan 18 2010 Jan 18 2010 CLEANING 4001 4002 Jan 18 2010 Jan 18 2010 CHECK 5001 Jan 18 2010 REPA...

Page 5: ...ription and operation 1 Testing and trouble shooting 1001 Schematics and Wiring diagram 2001 Disassembly 3001 Cleaning 4001 Check 5001 Repair 6001 Assembly 7001 Fits and clearances 8001 Special tools...

Page 6: ...general description and instructions for maintenance repair and an illustrated parts list IPL containing parts information 3 REVISIONS This manual will be updated as required by revisions Their effec...

Page 7: ...faucet are situated to the units front C A thermostat ensures a constant water temperature of 87 C 189 F D A overheat protector prevents the heater from excessive heating Should no water be in the ta...

Page 8: ...actors built into the unit Overheat protector Onto the kettle assy an overheat protector is mounted The sensor of this protector is mounted against one of the heating elements Should no water be in th...

Page 9: ...assy with water When the air is fully bled off and the kettle assy is full the faucet discharges water Allow the water discharge to fill approximately one cup or beaker and then close the faucet 3 Wa...

Page 10: ...n of phases A B and C on test bench ammeter Phase currents must be 14 5 0 2A If the phase currents are different relevant heating element A B or C is defective Replace heating element d Power lamp whi...

Page 11: ...Circuit function a A overheat protector is mounted on the lid assy to prevent the unit from excessive overheating The switch cuts off the power to the heating elements within 30 seconds of the tank ex...

Page 12: ...f the pressure relief valve opens 2 If valve opens at a pressure greater than 5 bar 72 psig the valve must be replaced 3 CABLE TEST Ref Fig 102 A cable test must be performed after maintenance has bee...

Page 13: ...L13471 11 Connector 1 1 1 1 1 A B C G G Relay Relay Relay Relay Kettle assy 2 2 2 2 A1 B1 C1 X2 GD1 P N L13471 19 L13471 33 Connector 1 1 1 1 1 1 A B C E F G Relay Relay Relay Case Kettle assy Relay...

Page 14: ...in 1500V AC for a minimal period of 1 minute There must be no arcing sparking or current leakage in excess of 2 0mA or other evidence of insulation breakdown 2 Insulation test Using the insulation con...

Page 15: ...charge must be within 77 80 C 170 176 F 5 If necessary adjust the thermostat by rotating set screw Clockwise rotation lower temperature Counter clockwise rotation higher temperature 6 Set power switch...

Page 16: ...ing galley connector MS3106E16S 1S or MS3106E24 27S depending on the connector used on the water heater 2 SCHEMATIC VIEW POWER BENCH Fig 101 shows a schematic view for a bench power supply Fig 101 Ben...

Page 17: ...155 L15155 02 L9 130 AB L15156 9 130 23 L15544 L15170 L15305 L15305 01 L15306 L15546 01 L9 514 AA L15546 L15138 L15138 L15138 L15889 9 913 22 9 913 20 9 913 23 9 913 21 9 130 24 Connector Connector Co...

Page 18: ...25 30 31 Jan 18 2010 CMM IPL 1010099 SERIES Page 2003 SCHEMATICS AND WIRING DIAGRAM Fig 102 Sheet 2 of 11 Wiring diagram L13471...

Page 19: ...40 07 B07A16 16 11 12 3 94 100 09 B09A16 16 12 13 3 94 100 10 B10A16 16 2 C1 4 ON 32 28 820 11 B11A16 16 4 OFF 10 1 7 09 180 12 B12A16 16 8 2 10 2 1 97 50 13 B13A16A 16 5 1 11 5 12 130 14 B14A16 16 4...

Page 20: ...25 30 31 Jan 18 2010 CMM IPL 1010099 SERIES Page 2005 SCHEMATICS AND WIRING DIAGRAM Fig 102 Sheet 4 of 11 Wiring diagram L13471 11...

Page 21: ...07 B07A14 14 11 12 7 87 200 08 B08A14N 14 2 X2 11 15 75 400 09 B09A14 14 12 13 14 17 360 10 B10A14 14 2 C1 4 ON 32 28 820 11 B11A14 14 4 OFF 10 1 7 09 180 12 B12A14 14 8 2 10 2 1 97 50 13 B13A14 14 4...

Page 22: ...25 30 31 Jan 18 2010 CMM IPL 1010099 SERIES Page 2007 SCHEMATICS AND WIRING DIAGRAM Fig 102 Sheet 6 of 11 Wiring diagram L13471 19 and L13471 33...

Page 23: ...12 13 3 94 100 10 B10A16C 16 2 C1 4 ON 32 28 820 11 B11A16C 16 4 OFF 10 1 7 09 180 12 B12A16N 16 8 2 10 2 1 97 50 13 B13A16A 16 5 1 11 5 12 130 14 B14A16C 16 4 OFF 3 1 35 83 910 15 B15A16C 16 2 X1 3 2...

Page 24: ...25 30 31 Jan 18 2010 CMM IPL 1010099 SERIES Page 2009 SCHEMATICS AND WIRING DIAGRAM Fig 102 Sheet 8 of 11 Wiring diagram L13471 32...

Page 25: ...B07A16 16 11 12 3 94 100 09 B09A16 16 12 13 3 94 100 10 B10A16C 16 2 C1 4 ON 32 28 820 11 B11A16C 16 4 OFF 10 1 7 09 180 12 B12A16N 16 8 2 10 2 1 97 50 13 B13A16A 16 5 1 11 5 12 130 14 B14A16C 16 4 O...

Page 26: ...25 30 31 Jan 18 2010 CMM IPL 1010099 SERIES Page 2011 SCHEMATICS AND WIRING DIAGRAM Fig 102 Sheet 10 of 11 Wiring diagram L13471 40...

Page 27: ...6C 16 4 ON 32 68 830 11 B11A16C 16 4 OFF 10 1 7 09 180 12 B12A16N 16 8 2 10 2 1 97 50 13 B13A16A 16 5A 1 11 7 87 200 14 B14A16C 16 4 OFF 15 1 36 61 930 15 B15A16C 16 15 2 3 15 80 16 B16A16C 16 8 1 33...

Page 28: ...t 540 from nipple 530 5 Remove screws 40 and front sheet assy 100 6 Disconnect wiring from power switch 4 60 and indicator lamps 4 80 4 100 7 Remove the power switch 4 60 and indicator lamps 4 80 4 10...

Page 29: ...ble clamps 150 and screws 160 from frame assy boiler and screw 200 from the kettle assy 4 Remove screw 20 clip nuts 30 and wiring loom with connector 10 NOTE If necessary wire harness binding cord may...

Page 30: ...ristics Harmless to ferrous metals aluminium etc No residual odour No irritating fumes or vapours Non abrasive pH value between 6 and 8 3 CLEAINING PRODECURE NOTE Make sure that the unit is disconnect...

Page 31: ...ng product to remove corrosion Use any corrosion removing compound according to the specification of the manufacturer of this corrosion removing compound Clean any treated surface after using a corros...

Page 32: ...or tapped parts for crossed or damaged threads Reject screws etc if thread damage exceeds 50 of one thread 3 Inspect the unit for leakage 4 Inspect the unit for corrosion 5 Inspect the entire electri...

Page 33: ...lexibility of leads to prevent the wiring harness from rubbing against edges of components or hardware D Where wiring is to be replaced use wire of type M22759 8 Mfg per QPL AS22759 LATEST AWG14 or AW...

Page 34: ...divider sheet 130 and fit the heating element assy 90 to the lid 30 using copper rings 180 and liquid sealant OmniFit seal 50H 4 Fit the overheat protector 140 to the lid 30 using a washer gasket 150...

Page 35: ...he base plate assy 140 using a spring washer 460 and a screw 450 3 Secure kettle assy using washers 180 spring washers 170 and nuts 160 4 Fit the drain valve 350 to the kettle assy 280 using Loctite 6...

Page 36: ...nd nut 370 to support the front sheet assy 100 when the drain valve 350 is connected to the front sheet assy 100 When not enough space is available the nut may be omitted 6 Install the handle position...

Page 37: ...bushings etc is required 2 TORQUE VALUES IPL Fig And Item No Item Torque 1 160 Nut 6 N m 4 42 lbf ft 8 3 40 Nut 35 N m 25 82 lbf ft 8 3 60 Valve 8 N m 5 90 lbf ft 5 3 170 Nut 70 N m 51 64 lbf ft 8 3...

Page 38: ...NAME AND ADDRESS PAGE BLOCK WHERE USED N A N A N A N A N A Bench power supply 115 200V AC 3 phase 400Hz 6KVA capacity with ammeters ranging 0 20A per phase Quick connect coupling matching outlet Handh...

Page 39: ...king compound Pipe thread sealing compound Pipe thread sealing compound Liquid sealant Seal lack yellow Cable loom thread sealant Cable binder Loctite 243 blue Not permanent Loctite 586 Loctite 648 Om...

Page 40: ...tionship to the assembly Parts are listed in general order of disassembly with the exception of attaching parts which are listed immediately following the items they attach 3 ORDERING SPARE PARTS A Or...

Page 41: ...number of the part 3 Turn to the corresponding parts list and look for the item number 5 LIST OF ABBREVIATIONS The following abbreviations may have used in this IPL AR As required ASSY Assembly CH Cro...

Page 42: ...0 02 9 040 02 9 040 02 9 040 03 9 040 04 9 040 23 9 040 23 9 042 01 9 042 02 9 042 02 9 042 03 9 042 04 9 042 07 9 050 10 9 083 36 9 083 37 9 083 37 9 130 02 9 130 03 9 130 04 1 4 4 5 1 5 5 1 4 1 3 4...

Page 43: ...L13471 11 L13471 19 L13471 32 L13471 33 L13471 40 32 00779 L15108 09 L15108 12 40 39176 L15109 L15109 08 L15109 09 L15113 L15113 02 L15113 05 L15115 L15115 01 4 102212 L15116 03 L15116 05 L15117 2A 2A...

Page 44: ...44 02 L15145 L15145 01 L15146 L15146 01 L15147 L15148 02 L15155 L15155 02 L15155 02 L15156 L15159 L15159 L15160 01 L15160 01 C L15160 01 C L15160 01 D L15160 01 D L15160 01 E L15160 01 E 1 1 1 1 1 1 1...

Page 45: ...01 L15287 01 L15288 L15288 01 L15289 02 L15289 02 L15305 L15305 01 L15306 L15306 L15308 L15544 L15546 L15546 L15546 01 L15546 01 L15549 L15550 L15550 L15551 L15551 02 L15551 A 1 1 1 4 5 4 5 5 4 5 5 5...

Page 46: ...042 AD L9 043 AA L9 045 AA L9 045 AC L9 045 AD L9 060 AC L9 061 AC L9 062 AA L9 119 AA L9 130 AB L9 130 AD L9 130 AG L9 130 AH L9 130 AM L9 130 AR L9 283 AA L9 514 AA L9 514 AA L9 920 AA 1 1 3 5 1 3 2...

Page 47: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10008 ILLUSTRATED PARTS LIST IPL Fig 1A 1C 1E 1F RAPID WATER HEATER...

Page 48: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10009 ILLUSTRATED PARTS LIST IPL Fig 1B 1D RAPID WATER HEATER...

Page 49: ...RAPID WATER HEATER RAPID WATER HEATER RAPID WATER HEATER RAPID WATER HEATER RAPID WATER HEATER FRAME ASSY BOILER FRAME ASSY BOILER FRAME ASSY BOILER FRAME ASSY BOILER SIDE SHEET ASSY SIDE PANEL ASSY...

Page 50: ...521 03 L15159 L17985 9 028 60 L17604 L17604 10 BLIND RIVET CSK 3 2 7 5 BLIND RIVET RD 3 2 6 1 BLIND RIVET CSK 3 2 7 5 PIPE CLIP PIPE CLIP WASHER FLAT M4 NUT HEX M4 KETTLE ASSY WITH LID ASSY FIG 3A KET...

Page 51: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10012 ILLUSTRATED PARTS LIST IPL Fig 2A TAP ASSY IPL Fig 2B FAUCET...

Page 52: ...050 10 L9 283 AA L9 130 AH 9 130 06 L9 130 AM 9 130 07 9 083 36 L15289 02 9 130 02 L9 045 AC L17287 9 130 04 9 130 03 L17286 FAUCET PPSHP 8 G3 8 RED HANDLE AERATOR BRACKET NR 19 HP ADAPTER M200ADAP AD...

Page 53: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10014 ILLUSTRATED PARTS LIST IPL Fig 3A KETTLE ASSY WITH LID ASSY...

Page 54: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10015 ILLUSTRATED PARTS LIST IPL Fig 3B KETTLE ASSY WITH LID ASSY...

Page 55: ...308 L15551 02 L15160 01 C L15160 01 D L15160 01 E L15552 L15176 02 KETTLE ASSY WITH LID ASSY KETTLE ASSY WITH LID ASSY KETTLE ASSY LID GALVANIZED NUT NUT SEALING WASHER PRESSURE RELIEF VALVE VALVE HOL...

Page 56: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10017 ILLUSTRATED PARTS LIST IPL Fig 4 ELECTRICAL INST ASSY for L13471 40...

Page 57: ...920 21 9 913 23 9 913 21 9 913 22 9 913 20 4 101479 9 005 02 ELEC INSTL L13471 40 CONNECTOR SCREW CLIP NUT RELAY MS27743 15 RELAY SOCKET S501 E1A10 SWITCH THERMOSTAT LAMP AMBER LAMP WHITE LIGHT BULB...

Page 58: ...25 30 31 Nov 16 2012 CMM IPL 1010099 SERIES Page 10019 ILLUSTRATED PARTS LIST IPL Fig 5 ELECTRICAL INST ASSY...

Page 59: ...4 069672 9 005 02 9 029 61 L9 042 AD 9 040 23 ELEC INSTL L13471 ELEC INSTL L13471 11 ELEC INSTL L13471 19 33 ELEC INSTL L13471 32 CONNECTOR CONNECTOR CONNECTOR MS3100E24 27P SCREW CLIP NUT RELAY TERMI...

Page 60: ...to the CLEANING chapter for appropriate cleaning and drying instructions 2 INSTRUCTIONS A Store heaters which are not in service in plastic foil Make sure that the unit is drained B Store spare parts...

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