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Zodiac Aerospace L13471 Maintenance Manual

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Initial issue: Unknow
Revised: Nov. 16, 2012
Revision: AA
COMPONENT MAINTENANCE MANUAL
WITH
RAPID WATER HEATER
P/N: L13471
L13471-11
L13471-19
L13471-32
L13471-33
L13471-40
Type: 1010099-6
Type: 1010099-6.1
Type: 1010099-6.2
Type: 1010099-6.3
Type: 1010099-6.2
Type: 1010099-6.2
25-30-31

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Summary of Contents for Zodiac Aerospace L13471

  • Page 1 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 L13471-33 Type: 1010099-6.2 L13471-40 Type: 1010099-6.2 25-30-31 Initial issue: Unknow Revised: Nov. 16, 2012 Revision: AA...
  • Page 3 CMM & IPL 1010099 SERIES SERVICE BULLETIN LIST SERVICE BULLETIN LIST Bulletin Revision Incorporation Subject Number Number Date Connect-127-01 Electrical connector replacement Jan. 05, 2006 25-30-31 Jan. 18, 2010...
  • Page 4 CMM & IPL 1010099 SERIES LIST OF EFFECTIVE PAGES SUBJECT PAGE DATE SUBJECT PAGE DATE TITLE PAGE Nov. 16, 2012 ASSEMBLY 7001 Nov. 16, 2012 7002 Nov. 16, 2012 RECORD OF REVISIONS Nov. 16, 2012 7003 Nov. 16, 2012 SERVICE BULLETIN LIST Jan.
  • Page 5 CMM & IPL 1010099 SERIES TABLE OF CONTENTS PAGE Description and operation 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, Fixtures and Equipment 9001 Illustrated parts list 10001...
  • Page 6 INTRODUCTION GENERAL This manual is intended for provision of such data as is necessary for repairing and servicing of rapid water heaters p/n L13471, L13471-11, L13471-19, L13471-32, L13471-33, L13471-40. The rapid water heater is manufactured by: DRIESSEN AEROSPACE GROUP NV...
  • Page 7 CMM & IPL 1010099 SERIES DESCRIPTION AND OPERATION DESCRIPTION The rapid water heater, an electrically operated and thermostatically controlled unit, is designed for use in an airplane galley to heat water to a temperature of 87°C (189°F) and then to maintain the water at this indicated temperature.
  • Page 8 CMM & IPL 1010099 SERIES DESCRIPTION AND OPERATION D. Electrical data: (1) Operating voltage 115/200V AC, 400Hz (2) Power consumption 5100W (3 elements of 1700W each) (3) Power factor (cos) (4) Electrical receptacle MS3100E16S-1P (L15155) CA3100E16S-1P-F80 (L15155-02) MS3100E24-27P (L9-130-AB) E. Water supply: (1) Operating pressure 3.1 –...
  • Page 9 CMM & IPL 1010099 SERIES DESCRIPTION AND OPERATION OPERATION CAUTION: DO NOT OPERATE THE WATER HEATER WITH WATER TANK EMPTY A. Initial filling NOTE: ENSURE THAT THE DRAIN VALVE HANDLE IS TURNED TO THE CLOSED POSITION Connect the unit to the water and electrical supply and place a cup or beaker under the faucet.
  • Page 10 CMM & IPL 1010099 SERIES TESTING AND TROUBLE SHOOTING GENERAL This chapter outlines procedures based on test point/location methods for bench/shop testing and trouble shooting of the rapid water heater. OPERATIONAL TESTS (Ref. Fig. 102) A. Heating elements circuit (Ref. Items 1 through 17) Circuit function (a) Heating elements (11,12,13) are activated/deactivated by the power switch (4) via the relay (2).
  • Page 11 CMM & IPL 1010099 SERIES TESTING AND TROUBLE SHOOTING C. Thermostat circuit (Ref. Item 6) The thermostat is set to 87°C (189°F) and controls the units water temperature. To check this do the following: (1) Fill unit with water. (2) Set power switch (4) to ON position. (3) Let the unit heat the content until the lamp amber (8) switches off.
  • Page 12 CMM & IPL 1010099 SERIES TESTING AND TROUBLE SHOOTING E. Water pressure. The ideal water supply pressure is between 3.1 bar (45 psig) and 3.8 bar (55 psig). CAUTION: The pressure relief must open between 4 and 5 bar (58-72 psig). (1) Raise pressure in water supply line to 5 bar (72 psig) and check if the pressure relief valve opens.
  • Page 13 TERMINAL P/N L13471 Connector Relay Relay Relay Kettle assy Relay P/N L13471-11 Connector Relay Relay Relay Relay Kettle assy P/N L13471-19 & L13471-33 Connector Relay Relay Relay Case Kettle assy Relay P/N L13471-32 Connector Relay Relay Relay Relay Kettle assy...
  • Page 14 CMM & IPL 1010099 SERIES TESTING AND TROUBLE SHOOTING DIELECTRIC AND INSULATION TEST (Ref. Fig. 102) An dielectric and insulation test must be performed after each overhaul. The insulation test must be performed after the dielectric test. WARNING: BEFORE TESTING DISCONNECT THE UNIT FROM POWER SOURCE. A.
  • Page 15 CMM & IPL 1010099 SERIES TESTING AND TROUBLE SHOOTING ADJUSTING THE TEMPERATURE SETTING A. The maximum temperature setting can be adjusted. The temperature must be adjusted every time the thermostat or a heating element is replaced. WARNING: A higher than prescribed water temperature may cause steam venting from the faucet.
  • Page 16 Fig. 101 shows a schematic view for a bench power supply. Fig. 101, Bench power supply Water heater Connector L15155 (L13471) L15155-02 (L13471-19, L13471-33 & L13471-40) L9-130-AB (L13471-11 & L13471-32) Connector MS3106E16S-1S (Connects to L15155 & L15155-02) MS3106E24-27S (Connects to L9-130-AB)
  • Page 17 CMM & IPL 1010099 SERIES SCHEMATICS AND WIRING DIAGRAM WIRING DIAGRAM WITH PARTS LIST AND WIRE LIST Fig. 102 shows the parts list of items used in the wiring diagram and applicable wiring diagram with wire list. ITEM/SYMBOL PART NUMBER NOMENCLATURE QUANTITY L15155...
  • Page 18 CMM & IPL 1010099 SERIES SCHEMATICS AND WIRING DIAGRAM Fig. 102, (Sheet 2 of 11) Wiring diagram – L13471 25-30-31 Page 2003 Jan. 18, 2010...
  • Page 19 36.68 B17A16 35.43 B18A16N 12.60 B19A14N 12.20 B20A14N 6.70 B21A16B 2’ 7.87 Wire AWG14, M22759/8. Driessen p/n 9-501-41 Wire AWG16, M22759/8. Driessen p/n 9-501-40 Fig. 102, (Sheet 3 of 11) Wire list – L13471 25-30-31 Page 2004 Jan. 18, 2010...
  • Page 20 CMM & IPL 1010099 SERIES SCHEMATICS AND WIRING DIAGRAM Fig. 102, (Sheet 4 of 11) Wiring diagram – L13471-11 25-30-31 Page 2005 Jan. 18, 2010...
  • Page 21 B15A14 9.25 B16A14 36.61 B17A14 35.43 B18A14N 7.68 B19A14N 12.20 B20A14N 6.69 Wire AWG14, M22759/8. Driessen p/n 9-501-41 Wire AWG16, M22759/8. Driessen p/n 9-501-40 Fig. 102 (Sheet 5 of 11) Wire list – L13471-11 25-30-31 Page 2006 Jan. 18, 2010...
  • Page 22 CMM & IPL 1010099 SERIES SCHEMATICS AND WIRING DIAGRAM Fig. 102, (Sheet 6 of 11) Wiring diagram – L13471-19 and L13471-33 25-30-31 Page 2007 Jan. 18, 2010...
  • Page 23 12.20 B20A14N 6.70 B14A16B 2’ 7.87 B22A14N 12.20 B23A14N 18.90 Wire AWG14, M22759/8. Driessen p/n 9-501-41 Wire AWG16, M22759/8. Driessen p/n 9-501-40 Fig. 102, (Sheet 7 of 11) Wire list – L13471-19 and L13471-33 25-30-31 Page 2008 Jan. 18, 2010...
  • Page 24 CMM & IPL 1010099 SERIES SCHEMATICS AND WIRING DIAGRAM Fig. 102, (Sheet 8 of 11) Wiring diagram – L13471-32 25-30-31 Page 2009 Jan. 18, 2010...
  • Page 25 36.61 B17A16N 35.43 B18A16N 13.78 B19A16N 12.20 B20A16N 6.70 B14A16B 2’ 7.87 Wire AWG14, M22759/8. Driessen p/n 9-501-41 Wire AWG16, M22759/8. Driessen p/n 9-501-40 Fig. 102, (Sheet 9 of 11) Wire list – L13471-32 25-30-31 Page 2010 Jan. 18, 2010...
  • Page 26 CMM & IPL 1010099 SERIES SCHEMATICS AND WIRING DIAGRAM Fig. 102, (Sheet 10 of 11) Wiring diagram – L13471-40 25-30-31 Page 2011 Jan. 18, 2010...
  • Page 27 12.20 B23A14N 18.90 B24A16C 3’ 7.87 B25A16C 3.15 B26A16C 2.95 B27A16N 3.54 Wire AWG14, M22759/8. Driessen p/n 9-501-41 Wire AWG16, M22759/8. Driessen p/n 9-501-40 Fig. 102, (Sheet 11 of 11) Wire list – L13471-40 25-30-31 Page 2012 Jan. 18, 2010...
  • Page 28 Disconnect nut (320) to remove the pipe (330) from the faucet (430). Remove nut (290) to remove the faucet (430) with adapter (300). (10) For units L13471-19, L13471-33 & L13471-40 only Remove screws (40) to remove the back sheet (600).
  • Page 29 D. Disassembly of kettle assy (Ref. IPL, Fig. 3,4 and 5) Remove thermostat (4/70) from kettle assy (10). Remove nut (40,40A) and sealing washer (50). For units L13471, L13471-19, L13471-33 and L13471-40 only Remove valve holder (70) with pressure relief valve (60) and sealing washers (50) and washer gasket (80).
  • Page 30 CMM & IPL 1010099 SERIES CLEANING GENERAL A. Correct and thorough cleaning is essential to maintain public health standards and satisfactory operations. B. Before use always check to see if the unit is clean, if it is dirty, clean it! C.
  • Page 31 CMM & IPL 1010099 SERIES CLEANING CORROSION NEUTRALISATION You can use a corrosion removing 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 corrosion removing compound. Inspect any surface treated with a corrosion removing compound after cleaning the treated surface.
  • Page 32 CMM & IPL 1010099 SERIES CHECK GENERAL Inspection of the rapid water heater must be done to guarantee proper and safe functioning of the rapid water heater. Inspections may be carried out by authorised personnel only. A. Prior to installation inspection. Any of the below mentioned deviations are reasons for rejection or repair.
  • Page 33 CMM & IPL 1010099 SERIES REPAIR GENERAL Except permissible repairs, as outlined in ASSEMBLY and DISASSEMBLY, repair of detailed parts and components during maintenance is considered neither practical nor reliable. In case of wear or damage components will not be repaired but replaced. Do not attempt to repair the rapid water heater or any of its components by welding.
  • Page 34 Fit a sealing washer (50) and nut (40,40A) using Loctite 586. (10) Fit the thermostat (4/70,5/70) to the kettle assy (10) using Teflon tape. (11) For units L13471, L13471-19, L13471-33 & L13471-40 only Fit the pressure relief valve (60) onto the valve holder (70) using Loctite 586.
  • Page 35 Fit the relay (40) with clip nuts (220) and screws (210). When previously used clip nuts are used, use Loctite 243 to secure the screws. For unit L13471-40 only Fit the relay socket (50) and the relay (40). C. Assembly of frame assy boiler (Ref. IPL, Fig. 1,3,4 and 5) Fit threaded rods (150) with nuts (160) to the base plate assy (140).
  • Page 36 Fit the front panel (130) with screws (40) to the frame assy boiler. Unit L13471 excluded Fit the top sheet (580) with screws (590) to the frame assy boiler. For unit L13471-19, L13471-33 & L13471-40 only Fit the back sheet (600) to the frame assy boiler (10) using screws (40). 25-30-31 Page 7003 Nov.
  • Page 37 CMM & IPL 1010099 SERIES FITS AND CLEARANCES GENERAL No measuring of sleeves, bushings etc. is required. TORQUE VALUES IPL Fig. And Item No. Item Torque 6 N.m (4.42 lbf.ft) ±8% 35 N.m (25.82 lbf.ft) ±8% Valve 8 N.m (5.90 lbf.ft) ±5% 70 N.m (51.64 lbf.ft)
  • Page 38 CMM & IPL 1010099 SERIES SPECIAL TOOLS, FIXTURES AND EQUIPMENT GENERAL Except for tools mentioned in the SPECIAL TOOLS section, standard tools are sufficient to perform the actions described in this manual. SPECIAL TOOLS NOTE: Equivalent alternatives can be used for listed items. PART No.
  • Page 39 CMM & IPL 1010099 SERIES SPECIAL TOOLS, FIXTURES AND EQUIPMENT CONSUMABLES NOTE: Equivalent alternatives can be used for listed items. PART No. APPLICATION ARTICLE PACKAGE TOOLING P0000320 Nut locking Loctite 243 blue 250 ml flask None compound Not permanent N.A. Pipe thread sealing Loctite 586 250 ml flask...
  • Page 40 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST GENERAL The illustrated parts list (IPL) contains the complete list of all the replaceable parts used in the rapid water heater. It starts with a numerical parts list followed by a detailed parts list made out of figures and related parts lists.
  • Page 41 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST B. The part number is unknown. (1) Refer to the figures in this IPL and search for the part needed. (2) Note the figure number and item number of the part. (3) Turn to the corresponding parts list and look for the item number. LIST OF ABBREVIATIONS The following abbreviations may have used in this IPL.
  • Page 42 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST NUMERICAL PARTS LIST PART NUMBER AIRLINE PART NO. FIG. ITEM 3-049966 4-101479 9-005-02 9-005-02 9-005-03 9-010-01 9-010-01 9-010-02 9-010-02 9-010-04 9-010-22 9-028-14 9-028-14 9-028-25 9-028-45 9-028-60 9-029-08 9-029-08 9-029-10 9-029-61 9-040-02 9-040-02 9-040-02 9-040-03 9-040-04...
  • Page 43 FIG. ITEM 9-130-05 9-130-06 9-130-07 9-130-20 9-130-23 9-130-24 9-900-80 9-913-20 9-913-21 9-931-22 9-913-23 9-920-21 9-921-60 9-921-60 9-921-62 9-921-62 9-921-66 9-921-66 L13471 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...
  • Page 44 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST NUMERICAL PARTS LIST PART NUMBER AIRLINE PART NO. FIG. ITEM L15117-02 L15118 L15118-01 L15120 L15120-04 L15120-07 L15121 L15123 L15124-12 L15125 L15125-12 4-103154 L15128-08 L15135 L15137-BV L15138 L15139 L15140 L15142 L15143-01 L15144-01 110A L15144-02 L15145 115A...
  • Page 45 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST NUMERICAL PARTS LIST PART NUMBER AIRLINE PART NO. FIG. ITEM L15162 L15163 L15164 L15165 L15165 L15166 L15166 L15167 L15170 L15170 L15172-02 L15172-08 L15172-11 L15172-19 L15172-20 L15176-01 L15176-02 L15284-01 L15285 L15285-01 L15287-01 L15288 L15288-01 L15289-02 L15289-02...
  • Page 46 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST NUMERICAL PARTS LIST PART NUMBER AIRLINE PART NO. FIG. ITEM L15551-B L15551-C L15552 L15889 L16409 L16410 L17286 L17287 L17604 L17604-10 L17985 L18592-02 L18619-02 L18619-02 L19521-03 -560 L21991 L9-006-AC L9-006-AC L9-006-AC L9-042-AD L9-042-AD L9-043-AA L9-045-AA L9-045-AC...
  • Page 47 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 1A, 1C, 1E, 1F, RAPID WATER HEATER 25-30-31 Page 10008 Nov. 16, 2012...
  • Page 48 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 1B, 1D, RAPID WATER HEATER 25-30-31 Page 10009 Nov. 16, 2012...
  • Page 49 1010099 SERIES ILLUSTRATED PARTS LIST AIRLINE UNITS PART USAGE PART NOMENCLATURE ITEM NUMBER CODE NUMBER ASSY L13471 RAPID WATER HEATER L13471-11 RAPID WATER HEATER L13471-19 RAPID WATER HEATER RAPID WATER HEATER L13471-32 L13471-33 RAPID WATER HEATER L13471-40 RAPID WATER HEATER 40-41029 .FRAME ASSY BOILER...
  • Page 50 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST AIRLINE UNITS PART USAGE PART NOMENCLATURE ITEM NUMBER CODE NUMBER ASSY L9-006-AC ..BLIND RIVET CSK 3.2*7.5 9-005-03 ..BLIND RIVET RD 3.2*6.1 L9-006-AC ..BLIND RIVET CSK 3.2*7.5 .PIPE CLIP L15288 L15288-01 .PIPE CLIP 9-040-02 .WASHER FLAT M4 9-010-02...
  • Page 51 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 2A, TAP ASSY IPL Fig. 2B, FAUCET 25-30-31 Page 10012 Nov. 16, 2012...
  • Page 52 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST AIRLINE UNITS PART USAGE PART NOMENCLATURE ITEM NUMBER CODE NUMBER ASSY 9-083-37 FAUCET PPSHP-8 G3/8 RED HANDLE 9-130-05 .AERATOR L9-130-AG .BRACKET NR 19-HP L9-130-AR .ADAPTER M200ADAP ADAPTER 9-050-10 .PIN TENSION 3*14 L9-283-AA .TAP LEVER 173-PSSR-1 .ADAPTER NR2-5PSCH L9-130-AH...
  • Page 53 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 3A, KETTLE ASSY WITH LID ASSY 25-30-31 Page 10014 Nov. 16, 2012...
  • Page 54 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 3B, KETTLE ASSY WITH LID ASSY 25-30-31 Page 10015 Nov. 16, 2012...
  • Page 55 115A L15145 L15140 .TUBE L15142 .DIVIDER SHEET L15305 .OVERHEAT PROTECTOR L9-130-AC .OVERHEAT PROTECTOR L9-045-AA .WASHER GASKET NR10295 (NOT FOR L13471-40) L9-130-AD .SENSOR CLAMP NR11009 L18619-02 ..NUT L15143-01 ..COPPER RING 9-040-23 ..WASHER FLAT M4 9-010-22 ..NUT HEX M4 L9-042-AD ..WASHER SPRING DIN127 L15176-01 .T-CONNECTOR...
  • Page 56 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 4, ELECTRICAL INST. ASSY (for L13471-40) 25-30-31 Page 10017 Nov. 16, 2012...
  • Page 57 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST AIRLINE UNITS PART USAGE PART NOMENCLATURE ITEM NUMBER CODE NUMBER ASSY L15172-20 ELEC. INSTL. L13471-40 L15155-02 .CONNECTOR .SCREW L15166 L15165 .CLIP NUT 9-130-23 .RELAY MS27743-15 9-130-24 .RELAY SOCKET S501-E1A10 L15170 .SWITCH L15306 .THERMOSTAT .LAMP AMBER...
  • Page 58 CMM & IPL 1010099 SERIES ILLUSTRATED PARTS LIST IPL Fig. 5, ELECTRICAL INST. ASSY 25-30-31 Page 10019 Nov. 16, 2012...
  • Page 59 UNITS PART USAGE PART NOMENCLATURE ITEM NUMBER CODE NUMBER ASSY L15172-02 ELEC. INSTL. L13471 L15172-08 ELEC. INSTL. L13471-11 ELEC. INSTL. L13471-19 & 33 L15172-11 L15172-19 ELEC. INSTL. L13471-32 L15155 .CONNECTOR L15155-02 .CONNECTOR L9-130-AB .CONNECTOR MS3100E24-27P L15166 .SCREW .CLIP NUT L15165 L15156 .RELAY...
  • Page 60 CMM & IPL 1010099 SERIES STORAGE GENERAL The rapid water heater should be thoroughly cleaned and dried before storage. Refer to the CLEANING chapter for appropriate cleaning and drying instructions. INSTRUCTIONS A. Store heaters which are not in service in plastic foil. Make sure that the unit is drained. B.

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