Troubleshooting; Mechanical - Raypak X94 Installation & Operating Instructions Manual

SECTION 5 - TROUBLESHOOTING

MECHANICAL

IMPORTANT NOTICE These instructions are intended for the use of qualified personnel who are specifically trained and experienced in the
installation of this type of heating equipment and related system components. Installation and service personnel may be required by some
states to be licensed. Persons not qualified shall not attempt to install this equipment nor attempt repairs according to these instructions.
PROBLEM
Harmonics, or whining noise *Debris or restriction in system..............
Heater going on and off
with Water SW Open
indication on LCD or in
Fault History
Valve opens but no flame
visible
Flame visible for a split
second
Liming or scale forming in
exchanger
Sooting
Yellow lazy flame
Outer jacket very hot
(paint blistered)
Hard lighting at startup
Takes too long to heat
pool or spa
Leaking at T&P gauge
Leaking at heat exchanger
Gasket brittle and leaking -
(overheated)
Combustion fan not running Fan relay...............................................
"Fan 5 min Delay",
"Fan Lockout" or "Fan RPM
Fault" indication
Heater turns on for less
than 4 seconds
(no display error)
* Indicates symptom which usually occurs on initial start-up.
CAUSE
*Debris in gas line..................................
Low flow.................................................
Dirty filter................................................
Low water level in pool..........................
External bypass setting out of
adjustment............................................
Manifold pressure too low..................
Ignition not being sensed....................
Pool water............................................
Bypassing too much water...................
Low water temperatures.........................
*Air starvation.........................................
*Improper venting...................................
*Insects or debris clogging
burner intake ports...............................
Air intake clogged or incorrect
fan operation..........................................
*Insects or debris clogging
burner intake ports.................................
Air intake feedback to regulator
disconnected.......................................... Check that tubing between air intake adapter and regulator is connected
*Broken refractory caused by
shipping damage or improper
combustion..........................................
Excessive sooting of heat exchanger....
Igniter faulty.....................................
Under-sized heater...............................
Filter not running long enough.............
Dirty filter..............................................
Gas line or meter undersized...............
Overacid...............................................
Overacid...............................................
Refractory damage..............................
Sooted heater.......................................
Fan........................................................
Burned motor .......................................
Motor control failure..............................
Wiring....................................................
Incorrect supply wiring..........................
PC Board short.....................................
Ignition not sensed........................... Clean igniter with wire brush.
SOLUTION
Locate the restriction and remove. Flush system and clean.
Remove debris or blow out gas line.
Scale forming in heat exchanger - clean heat exchanger and
check pool pH and total alkalinity.
Clean or replace filter.
Raise water level.
Adjust bypass.
Increase manifold pressure (turn clockwise slightly).
Replace ignition wire. Check connections. Increase manifold pressure
(turn clockwise slightly).
See Water Chemistry on page 2.
Inspect bypass for movement, if no movement, replace.
Maintain water body temperatures above 50ºF (10ºC).
Refer to installation instructions.
Follow recommended installation instructions.
Clean burners with a gentle application of compressed air, do not use
a brush.
Check for debris upstream of fan intake. Check intake air filter suction
pressure, replace filter if dirty.
Clean burners with a gentle application of compressed air, do not use
a brush.
and free of obstruction. See Fig. 1.
Replace refractory panels.
Determine cause of sooting & correct.
Replace igniter
Calculate heating capacity of heater or refer to heater sizing chart.
Heating Capacity =
This does not take into account heat loss due to weather.
Reset time clock.
Clean filter.
Refer to installation instructions.
Replace T&P gauge and maintain proper water chemistry.
Replace heat exchanger and maintain proper water chemistry.
Replace refractory.
Determine cause of sooting and correct.
Replace fan relay.
Loose connection or failed motor.
Incorrect wiring, replace blower.
Replace blower.
Check for loose or broken (verify continuity) wiring/ground/ignition wire.
Check incoming power for correct voltage. There should be
no power on the neutral line.
Replace board if no strength signal is being detected.
44
Htr. output(BTUH)
Pool gallonage x 8.33