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Raypak 131 User Manual

Raypak 131
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SERVICE INSTRUCTIONS
Raypak 131 Pool Heater
TM020
Revision: A
Published: April 09
Spartan
P0131
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Raypak 131 Specifications

General IconGeneral
BrandRaypak
Model131
CategorySwimming Pool Heater
LanguageEnglish

Summary

Safety Warning

Pool Heater Model Identification

Details on how to interpret the model number to understand heater specifications.

Specifications

Preventative Maintenance

Water Treatment (Pool Balance)

Recommended water chemistry levels for optimal heater performance and longevity.

Product Changes

Gas Valve Change

Information on the replacement of gas valves in different model production dates.

Change to Black Control Board

Details on the evolution of control boards and their identification.

Plumbing & Installation Diagram

Addition of Auto Reset PCB (Incorporating Safety Lock out circuit)

Describes the auto reset PCB and its role in safety lockout circuits.

Lighting Instructions

Wiring Diagrams

131 Wiring Diagram – Grey Control Board

Electrical schematic for heaters with a grey control board.

131 Wiring Diagram – Black Control Board (prior to 14/4/09)

131 Wiring Diagram – Black Control Board (14/4/09 onwards)

Sequence of Operation

Pump Operation

Explains the role of the pump in the heater's ignition and operation sequence.

Operational Flow Chart 1

Operational Flow Chart 2

Components and Their Function

Gas Valve

Details the function and types of gas valves used in the heater.

Hot Surface Igniter

Explains the function of the igniter in starting the burner.

Flame Sensor

Describes the probe that detects flame presence.

55°C Outlet High Limit

Water Pressure Switch

Explains the function of the pressure switch for detecting water flow.

Water Flow Switch

Explains the function of the flow switch for detecting water flow.

Water Temperature Probe

Describes the probe that measures inlet water temperature.

Control Board (Controller)

Details the electronic PCB that manages heater operations.

Fault Indication

Water Pressure Switch Indication (black boards only)

How the controller indicates low water pressure or no flow.

No Mains Power Indication & Power Backup (black boards only)

Describes power backup and 'PO' display for loss of mains power.

Fault Finding

Test Equipment

Lists essential test equipment for diagnostic procedures.

General Fault Finding Chart

Fault Finding Chart 1

Fault Finding Chart 1.1

Fault Finding Chart 1.2

Troubleshooting steps for control board and fuse issues.

Fault Finding Chart 1.3

Fault Finding Chart 1.4

Fault Finding Chart 1.5

Fault Finding Chart 1.6 & 1.7

Fault Finding Chart 1.8

Fault Finding Chart 2

Fault Finding Chart 3

Fault Finding Chart 4

Fault Finding Chart 5

Fault Finding Chart 6

Fault Finding Chart 7

Troubleshooting for remote controller issues.

Fault Finding Chart 8

Fault Finding Chart 9

Test Procedures

Guides on how to perform specific diagnostic tests.

Fault Finding Tests 1 – 2

Fault Finding Tests 3 – 6

Fault Finding Tests 7 – 9

Fault Finding Tests 10A – 11B

Fault Finding Tests 12 – 15

Fault Finding Tests 16 – 19

Fault Finding Tests 20 – 21

Component Adjustment Procedures

Burner Pressure Adjustment

Step-by-step guide to adjust the gas valve burner pressure regulator.

Pressure Switch Adjustment

Flow Switch Adjustment

Instructions for adjusting the flow switch for correct water flow detection.

Component Replacement Procedures

Front Access Panel

Procedure for removing and replacing the front access panel.

Display Panel Removal

Steps for safely removing the display panel and its components.

Top Panel

Front / Rear Upper Grille

Instructions for removing and refitting the front and rear grilles.

Upper In/Out Header Panel

Procedure for removing and replacing the upper in/out header panel.

Lower In/Out Header Panel

Procedure for removing and replacing the lower in/out header panel.

Flue Diverter Assembly

Draft Intake Diverter

Procedure for removing and replacing the draft intake diverter.

Flue Collector

Steps to remove and replace the flue collector.

Right Hand Side Panel

Left Hand Side Panel

Procedure for removing and reinstalling the left hand side panel.

Base Assembly

45°C Inlet High Limit

Procedure for removing and replacing the 45°C inlet high limit switch.

Water Temperature Probe

Procedure for removing and replacing the water temperature probe.

Pressure Switch

55°C Outlet High Limit

Procedure for removing and replacing the 55°C outlet high limit switch.

In/Out Header

Bypass Valve

Procedure for removing and replacing the bypass valve components.

Heat Exchanger

Procedure for removing and reinstalling the heat exchanger.

Burner Assembly

Burner Manifold & Injectors

Procedure for replacing the burner manifold and individual injectors.

Gas Valve

Refractories & Top Refractory Retainers

Procedure for handling and replacing refractory components.

Lower Refractory Retainers and Refractory Supports

Rear Refractory Support

Procedure for removing and refitting the rear refractory support.

Front Refractory Support

Procedure for removing and refitting the front refractory support.

Igniter & Flame Rod Assembly

Reset Button

Procedure for replacing the reset button assembly.

Control Board

Procedure for replacing the main control board.

Terminal Block

Procedure for removing and replacing the terminal block.

RAM Ignition Module

Cord Set

Procedure for replacing the power cord set.

Relay 1 / Relay 2

Procedure for replacing individual relays.

Relay Base

Procedure for replacing the relay base assembly.

Transformer

Wiring Loom

Procedure for removing and reinstalling the main wiring loom.

Exploded View

Replacement Parts List

Gas Type Conversion Procedure

Raypak Pool and Spa Heater Warranty (Australia Only)

Warranty conditions

Conditions and requirements for warranty claims on the heater.

Warranty Exclusions

Situations and damages that will void the heater's warranty.

Document Revision History

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