Raypak 259 - MECHANICAL TROUBLESHOOTING GUIDE; Common Mechanical Problems and Solutions

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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.
SECTION 5 - TROUBLESHOOTING
* Indicates symptom which usually occurs on initial start-up.
MECHANICAL
PROBLEM CAUSE SOLUTION
Harmonics, or whining noise *Debris or restriction in system..............
*Debris in gas line..................................
Low flow.................................................
Heater going on and off Dirty filter................................................
continuously Low water level in pool..........................
External bypass setting out of
adjustment............................................
Valve opens but no flame Manifold pressure too low………………
visible
Flame visible for a split Ignition not being sensed………………..
second
Liming or scale forming in Pool water............................................
exchanger Bypassing too much water...................
Sooting High flow rates.....................................
*Air starvation.........................................
*Improper venting...................................
*Insects or debris clogging
burner intake ports...............................
Yellow lazy flame Air intake clogged or incorrect
fan operation..........................................
*Insects or debris clogging
burner intake ports.................................
Outer jacket very hot *Broken refractory caused by
(paint blistered) shipping damage or improper
combustion..........................................
Excessive sooting of heat exchanger....
Hard lighting at startup Igniter faulty……………………………….
Takes too long to heat Under-sized heater...............................
pool or spa Htr. output(BTUH)
Pool gallonage x 8.33
Filter not running long enough.............
Dirty filter..............................................
Gas line or meter undersized...............
Leaking at well Overacid...............................................
Leaking at heat exchanger Overacid...............................................
Gasket brittle and leaking - Heater running after pump shuts off....
(overheated) Refractory damage..............................
Sooted heater.......................................
Combustion fan not running Fan relay..............................................
“Fan 5 min Delay” signal or Fan........................................................
“Fan Lockout” signal Burned motor ......................................
Air pressure switch...............................
Heater turns on for less Wiring....................................................
than 4 seconds Incorrect supply wiring..........................
(no display error)
PC Board short.....................................
Ignition not sensed………………….…..
Clean igniter with wire brush.
Replace board if no strength signal is being detected.
Replace fan relay.
Loose connection or failed motor.
Incorrect wiring, replace blower.
Replace air switch.
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.
Check for debris upstream of fan intake. Verify Blower Suction
Pressure, see page 5, is within range.
Clean burner.
This does not take into account heat loss due to weather.
Replace igniter
Reset time clock.
Clean filter.
Refer to installation instructions.
Replace well and maintain proper water chemistry.
See Water Chemistry on page 2.
Inspect bypass for movement, if no movement, replace.
Reduce by adding manual bypass valve.
Adjust manual bypass valve until heater outlet water
temperature is between 105°F and 110°F.
Heating Capacity =
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.
Determine cause of sooting & correct.
Calculate heating capacity of heater or refer to heater sizing chart.
Replace refractory panels.
See Pressure Switch Adjustment.
Replace refractory.
Determine cause of sooting and correct.
Replace heat exchanger and maintain proper water chemistry.
Clean burners.
Refer to installation instructions.
Follow recommended installation instructions.
Replace ignition wire. Check connections.
Adjust bypass.
Increase manifold pressure (turn clockwise slightly).