Zodiac Aerospace L13471 User manual

25-30-31
Initial issue: Unknow
Revised: Nov. 16, 2012
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
L13471-33 Type: 1010099-6.2
L13471-40 Type: 1010099-6.2

25-30-31 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, 2006

25-30-31 Nov. 16, 2012
CMM & IPL
1010099 SERIES
LIST OF EFFECTIVE PAGES
SUBJECT
PAGE DATE
TITLE PAGE Nov. 16, 2012
RECORD OF REVISIONS Nov. 16, 2012
SERVICE BULLETIN LIST Jan. 18, 2010
LIST OF EFFECTIVE
PAGES
Nov. 16, 2012
TABLE OF CONTENTS Jan. 18, 2010
INTRODUCTION Oct. 24, 2011
DESCRIPTION AND
OPERATION
1
2
3
Nov. 16, 2012
Nov. 16, 2012
Nov. 16, 2012
TESTING AND TROUBLE
SHOOTING
1001
1002
1003
1004
1005
1006
Oct. 24, 2011
Oct. 24, 2011
Oct. 24, 2011
Oct. 24, 2011
Oct. 24, 2011
Oct. 24, 2011
SCHEMATICS AND
WIRING DIAGRAM
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011
2012
Jan. 18, 2010
Jan. 18, 2010
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DISASSEMBLY 3001
3002
Jan. 18, 2010
Jan. 18, 2010
CLEANING 4001
4002
Jan. 18, 2010
Jan. 18, 2010
CHECK 5001 Jan. 18, 2010
REPAIR 6001 Oct. 24, 2011
SUBJECT
PAGE DATE
ASSEMBLY 7001
7002
7003
Nov. 16, 2012
Nov. 16, 2012
Nov. 16, 2012
FITS AND
CLEARANCES
8001 Jan. 18, 2010
SPECIAL TOOLS,
FIXTURES AND
EQUIPMENT
9001
9002
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Nov. 16, 2012
ILLUSTRATED PARTS
LIST
10001
10002
10003
10004
10005
10006
10007
10008
10009
10010
10011
10012
10013
10014
10015
10016
10017
10018
10019
10020
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STORAGE 15001 Jan. 18, 2010

25-30-31 Jan. 18, 2010
CMM & IPL
1010099 SERIES
TABLE OF CONTENTS
PAGE
Description 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, Fixtures and Equipment 9001
Illustrated parts list 10001
Storage 15001

25-30-31 Oct. 24, 2011
CMM & IPL
1010099 SERIES
INTRODUCTION
1 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
Toermalijnstraat 16
1812 RL Alkmaar
The Netherlands
Tel. ...-31(0)88 3743800
Fax. ...-31(0)88 3743120
… = International entrance number
(0)= For national use only
2 LAYOUT OF THIS MANUAL
This manual has been compiled in accordance with the requirement set out in ATA 100. This
manual contains a 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 effect on the manual will be evident by
the re-issue of the pages involved, and the record of revisions, which will show the latest revision
symbol and date.
4 RELIABILITY
The operational reliability of any rapid water heater will be guaranteed ONLY if the conditions
pertaining to inspection, maintenance and repair specified in this manual are strictly complied
with.
5 SHOP VERIFICATION
The procedures within this manual have been shop verified by the manufacturer. The sections
DISASSEMBLY, ASSEMBLY and TESTING were verified by actually performing the functions
described in the respective sections.

25-30-31 Nov. 16, 2012
CMM & IPL
1010099 SERIES
Page 1
DESCRIPTION AND OPERATION
1 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.
Rapid water heater general arrangement:
A. The frame assy boiler, kettle assy and hose are stainless steel. The lid assy is a tin-plated
brass casting.
B. A connector is attached to the unit’s rear wall to provide an electrical connection to the galley
power circuit. The ON/OFF power switch, indicator lamps and 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
tank, the overheat protector, switches off the heating elements. The overheat protector must
be reset manually. This can be done without dismantling the rapid water heater.
2 TECHNICAL DATA
A. Hot water capacity:
(1) Heater capacity 4.0 litre (1.06 US gal)
(2) Initial heating-up period 10 minutes
(3) Water temperature 87°C (189°F)
max. 89°C (192°F)
min. 85°C (185°F)
(4) Output at 87°C (189°F) 1.5 litre (0.4 US gal)
(5) Heating interval 1.5 minutes
(6) Additional output 1.5 litre (0.4 US gal)
B. Overall dimensions:
(1) Width: 163.5 mm (6.44”)
(2) Height: 330.0 mm (13.00”)
(3) Length: (excluding water tap) 293.5 mm (11.56”)
C. Weight:
(1) Empty: 10.0 kg (22.0 lbs)
(2) Full: 14.0 kg (30.8 lbs)

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CMM & IPL
1010099 SERIES
Page 2
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) 1
(4) Electrical receptacle MS3100E16S-1P (L15155)
CA3100E16S-1P-F80 (L15155-02)
MS3100E24-27P (L9-130-AB)
E. Water supply:
(1) Operating pressure 3.1 – 3.8 bar (45 - 55 psig)
(2) Water connection Quick connect coupling type HANSEN
series HK2HIL16 (9-900-80)
(3) Pressure relief valve 4.5 bar (65 psig) (9-130-20)
3 SAFETY FACTORS
There are various safety factors 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 the tank, the protector, switches off the heating
elements. The protector must be reset manually.
Pressure relief valve - A pressure relief valve is used to prevent the water pressure reaching
a dangerous high level.
4 CONTROL PANEL
On the front of the unit an ON/OFF power switch is located to turn the unit on or off.
There are also two indicator lamps that tell you if the unit is turned on and give you the status of
the heating up phase.
On the front of the unit a placard gives information about the exact meaning of the indicator
lamps.

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CMM & IPL
1010099 SERIES
Page 3
DESCRIPTION AND OPERATION
5 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
(1) Connect the unit to the water and electrical supply and place a cup or beaker under the
faucet.
(2) Open the faucet to bleed air from the kettle assy.
This action simultaneously fills the kettle 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) Water heater is ready for use.
CAUTION: DO NOT TAP MULTIPLE CUPS, INTENDED USE OF THE BOILER IS TO DRAW
1 LITER AT THE TIME
B. Operating procedure
(1) Set power switch to ON position. This activates the heating phase.
(2) Wait until heating phase is completed and amber lamp extinguishes.
(3) Hot water can be drawn from the heater.
(4) The heater cycle is now established and hot water can be drawn from the heater
whenever the amber lamp extinguishes.

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CMM & IPL
1010099 SERIES
Page 1001
TESTING AND TROUBLE SHOOTING
1 GENERAL
This chapter outlines procedures based on test point/location methods for bench/shop testing and
trouble shooting of the rapid water heater.
2 OPERATIONAL TESTS (Ref. Fig. 102)
A. Heating elements circuit (Ref. Items 1 through 17)
(1) Circuit function
(a) Heating elements (11,12,13) are activated/deactivated by the power switch (4) via
the relay (2).
(b) The relay is controlled by a thermostat (6) to control the operation of the heating
elements (11,12,13).
(2) Check procedure
(a) Connect water heater to bench power supply (Ref. Fig. 101).
(b) Set power switch (4) to ON position.
(c) Observe current consumption 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 white (10) and lamp amber (8) illuminated, no readout on ammeters.
Heating elements (11,12,13) are defective and have to be replaced or relay (2) is
defective and has to be replaced.
(e) Lamp white (10) illuminated, lamp amber (8) extinguished, no readout on the
ammeters. Overheat protector is activated or relay or the thermostat is defective.
Reset overheat protector (5) or replace relay (2) or thermostat (6).
B. Lamps (Ref. Items 8,10)
(1) Circuit function
(a) Lamps (8,10) illuminate when power switch (4) is set to ON position.
(2) Check procedure
(a) Use power switch (4) to switch on a cold rapid water heater.
(b) If lamp amber (8) or lamp white (10) does not illuminate, bulb (9) is defective.
Replace relevant bulb.

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1010099 SERIES
Page 1002
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.
(4) Draw one litre (0.26 US gal) of water and reheat the unit until the lamp amber (8)
switches of again. Repeat this three times.
(5) Draw one litre (0.26 US gal) of water and measure the temperature. The temperature
must be between a minimum of 85°C (185°F) and a maximum of 89°C (192°F). If the
temperature deviates from these values the thermostat must be re-adjusted. (See section
ADJUSTING THE TEMPERATURE SETTING).
D. Overheat protector (Ref. IPL, Fig. 3)
(1) 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 exceeding a temperature of 135°C (275°F).
(b) The overheat protector temperature is between 135°C (275°F) and 165°C (329°F).
(c) The overheat protector must be re-set manually. This is achieved by depressing the
blue button located in the top of the switch.
NOTE: The kettle assy interior should be allowed to cool before the switch is reset.
(2) Check procedure
(a) Disconnect water hose from water supply.
(b) Insert adapter type 2KILF16 into water hose snap coupling (Ref. IPL, Fig. 1).
(c) Open faucet and empty the water tank.
(d) Activate the heater and check the time needed until the blue button of the overheat
protector will pop up indicating that heating is stopped.
(e) Overheat protector must de-activate the circuit within 1 minute.
(f) If 1 minute is exceeded for this test, the overheat protector must be replaced.

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CMM & IPL
1010099 SERIES
Page 1003
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.
(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 been done to the cable loom. This is to
check the connections of the electrical plug.
WARNING: BEFORE TESTING DISCONNECT THE UNIT FROM POWER SOURCE.
A. General
Use the insulation & continuity tester (range Ω) to test the continuity.
B. Test preparation
(1) Remove bulbs from indicator lamps (8,10).
(2) Set power switch (4) to ON position.

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CMM & IPL
1010099 SERIES
Page 1004
TESTING AND TROUBLE SHOOTING
C. Measuring procedure.
Perform continuity check between the following:
PART ITEM TERMINAL PART ITEM TERMINAL
P/N L13471
Connector 1
1
1
1
1
A
B
C
F
G
Relay
Relay
Relay
Kettle assy
Relay
2
2
2
2
A1
B1
C1
GD1
X2
P/N 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
2
2
2
2
A1
B1
C1
GD4
GD1
X2
P/N L13471-32
Connector 1
1
1
1
1
A
B
C
D
G
Relay
Relay
Relay
Relay
Kettle assy
2
2
2
2
A1
B1
C1
X2
GD2
P/N L13471-40
Connector 1
1
1
1
1
1
1
A
B
C
E
F
G
G
Relay socket
Relay socket
Relay socket
Case
Kettle assy
Relay socket
Lamp
17
17
17
17
8
A1
B1
C1
GD4
GD2
X2
2

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CMM & IPL
1010099 SERIES
Page 1005
TESTING AND TROUBLE SHOOTING
4 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. General
(1) Dielectric test.
Using the flash tester, apply 1500V AC and maintain 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 & continuity tester (range MΩ, 500V), apply 500V DC. The measured
insulation must be a minimum of 200MΩ.
B. Test preparation
(1) Disconnect wiring from heating elements (11,12,13), thermostat (6) and relay (2).
(2) Remove bulbs form indicator lamps (8,10).
(3) Set power switch (4) to ON position.
C. Measuring procedure
Perform terminal to terminal dielectric and insulation resistance test between terminals A,B,C
and G of connector (1).

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CMM & IPL
1010099 SERIES
Page 1006
TESTING AND TROUBLE SHOOTING
5 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. This is because the cabin air pressure of an aircraft flying at high altitudes is lower.
Opening the faucet creates a pressure drop in the kettle assy which may turn the hot water
into steam.
Hot steam is dangerous and may cause burn. Therefore it is strongly recommended not to
exceed the maximum prescribed water temperature.
B. Procedure.
(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.
(4) Draw one litre (0.26 US gal) of water and measure the temperature. The water
temperature of this first discharge 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 (4) to OFF and fill the unit with cold water.
(7) Heat up and repeat measuring procedure as described in (3) through (6) until the water
temperature of the first discharge is correct.
(8) Reheat the unit until lamp amber (8) switches off.
(9) Draw one litre (0.26 US gal) of water.
(10) Reheat the unit until lamp amber (8) switches off.
(11) Draw one litre (0.26 US gal) of water and measure the temperature.
(12) Note temperature and duration of the next heating period.
(13) Repeat measuring procedure described in (10) through (12) eight to ten times.
NOTE: The temperature of water drawn off after each heating period must be constant at a
minimum of 85°C (185°F) and a maximum of 89°C (192°F). If the temperature
deviates from these values the thermostat must be re-adjusted.
NOTE: Heating up intervals must be constant at constant water temperature.
(14) When the temperature setting is correct use some seal lack to secure the adjustment
screw of the thermostat.

25-30-31 Jan. 18, 2010
CMM & IPL
1010099 SERIES
Page 2001
SCHEMATICS AND WIRING DIAGRAM
1 GENERAL
The water heater is designed to connect to the galley water supply using a quick connect coupling
type 2HIL16 of Hansen Mfg Co. and to the electrical power supply using 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, Bench power supply
1. Water heater
2. Connector L15155 (L13471)
L15155-02 (L13471-19, L13471-33 & L13471-40)
L9-130-AB (L13471-11 & L13471-32)
3. Connector MS3106E16S-1S (Connects to L15155 & L15155-02)
MS3106E24-27S (Connects to L9-130-AB)
4. Three Ammeters
5. Bench power supply AC

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CMM & IPL
1010099 SERIES
Page 2002
SCHEMATICS AND WIRING DIAGRAM
3 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
1
1A
1B
2
2A
3
4
5
5A
6
8
9
10
11
12
13
14
15
15.1
16
16.1
17
L15155
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
Connector
Relay
Relay
Terminal block
Switch
Overheat protector
Overheat protector
Thermostat
Lamp amber
Light bulb
Lamp white
Heating element
Heating element
Heating element
Terminal cover
Connector house
Connector pin
Connector house
Connector pin
Relay socket
1
1
1
1
1
1
1
1
1
1
1
AR
1
1
1
1
1
1
2
1
2
1
Fig. 102, (Sheet 1 of 11)
Wiring diagram parts list

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CMM & IPL
1010099 SERIES
Page 2003
SCHEMATICS AND WIRING DIAGRAM
Fig. 102, (Sheet 2 of 11)
Wiring diagram – L13471

25-30-31 Jan. 18, 2010
CMM & IPL
1010099 SERIES
Page 2004
SCHEMATICS AND WIRING DIAGRAM
WIRE
NO.
NOTATION SIZE
AWG
FROM
ITEM
CONTACT TO
ITEM
CONTACT LENGTH
INCHES
LENGTH
mm
01 B01A16A 16 1 A 2 A1 15.75 400
02 B02A16B 16 1 B 2 B1 12.20 310
03 B03A16C 16 1 C 2 C1 15.75 400
04 B04A16A 16 2 A2 5 1 29.13 740
05 B05A16B 16 2 B2 5 2 30.31 770
06 B06A16C 16 2 C2 13 25.20 640
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 OFF 3 1 35.83 910
15 B15A16 16 2 X1 3 2 9.25 235
16 B16A16 16 2 X1 8 1 36.68 830
17 B17A16 16 2 X2 10 2 35.43 900
18 B18A16N 16 1 G 2 X2 12.60 320
19 B19A14N 14 GD1 GD2 12.20 310
20 B20A14N 14 1 F GD2 6.70 170
21 B21A16B 16 5 2’ 12 7.87 200
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

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CMM & IPL
1010099 SERIES
Page 2005
SCHEMATICS AND WIRING DIAGRAM
Fig. 102, (Sheet 4 of 11)
Wiring diagram – L13471-11