Raypak Heater pilot wont light after replacing heat exchanger

[Rack55]

Raypak 156A heater, 5 years old. Just replaced the heat exchanger as the original had developed leaks.

After installing the new heat exchanger, the pilot will not light. I get a “ignition lockout / no pilot sensed” error message.

I have tried multiple times. Propane is not an issue. It worked fine 2 days ago with the old heat exchanger.

My only guess is that the pilot could have gotten wet during the install. Could this be my issue? I really do not want to remove the burner tray and pilot if I don’t have to.

Any thoughts or suggestions help, thanks!

 

[ajw22]

Let's see if @1poolman1 @ps0303 @Pool Clown has ideas.

 

[1poolman1]

Are you sure it isn't lighting or the flame isn't being rectified (sensed)? You need to get down very low to see. You may need to remove the pilot burner to clean it after working on the heater above the firebox. Check that you have a good ground wire.
Propane heaters "lock out" after a certain number of tries so that any propane that may have pooled in the heater doesn't explode if there is ignition.

 

[Rack55]

I can’t see the pilot, but there is a small window to check if the burners are lit. Either way, no, there is no fire.

Removing the pilot to inspect and clean looks like a big task that I was hoping to avoid, but might have no choice.

 

[Rack55]

Update. Just tried again after leaving it for a few hours. Now, I can hear the “clunk” of I believe the propane switch opening, and the display says “spark” as it normally would when it’s firing up. However instead of hearing the igniter “buzz” 3 times repeatedly, there is no buzz at all. No flame. Not good.

Does this make any sense?

 

[ajw22]

Check that you don't have a valve closed in the gas line from when you did the other work.

 

[1poolman1]

"Clunk" is the pilot valve opening. Apparently you're not getting spark. Since you worked above the pilot, something may have fallen onto the pilot and is shorting the electrode. Might try some compresed air at the pilot to see if it can be cleared.
Might open the control panel and check if there is spark at the board. Should be a small blue wire. Pull it loose and listen. Keep your hands away from the connection on the board, spark is about 30k volts. Hurts like crazy. If no spark, may need a new board.

 

[Rack55]

There’s gas coming through, tanks and valves are all open and I can smell it at the unit when I’m trying to light.

 

[wireform]

Be careful with the smell of gas and one decent spark it can pop in your face and be extremely dangerous.

 

[ps0303]

Sounds like the igniter is clogged. Probably from the leak and it's now rusted. Pull it out and inspect.

 

[Rack55]

Update. There is actually a very faint “buzz” of the igniter attempting to spark, but much quieter than usual and has been a sudden change.

I cleaned up all the connections I could, a grounding wire had some rust and the high tension wire to the pilot had some insect debris to be cleaned out but nothing major. Either way, no change.

I suspect I need to replace the pilot, but at another $120 on top of the $800 I’m already in for the heat exchanger I am really trying not to. Is it possible to remove and clean the pilot? By “igniter is clogged” do you mean the pilot tube?

Thanks again to everyone who’s helped out.

 

[wireform]

You may smell gas and hear the ignition sound but if the burner tube at the ignitor has no gas flow because the orifice has a spider web it won't ignite.

 

[Rack55]

You may smell gas and hear the ignition sound but if the burner tube at the ignitor has no gas flow because the orifice has a spider web it won't ignite.

Is that something I can pull out and clean up?

 

[wireform]

If you disconnect the gas line you should be able to pull out the complete burner tray. You'll have to find all the hold backs such as wires and a whole bunch of sheet metal screws but if it was put there it will come out.

 

[Poolbreh]

I usually don’t remove the whole tray when dealing with the pilot unless the burners need cleaning as well. I loosen the tubing and unscrew the ground bolt and the firebox has a niche that slides out. Clean everything thoroughly spoon fire box tubing orifice etc. it needs a good ground path to spark.

 

[Rack55]

Update for everyone, and any future readers with a similar problem. Turns out the pilot was indeed wet from the replacement of the heat exchanger. Left it for a few hot dry days, and it fired right up. Thanks to everyone who replied