Rheem | GTC Series | Specifications | Rheem GTC Series Specifications

Rheem GTC Series Specifications
SERVICE
INSTRUCTIONS
16, 18, 20 Litre
Continuous Flow Gas Water Heater
TM040
Revision: A
Published: June 09
Everhot
274020
276020
This document is stored and maintained electronically by
Vulcan
244016
244020
246016
246020
Rheem
874018
874020
876018
876020
Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”
Contents
Introduction .......................................................................................................................... 3
Safety Warning .................................................................................................................... 3
Water Heater Model Identification ........................................................................................ 4
Specifications....................................................................................................................... 5
Wiring Diagram .................................................................................................................... 6
Preset Temperature Adjustment .......................................................................................... 7
Sequence of Operation ........................................................................................................ 8
In-series Gas Boosting....................................................................................................... 10
Tempering Valves .............................................................................................................. 11
Controllers ......................................................................................................................... 12
Bath Fill Operation ............................................................................................................. 17
EZ-Link™ System .............................................................................................................. 18
EZ-Link Error Code Display............................................................................................ 19
EZ-Link Fault Finding ..................................................................................................... 19
Operational Flow Charts .................................................................................................... 21
Error Codes ....................................................................................................................... 24
Diagnostic Test Points ....................................................................................................... 25
Maintenance Information ................................................................................................... 26
Clearing Error Code History ............................................................................................... 28
Resetting Error Codes ....................................................................................................... 28
Fault Finding ...................................................................................................................... 28
Fault Diagnosis Sequence ................................................................................................. 29
Power Supply Fault Finding ............................................................................................... 30
No Error Code Fault Finding .............................................................................................. 32
Error Code 11 .................................................................................................................... 34
Error Code 12 .................................................................................................................... 36
Error Code 14 .................................................................................................................... 37
Error Code 15 .................................................................................................................... 38
Error Code 16 .................................................................................................................... 38
Error Code 24 .................................................................................................................... 39
Error Code 29 .................................................................................................................... 40
Error Code 31, 32, 33 & 34 ................................................................................................ 40
Error Code 35 .................................................................................................................... 41
Error Code 51, 72, 80, 81 .................................................................................................. 41
Error Code 52 .................................................................................................................... 42
Error Code 61 .................................................................................................................... 42
Error Code 65 .................................................................................................................... 43
Error Code 71 .................................................................................................................... 45
Error Code 76 .................................................................................................................... 45
Error Code 79 .................................................................................................................... 45
Error Code 82 .................................................................................................................... 46
Error Code 99 & 10 ............................................................................................................ 46
Burner Gas Pressure Check .............................................................................................. 46
Component Replacement Procedures ............................................................................... 48
Exploded View – Water Heater .......................................................................................... 56
Exploded View - Wiring ...................................................................................................... 58
Gas Conversion Procedure................................................................................................ 59
Warranty ............................................................................................................................ 60
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Introduction
The information provided in these service instructions is based on the water heater being
installed in accordance with AS 5601and the Installation Instructions provided with each
water heater.
Should you require further technical advice on a continuous flow gas water heater, contact
your nearest Rheem Service Department where genuine replacement parts are also
available.
Safety Warning
The purpose of this service manual is to provide sufficient information to allow a person
with the skills as required by the Regulatory Authorities to carry out effective repairs to a
continuous flow gas water heater in the minimum of time.
Safety precautions or areas where extra care should be observed when conducting tests
outlined in this service manual are indicated by print in bold italics and/or a warning
symbol. Take care to observe the recommended procedure.
“Live” testing to be conducted. Personal Protective Clothing (PPE) shall
be worn and an RCD shall be installed between the power point and 3-pin
cord of the water heater to reduce the risk of electric shock.
Isolate power before conducting the indicated test
Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to
reduce the risk of scalding.
General warning symbol. Observe the instructions accompanying the
symbol.
If the supply cord is damaged, it must be replaced by the manufacturer or
its service agent or a similarly qualified person in order to avoid a hazard.
When conducting repairs to a gas appliance the gas train including
injector sizes must not be altered or modified in any way.
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Water Heater Model Identification
The identification numbers are designed to convey detailed information about the water
heater to which it is attached. The model number consists of 6 digits and up to 3 letters.
87
4
020
N
F
/J
Model Number
87 – Rheem
27 – Everhot
24 – Vulcan
Temperature Setting
4 – 60ºC Set temp
6 – 48ºC Set temp
Capacity
Nominal litres/minute @ 25 ºC rise
Gas Type
N – Natural
P – Propane
F – Frost protection fitted
Casing Colour
J – Joey Grey
No letter – Refer below
Casing colour variations:
Rheem - Antique White
Vulcan - Shale Grey
Everhot - Joey Grey
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Specifications
244016NF
244016PF
246016NF
246016PF
NG
Prop
Model
Gas Type
874018NF
874018PF
876018NF
876018PF
NG
Prop
244, 274, 874020NF
244, 274, 874020PF
246, 276, 876020NF
246, 276, 876020PF
NG
Prop
Max hourly gas consumption (MJ/Hr)
123
138
153
Output (kW)
27.9
31.4
34.9
Heating Capacity (L/min @ 40ºC rise)
10.0
11.3
12.5
Mass Empty (kg)
20
20
20
Min inlet water pressure (kPa)
140
140
140
Max inlet water pressure (kPa)
1000
1000
1000
Min inlet gas pressure (kPa)
1.13
2.75
Max inlet gas pressure (kPa)
1.13
2.75
3.5
1.13
3.5
2.75
3.5
Min burner gas test pressure (kPa)
0.170
0.190
0.170
0.190
0.170
0.190
Max burner gas test pressure (kPa)
0.645
0.880
0.758
1.100
0.870
1.185
Continuous Spark
Ignition System
Standard
66
66
66
Anti-frost**
147
147
151
Gas connection diameter (mm)
R¾/20
R¾/20
R¾/20
Water connection diameter (mm)
R¾/20
R¾/20
R¾/20
1750
1750
1750
Kitchen Controller
Y
Y
Y
Bathroom 1 Controller
Y
Y
Y
Bathroom 2 Controller
Y
Y
Y
Deluxe Kitchen Controller
Y
Y
Y
Deluxe Bathroom 1 Controller
Y
Y
Y
Deluxe Bathroom 2 Controller
Y
Y
Y
Power (Watts)
Consumption
Relief Valve Pressure (kPa)
** Maximum power consumption when anti-frost heaters are energised.
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Wiring Diagram
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Preset Temperature Adjustment
Factory pre-set and maximum hot water outlet temperature settings for each water heater
series are shown below:
Model
244, 274, 874 Series
246, 276, 876 Series
Factory setting
60ºC
48ºC
Maximum Temp
60ºC
48ºC
Solar Compatible
Y
N
Voltages up to 240 volts will be present within the water heater, take care
not to touch wiring terminals. Use an insulated tool when operating the DIP
switch or MIN and MAX buttons.
To adjust the preset temperature:
1. Remove the front cover from the water heater.
2. Turn DIP switches 3 and 4 ON (up position) on the PCB.
3. The temperature setting will be displayed by a series of flashes from the red LED, with
a three (3) second pause between each series of flashes. The temperature settings
and series of flashes are:
Preset Temperature Settings
Flashes
244, 274 874 series
246, 276, 876 series
Minimum temperature setting
1 flash
50°C
40°C
Mid temperature setting
2 flashes
55°C
43°C
Maximum temperature setting
3 flashes
60°C
48°C
4. Press the MIN or MAX button, located above the DIP Switches, until the desired
temperature is reached (indicated by the number of flashes from the red LED).
5. Turn DIP SWITCHES 3 and 4 off (down position).
6. The red LED will go out. The preset outlet temperature is now set.
7. Refit the front cover to the water heater.
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Sequence of Operation
Refer to „Sequence of Operation Component Diagram‟ on page 9 to view components
shown in brackets e.g. (1)
1. When a hot water tap (1) is opened, cold water (or preheated water if a solar preheater is installed) enters the water heater and passes through the Water Flow Sensor
(3) and Heat Exchanger (18). Note: The inlet water temperature must be less than or
equal to 58ºC and less than or equal to the set point temperature minus 2ºC for
operation to occur past this point; otherwise water will pass straight through the heat
exchanger and fan and burner operation will not occur (for more information on this
subject refer to the section titled „In-series Gas Boosting‟ on page 10).
2. The Water Flow Sensor (3) sends a pulse signal to the PCB (7). Once the pulse signal
reaches a pre designated frequency (at a min. flow rate of 2.5lpm) the PCB (7)
activates the Fan Motor (24) and the Fan (23) starts rotating.
3. After the Fan (23) completes a pre purge, the Gas Inlet Solenoid Valve (9), Gas
Solenoid Valve 1 (10) and Gas Solenoid Valve 2 (11) open at the same time. The
Proportional Gas Flow Regulating Valve (12) adjusts the gas flow rate to ensure
adequate gas for ignition and gas is then supplied to the Burner (14).
4. At the same time the Gas Solenoid Valves open the Igniter (15) starts sparking
continuously and ignites the gas at the Burner (14). After the flame sensor (17) detects
burner flame, the Proportional Gas Valve (12) begins to control the gas flow rate. If
there is a difference between the hot water temperature detected by the Hot Water
Outlet Thermistor (6) and that set on the water heater or selected on the controller (if
fitted) the PCB (7) adjusts the hot water temperature by opening and closing the Gas
Solenoid Valve 1 (10), the Gas Solenoid Valve 2 (11) and the Proportional Gas Flow
Regulating Valve (12). The water flow rate is also adjusted via the Water Flow Servo
Motor (2) to ensure the selected temperature of hot water is delivered.
5. As the gas flow rate, controlled by the Proportional Gas Flow Regulating Valve (12)
changes, the PCB (7) varies the speed of the Fan Motor (24) to maintain the correct air
gas mix ratio.
6. When the hot tap (1) is closed, the pulse signal from the Water Flow Sensor (3) stops
and the burner flame is extinguished by closing Gas Solenoid Valves 1 (10), 2 (11), and
the Gas Inlet Solenoid Valve (9). The post purge operation then commences.
7. Once the post-purge operation ends (up to 6 minutes) power to the Fan Motor (24) is
cut and the Fan (23) stops.
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Sequence of Operation Component Diagram
1)
2)
3)
4)
5)
6)
7)
8)
9)
10)
11)
12)
13)
14)
15)
16)
17)
18)
19)
20)
21)
22)
23)
24)
25)
26)
Hot Water Tap
Water Flow Servo Motor
Water Flow Sensor
Inlet Water Temperature Thermistor
Combustion Chamber Thermistor
Outlet Water Temperature Thermistor
PCB
Water Filter (Strainer)
Gas Inlet Solenoid Valve
Gas Solenoid Valve 1
Gas Solenoid Valve 2
Proportional Gas Solenoid Valve
Nozzle
Burner
Igniter
Igniter Electrode
Flame Sensor
Heat Exchanger
Over Temperature Limiter
Exhaust (Flue) Outlet
Combustion Chamber
Anti Frost Heater
Fan
Fan Motor
Drain Plug With Relief Valve.
Controller (Optional)
Bypass Operation
The bypass is a section of copper pipe work connected between the water body assembly
(effectively the cold water inlet) and the outlet of the heat exchanger and allows a quantity
of cold water to bypass the heat exchanger. The purpose of the bypass is to ensure the
heat exchanger operates at temperatures above the dew point of the combustion gases,
ensuring condensate is not produced, but low enough to maximise the heat exchangers
life. A solenoid valve fitted to the water body assembly controls the bypass. The PCB
activates the solenoid based on heat exchanger temperature and selected outlet water
temperature.
Anti-Frost Heater Circuit
All models have an anti frost heater circuit. The anti-frost heaters are wired in series and
operate independently from the water heater.
A thermostat sensing ambient air temperature, positioned in the wiring loom near the
bottom of the water heater, activates the anti-frost heaters when the ambient air
temperature falls to 4ºC +4ºC/-2ºC and deactivates the anti-frost heaters when the
temperature rises above 12ºC.
In the event a heater block becomes open circuit the total heater circuit is rendered
inoperable. The circuit is split into two sections with 4 heaters in total.
Refer to „Anti-Frost Heaters‟ on page 52 for replacement procedure.
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In-series Gas Boosting
Temperature controllers must not be fitted if this water heater is installed
as part of a solar water heater system because water at a temperature
much higher than the controller setting can be delivered.
246, 276, 876 series water heaters are not suitable for use as in-series solar
gas boosters.
The 244, 274, 874 series may be installed as an in-series booster water heater to a solar
preheat water heater. In this application the outlet temperature setting of the heater must
be set at 60 C. Refer to page 7 for details on checking and adjusting the outlet
temperature.
When the inlet water temperature is 58°C or higher the fan and burner will not operate
despite water flowing through the heat exchanger. When the inlet water temperature is
less than or equal to 57°C the burner will fire and boost the outlet temperature to 60°C
provided the flow rate is greater than 3 litres per minute.
Note: If an existing 871 series Integrity water heater with a bypass valve is replaced with a
244, 274, 874 series heater, the solar bypass valve must be removed and the plumbing
connections remade directly to the inlet and outlet water connections of the replacement
244, 274, 874 series water heater.
In-series Gas Boosting - Solar Loline Installation
Typical Installation - Solar In-Line Gas Booster
Solar Pumped Open Circuit Systems
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In-series Gas Boosting - Solar Hiline Installation
TYPICAL INSTALLATION
SOLAR CLOSED CIRCUIT THERMOSIPHON WITH
BOOSTER
246, 276, 876 series modelsIN-SERIES
comply withGAS
AS/NZS
3498 and therefore do not require a
Tempering Valves
tempering valve to be fitted unless the unit is installed 
in an early childhood centre, school,

nursing home or a facility for young, aged, sick or disabled
people.
It may be required by regulations that an approved
temperature limiting device be fitted on 244, 274, 874
series models. Where a tempering valve is fitted and
there is not a separate untempered line for the
kitchen or laundry areas, the kitchen temperature
controller will be able to display temperatures above
50°C however the delivered water temperature at the
tap will be that set by the tempering valve which will
be no hotter than 50°C.
To enable delivery of hot water at temperatures
above 50°C a separate untempered line must be
provided that supplies hot water exclusively to
kitchen and laundry areas (refer to diagram).
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Controllers
Continuous flow gas water heaters can be fitted with optional controllers as long as they
are not being used in conjunction with a solar system. There are 2 types of controllers
available, standard or deluxe:
Controller Type
Standard
Deluxe
Bathroom 1
299854
299859
Bathroom 2
299855
299860
Kitchen
299853
299858
Standard and deluxe controllers cannot be mixed in a single installation; other
manufacturers‟ controllers cannot be used.
One, two or three unique controllers can be installed, however if a Bathroom controller is
installed without a Kitchen controller then the maximum selectable hot water temperature
will be limited to 50°C when connected to an 244, 274, 874 series model or 48°C when
connected to an 246, 276, 876 series model.
246, 276, 876 series models are factory set so that they cannot deliver water hotter than
48°C.
When no hot water is flowing, temperatures can be selected between 37°C and 43°C by
pressing and holding the temperature control buttons, to select temperatures above 43°C
press the temperature control button once for each selection.
A controller must be turned on and must display the „Priority‟ indicator in order to allow
adjustment of water temperature.
When hot water is flowing, the temperature can be increased from 37°C to 43°C only. The
water temperature can be decreased from any setting whether hot water is flowing or not.
Standard Controller
Controller
„In use‟ light
Controller
„priority‟ light
Water
temperature
adjustment
buttons
Controller
display panel
(water temp or
water volume)
Controller
ON / OFF
button
Water volume
button
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Standard Controllers (cont‟d)
Note: If one or more controllers are installed, at least one must be ON for the water heater
to operate. If all controllers are OFF the water heater will only deliver cold water.
Selectable Temperatures:
Kitchen Controller:
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50*, 55*, 60°C*
Bathroom Controllers:
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50°C*
* Temperatures above 48°C are not available on controllers fitted to 246, 276, 876 series
models as these units have a maximum selectable temperature of 48°C at all locations.
ON / OFF button
This button must be pressed once to turn on the controller. The
light in the button will glow when the controller is on. A
controller cannot be turned on if water is flowing from a hot tap.
To turn off a controller, press the on / off button once. The light
will go out. A controller can be turned off whilst water is flowing.
Priority light
This light will glow on a controller when that controller has
priority. The Bathroom controller(s), if they are turned on, have
priority over the Kitchen controller. Priority means that controller
has control of the water heater temperature setting. The water
temperature setting can only be adjusted by the controller that
has priority.
In use light
This light will glow on all controllers, whether they are on or off,
when hot water is flowing, regardless of which controller has
priority.
Display panel
The current temperature setting is displayed on all controllers
(whether hot water is flowing or not), when any controller is on.
If all controllers are off, then the display remains blank. The
water volume can also be displayed on the Kitchen controller.
The x10l symbol glows when the water volume is displayed.
 (up button)
The up button increases the temperature setting.
 (down button)
The down button decreases the temperature setting.
water volume button
(Kitchen controller only) – This feature enables an alarm to
sound when a set volume of water has flowed through the water
heater (refer to notes below).
Water volume notes:
The water volume function is designed to warn, by a beeping sound, that a certain
volume of water has been delivered from the water heater. It does not stop either the
flow of or the heating of water.
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The Kitchen controller does not require priority nor to be on in order to set the water
volume function.
The water volume function can be set whilst a hot tap is open.
The water volume alarm will only sound from the kitchen controller.
The factory preset water volume is 180 litres.
To turn off the water volume function before the alarm sounds, press the water volume
button twice.
The water volume is measured as the water flows through the water heater. Therefore if
more than one hot tap is open, the alarm will respond to the total water volume drawn
from all taps and the expected water volume from the first tap will be decreased.
If the hot tap is closed before the set water volume flows through the water heater and
the water volume button is left on, then the alarm will sound when the remaining water
volume is consumed during a later operation. To prevent the alarm from sounding,
press the water volume button twice to turn it off.
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Deluxe Controller
(Shown with Bath-Fill control cover open)
Heater operating
light
Bath-Fill
operating light
Controller
„ACTIVE‟ light
Water temperature in
Degrees Celsius
Bath-Fill Water
Volume in
litres
ACTIVE
Assistance call
button
General purpose
water temperature
adjustment buttons
Controller
ON / OFF button
Bath-Fill mode
On/Off button
Speaker
Bath-Fill mode
Water Volume
adjustment
buttons
Bath-Fill mode
Temperature
adjustment
buttons
Note: If one or more controllers are installed, at least one must be ON for the water heater
to operate. If all controllers are OFF the water heater will only deliver cold water.
Selectable Temperatures:
Deluxe Kitchen Controller:
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50*, 55*, 60°C*
Deluxe Bathroom Controllers:
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50°C*
Bath-Fill Mode – All Deluxe Controllers:
37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48°C
* Temperatures above 48 degrees are not available on controllers fitted to 246, 276 & 876
models as these units have a maximum selectable temperature of 48°C at all locations.
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Deluxe Controller Functions
ON / OFF button
Press once to turn on the controller. The button will glow when
the controller is on. A controller cannot be turned on if water is
flowing from a hot tap. Press the button to turn off the controller.
A controller can be turned off whilst water is flowing.
Bath-Fill button
Initiates Bath-Fill mode and once pressed will display the last
used Bath-Fill water volume in litres and the last used Bath-Fill
temperature in °C. The displayed Bath-Fill water volume and
temperature can be adjusted by using the Bath-Fill water
volume and temperature control buttons located beneath the
hinged panel
Bath-Fill operating light
Illuminates whenever Bath-Fill mode is in operation.
Bath-Fill Temperature
 (up button)
Increases the Bath-Fill temperature setting.
Bath-Fill Temperature
 (down button)
Decreases the Bath-Fill temperature setting.
Bath Fill Water Volume
 (up button)
Increases the Bath-Fill water volume setting in increments of 10
litres up to 500 litres. A further setting of 990 litres can be
selected
Bath Fill Water Volume
 (down button)
Decreases the Bath-Fill water volume setting
Assistance Call button
When pressed sounds a message or alert tone on the Kitchen
Controller indicating that assistance is required in the bathroom.
Bath-Fill Water Volume
display
Displays the selected Bath-Fill water volume in litres. The
quantity of water can be adjusted using the Bath-Fill Water
Volume adjustment buttons located beneath the hinged panel
Heater Operating light
Illuminates on all controllers when hot water is flowing
Heater ACTIVE light
Illuminates when that controller is „active‟. The Bathroom
controller when turned on, have priority over the Kitchen
controller. Priority means that a controller has control of the
water heater temperature setting. The water temperature setting
can only be adjusted by the controller that is displaying the
ACTIVE message.
Temperature Display
Displays the current temperature setting on all controllers in °C
when any controller is on. If all controllers are off the display
remains blank.
 (up button)
Increases the general purpose temperature setting.
 (down button)
Decreases the general purpose temperature setting.
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Bath Fill Operation
B
Bath Fill Operation
Deluxe controllers only
Bath fill switch on
Bath fill lamp on
Hot water volume indicator on
Hot water volume on
Hot water temperature
indicator on
Bath fill switch on less
than 6 hours?
NO
YES
YES
Hot water tap open
Combustion A - B
Bath fill switch off?
Bath fill lamp off
NO
Hot water volume indicator off
Water delivered less
than or equal to set
volume?
YES
Hot water volume off
Hot water temperature
indicator off
NO
Burner Off
Bath fill lamp flashing
Hot water volume indicator off
Hot water volume off
Hot water temperature
indicator off
Water flow control valve
closed
8.5 seconds later
Water flow sensor off?
NO
65 Flashing
YES
Hot water tap closed
NO
Bath fill switch off?
YES
Water flow control valve
open
Bath fill lamp off
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completed
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EZ-Link™ System
The EZ-Link system is used to electronically control two
identical water heaters, plumbed in parallel, from the same
temperature controller in order for them to operate as one.
Depending upon the hot water demand, one or both units
may be in operation.
The EZ-Link system consists of a cable that is connected
between the PCB‟s.
Controller Cable
(one water heater only)
The cable is connected into connector E on each
PCB and dip switch 4 is turned to the „on‟
position in each water heater (refer to diagram
opposite).
2
4
E
REMOTE
CONTROLLER
TERMINAL
ON
3
ON
1
2
3
4
1 2 3 4
E
Secure
cable
with cable
clamp &
screw
OFF
ON
Ez-Link
Cable
DIP1
If it becomes necessary to test the operation of
both units, increase the hot water flow by
opening multiple hot water outlets simultaneously
until both units operate.
SW2
ON
1
1 2 3 4
OFF
DIP1
SW1
Dip Switch 4
in the on (up) position
MANIFOLD INSTALLATION - EZ LINK CONNECTION
TWO CONTINUOUS FLOW WATER HEATERS
eaves, balconies
& other projections
to return wall &
openings into building
no minimum
distance
requirement
350
300
MIN
Ez-Link Cable Connection
300 MIN
Temperature
Controller
(installed indoors)
in use
priority
°C
x10
check
hot water
temperature
before use
water
volume
on
off
Weatherproof
GPO x 2
K
Controller
Cable
The diagram opposite details a typical
installation utilising the EZ-Link
system.
Ez-Link
Cable
COLD WATER SUPPLY
HOT WATER
TO OUTLETS
GAS SUPPLY
PIPE SIZES:
Manifold DN25
Branches DN20
NOTE:
PRESSURE
LIMITING DEVICE
(PLV)
REQUIRED TO
TLD IF PLV
INSTALLED AT
WATER HEATER
NOTE: NON RETURN
VALVES (NRV)
REQUIRED ON COLD AND
HOT SUPPLY LINES TO A
TEMPERATURE LIMITING
DEVICE (TLD) IF NOT
INCORPORATED IN TLD.
TEMPERATURE LIMITING DEVICE
IF REQUIRED
SUITABLE FOR MAXIMUM FLOW.
COLD WATER
TEMPERED
WATER
TO
OUTLETS
SUPPLY
LEGEND
ISOLATION VALVE (FULL FLOW)
PRESSURE LIMITING VALVE
NON RETURN VALVE
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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EZ-Link Error Code Display
If a fault is present with one of the water heaters connected via the EZ-Link system, in
addition to displaying the normal error codes, the controller will also display a 1 or a 2 to
indicate which unit is at fault.
1 indicates the unit to which the controller is connected has the fault, 2 indicates the unit
which does not have the controller connected has the fault.
EZ-Link Fault Finding
EZ Link
Is the complaint for no hot water?
Is the EZ-Link cable firmly plugged into
connector E on both water heaters?
YES
NO
Connect the EZ-Link wiring correctly
NO
Isolate power to both units, set dip
switch 4 to the „on‟ position and
restore power
NO
A controller must be connected to one
of the water heaters for the EZ-Link
system to function
YES
Fault with controller or EZ-Link Cable
Replace controller or EZ-Link cable &
reset dip switch 4 to the „on‟ position in
both water heaters
YES
Is dip switch 4 on both heaters set to the
„on‟ position?
YES
Is a controller connected to one of the
water heaters?
NO
YES
Disconnect the controller, EZ-Link cable
and set dip switch 4 on both heaters to
the „off‟ position. Do the water heaters
operate individually?
Water inlet and outlet connections
connected back the front
Flow rate less than 3 litres/minute/unit
NO
Is the complaint for incorrect
water temperature?
YES
Is more than one controller fitted?
Is an error code
1. Being displayed by the controller, or
2. Stored in the maintenance memory?
YES
NO
YES
Conduct fault finding on the water
heater indicated by the controller
display as having a fault (1 or 2) and
based on the error code displayed.
Fluctuating water temperature may be
due to low water supply pressure;
small pipe sizing; incorrect
manifolding; massaging shower
heads; crossed connection; insufficient
gas pressure
The EZ-Link system is flow rate
dependant. It is normal for only one
heater to operate under low flow
conditions.
NO
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
D.O.I: 2/06/2009
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Remove the additional controllers.
ONE controller ONLY may be used
with the EZ-Link System
Incorrect water temperature may be
due to low gas pressure; incorrect
burner pressure setting; faulty or
contaminated thermistor(s)
NO
NO
Is the complaint for low or
fluctuating water temperature?
YES
19
Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”
About the Operational Flow Charts
The Operational Flow Charts provide information on the start up sequence and, in the
event a failure occurs at any point of the start up sequence, what error code will be
displayed. Error codes are displayed via the red LED mounted on the PCB (refer to page
27 for details regarding interpretation of LED flashing pattern). If fitted, the controllers will
also display the full range of error codes.
The Sequence Number Table below indicates the section of the operational sequence
(boxed numbers on the operational flow chart) where the fault occurred.
Circled numbers, adjacent to the component or function, indicate the diagnostic test point
required to diagnose the fault. Refer to the table on page 25.
By locating the error code in the diagnosis charts the component/s or fault can be quickly
identified and tested using the diagnostic procedures outlined in this manual.
Notes and Abbreviations used in the Operational Flow Charts
P.G.F.R Valve
G.I.S.V.
O.H.L
I.U.I
Proportional Gas Flow Regulating Valve
Gas Inlet solenoid Valve
Over Heat Limiter
In Use Indicator (Combustion Indicator)
F.F
I.C
S.V. 1
S.V. 2
Flame Failure
Integrated Circuit
Solenoid Valve 1
Solenoid Valve 2
Stepping gas rate change sequence by solenoid
Model
16/18/20L
Step 1
S.V. 1 ON
Step 2
S.V. 2 ON
Step 3
S.V. 1 & 2 ON
Burner Configuration (Burner Change-Over Assembly)
Model
16/18/20L
Burner 1
Right Solenoid (S.V. 1)
Burner 2
Left Solenoid (S.V. 2)
Sequence Number Table
Sequence Number
Operational Flow Chart Section
- 0 to -9
A0 - A9
P0 - P9
C0 - C9
E0 - E9
H0 - H9
J0 - J9
L0 - L9
1
2
3
4
5
Test Equipment
A list of test equipment which will assist in conducting diagnostic procedures is provided
below. This equipment is available from Rheem Service Spare Parts Department.
Flame detection simulator
Flame sensor current (uA) detection kit
Fine probe adapter kit
Heat exchanger fin brush
Probe to alligator clip kit
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Operational Flow Charts
Operation Flow Chart 1
Plug In
Power On
1
Error code cleared
YES
Bath fill
operation
On/Off lamp Off
Remote controller
display off
Initial check
normal?
B
Isolate Power
Remote controller
switched on
NO
Gas type control
data failure
Communication
problem between
remote controller
and the heater
82 (H) Flashing
76 Flashing
Remote controller
switched off
Fan Off
(10 seconds later)
On/Off lamp On
Fan On
Remote controller
display on
Fan motor current
detection failure
G.I.S.V control
failure
Over heat limiter
failure
79 (G) Flashing
71 (C) Flashing
14 (E) Flashing
2
5
Water Flow Sensor off
Hot water tap open
E
NO
Water flow sensor
on?
3
NO
YES
Inlet temp ≤ 58ºC
or 2ºC below set
temp?
1
Hot water tap closed
Inlet temp > 60ºC
or set temp?
NO
YES
Burner does not
operate
YES
Max & Min
buttons off?
NO
20 seconds later
Water Inlet
YES
4
Fan On
24 (C) Flashing
Fan On
5
31 (E) Flashing
6
Heat Exchanger
32 (E) Flashing
Thermistors
normal?
YES
Fan speed
normal?
4
YES
Leakage >
than 0.1uA
9
2
Hot Water Outlet
Ambient Air
NO
5 seconds later
7
33 (E) Flashing
16
34 (E) Flashing
61 (B) Flashing
A
False flame
detected?
8
NO
YES
5 seconds later
72 (D) Flashing
G.I.S.V (SVO) off
NO
A
P.G.F.R Valve on
S.V. 1 (SV1) off
S.V. 2 (SV2) off
10
G.I.S.V (SVO) on
Igniter off
11
Igniter on
S.V. 2 (SV2) off
P.G.F.R Valve off
S.V. 1 (SV1) off
12
S.V.1 (SV1) on
P.G.F.R Valve off
13
S.V. 2 (SV2) on
9
P.G.F.R Valve on
14
Flame detected?
P.G.F.R Valve off
I.U.I Off
G.I.S.V (SVO) off
YES
3
First ignition
trial?
NO
3 seconds later
Leakage >
than 0.1uA
NO
11 (A) Flashing
YES
F
F1
Note: Refer to page 20 for details on interpreting chart abbreviations. Refer to page 27 for details on interpreting LED flashing pattern.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Operational Flow Chart 2
F
F1
I.U.I on
Igniter off
Proportional temperature
adjustment
Gas rate change-over
done by solenoid valves
G.I.S.V control
failure
Communication
problem between
remote controller and
water heater
Fan motor
current detection
failure
71 (C) Flashing
76 Flashing
79 (G) Flashing
Thermistor
connections
crossed
P.G.F.R control
failure
Fan failure
Malfunction of
water volume
control motor
35 (E) Flashing
52 (C) Flashing
61 (B) Flashing
65 (G) Flashing
Water inlet
thermistor
disconnected
Heat exchanger
thermistor
disconnected
Outlet thermistor
disconnected
Ambient air
thermistor
disconnected
Heat exchanger
outlet temp too low
31 (E) Flashing
32 (E) Flashing
33 (E) Flashing
34 (E) Flashing
29 (G) Flashing
Post purge failure
O.H.L failure
Outlet water temp
exceeded 97 degrees
for more than 15
seconds
Heat exchanger water
temp exceeded 97
degrees for more than
15 seconds
Outlet water
temperature too
high
Abnormal
combustion
81 (F) Flashing
14 (E) Flashing
15 (E) Flashing
15 (E) Flashing
16 (E) Flashing
99 (G) Flashing
Hot water volume
adjustment
Incorrect
combustion
alarm level?
E
YES
NO
05 Flashing
NO
Igniter off
S.V. 2 (SV2) off
3
11 (A) Flashing
S.V. 1 (SV1) off
Decrease of
fan speed?
(warning)?
G.I.S.V (SVO) off
P.G.F.R Valve off
12 (A) Flashing
NO
Ignition failure
after flame failure
YES
10 Flashing
YES
NO
First ignition
trial?
I.U.I off
Safety device
working?
Cross light failure
Flame Failure
YES
Note: Refer to page 20 for details on interpreting chart abbreviations. Refer to page 27 for details on interpreting LED flashing pattern.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Operational Flow Chart 3
Hot water tap closed
Post Purge Shut Down Function
Water flow sensor off
G.I.S.V (SVO) off
or
[S.V. 1-2 (SV1-2) off]
Check gas cut off function by
alternating the closing order of
gas valves SVO and SV1-2 at
each shut down
P.G.F.R Valve at
minimum
Fan motor at minimum
I.U.I off
YES
Flame current
detected less than
0.1uA?
4
NO
8 seconds later
YES
S.V. 1-2 (SV1-2)
failure
G.I.S.V (SV0) failure
80(F) Flashing
51(F) Flashing
G.I.S.V (SVO) off
[S.V. 1-2 (SV1-2) off]
P.G.F.R Valve off
S.V. 1 (SV1) off
S.V. 2 (SV2) off
G.I.S.V (SV0) off
Fan motor speed
checked during
operation?
P.G.F.R valve off
YES
Fan off
Fan
motor current check
ok?
5
NO
10 seconds later
Isolate power
NO
Abnormal combustion
YES
Locate and repair fault
and restore power
99(G) Flashing
Fan off
Fan off
10 seconds later
Approx. 6 minutes later
Isolate power
Locate and repair fault.
Refer to procedure on page
23 to clear error code 99.
Note: Refer to page 20 for details on interpreting chart abbreviations. Refer to page 27 for details on interpreting LED flashing pattern.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Codes
The following table outlines the error codes, possible causes and diagnostic tests to
conduct. More detailed diagnosis is outlined in the fault finding and operational flow charts.
Error Code
LED pattern
Fault Condition
Items To Check
05
10
-
Heat Exchange outlet temp too low
Abnormal low rate combustion
11
A
Ignition failure at start up
Cross light failure
12
A
Flame failure during operation
14
E
Over heating
15
E
Very high temperature
16
24
E
C
29
G
31
E
32
E
33
E
34
E
35
E
Outlet water temp too high
Operational switch faulty
Heat Exchange outlet temperature too
low
Inlet thermistor open circuit
Heat exchanger thermistor open
circuit
Outlet thermistor open circuit
Ambient air thermistor open/short
circuit
Thermistor connections crossed
51
F
G.I.S Valve failure
52
C
P.G.F.R control failure
61
B
65
G
Abnormal fan speed
Malfunction of water volume control
motor
71
C
G.I.S valve control failure
72
D
76
-
79
G
Detected false flame
Communication problem between
controller and water heater
Fan motor current detection failure
80
F
Gas cut off defective
81
F
82
H
Post purge malfunction (Solenoid
valve 1 failure)
Functional problem on GTC board
99
G
Abnormal combustion
Heat Exchanger, Air inlet.
Blockage in the h/exchanger, fan, air intake or flue
P.G.F.R Valve - diagnostic point 9
G.I.S Valve - diagnostic point 10
Igniter - diagnostic point 11
Solenoid valves 1 & 2 - diagnostic points 12 & 13,
Flame sensors 1 & 2 - diagnostic point 14
P.G.F.R Valve - diagnostic point 9
G.I.S Valve - diagnostic point 10
Solenoid valves 1 & 2 - diagnostic points 12 & 13,
Flame sensors 1 & 2 - diagnostic point 14
Over Heat Limiter - diagnostic point 2
Heat exchanger thermistor - diagnostic point 6
Hot water outlet thermistor - diagnostic point 7
P.G.F.R Valve - diagnostic point 9
P.G.F.R Valve - diagnostic point 9
MAX or MIN button on IC board
Heat Exchanger, Clean air inlet.
Water inlet thermistor - diagnostic point 5
Heat exchanger thermistor - diagnostic point 6
Hot water thermistor - diagnostic point 7
Ambient air thermistor - diagnostic point 16
Connection points of thermistors
G.I.S Valve - diagnostic point 10
Flame sensor 1 & 2 - diagnostic point 14
P.G.F.R Valve – diagnostic point 9
IC Board
Fan motor – diagnostic point 4
Water volume control motor - diagnostic point 15
Gas Inlet Solenoid Valve - diagnostic point 10
IC Board (PCB)
Flame sensors 1 & 2 - diagnostic point 8
Controller, IC Board or cable
Fan motor – diagnostic point 4, IC Board
Solenoid valve 1 & 2 - diagnostic points 12 & 13
Flame sensor 1 & 2 - diagnostic point 14
Solenoid valve 1 & 2 - diagnostic points 12 & 13
Flame sensor 1 & 2 - diagnostic point 14
Gas type setting failure, IC board
Blockage in the heat exchanger, fan, air intake or
flue way
Note: Refer to page 20 for interpretation of abbreviations. Refer to page 27 for details on interpreting LED flashing pattern.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Diagnostic Test Points
Refer to wiring diagram on page 6 for connector and wiring positions.
Test
Point
1
2
3
4
Measuring Point
Wire Nº
Connector
& colour
H&I
R–R
T
W1 – W2
R
F
BR1 – BK2
R3 – BK2
B4 – W6
R3 – B4
Y1 – B4
5
Q
W6 – BK3
6
Q
Y5 – BK3
7
Q
R4 – BK3
8
L&J
K&J
W1 – Earth
R1 – Earth
9
Q
R1 – BK2
10
J
Y1 – BK5
11
G
GY2 – GY5
12
J
W2 – BK5
13
J
R3 – BK5
14
L&J
K&J
15
B
W1 – Earth
R1 – Earth
W2 – BK8
R7 – BK8
GR6 – BK8
16
Q
B7 – BK3
Normal Condition
AC 90V – 110V
50 kilo-ohms – 500 kilo-ohms
DC 2V– 5V(Pulse) *
More than 1310 pulse/min
DC 11V – 17V
DC 120V – 160V
DC 12V – 18V
DC 4V – 10V(Pulse) *
More than 4800 pulse/min
@ 20ºC – 10.3 kilo-ohms
@ 40ºC – 4.9 kilo-ohms
@ 20ºC – 10.3 kilo-ohms
@ 40ºC – 4.9 kilo-ohms
@ 20ºC – 10.3 kilo-ohms
@ 40ºC – 4.9 kilo-ohms
AC 3V – 20V **
AC 3V – 20V **
DC 1.5V – 14.0V
40 ohms – 80 ohms
DC 75V – 100V
0.8 kilo-ohms – 2.2 kilo-ohms
AC 90V – 110V
DC 75V – 100V
0.8 kilo-ohms – 2.2 kilo-ohms
DC 75V – 100V
0.8 kilo-ohms – 2.2 kilo-ohms
AC 1V – 100V **
AC 1V – 100V **
DC 8V – 16V
DC 8V – 16V
Less than DC 1V (Limiter on)
DC 4V – 6V (Limiter off)
@ 20ºC – 10.3 kilo-ohms
@ 40ºC – 4.9 kilo-ohms
Items Under Test
Main Power
Overheat Limiter
Water Flow Sensor pulse signal
Water Flow Sensor
Fan Motor
Fan Motor pulse signal
Water Inlet Thermistor
Heat Exchanger Thermistor
Hot Water Outlet Thermistor
Flame Sensor not detecting flame
Proportional Gas Flow R. V
Gas Inlet Solenoid Valve
Igniter
Solenoid Valve 1
Solenoid Valve 2
Flame Sensor detecting flame.
Water Volume Control Motor position
switch
Ambient Air Thermistor
NOTES:
* : Approximate reading measured by digital multimeter on DC range.
** : Approximate reading measured by digital multimeter on AC range.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Maintenance Information
Information relating to both the current and past operation of the water heater can be
obtained from the memory; this information is referred to as the maintenance information.
The table below details the information that can be recalled from the memory i.e. to view
the current temperature being measured by the outlet thermistor select 5Y, refer to page
27 for the procedure to display maintenance information.
Maintenance Table
Left digit in LED display (Numerical)
3
4
5
6
7
8
9
F
Sequence number of the previous 8 faults
Management
Number
Null
C
Total combustion
starts X 10,000
Total combustion operations since last error X 10,000 hours
Null
D
Total combustion
starts X 100
Total combustion operations since last error X 100 hours
Null
H
Total combustion
period X 1000 hrs
Total combustion period since last error X 1,000 hours
Null
J
Total combustion
period X 10 hrs
Total combustion period since last error X 10 hours
Null
Y
Water Flow Sensor
Litres / minute
2
Management
Number
Null
A
Null
Null
Heat Exchanger
Thermistor temp ºC
Hot Water Outlet
Thermistor temp ºC
Fan speed X100 RPM
Fan Motor current curve
- average
Fan Motor current curve
- after tap closure
Fan Motor current curve
-present combustion
Null
Null
Null
Null
Sequence number
Water Inlet Thermistor
temp. ºC
Fan Motor Current
Power for P.G.F.R
Valve
Ambient Air Thermistor
temp. ºC
Error Code for the previous 8 faults
Fan detective value
E
Right digit in LED display (Alphabetical)
1
Flame sensor status (See
table below)
0
Flame Sensor Status
Model
0y Information
Flame Sensor 1
Flame Sensor 2
All 16, 18 & 20L Models
01
02
O
X
X
O
00
X
X
03
O
O
X = Flame sensor is not detecting flame. O = Flame sensor is detecting flame
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Displaying Maintenance Information
With Controller:
Isolate power whilst connecting a controller.
1.
2.
3.
4.
Fit controller if not already fitted.
Restore power supply and ensure the controller is turned on.
Press the temperature increase and decrease buttons simultaneously for 3 seconds.
Use the temperature decrease button to change the left digit (0→1etc.) in the controller
display to the required maintenance code identified from the maintenance table on
page 26.
5. Use the temperature increase button to change the right digit (E→F etc.) in the
controller display to the required maintenance code identified from the maintenance
table on page 26.
6. The maintenance code and the value of that code will alternate on the LED display of
the Controller.
7. Press the on/off button twice on the controller to cancel maintenance information.
Without Controller:
Voltages up to 240 volts will be present within the water heater, take care
not to touch wiring terminals. Use an insulated tool when operating the
DIP switch or MIN and MAX buttons.
If a controller is not fitted, the red LED on the PCB can be used to show error code history.
This method will only provide limited information regarding error codes. Specific
maintenance information as listed on page 26 is not available unless a controller is fitted.
1. If the unit is in a fault condition, the red LED on PCB will be flashing. Previous error
codes can be viewed by modifying the dip switch positions as below:
Dip
Switch
1
2
3
4
State of
Switch
OFF
ON
OFF
ON
OFF
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
State of Display
Normal Mode
Latest Error Code
2nd Error Code
3rd Error Code
A
B
C
2. The red LED will flash in a
specific pattern. Refer to
adjacent chart in conjunction
with error code information on
page 24 to determine fault.
D
E
F
G
0.5sec.
H
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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0.5sec.
3sec.
0.2sec.
27
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Clearing Error Code History
Voltages up to 240 volts will be present within the water heater, take care
not to touch wiring terminals. Use an insulated tool when operating the DIP
switches or MIN and MAX buttons.
After repairing the water heater the existing error code history should be cleared. This will
allow fresh data to be stored and reduce the risk of confusion should it be necessary to
service the water heater in the future.
To clear the error code history:
1.
2.
3.
4.
5.
Ensure all controllers (if fitted) are turned off and all hot taps are closed.
Remove the front panel of the water heater.
Ensure all DIP SWITCHES are in the off position (down position).
Turn DIP SWITCH 1 on (up position) and then off (down position) again.
Within 5 seconds of turning DIP SWITCH 1 off, press and hold either the MIN or MAX
button for more than 2 seconds.
6. Refit the water heater front panel.
Resetting Error Codes
Most error codes can be reset by shutting off the hot water flow and turning the controllers
(if fitted) off and then on again. It may also be necessary to isolate and restore the power.
Where controllers are not fitted it may be necessary to turn the power off at the water
heater to clear the error code.
To reset Error Code 99 it is necessary to:
1.
2.
3.
4.
Ensure all controllers (if fitted) are turned off and all hot taps are closed.
Ensure all DIP SWITCHES are in the off position (down position).
Turn DIP SWITCH 2 on (up position) and then off (down position).
Within 5 seconds of turning DIP SWITCH 2 off, press and hold both the MIN and MAX
buttons for more than 2 seconds.
5. Refit the water heater front panel.
Fault Finding
When measuring resistance of a part, turn off the electric power and be sure to
disconnect the part completely before measuring (from connector or terminal).
Resistance checks are performed on the part while it is disconnected from the
control board.
“Live” testing to be conducted. Personal Protective Clothing (PPE) shall be
worn to reduce the risk of electric shock. Refer to Rheem Safety Procedure
on electrical testing.
All Molex connections only go to one location and fit one way. You do not need to
force a connection. Connections are also colour coded to aid in reassembly.
CAUTION: When performing maintenance and/or servicing the water heater,
wait for the water heater to become cool. Be careful to avoid injury on the
sharp edges.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Fault Diagnosis Sequence
Ensure power is turned on.
Is remote controller fitted?
NO
YES
If a remote control is unavailable, fault diagnosis can
be made via the red LED on PCB (refer to pages 19
& 22 for LED flashing pattern information).
Does the remote control
power up if the on/off button
is depressed?
It is recommended that a remote
controller be fitted to assist faultfinding.
NO
Follow the „Power Supply Fault
Finding‟ flow chart
YES
Follow the fault finding flow chart
for the error code displayed
NO
Follow the „No Error Code Fault
Finding‟ flow chart
YES
Follow the fault finding flow chart
for the error code displayed
YES
Is an error code displayed?
NO
Open a hot tap
Did the fan commence
operation?
YES
Is an error code displayed?
NO
NO
Ignition Retry
Does the burner light
NO
Is an error code displayed?
YES
YES
Is an error code displayed?
YES
Follow the fault finding flow chart
for the error code displayed
YES
Follow the fault finding flow chart
for the error code displayed
NO
Close the hot tap
Is an error code displayed?
NO
Heater operation appears to be
normal
The red LED on PCB can only supply limited information. For specific fault identification use a controller.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Power Supply Fault Finding
Is 240VAC present at the
power point?
NO
No power supply.
Check fuse/circuit breaker/GPO
NO
Check:
Heater internal wiring - repair
Cordset open circuit - replace
Power filter open circuit - replace
NO
Transformer failed – replace
YES
Is 240VAC present at the
transformers primary
winding?
TEST 1
YES
Is 90 -110VAC
present at the PCB?
TEST 2
YES
Can maintenance information
be displayed on remote
controller?
Is 12V DC present
at the PCB?
TEST 3
NO
YES
Remote controller cable open
circuit? – replace
Remote controller failed? - replace
YES
When maintenance information
appears but operational lamp
doesn‟t light, replace controller
NO
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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PCB failed - replace
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Fault Finding Tests 1 – 3
Components will be “Live” when conducting tests, exercise caution.
Test 1
Power Filter
Using a multimeter set on the AC volts scale, measure the voltage at the connector plug to the
transformer primary winding.
Normal voltage is between 230V and 250V.
JAPAN
JAPAN
JAPAN
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
Test 2
Test 3
H
C
D
I
Using a multimeter set on the AC volts scale, Using a multimeter set on the DC volts scale,
measure the voltage between red wires at measure the voltage between terminals C &
terminals H & I on the PCB.
D on the PCB.
Normal voltage is between 90V and 110V.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Normal voltage is 12V.
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No Error Code Fault Finding
A
Is the unit used as
an in-series gas
booster?
YES
NO
Read
maintenance
information 1y
Is 1y displaying a
flow greater than
2.5lpm?
1y = Water flow
detected by water
flow sensor
NO
Is water flow
through unit greater
than 2.5lpm?
YES
Replace the PCB assembly.
NO
Open hot tap further.
NO
Replace the PCB assembly.
YES
Are controllers
fitted?
YES
Controllers must not be
fitted when used as an
in-series gas booster.
Remove controllers.
Is the voltage
between terminals 2
& 3 at connector R
normal?
Test 4
YES
Is the voltage
between terminals 1
& 2 at connector R
normal?
Test 5
YES
NO
Is the flow sensor
turbine jammed?
Test 6
NO
YES
Replace the water flow sensor. If
the fault persists replace the
water body assembly.
NO
246, 276, 876 Series models are
not suitable for use as in-series
gas boosters.
246, 276, 876 Series
What is
the model
number?
Free the flow sensor turbine.
244, 274, 874 Series
Is a solar bypass
valve fitted?
244, 274, 874 Series models do
not require a solar bypass valve.
Remove the solar bypass valve
and remake water connections
directly to unit.
YES
NO
Read maintenance
information 3y
Is the water entering
the unit < 58ºC or
< the set temp - 2ºC?
3y = Water temp
detected by water
inlet thermistor
YES
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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NO
Water will flow straight through
the unit without ignition attempt.
Normal operation.
A
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Fault Finding Tests 4 – 6
Test 4 - Diagnostic Point 3
Test 5 - Diagnostic Point 3
MAX.
MAX.
3 4
3 4
R
R
Conduct test with water flowing.
Conduct test with water flowing.
Using a multimeter set on the DC volts scale, Using a multimeter set on the DC volts scale,
measure the voltage between 3 Red and 2 Black measure the voltage between 1 Brown and 2
on connector R.
Black on connector R.
Normal voltage should be between DC11 – 17V.
Normal voltage should be between DC2 – 5V.
Test 6
Remove the flow sensor turbine. Refer to „Flow Sensor Turbine‟ procedure on page 51.
The flow sensor turbine should spin freely. Check for wear or blockage by foreign material such
as thread tape. The power must be isolated during water flow sensor removal.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 11
Error Code 11
Is there gas available?
Open gas isolation valve or advise
customer to contact gas provider
NO
YES
Did the burner ignite?
YES
Display maintenance information
„0y‟ on remote control.
Attempt ignition again.
Replace PCB
NO
Does „0y‟ indicate 01, 02 or
03 when a flame is visible?
NO
NO
YES
YES
Is the burner gas pressure
correct?
Clean or replace the main burner.
YES
NO
Check:
Combustion chamber for debris
Flame sensor wiring - repair.
Flame rods - replace
Did the igniter spark?
NO
Is there any voltage at the
flame sensors?
TEST 7
Adjust the burner pressure
Refer to section on burner
pressure adjustment
Is voltage supplied to the
igniter?
TEST 8
YES
NO
Replace ignition module or HV
cable
YES
Is there voltage at GISV and
gas solenoid valves 1 & 2?
TEST 9
Replace PCB
Check wiring, if intact replace the
PCB
NO
YES
Is there voltage at the
proportional gas valve?
TEST 10
NO
YES
Is the resistance of the
GISV and gas solenoid
valves 1 & 2 correct?
TEST 11
NO
Replace proportional gas valve
YES
Is the resistance of the
proportional gas valve
correct?
TEST 12
NO
YES
Check gas solenoid valves for
mechanical failure.
Replace if necessary.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Fault Finding Tests 7 – 12
Test 7 - Diagnostic Point 8
2
3
4
JAP
1
MAX.
12VDC
L
K
OMRON
G5NB-1A4
12VDC
MIN.
Test 8 - Diagnostic Point 11
G
Body Earthing
Conduct test with no water flow
Conduct test with water flowing
Using a multimeter set on the AC volts scale, Using a multimeter set on the AC volts scale,
measure the voltage between terminals W1 on measure the voltage between the grey wires at
connector L and earth and between terminals connector G.
R1 on connector K and earth.
When ignition sequence commences, voltage
Normal voltage should be between AC3 – 20V. should be between 90 - 110VAC until flame is
detected. (Note: Duration is approx 3 seconds)
12VDC
OMRON
G5NB-1A4
12VDC
JAP
OMRON
12VDC
12VDC
OMRON
G5NB-1A4
1
2
3
OMRON
G5NB-1A4
5
6
J
JAPAN
Test 11
JAPAN
Test 9
G
Using a multimeter set on the DC volts scale, Using a multimeter set on the kilo-ohms scale,
measure the voltage with connector J plugged measure the resistance with connector J
unplugged from the PCB.
into PCB.
1
2
Test
Point
1 Yellow
5 Black
2 White
5 Black
3 Red
5 Black
Diagnostic
Point
Solenoid Valve
10
GISV
12
1
13
2
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Normal
Resistance
0.8Kohms
to
2.2Kohms
GISV
Normal
Voltage
DC75 to
DC120V
Solenoid
Valve
Test
Point
1 Yellow
5 Black
2 White
5 Black
3 Red
5 Black
Diagnostic
Point
10
12
13
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Tests 10 and 12 - Diagnostic Point 9
Test 10: Conduct test with water flowing.
Using a multimeter set on the DC volts scale,
measure the voltage between 1 Red and 2 Black at
connector Q whilst plugged into PCB.
Normal voltage is between DC1.5 and 14.0V.
2 - Black
1 - Red
T
R
JAPAN
JAPAN
JAPAN
JAPAN
JAPAN
JAPAN
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
Q
Test 12: Isolate power before conducting test.
Using a multimeter set on the ohms scale, measure
the resistance between 1 Red and 2 Black at
connector Q whilst unplugged from the PCB.
Normal resistance is between 40 ohms and 80
ohms.
Error Code 12
Error Code 12
Is the inlet gas pressure
correct?
NO
Advise customer to contact
installer and correct
YES
Follow the fault finding chart for
error code 11
NO
Replace PCB
NO
Adjust the burner pressure
Refer to section on burner gas
pressure adjustment
YES
Attempt to operate the water
heater by opening a hot tap
Is error code 11 displayed?
NO
Is there any voltage at the
flame sensors?
TEST 7
YES
Refer to „Burner Gas
Pressure Check‟
Are the min and max burner
pressures correct?
Check flame sensor wiring for
breaks
Adjust or replace flame sensors
YES
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 14
Error Code 14
Is the Over Heat Limiter
resistance correct?
TEST 13
Determine cause of OHL failure.
Replace OHL
NO
YES
Replace the PCB
Fault Finding Test 13
Test 13
MAX.
3
Unplug T connector from PCB and using a
multimeter set on the kilo-ohms scale, measure
the resistance of the Over Heat Limiter
Assembly.
4
T
R
Normal resistance should be between
50 kilo-ohms - 500 kilo-ohms.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 15
Error Code 15
YES
Replace PCB
Measure the hot water outlet
temperature
Is the resistance of the heat
exchanger thermistor normal?
TEST 14
Display maintenance information
„5y‟ on remote control
NO
Replace heat exchanger
thermistor
NO
Replace hot outlet thermistor
YES
Does the measured hot water
temperature match that
indicated by 5y?
Is the resistance of the hot
outlet thermistor normal?
TEST 14
NO
YES
Check the burner pressure and
adjust if necessary.
Refer to section on burner
pressure adjustment
Check wiring. Ensure all
connections are securely
fastened.
Error Code 16
Error Code 16*
**Is the unit used as an
in-series gas booster?
*Error 16 will occur if the unit heats the
water to 20oC above the set point – 3oC
eg: 60 + 20 – 3 = 77oC.
Is the inlet water
temperature >58oC?
YES
YES
The gas booster should not
operate with an inlet temperature
in excess of 58oC
NO
Is the resistance of the cold
water inlet thermistor normal?
TEST 14
** 246, 276, 876 series heaters are
unsuitable for use as in-series gas boosters.
NO
NO
Replace cold water inlet
thermistor
YES
Is the resistance of the
proportional gas valve
correct?
TEST 12
YES
Replace the proportional gas flow
regulating valve
NO
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Replace PCB
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Fault Finding Test 14
Test 14 – Diagnostic Points 5, 6, 7 & 16
5 - Yellow
4 - Red
3 - Black
T
Isolate power before conducting test.
R
JAPAN
JAPAN
JAPAN
JAPAN
JAPAN
JAPAN
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
Q
Using a multimeter set on the ohms scale,
measure the resistance at connector Q whilst
unplugged from the PCB.
Maintenance display code
Diagnostic Point
2y: Ambient Air Thermistor
16
3y: Cold Inlet Thermistor
5
Test Point
7 Blue
3 Black
6 White
3 Black
4y: Heat Exchanger Thermistor
6
5 Yellow
3 Black
5y: Hot Water Outlet Thermistor
7
4 Red
3 Black
Measured Value
@20ºC – 10.3 kilo-ohms
@40ºC – 4.9 kilo-ohms
Error Code 24
Error Code 24
Is the Min or Max button
depressed?
TEST 16
Release the Min/Max buttons and
re-open a hot tap
YES
NO
Replace the PCB
Fault Finding Test 16
Test 16
Ensure the min/max
MIN.
1
Are the controller cables or any other
cables/components inadvertently depressing
the Min or Max buttons on PCB?
MAX.
2 3
4
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 29
Error Code 29
YES
Replace PCB
Measure the hot water outlet
temperature
Is the resistance of the heat
exchanger thermistor normal?
TEST 14
Display maintenance information
„5y‟ on remote control
NO
Replace heat exchanger
thermistor
NO
Replace hot outlet thermistor
YES
Does the measured hot water
temperature match that
indicated by 5y?
Is the resistance of the hot
outlet thermistor normal?
TEST 14
NO
YES
Check heat exchanger for
blockage/restriction (possible
scale build-up). Ensure air inlet is
clear and free of debris
Check the burner pressure and
adjust if necessary.
Refer to section on burner
pressure adjustment
Error Code 31, 32, 33 & 34
Error Code 31, 32, 33, 34
Is the resistance of the
relevant* thermistor normal?
TEST 14
YES
NO
Replace the relevant
thermistor
* Thermistor error codes:
31 = Water inlet thermistor
32= Heat exchanger thermistor
33 – Hot water outlet thermistor
34 = Ambient air thermistor
Is the relevant thermistor
connection to the PCB intact?
NO
YES
Replace PCB
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Repair connection or replace
thermistor if wiring damaged
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Error Code 35
Error Code 35
Are the cold and hot water
connections to the water
heater reversed?
Reconnect plumbing to the
water heater correctly
YES
Cold water inlet and hot water
outlet thermistors positions
reversed.
Swap thermistors positions
NO
Error Code 51, 72, 80, 81
Error Code 51, 72, 80, 81
Does the flame extinguish
completely?
NO
Replace proportional gas flow
regulating valve
NO
Isolate power supply for 10
seconds to clear error code.
Restore power. Continue fault
diagnosis if an error reoccurs.
YES
Display maintenance information
„0y‟ on remote control
Does flame detection
maintenance information „0y‟
indicate 01, 02 or 03?
YES
Detach both flame sensors from
connectors L & K on PCB.
Display maintenance information
„0y‟ on remote control
Maintenance Info “0y”
00
01
02
03
Flame Rod 1
x
o
x
o
Flame Rod 2
x
x
o
o
X = No flame detected O = Flame detected
Does flame detection
maintenance information „0y‟
indicate 01, 02 or 03?
NO
Clean or replace the relevant
flame rod
YES
Replace the PCB
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 52
Error Code 52
Is the resistance of the
proportional gas flow
regulating valve normal?
TEST 12
Replace PCB
YES
Replace the proportional gas flow
regulating valve
NO
Error Code 61
Error Code 61
Min
Max
Fan Speed (x 100) RPM
Display maintenance information
„6y‟ on remote control
Is the correct fan speed
indicated?
Maintenance Info „6y‟
NO
Is voltage being supplied to
the fan motor?
TEST 17
NG
Prop
NG
Prop
26
26
58
60
NO
Replace the PCB
YES
Is the fan motor rotating?
NO
YES
YES
Is a pulse signal detected
from fan motor?
TEST 18
The error was likely to be caused
by a fluctuation in the power
supply. Isolate power to clear error
code.
YES
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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NO
Replace the fan assembly
Replace the PCB
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Fault Finding Tests 17 & 18
Tests 17 and 18 – Diagnostic Point 4
Conduct test with water flowing
6 - White
4 - Blue
3 - Red
Using a multimeter set on the DC volts scale, measure
the voltage at connector F whilst plugged into PCB.
Test
1 - Yellow
Check Point
Measured Value
4 Blue – 6 White
DC120 - 160V
3 Red – 4 Blue
DC12 - 18V
1 Yellow – 4 Blue
DC4 - 10V
(or measurement by pulse
counter of not less than
4800 pulses per minute)
F
17
JAPAN
JAPAN
JAPAN
JAPAN
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
OMRON
G5NB-1A4
12VDC
JAPAN
G
18
Error Code 65
Error Code 65
Isolate power to unit for 10
seconds and restore power
Set temperature 48oC or below
Is the resistance of the
bypass solenoid correct?
TEST 19
Set temperature above 48oC
NO
Replace water body assembly
NO
Replace the PCB
YES
YES
Is there voltage at bypass
solenoid?
TEST 20
Is the voltage of water control
motor normal?
TEST 21
NO
Replace the PCB
NO
Replace the PCB
YES
Is the voltage of water control
motor normal during use?
TEST 22
YES
Replace water body assembly
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Fault Finding Tests 19 - 22
Test 19 and 20
TEST 19: Unplug connector G from the PCB and
using a multimeter set on the kilo-ohms scale,
measure the resistance between 3 Green and 6
Green.
Normal resistance should be between 0.6kiloohms and 2.8kilo-ohms.
JAPAN
JAPAN
12VDC
OMRON
G5NB-1A4
12VDC
F
G
Conduct test with water flowing
TEST 20: Using a multimeter set on the DC volts
scale, measure the voltage between 3 Green and
6 Green on connector G.
Normal voltage should be between DC70 – 110V.
Test 21 - Diagnostic Point 15
Test 22 - Diagnostic Point 15
8
8
MAX.
MAX.
2
B
3
B
4
3
Conduct test with water flowing
4
Conduct test with water flowing
Using a multimeter set on the DC volts scale, Using a multimeter set on the DC volts scale,
measure the voltage at connector B whilst measure the voltage at connector B whilst
plugged into PCB.
plugged into PCB.
Check Point
Measured Value
Check Point
Measured Value
7 Red - 8 Black
DC8 – 16V
2 White - 8 Black
DC8 – 16V
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 71
Error Code 71
Is there voltage at gas inlet
solenoid valve?
TEST 9
NO
Check wiring, if intact replace the
PCB
NO
Replace proportional gas valve
YES
Is the resistance of the
GISV correct?
TEST 11
YES
Check gas inlet solenoid valve for
mechanical failure.
Replace PGFR valve if necessary.
Error Code 76
Check cables to all temperature controllers. Replace any cables that are open circuit. If no
open circuit cables are found, replace the controller.
Error Code 79
Error Code 79
Isolate power, remove the F
connector from
the PCB and restore power
Is error code 79
redisplayed?
YES
Replace the PCB
YES
Replace the fan assembly
NO
Isolate power, refit the F
connector to
the PCB and restore power
Is error code 79
redisplayed?
Error code due to supply
voltage drop
NO
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Error Code 82
If error code 82 appears a new PCB is required to be fitted.
Error Code 99 & 10
Isolate power supply; clean the heat exchanger, fan and air inlet opening. Restore power
supply and attempt ignition. If the error code re-appears, replace the PCB.
Burner Gas Pressure Check
Voltages up to 240 volts will be present within the water heater, take care
not to touch wiring terminals. Use an insulated tool when operating the DIP
switch or MIN and MAX buttons.
Minimum Burner Gas Pressure
1. Remove the front panel from the water heater.
2. Remove burner pressure test point screw and fit manometer.
3. Connect a controller (if one is not present) and turn on.
4. Open a hot tap slowly, to achieve the minimum flow rate at which the burners will
ignite.
5. Press and hold the MIN button (“1L” is displayed on the controller) and observe the
reading on the manometer.
6. Release the MIN button. If the reading observed in step 5 agrees with the rating label,
no further adjustment is required.
Maximum Burner Gas Pressure
7. Open the hot tap fully to achieve maximum flow rate.
8. Press and hold the MAX button (“3H” is displayed on the display) and observe the
reading on the manometer.
9. Release the MAX button. If the reading observed in step 8 agrees with the rating label,
no further adjustment is required.
10.Turn the hot tap off.
11.Remove manometer and refit the burner test point screw ensuring the seal is gas tight.
12.Disconnect controller if connected in step 3.
13. Refit the front panel to the water heater.
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Burner Gas Pressure Adjustment
Adjustment of the burner pressure will not overcome problems associated
with poor supply pressure or incorrect gas supply pipe sizing.
Minimum Burner Gas Pressure
1. Remove the front panel from the water heater.
2. Remove burner test point screw and fit manometer.
3. Connect a controller (if one is not present) and turn on. NOTE: Isolate power while
connecting the controller.
4. Open a hot tap slowly, to achieve the minimum flow rate at which the burners will ignite.
5. Press and hold the adjuster button (“LH” is displayed on controller display)
NOTE: The adjuster button must be held down continuously through steps 5 and 6.
6. Press the MIN button and observe the reading on the manometer.
NOTE: While the MIN button is pressed, the gas pressure will at first increase then
decrease, cycling between an upper gas pressure limit (39 on controller display) and a
lower gas pressure limit (01 on controller display).
7. Release the MIN and adjuster buttons when the minimum test point pressure shown on
the manometer agrees with the rating label.
NOTE: If the burners extinguish or an error code starts to flash on the controller display
during this procedure, release the MIN and adjuster buttons, close the hot tap, clear the
error code, turn on the water heater and recommence the procedure from step 3. To reset
an error code, follow the procedure on page 28.
Maximum Burner Gas Pressure
8. Open the hot tap fully to achieve maximum flow rate.
9. Press and hold the adjuster button (“LH” is displayed on controller display).
NOTE: The adjuster button must be held down continuously through steps 9 and 10.
10. Press the MAX button and observe the reading on the manometer.
NOTE: While the MAX button is pressed, the gas pressure will at first increase then
decrease, cycling between an upper gas pressure limit (39 on controller display) and a
lower gas pressure limit (01 on controller display).
11. Release the MAX and adjuster buttons when the maximum test point pressure shown
on the manometer agrees with the rating label.
12.Turn the hot tap off, remove manometer and refit the burner test point screw ensuring
the seal is gas tight.
13.Disconnect the controller if connected in step 3. Note: Isolate power while
disconnecting the controller.
14.Refit the front panel to the water heater.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Component Replacement Procedures
Front Panel
1. Isolate power, gas and water supplies.
2. Remove four screws, two from the top and two from the bottom of the Front Panel.
3. Remove the Front Panel.
PCB Assembly
1.
2.
3.
4.
5.
6.
7.
Isolate power supply.
Remove the Front Panel. Refer to „Front Panel‟ procedure above.
Remove the retaining screw at top left hand side of the PCB.
Disconnect the multi-pin connectors from the PCB Assembly.
Undo the two red wires from transformer at bottom right hand side of PCB.
Carefully remove the PCB assembly.
Reassembly in reverse order of above. Note: When replacing a faulty PCB it is
important to ensure that the correct PCB is installed. Fitment of an incorrect PCB may
result in unit malfunction or a breach of the approval of the unit. Eg: If an 876 series
heater is installed and an 874 series PCB is incorrectly used to replace a faulty PCB
then the maximum temperature setting may exceed the approved maximum
temperature setting of 48ºC for an 876 series heater.
8. Restore power supply.
Lower Burner Assembly
1. Remove the Front Panel. Refer to „Front Panel‟ procedure above.
2. Remove the fourteen screws retaining the Lower Burner Assembly. Includes three
from the Proportional Gas Flow Regulating Valve and one retaining the Igniter.
3. Gently remove Lower Burner Assembly.
4. Reassemble in reverse order of above. Replace gaskets if required.
5. Test for gas leaks using soapy water solution.
Combustion Chamber Front Panel
1. Remove the Lower Burner Assembly. Refer to „Lower Burner Assembly‟ procedure
above.
2. Remove seven screws retaining the Combustion Chamber Front Panel.
3. Gently remove the Combustion Chamber Front Panel.
4. Reassemble in reverse order of above. Replace gaskets if required. NOTE: Ensure
wiring to Igniter and Flame Sensors is not pinched during reassembly.
5. Test for gas leaks using soapy water solution.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Upper Burner Assembly
1. Remove the Combustion Chamber Front Panel. Refer to „Combustion Chamber Front
Panel‟ procedure on page 48.
2. Remove two retaining screws located on the underside of Upper Burner Assembly.
3. Remove the Upper Burner Assembly by sliding forward out of the Heat Exchanger.
4. Reassemble in reverse order of above being careful not to pinch or damage wiring.
Replace gaskets if required.
5. Test for gas leaks using soapy water solution.
Flame Sensor
1. Remove the Upper Burner Assembly. Refer to „Upper Burner Assembly‟ procedure
above.
2. Remove the protective silicon tube and flame sensor lead from Flame Sensor A or B.
3. Loosen retaining screw from Flame Sensor Holder A or B and remove Flame Sensor.
4. Reassemble in reverse order of above. Replace gaskets if required.
5. Test for gas leaks with soapy water solution.
Igniter Electrode
1. Remove the Upper Burner Assembly. Refer to „Upper Burner Assembly‟ procedure
above.
2. Remove the protective silicon tube and spark lead from Igniter Electrode.
3. Loosen retaining screw from right hand flame sensor holder and remove the Igniter
Electrode.
4. Reassemble in reverse order of above. Replace gaskets if required. NOTE: Ensure
wiring to igniter and flame sensors is not pinched during reassembly.
5. Test for gas leaks with soapy water solution.
Proportional Gas Flow Regulating Valve
1. Remove the Lower Burner Assembly. Refer to „Lower Burner Assembly‟ procedure on
page 48.
2. Disconnect the gas supply pipe from the Gas Inlet Connection.
3. Remove the three silver screws from the Gas Inlet Connector on the outside of the
water heater cabinet.
4. Carefully remove the Proportional Gas Flow Regulating Valve (PGFR) from the water
heater.
5. Disconnect the multi-pin wiring plugs from the Gas Inlet Solenoid Valve (GISV), the
Proportional Gas Flow Regulating Valve (PGFR) and Solenoid Valves 1 & 2.
6. Reassemble in reverse order of above. Replace gaskets if required.
7. Test for gas leaks with soapy water solution.
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Power cord
1.
2.
3.
4.
5.
Switch off power at power point and unplug power cord from power point.
Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48.
Undo cord clamp screw located on bottom right hand side of PCB and remove clamp.
Disconnect Earth connection at PCB holder.
Disconnect the power cable wiring loom plug and withdraw power cable through slot in
the water heater jacket.
6. Reassemble in reverse order of above.
Water Body Assembly
Do not attempt to dismantle the servomotor, this is factory calibrated.
Adjustments will render the water heater either inoperable or cause incorrect
water temperature delivery.
1. Remove the Proportional Gas Flow Regulating Valve. Refer to „Proportional Gas Flow
Regulating Valve‟ procedure on page 49.
2. Disconnect the cold water supply pipe from the cold water Inlet Connection.
3. Unscrew the Water Drain Valve assembly (item 32) and Pressure Relief Valve (item
30) and drain the water heater.
4. Remove the screw from the Retaining Flange (item 26) and remove Flange.
5. Carefully disengage the two copper pipes from the Water Body Assembly.
6. Disconnect the wiring to the Bypass Solenoid.
7. Remove the four screws from the cold water Inlet Connector on the underside of the
water heater cabinet and withdraw the Inlet Connector and o-ring from the base of the
water heater.
8. Carefully remove the Water Body Assembly from the water heater.
9. Disconnect the multi-pin connectors from the servomotor, Water Flow Sensor and Cold
Water Thermistor at the PCB. Note: Some wiring retainers will need to be released to
allow wiring to be removed.
10. Remove the retaining screw from the Anti-Frost Heater and remove.
11. Reassemble in reverse order of above, replacing pipe o-rings (item 6) if required.
12. Test for gas and water leaks.
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Flow Sensor Turbine
1. Isolate cold water supply.
2. Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48.
3. Unscrew the Water Drain Valve assembly (item 32) and Pressure Relief Valve (item
30) and drain the water heater.
4. Disconnect the cold water supply pipe from the cold water Inlet Connection.
5. Disconnect the Bypass Solenoid wiring loom plug.
6. Remove two retaining screws holding the Flow Sensor to the Water Body Assembly
and remove Flow Sensor.
7. Using a flat blade screwdriver lever the metal disc and o-ring from the Flow Sensor
housing on the Water Body Assembly. Lever the disc out by placing the shaft of the
screwdriver across the disc with the tip of the screwdriver on the far inside edge of the
disc.
8. Remove the four screws from the cold water Inlet Connector and withdraw the Inlet
Connector and o-ring from the base of the water heater.
9. Gently withdraw the Flow Sensor Turbine out through the water inlet of the water Body
Assembly using a pair of long nose pliers.
10. Reassemble in reverse order of above ensuring open slot on turbine is centred and
facing towards the face of the flow sensor.
Combustion Fan Motor
1. Remove the PCB Assembly. Refer to „PCB Assembly‟ procedure on page 48.
2. Remove the two screws retaining the Power Filter (item 9) to the Combustion Fan
Motor.
3. Remove the remaining three screws retaining the Fan Motor and lift Fan Motor clear.
4. Disconnect the multi-pin wiring plug from the Fan Motor.
5. Reassemble in reverse order of above.
Igniter
1. Remove the Upper Burner Assembly. Refer to „Upper Burner Assembly‟ procedure on
page 49.
2. Disconnect black high voltage lead from Igniter Electrode on the right hand side of the
Upper Burner Assembly.
3. Disconnect the multi pin connector from the Igniter.
4. Replace the Igniter.
5. Reassemble in reverse order of above. NOTE: Ensure wiring to Igniter Electrode and
Flame Sensors is not pinched during reassembly.
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Anti-Frost Heaters
1. Remove the PCB Assembly. Refer to „PCB Assembly‟ procedure on page 48.
2. Disconnect connector plugs at the Anti-Frost Thermostat and Power Cord
Heat Exchanger and Hot Water Outlet Connection Heaters
3. Remove the two screws from the hot water Outlet Flange to release the hot water
outlet Anti-Frost Heater.
4. Unclip the 2 Anti-Frost Heaters from the Heat Exchanger (Note the positions of both).
5. Remove the Anti-Frost Heaters and wiring (Some wiring retainers will need to be
released to remove wiring).
6. Reassemble in reverse of above ensuring anti-frost heaters are fitted in correct
positions.
Water Body Assembly Heater
2. Remove the Water Body Assembly (item 24 on exploded view). Refer to „Water Body
Assembly‟ procedure on page 50.
3. Remove the Anti-Frost Heater retaining clip.
4. Remove the Anti-Frost Heater and wiring (Some wiring retainers will need to be
released to remove wiring).
5. Reassemble in reverse order of above.
Heat Exchanger Removal
1. Remove the Upper Burner Assembly. Refer to „Upper Burner Assembly‟ procedure on
page 49.
2. Remove the two Flame Sensor leads (items 12 and 13) and Ignition Lead from the
rubber cable glands in the underside of the Heat Exchange Assembly.
3. Remove the two screws retaining the Power Filter (item 9) from the Fan Assembly and
reposition Power Filter clear of Fan Assembly.
4. Remove the screw from the Water Body Assembly Flange (item 26) and remove
Flange.
5. Carefully disengage the two pipes from the Water Body Assembly.
6. Remove the two screws from the hot water Outlet Flange retaining the hot water outlet
pipe and carefully disengage the pipe.
7. Disconnect the multi-pin wiring connector from the Heat Exchanger Thermistor.
8. Disconnect the anti-frost wiring loom connector at the Anti-Frost Thermostat (item 15)
and the hot water outlet Anti-Frost Heater (item 7). Remove Anti-Frost Heater from hot
the Outlet Connector.
9. Open the Over Heat Limiter to gain access to Heat Exchanger Assembly. Remove
wiring retainer that joins Anti-Frost Heater wiring to the Over Heat Limiter wiring.
10. Remove the four screws retaining the Heat Exchanger. One from each side of the Heat
Exchanger and two from the top of the water heater cabinet above the flue outlet.
11. Remove Heat Exchanger by gently lifting the assembly up and clear of the water heater
cabinet.
12. Disconnect the multi-pin wiring plug from the Fan Motor to completely free Heat
Exchanger Assembly from the water heater.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Heat Exchanger Replacement
1. Remove the Heat Exchanger. Refer „Heat Exchanger Removal‟ procedure on page 52.
2. Remove the Heat Exchanger Thermistor, Anti-Frost Heaters, Fan Assembly and Fan
Cowling from the old Heat Exchanger and refit to the replacement Heat Exchanger.
3. Check the Over Heat Limiter. Replace if damaged or open circuit.
4. Reassemble in reverse order of above.
5. Test for gas leaks using soapy water solution
6. Check for water leaks.
7. Check and if necessary adjust the MIN and MAX burner gas pressures. Refer to
„Burner Gas Pressure Check‟ procedure on page 46 and „Burner Gas Pressure
Adjustment‟ procedure on page 47.
Flow Sensor
1.
2.
3.
4.
Isolate cold water supply.
Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48.
Disconnect the Flow Sensor multi-pin wiring plug at the PCB.
Remove two screws retaining the Flow Sensor at the base of the Water Body
Assembly.
5. Remove the Flow Sensor (Note: water may escape during this procedure).
6. Reassemble in reverse order of above.
Bypass Solenoid
The Bypass Solenoid is only available as part of the Water Body Assembly. Refer to
„Water Body Assembly‟ procedure on page 50.
Thermistors
1.
2.
3.
4.
Isolate cold water supply.
Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48.
Relieve water pressure through a hot tap.
Locate the Thermistor requiring replacement. Note: The PCB will need to be removed
to gain access to the Hot Outlet Thermistor. Refer to PCB Assembly procedure on page
48.
5. Disconnect the relevant multi-pin plug from the PCB. Note: Some wiring retainers will
need to be released to allow wiring to be removed.
6. Remove the retaining screws and withdraw the Thermistor taking care not to damage
the o-ring (Note: with the exception of the Ambient Air Thermistor, water may escape
during this procedure).
7. Reassemble in reverse order of above.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Over Heat Limiter
Replacement of the Over Heat Limiter requires removal and possible replacement of the
Heat Exchanger.
1. Remove the Heat Exchanger. Refer „Heat Exchanger Removal‟ procedure on page 52.
2. Remove the two white wires from the terminal block on the right hand side of the Over
Heat Limiter.
3. Remove the two plastic rivets retaining the Over Heat Limiter to the back of the water
heater cabinet and remove the Over Heat Limiter.
4. Inspect the Heat Exchanger for holes or combustion damage. (Replace Heat
Exchanger if necessary)
5. Reassemble in reverse order of above (Note: Ensure all multi-pin plugs are
reconnected and all wiring is neatly repositioned and retained to prevent damage
during operation).
6. Test operation of water heater.
7. Check and if necessary adjust the MIN and MAX burner gas pressures. Refer to
„Burner Gas Pressure Check‟ procedure on page 46 and „Burner Gas Pressure
Adjustment‟ procedure on page 47.
Controller
1. Isolate power at the water heater.
2. Remove the small Phillips head screw from the bottom of the Controller.
3. Gently pivot the Controller up from the bottom and then lift up and off upper retaining
lugs.
4. Kitchen Controller: Disconnect the wiring from the terminals on the back of the
Controller (Note: The wiring is not polarity sensitive).
Bathroom Controllers: Disconnect the multi-pin plug.
5. Reassemble in reverse order of above.
Transformer
1. Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48.
2. Disconnect the Transformer secondary windings from the bottom right hand side of the
PCB (2 x red wires).
3. Disconnect the multi-pin plug to the Transformer.
4. Remove the four outside screws on the underside of the water heater retaining the
Transformer base to the water heater cabinet.
5. Lower the Transformer and base plate from the base of the water heater.
6. Remove two screws retaining Transformer to the transformer base plate.
7. Reassemble in reverse order of above.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Power Filter
1. Remove the PCB Assembly. Refer to „PCB Assembly‟ procedure on page 48.
2. Disconnect the incoming and outgoing Power Filter wiring loom plugs.
Note: Some wiring retainers will need to be released to allow wiring to be removed.
3. Remove the two screws retaining the Power Filter to the mounting bracket on the Fan
Assembly.
4. Remove the Power Filter. Note: An earth wire is connected to the power filter mounting
bracket. Ensure it is reconnected when the Power Filter is refitted.
5. Reassemble in reverse order of above.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Exploded View – Water Heater
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Replacement Parts List – Water Heater
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
Description
Heater Cabinet
Front Cover Assembly
Over Heat Limiter
Combustion Chamber Kit – Natural Gas
Combustion Chamber Kit – LPG
O-Ring P16 EPT
O-Ring P-12.7 EPT
Fan adapter
Fan Assy
Power Filter
PCB Assy to suit 874018NF
PCB Assy to suit 874018PF
PCB Assy to suit 874020NF
PCB Assy to suit 874020PF
PCB Assy to suit 876018NF
PCB Assy to suit 876018PF
PCB Assy to suit 876020NF
PCB Assy to suit 876020PF
Insulation Type Bracket
Pan Head 5 x 10
Electrode E
Silicon Tube
Electrode
Upper Burner Assy – Natural Gas
Upper Burner Assy – LPG
Burner Damper – Natural Gas
Burner Damper - LPG
Proportional Gas Flow Regulating Valve
Gasket
Gas Inlet Connector ¾”
PCB Assy Holder
By-pass Connecting Assy
Quick Fastener
Water Body Assy
Power Filter Bracket
Flange
PCB Holder
Hot Water Outlet Connector ¾”
Flange
Safety Valve Assy (Pressure Relief)
Water Inlet Connector
Water Drain Valve Assy
Gasket
Lower Burner Assy – Natural Gas
Lower Burner Assy – LPG
Igniter Mounting Bracket
Igniter Assy
Transformer Assy
Transformer Box Bottom Holder
Burner Front Panel Assy
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Part Number
N/A
31-86022-00
31-80280-00
31-86142-00
31-86141-00
WH0020034
WH0020035
N/A
31-61073-00
31-86104-00
31-86150-05
31-86150-06
31-86150-07
31-86150-08
31-86150-09
31-86150-10
31-86150-11
31-86150-12
WH0020002
09-11653-00
31-61465-00
31-53479-00
31-53439-00
31-66311-00
31-61111-00
31-80344-00
31-80359-00
31-86051-00
31-53256-00
31-86054-00
31-63097-00
31-86121-00
31-53347-00
31-86057-00
N/A
10-88332-00
31-63096-00
31-86062-00
10-88399-00
04-38888-00
10-65408-00
WH0020024
09-03478-00
31-86046-00
31-61103-00
N/A
09-74560-00
31-86102-00
31-86111-00
31-61065-00
57
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Exploded View - Wiring
11
8
9
14
3
10
5
6
4
13
12
16
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Replacement Parts List - Wiring
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description
Part Number
Power Supply Cord Assy
Heat Exchanger Thermistor
Outlet Hot Water Thermistor
Ambient Air Thermistor
Water Inlet Thermistor
Hall IC Assy C
Anti-Frost Heater B
Heater Holder B
Anti-Frost Heater A
Heater Holder
Heater Holder C
FR Connecting Cord Assy A
FR Connecting Cord Assy B
Fuse
Thermostat
120V Wire Assy
31-76652-00
09-76934-00
09-76932-00
31-63794-00
09-76931-00
31-50245-00
31-71643-00
WH0020051
31-71644-00
N/A
WH0020050
31-63738-00
31-63739-00
WH0020069
20-57072-00
31-86114-00
Note: For controller and controller cable part numbers refer to page 12.
Gas Conversion Procedure
The models covered in these service instructions are unsuitable for gas type conversion in
the field. Contact Rheem Service for further instruction if gas type conversion is required.
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Warranty
Electronic Instantaneous Gas Water Heater Warranty (Australia only)
Warranty conditions
1. This warranty is applicable only to water heaters manufactured from 1st January 2001.
2. The water heater must be installed in accordance with the Rheem water heater installation instructions,
supplied with the water heater, and in accordance with all relevant statutory and local requirements of the
State in which the water heater is to be installed.
3. Where a failed component or water heater is replaced under Warranty, the balance of the original
warranty period will remain effective. The replaced part or water heater does not carry a new warranty.
4. Where the water heater is installed outside the boundaries of a metropolitan area as defined by Rheem or
further than 25 km from a regional Rheem Service branch office, or an Accredited Service Agent, the cost
of transport, insurance and travelling costs between the nearest Rheem Service Accredited Service
Agent‟s premises and the installed site shall be the owner‟s responsibility.
5. The warranty only applies to the water heater and original or genuine company component replacement
parts and therefore does not cover any plumbing or electrical parts supplied by the installer and not an
integral part of the water heater, eg. pressure limiting valve; isolation valves, non-return valve, electrical
switches, pumps, or fuse.
6. The water heater must be sized to supply the hot water demand in accordance with the guidelines in
Rheem water heater literature
Warranty Exclusions
1. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE
RHEEM ELECTRONIC INSTANTANEOUS WATER HEATER WARRANTY ABOVE, BUT THE
FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO BECOME
VOID, AND MAY INCUR A SERVICE CHARGE AND COST OF PARTS.
a)
b)
c)
d)
e)
Accidental damage: Acts of God, failure due to misuse; incorrect installation; attempts to repair the water heater
other than by a Rheem Accredited Service Agent or the Rheem Service Department.
Where it is found there is nothing wrong with the water heater, where the complaint is related to excessive discharge
from the temperature and pressure relief valve due to high water pressure; where there is no flow of hot water due to
faulty plumbing; where water leaks are related to plumbing and not the water heater components; where there is a
failure of gas, electricity or water supplies; where the supply of gas, electricity or water does not comply with relevant
codes or acts.
Where the water heater or water heater component failed directly or indirectly as a result of: excessive water
pressure; excessive temperature and/or thermal input; corrosive atmosphere; ice formation in the pipework to or
from the water heater; ice formation in the water ways of a water heater without a frost protection system; ice
formation in the waterways of a water heater with a frost protection system where the electricity supply has been
switched off or has failed and the water heater has not been drained in accordance with the instructions; ice
formation in the waterways of a water heater with a frost protection system due to an ambient temperature below 20ºC (including wind chill factor)
Where the water heater is located in a position that does not comply with the Rheem water heater installation
instructions or relevant statutory requirements, causing the need for major dismantling or removal of cupboards,
doors or walls, or use of special equipment to bring the water heater to floor level, or to a serviceable position.
Repairs to the water heater due to scale formation in the waterways when the water heater has been connected to a
harmful water supply as outlined in the Owner‟s Guide and Installation Instruction booklet.
2. SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY
EXCLUDES ANY AND ALL CLAIMS FOR DAMAGE TO FURNITURE, WALLS,
FOUNDATIONS OR ANY OTHER CONSEQUENTIAL LOSS EITHER DIRECTLY OR
INDIRECTLY DUE TO LEAKAGE FROM THE WATER HEATER.
In addition to this warranty, the Trade Practices Act 1974 and similar laws in each state and territory provide the owner
under certain circumstances with certain minimum statutory rights in relation to your Rheem water heater. This warranty
must be read subject to that legislation and nothing in this warranty has the effect of excluding, restricting those rights.
NOTE: Every care has been taken to ensure accuracy in preparation of this publication. No liability can be accepted for
any consequences which may arise as a result of its application.
Rheem Australia Pty Ltd
ABN 21 098 823 511
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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Document Revision History
Title:
16-20L Continuous Flow Gas Water Heater Service
Instructions
Document Nº: TM040
REV
Details of change
A
Service instructions issued for 16-20L continuous flow gas water heater
TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions
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D.O.I.
06/09
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