Rheem 875 Series Specifications

SERVICE INSTRUCTIONS

18 & 20L Integrity

Electronic Gas Instantaneous Water Heater

TM002

R e v i i i s i i i o n : : : E

P u b l l l i i i s h e d : : : N o v e m b e r r r 0 7

871018

875018

871020

875020

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Contents

Safety Warning ....................................................................................................................3

Introduction ..........................................................................................................................3

Water Heater Model Identification........................................................................................3

Specifications.......................................................................................................................4

Preset Temperature Adjustment ..........................................................................................5

Wiring Diagram - Models with Mechanical Bypass ..............................................................6

Wiring Diagram - Models with Solenoid Operated Bypass...................................................7

Sequence of Operation ........................................................................................................8

Bypass Operation ................................................................................................................9

Anti-Frost Heater Circuit ....................................................................................................10

Product Changes ...............................................................................................................10

Software Changes..........................................................................................................10

In-series Gas Boosting.......................................................................................................11

Tempering Valves..............................................................................................................16

Remote Controllers............................................................................................................16

Standard Controller ........................................................................................................17

How to Fault Find...............................................................................................................19

Operational Flow Charts ....................................................................................................21

Error Codes .......................................................................................................................24

Diagnostic Test Points .......................................................................................................25

Maintenance Information ...................................................................................................26

Displaying Maintenance Information ..............................................................................27

Clearing Error Code History...............................................................................................27

Resetting Error Codes .......................................................................................................28

Fault Diagnosis Sequence (Fault Finding Chart G) ...........................................................29

Fault Finding Chart 1 .........................................................................................................30



Fault Finding Chart 3.1 ......................................................................................................36


Fault Finding Charts 3.3 and 3.5........................................................................................39




Fault Finding Charts 4 and 4.1...........................................................................................44



Burner Gas Pressure Check ..............................................................................................47

Component Replacement Procedures...............................................................................48

Exploded View 1 – 871018 & 871020 Models ...................................................................55

Exploded View 2 – 871018 & 871020 Models ...................................................................57

Exploded View 3 – 871/875018-B & 871/875020-B Models ..............................................59

Exploded View 4 – 871/875018-B & 871/875020-B Models ..............................................61

Gas Type Conversion Procedure.......................................................................................63

Warranty ............................................................................................................................64

Document Revision History................................................................................................65

TM002 Integrity 18 & 20L Service Instructions REV: E

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2


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

Rheem Instantaneous 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.

Certain diagnostic procedures outlined in these Service Instructions require “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.

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.

Introduction

The information provided in these instructions is based on the water heater being installed in accordance with the Installation Instructions provided with each water heater.

Should you require further technical advice on a Rheem Integrity Water Heater, contact your nearest Rheem Service Department where genuine replacement parts are also available.

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.

8 7 1 018 N F -B

Model Number

8 - Rheem

2 - *Everhot

Location

7 - External

Ignition Type

1 - Electronic 60ºC Max temp

5 - Electronic 48ºC Max temp

Capacity

Nominal litres/minute @ 25 ºC rise

Gas Type

N - Natural

P - Propane

F - Frost protection fitted

Version

Internal Use Only


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Specifications

Model

871018N0

871018NF

875018NF

871018NF-B

875018NF-B

871018PF

875018PF

871018PF-B

875018PF-B

871020N0

871020NF

875020NF

871020NF-B

875020NF-B

Specification Gas Type

Max hourly gas consumption (MJ/Hr)

Min hourly gas consumption (MJ/Hr)

Min inlet water pressure (kPa)

Max inlet water pressure (kPa)

Min inlet gas pressure (kPa)

Max inlet gas pressure (kPa)

Max burner gas test pressure (kPa)

Min burner gas test pressure (kPa)

Ignition System

Power (Watts)

Consumption

Gas connection diameter (mm)

Water connection diameter (mm)

Relief Valve Pressure (kPa)

Kitchen Controller

Bathroom 1 Controller

Natural

157

24

140

1000

1.13

3.5

0.903

0.182

Propane

157

24

140

1000

2.75

Natural

157

24

140

1000

1.13

3.5

1.50

3.5

0.903

0.32 0.182

Continuous Spark

R¾/20

R½/15

1750

Y

Y

R¾/20

R½/15

1750

Y

Y

Bathroom 2 Controller

Deluxe Kitchen Controller

Deluxe Bathroom 1 Controller

Y

N

N

Y

N

N

Deluxe Bathroom 2 Controller N N

* Maximum power consumption when anti-frost heaters are energised.

N

Y

N

N

R¾/20

R½/15

1750

Y

Y

871020PF

875020PF

871020PF-B

875020PF-B

Propane

157

24

140

1000

2.75

3.5

1.50

0.32

R¾/20

R½/15

1750

Y

Y

Y

N

N

N


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Preset Temperature Adjustment

It is possible to choose a preset outlet water temperature setting when remote controllers are not fitted. The water heater comes factory set at 50ºC on 871 series models or 48ºC on 875 series models.

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 I.C. Board. The current preset temperature is displayed on the LED.

3. Press the MIN or MAX button, located under the DIP Switches, until the desired temperature is displayed. Available temperatures are:

871 series models: 40ºC, 43ºC, 50ºC, 55ºC and 60ºC

875 series models: 40ºC, 43ºC and 48ºC

4. Turn DIP SWITCHES 3 and 4 off (down position). The temperature display is now turned off.

5. Refit the front cover to the water heater.


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Wiring Diagram - Models with Mechanical Bypass


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Wiring Diagram - Models with Solenoid Operated Bypass


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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 (19). Note: For 871020 model heaters fitted with a comparator the inlet water temperature must be less than or equal to 57ºC and for 871020-B models 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 11).

2. The Water Flow Sensor (3) sends a pulse signal to the PCB (27). Once the pulse signal reaches a pre designated frequency (at minimum flow rate) the PCB (27) activates the Fan Motor (25) and the Fan (24) starts rotating.

3. After the Fan (24) 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 (13) adjusts the gas flow rate to ensure adequate gas for ignition and gas is then supplied to the Burner (15).

4. At the same time the Gas Solenoid Valves open the Igniter (16) starts sparking continuously and ignites the gas at the Burner (15). After the flame sensor (18) detects burner flame, the Proportional Gas Valve (13) 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 remote controller (if fitted) the PCB (27) adjusts the hot water temperature by opening and closing the Gas Solenoid Valves 1 (10), 2 (11) and 3 (12) and adjusting the

Proportional Gas Flow Regulating Valve (13). The water flow rate is also adjusted via the Water Flow Servo Motor (7) to ensure the selected temperature of hot water is delivered.

5. As the gas flow rate, controlled by the Proportional Gas Flow Regulating Valve (13) changes the PCB (27) varies the speed of the Fan Motor (25) 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), 3

(12) 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 (25) is cut and the Fan (24) stops.


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Sequence of Operation Component Diagram

3 Water Flow Sensor

4 Inlet Water Temperature Thermistor

5 Combustion Chamber Thermistor

6 Outlet Water Temperature Thermistor

7 Water Flow Servo Motor

8 Water Filter (Strainer)

9 Gas Inlet Solenoid Valve

10 Gas Solenoid Valve 1

11 Gas Solenoid Valve 2

12

Gas Solenoid Valve 3 (not fitted on 18 &

20L models)

14 Nozzle

15 Burner

16 Igniter

20 Over Temperature Limiter

23

Anti Frost Heater (Models with F in model number only e.g. 871020NF)

24 Fan

26 Drain Plug With Relief Valve.

27 PCB

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 valve fitted to the water body assembly controls the bypass. Two types of bypass valve are utilised in 18 and 20 litre Integrity’s.

Mechanical Bypass

Some models without a -B suffix in the model number utilise a mechanical bypass e.g.

871020NF and some models without a -B suffix utilise a solenoid operated bypass. To determine what kind of bypass is utilised in models without a -B suffix compare the

appliance to the wiring diagrams on pages 6 & 7.

The mechanical bypass is a small spring loaded valve located in the water body assembly.

The spring is temperature sensitive, as the cold water temperature decreases the spring tension increases reducing the amount of cold water flowing through the bypass. The bypass operates at all times when water is flowing.

Solenoid Operated Bypass

Models with a -B suffix in the model number utilise a solenoid operated bypass e.g.

871020NF-B. Some models without a -B suffix also utilise a solenoid operated bypass e.g.

871020NF. To determine what kind of bypass is utilised for models without a -B suffix

compare the appliance to the wiring diagrams on pages 6 & 7.


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The solenoid operated bypass comprises a valve (located in the water body assembly) that is controlled by a solenoid (mounted on the water body assembly). The PCB activates the solenoid at the following predetermined temperatures:

Without Touch Pads: When the unit is preset at 40 or 43 degrees.

With Touch Pads: When temperatures from 37 to 46 degrees are selected.

At all other times the bypass does not operate.

Anti-Frost Heater Circuit

Models with an ‘F’ in the model number have an anti frost heater circuit e.g. 871020NF-B.

The anti-frost heaters are wired in series and operate independently from the water heater.

18 and 20 litre models have a 58-watt anti-frost system.

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 total heater circuit measures 993.2 ohms.

The circuit is split into two sections with 4 heaters in total. To determine which section has failed, isolate the power to the water heater and unplug the wiring connectors at the thermostat, cord set and the water body assembly heater block. The heat exchanger and hot water outlet heater’s resistance (3 heater blocks) is 719.2 ohms. The resistance of the water body assembly heater is 274 ohms. Refer to Procedure 10 on page 51 for replacement procedure.

Product Changes

Software Changes

Models manufactured after July 2006 have a change to the software which controls the operation of the heater. When an inlet water temperature of more than 58ºC and more than the set point temperature minus 2ºC is detected by the inlet water temperature thermistor, the fan and burner will not operate.

This function has been introduced to enhance the operation of the water heater and remove the need for a Solar Bypass Valve when the Integrity 20 is connected as an inseries gas booster to a solar water heating system (for more information refer to ‘In-series

Gas Boosting’ on page 11). Note: 875 series models and 18 Litre Integrity’s are not

suitable for use as in-series gas boosters.

Models with the revised software have a -B suffix added to the model number i.e.

871020NF-B.


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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.

If a solar pre-heater has been installed to an existing Integrity water heater installation then a solar bypass valve or a comparator must be fitted at this water heater and any controllers, if fitted, must be disconnected and removed.

Note: models ending with -B do not require a solar bypass valve or a comparator.

875 series models and 18 Litre Integrity’s are not suitable for use as inseries gas boosters.

871020-B Models

Where an 871020-B model Integrity is installed to provide in-series gas boosting a solar bypass valve or a comparator is not required. 871020-B models have had a change made to the operating software which eliminates the need for either of these components.

The software now electronically mimics a bypass valve so that when the inlet water temperature is above 58°C 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

58°C the burner will fire and boost the outlet temperature to 60°C provided the flow rate is greater than 3 litres per minute. 20L models with modified software can be identified by a

B suffix in the model number i.e. 871020NF-B.

The preset outlet temperature of the Integrity, when installed as an in-series gas booster to a solar water heater, must be set at 60 °C for the system to operate correctly.

The factory preset outlet temperature of all Integrity models is 50 °C; during a new installation it will be necessary to reset the outlet temperature to 60

°C. Refer to page 5 for

details on checking and adjusting the outlet temperature.

Note: If an 871020 model heater is replaced with an 871020-B model heater and the existing 871020 heater is used as an in-line booster and has a solar bypass valve fitted, the solar bypass valve must be removed and the plumbing connections remade directly to

the Integrity inlet and outlet water connections (refer to diagrams on pages 11 & 12).

In-series Gas Boosting 871020-B Solar Loline Installation

Note: This plumbing diagram is also applicable to 871020 model heaters fitted with a comparator.

For more information on comparators refer to page

13.


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In-series Gas Boosting 871020-B Solar Hiline Installation

Note: This plumbing diagram is also applicable to 871020 model heaters fitted with a comparator.

For more information on

comparators refer to page 13.

871020 Models

Where an 871020 model Integrity is installed to provide in-series gas boosting a solar bypass valve is fitted across the Integrity inlet and outlet water connections to prevent the water heater from operating when the outlet water temperature from the solar system is

above 57°C (refer to diagrams on page 13). A disconnection union must always be

provided at the solar preheated water inlet and hot water outlet on the solar bypass valve to allow for removal of the valve.

The solar bypass valve has been specifically designed to work with Rheem Integrity

871020 models heaters. Models ending with -B do not require a bypass valve. 875 series model water heaters and 18 Litre Integrity’s are not suitable for use as in-series boosters.

The preset outlet temperature of the Integrity, when installed as an in-series gas booster to a solar water heater, must be set at 60 °C for the system to operate correctly.

The factory preset outlet temperature of all Integrity models is 50 °C; during a new installation it will be necessary to reset the outlet temperature to 60

°C. Refer to page 5 for

details on checking and adjusting the outlet temperature.

There are two types of solar bypass valves currently in use (Paloma & RMC) and whilst both operate in the same manner the plumbing arrangement at the valve differs according

to the type of solar bypass valve used (refer to diagrams on page 13). Solar bypass valves

are no longer available and if faulty are to be removed and a Comparator installed. Refer

to pages 13 & 14 for information on comparators.


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Paloma Solar Bypass Valve RMC Solar Bypass Valve

Inlet water from solar water heater

Hot water outlet

Note: If an 871020 model heater is replaced with an 871020-B model heater and the existing 871020 heater is used as an in-line booster and has a solar bypass valve fitted, the solar bypass valve must be removed and the plumbing connections remade directly to

the Integrity inlet and outlet water connections (refer to diagrams on pages 11 & 12).

Solar Bypass Valve Operation

When the water temperature entering the solar bypass valve is above 57°C a temperature sensitive mechanism moves the valve spindle preventing water from entering the Integrity and allowing the water to flow through the solar bypass valve to the hot water outlet.

If the water temperature from the solar storage tank entering the solar bypass valve is below 57°C the temperature sensitive mechanism retracts the valve allowing water to enter the Integrity and preventing flow through the solar bypass valve. The Integrity will boost the water temperature to 60°C at the hot water outlet provided the flow rate is greater than 3 litres per minute.

Replacement of Solar Bypass Valve with a Comparator

An electronic device called a Comparator (part number 052127) is now available to replace the solar bypass valve and is suitable for use on Rheem 871020 models heaters. NOTE: 20L models with a

-B suffix in the model number do not require either a solar bypass valve or a comparator.

Solar bypass valves are no longer available and if faulty are to be

removed and a Comparator installed. Refer to page 14 for the

procedure on installing a comparator.

The purpose of the comparator is to interrupt the operation of the burner when the inlet water temperature rises above 57°C.

The comparator is connected to the water flow sensor wiring and the inlet temperature sensor (cold sensor) wiring; both these components are mounted on the water body within the gas booster. The comparator monitors the inlet water temperature and when the temperature rises above 57°C the comparator interrupts the signal from the flow sensor to the PCB causing the burner to shut down.


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Removing a Solar Bypass Valve and Installing a Comparator

1. Ensure power and water to the water heater is isolated.

2. Remove the front cover (refer to component procedure 1 on

page 48).

3. Locate the 2 pin wiring plug in the wiring loom to the cold sensor mounted on the water body (refer to fig 1) and disconnect.

2 pin cold sensor wiring plug disconnected

Cold sensor

Fig 1

4. Plug the 2 pin male and female connectors from the comparator into the plugs attached to the cold sensor and the main wiring loom (refer to fig 2). NOTE: If the comparator connectors do not fit the cold sensor and main wiring loom plugs the model is an 871020-B model which does not require a comparator.

Comparator connected to cold sensor wiring

Fig 2

5. Locate the 3 pin wiring plug in the wiring loom to the flow sensor (refer to fig 3) and disconnect

3 pin flow sensor wiring plug disconnected

Fig 3

6. Plug the 3 pin male and female connectors from the comparator into the plugs attached to the flow sensor and the main wiring loom (refer to fig 4).

Comparator connected to flow sensor wiring

Fig 4

7. Position and secure the comparator in a safe position using the existing wiring ties securing the wiring loom (refer to fig

5).

Comparator and wiring secured in place

Fig 5

8. Refit the front cover.

9. Remove the bypass valve and associated fittings and connect the inlet and outlet pipe work directly to the gas booster. NOTE: This may require the pipe work to be extended; unions must be used at the inlet and outlet to enable removal of the gas

booster for serving if required (refer to diagrams on pages 11 & 12).

10. Restore water and power supplies.


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In-series Gas Boosting 871020 Solar Loline Installation

Note: For 871020 model heaters fitted with a comparator refer to diagram on page 11. For

more information on comparators refer to page 13.

In-series Gas Boosting 871020 Solar Hiline Installation

Note: For 871020 model heaters fitted with a comparator refer to diagram on page 11. For

more information on comparators refer to page 13.


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Tempering Valves

875 series models comply with AS/NZS 3498 and therefore do not require a tempering valve.

On 871 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 o C however the delivered water temperature at the tap will be that set by the tempering valve which will be no hotter than 50 o C.

To enable delivery of hot water at temperatures above 50 o C a separate untempered line must be provided that supplies hot water exclusively to kitchen and laundry areas (refer to diagram below).

Remote Controllers

Integrity 18 and 20 Litre electronic instantaneous gas water heaters can be fitted with optional remote controllers.

There are 2 types of controller available, standard or deluxe; however only standard controllers can be used with an 18 or 20 litre Integrity.

Controller Type Bathroom 1 Bathroom 2 Kitchen

Standard 299854 299855 299853

Standard and deluxe controllers cannot be mixed in a single installation; an individual water heater must have ALL standard type controllers fitted, other manufacturers’ controllers cannot be used.

One, two or three 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 o C when connected to an 871 series model or 48 o C when connected to an 875 series model.


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875 series models are factory set and limited so that they cannot deliver water hotter than

48 o C.

When no hot water is flowing, temperatures can be selected between 37 o C and 43 o C by pressing and holding the temperature control buttons, to select temperatures above 43 o 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 o C to 43 o 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

Controller display panel

(water temp or water volume)

Water volume button

Water temperature adjustment buttons

Controller

ON / OFF button

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 o C*

Bathroom Controllers:

37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50 o C*

* Temperatures above 48 degrees are not available on controllers fitted to 875 series models as these units have a maximum selectable temperature of 48 o C at all locations.


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ON / OFF button

Priority light

In use light

Display panel

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.

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.

This light will glow on all controllers, whether they are on or off, when hot water is flowing, regardless of which controller has priority.

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. i (up button) The up button increases the temperature setting. j (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.

• 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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How to Fault Find

When conducting fault finding techniques it is important to understand that the same error code with a different sequence number can be displayed at different points during the operational sequence of the water heater. It is important to determine where the fault occurred in relationship to the operational sequence of the water heater before commencing fault finding tests, as the tests may differ even though the same error code can be displayed.

If a fault occurs the LED display will alternate between the error code for the fault and a sequence number that indicates where in the operational sequence of the water heater the fault occurred. The operational flow charts are broken into 5 sections designated by boxed

numbers. The table on page 20 converts the sequence number displayed on the LED to

the appropriate operational flow chart section.

The flow diagram below outlines the recommended procedure to successfully diagnose, test and rectify faults on the Integrity range of water heaters.

1

Identify sequence number and error code displayed on LED.

2

Convert the sequence number to an operational flow chart section number using the sequence number table

3

Locate the operational flow chart section identified in step 2

4

Locate the error code within the operational flow chart section identified in step 2 and take note of where the fault occurred during the operational sequence.

5

Using the fault diagnosis flow chart locate the correct fault finding flow chart to use.

6

Follow the fault finding flow chart identified in step 5 until the error code displayed on the

LED is located.

7

Conduct the necessary tests outlined to identify and rectify the fault.

8

Additional information on components, performance and past history can be gained from the maintenance information stored in the PCB.


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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.

When a fault occurs, an error code and sequence number will alternate in the LED display.

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 (displayed on the water heater or remote controller) 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 on the Operational Flow Charts

P.G.F.R Valve Proportional Gas Flow Regulating Valve F.F

G.I.S.V.

Gas Inlet solenoid Valve

I.C

O.H.L

C.I

Over Heat Limiter

Combustion Indicator

S.V. 1

S.V. 2

Flame Failure

Integrated Circuit

Solenoid Valve 1

Solenoid Valve 2

Model

18/20L

Stepping gas rate change sequence by solenoid

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

18/20L

Burner 1

Right Solenoid (S.V. 1)

Burner 2

Left Solenoid (S.V. 2)

Sequence Number

Sequence Number Table

- 0 to -9

A0 - A9

P0 - P9

C0 - C9 E0 - E9

H0 - H9

J0 - J9

L0 - L9

U0 - U9

Operational Flow Chart Section 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

WH0020080

WH0020081

Fine probe adapter kit

Heat exchanger fin brush

Probe to alligator clip kit

WH0020082

WH0020083

WH0020084


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20


Operational Flow Charts

1

Plug In

Power On

Y

Initial check normal?

YES

Remote controller switched on

NO

On/Off lamp On

Remote controller display on

Hot water tap open

3

Water flow sensor on?

NO

Operation Flow Chart 1

Error code cleared Isolate Power

Functional problem on gas type circuit board

82 Flashing

Fan motor current detection failure

79 Flashing

Communication problem between remote controller and the heater

76 Flashing

G.I.S.V control failure

71 Flashing

Over heat limiter failure

14 Flashing

2

On/Off lamp Off

Remote controller display off

Remote controller switched off

Fan Off

10 seconds later

Fan On 5

YES

Input temp

> 60ºC or > set temp?

NO

Water Flow Sensor off

NO

Hot water tap closed

1

YES

871018-B / 875018-B

871020-B / 875020-B

871018 / 875018

871020 / 875020

Input temp

< or = 58ºC &

< or = set temp

- 2ºC?

YES

2

4

5

6

7

8

4

Max & Min buttons off?

NO

20 seconds later

YES

Fan On

Inlet thermistor ok?

YES

Heat exchanger thermistor ok?

YES

Outlet thermistor ok?

YES

NO

NO

NO

Ambient air thermistor ok?

YES

Fan speed normal?

YES

NO

5 seconds later

24 Flashing

31 Flashing

32 Flashing

33 Flashing

34 Flashing

61 Flashing

Fan On

9

False flame detected?

Leakage > than 0.1uA

NO

10 P.G.F.R Valve on

YES

5 seconds later

F

72 Flashing

F1

Note: see page 20 for details on interpreting chart abbreviations.


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21


Operational Flow Chart 2

F F1

11

12

G.I.S.V (SVO) on

Igniter on

P.G.F.R Valve off

13

14

S.V.1 (SV1) on

S.V. 2 (SV2) on

0.1 seconds later

10 P.G.F.R Valve on

Igniter off

S.V. 2 (SV2) off

S.V. 1 (SV1) off

G.I.S.V (SVO) off

P.G.F.R Valve off

3

NO

16

Leakage > than 0.1uA

Flame

Detected?

YES

3 seconds later

NO

[on] displayed

C.I. on

Igniter off

Proportional temperature adjustment

Hot water volume adjustment

Gas rate change-over done by solenoid valves

871018-B / 875018-B

871020-B / 875020-B

& *solenoid bypass models

*Mechanical bypass models

Low rate combustion?

First ignition trial?

NO

11 Flashing

Igniter off

YES

Set temp. 46 degrees or lower?

NO

19 YES

Solenoid bypass valve on

*For models without a -B suffix e.g. 871020NF compare appliance to wiring diagram to determine whether it has a mechanical or solenoid operated bypass

Solenoid bypass valve off

G.I.S.V (SVO) off

S.V. 1 (SV1) off

S.V. 2 (SV2) off

P.G.F.R Valve off

C.I. Off

16 Flashing 71 Flashing 76 Flashing 61 Flashing 81 Flashing 65 Flashing 52 Flashing 99 Flashing

Outlet water temperature too high

G.I.S.V control failure

Communication problem between remote controller and water heater

Abnormal fan speed

Post purge failure

Malfunction of water volume control motor

P.G.F.R control failure

Abnormal combustion

YES

10 Flashing NO 79 Flashing 14 Flashing 15 Flashing 31 Flashing 32 Flashing 33 Flashing 34 Flashing 35 Flashing 11 Flashing 12 Flashing 56 Flashing

Safety device working?

Fan motor current detection failure

O.H.L failure

Outlet water temp exceeded

97 degrees for more than 15 seconds

Water inlet thermistor disconnected

Heat exchanger thermistor disconnected

Outlet thermistor disconnected

Ambient air thermistor disconnected

Thermistor connections crossed

Cross light failure

Flame Failure

Z

YES


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22


Malfunction of water by-pass solenoid valve.

Operation Flow Chart 3

Post Purge Shut Down Function Hot tap closed

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

4

P.G.F.R Valve at minimum

Fan motor at minimum

LED off

Fan motor at minimum

C.I. Off

YES

Flame current detected less than

8 seconds later

0.1uA?

YES

G.I.S.V (SVO) off or

[S.V. 1-2 (SV1-2) off]

P.G.F.R Valve off

YES

Fan motor speed checked during operation?

YES

5

NO

Fan motor current check ok?

NO

NO

Abnormal combustion

YES

Fan off

Approx. 6 minutes later

99 Flashing

Fan off

S.V. 1-2 (SV1-2) failure

80 Flashing

10 seconds later

Isolate power

G.I.S.V (SV0) failure

51 Flashing

S.V. 1 (SV1) off

S.V. 2 (SV2) off

G.I.S.V (SV0) off

P.G.F.R valve off

Fan off

Isolate power

Locate and repair fault and restore power

10 seconds later

Locate and repair fault

Use procedure to clear error code 99



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23


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

Fault Condition Items To Check

10

11

12

14

15

Abnormal low rate combustion

Ignition failure at start up

Cross light failure

Flame failure during operation

Over heating

Very high temperature

Blockage in the heat exchanger, fan, air intake or flue

P.G.F.R Valve - diagnostic point 10

G.I.S Valve - diagnostic point 11

Igniter - diagnostic point 12

Solenoid valves 1 & 2 - diagnostic points 13 & 14

Flame sensors 1 & 2 - diagnostic point 16



Solenoid valves 1 & 2 - diagnostic points 13 & 14


Over Heat Limiter - diagnostic point 2

Heat exchanger thermistor - diagnostic point 6

Hot water outlet thermistor - diagnostic point 7



MAX or MIN button on IC board

Water inlet thermistor - diagnostic point 5

16 Outlet water temp too high

24 Operational switch faulty

31 Inlet thermistor open circuit

32

Heat exchanger thermistor open circuit

Heat exchanger thermistor - diagnostic point 6

33 Outlet thermistor open circuit Hot water thermistor - diagnostic point 7

34 Ambient air thermistor open circuit Ambient air thermistor - diagnostic point 8

35 Thermistor connections crossed

51 Gas cut off malfunction

Connection points of thermistors


Flame sensor 1 & 2 - diagnostic point 16

P.G.F.R Valve – diagnostic point 10

52 P.G.F.R control failure Gas type circuit board

IC Board

56 Bypass solenoid failure Water Bypass solenoid – diagnostic point 19

61 Abnormal fan speed

65

Malfunction of water volume control motor

Fan motor – diagnostic point 4

Water volume control motor - diagnostic points 18 & 19

71 G.I.S valve control failure

72 Detected false flame

76

Communication problem between controller and water heater

Gas. Inlet Solenoid Valve IC Board (PCB) - diagnostic point 11


Remote controller IC Board or cable

79 Fan motor current detection failure Fan motor IC Board – diagnostic point 4

80

81

82

Gas cut off defective

Post purge malfunction (Solenoid valve 1 failure)

Functional problem on gas type circuit board

Solenoid valve 1 & 2 - diagnostic points 13 & 14


Solenoid valve 1 & 2 - diagnostic points 13 & 14


Gas type circuit board

Blockage in the heat exchanger, fan, air intake or flue way

Note: see page 20 for interpretation of abbreviations.


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24


Diagnostic Test Points

Refer to wiring diagram, page 7, for connector and wiring positions.

Test

Measuring Point

Point Connector

Wire Nº

& colour

Normal Condition Items Under Test

1

2

A

B

R1 – R2

W8 – W12

AC 85V – 120V Main Power

50 kilo-ohms – 500 kilo-ohms Overheat Limiter

DC 2V– 5V(Pulse) *1

More than 1310 pulse/min

Water Flow Sensor pulse signal

Water Flow Sensor R11 – BL10 DC 7V – 15V

B4 – W6 DC 120V – 170V

DC 11V – 19V

DC 4V – 10V(Pulse) *1

Y1 – B4

More than 4800 pulse/min

@ 20ºC – 10.3 kilo-ohms

5 B Y6 – BL7



6

12

B

L

W5 – BL7

R2 – R8



7

11

B

L

R4 – BL7

Y9 – BL10



8

10

B

B

B3 – BL7

R1 – BL2


9 J

AC 2V – 20V *2

AC 2V – 20V *2

DC 1.5V – 8.0V

42 ohms – 97 ohms

DC 70V – 110V

0.8 kilo-ohms – 2.2 kilo-ohms

AC 85V – 120V

Fan Motor

Fan Motor is pulse signal

Water Inlet Thermistor

Heat Exchanger Thermistor

Hot Water Outlet Thermistor

Ambient Air Thermistor

Flame Sensor detecting flame

Proportional Gas Flow Regulating

Gas Inlet Solenoid Valve

Igniter

13

14

L

L

R3 – BL10

W4 – BL10

W2 – BL8

GR6 – BL8

DC 70V – 110V


DC 70V – 110V


AC 2V – 20V *2

AC 2V – 20V *2

DC 8V – 16V

DC 8V – 16V

Less than DC 1V (Limiter off)

DC 4V – 6V (Limiter on)

Solenoid Valve 1

Solenoid Valve 2

Flame Sensor not detecting flame.

Water Volume Control Motor position switch

19 L O6 – O12

DC 70 – 110V


Water Bypass Solenoid (models with -B suffix in model number only e.g. 871020NF-B)

NOTES:

*1: Approximate reading measured by digital multimeter on DC range.

*2:

Approximate reading measured by digital multimeter on AC range.


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25


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)

0 1 2 3 4 5 6 7 8 9

E Null Error Code for the previous 8 faults Null

F Null Sequence number of the previous 8 faults Null

C

D

Total combustion starts X 10,000

Total combustion starts X 100

H

Total combustion period X 1000 hrs

J

Total combustion period X 10 hrs

Total combustion operations since last error X 10,000 hours

Total combustion operations since last error X 100 hours

Total combustion period since last error X 1,000 hours

Total combustion period since last error X 10 hours

Null

Null

Null

Null

Y Null

A Null Null Null Null

Flame Sensor Status

Model

R0y Information 00 01

18 & 20L

02

Flame Sensor 1

Flame Sensor 2

X

X

O

X

X

O

X

= Flame sensor is not detecting flame. O = Flame sensor is detecting flame

03

O

O


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26


Displaying Maintenance Information

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.

At the Water Heater

1. Remove the front panel from the water heater.

2. Using an insulated tool, turn DIP SWITCH 1 on (refer to figure 1).

3. Use the MIN button to change the left digit (0→1etc.) in the LED display to the required maintenance code identified from the

maintenance table on page 26.

4. Use the MAX button to change the right digit (E→F etc.) in the LED display to the required maintenance code identified from the

maintenance table on page 26.

5. The maintenance code and the value of that code will alternate on the LED display.

6. Turn DIP SWITCH 1 off (down position) when diagnosis is complete.

7. Refit the front panel to the water heater.

Fig 1

NOTE:

Turning on DIP SWITCH 2 will lock the display if required.

From a Remote Controller

1. Ensure the Remote Controller is turned off.

2. Press the temperature increase and decrease buttons simultaneously for 3 seconds

3. Use Temperature decrease button to change the left digit (0→1etc.) in the LED display

to the required maintenance code identified from the maintenance table on page 26.

4. Use the Temperature increase button to change the right digit (E→F etc.) in the LED display to the required maintenance code identified from the maintenance table on

page 26.

5. The maintenance code and the value of that code will alternate on the LED display of the Remote Controller.

6. Press the on/off button twice on the Remote Controller to cancel maintenance information.

Clearing Error Code History

After successfully 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. Ensure all controllers (if fitted) are turned off and all hot taps are closed.

2. Remove the front panel of the water heater.

3. Turn DIP SWITCH 1 on (up position) and then off (down position) again.

4. Within 5 seconds of turning DIP SWITCH 1 off, press and hold either the MIN or MAX button for more than 2 seconds. “CL” will flash in the LED display indicating the history is cleared.

5. Refit the water heater front panel.


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27


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.

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 reset Error Code 99 it is necessary to:

1. Ensure water is not flowing through the water heater.

2. Turn off remote controllers (if fitted).

3. Ensure all DIP SWITCHES are in the off position (down position).

4. Turn DIP SWITCH 2 on (up position) and then off (down position).

5. Within 5 seconds of turning DIP SWITCH 2 off, press and hold both the MIN and MAX buttons for more than 2 seconds.

6. “UL” will flash in the LED display and then become steady.

7. Turn on a controller (if fitted) then open and close a hot water tap to complete the procedure.


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28


Fault Diagnosis Sequence (Fault Finding Chart G)

General Fault Finding Chart

G

Turn on power to the water heater

NOTE: The bars are displayed for approx. 10 seconds

Are 2 bars displayed on the NO

LED?

YES

YES

Turn on the controller using the ON/

OFF button

Does the LED in the

ON/OFF button glow?

Are controllers fitted?

YES

NO

Is an error code being displayed?

YES

NO

Open a hot tap

Does the fan commence operation?

No error code is displayed for this fault

NO

YES


YES

NO

1

2

4

NO

Did the burner light?

NO

NO


Ignition retry

YES

Close the hot tap

YES

3

Is error code 51 or 80 displayed?

YES

3.5

NO

End

If the water heater operated normally, follow flow charts 2,

3 or 5 depending on the previous error codes displayed in the maintenance history accessed from the PCB


D.O.I: 7/11/2007

29


Fault Finding Chart 1


Power Supply

1

Is 240 volts AC Present at the power point?

YES

Is

240 volts

AC Present at the

Test 1 transformers primary winding?

YES

Is

The transformers

Test 2 output voltage 90 - 110 volts AC?

NO

NO

NO

No power supply. Check household wiring.

Cordset open circuit? - replace.

Inline fuses open circuit – replace.

Internal wiring from terminal block or transformer open circuit – repair.

Transformer failed – replace.

Is

90 - 110 volts AC

Present at the

PCB?

Test 3

YES

Turn DIP switch 1 on.

Test 4

NO Power filter open circuit – replace.

Error code

Displayed?

YES

Remote controller failed – replace.

Remote controller cable open circuit – replace.

NO PCB failed – replace.


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30


Fault Finding Tests 1 – 4

Components will be “Live” when conducting tests, exercise caution.

Test 1 Test 2

Measure the voltage at the connector plug to Measure the voltage at the connector plug the transformer primary winding with a from the transformer secondary winding with multimeter set on the AC voltage scale. If the voltage is between 230V and 250V the cord set and inline fuses are ok.

a multimeter set on the AC voltage scale. If the voltage is between 90V and 110V the transformer is ok.

Test 3 Test 4

Measure the voltage at connector A between

R1 and R2 on the PCB with a multimeter set on the AC voltage scale. If the voltage is between 90V and 110V the power filter is ok.

Using an insulated tool, turn DIP switch 1 on


D.O.I: 7/11/2007

31



2

System Not Ready

Is error code 14 displayed?

Overheating

YES

NO


Solenoid valve malfunction

NO


Communication failure

Is the resistance of the over temp limiter normal?

YES

Test 5

Is the remote controller cable open circuit?

NO


NO

Fan detecting circuit failure

YES


Gas type connector malfunction

NO

YES

Replace over temperature limiter and check for damage in the combustion chamber. Check and reset minimum and maximum burner pressures if required.

Replace the PCB assembly.

NO

*Remove the K connector from the fan motor and restore power

Test 6

Is error code 79 redisplayed?

YES

Replace the remote controller cable.

Check power point is properly earthed. Check cord set earth wire for continuity.

* WARNING

Disconnect power prior to removing or inserting connector plugs

NO

*Refit K connector and restore power.


YES Replace the fan motor.

YES

Remove and reinsert the gas type connector.

NO

Error code due to supply voltage drop.

YES



NO

Gas type connector was originally not inserted correctly.

YES

Faulty gas type connector - replace.


D.O.I: 7/11/2007

32



Isolate power before removing connector plugs

Test 5 Test 6

Unplug connector B from the PCB and measure

Assembly. Resistance should be between 50kiloohms and 500 kilo-ohms. within 30 seconds.

Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution

Test 7

Use an insulated tool when operating the DIP switch or MIN and MAX buttons

Test 8 – Diagnostic points 5, 6, 7 & 8

Error code

31

32

33

Maintenance

Display

Code

3y: Water

Inlet

Thermistor

4y:

Combustion

Chamber

Thermistor

5y: Hot

Water Outlet

Thermistor

Diag

Point

5

6

7

Test Point

Measured

Value

6 Yellow

7 Black

5 White

7 Black

4 Red

7 Black

20ºC –

10.3 kiloohms

40ºC –

4.9 kiloohms

34

2y: Ambient

Air

Thermistor

8

3 Blue

7 Black

25ºC –

5.0 kiloohms

5ºC –

12.7 kiloohms


D.O.I: 7/11/2007

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3

Ignition and Temperature Control


Operation switch malfunction

YES

Is error code 24 shown on error code display also?

NO

NO Replace the remote controller.

YES

Test 7

Also when

Min/Max button is pressed?

YES

Release the Min/Max buttons and re-open a hot tap.

NO

Thermistor malfunction

*Is error code 31, 32, 33 or YES

34 displayed?

NO

*Is the

Test 8 resistance of the relevant thermistor normal?

YES

*Thermistor error codes

31 = Water inlet thermistor

32 = Heat exchanger thermistor

33 = Hot water outlet thermistor

34 = Ambient air thermistor

NO


Replace the relevant thermistor.


Fan speed abnormal

YES

Is voltage being supplied to the fan motor?

Test 9

NO Replace the PCB assembly.

YES

Is the fan motor rotating?

NO

NO

YES

Is a

Test 10 pulse signal being sent from the fan

NO motor?

Replace the fan motor assembly.

3.1

YES Replace the PCB assembly.


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Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution

Tests 9 and 10 – Diagnostic Point 4 Test 11

Test

9

10

Diagnostic Point 4

Conduct test with water flowing

Check Point Measured Value

4 Blue – 6 White

3 Red – 4 Blue

DC120 -160V

DC11 -19V

1 Yellow –

4 Blue

DC4 –10V

(or measurement by pulse counter of not less than 4800 pulses per minute)

Test 12 - Diagnostic Point 9

Isolate power before removing connector plugs

Unplug connector J from the PCB and select maintenance information 0y on the L.E.D display.

If 01-07 is displayed the PCB has failed. If 00 is displayed there may be current leakage to earth


Conduct test with no water flow

Measure the voltage between terminals 1 & 2 on connector J and earth. Voltage should be between AC2 – 20V


When ignition sequence commences, normal voltage should be between AC 85 - 110V until flame is detected.

(Note: Duration is approximately 3 seconds)


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35


Fault Finding Chart 3.1

3.1

Is error

False flame detection malfunction code 72 displayed?

YES

Test 11

Is flame detection signal in maintenance information

00?


NO


Ignition failure or cross light failure

YES

Did the burner ignite?

YES

Clean or replace the combustion chamber front panel assembly.

YES

NO

Is there any voltage at the flame sensors?

Test 12


YES

NO

Did the igniter spark?

NO

Test 13

Is voltage supplied to the igniter?

NO

YES

3.2


3.3

YES

Replace the igniter assembly, electrode or cable.


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3.2

Is gas available?

NO

YES

Is the gas pressure correct at the burner test point?

YES

NO

Is

Test 14 there voltage at the gas inlet solenoid valve?

YES

Is the

Test 15 resistance of the gas inlet solenoid valve normal?

Test 18

Is there voltage at solenoid valves 1 & 2?

YES

YES

Is the resistance of

Test 19 solenoid valves 1 & 2 normal?

YES

Is there Test 16 voltage at the proportional gas flow regulating valve?

YES

Is the resistance of the

Test 17 proportional gas flow regulating valve normal?

NO

NO

NO

NO

NO

YES

Open the gas isolation valve.


Replace the proportional gas flow regulating valve assembly.


Replace the proportional gas flow regulating valve assembly.

Set burner pressure correctly.

Replace the combustion chamber front panel assembly.

Clean the burner.

NO

Replace the burner change over assembly.


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37



Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution.

Tests 14, 15, 18 and 19

NOTE:

Measure the voltage with connector L plugged into PCB

Measure the resistance with connector L unplugged from the PCB

Test

Solenoid

Valve

Normal

Voltage

Test Point

Diagnostic

Point

Test

Solenoid

Valve

Normal

Resistance

Test Point

Diagnostic

Point

14

18

GISV

1

2

9 Yellow

10 Black

3 Red

10 Black

4 White

10 Black

11

13

14

15

19

GISV

1

2

9 Yellow

10 Black

3 Red

10 Black

4 White

10 Black

11

13

14

Tests 16 and 17 - Diagnostic Point 10 Test 22 – Diagnostic Points 6 and 7

Test 16 – Conduct test with water flowing

Measure the voltage with connector B

Error

Code plugged into PCB. Normal voltage is between DC1.5 and 8.0V.

32

Test 17 – Isolate power before conducting test.

Measure the resistance with connector B unplugged from the PCB. Normal resistance is between 42 ohms and 97 ohms.

33

Maintenance display code

Diagnostic

Point

4y:

Combustion

Chamber

Thermistor

6

5y: Hot

Water Outlet

Thermistor

7

Test Point

Measured

Value

5 White

7 Black

4 Red

7 Black

@20ºC –

10.3 kiloohms

@40ºC –

4.9 kiloohms


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38


Fault Finding Charts 3.3 and 3.5

3.3


Flame failure

YES

NO

Is error code 10 or 99 displayed?

Abnormal combustion

NO


Very high temperature

YES

NO


Thermistor connection failure

Are the max and min burner pressures correct?

YES

NO

YES

Adjust maximum and minimum burner pressures.

3.2

Clean the heat exchanger, combustion chamber, fan and air intake. For error code 99 reset the

PCB by following the procedure in the section on ‘Error Codes’.

*Is the resistance of the thermistors correct?

Test 22

NO

*Combustion chamber and hot water outlet thermistors

YES

YES

Replace the relevant thermistor.

Adjust maximum and minimum burner pressures.

Thermistor connections crossed.

Reposition thermistor connections correctly.

3.5

NO


Purge failure

YES

Does the flame extinguish completely?

YES

Test 11

Is the flame detection maintenance information indicating 00?

NO

NO

For error code 80 or 81 replace the burner assembly.

For error code 51 replace the proportional gas flow regulating valve.


YES

Replace the combustion chamber front panel assembly.

NO

3.6


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39



3.6

Water flow servo malfunction


YES

871018-B

875018-B

871020-B

875020-B

& *solenoid bypass models.

*Mechanical bypass models.

Integrity

Temp set below 46º.

Integrity

Temp set above 46º.

*For models without a

-B suffix e.g.

871020NF compare appliance to wiring diagram to determine whether it has a mechanical or solenoid operated bypass

Tests 23,

24 & 25

Is diagnostic point 18 normal?

NO

Is the bypass solenoid open circuit?

Test 30

YES

Replace water body assembly.

NO

Note: the bypass solenoid is activated only if the set temperature is below 46 degrees.

Is the

PCB supplying power to the solenoid?

Test 31

NO

YES

Replace PCB assembly.

Is the

Tests 23 & 24 voltage at connector between H2 & H8 and H7

& H8 normal?

NO

NO

YES

YES

Test 25

Is the water flow servo motor at

ON position?

NO

YES

Set the hot water temperature at 60º and fully open a hot water tap.

Isolate and then restore power.

Is the water flow servo motor functional?

After power is restored the water flow servo motor limiter should move to the fully open position

NO Replace water body assembly.

YES

*Is maintenance information 5y displaying

60?

*5Y is the temperature of the hot water outlet thermistor

NO


YES

Is the resistance of the

Test 15 proportional gas flow regulating valve normal?

NO

YES Replace PCB assembly.

Replace the proportional gas flow regulating valve.

NO

3.7


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40



Test 23 - Diagnostic Point 18 Test 24 - Diagnostic Point 18


Test Point

Connector H

Measured Value


Test Point

Connector H

Measured Value

2 White - 8 Black DC8 – 16V 7 Red - 8 Black DC8 – 16V

Components will be “Live” when conducting tests, exercise caution

Test 25 - Diagnostic Point 18 Test 28 - Diagnostic Point 3

Test Point

Connector H

6 Green - 8 Black

Measured Value

On position < DC1V

Off position DC4 – 6V


Measure the voltage between 11 Red and 10

Black on connector B.

Voltage should be between DC7 – 15V


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3.7


Outlet water temp too high

YES

*Is the

Integrity used as an in-series gas booster?

YES

*875 series model

Is the

Integrity outlet temp set at 60ºC ?

NO heaters are unsuitable for use as in-series gas boosters

YES

**Is the

Integrity inlet water temp

> 77ºC?

NO

Set the Integrity outlet temp to

60ºC

**Error code 16 will occur if the

Integrity heats the water to 20º above the set point -3ºC.

60+20-3=77ºC

YES

NO

NO

Is a solar bypass valve fitted?

YES

NO

Is a

Comparator fitted?

YES

Faulty solar bypass valve.

Remove solar bypass valve and fit a comparator.

Replace the comparator.

NO

Is the heater an 871018-B

or 871020-B model?

NO Fit a comparator.

YES

Malfunction of


water bypass solenoid

YES

Is the Test 15 resistance of the proportional gas flow regulating valve normal?

NO


Replace the proportional gas flow regulating valve.

871018-B

875018-B

871020-B

875020-B

& *solenoid bypass models

*Mechanical bypass models

Is the

PCB supplying

Test 31 power to the solenoid?


Note: the bypass solenoid is activated only if the set temperature is below 46 degrees.

YES

Replace the water body assembly.

*For models without a -B suffix e.g. 871020NF compare appliance to wiring diagram to determine whether it has a mechanical or solenoid operated bypass

NO

3.8


D.O.I: 7/11/2007

42



3.8

Error code

79 displayed.

Fan current detecting circuit failure

Was

Error code 79 displayed prior to opening the hot tap?

YES

2

NO


Note: only replace the PCB assembly if error code 79 is displayed during combustion.





Measure the voltage between 9 Brown and 10 Black on connector B.

Voltage should be between DC2 – 5V

Test 30 and 31 - Diagnostic Point 19

Test 30

Isolate power when conducting resistance test

Unplug connector L from the PCB and measure the resistance between 6

Orange and 12 Orange.

Resistance should be between 0.6kiloohms and 2.8kilo-ohms .

Test 31



Measure the voltage between 6 Orange and 12 Orange on connector L.

Voltage should be between DC70 –

110V


D.O.I: 7/11/2007

43


Fault Finding Charts 4 and 4.1

4 4.1

Is the

Integrity used as an in-series gas booster?

YES

NO

Read maintenance information 1y

1y = Water flow detected by water flow sensor

Are

Controllers fitted?

YES

Controllers must not be fitted when an Integrity is used as an in-series gas booster. Remove controllers.

NO

Is the water flow more than 3 litres/min?

NO

Is the voltage between

Test 28 connector B10 & 11 normal?

NO

YES

Is the

Test 29 voltage between connector B9 & 10 normal?

NO

Test 33

Is the flow sensor turbine YES jammed?

YES


YES

Free the flow sensor turbine.

875 series model or 18L model

What model is the

Integrity ?

871020

871020-B

NO

Replace the water flow sensor. If the fault persists replace the water body assembly.

875 series models and 18 Litre models are not suitable for use as in-series gas boosters.

4.2


YES

871020-B models do not require a solar bypass valve. Remove the solar bypass valve and remake water connections directly to

Integrity.

NO


3y = Water temp detected by water inlet thermistor

Is the

water entering the Integrity < or = 58ºC or

< or = the set temp

- 2ºC?

NO

Water will flow straight through the Integrity and the Integrity will not operate. Normal operation.

YES

4.1


D.O.I: 7/11/2007

44



4.2


NO

Is a comparator fitted?

YES


3y = Water temp detected by water inlet thermistor

YES


NO



YES



NO

Test 32

Is the water flow sensor working?

NO

Is a comparator fitted?

NO

4.3

YES

NO

Is the water entering the Integrity

> 57ºC?

NO


YES


YES

NO

Test 33

Is the flow sensor turbine jammed?

NO

871020 models must have a solar bypass valve or a comparator fitted when used as an in-series gas booster. If a solar bypass valve and a comparator are fitted, remove the solar bypass valve.

If neither is fitted fit a comparator.

YES

YES

Water will flow straight through the Integrity and the Integrity will not operate. Normal operation.


Free the flow sensor turbine.


YES Replace the comparator.


D.O.I: 7/11/2007

45



4.3

Is the preheated water to the solar bypass valve >

57ºC?

NO



YES

Water will be diverted by the solar bypass valve. No water will flow through the Integrity therefore it will not operate.

Normal operation.



NO

Is water

flowing through the solar bypass valve to the

Integrity water inlet?

YES

Is the


NO

NO

Remove the solar bypass valve and fit a comparator.

YES

Is the



NO

Test 33

Is the flow sensor turbine jammed?

YES Free the flow sensor turbine.

NO



D.O.I: 7/11/2007

46


Fault Finding Tests 32 and 33

Test 32

Test 33

Components will be “Live” when conducting test, exercise caution


Measure the voltage at the 3 pin connector located between the water flow sensor and the comparator.

Measure the voltage between the brown and black wires at this connector.

Voltage should be between DC2 – 5V.

Isolate power when removing flow turbine

Remove flow sensor turbine by following

component replacement procedure 21 on page 53.

The flow sensor turbine should spin freely. Check for wear or blockage by foreign material such as thread tape.

Burner Gas Pressure Check


Minimum Burner Gas Pressure


2. Remove burner test point screw and fit manometer.

3. Turn on the remote controller (If fitted).

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 LED) 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 LED) 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.



D.O.I: 7/11/2007

47


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


2. Remove burner test point screw and fit manometer.

3. Turn on the remote controller (If fitted).

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 the LED)

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 LED display) and a lower gas pressure limit (01 on LED 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 LED 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 the LED).

NOTE:

The adjuster button must be held down continuously through steps 10 and 11.

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 LED display) and a lower gas pressure limit (01 on LED 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.


Component Replacement Procedures

Front Panel Removal: (Procedure 1)

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.


D.O.I: 7/11/2007

48


Burner Change-Over Assembly: (Procedure 2)

1. Remove the front panel. Refer to Procedure 1.

2. Disconnect the wiring plug from each of the solenoid valves. (Note which plug goes to each valve

)

3. Remove the screw retaining the ignition pack to the Burner Change Over Assembly.

4. Remove the six screws retaining the Burner Change Over Assembly. Four from the

Combustion Chamber Front Panel and two from the Proportional Gas Flow Regulating

Valve Assembly.

5. Remove the Burner Change Over Assembly.

6. Reassemble in reverse order of above. Replace gaskets (item numbers 105 and 108) if required.

7. Test for gas leaks using soapy water solution

Combustion Chamber Front Panel Assembly: (Procedure 3)

1. Remove the front panel and Burner Change Over Assembly. Refer to Procedures 1 and 2.

2. Disconnect wiring from the flame sensors and spark electrode (Note which wire goes to each flame sensor ).

3. Remove screws (10 off) retaining the Combustion Chamber Front Panel.

4. Gently remove the Combustion Chamber Front Panel Assembly.


6. Test for gas leaks using soapy water solution.

Lower Burner Assembly: (Procedure 4)

1. Remove the front panel, Burner Change Over Assembly and Combustion Chamber

Front Panel Assembly. Refer to Procedures 1, 2 and 3.

2. Remove the 2 screws retaining the Lower Burner Assembly and remove Lower Burner

Assembly.



Upper Burner Assembly: (Procedure 5)

1. Remove the front panel, Burner Change Over Assembly, Combustion Chamber Front

Panel Assembly and Lower Burner Assembly. Refer to Procedures 1, 2, 3 and 4.

2. Remove the Upper Burner Assembly by sliding forward out of the heat exchanger assembly.

3. Reassemble in reverse order of above being careful not to pinch or damage wiring.

Replace gaskets (item numbers 105 and 108) if required.


PCB Assembly: (Procedure 6)


2. Remove the screw retaining the PCB Assembly in the water heater.

3. Carefully remove the PCB Assembly complete.

4. Disconnect the multi-pin connectors from the PCB Assembly.

5. Remove the Gas Type Connector IC board and fit to replacement PCB Assembly.

6. Reassemble in reverse order of above.


D.O.I: 7/11/2007

49


Proportional Gas Flow Regulating Valve: (Procedure 7)

1. Remove the front panel and Burner Change Over Assembly. Refer to Procedures 1 and 2.

2. Disconnect the gas supply pipe from the gas inlet connection.

3. Remove the three screws from the gas inlet connector and withdraw the connector and o-ring from the base of the water heater.

4. Carefully remove the Proportional Gas Flow Regulating Valve from the water heater.

5. Disconnect the multi-pin wiring plug from the Gas Inlet Solenoid Valve and the red and black wires from the proportioning valve. Note: The proportional valve terminals are marked + for red and – for black.


7. Test for gas leaks with soapy water solution.

Water Body Assembly: (Procedure 8)

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 front panel, Burner Change Over Assembly and Proportional Gas Flow

Regulating Valve. Refer to Procedures 1, 2 and 6.

2. Disconnect the cold water supply pipe from the cold-water inlet connection.

3. Unscrew the water drain plug (item 405) and relief valve (item 431) and drain the water heater.

4. Remove the screw/s from the flange (item 419) and remove.

5. Carefully disengage the two 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 and withdraw the 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 motor, flow sensor and cold water thermistor.

10. Remove the retaining screw from the anti-frost heater and remove. (If fitted)

11. Reassemble in reverse order of above, replacing pipe o-rings (item 427) if required.

12. Test for gas and water leaks.

Combustion Fan Motor: (Procedure 9)


2. Remove the screw retaining the Cord Connector, item 008.

3. Remove the screw retaining the Terminal Block Assembly, item 768.

4. Remove the screws retaining the mounting bracket for the transformer and the power filter to the Fan Motor Assembly and reposition the transformer and power filter temporarily.

5. Remove the remaining screw retaining the Fan Motor Assembly and lift the Fan Motor clear.

6. Disconnect the multi-pin wiring plug from the Fan Motor.



D.O.I: 7/11/2007

50


Anti-Frost Heaters: (Procedure 10)

Note: Only models with an ‘F’ in the model number are fitted with anti-frost heaters e.g.

871020NF.


Heat Exchanger and Hot Water Outlet Connection Heaters

1. Disconnect connector plugs at the sensing thermostat and at the power cord.

2. Remove Flange (item 445) to release the Hot Water Outlet Anti-frost Heater.

3. Unclip the 2 anti-frost heaters from the heat exchanger (Note the positions of both).

4. Remove the Anti-frost Heaters and wiring (Some wiring retainers will need to be released to remove wiring).

5. Reassemble in reverse of above ensuring anti-frost heaters are fitted in correct positions.

Water Body Assembly Heater

1. Disconnect connector plugs at the cord set and at the sensing thermostat.

2. Remove the Water Body Assembly (item 410). Refer to Procedure 7.

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).


Heat Exchanger Removal/Replacement: (Procedure 11)

1. Follow the steps in Procedure 5, Upper Burner Assembly.

2. Remove the screw/s from the Water Body Assembly flange (item 419) and remove.

3. Carefully disengage the two pipes from the Water Body Assembly.

4. Remove the two screws from the hot water outlet flange (item 445) retaining the hot water outlet pipe and carefully disengage the pipe.

5. Disconnect the multi-pin wiring connector from the top heat exchanger thermistor.

6. Anti-Frost Models Only: Disconnect the wiring loom connector at the thermostat (item

714) and the hot water outlet heater (item 705).

7. Remove 5 screws retaining the heat exchanger assembly. One from each side of the heat exchanger, two screws from the bracket above the flue outlet and one screw from the fan case assembly (item 729).

8. Remove two screws retaining the bracket (above the flue terminal) and remove the bracket. (Note: The bracket is glued in place, a small amount of force is required to remove it).

9. Remove Heat Exchanger Assembly by gently moving the top forward out of the water heater then lift the assembly up and clear.

10. Disconnect the multi-pin wiring plug from the Fan Motor to completely free Heat

Exchanger Assembly from water heater.

11. Remove the top Thermistor, Anti-Frost Heaters (if fitted) and the Fan Motor and

Cowling Assembly from the old Heat Exchanger and refit to the replacement Heat

Exchanger Assembly.

12. Replace the Over Heat Limiter if damaged or open circuit.


14. Test for gas leaks using soapy water solution

15. Check for water leaks.

16. Check and if necessary adjust MIN and MAX burner gas pressures. Refer to Procedure on page 48.


D.O.I: 7/11/2007

51


Ignition Pack Replacement: (Procedure 12)


2. Disconnect high voltage lead from spark electrode.

3. Disconnect the multi pin connector from the Ignition Pack.

4. Remove the retaining screw.

5. Remove the Ignition Pack.


Flow Sensor: (Procedure 13)

1. Isolate cold water supply.


3. Disconnect the multi-pin plug to the flow sensor.

4. Remove 2 Philips head retaining screws.

5. Remove Flow Sensor (Note: Water may escape during this procedure).


Bypass Solenoid: (Procedure 14)

Note: Models with a -B suffix in the model number are fitted with a bypass solenoid e.g.

871020NF-B. For models without a -B suffix compare the appliance to the wiring diagrams

located on pages 6 & 7 to determine whether it has a mechanical or solenoid bypass.

The bypass solenoid is only available as part of the water body assembly. Follow procedure 7.

Thermistors: (Procedure 15)

1. Remove the front Panel. Refer to Procedure 1.

2. Relieve water pressure through a hot tap.

3. Locate the Thermistor requiring replacement.

4. Disconnect the multi-pin plug from the Thermistor.

5. 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).


Over Heat Limiter Assembly: (Procedure 16)

Replacement of the Over Heat Limiter requires removal and possible replacement of the

Heat Exchanger.

1. Follow Procedure 11 to step 10.

2. Disconnect the multi-pin plug to the Over Heat Limiter Assembly.

3. Remove the screws retaining the Over Heat Limiter Assembly to the Jacket back and remove the Over Heat Limiter Assembly.

4. Inspect the heat exchanger for holes or combustion damage.

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 and ensure the MIN and MAX burner gas pressures are correct. Refer to Procedure on page 48.


D.O.I: 7/11/2007

52


Remote Controller: (Procedure 17)

1. Isolate power at the water heater.

2. Remove the small Philips head screw from the bottom of the Remote Controller.

3. Gently pivot the Remote 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.


Gas Type Circuit Board: (Procedure 18)


2. Gently unplug the Gas Type Circuit Board from the PCB.


4. Restore power.

5. Press the MAX button. On all 18 & 20L Integrity models 3H should be displayed.

6. Test operation of water heater and ensure the MIN and MAX burner gas pressures are correct. Refer to Procedure on page 48.

Transformer: (Procedure 19)


2. Disconnect the primary and secondary winding multi-pin plugs to the Transformer.

3. Remove the 2 Philips head screws retaining the Transformer.


Power Filter: (Procedure 20)


2. Disconnect the incoming and outgoing wiring loom plugs.

3. Remove the 2 Philips head screws retaining the filter to the mounting bracket.

4. Remove the Power Filter.


Solar Bypass Valve: (Procedure 21)

Solar bypass valves are no longer available and if faulty are to be removed and a

Comparator installed. Refer to page 14 for the procedure on installing a comparator.

NOTE: 20L models with a -B suffix in the model number do not require either a bypass valve or a comparator.

Flow Sensor Turbine: (Procedure 21)

1. Isolate cold water supply.


3. Unscrew the water drain plug (item 405) and relief valve (item 431) 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.


D.O.I: 7/11/2007

53


6. Remove 2 Philips head retaining screws holding flow sensor to water body assembly and remove flow sensor.

7. Using a flat bladed screwdriver lever the metal disc and o-ring from flow sensor housing on 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 connector and o-ring from the base of the water heater.

9. Gently withdraw flow sensor turbine out from water inlet of 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.

Power cord: (Procedure 22)

1. Switch off power at power point and unplug power cord from power point.

2. Unscrew screw on power inlet cover and remove power inlet cover.

3. Undo cord clamp screw located next to power filter and remove clamp.

4. Disconnect the power cable wiring loom plug and withdraw power cable through slot in heater jacket.



D.O.I: 7/11/2007

54


Exploded View 1 – 871018 & 871020 Models


D.O.I: 7/11/2007

55


Replacement Parts List Exploded View 1 – 871018 & 871020 Models

Ref.

No.

001 Front Panel Assembly (50 & 60ºC Models)

066 Fixing Plate B

100 Gas Inlet Connector

103 Proportional Gas Flow Regulating Valve

104 O-ring

105 Gasket

108 Gasket

111 Upper Burner Assembly

120 Lower Burner Assembly - NG

120 Lower Burner Assembly - LP

123 Primary Air Adjuster

160 Burner Change-Over Assembly

401

Water Inlet Connector Assembly (¾)

Water Inlet Connector Assembly (½)

402 O-ring

403 CS Type Snap Ring

405 Water Drain Valve Assembly (inc. water filter)

407 Water Filter – use WH0020024

409 O-ring

410

415

422

430

434

701

768

828

Water Body Assembly

Heat Exchanger & Combustion Chamber Kit

419 Flange

Combustion Chamber Front Panel Assembly

427 O-ring

429 O-ring

Hot water Outlet Connector (¾)

Hot water Outlet Connector (½)

431 Relief Valve Assembly

433 O-ring

Safety Valve Band

445 Flange

Over Heat Limiter Assembly

Terminal Block Assembly

Truss Gasket Screw 4 x 10

WH0020000

WH0020001

WH0020002

WH0020003

WH0020004

WH0020005

WH0020006

WH0020007

WH0020009

WH0020010

WH0020012

WH0020013

WH0020015

WH0020017

WH0020085

WH0020019

Not fitted

WH0020086

WH0020021

Not fitted

WH0020022

WH0020023

WH0020024

N/A

WH0020026

WH0020027

WH0020028

WH0020029

WH0020031

WH0020032

WH0020034

WH0020035

Not fitted WH0020036

WH0020087 Not fitted

WH0020037

WH0020038

WH0020039

WH0020040

WH0020042

WH0020043

WH0020044


D.O.I: 7/11/2007

56


Exploded View 2 – 871018 & 871020 Models


D.O.I: 7/11/2007

57


Replacement Parts List Exploded View 2 – 871018 & 871020

Ref. No . Description 871018/020

133 Silicone Tube (Insulator) WH0020045

134 Silicone Tube (Insulator) WH0020046

WH0020047

710

712

Anti-Frost Heater “C” Clamp

Ambient Air Temp Thermistor Assy

WH0020088

WH0020049

WH0020050

WH0020051

WH0020052

WH0020181

WH0020054

715 Inlet and Heat exchanger Thermistor

716 O-ring – Thermistor

723 Hall Effect I.C. Assembly

737

751

Flame Sensor Loom

Gas Type Connector - NG

751 Gas Type Connector - LP

757 100 volt loom

WH0020053

WH0020055

WH0020056

WH0020057

WH0020058

WH0020059

WH0020060

WH0020182

WH0020064

768

771

775

780


Not Fitted (Australian Models)

Fuse - In line Note: PCB fuses not fitted

Power Cord With Clamp

781 Clamp – Power Cord

783 240-110 Volt Transformer Assembly

784 Not Fitted (Australian Models)

WH0020065

WH0020089

WH0020067

WH0020068

N/F

WH0020079

WH0020069

WH0020071

WH0020072

WH0020073

N/F

Not

Shown

Gas Conversion Kit - LP to NG WH0020074

Not

Shown

Gas Conversion Kit - NG to LP WH0020076

Note: For controller and controller cable part numbers refer to page 16


D.O.I: 7/11/2007

58


Exploded View 3 – 871/875018-B & 871/875020-B Models


D.O.I: 7/11/2007

59


Replacement Parts List Exploded View 3 – 871/875018-B & 871/875020-B Models

Ref.

No.

Description

001 Front Panel Assembly (50 & 60ºC Models)

066 Fixing Plate B

100 Gas Inlet Connector

103 Proportional Gas Flow Regulating Valve

104 O-ring

105 Gasket

108 Gasket

111 Upper Burner Assembly

120 Lower Burner Assembly - NG

120 Lower Burner Assembly - LP

123 Primary Air Adjuster

160 Burner Change-Over Assy (Inc. solenoids)

401

Water Inlet Connector Assembly (¾)

871018-B 871020-B

875018-B B875020-B

WH0020000

WH0020001

WH0020002

WH0020003

WH0020004

WH0020005

WH0020006

WH0020176

WH0020009

WH0020010

WH0020012

WH0020013

WH0020015

WH0020017

WH0020085

WH0020019


402 O-ring

403 CS Type Snap Ring

405 Water Drain Valve Assy (includes water filter)

407 Water Filter – use WH0020024

409 O-ring

410

415

419 Flange

422

427 O-ring

429 O-ring

430

Water Body Assy including solenoid bypass

Heat Exchanger and Combustion Chamber Kit

Combustion Chamber Front Panel Assembly

Hot water Outlet Connector (¾)

431 Relief Valve Assembly

433 O-ring

434 Safety Valve Band

445 Flange

701 Over Heat Limiter Assembly

768 Terminal Block Assembly

828 Truss Gasket Screw 4 x 10

WH0020022

WH0020023

WH0020024

N/A

WH0020026

WH0020027

WH0020177

WH0020178

WH0020031

WH0020032

WH0020034

WH0020035


WH0020037

WH0020038

WH0020039

WH0020040

WH0020042

WH0020043

WH0020044


D.O.I: 7/11/2007

60


Exploded View 4 – 871/875018-B & 871/875020-B Models


D.O.I: 7/11/2007

61


Replacement Parts List Exploded View 4 – 871/875018-B & 871/875020-B Models

Fitted with solenoid operated bypass

871018-B 875018-B

Ref. No

. Description

133

134

710

712

715

716

723

737

Silicone Tube (Insulator)

Silicone Tube (Insulator)

Anti-Frost Heater “C” Clamp

Ambient Air Temp Thermistor Assy

Inlet and Heat exchanger Thermistor

O-ring – Thermistor

Hall Effect I.C. Assembly

Flame Sensor Loom

871020-B 875020-B

WH0020045

WH0020046

WH0020047

WH0020088

WH0020049

WH0020050

WH0020051

WH0020052

WH0020181

WH0020054

WH0020180

WH0020055

WH0020056

WH0020057

WH0020058

WH0020059

WH0020060

751

768

771

Gas Type Connector - NG

751 Gas Type Connector - LP

757 100 volt loom


Not Fitted (Australian Models)

WH0020184 WH0020196

WH0020183 31-23748-00

WH0020089

WH0020067

775 Fuse – In line Note: PCB fuses not fitted

780 Power Cord With Clamp

781 Clamp – Power Cord

783 240 -110 Volt Transformer Assembly

784 Not Fitted (Australian Models)

Not

Shown

Gas Conversion Kit - LP to NG WH0020188

Not

Shown

Gas Conversion Kit - NG to LP WH0020190

Note: For controller and controller cable part numbers refer to page 16.

WH0020068

N/F

WH0020079

WH0020069

WH0020071

WH0020072

WH0020073

N/F

WH0020015

WH0020196

WH0020017

31-23748-00


D.O.I: 7/11/2007

62


Gas Type Conversion Procedure

1. Isolate the power and gas supply to the water heater.

2. Remove the front panel. (Refer to Procedure 1)

3. Remove the Burner Change Over Assembly (Refer to Figure 1 and Procedure 2)

4. Remove the Combustion Chamber Front Panel Assembly. (Refer to Figure 2 and

Procedure 3)

5. Remove the Lower Burner Assembly, (Refer to Figure 2 and Procedure 4) and refit replacement for required gas type and water heater capacity.

6. Refit the Combustion Chamber Front Panel Assembly.

7. Refit the Burner Change Over Assembly.

8. Remove the Gas Type Connector, (Refer to Figure 3 and Procedure 17) and refit replacement for required gas type and water heater capacity.

9. Restore the power and gas supply.

10. Using an insulated tool, adjust the minimum and maximum burner gas pressures

(Figure 4) to that required for the size, model and gas type (refer to specifications table on page 4) following the Burner Gas Pressure Adjustment procedure on page 48.

11. Fit the correct gas type label and alter the test point pressures on the rating label to reflect the new gas type.


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63


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.

R h e e m A u s t t r r a l l i i a P t t y L t t d A B N 2 1 0 9 8 8 2 3 5 1 1


D.O.I: 7/11/2007

64


A

B

C

D

E

Document Revision History

Title: Integrity 18 & 20L Service Instructions

Document

Number:

TM002

Service Instructions issued for 871018, 871020, 871024

Rheem Integrity

References to Southcorp Water Heaters replaced with Rheem

Australia

Models with Solenoid bypass added

Diagnostics for Error Code 56 added

Update of font, ABN number, contents page, title page and standardisation of layout. Addition of version -B models.

Removal of 24L models (refer TM031 for 24L models).

05/01

03/02

11/02

01/04

11/07


D.O.I: 7/11/2007

65


Rheem 875 Series Specifications

SERVICE INSTRUCTIONS

18 & 20L Integrity

Electronic Gas Instantaneous Water Heater

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Rheem 875 Series Specifications

SERVICE INSTRUCTIONS

18 & 20L Integrity

Electronic Gas Instantaneous Water Heater

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Table of contents