Rheem 27 874 Series Service Instructions Manual Download Page 35

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TM049 27L Continuous Flow Service Instructions
REV AL

– Issued April 2019

This document is stored and maintained electronically by Rheem Technical Support.

All printed copies are deemed “uncontrolled”.

11 Flashing

Operational Flow Chart 2

S.V. 2 (SV2) on

P.G.F.R Valve on

S.V. 1 (SV1) off

Igniter off

P.G.F.R Valve off

S.V. 3 (SV3) off

S.V. 2 (SV2) off

I.U.I. Off

Leakage >

than 0.1uA

3 seconds later

P.G.F.R Valve off

YES

G.I.S.V (SVO) off

S.V. 1 (SV1) off

S.V. 2 (SV2) off

S.V. 3 (SV3) off

I.U.I on

Igniter off

YES

Proportional temperature

adjustment

Gas rate change-over

done by solenoid valves

Hot water volume adjustment

Solenoid bypass valve on

Solenoid bypass valve off

YES

10 Flashing

YES

31 Flashing

32 Flashing

33 Flashing

34 Flashing

35 Flashing

79 Flashing

14 Flashing

29 Flashing

99 Flashing

16 Flashing

71 Flashing

76 Flashing

61 Flashing

81 Flashing

65 Flashing

52 Flashing

YES

Outlet water

temp exceeded

97ºC for more

than 15 seconds

15 Flashing

Water inlet

thermistor

disconnected

Outlet water
temperature

too high

Heat

Exchange

outlet temp too

low

Abnormal

combustion

Heat

exchanger

thermistor

disconnected

O.H.L failure

Fan motor

current

detection

failure

Thermistor

connections

crossed

Ambient air

thermistor

disconnected

Outlet

thermistor

disconnected

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

Flame Detected?

Set temp.

46ºC or lower?

Low rate

combustion?

Heat exchange

outlet temp too

low?

05 Flashing

YES

Ignition

Failure

Flame

Failure

I.U.I. Off

First Ignition

Trial?

11 Flashing

12 Flashing

S.V. 1 (SV1) off

P.G.F.R Valve off

S.V. 3 (SV3) off

S.V. 2 (SV2) off

YES

Safety device

working?

First ignition

trial?

S.V. 1 (SV1) on

Igniter off

G.I.S.V (SVO) off

66 Flashing

Malfunction of

water bypass
control motor

Summary of Contents for 27 874 Series

Page 1: ...heem Australia Pty Ltd ABN 21 098 823 511 27 Litre External Internal Electronic Gas Continuous Flow Water Heater TM049 First Issued Dec 09 Revision AL Issued April 2019 Solahart Edwards Everhot Vulcan Rheem 10143272 362027 274X27 244X27 862X27 10143273 372027 276X27 864X27 10143274 374X27 866X27 10143275 872X27 874X27 876X27 ...

Page 2: ...ERATURE ADJUSTMENT 14 SEQUENCE OF OPERATION 16 COMPONENTS AND THEIR FUNCTION 18 IN SERIES GAS BOOSTING 19 TEMPERING VALVES 20 REMOTE TEMPERATURE CONTROLLERS 21 Bath Fill Operation 26 EZ LINK SYSTEM 28 MAINTENANCE INFORMATION 30 RESETTING ERROR CODES 32 OPERATIONAL FLOW CHARTS 33 ERROR CODES 37 DIAGNOSTIC TEST POINTS 39 THERMISTOR RESISTANCE CHART 40 FAULT FINDING 40 Fault Diagnosis Sequence 41 Pow...

Page 3: ...de 35 54 Error Code 51 55 Error Code 52 56 Error Code 61 56 Error Code 65 60 Error Code 66 60 Error Code 71 61 Error Code 72 61 Error Code 76 62 Error Code 79 62 Error Code 80 63 Error Code 82 63 Error Code 90 63 Error Code 99 Warning Code 10 64 EziSET Fault Finding 65 BURNER GAS PRESSURE CHECK ADJUSTMENT 67 COMPONENT REPLACEMENT PROCEDURES 68 FLUING REQUIREMENTS FOR INTERNAL MODELS 79 DOCUMENT RE...

Page 4: ...ing symbol Take care to observe the recommended procedure Live Testing A number of test procedures detailed within this service instruction require live testing to be conducted All State and Territory Authorities stipulate requirements that must be met before working live i e conducting a risk assessment and or preparing a safe work method statement and wearing appropriate PPE It is the responsibi...

Page 5: ...te The 2kΩ resistor is used to simulate the body resistance of a typical person Diagram 2 Procedure Personal Protective Equipment electrical insulating gloves should be worn when conducting this procedure to reduce the risk of electric shock 1 Connect the resistance box between the metal casing of the appliance and the main Earth electrode Spike using the long trailing lead as shown in diagram 2 2...

Page 6: ...sistance scale 3 Measure between the Earth pin on the 3 pin plug and the heater jacket a reading of 0 5Ω should be obtained If a reading greater than 0 5Ω is returned check the earth connection at the water heater if ok replace the cord Procedure 2 Insulation resistance of the water heater Active Circuit reading not to be below 1MΩ 4 Connect megger leads to the Active and Earth pins of the 3 pin p...

Page 7: ...n External 27 Everhot External 36 Edwards Internal 37 Edwards External Max Temperature 2 82ºC 60ºC factory set 4 75ºC 60ºC factory set 6 48ºC 48ºC factory set Star Rating 0 5 Star 6 6 Star Capacity 27 27L min 25 ºC rise Gas Type N Natural P Propane F Frost protection fitted Colour J Joey Grey No letter Refer below Casing colour variations Rheem Edwards Solahart Antique White Everhot Joey Grey Sola...

Page 8: ...an 5 Star 6 Star Vulcan Gas CF 60ºC 27l m Nat Pro Ext Site Int 244027NF J PF J 244627NF J PF J Everhot 5 Star 6 Star Everhot Gas CF 60ºC 27l m Nat Pro Ext 274027NF PF 274627NF PF Everhot Gas CF 50ºC 27l m Nat Pro Ext 276027NF PF 276627NF PF Solahart 5 Star 6 Star Solahart Gas CF 60ºC 27l m Nat Pro Ext 10143272 73 10143274 75 Edwards 5 Star 6 Star Edwards Gas CF 82ºC 27L M Nat Pro Ext 372027NF PF E...

Page 9: ...a mm 16 x 2 05 16 x 1 25 Burner Test Point Pressure kPa Indoor Min 0 165 0 252 Max 0 900 1 3251 1 5502 Outdoor Min 0 193 0 277 Max 0 905 1 4301 1 5402 Min Inlet Gas Pressure kPa 1 13 2 75 Max Inlet Gas Pressure kPa 3 5 Relief Valve Setting kPa 1750 Electrical Rating 240 VAC 50Hz 3 Amps Fuse 2 x 3A Fuse line voltage 5A fuse on power supply PCB Safety Devices Over Heat Limiter for Heat Exchanger Hea...

Page 10: ...1 I R GR K BK R Y BR G W 1 2 3 4 5 6 8 7 R BK BK R BL 4 3 2 1 7 6 5 P Y W 1 2 3 4 USUALLY DISCONNECTED BL O W BR R BK 4 3 2 1 8 7 6 5 N O 9 Y G M 5 6 7 8 1 2 3 4 G Y BK R BR W O BL Q BR Y 9 5 6 7 8 1 2 3 4 GY BL BK W R G O 4 3 2 1 5 R 1 2 3 S BR BK R GAS TYPE CONNECTOR FLOW WATER SENSOR W W 2 1 T LIMITER OVERHEAT W 1 U FLAME ROD 1 2 3 V BL BL BATH REMOTE CONTROL 2 CONTROL 1 REMOTE BATH KITCHEN REM...

Page 11: ...t number 052310 the kit is suitable for use with 50oC models only 876027 876627 866027 866627 models The kit is required to be installed by a qualified technician it includes a PCB refer A that is to be fitted inside the water heater and a PLT plug Power Line Telecommunication that is to be connected to a GPO and wireless router in the home wireless router is not supplied however any home with an ...

Page 12: ... 872 Series Commercial Models The revised water body part number 41 18374 00 is now available as a spare part to use as a service replacement for any commercial models 862 872 Series however it must be noted when fitting this revised water body to an existing heater manufactured pre Feb 2018 it will also be necessary to replace the main PCB part number 41 18376 00 Failure to replace the PCB will r...

Page 13: ...h digit eg 874627NF The 5 star internal models require a water heater flue adapter p n 295121 to be fitted to the flue outlet and if required a condensate drain section p n 295120 is to be fitted directly to this adaptor however the water heater flue adapter and the condensate drain are now included as part of the 6 star heater s flue outlet assembly refer images below 86X027 model 5 Star 86X627 m...

Page 14: ...tches 5 Turn dip switches 3 and 4 to the OFF down position on the DIP1 set of dip switches on the PCB 6 The LED1 display will go blank The preset outlet temperature is now set 7 Refit the front cover to the water heater Outlet Temperature Compensation Adjustment applicable to 50oC models only The maximum outlet temperature may be adjusted to compensate for temperature losses in the pipe work betwe...

Page 15: ...ress the MAX button once to increase the preset outlet temperature setting to the next increment Each press of the MAX button will increase the temperature setting by one increment The increments are 48 50 51 52 The MAX button is located underneath the DIP 1 and DIP 2 set of DIP switches 13 Switch dip switches 1 and 2 to the off down position on the DIP 2 set of DIP switches on the I C Board The L...

Page 16: ... a min flow rate of 2L m the PCB 7 activates the Fan Motor 24 and the Fan 23 starts rotating 3 After the Fan 23 completes a pre purge to ensure the vent is clear the Proportional Gas Flow Regulator 12 allows gas to flow to the Burner 14 At the same time the Igniter 15 starts sparking continuously and ignites the gas at the Burner 14 4 After ignition the Flame Rods 17 sense and monitor the burner f...

Page 17: ...ody assembly 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 The PCB activates the water bypass control motor based on heat exchang...

Page 18: ... that delivers hot water to the piping system and measure the hot water outlet temperature with the aid of a thermistor Gas Inlet Connection A connection port separate from the gas valve to connect the incoming gas supply PCB Printed Circuit Board The control board that processes all the inputs required to make the heater operate Remote Temperature Controller Digital control panel that allows user...

Page 19: ...setting of the heater must be set at a minimum of 70 C to comply with the requirements of AS3498 Refer to page 14 for details on checking and adjusting the outlet temperature When the inlet water temperature is 58 C or higher the fan and burner will not operate despite water flowing through the heat exchanger When the inlet water temperature is less than or equal to 57 C the burner will fire and b...

Page 20: ...eople It may be required by regulations that an approved temperature limiting device be fitted on all other models Where a tempering valve is fitted and there is not a separate untempered line for the kitchen or laundry areas the kitchen temperature controller will be able to display temperatures above 50 C however the delivered water temperature at the tap will be that set by the tempering valve ...

Page 21: ...or three unique controllers can be installed however if a Bathroom controller is installed without a Kitchen controller then the maximum selectable hot water temperature will be limited to 50 C when connected to a 274 864 874 862 872 863 873 372 series model or 48 C when connected to a 276 866 876 series model 276 866 876 models are factory set so that they cannot deliver water hotter than 48 C Wh...

Page 22: ...nce The light will go out A controller can be turned off whilst water is flowing Priority light This light will glow on a controller when that controller has priority The Bathroom controller s if they are turned on have priority over the Kitchen controller Priority means that controller has control of the water heater temperature setting The water temperature setting can only be adjusted by the co...

Page 23: ...rd Controllers cont d 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 dr...

Page 24: ... 47 48 50 55 60 C Deluxe Bathroom Controllers 37 38 39 40 41 42 43 44 45 46 47 48 50 C Bath Fill Mode All Deluxe Controllers 37 38 39 40 41 42 43 44 45 46 47 48 C Temperatures above 48 degrees are not available on controllers fitted to 276 866 876 models as these units have a maximum selectable temperature of 48 C at all locations Bath Fill Water Volume in litres Heater operating light Controller ...

Page 25: ... 500 litres A further setting of 990 litres can be selected Bath Fill Water Volume down button Decreases the Bath Fill water volume setting Assistance Call button When pressed sounds a message or alert tone on the Kitchen Controller indicating that assistance is required in the bathroom Bath Fill Water Volume display Displays the selected Bath Fill water volume in litres The quantity of water can ...

Page 26: ...ap open YES Bath fill lamp off Hot water volume indicator off Hot water volume off Bath fill operation completed Hot water temperature indicator off NO Combustion A B NO YES Burner Off NO YES Bath fill lamp flashing Hot water volume indicator off Hot water volume off Hot water temperature indicator off Water flow control valve closed 65 Flashing 8 5 seconds later Hot water tap closed YES Bath fill...

Page 27: ... of non use the non use session timeout time can be adjusted from the SETTINGS page if desired At this point priority may be assumed by another device by depressing the HOT WATER button The Scan button appears when the App cannot detect EziSET on network refer figure 4 Press Scan to start searching for EziSET on the network again Once EziSET is detected the App will automatically connect and figur...

Page 28: ... same model as the performance of two different models cannot be guaranteed If it becomes necessary to test the operation of both units increase the hot water flow by opening multiple hot water outlets simultaneously until both units operate The diagram opposite details a typical installation utilising the EZ Link system EZ Link Error Code Display on Remote Control if fitted If a fault is present ...

Page 29: ...as having a fault 1 or 2 and based on the error code displayed Is an error code 1 Being displayed by the controller or 2 Stored in the maintenance memory YES YES Fluctuating water temperature may be due to low water supply pressure small pipe sizing incorrect manifolding massaging shower heads crossed connection insufficient gas pressure NO Is the complaint for no hot water YES NO Fault with contr...

Page 30: ...ombustion starts X 100 Total combustion operations since last error X 100 Null H Total combustion period X 1000 hrs Total combustion period since last error X 1 000 hours Null J Total combustion period X 10 hrs Total combustion period since last error X 10 hours Null Y Flame sensor status See table below Water Flow Sensor Litres minute Ambient Air Thermistor temp ºC Water Inlet Thermistor temp ºC ...

Page 31: ...he DIP1 set of dip switches whilst dip switch 1 is also in the ON up position 8 Switch all DIP1 dip switches to the OFF down position to return to normal operation With Remote Controller Isolate power whilst connecting a remote controller 1 Fit remote controller if not already fitted 2 Restore power supply and ensure the remote controller is turned off 3 Press the temperature increase and decrease...

Page 32: ...ain 5 Within 5 seconds of turning DIP SWITCH 1 off press and hold either the MIN or MAX button for more than 2 seconds 6 Verify clearing of fault history by entering Maintenance Mode and check the code at location 1E it should read no record 7 Refit the water heater front panel RESETTING ERROR CODES Most error codes can be reset by shutting off the hot water flow and turning the controllers if fit...

Page 33: ...locating the error code in the diagnosis charts the component s or fault can be quickly identified and tested using the diagnostic procedures outlined in this manual Notes and Abbreviations used in the Operational Flow Charts P G F R Valve Proportional Gas Flow Regulating Valve F F Flame Failure G I S V Gas Inlet Solenoid Valve SV0 S V 1 Solenoid Valve 1 O H L Over Heat Limiter S V 2 Solenoid Valv...

Page 34: ...ller display on On Off lamp Off On Off lamp On Fan On Fan Off 10 seconds later 5 14 Flashing Over heat limiter failure YES B Bath fill operation Water Flow Sensor off Hot water tap closed Hot water tap open 2 3 YES 24 Flashing NO 20 seconds later Fan On Fan On YES 4 F F1 5 31 Flashing YES 32 Flashing NO 6 33 Flashing NO YES 7 YES 17 34 Flashing NO YES 4 61 Flashing NO 5 seconds later YES 8 72 Flas...

Page 35: ...1 Flashing 81 Flashing 65 Flashing 52 Flashing NO NO YES Outlet water temp exceeded 97ºC for more than 15 seconds 15 Flashing Water inlet thermistor disconnected Outlet water temperature too high Heat Exchange outlet temp too low Abnormal combustion Heat exchanger thermistor disconnected O H L failure Fan motor current detection failure Thermistor connections crossed Ambient air thermistor disconn...

Page 36: ...ater flow sensor off Fan motor at minimum I U I off S V 1 3 SV1 3 failure 80 Flashing 8 seconds later NO G I S V SV0 failure 51 Flashing G I S V SVO off S V 1 3 SV1 3 off P G F R Valve off Fan off YES Abnormal combustion NO 99 Flashing Fan off Isolate power Locate and repair fault Clear error code 99 S V 1 SV1 off S V 2 SV2 off Fan off S V 3 SV3 off G I S V SV0 off Isolate power Locate and repair ...

Page 37: ...hort circuits Check power supply for proper voltage and voltage drops Disconnect remote control Check heat exchange thermistor and transformer 14 Overheat Limiter Fault Ensure high fire and low fire gas burner pressure is correct Check gas type of unit and ensure it matches gas type being used Check heat exchanger for cracks and or separations Check gas type connector Check for restrictions in air...

Page 38: ...ult Ensure flame rod is touching flame when unit fires Check inside burner chamber for any foreign material blocking flame at flame rod Check all wiring to flame rod for damage Check flame rod for proper voltage Remove flame rod and check clean with steel wool 76 Communication Fault with Remote Control Check remote control wiring for loose or damaged connections Bypass remote control cable by conn...

Page 39: ...stor 7 P R4 BK3 Hot water outlet thermistor 17 P BL7 BK3 Ambient air thermistor 8 U W1 GND 0 3 100VAC Flame rod not detecting flame 14 1 100VAC Flame rod detecting flame 9 P R1 BK2 1 5 14 VDC PGFR Proportional Gas Flow Regulating Valve 40 80Ω 10 W Y1 BK8 75 100 VDC GISV 0 Gas Inlet Solenoid Valve 0 Primary fuel inlet to gas valve 0 8 2 4kΩ 11 G R1 R4 90 110VAC Igniter 12 W W2 BK8 75 100VDC Solenoi...

Page 40: ...52 86 1 169 10 15 449 36 5 653 62 2 367 88 1 106 12 14 221 38 5 264 64 2 225 90 1 048 14 13 104 40 4 905 66 2 092 92 0 993 16 12 086 42 4 574 68 1 968 94 0 941 18 11 157 44 4 269 70 1 853 96 0 893 20 10 309 46 3 987 72 1 746 98 0 847 22 9 534 48 3 726 74 1 646 24 8 826 50 3 485 76 1 552 FAULT FINDING When measuring resistance of a part turn off the electric power and be sure to disconnect the part...

Page 41: ...finding flow chart for the error code displayed YES Open a hot tap NO Did the fan commence operation Follow the No Error Code Fault Finding flow chart NO Is an error code displayed YES Follow the fault finding flow chart for the error code displayed YES Follow the fault finding flow chart for the error code displayed Does the burner light NO Is an error code displayed NO NO Ignition Retry Close th...

Page 42: ...terminal I on control PCB TEST 3 YES NO YES Replace Control PCB Rectify wiring and fully insert all multi pin connectors NO Are multi pin connectors plugged into terminal Q on PCB and terminals Y Z on LED1 YES Are the two x 3A inline fuses intact TEST 2 Replace fuses Investigate cause of failure NO YES Is 5A fuse on power supply PCB intact TEST 2 YES Replace transformer NO YES Is wiring correct an...

Page 43: ...measure the resistance between the blue and brown wires at terminal D whilst the multi pin connector is unplugged from the power supply PCB Resistance should be 16 22Ω outdoor and 10 14Ω indoor models NOTE if the value is below 10 ohms it will cause the fuse to blow during the start up cycle without fault code being displayed 12VDC JAPAN G5NB 1A4 OMRON 12VDC JAPAN G5NB 1A4 OMRON 12VDC JAPAN G5NB 1...

Page 44: ... straight through the unit without ignition attempt Normal operation NO YES Read maintenance information 3y 3y Water temp detected by water inlet thermistor 276 866 876 Series 276 876 Series models are not suitable for use as in series gas boosters What is the model number NO Free the flow sensor turbine YES Is the unit used as an in series gas booster Is 1y displaying a flow greater than 2 5lpm I...

Page 45: ...ltimeter set on the DC volts scale measure the voltage between 1 Brown and 2 Black at terminal S on the control PCB Normal voltage should be between DC2 5V Test 7 Remove the flow sensor turbine Refer to Flow Sensor Turbine procedure on page 72 Check for excessive wear of turbine or blockage by foreign material such as thread tape The power must be isolated during water flow sensor removal G5NB 1A4...

Page 46: ...m gas lines 3 Ensure appliance is properly earthed 4 Ensure gas line meter and regulator are sized properly 5 Ensure gas type and gas pressure to the unit is correct Error Code 11 Scenario 1 Is voltage supplied to the ignition module TEST 8 Replace power supply PCB NO YES Fan is operating igniter does not spark Replace power supply PCB Is wiring from power supply PCB to ignition module intact YES ...

Page 47: ...portional gas valve TEST 10 YES NO YES Is the resistance of the proportional gas valve correct TEST 12 YES NO YES Fan is operating igniter does spark main burner does not ignite Error Code 11 Scenario 3 Is there any voltage at the flame sensor connection on control PCB TEST 13 Replace control PCB YES NO Refer to Error Code 12 procedures Display maintenance information 0y during an ignition attempt...

Page 48: ...le measure the voltage with multi pin connector plugged into terminal W on control PCB Using a multimeter set on the kilo ohms scale measure the resistance with multi pin connector unplugged from terminal W on control PCB Solenoid Valve Normal Voltage Test Point Diagnostic Point Solenoid Valve Normal Resistance Test Point Diagnostic Point GISV DC75 to DC100V 1 Yellow 8 Black 10 GISV 0 8 kilo ohms ...

Page 49: ... resistance between 1 Red and 2 Black at terminal P whilst unplugged from the PCB Normal resistance is between 40 ohms and 80 ohms Test 13 Test 14 Conduct test with flame present Using a multimeter set on the AC volts scale measure the voltage between W1 at terminal U and earth Normal voltage should be 1 100VAC Unplug multi pin connector from terminal T on control PCB and using a multimeter set on...

Page 50: ...all air from gas lines 2 Ensure appliance is properly earthed 3 Ensure gas line meter and regulator are sized properly 4 Ensure gas type and gas pressure is correct Error Code 12 Is the inlet gas pressure correct Advise customer to contact installer to rectify NO Are the min and max burner gas pressures correct YES NO Refer to Burner Gas Pressure Check Attempt to operate the water heater by openin...

Page 51: ...ti pin connector at terminal T on control PCB properly connected YES Fully insert multi pin connector into terminal T on control PCB NO Error Code 15 Boiling Safety Device The heat exchanger is too hot At a minimum check the following 1 Check for foreign material that may restrict airflow through the exhaust flue or terminal 2 Back flush the unit to remove any sediment build up in the heat exchang...

Page 52: ... operate with an inlet temperature in excess of 58o C Error 16 will occur if the unit heats the water to 20o C above the set point 3o C eg 60 20 3 77o C Is the unit used as an in series gas booster 276 866 876 series heaters are unsuitable for use as in series gas boosters Is the inlet water temperature 58o C Replace control PCB Is the resistance of the proportional gas valve correct TEST 12 Repla...

Page 53: ... Test 16 Are the controller cables or any other cables components inadvertently depressing the Min Max or Adjuster buttons on PCB Error Code 29 Heat exchanger outlet temperature is too low Error Code 29 Measure the hot water outlet temperature Does the measured hot water temperature match that indicated by 5y Is the resistance of the hot outlet thermistor normal TEST 15 NO Check the burner pressur...

Page 54: ...eat exchanger thermistor 33 Hot water outlet thermistor 34 Ambient air thermistor YES YES Is the wiring between control PCB and thermistor intact Is the thermistor multi pin connector fully inserted into terminal P on control PCB YES Replace control PCB Rectify wiring NO Error Code 35 Improper Thermistor Connections Error Code 35 Is the cold and hot water pipework to the water heater reversed Reco...

Page 55: ...lace gas valve assembly NO Does the flame extinguish completely after shut down Does flame detection maintenance information 0y indicate 01 YES Clean or replace the flame rod electrode NO Replace the control PCB YES Does flame detection maintenance information 0y indicate 01 Isolate power supply for 10 seconds to clear error code Restore power Continue fault diagnosis if an error reoccurs Detach f...

Page 56: ...ode 61 Combustion fan failure Error Code 61 Is fan speed correct TEST 25 Replace the transformer Replace the control PCB The error was likely to be caused by a fluctuation in the power supply Isolate power to clear error code YES 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 re...

Page 57: ...ress MIN SW1 or MAX SW2 button to initiate fan operation Test measurements are to be as follows Test Check Point Measured Value 18 6 Red 4 Black Indoor DC144 192V 6 White 4 Blue Outdoor 19 3 White 4 Black Indoor DC12 18V 3 Red 4 Blue Outdoor Test 20 21 Disconnect the fan plug connector J and power plug connector I from control PCB Using a multimeter set on the kilo ohms scale insert the multimeter...

Page 58: ...ents are to be as follows Plug Check Point Measured Value Outdoor Indoor E 6 Red 3 Black 5 8Ω 3 6Ω E 11 Yellow 3 Black 7 11Ω 5 8Ω E 1 Grey 7 Grey 12 18Ω 10 16Ω D 1 Brown 3 Blue 16 22Ω 10 14Ω Test 23 24 Disconnect the fan plug connector J from control PCB Remove the protective covers from connector J to enable clear access for multimeter test probes Using a multimeter set on the kilo ohms scale ins...

Page 59: ...N SW1 button to initiate low fire fan operation and use table below to confirm fan speed is correct Depress and hold MAX SW2 button to initiate high fire fan operation and use table below to confirm fan speed is correct Fan speeds are to be as follows 5 Star Models Sea Level 1000 2000 Metres 2001 3000 Metres Model MIN MAX MIN MAX MIN MAX 27L Ext NG 2700 6700 2900 7100 3100 7500 27L Int NG 2700 605...

Page 60: ... Check wiring if intact replace the control PCB NO YES Replace water volume control assembly Is the voltage to the water volume control motor normal TEST 26 Check wiring if intact replace the control PCB NO YES Error Code 66 Water Bypass Control Motor fault Error Code 66 Isolate power to unit for 10 seconds and restore power When motor operates is the voltage to the water bypass control motor norm...

Page 61: ... Check Point Measured Value Test Check Point Measured Value 26 7 Red 8 Black DC8 16V 28 7 Red 8 Black DC8 16V 27 2 White 8 Black DC8 16V 29 2 White 8 Black DC8 16V Error Code 71 Gas Inlet Solenoid Valve GISV fault Error Code 71 Check wiring if intact replace the control PCB NO Is there voltage at the GISV TEST 9 Replace the gas valve assembly YES Is multi pin plug fully inserted into terminal W on...

Page 62: ...item YES Remove all remote control cables from terminal block on underside of heater Inspect each of the remote controls that are fitted to the appliance and ensure that there is no duplication of controllers Replace control PCB Error code 76 will remain if more than 1 type of the same controller is fitted NO Error Code 79 Fan Motor Current Fault Error Code 79 Is error code 79 redisplayed YES Isol...

Page 63: ...odel and gas type of appliance NO YES Has error code 82 reappeared after restoring power supply Replace control PCB and gas type connector The appliance seems to be normal YES NO Error Code 90 Indoor Models Blocked Flue The fluing system has failed the pre purge test At a minimum check the following 1 Ensure maximum vertical vent length and elbows do not exceed allowable limits 2 Ensure maximum ho...

Page 64: ... structure from the water heater If this fixes the problem then the issue lies in the fluing If this does not fix the problem then the issue lies in the fan motor or printed circuit board Warning Code P1 Water flow rate is less than minimum for main burner ignition The unit must have 2 5 litres per minute before the main burner will light or sustain burner When water flow does not reach minimum fl...

Page 65: ...hones that have a minimum operating system of iOS 8 1 iPhone 5 excluding iPhone 5C or Android 4 0 or later Windows phones are not compatible Power Line Telecommunication PLT Plug The EziSET kit includes a Power Line Telecommunication PLT plug pictured right and PCB which have been factory paired It is critical for correct operation that the reset and pair buttons on the underside of PLT plug refer...

Page 66: ...ower supply is not switched on Ensure PLT plugged in and GPO switched on LED 3 L3 Blue LED Flashing Normal Indicates active communication Solid No active communication Ensure PLT and router are plugged in and switched on and Ethernet cable is connected to both LED 4 L4 Green LED ON Normal Power supply is ON OFF Power supply is OFF Ensure CF heater is plugged in and switched on LED 5 L5 Dual LED Gr...

Page 67: ...Open the hot water tap fully to allow the water heater to ignite at maximum operating flow Multiple outlets may need to be opened in order to achieve maximum water flow 14 Press and hold the MAX button 3H is shown on the LED display and observe the reading on the manometer 15 Release the MAX button If the reading observed in step 14 matches the maximum gas pressure indicated on the rating label no...

Page 68: ...o use is dependent on the type of water body assembly that is installed i e if the water body has a black plug on the flow sensor wiring loom the PCB must have a matching black socket refer TB18 001 for further details Power Supply PCB Procedure 3 1 Isolate power supply 2 Remove the front cover and control PCB Refer to procedures 1 and 2 3 Remove the four screws that are retaining the PCB housing ...

Page 69: ...s valve and burner assembly one at top left hand side and one at top right hand side of manifold and four at gas valve assembly on bottom right hand side of manifold 7 Lift the burner manifold up to remove from heater cabinet 8 Reassemble in reverse order of above NOTE Ensure wiring to igniter and flame sensor is not pinched during reassembly Ensure the three gaskets on gas valve assembly are inta...

Page 70: ...d on bottom left hand side of PCB and remove clamp 4 Disconnect Earth connection at PCB housing 5 Disconnect the power cable wiring loom plug and withdraw power cable through slot in heater jacket 6 Reassemble in reverse order of above Proportional Gas Flow Regulating Valve Procedure 10 1 Isolate power and gas supplies 2 Remove the front cover OK monitor and plate burner cover plate and gas manifo...

Page 71: ...ter solution Water Bypass Control Assembly Procedure 12 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 Isolate power and water supplies 2 Unscrew the water drain plug and pressure relief valve and drain the water heater 3 Remove the front panel Refer to procedure 1 4 Re...

Page 72: ...heater cabinet 9 Reassemble in reverse order of above Ensure an O ring is fitted to each of the connections on the water volume control assembly Note When replacing the water body assembly it is important to ensure that the correct PCB is installed as fitment of an incorrect PCB will result in unit malfunction There are two PCB options available and the correct type to use is dependent on the type...

Page 73: ...cover control PCB power supply PCB and water bypass control assembly Refer to procedures 1 2 3 and 12 4 Rotate the water volume control assembly to the left to expose the cold water inlet thermistor 5 Remove the thermistor retaining screw and withdraw the thermistor taking care not to damage the o ring Ensure o ring remains located within thermistor housing 6 Disconnect the cold inlet thermistor l...

Page 74: ...care not to damage the o ring Note Water may escape during this procedure Ensure o ring remains located within thermistor housing 6 Disconnect the heat exchanger thermistor lead from the yellow cable connector 7 Reassemble in reverse order of above 8 Position the Overheat Limiter correctly as per step 6 of procedure 23 on page 76 Anti Frost Heaters Procedure 20 1 Isolate power supply 2 Remove fron...

Page 75: ... to the right of fan housing Indoor Model Remove the seventeen screws retaining the heat exchanger Eight from the outside of the heater cabinet around the flue outlet six from the flue assembly one from each side of the flue terminal and one from the bottom of combustion chamber to the right of fan housing 7 Remove heat exchanger by gently lifting the assembly up and clear of heater cabinet 8 Some...

Page 76: ... the overheat limiter assembly 5 Reassemble in reverse order of above 6 Reposition the Overheat Limiter as per the following procedure Failure to follow this step may lead to premature OHL failure When closing the OHL the short end should be at the front and joined at position 0 refer to fig 1 for both indoor and outdoor models The long end of the OHL must then be positioned on the cable guide ret...

Page 77: ...cover LED display control PCB power supply PCB and PGFR Refer to procedures 1 2 3 4 and 10 3 Disconnect primary transformer windings blue brown wires from middle of power supply PCB Terminal C 4 Disconnect the secondary windings from the top left hand side of power supply PCB Terminal E 5 Remove the four screws retaining the transformer to the back of the water heater cabinet 6 Lift the transforme...

Page 78: ...e main PCB and remove 6 Reassemble in reverse order of above Note The EziSET PCB and PLT must be a matched paired therefore the PLT plug is required to also be replaced if the EziSET PCB requires replacement individual spare parts are not available use complete EziSET kit 052310 when replacing parts EziSET Power Line Telecommunication PLT Procedure 28 1 Switch off the GPO that the PLT is plugged i...

Page 79: ...ment on the flue to maintain a minimum distance from combustible materials The water heater flue may be terminated either horizontally with a horizontal flue terminal or vertically with a vertical flue terminal The secondary flue must be self supporting and not impose a load on the water heater Warning Never operate the water heater unless it is has been installed in accordance with the installati...

Page 80: ...or a multiple unit installation a minimum distance between flue terminations must be maintained to prevent recirculation of flue gases Maintain a centre to centre distance between flue terminations of 450 mm Vertical Flue Terminal Location At least 500 mm between the underside of the flue terminal and the nearest part of a non trafficable roof At least 2000 mm between the underside of the flue ter...

Page 81: ...ilure of the water heater A drain line must be connected to the spigot on the condensate trap The drain line is to incorporate a trap and filled with water prior to the operation of the water heater The drain line from the trap to the point of discharge should be as short as possible have a continuously downward fall all the way from the water heater to the discharge outlet and have no tap valves ...

Page 82: ...ally by Rheem Technical Support All printed copies are deemed uncontrolled 82 Fluing Requirements for internal Models cont Typical Installation Typical Installation Vertical Flue Vertical Terminal with Vertical and Horizontal Sections Typical Installation Horizontal Terminal with Multiple Vertical and Horizontal Sections ...

Page 83: ...duct release Added transformer primary winding resistance test to FF chart Edwards Solahart models added 05 12 F Revision to EZ link information on pages 22 23 07 12 G Error code 99 reset procedure added 11 12 H Correction to spare part details Item 17 17b on pages 72 73 12 12 I Exploded views and replacement parts lists removed Now form part of Spare parts manual SPM CFGWH 08 13 AJ Addition of to...

Page 84: ... Flow Service Instructions REV AL Issued April 2019 This document is stored and maintained electronically by Rheem Technical Support All printed copies are deemed uncontrolled 84 Rheem Australia Pty Ltd ABN 21 098 823 511 ...

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