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TM081 Rheem 834 Series Hydroelectric CFGWH Service Instructions 
REV: AA Issued: 22/02/17 

 

This document is stored and maintained electronically by Rheem Technical Support. All printed copies are deemed uncontrolled.

 

17 

Gas  Valve

:  An  electromagnetic  valve  designed  to  control  gas  flow  to  the  pilot  and  main 

burner.  All  heaters  utilise  a  CK-690  gas  valve  which  is  equipped  with  an  internal  gas 
regulator, pilot solenoid valve (SV1) main burner safety solenoid valve (SV2), main burner 
solenoid  valve  (SV3)  and  motorised  actuated  solenoid  valve  (MASV).  Also  refer  to  'Gas 
Valve' on page 18. 

Hot  Water  Outlet  Temperature  Sensor: 

A  thermistor  type  sensor  utilised  to  detect  the 

heater's  hot  water  outlet  temperature  i.e.  the  resistance  value  of  the  sensor  will  change 
according  to  the  detected  water  temperature.  The  sensor  is  installed  in  a  well  in  the  hot 
water outlet and is connected to the temperature controller which monitors the resistance 
value  of  the  sensor  to  determine  the  heater's  outlet  water  temperature.  Also  refer  to 
'Testing the Hot Water Outlet Temperature Sensor' on page 39. 

Overheat Switch:

 An electromechanical device (bi-metallic switch) designed to shut down 

the  heater  in  case  of  excessive  temperature.  The  overheat  switch  will  open  circuit  (trip) 
when  the  detected  temperature  reaches  95°C  ±  4.5°C  and  must  be  manually  reset  by 
pressing  and  releasing  the  reset  button  on  the  overheat  switch  once  temperatures  have 
fallen to 

≤ 90°C. The overheat switch is a safety backup in case the hot water outlet 85°C 

shut  down  (software)  function  does  not  operate.  Also  refer  to  'Resetting  the  Overheat 
Switch' on page 46. 

Pilot:

 A small burner utilised to light the heater during the ignition period. The main burner 

cross  lights  from  the  pilot.  834  Series  Hydroelectric  Instantaneous  Gas  Water  Heaters 
have  an  interrupted  pilot  i.e.  the  pilot  is  lit  during  the  ignition  period  and  is  extinguished 
during normal operation of the main burner. 

Main  Burner: 

The main  burner is located at  the  bottom of the heat  exchanger assembly 

and is where gas delivered by the gas  valve is combusted.  The gas mixture flows out  of 
the perforations on the top surface of the burner bars where it is combusted providing an 
even burner flame. 

Burner Manifold: 

The burner manifold directs gas from the gas valve to the burner.  The 

burner manifold has a series of injectors that deliver gas to the rear of the burner bars. 

Heat Exchanger Assembly:

 The heat exchanger assembly is where heat transfer occurs. 

The assembly is comprised of a burner, fin tube and flue collector. The burner is located at 
the bottom of the heat exchanger and the fin tube is located above the burner. Water flows 
through the fin tube where heat transfer occurs from the burner flame. The fins on the tube 
bundle  help  to  capture  heat  whilst  allowing  hot  flue  gasses  to  flow  through  to  the  flue 
collector where they are directed to the flue outlet by natural draught. 

Air Intake Louvre /  Flue  Terminal:

 The air intake provides air for combustion whilst  the 

flue terminal provides a point of discharge for combustion gasses.

 

Pressure  Relief  Valve:

  The  PRV  provides  pressure  relief  in  case  of  system  over 

pressure. The PRV is located on the hot water outlet and also acts as a drain plug.

 

Rating label:

 The rating label details the model number, serial  number, gas type, burner 

pressure and other heater specifications. The rating label is located on the right side of the 
water heater. 
 

 

Summary of Contents for 834 Series

Page 1: ...re deemed uncontrolled R Rh he ee em m A Au us st tr ra al li ia a P Pt ty y L Lt td d A AB BN N 2 21 1 0 09 98 8 8 82 23 3 5 51 11 1 SERVICE INSTRUCTIONS 834 Series Hydroelectric Instantaneous Gas Wa...

Page 2: ...er ON Lighting Instructions 15 To Turn the Heater OFF 15 COMPONENTS AND THEIR FUNCTION 16 Gas Valve 18 Temperature Controller 18 Ignition Module 19 PRODUCT CHANGES 19 FAULT FINDING 20 Common Complaint...

Page 3: ...t information to allow a person with the skills as required by the Regulatory Authorities to carry out effective repairs to a 834 Series Hydroelectric Instantaneous Gas Water Heater in an efficient ma...

Page 4: ...8 125 Electrical Supply 3 7 VDC battery integral hydro electric generator Gas Supply Connection R 3 4 BSP Female Min Gas Pressure 1 13 kPa 2 75 kPa 1 13 kPa 2 75 kPa Max Gas Pressure 3 5 kPa 3 5 kPa 3...

Page 5: ...d wire to black wire Yellow wire output motor operation pulse check Hot Water Outlet Temperature Sensor For temp resistance chart refer to Testing the Hot Water Outlet Temperature Sensor on page 39 Ov...

Page 6: ...hydrocarbon which can catch fire Close the cold water isolation valve to the water heater to prevent the water heater from operating while you spray around the water heater Open the cold water isolati...

Page 7: ...on again To reinstate the heater after draining refer to To Turn The Heater ON Lighting Instructions on page 15 The hot water outlet drain plug is also the heater s PRV Do not use any other type of f...

Page 8: ...ies Hydroelectric CFGWH Service Instructions REV AA Issued 22 02 17 This document is stored and maintained electronically by Rheem Technical Support All printed copies are deemed uncontrolled 8 WIRING...

Page 9: ...water heaters setpoint temperature The temperature limiting device must have a specified minimum temperature differential between the hot water inlet and the tempered water outlet of no greater than...

Page 10: ...ence of Operation and Operational Flow Chart sections detail heater operation Sequence of Operation Refer to Sequence of Operation Component Diagram on page 13 to view components shown in brackets e g...

Page 11: ...heater is reduced by 1 4L m the pilot 11 will light SV1 12 energised the main burner 5 will extinguish SV21 6 SV3 7 de energised the MASV will readjust and the main burner will relight SV2 SV3 energis...

Page 12: ...pendent on initial water flow rate and inlet water pressure The water throttle valve is de energised when the hot water outlet temperature sensor detects 20 C or 12 5 seconds has expired Note This fun...

Page 13: ...Hydroelectric Generator 11 Pilot 2 Water Flow Sensor 12 SV1 Pilot Solenoid Valve 3 Temperature Controller 13 Heat Exchanger 4 MASV Motor Actuated Solenoid Valve 14 Air Intake Louvre 5 Main Burner 15 F...

Page 14: ...ame detected 0 5 A within 45 seconds NO Critical fault Igniter pulse ignition spark off SV2 SV3 energised after 4 seconds YES Battery recharge function on until battery voltage is 3 5 VDC NO Hydro ele...

Page 15: ...tap when water runs freely from it when air is purged water will run freely from the hot tap without spluttering 5 Fully open the gas isolation valve at the gas inlet to the water heater The water hea...

Page 16: ...that is also proportionate to the water flow rate through the heater The temperature controller uses the pulse signal to determine if there is sufficient water flow for heater operation 3 L m Water Th...

Page 17: ...Pilot A small burner utilised to light the heater during the ignition period The main burner cross lights from the pilot 834 Series Hydroelectric Instantaneous Gas Water Heaters have an interrupted p...

Page 18: ...wing pages for gas valve information Gas Valve Information Page Wiring Diagram 8 Sequence of Operation written explanation 10 Operational Flow Chart 14 Checking Inlet Gas Pressure 47 Checking Adjustin...

Page 19: ...The P700 ignition module provides a pulsed high voltage to the ignition rod to create a spark for pilot ignition The ignition module also proves and supervises the pilot and burner flame via the flam...

Page 20: ...s i e solenoid valves ball cocks loose pipes sharp angles in pipe work faulty or worn valve parts or neighbouring equipment High water pressure areas will have more complaints of this nature and the u...

Page 21: ...on may also occur if the heater is faulty Critical Fault Indication If any of the following critical faults are detected the burner will shut down and the red LED will illuminate and flash with a two...

Page 22: ...er Noisy heater Does the temperature controller red LED indicate a fault when water is flowing through the heater 2 3 Water flow rate through the heater must be 3 L m for the water heater to operate 1...

Page 23: ...orrect gas type for the premises gas supply Overheat switch has been reset Continue fault finding to determine why switch had tripped Are temp controller DIP switches 1 6 in the correct position Refer...

Page 24: ...Replace ignition module NO Fault rectified Replace temperature controller and reinstall original ignition module Does red LED 2 flash fault indication persist YES Fault Finding Chart Red LED 3 Flash...

Page 25: ...n rod and or pilot hood or replace pilot assembly ignition rod is not available as a spare part YES NO Is ignition rod gap correct YES Correctly adjust ignition rod gap Refer to Checking Adjusting the...

Page 26: ...ke up to 225 seconds to occur from when a hot tap is opened Are all wiring plugs and wiring connectors firmly connected YES NO Firmly connect wiring connector s and or plug s Fully open gas isolation...

Page 27: ...essure in the Component Adjustment Procedures Checks section NO Is gas inlet pressure correct Advise customer that gas supply pressure is not within specifications NO YES NG 1 13 3 5 kPa LPG 2 75 3 5...

Page 28: ...LED Continuously Flashing Battery disconnected or battery voltage too low 3 1 VDC Is correct type of battery installed in temp controller YES NO Is battery voltage 3 1 VDC TEST 11 end of battery in do...

Page 29: ...valve fully open YES Advise customer that water supply pressure is not within specification NO Minimum water supply pressure is 150 kPa Is water supply pressure adequate Fully open cold water isolato...

Page 30: ...Finding Chart 1 1 1 1 NO Heater not operating continued YES Replace temperature controller Does hydroelectric generator generate 1 1 1 7 VDC TEST 12 Replace hydroelectric generator flow sensor assembl...

Page 31: ...VDC present at SV1 during ignition period TEST 8 Replace ignition module NO Is pilot feed pipe pilot injector or pilot assy dirty or blocked YES Replace gas valve assembly Clean or replace pilot feed...

Page 32: ...be correctly adjusted Fault rectified Check heater operation NO YES Can gas valve internal gas regulator be adjusted Fault rectified Check heater operation NO YES NO Replace temperature controller and...

Page 33: ...Adjusting Burner Gas Pressure in the Component Adjustment Procedures Checks section NO YES Is gas inlet pressure correct Advise customer that gas supply pressure is not within specifications NO NG 1...

Page 34: ...ontrolled 34 Fault Finding Chart 2 1 2 1 Water not hot enough continued Replace hot water outlet temperature sensor NO Is hot water outlet temp sensor ok TEST 1 Are main burner injectors correct size...

Page 35: ...on NO Is gas inlet pressure correct Advise customer that gas supply pressure is not within specifications NO YES NG 1 13 3 5 kPa LPG 2 75 3 5 kPa Replace heater with a heater of the correct gas type I...

Page 36: ...heat exchanger cold water pipe connection o ring Replace hydroelectric generator water flow sensor assembly Is leak from seasonal adjustment valve NO YES NO Is leak from hydro electric generator wate...

Page 37: ...PRV or replace PRV o ring YES NO Tighten or remake hot water outlet plumbing connection Existing pressure limiting valve faulty Replace pressure limiting valve and replace PRV it still discharges Is...

Page 38: ...ures Checks section Is gas inlet pressure correct Advise customer that gas supply pressure is not within specifications NO YES NG 1 13 3 5 kPa LPG 2 75 3 5 kPa Is heater the correct gas type for the p...

Page 39: ...lerance of 2 C Note If a spot thermometer is not available or the temperature at the sensor cannot be accurately measured remove sensor from sensor well refer to component replacement procedure 24 on...

Page 40: ...ing result should be obtained Less than 1 ohm overheat switch has not tripped Test 3 Isolate water supply to heater to prevent heater from operating Disconnect SV3 MASV wiring loom plug and using a mu...

Page 41: ...lowing result should be obtained prior to the ignition period when water flow is not present 0 VDC Test 6 Using a multimeter set on the DC voltage scale measure between SV2 wiring terminal green wire...

Page 42: ...h wire on the gas valve body The following result should be obtained during the ignition period 1 1 2 1 VDC Test 9 Using a multimeter set on the DC voltage scale measure between SV2 wiring terminal gr...

Page 43: ...the two terminals on the battery The following result should be obtained 3 1 VDC Test 12 Using a multimeter set on the DC voltage scale measure between wiring pin 1 black wire and wiring pin 2 red wi...

Page 44: ...l printed copies are deemed uncontrolled 44 Fault Finding Tests 14 Test 14 Using a digital multimeter set on the frequency Hz scale measure between wiring pin 8 orange wire and wiring pin 9 orange wir...

Page 45: ...r to component replacement procedure 1 on page 50 3 Set temperature controller DIP switches 7 and 8 to the desired setting as indicated in the Setpoint Temperature Table Note DIP switch up ON 4 Replac...

Page 46: ...the ignition rod and the closest part of the pilot hood The gap should be 3 5 4 0 mm 3 If the gap requires adjusting remove the ignition rod hold the ignition rod metal section with a pair of long nos...

Page 47: ...rner is operating at full capacity 8 Check manometer reading whilst burner is operating Inlet gas pressure should be 1 13 3 5 kPa for Natural Gas or 2 75 3 5 kPa for Propane 9 Close the hot tap s 10 T...

Page 48: ...perate on the maximum gas pressure setting 12 Observe the gas pressure reading on the manometer and compare to the maximum test point gas pressure stated on the rating label 13 If adjustment is requir...

Page 49: ...ocedure on page 47 and follow the relevant instructions below whilst performing step 9 If the minimum burner gas pressure can be obtained proceed directly to step 4 of this procedure If the minimum bu...

Page 50: ...the risk of scalding It is good practice to ensure wiring does not touch metallic components that are likely to become hot Use cable ties where required and do not attach cable ties to metallic compo...

Page 51: ...semble in reverse order of above Note When reconnecting ignition module leads ensure top ignition module lead connects to ignition rod and bottom ignition module lead connects to flame rod Pilot Assem...

Page 52: ...elow heater 2 Isolate gas supply to heater by closing gas isolation valve located below heater 3 Remove front panel by following steps 1 2 of procedure 1 4 Using a 9 mm spanner hold pilot injector and...

Page 53: ...tlet drain plug 5 Remove two Phillips head screws retaining pilot shield and remove pilot shield 6 Disconnect high tension lead from ignition rod by pulling lead away from ignition rod 7 Disconnect hi...

Page 54: ...eads ensure top ignition module lead connects to ignition rod and bottom ignition module lead connects to flame rod Take care not to cross thread large hex head nut at the burner manifold to gas valve...

Page 55: ...gas valve assembly will need to be replaced 1 Remove gas valve by performing steps 1 9 of procedure 13 2 Disconnect pipe work from gas inlet connection 3 Remove two Phillips head screws retaining gas...

Page 56: ...ng a hot tap then drain the heater by disconnecting plumbing from cold water inlet connection and removing the hot water outlet drain plug 5 After heater has drained remove clamp from heat exchanger c...

Page 57: ...es apart be careful not to lose assembly o ring 3 Reassemble in reverse order of above ensuring o rings are clean free from cracks and lubricated with silicone grease if dry 4 Start heater and check f...

Page 58: ...emove five Phillips head screws retaining flue collector flue terminal assembly to heater surround panel 8 Remove two Phillips head screws retaining flue collector flue terminal assembly fixing bracke...

Page 59: ...ng cold water inlet isolation valve located below heater 2 Remove front panel by following steps 1 2 of procedure 1 3 Disconnect sensor wiring loom plug 4 Relieve system pressure by opening and then c...

Page 60: ...g Procedure 26 1 Isolate water supply to heater by closing cold water inlet isolation valve located below heater 2 Relieve system pressure by opening and then closing a hot tap 3 Unscrew PRV Drain plu...

Page 61: ...REVISION HISTORY Title Rheem 834 Series Hydroelectric CFGWH Service Instructions Document N TM081 Rev Details of change D O I 00 Service Manual Issued for 834 Series Water Heaters 10 16 AA Adjusting b...

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