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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.

CONTENTS

INTRODUCTION ................................................................................................................. 3

SAFETY WARNINGS .......................................................................................................... 3

MODEL IDENTIFICATION ................................................................................................... 4

SPECIFICATIONS ............................................................................................................... 4

PREVENTATIVE MAINTENANCE ...................................................................................... 6

Frost Protection & Draining the Water Heater .................................................................. 7

INSTALLATION ................................................................................................................... 7

WIRING DIAGRAM

– ALL MODELS ................................................................................... 8

PLUMBING DIAGRAMS ...................................................................................................... 9

OPERATION ...................................................................................................................... 10

Sequence of Operation .................................................................................................. 10

Sequence of Operation Component Diagram ............................................................. 13

Operational Flow Chart

– All Models .............................................................................. 14

To Turn the Heater 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 Complaints ...................................................................................................... 20

Operational & Fault Indication ........................................................................................ 21

Fault Finding Charts ....................................................................................................... 22

Fault Diagnosis Sequence (General Fault Finding Chart) .......................................... 22

Fault Finding Tests ......................................................................................................... 39

COMPONENT ADJUSTMENT PROCEDURES & CHECKS ............................................. 45

Adjusting the Seasonal Adjustment Valve ...................................................................... 45

Adjusting the Setpoint Temperature ............................................................................... 45

DIP Switch Adjustments ................................................................................................. 45

Resetting the Overheat Switch ....................................................................................... 46

Adjusting the Ignition Rod Gap ....................................................................................... 46

Adjusting the Flame Sensor ........................................................................................... 46

Checking Inlet Gas Pressure .......................................................................................... 47

Checking & Adjusting Burner Gas Pressure ................................................................... 47

Adjusting the Gas Valve Gas Regulator ......................................................................... 49

COMPONENT REPLACEMENT PROCEDURES ............................................................. 50

DOCUMENT REVISION HISTORY ................................................................................... 61

Содержание 834 Series

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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