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TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B
D.O.I: February 2008

This document is stored and maintained electronically by

Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Exploded View 1 871018 / 871020 / 871024 Replacement Parts List

Ref.

No.

Description

871018
871020

871024

001

Front Panel Assembly

WH0020000

003

Jacket Assembly

WH0020001

004

Mounting Bracket

WH0020002

006

Reinforcing Plate

WH0020003

008

Cord Connector

WH0020004

066

Fixing Plate B

WH0020005

100

Gas Inlet Connector

WH0020006

103

Proportional Gas Flow Regulating Valve

WH0020007

104

„O‟ ring

WH0020009

105

Gasket

WH0020010

108

Gasket

WH0020012

111

Upper Burner Assembly

WH0020013

WH0020014

120

Lower Burner Assembly - NG

WH0020015

WH0020016

120

Lower Burner Assembly - LP

WH0020017

WH0020018

123

Primary Air Adjuster

WH0020085

160

Burner Change-Over Assembly

WH0020019

WH0020020

401

Water Inlet Connector Assembly (¾)

WH0020021

Water Inlet Connector Assembly (½) - 18 litre only

WH0020086

402

„O‟ ring

WH0020022

403

CS Type Snap Ring

WH0020023

405

Water Drain Valve Assembly (includes water filter)

WH0020024

407

Water Filter

– use WH0020024

N/A

408

Plug Band

WH0020026

409

„O‟ ring

WH0020027

410

Water Body Assembly

WH0020028

415

Heat Exchanger and Combustion Chamber Kit

WH0020029

WH0020030

419

Flange

WH0020031

422

Combustion Chamber Front Panel Assembly

WH0020032

WH0020033

427

„O‟ ring

WH0020034

429

„O‟ ring

WH0020035

430

Hot water Outlet Connector (¾)

WH0020036

Hot water Outlet Connector (½)

– 18 litre only

WH0020087

431

Relief Valve Assembly

WH0020037

433

„O‟ ring

WH0020038

434

Safety Valve Band

WH0020039

445

Flange

WH0020040

701

Over Heat Limiter Assembly

WH0020042

768

Terminal Block Assembly

WH0020043

828

Truss Gasket Screw 4 x 10

WH0020044

Содержание 871018

Страница 1: ...Electronic Gas Continuous Flow Water Heater TM031 R R Re e ev v vi iis s si iio o on n n B B B P P Pu u ub b bl lli iis s sh h he e ed d d F F Fe e eb b br r ru u ua a ar r ry y y 0 0 08 8 8 871018 87...

Страница 2: ...rror Code History 31 Resetting Error Codes 32 Fault Diagnosis Sequence Fault Finding Chart G 33 Fault Finding Chart 1 34 Fault Finding Chart 2 36 Fault Finding Chart 3 38 Fault Finding Chart 3 1 40 Fa...

Страница 3: ...D 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 servic...

Страница 4: ...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 te...

Страница 5: ...vice Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 5 Wiring Diagr...

Страница 6: ...6 Wiring Diagram Models with Solenoid Operated Bypass...

Страница 7: ...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 Valv...

Страница 8: ...024 B 871024 C 871024 871024 B 871024 C Max burner gas test pressure kPa 0 903 1 5 0 903 1 5 0 71 0 912 0 71 1 078 0 965 1 2 Min burner gas test pressure kPa 0 182 0 32 0 182 0 32 0 15 0 17 0 16 0 22...

Страница 9: ...perates 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 co...

Страница 10: ...he resistance of the water body assembly heater is 137 1 ohms for the 24 and 26 litre models Refer to Procedure 10 on page 55 for replacement procedure Product Changes Software Changes 18 and 20 litre...

Страница 11: ...00 31 76653 00 758 Signal Loom WH0020067 31 76655 00 773 Power Filter WH0020079 31 71642 00 780 Power cord WH0020071 31 76652 00 783 Transformer WH0020073 31 71646 00 784 Connecting Cord 31 23492 00...

Страница 12: ...BP connectors otherwise in addition to the power filter it will also be necessary to replace Connecting Cord Pt N 31 71641 00 item 784 Power Cord Pt N 31 76652 00 item 780 Transformer Pt N 31 71646 00...

Страница 13: ...Pt N 20 64773 00 item 717 Ambient air thermistor now part of the signal loom Pt N 31 76655 00 item 758 Outlet thermistor Pt N 20 64774 00 item 713 Overheat Limiter Pt N 31 79562 00 item 701 Flow Sens...

Страница 14: ...0 43805 00 This part may be connected to existing wiring utilising electrical BP connectors otherwise in addition to the flow sensor it will also be necessary to replace Signal Loom Pt N 31 76655 00 i...

Страница 15: ...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 20 and 26 models with modified softwa...

Страница 16: ...allow for removal of the valve The solar bypass valve has been specifically designed to work with Rheem Integrity models listed above 20 and 26 models ending with a B do not require a bypass valve 24...

Страница 17: ...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 Val...

Страница 18: ...3 and disconnect 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 7 Position and secure the comparato...

Страница 19: ...71024 871024 B 871026 Solar Loline Installation Note For 871020 871024 871024 B and 871026 model heaters fitted with a comparator refer to diagram on page 15 For more information on comparators refer...

Страница 20: ...e Integrity 18 20 24 and 26 Litre electronic continuous flow gas water heater can be fitted with optional remote controllers Controller Type Bathroom 1 Controller Bathroom 2 Controller Kitchen Control...

Страница 21: ...troller 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 ov...

Страница 22: ...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...

Страница 23: ...hart section shown directly below where the Sequence Number falls The flow diagram below outlines the recommended procedure to successfully diagnose test and rectify faults on the Integrity range of w...

Страница 24: ...ed 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 I C Integrated Ci...

Страница 25: ...tched off Remote controller display off Remote controller display on On Off lamp Off On Off lamp On Fan On Fan Off 10 seconds later 5 14 Flashing Over heat limiter failure B Bath fill operation Water...

Страница 26: ...es or lower 16 Solenoid bypass valve off YES NO Low rate combustion 10 Flashing YES 3 19 79 Flashing 14 Flashing 31 Flashing 32 Flashing 33 Flashing 34 Flashing 35 Flashing 11 Flashing 12 Flashing 56...

Страница 27: ...t minimum 4 5 Post Purge Shut Down Function Water flow sensor off Check gas cut off function by alternating the closing order of gas valves SVO and SV 1 3 at each shut down Fan motor at minimum LED of...

Страница 28: ...nlet thermistor diagnostic point 5 32 Heat exchanger thermistor open circuit Heat exchanger thermistor diagnostic point 6 33 Outlet thermistor open circuit Hot water thermistor diagnostic point 7 34 A...

Страница 29: ...ater Outlet Thermistor 40 C 4 9 kilo ohms 8 B B3 BL7 25 C 5 0 kilo ohms Ambient Air Thermistor 5 C 12 7 kilo ohms 9 J R1 Earth AC 2V 20V 2 Flame Sensor detecting flame W3 Earth AC 2V 20V 2 B2 Earth AC...

Страница 30: ...ustion operations since last error X 10 000 hours Null D Total combustion starts X 100 Total combustion operations since last error X 100 hours Null H Total combustion period X 1000 hrs Total combusti...

Страница 31: ...nsure 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 LE...

Страница 32: ...r 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...

Страница 33: ...End 5 YES NO If the water heater operated normally follow procedures 2 3 or 5 depending on the previous error codes displayed in the maintenance history accessed from the PCB NOTE If the power has be...

Страница 34: ...pply Is 240 volts AC Present at the power point NO No power supply Check household wiring YES Test 1 Cordset open circuit replace Inline fuses open circuit replace Internal wiring from terminal block...

Страница 35: ...transformer primary winding with a multimeter set on the AC voltage scale If the voltage is between 230V and 250V the cord set and inline fuses are ok Measure the voltage at the connector plug from t...

Страница 36: ...24 26L Service Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 36...

Страница 37: ...nnector K from the PCB Restore power and check if error code 79 is displayed within 30 seconds Isolate power when conducting resistance tests Live components present during voltage tests exercise caut...

Страница 38: ...code 24 shown on error code display also Replace the remote controller NO Also when Min Max button is pressed YES Release the Min Max buttons and re open a hot tap YES Replace the PCB assembly NO YES...

Страница 39: ...tor 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 9...

Страница 40: ...ion Ignition failure or cross light failure Test 11 NO Is flame detection signal in maintenance information 00 Replace the PCB assembly NO YES Clean or replace the combustion chamber front panel assem...

Страница 41: ...urner pressure correctly Replace the combustion chamber front panel assembly Clean the burner YES Test 17 3 2 Replace the proportional gas flow regulating valve assembly Is the gas pressure correct at...

Страница 42: ...ic Point 14 GISV DC70 to DC100V 9 Yellow 10 Black 11 15 GISV 0 8kilo ohms to 2 2kilo ohms 9 Yellow 10 Black 11 18 1 3 Red 10 Black 13 19 1 3 Red 10 Black 13 2 4 White 10 Black 14 2 4 White 10 Black 14...

Страница 43: ...enance information indicating 00 Replace the PCB assembly NO YES Test 11 Replace the combustion chamber front panel or remove the upper burner assembly and replace flame sensors depending on the model...

Страница 44: ...he set temperature is below 46 degrees Is the voltage at connector between H2 H8 and H7 H8 normal Test 31 NO NO Replace water body assembly YES Tests 23 24 Is the water flow servo motor at ON position...

Страница 45: ...st with water flowing Conduct test with water flowing 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...

Страница 46: ...grity outlet temp set at60 C Set the Integrity outlet temp to 60 C NO YES Error code16 will occur if the Integrity heats the water to 20 above the set point 3 C 60 20 3 77 C YES Is the resistance of t...

Страница 47: ...ault Finding Tests 29 31 Test 29 Diagnostic Point 3 Components will be Live when conducting tests exercise caution Conduct test with water flowing Measure the voltage between 9 Brown and 10 Black on c...

Страница 48: ...ster Remove controllers YES Test 29 NO Is a solar bypass valve fitted 871024 C models do not require a solar bypass valve Remove the solar bypass valve and remake water connections directly to Integri...

Страница 49: ...ring the Integrity 57 C YES Water will flow straight through the Integrity and the Integrity will not operate Normal operation Is the water flow more than 3 litres min Replace the PCB assembly YES Is...

Страница 50: ...to the solar bypass valve 57 C Read maintenance information 1y 1y Water flow detected by water flow sensor Water will be diverted by the solar bypass valve No water will flow through the Integrity the...

Страница 51: ...r heater take care not to touch wiring terminals Use an insulated tool when operating the DIP switch or MIN and MAX buttons Minimum Burner Gas Pressure 1 Remove the front panel from the water heater 2...

Страница 52: ...ometer 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 clea...

Страница 53: ...Front Panel Assembly 4 Reassemble in reverse order of above Replace gaskets item numbers 105 and 108 if required 5 Test for gas leaks using soapy water solution Lower Burner Assembly Procedure 4 1 Re...

Страница 54: ...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...

Страница 55: ...rner 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 o...

Страница 56: ...t in any model heater other interconnecting components may also require replacing Refer to Product Changes on page 10 and Parts Replacement Scenarios on page 11 for more information 1 Isolate cold wat...

Страница 57: ...dure 16 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...

Страница 58: ...heater 4 Disconnect the cold water supply pipe from the cold water inlet connection 5 Disconnect the bypass solenoid wiring loom plug 6 Remove 2 Philips head retaining screws holding flow sensor to w...

Страница 59: ...age 11 for more information 1 Isolate power at the water heater 2 Disconnect connecting cord wiring loom plug to power cord 3 Disconnect remaining two connecting cord wiring loom plugs and remove conn...

Страница 60: ...Service Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 60 Exploded...

Страница 61: ...imary Air Adjuster WH0020085 NF 160 Burner Change Over Assembly WH0020019 WH0020020 401 Water Inlet Connector Assembly WH0020021 WH0020021 Water Inlet Connector Assembly 18 litre only WH0020086 NF 402...

Страница 62: ...Service Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 62 Exploded...

Страница 63: ...20058 735 Ignition Pack WH0020059 WH0020059 737 Flame Sensor Loom WH0020060 WH0020061 745 PCB Assembly WH0020062 WH0020062 751 Gas Type Connector NG WH0020064 WH0020063 751 Gas Type Connector LP WH002...

Страница 64: ...26L Service Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 64 Expl...

Страница 65: ...ssembly WH0020020 401 Water Inlet Connector Assembly 10 65408 00 402 O ring WH0020022 403 CS Type Snap Ring WH0020023 405 Water Drain Valve Assembly includes water filter WH0020024 407 Water Filter 21...

Страница 66: ...26L Service Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 66 Expl...

Страница 67: ...1 76655 00 716 O ring Thermistor WH0020055 723 Hall Effect I C Assembly 20 43805 00 728 Combustion Fan WH0020057 729 Fan Case Assembly 10 88629 00 735 Ignition Pack 31 76722 00 737 Flame Sensor Loom 3...

Страница 68: ...tions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 68 Exploded View 3 871024...

Страница 69: ...P WH0020018 160 Burner Change Over Assy Including solenoids WH0020020 401 Water Inlet Connector Assembly 10 65408 00 402 O ring WH0020022 403 CS Type Snap Ring WH0020023 405 Water Drain Valve Assy inc...

Страница 70: ...tions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 70 Exploded View 4 871024...

Страница 71: ...3 Hall Effect I C Assembly 20 43805 00 728 Combustion Fan WH0020057 729 Fan Case Assembly 10 88629 00 735 Ignition Pack 31 76722 00 737 Flame Sensor Loom 31 76721 00 745 PCB Assembly 31 76623 0S 751 G...

Страница 72: ...V B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 72 Exploded View 5 871024 871026 8...

Страница 73: ...rods 31 76237 00 160 Burner Change Over Assembly WH0020020 401 Water Inlet Connector Assembly 26 L 10 65408 00 402 O ring WH0020022 403 CS Type Snap Ring WH0020023 405 Water Drain Valve Assy includes...

Страница 74: ...B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 74 Exploded View 6 871024 C 871026...

Страница 75: ...WH0020057 729 Fan Case Assembly 10 88629 00 735 Ignition Pack 31 76722 00 737 Flame Sensor Loom 31 76721 00 745 PCB Assembly 31 76623 0S 751 Gas Type Connector NG 31 76581 00 31 76592 00 Gas Type Con...

Страница 76: ...and Procedure 23 7 Fit replacement Propane lower burner assembly Propane NG 6 Install Nozzle plate and nozzle plate screws models ending with C suffix only Refer to figure 3 and Procedure 23 7 Fit rep...

Страница 77: ...26L Service Instructions REV B D O I February 2008 This document is stored and maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 77 Fig...

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