SERVICE INSTRUCTIONS 18 & 20L Integrity Electronic Gas Instantaneous Water Heater TM002 R Reevviissiioonn:: EE PPuubblliisshheedd:: N Noovveem mbbeerr 0077 871018 875018 871020 875020 This document is stored and maintained electronically by Service.
Contents Safety Warning ....................................................................................................................3 Introduction ..........................................................................................................................3 Water Heater Model Identification........................................................................................3 Specifications................................................................................................
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.
Specifications 871018N0 871018NF 875018NF 871018NF-B 875018NF-B 871018PF 875018PF 871018PF-B 875018PF-B 871020N0 871020NF 875020NF 871020NF-B 875020NF-B 871020PF 875020PF 871020PF-B 875020PF-B Natural Propane Natural Propane Max hourly gas consumption (MJ/Hr) 157 157 157 157 Min hourly gas consumption (MJ/Hr) 24 24 24 24 Min inlet water pressure (kPa) 140 140 140 140 Max inlet water pressure (kPa) 1000 1000 1000 1000 Min inlet gas pressure (kPa) 1.13 2.75 1.13 2.
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.
Wiring Diagram - Models with Mechanical Bypass TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by 6 Service.
Wiring Diagram - Models with Solenoid Operated Bypass TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by 7 Service.
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).
Sequence of Operation Component Diagram 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Hot Water Tap Bypass Control Valve Water Flow Sensor Inlet Water Temperature Thermistor Combustion Chamber Thermistor Outlet Water Temperature Thermistor Water Flow Servo Motor Water Filter (Strainer) Gas Inlet Solenoid Valve Gas Solenoid Valve 1 Gas Solenoid Valve 2 Gas Solenoid Valve 3 (not fitted on 18 & 20L models) PGFR Valve Nozzle Burner Igniter Igniter Electrode Flame Sensor Heat Exchanger
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.
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.
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.
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).
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.
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. TM002 Integrity 18 & 20L Service Instructions REV: E D.O.
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 50oC however the delivered water temperature at the tap will be that set by the tempering valve which will be no hotter than 50oC.
875 series models are factory set and limited so that they cannot deliver water hotter than 48oC. When no hot water is flowing, temperatures can be selected between 37oC and 43oC by pressing and holding the temperature control buttons, to select temperatures above 43oC 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.
ON / OFF button 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. Priority light This light will glow on a controller when that controller has priority.
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.
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.
Operational Flow Charts Operation Flow Chart 1 Plug In Power On 1 Error code cleared Isolate Power On/Off lamp Off Remote controller display off Initial check normal? NO Functional problem on gas type circuit board Communication problem between remote controller and the heater 82 Flashing 76 Flashing YES Remote controller switched on Remote controller switched off Fan Off 10 seconds later On/Off lamp On Remote controller display on Fan motor current detection failure G.I.S.
F 11 12 Operational Flow Chart 2 F1 G.I.S.V (SVO) on Igniter on Igniter off P.G.F.R Valve off 13 S.V.1 (SV1) on 14 S.V. 2 (SV2) on 10 P.G.F.R Valve on 16 Flame Detected? Leakage > than 0.1uA S.V. 2 (SV2) off S.V. 1 (SV1) off 0.1 seconds later G.I.S.V (SVO) off P.G.F.R Valve off First ignition trial? NO 3 seconds later YES G.I.S.V (SVO) off S.V. 1 (SV1) off S.V. 2 (SV2) off YES P.G.F.R Valve off NO [on] displayed C.I.
Operation Flow Chart 3 Hot tap closed Post Purge Shut Down Function 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 P.G.F.R Valve at minimum Fan motor at minimum LED off Fan motor at minimum C.I. Off YES 4 8 seconds later Flame current detected less than 0.1uA? NO YES G.I.S.V (SVO) off or [S.V. 1-2 (SV1-2) off] S.V. 1-2 (SV1-2) failure G.I.S.
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.
Diagnostic Test Points Refer to wiring diagram, page 7, for connector and wiring positions.
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.
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.
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.
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.
Fault Finding Chart 1 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. Power Supply 1 Is 240 volts AC Present at the power point? No power supply. Check household wiring. NO YES Is Test 1 240 volts AC Present at the transformers primary winding? NO Cordset open circuit? - replace. Inline fuses open circuit – replace.
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 the 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 the transformer secondary winding with a multimeter set on the AC voltage scale. If the voltage is between 90V and 110V the transformer is ok.
Fault Finding Chart 2 System Not Ready 2 Overheating Is error code 14 displayed? YES Test 5 Is the resistance of the over temp limiter normal? Replace over temperature limiter and check for damage in the combustion chamber. Check and reset minimum and maximum burner pressures if required. NO YES NO Is error code 71 displayed? Solenoid valve malfunction YES Replace the PCB assembly.
Fault Finding Tests 5 – 8 Isolate power before removing connector plugs Test 5 Test 6 Unplug connector B from the PCB and measure Unplug connector K from the PCB. Restore the resistance of the Over Heat Limiter power and check if error code 79 is displayed Assembly. Resistance should be between 50kilowithin 30 seconds. ohms and 500 kilo-ohms. Isolate power when conducting resistance tests.
Fault Finding Chart 3 Ignition and Temperature Control 3 Is error code 24 displayed? Operation switch malfunction YES Is error code 24 shown on error code display also? NO Test 7 Also when Min/Max button is YES pressed? YES Replace the remote controller. Release the Min/Max buttons and re-open a hot tap.
Fault Finding Tests 9 – 13 Isolate power when conducting resistance tests.
Fault Finding Chart 3.1 3.1 False flame detection malfunction Is error code 72 displayed? YES Test 11 Is flame detection signal in maintenance information 00? NO Replace the PCB assembly. NO Clean or replace the combustion chamber front panel assembly. YES Ignition failure or cross light failure Is error code 11 YES displayed? Did the burner ignite? YES Is there any voltage at the flame sensors? Test 12 NO Replace the PCB assembly. NO YES NO Did the igniter spark? YES 3.
Fault Finding Chart 3.2 3.2 Is gas available? NO Open the gas isolation valve. YES Is the gas pressure correct at the burner test point? NO Test 14 Is there voltage at the gas inlet solenoid valve? NO Replace the PCB assembly. NO Replace the proportional gas flow regulating valve assembly.
Fault Finding Tests 14 – 22 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 Solenoid Valve 14 GISV 1 18 2 Normal Voltage Test Point 9 Yellow 10 Black 3 Red 10 Black 4 White 10 Black Diagnostic Point Test Solenoid Valve 11 15 GISV 13 1 19 14 2 Tests 16 and 17 - Diagnostic Point 10 Normal Resistance Test Point 0.8kilo-ohms to 2.
Fault Finding Charts 3.3 and 3.5 3.3 Is error code 12 displayed? Flame failure YES Are the max and min burner pressures correct? NO NO Is error code 10 or 99 displayed? YES Abnormal combustion 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’.
Fault Finding Chart 3.6 3.6 Water flow servo malfunction Is error code 65 displayed? YES 871018-B 875018-B 871020-B 875020-B & *solenoid bypass models. *Mechanical bypass models. Test 30 Is the bypass solenoid open circuit? Integrity Temp set below 46º. Integrity Temp set above 46º. Replace water body assembly. NO *For models without a -B suffix e.g.
Fault Finding Tests 23 – 28 Test 23 - Diagnostic Point 18 Test 24 - Diagnostic Point 18 Conduct test 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” when conducting tests, exercise caution Test 25 - Diagnostic Point 18 Test 28 - Diagnostic Point 3 Test Point Connector H Measured Value Conduct test with water flowing 6 Green - 8 Black
Fault Finding Chart 3.7 3.7 Is error code 16 displayed? Outlet water temp too high *Is the Is the Set the Integrity Integrity used as YES NO Integrity outlet temp outlet temp to an in-series gas set at 60ºC ? 60ºC booster? *875 series model heaters are unsuitable for **Error code 16 will occur if the YES use as in-series gas Integrity heats the water to 20º boosters above the set point -3ºC.
Fault Finding Chart 3.8 3.8 Fan current detecting circuit failure Error code 79 displayed. Was Error code 79 displayed prior to opening the hot tap? YES 2 Replace the PCB assembly. Note: only replace the PCB assembly if error code 79 is displayed during combustion. NO Fault 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 connector B.
Fault Finding Charts 4 and 4.1 4 Is the Integrity used as an in-series gas booster? YES Are Controllers fitted? 4.1 Read maintenance information 1y Is the water flow more than 3 litres/min? 1y = Water flow detected by water flow sensor NO NO YES Test 28 Is the voltage between NO connector B10 & 11 normal? YES Controllers must not be fitted when an Integrity is used as an in-series gas booster. Remove controllers. Replace the PCB assembly.
Fault Finding Chart 4.2 4.2 Is a solar bypass valve fitted? YES Is a comparator fitted? YES 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. NO NO 4.
Fault Finding Chart 4.3 4.3 Is the preheated water to the solar bypass valve > 57ºC? YES Water will be diverted by the solar bypass valve. No water will flow through the Integrity therefore it will not operate. Normal operation. YES Replace the PCB assembly.
Fault Finding Tests 32 and 33 Test 32 Components will be “Live” when conducting test, exercise caution Conduct test with water flowing 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. Test 33 Isolate power when removing flow turbine Remove flow sensor turbine by following component replacement procedure 21 on page 53.
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 1. 2. 3. 4. 5. Remove the front panel from the water heater. Remove burner test point screw and fit manometer. Turn on the remote controller (If fitted). Open a hot tap slowly, to achieve the minimum flow rate at which the burners will ignite.
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.
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.
Anti-Frost Heaters: (Procedure 10) Note: Only models with an ‘F’ in the model number are fitted with anti-frost heaters e.g. 871020NF. 1. Remove the front panel. Refer to Procedure 1. Heat Exchanger and Hot Water Outlet Connection Heaters 1. 2. 3. 4. Disconnect connector plugs at the sensing thermostat and at the power cord. Remove Flange (item 445) to release the Hot Water Outlet Anti-frost Heater. Unclip the 2 anti-frost heaters from the heat exchanger (Note the positions of both).
Ignition Pack Replacement: (Procedure 12) 1. 2. 3. 4. 5. 6. Remove the front panel. Refer to Procedure 1. Disconnect high voltage lead from spark electrode. Disconnect the multi pin connector from the Ignition Pack. Remove the retaining screw. Remove the Ignition Pack. Reassemble in reverse order of above. Flow Sensor: (Procedure 13) 1. 2. 3. 4. 5. 6. Isolate cold water supply. Remove the front panel. Refer to Procedure 1. Disconnect the multi-pin plug to the flow sensor.
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. 5. Reassemble in reverse order of above.
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.
Exploded View 1 – 871018 & 871020 Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by 55 Service.
Replacement Parts List Exploded View 1 – 871018 & 871020 Models Ref. No.
Exploded View 2 – 871018 & 871020 Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by 57 Service.
Replacement Parts List Exploded View 2 – 871018 & 871020 Ref. No.
Exploded View 3 – 871/875018-B & 871/875020-B Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by 59 Service.
Replacement Parts List Exploded View 3 – 871/875018-B & 871/875020-B Models Ref. No.
Exploded View 4 – 871/875018-B & 871/875020-B Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by 61 Service.
Replacement Parts List Exploded View 4 – 871/875018-B & 871/875020-B Models Fitted with solenoid operated bypass Silicone Tube (Insulator) Silicone Tube (Insulator) Anti-Frost Heater Anti-Frost Heater Assembly Anti-Frost Heater Clamp Anti-Frost Heater “C” Clamp Anti-Frost Heater Clamp Ambient Air Temp Thermistor Assy Outlet Thermistor Thermostat Assembly Inlet and Heat exchanger Thermistor O-ring – Thermistor Hall Effect I.C.
Gas Type Conversion Procedure 1. 2. 3. 4. Isolate the power and gas supply to the water heater. Remove the front panel. (Refer to Procedure 1) Remove the Burner Change Over Assembly (Refer to Figure 1 and Procedure 2) 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.
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.
Document Revision History Title: Integrity 18 & 20L Service Instructions Revision A B C D E Document Number: Details of change 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).