SERVICE INSTRUCTIONS 16, 18, 20 Litre Continuous Flow Gas Water Heater TM040 Revision: A Published: June 09 Everhot 274020 276020 This document is stored and maintained electronically by Vulcan 244016 244020 246016 246020 Rheem 874018 874020 876018 876020 Service.
Contents Introduction .......................................................................................................................... 3 Safety Warning .................................................................................................................... 3 Water Heater Model Identification ........................................................................................ 4 Specifications............................................................................................
Introduction The information provided in these service instructions is based on the water heater being installed in accordance with AS 5601and the Installation Instructions provided with each water heater. Should you require further technical advice on a continuous flow gas water heater, contact your nearest Rheem Service Department where genuine replacement parts are also available.
Water Heater Model Identification The identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 6 digits and up to 3 letters.
Specifications 244016NF 244016PF 246016NF 246016PF NG Prop Model Gas Type 874018NF 874018PF 876018NF 876018PF NG Prop 244, 274, 874020NF 244, 274, 874020PF 246, 276, 876020NF 246, 276, 876020PF NG Prop Max hourly gas consumption (MJ/Hr) 123 138 153 Output (kW) 27.9 31.4 34.9 Heating Capacity (L/min @ 40ºC rise) 10.0 11.3 12.5 Mass Empty (kg) 20 20 20 Min inlet water pressure (kPa) 140 140 140 Max inlet water pressure (kPa) 1000 1000 1000 Min inlet gas pressure (kPa) 1.13 2.
Wiring Diagram TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions D.O.I: 2/06/2009 This document is stored and maintained electronically by 6 Service.
Preset Temperature Adjustment Factory pre-set and maximum hot water outlet temperature settings for each water heater series are shown below: Model 244, 274, 874 Series 246, 276, 876 Series Factory setting 60ºC 48ºC Maximum Temp 60ºC 48ºC Solar Compatible Y N 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.
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 (18).
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) Hot Water Tap Water Flow Servo Motor Water Flow Sensor Inlet Water Temperature Thermistor Combustion Chamber Thermistor Outlet Water Temperature Thermistor PCB Water Filter (Strainer) Gas Inlet Solenoid Valve Gas Solenoid Valve 1 Gas Solenoid Valve 2 Proportional Gas Solenoid Valve Nozzle Burner Igniter Igniter Electrode Flame Sensor Heat Exchanger Over Temperature Limiter
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. 246, 276, 876 series water heaters are not suitable for use as in-series solar gas boosters. The 244, 274, 874 series may be installed as an in-series booster water heater to a solar preheat water heater.
In-series Gas Boosting - Solar Hiline Installation TYPICAL INSTALLATION SOLAR CLOSED CIRCUIT THERMOSIPHON WITH BOOSTER 246, 276, 876 series modelsIN-SERIES comply withGAS AS/NZS 3498 and therefore do not require a Tempering Valves tempering valve to be fitted unless the unit is installed in an early childhood centre, school, nursing home or a facility for young, aged, sick or disabled people.
Controllers Continuous flow gas water heaters can be fitted with optional controllers as long as they are not being used in conjunction with a solar system. There are 2 types of controllers available, standard or deluxe: Controller Type Standard Deluxe Bathroom 1 299854 299859 Bathroom 2 299855 299860 Kitchen 299853 299858 Standard and deluxe controllers cannot be mixed in a single installation; other manufacturers‟ controllers cannot be used.
Standard Controllers (cont‟d) Note: If one or more controllers are installed, at least one must be ON for the water heater to operate. If all controllers are OFF the water heater will only deliver cold water.
The 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 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.
Deluxe Controller (Shown with Bath-Fill control cover open) Heater operating light Bath-Fill operating light Controller „ACTIVE‟ light Water temperature in Degrees Celsius Bath-Fill Water Volume in litres ACTIVE Assistance call button General purpose water temperature adjustment buttons Controller ON / OFF button Bath-Fill mode On/Off button Speaker Bath-Fill mode Water Volume adjustment buttons Bath-Fill mode Temperature adjustment buttons Note: If one or more controllers are installed, at leas
Deluxe Controller Functions ON / OFF button Press once to turn on the controller. The button will glow when the controller is on. A controller cannot be turned on if water is flowing from a hot tap. Press the button to turn off the controller. A controller can be turned off whilst water is flowing. Bath-Fill button Initiates Bath-Fill mode and once pressed will display the last used Bath-Fill water volume in litres and the last used Bath-Fill temperature in °C.
Bath Fill Operation B Bath Fill Operation Deluxe controllers only Bath fill switch on Bath fill lamp on Hot water volume indicator on Hot water volume on Hot water temperature indicator on Bath fill switch on less than 6 hours? NO YES YES Hot water tap open Combustion A - B Bath fill switch off? Bath fill lamp off NO Hot water volume indicator off Water delivered less than or equal to set volume? YES Hot water volume off Hot water temperature indicator off NO Burner Off Bath fill lamp flashing
EZ-Link™ System The EZ-Link system is used to electronically control two identical water heaters, plumbed in parallel, from the same temperature controller in order for them to operate as one. Depending upon the hot water demand, one or both units may be in operation. The EZ-Link system consists of a cable that is connected between the PCB‟s.
EZ-Link Error Code Display If a fault is present with one of the water heaters connected via the EZ-Link system, in addition to displaying the normal error codes, the controller will also display a 1 or a 2 to indicate which unit is at fault. 1 indicates the unit to which the controller is connected has the fault, 2 indicates the unit which does not have the controller connected has the fault.
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. Error codes are displayed via the red LED mounted on the PCB (refer to page 27 for details regarding interpretation of LED flashing pattern). If fitted, the controllers will also display the full range of error codes.
Operational Flow Charts Operation Flow Chart 1 Plug In Power On 1 Error code cleared YES Bath fill operation On/Off lamp Off Remote controller display off Initial check normal? B Isolate Power Remote controller switched on NO Gas type control data failure Communication problem between remote controller and the heater 82 (H) Flashing 76 Flashing Remote controller switched off Fan Off (10 seconds later) On/Off lamp On Fan On Remote controller display on Fan motor current detection failure G.
Operational Flow Chart 2 F F1 I.U.I on Igniter off Proportional temperature adjustment Gas rate change-over done by solenoid valves G.I.S.V control failure Communication problem between remote controller and water heater Fan motor current detection failure 71 (C) Flashing 76 Flashing 79 (G) Flashing Thermistor connections crossed P.G.F.
Operational Flow Chart 3 Hot water 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 I.U.I off YES Flame current detected less than 0.1uA? 4 NO 8 seconds later YES S.V. 1-2 (SV1-2) failure G.I.S.V (SV0) failure 80(F) Flashing 51(F) Flashing G.I.S.V (SVO) off [S.V. 1-2 (SV1-2) off] P.G.F.
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 on page 6 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 With Controller: Isolate power whilst connecting a controller. 1. 2. 3. 4. Fit controller if not already fitted. Restore power supply and ensure the controller is turned on. Press the temperature increase and decrease buttons simultaneously for 3 seconds. Use the temperature decrease button to change the left digit (0→1etc.) in the controller display to the required maintenance code identified from the maintenance table on page 26. 5.
Clearing Error Code History 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 switches or MIN and MAX buttons. After repairing the water heater the existing error code history should be cleared. This will allow fresh data to be stored and reduce the risk of confusion should it be necessary to service the water heater in the future. To clear the error code history: 1. 2. 3. 4. 5.
Fault Diagnosis Sequence Ensure power is turned on. Is remote controller fitted? NO YES If a remote control is unavailable, fault diagnosis can be made via the red LED on PCB (refer to pages 19 & 22 for LED flashing pattern information). Does the remote control power up if the on/off button is depressed? It is recommended that a remote controller be fitted to assist faultfinding.
Power Supply Fault Finding Is 240VAC present at the power point? NO No power supply.
Fault Finding Tests 1 – 3 Components will be “Live” when conducting tests, exercise caution. Test 1 Power Filter Using a multimeter set on the AC volts scale, measure the voltage at the connector plug to the transformer primary winding. Normal voltage is between 230V and 250V.
No Error Code Fault Finding A Is the unit used as an in-series gas booster? YES NO Read maintenance information 1y Is 1y displaying a flow greater than 2.5lpm? 1y = Water flow detected by water flow sensor NO Is water flow through unit greater than 2.5lpm? YES Replace the PCB assembly. NO Open hot tap further. NO Replace the PCB assembly. YES Are controllers fitted? YES Controllers must not be fitted when used as an in-series gas booster. Remove controllers.
Fault Finding Tests 4 – 6 Test 4 - Diagnostic Point 3 Test 5 - Diagnostic Point 3 MAX. MAX. 3 4 3 4 R R Conduct test with water flowing. Conduct test with water flowing. Using a multimeter set on the DC volts scale, Using a multimeter set on the DC volts scale, measure the voltage between 3 Red and 2 Black measure the voltage between 1 Brown and 2 on connector R. Black on connector R. Normal voltage should be between DC11 – 17V. Normal voltage should be between DC2 – 5V.
Error Code 11 Error Code 11 Is there gas available? Open gas isolation valve or advise customer to contact gas provider NO YES Did the burner ignite? YES Display maintenance information „0y‟ on remote control. Attempt ignition again. Replace PCB NO Does „0y‟ indicate 01, 02 or 03 when a flame is visible? NO NO YES YES Is the burner gas pressure correct? Clean or replace the main burner. YES NO Check: Combustion chamber for debris Flame sensor wiring - repair.
Fault Finding Tests 7 – 12 Test 7 - Diagnostic Point 8 2 3 4 JAP 1 MAX. 12VDC L K OMRON G5NB-1A4 12VDC MIN. Test 8 - Diagnostic Point 11 G Body Earthing Conduct test with no water flow Conduct test with water flowing Using a multimeter set on the AC volts scale, Using a multimeter set on the AC volts scale, measure the voltage between terminals W1 on measure the voltage between the grey wires at connector L and earth and between terminals connector G. R1 on connector K and earth.
Tests 10 and 12 - Diagnostic Point 9 Test 10: Conduct test with water flowing. Using a multimeter set on the DC volts scale, measure the voltage between 1 Red and 2 Black at connector Q whilst plugged into PCB. Normal voltage is between DC1.5 and 14.0V. 2 - Black 1 - Red T R JAPAN JAPAN JAPAN JAPAN JAPAN JAPAN OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC Q Test 12: Isolate power before conducting test.
Error Code 14 Error Code 14 Is the Over Heat Limiter resistance correct? TEST 13 Determine cause of OHL failure. Replace OHL NO YES Replace the PCB Fault Finding Test 13 Test 13 MAX. 3 Unplug T connector from PCB and using a multimeter set on the kilo-ohms scale, measure the resistance of the Over Heat Limiter Assembly. 4 T R Normal resistance should be between 50 kilo-ohms - 500 kilo-ohms. TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions D.O.
Error Code 15 Error Code 15 YES Replace PCB Measure the hot water outlet temperature Is the resistance of the heat exchanger thermistor normal? TEST 14 Display maintenance information „5y‟ on remote control NO Replace heat exchanger thermistor NO Replace hot outlet thermistor YES Does the measured hot water temperature match that indicated by 5y? Is the resistance of the hot outlet thermistor normal? TEST 14 NO YES Check the burner pressure and adjust if necessary.
Fault Finding Test 14 Test 14 – Diagnostic Points 5, 6, 7 & 16 5 - Yellow 4 - Red 3 - Black T Isolate power before conducting test. R JAPAN JAPAN JAPAN JAPAN JAPAN JAPAN OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC OMRON G5NB-1A4 12VDC Q Using a multimeter set on the ohms scale, measure the resistance at connector Q whilst unplugged from the PCB.
Error Code 29 Error Code 29 YES Replace PCB Measure the hot water outlet temperature Is the resistance of the heat exchanger thermistor normal? TEST 14 Display maintenance information „5y‟ on remote control NO Replace heat exchanger thermistor NO Replace hot outlet thermistor YES Does the measured hot water temperature match that indicated by 5y? Is the resistance of the hot outlet thermistor normal? TEST 14 NO YES Check heat exchanger for blockage/restriction (possible scale build-up).
Error Code 35 Error Code 35 Are the cold and hot water connections to the water heater reversed? Reconnect plumbing to the water heater correctly YES Cold water inlet and hot water outlet thermistors positions reversed. Swap thermistors positions NO Error Code 51, 72, 80, 81 Error Code 51, 72, 80, 81 Does the flame extinguish completely? NO Replace proportional gas flow regulating valve NO Isolate power supply for 10 seconds to clear error code. Restore power.
Error Code 52 Error Code 52 Is the resistance of the proportional gas flow regulating valve normal? TEST 12 Replace PCB YES Replace the proportional gas flow regulating valve NO Error Code 61 Error Code 61 Min Max Fan Speed (x 100) RPM Display maintenance information „6y‟ on remote control Is the correct fan speed indicated? Maintenance Info „6y‟ NO Is voltage being supplied to the fan motor? TEST 17 NG Prop NG Prop 26 26 58 60 NO Replace the PCB YES Is the fan motor rotating? NO
Fault Finding Tests 17 & 18 Tests 17 and 18 – Diagnostic Point 4 Conduct test with water flowing 6 - White 4 - Blue 3 - Red Using a multimeter set on the DC volts scale, measure the voltage at connector F whilst plugged into PCB.
Fault Finding Tests 19 - 22 Test 19 and 20 TEST 19: Unplug connector G from the PCB and using a multimeter set on the kilo-ohms scale, measure the resistance between 3 Green and 6 Green. Normal resistance should be between 0.6kiloohms and 2.8kilo-ohms. JAPAN JAPAN 12VDC OMRON G5NB-1A4 12VDC F G Conduct test with water flowing TEST 20: Using a multimeter set on the DC volts scale, measure the voltage between 3 Green and 6 Green on connector G. Normal voltage should be between DC70 – 110V.
Error Code 71 Error Code 71 Is there voltage at gas inlet solenoid valve? TEST 9 NO Check wiring, if intact replace the PCB NO Replace proportional gas valve YES Is the resistance of the GISV correct? TEST 11 YES Check gas inlet solenoid valve for mechanical failure. Replace PGFR valve if necessary. Error Code 76 Check cables to all temperature controllers. Replace any cables that are open circuit. If no open circuit cables are found, replace the controller.
Error Code 82 If error code 82 appears a new PCB is required to be fitted. Error Code 99 & 10 Isolate power supply; clean the heat exchanger, fan and air inlet opening. Restore power supply and attempt ignition. If the error code re-appears, replace the PCB. Burner Gas Pressure Check 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. Minimum Burner Gas Pressure 1.
Burner Gas Pressure 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. Remove the front panel from the water heater. 2. Remove burner test point screw and fit manometer. 3. Connect a controller (if one is not present) and turn on. NOTE: Isolate power while connecting the controller. 4. Open a hot tap slowly, to achieve the minimum flow rate at which the burners will ignite. 5.
Component Replacement Procedures Front Panel 1. Isolate power, gas and water supplies. 2. Remove four screws, two from the top and two from the bottom of the Front Panel. 3. Remove the Front Panel. PCB Assembly 1. 2. 3. 4. 5. 6. 7. Isolate power supply. Remove the Front Panel. Refer to „Front Panel‟ procedure above. Remove the retaining screw at top left hand side of the PCB. Disconnect the multi-pin connectors from the PCB Assembly. Undo the two red wires from transformer at bottom right hand side of PCB.
Upper Burner Assembly 1. Remove the Combustion Chamber Front Panel. Refer to „Combustion Chamber Front Panel‟ procedure on page 48. 2. Remove two retaining screws located on the underside of Upper Burner Assembly. 3. Remove the Upper Burner Assembly by sliding forward out of the Heat Exchanger. 4. Reassemble in reverse order of above being careful not to pinch or damage wiring. Replace gaskets if required. 5. Test for gas leaks using soapy water solution. Flame Sensor 1. Remove the Upper Burner Assembly.
Power cord 1. 2. 3. 4. 5. Switch off power at power point and unplug power cord from power point. Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48. Undo cord clamp screw located on bottom right hand side of PCB and remove clamp. Disconnect Earth connection at PCB holder. Disconnect the power cable wiring loom plug and withdraw power cable through slot in the water heater jacket. 6. Reassemble in reverse order of above.
Flow Sensor Turbine 1. Isolate cold water supply. 2. Remove the Front Panel. Refer to „Front Panel‟ procedure on page 48. 3. Unscrew the Water Drain Valve assembly (item 32) and Pressure Relief Valve (item 30) and drain the water heater. 4. Disconnect the cold water supply pipe from the cold water Inlet Connection. 5. Disconnect the Bypass Solenoid wiring loom plug. 6. Remove two retaining screws holding the Flow Sensor to the Water Body Assembly and remove Flow Sensor. 7.
Anti-Frost Heaters 1. Remove the PCB Assembly. Refer to „PCB Assembly‟ procedure on page 48. 2. Disconnect connector plugs at the Anti-Frost Thermostat and Power Cord Heat Exchanger and Hot Water Outlet Connection Heaters 3. Remove the two screws from the hot water Outlet Flange to release the hot water outlet Anti-Frost Heater. 4. Unclip the 2 Anti-Frost Heaters from the Heat Exchanger (Note the positions of both). 5.
Heat Exchanger Replacement 1. Remove the Heat Exchanger. Refer „Heat Exchanger Removal‟ procedure on page 52. 2. Remove the Heat Exchanger Thermistor, Anti-Frost Heaters, Fan Assembly and Fan Cowling from the old Heat Exchanger and refit to the replacement Heat Exchanger. 3. Check the Over Heat Limiter. Replace if damaged or open circuit. 4. Reassemble in reverse order of above. 5. Test for gas leaks using soapy water solution 6. Check for water leaks. 7.
Over Heat Limiter Replacement of the Over Heat Limiter requires removal and possible replacement of the Heat Exchanger. 1. Remove the Heat Exchanger. Refer „Heat Exchanger Removal‟ procedure on page 52. 2. Remove the two white wires from the terminal block on the right hand side of the Over Heat Limiter. 3. Remove the two plastic rivets retaining the Over Heat Limiter to the back of the water heater cabinet and remove the Over Heat Limiter. 4. Inspect the Heat Exchanger for holes or combustion damage.
Power Filter 1. Remove the PCB Assembly. Refer to „PCB Assembly‟ procedure on page 48. 2. Disconnect the incoming and outgoing Power Filter wiring loom plugs. Note: Some wiring retainers will need to be released to allow wiring to be removed. 3. Remove the two screws retaining the Power Filter to the mounting bracket on the Fan Assembly. 4. Remove the Power Filter. Note: An earth wire is connected to the power filter mounting bracket. Ensure it is reconnected when the Power Filter is refitted. 5.
Exploded View – Water Heater TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions D.O.I: 2/06/2009 This document is stored and maintained electronically by 56 Service.
Replacement Parts List – Water Heater No. 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 28 29 30 31 32 33 34 35 36 37 38 39 Description Heater Cabinet Front Cover Assembly Over Heat Limiter Combustion Chamber Kit – Natural Gas Combustion Chamber Kit – LPG O-Ring P16 EPT O-Ring P-12.
Exploded View - Wiring 11 8 9 14 3 10 5 6 4 13 12 16 TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions D.O.I: 2/06/2009 This document is stored and maintained electronically by 58 Service.
Replacement Parts List - Wiring No.
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: 16-20L Continuous Flow Gas Water Heater Service Instructions Document Nº: TM040 REV Details of change A Service instructions issued for 16-20L continuous flow gas water heater TM040 16, 18 & 20L Continuous Flow Gas Water Heater Service Instructions D.O.I: 2/06/2009 This document is stored and maintained electronically by D.O.I. 06/09 61 Service.
