Rheem Australia Pty Ltd Title: - Service Instructions for Rheem Solar Loline with Electric Boosting Revision A B Document control header Document Number: - TM007 Details of change Service Instructions issued for 511 series Loline with electric boosting References to Southcorp Water Heaters replaced by Rheem Australia Pty Ltd. Model 511430 added Solar Loline with electric boosting Service Instructions REV: B Date of Issue: 1/03/2002 D.O.I.
SOLAR RHEEM AUSTRALIA PTY LTD SERVICE INSTRUCTIONS RHEEM SOLAR LOLINE WITH ELECTRIC BOOSTING MODELS 511270 511340 511430 Rheem Australia Pty Ltd Revision: B Solar Loline with Electric Boosting Service Instructions REV: B Date of Issue: 1/03/2002 ABN 21 098 823 511 Published: March 2002 1
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 Solar Loline 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.
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 7 digits and 1 letter.
SEQUENTIAL FREEZE PRINCIPLE The sequential freeze collector features tapered risers that reduce in diameter along their length from 12.7mm at the header pipes to 9.5mm at the centre. During periods of low ambient air temperatures the water in the collectors will freeze at the narrowest point of the tapered riser first, due to the small volume of water present, and then continue to freeze in a controlled fashion along the length of the riser. This is known as sequential freeze.
COMPONENTS AND THEIR FUNCTION Temperature and Pressure Relief Valve (T&PR) A valve designed to provide automatic relief by discharging water in case of excessive temperature, pressure or both. Never fit a T&PR Valve with a pressure rating greater than that indicated on the product-rating label. Outlet Delivery Tube (Dip Tube) A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water from the highest point to the outlet connection. It also acts as a fitting liner.
HOT WATER PHYSICS RELATED TO SOLAR WATER HEATERS There are physical properties of hot water that are common to all types of heating mediums. However, with solar heating an understanding of these properties will be of assistance to servicing a solar water heater. Stratification The term used to describe thermal stratification within a water heater where hot water will lie above cooler water without mixing.
COMMON FAULTS When a complaint is lodged about the performance of a hot water system there are a number of causes that should be checked and eliminated. In an attempt to pinpoint the most likely cause it is important to discuss with the customer their reasons for the complaint, the duration of the problem, any change in circumstances or usage and recent weather conditions. This information in conjunction with the following listed common complaints will assist you in locating the most likely cause.
COMMON FAULTS (continued) Hot water plumbing leaks If hot water has not been used for a period of time, feeling the temperature of the hot water line may give an indication of water flow if the pipe is warm. The method of checking for plumbing leaks is: 1. Turn off the stopcock on the cold water supply to the water heater. 2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock is operating correctly. 3. Turn off the hot tap. 4.
FAULT FINDING Fault Diagnosis Sequence Is the complaint for no hot water? YES Has there been periods of high solar gain? NO Is the complaint for insufficient hot water? NO Electric booster circuit 1 YES Collector circuit 2 YES 3 NO 4 YES 5 YES 6 YES 7 YES 8 NO Is the complaint for water too hot? YES Does the problem occur only during periods of high solar gain? NO Is the complaint for high energy bills? NO Is the complaint for leaking? NO Is the complaint for noise? Solar Lol
FAULT FINDING Electric Booster Circuit 1 Is the electric booster connected to an off peak tariff? TEST 1 Is 240 volts present at the terminal block ? NO Is a switch to control the booster, installed in the house? NO YES YES Possible failure of the off peak relay or missed signal from energy supplier. Continue with diagnosis to confirm booster circuit is operational.
FAULT FINDING No Hot Water - Electric Booster 1.
FAULT FINDING 1.
FAULT FINDING Differential Controller 2 TEST 8 Is 240 volts present at the terminal block? NO Plug LED test board into differential controller YES Is the green LED flashing? Isolate power when connecting LED test board 3 flashes Short circuit - hot sensor 4 flashes Open circuit hot sensor 5 flashes Short circuit - cold sensor 6 flashes Open circuit cold sensor 7 flashes Open circuit hot sensor defrost mode 8 flashes Short circuit - hot sensor defrost mode YES NO TEST 9 Restore power at GPO if tur
DIFFERENTIAL CONTROLLER The differential controller receives information from the hot sensor, measuring water temperature at the collectors, and the cold sensor measuring water temperature at the bottom of the tank. If the water temperature at the hot sensor is 8ºC above the temperature being sensed by the cold-water sensor the differential controller turns a circulator pump on.
FAULT FINDING 2.1 Collector Circuit Are the collectors facing within 45 degrees of north? NO Reposition collectors onto a cross pitch roof stand or relocate to a northerly aspect. YES Advise customer to prune trees if possible or reposition collectors to shade free location. YES Reposition collectors onto a flat roof stand.
FAULT FINDING Collector Circuit 2.2 Are there any water leaks around the collectors or heater? Is the leak, discharge from the T & PR valve? YES NO YES Is the dip tube fitted and in the correct position? Refer to exploded view NO NO Rectify leaks at connectors or fittings. Replace collector or tank if leaking 3.1 Replace or reposition dip tube correctly YES Open the bleed valve at the water heater. (Located in the hot water return plumbing from the collectors.
FAULT FINDING Insufficient Hot Water 3 Is the water heater of sufficient size for the customers needs? NO Has the usage pattern changed recently? i.e. additional appliances or people using hot water YES Recommend a water heater of sufficient capacity to meet customers needs NO YES 3.
FAULT FINDING Water too hot - Booster Circuit 4 Does water temperature at hot tap correspond with or near thermostat setting? NO Advise customer on operation of Loline system and benefits of storing water at 70 degrees.
FAULT FINDING Water too hot - Collector Circuit 5 Is the water temperature at the hot NO tap above 75 degrees? Warning: Water under pressure and at temperatures up to 150 degrees may be present in the collector. YES Isolate water supply and relieve pressure through a hot tap prior to opening the collector pipe work. Is the circulator Is Plug LED test board pump operating when a fault code into differential YES the water temperature in the flashing? controller.
FAULT FINDING Leaking Water 7 Is the leak from the tank? Is the leak from theT&PR valve? YES YES 3.1 NO Is the leak from a collector connector/s? NO YES Replace o'rings and connector/s if damaged or cracked NO Is the leak from the collector? Reseal the anode YES Replace the gaskets Check for stripped bolts YES Reseal the plumbing fitting NO Cylinder may be leaking, feel for hot spots on the jacket and remove pipe escutcheons to confirm leak.
FAULT FINDING 8 Noisy Water Heater Is the noise only evident when hot water is being drawn off during periods of high solar gain? YES Noise is caused by FLASH STEAM. Refer to page 8 physical properties of hot water YES Check for: Noisy burner operation due to incorrect gas pressure or aeration. Poor quality water supply i.
COMPONENT REPLACEMENT Draining the Water Heater (Procedure 1) 1. Isolate the power supply to the water heater (switchboard) and unplug the differential controller (GPO). 2. Isolate the water supply to the water heater. 3. Relieve pressure from the water heater through the temperature and pressure relief valve or a hot tap. 4. Disconnect the cold water supply pipe 5. Fit a drain hose to the cold water connection and run the other end to a drain or safe location. 6.
COMPONENT REPLACEMENT Circulator Pump (Procedure 5) Warning: The collectors may be at stagnation temperature, water under pressure and at temperatures up to 150ºC may be present. Exercise caution to prevent burns or scalds. 1. Using a flat blade screwdriver open the bleed valve (refer to diagram on page 25) and purge water through the collectors to dissipate excess temperature. 2. Close the bleed valve once excess temperature is removed. 3.
COMPONENT REPLACEMENT Anode (Procedure 8) 1. 2. 3. 4. 5. 6. 7. 8. 9. Isolate the power supply to the water heater (switchboard) and unplug the differential controller (GPO). Isolate water supply to the water heater. Relieve pressure from the water heater through the temperature and relief valve or a hot tap. Remove the anode cap. Using a 27mm tube or socket spanner remove the anode. Apply thread seal tape to replacement anode, refit and tighten. Restore water supply and check for leaks.
PURGING AIR FROM THE COLLECTORS An air eliminator is not fitted to the sequential freeze collector system. Upon completion of any repairs to the collectors, circulator pump, pipe work to and from the collectors or recommissioning if the tank has been drained it will be necessary to purge the air from the collector circuit. To purge air from the collector circuit ensure the tank is full of water and that all hot taps are turned off.
COMPONENT TESTS TEST 1 TEST 5 Caution, “Live” components exercise care Ensure power is isolated before conducting test Using a multimeter on the AC voltage scale, measure between Using a multimeter on the x1 resistance scale, measure active and neutral on the terminal block. The voltage should be between terminals 3L and 4L on the thermostat. The reading approximately 240 volts. should be 0 ohms.
COMPONENT TESTS TEST 8 Isolate power before conducting test Unplug the cord set from the GPO. Using a multimeter on the x1 resistance scale measure each conductor in the cord set. Normal resistance for each conductor is 0 ohms. TEST 9 Isolate power before conducting test Disconnect the pump wiring from the differential controller PCB and using a multimeter on the x1 resistance scale, measure the resistance of the pump motor. Normal resistance is 73 ohms +/- 5%.
EXPLODED VIEW – CONTROL BOX REPLACEMENT PARTS LIST Item 1-10 1 2 3 4 5 Component Controller Assembly Complete Lock Ring Sealing Gasket – Circulator PCB Support Housing Differential Controller PCB Solar Loline with Electric Boosting Service Instructions REV: B Date of Issue: 1/03/2002 Part Item Component Number 052104 6 Circulator 052109 7 Cable Grip – Cord Set 052106 8 Cable Grip – Sensor Cable 890264 9 Cord Set 052108 10 Cold Sensor 052113 28 Part Number 836053 890267 890268 890244 056002
EXPLODED VIEW - COLLECTORS REPLACEMENT PARTS LIST Item 1 2 3 4 5 6 Component O’ring Spring Clip Quick Connect to ½” BSP adapter Retaining Clip Connector Collector (Chrome Black) Angle Bracket (2 collectors) 7 Angle Bracket (1 collector) 8 End Plug 9 Connector (Hot Sensor) 10 Hot Sensor * Hot and Cold Sensor O ’ring 11 Collector Strap * Not illustrated Solar Loline with Electric Boosting Service Instructions REV: B Date of Issue: 1/03/2002 29 Part Number 087023 088005 195704 088006 195701 SCT200 191613
EXPLODED VIEW – WATER HEATER Solar convertible cold water inlet detail Solar Loline with Electric Boosting Service Instructions REV: B Date of Issue: 1/03/2002 30
REPLACEMENT PARTS LISTS Item 1 2 3 4 5 6 * 7 8 9 10 11 12 13 14 15 Component 511270 890281 088064 069405 221404-1 223601 056002 087025 220341 220340 890244 052104 220641 221408-1 225601 100647-1 221720-1 221914 221924 222036 120503 051350 102501 226921 051521 050704 050316 050317 050318 051404 100726-1 100642-1 224702 890258 Sensor Retaining Clip Cold Sensor Tee Extension Fitting Pipe Seal Inlet/Outlet Connecting Pipe Cold Sensor Hot and Cold Sensor O’ring Non-return Valve Bleed Valve Cord Set Pump Box
CIRCUIT DIAGRAMS Differential Controller (Control Box) Pump Water Heater (Electric Booster) Solar Loline with Electric Boosting Service Instructions REV: B Date of Issue: 1/03/2002 32
RHEEM SOLAR WATER HEATER WARRANTY - AUSTRALIA ONLY Rheem Australia Pty Ltd will: a) Repair or, if necessary replace any Rheem solar water heater; or b) Replace any component (or, if necessary, arrange the installation of a new water heater), which falls within the Warranty Periods specified below, in accordance with and subject to the following table, conditions and exclusions.
