Rheem 310 Series, 551310 Service Instructions Manual

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.

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SERVICE INSTRUCTIONS

310 Series Heat Pump

TM025

551310

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

This document is stored and maintained electronically by

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

Contents

Safety Warning....................................................................................................................2

Introduction..........................................................................................................................2

Specifications.......................................................................................................................3

Preventative Maintenance ...................................................................................................3

Operation.............................................................................................................................4

Electronic Controller ............................................................................................................5

Operating Sequence Flow Charts:.......................................................................................6

Refrigeration Terms and their Meaning................................................................................8

Components and their Function...........................................................................................8

Common Faults ...................................................................................................................9

Wiring Diagram..................................................................................................................11

Refrigeration Sealed System Diagram...............................................................................12

LED Indication ...................................................................................................................12

Fault Finding......................................................................................................................14

Refrigerant Charge ............................................................................................................45

Electrical Insulation Testing...............................................................................................46

Component Replacement Procedures – Water Heater......................................................47

Component Replacement Procedures – Refrigeration Plant .............................................52

Component Replacement Procedures – Sealed Refrigeration System .............................57

Exploded View - Refrigeration Plant ..................................................................................62

Replacement Parts List – Refrigeration Plant.................................................................63

Exploded View - Water Heater...........................................................................................64

Replacement Parts List – Water Heater.........................................................................65

Rheem Electric Water Heater Warranty - (Australia Only).................................................66

Document Revision History................................................................................................67

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

This document is stored and maintained electronically by

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

Safety Warning

The purpose of this Service Manual is to provide sufficient information to allow a person with the skills as required by the controlling Regulatory Authorities to carry out effective repairs to a Rheem 310 series Heat Pump Water Heater in the minimum of time.

Safety precautions or areas where extra care should be observed when conducting tests outlined in this manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended procedure.

Certain diagnostic procedures outlined in these service instructions require “live” testing to be conducted. Wear Personal Protective Equipment (PPE) when conducting these tests to prevent the risk of electric shock. (Refer to the Rheem Safety Procedure on electrical testing)

R134A is a controlled substance under the fair trading act. Personnel qualified and licensed to work with refrigerants may only carry out service and repair to the sealed refrigeration system. During repair the refrigerant

must be recovered, not vented to atmosphere.

Environmental

At the end of the service life of a Rheem heat pump the refrigerant must be recovered by personnel qualified and licensed to work with refrigerants prior to the unit being disposed of. Refrigerants must not be vented to

atmosphere.

Introduction

The information provided in these instructions is based on the water heater being installed in accordance with the Installation Instructions provided with each water heater.

Should you require further technical advice on a Rheem 310 Series Heat Pump Water Heater, contact your nearest Rheem Service Department where all genuine replacement parts are also available.

Heater Model Identification

All identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 8 digits.

5 X X 310 0 X 5 – Renewable Energy Model

5 – Air Sourced 9 – Solar Sourced

0 – No Heating Units 1 – Booster Element

Storage Capacity in Litres No Reference – System Requirement 0 – Element Not fitted

5 – 2400 watts 7 – 3600 watts

Note: Model number, serial number and date of manufacture should be quoted in all correspondence.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Specifications

Water Heater

Model 551310

Capacity - Litres 310 Boost Capacity - Litres 220 Booster element rating - kW 2.4 or 3.6 T&PR valve Rating - kPa 1000

With ECV 680

Maximum inlet pressure - kPa

Without ECV 800 Inlet / Outlet RP¾/20

Water Connections

T&PR RP½/15 Quantity 1

Anode

Length 1153 Control board thermostat setting (fixed) 60ºC Limp mode mechanical thermostat setting 70ºC Mechanical thermostat ECO setting 88ºC

Refrigeration System

Parameter 551310

Sound rating 51 dBA @1.5m Superheat setting (Factory) +6ºC at 10ºC Evaporator temp. Refrigerant charge R134A 1050 grams Compressor internal OTC Open 150ºC. Close 90ºC (automatic reset)

Compressor winding resistance

Run winding - Red & Blue: 2.2 ohms at 20ºC

Start winding - Red & Black: 3.27 ohms at 20ºC

Compressor Capacitor 35µF 240 VAC 50HZ Fan winding resistance

Run winding – Black & Brown: 184 ohms at 20ºC

Start winding – Black & Blue: 238 ohms at 20ºC Fan Capacitor 2µF 240 VAC 50HZ Circulator winding resistance 75.3 ohms @ 20ºC

Preventative Maintenance

It is suggested for peak performance that the water heater be serviced annually.

1. Check for discharge from the T&PR valve. When the element or heat pump is

operating a small discharge of water may be evident. Operate the valve-easing lever to ensure the valve opens and resets properly. Always open and close the valve gently. The T&PR valve should be replaced at 5 yearly intervals.

2. Check for leaks at all cylinder fittings.

3. Check for signs of excessive corrosion on the water heater jacket.

4. Isolate power to the water heater and check all electrical connections for signs of

overheating due to poor connection.

5. Conduct an 'Electrical insulation test' on the water heater (refer to page 46).

6. Check evaporator fins and fan blade for build up of dust or debris.

7. Check for sludge build up and if necessary drain and flush tank.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Operation

Operation – Water System:

The heat pump utilises a form of heating called ‘top down’ heating. The circulator (1) draws cooler water from the bottom of the cylinder via the long dropper tube (2). The water passes through the heat exchanger (condenser) (3) where it is heated by the refrigerant and is then returned to the top of the cylinder via a short dropper tube (4).

Operation – Heat Pump Mode:

During normal operation in ‘heat pump’ mode the electronic controller (control board) holds a control relay in the energised state and power for the compressor is passed to an electronic switch (called a triac) via the normally open relay contact.

The operation of the compressor causes a pressure difference within the sealed refrigeration system. This pressure difference causes the refrigerant to move around the sealed system. The refrigerant enters the evaporator (5) as a liquid, as the refrigerant absorbs heat from the atmosphere it changes state, at low pressure, from a sub cooled liquid to a super heated vapour or gas (evaporates). The vapour then enters the compressor (6) and obtains more heat, known as heat of compression, and passes into the heat exchanger as a super heated vapour at high pressure.

As the refrigerant passes through the heat exchanger it gives off heat which is absorbed by the water flowing through a separate chamber inside the heat exchanger. As the refrigerant gives off heat it cools and changes state back into a liquid (condenses). The refrigerant then enters the evaporator again and the cycle is repeated.

Operation – Boost Mode:

The controller will enter ‘boost’ mode when atmospheric conditions are unsuitable for heat pump operation or a possible failure of the refrigeration or water circuits has been detected. The following error conditions will initiate boost mode:

1. The temperature sensed by the ambient air sensor is below 0°C.

2. The water leaving the heat exchanger is greater than 80°C.

3. The compressor discharge temperature is greater than 110°C.

4. The evaporator temperature is less than -3°C.

5. The failure of sensors S3, S4 or S5.

6. The compressor is not running based on either of the following conditions:

a. After 2 minutes in controller sequence 3 the compressor discharge temperature has

not risen 15°C above ambient.

b. In controller sequence 4 the water temperature rise across the heat exchanger

(condenser) is less than 8°C.

In boost mode the electronic controller continues to control the temperature of the water in the cylinder and the circulator however the control relay is de-energised switching the power supply from the compressor triac to the element.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Boost mode allows 220 litres of 60ºC hot water to be provided by electric boosting. During this mode the circulator will cycle on and off periodically allowing for the 220 litre boost capacity rather than just the amount of water above the element as is the case with a conventional electric boost system.

Once a heating cycle is completed the error is cleared and normal operation is resumed on the next call for heat.

Note: If sensor S4 fails the system will operate on boost mode however the temperature will in this case be controlled by the mechanical thermostat and 220 litres of 70ºC water will be available.

Operation – Limp Mode:

Limp mode will only occur due to the failure of both sensors S1 and S4. In limp mode the electronic controller no longer controls the operation of the heat pump

and both ‘heat pump’ mode and ‘boost’ mode are rendered inoperable. The control relay is de-energised switching the power supply from the compressor triac to the element.

Limp mode allows 111 litres of hot water to be provided by electric boosting and the water temperature is controlled by the mechanical thermostat which is set to 70°C; in this condition only the water in the zone above the element is heated as the circulator does not operate.

It should be noted that if sensor S1 fails and sensor S4 is operational the system operates in boost mode however the circulator cannot operate. In this case the end result is an operation similar to limp mode in which 111 litres of water is heated by the booster and the temperature controlled to 70ºC by the Robertshaw thermostat.

Electronic Controller

The main features of the electronic controller (control board) are shown on the diagram opposite. The inputs to the software are shown in blue and the outputs that control the heat pump are shown in red.

The connection marked “relay element” energises or de-energises a relay that switches from heat pump heating to electric element heating when the system operates in “boost” or “limp” mode.

The “Compressor TRIAC” switches the power to the compressor on and off.

The “Communication port” can be used in conjunction with a computer to read the inputs and outputs from the software. This information may be logged using specially designed logging software (Contact Rheem Service for more information regarding this software).

The “Software loading port” is only used for loading software on to the control board.

The green and red LED’s indicate the condition of the heat pump (refer to the section titled “LED Indication” on page 12).

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Operating Sequence Flow Charts:

Page 1 of 2:

Power to controller

Tank

sensors S3-S5

ok?

YES

Heat

pump sensors

T0-T4 ok?

Sequence 0

S4< 44.5°C

or S3 < 50°C

YES

Call for heat

Green LED solid

System in stand by mode

Set paramaters

Seq 1

Circulator on

Seq 2

Compressor on

Evaporator fan on

30 seconds later

Circulator to minimum flow rate

Sequence 3

= or > than

57°C?

Cylinder sensors

Heat exchanger

outlet sensor

Sequence 4

Circulator to variable speed

YES

Use value of T4 and T1 to set circulator flow

rate to achieve 62°C at heat exchanger outlet

= 60°C?

Fault

detected?

S4 > 53°C

or S5 > 50°C?

<0°C?

YES

Green LED flashing

At maximum flow rate

Circulator off

Compressor off

Evaporator off

Refrigeration

Heating cycle

ends

Adjust pump

flow rate

T4 < 0°CT0 > 80°C T2 < -3°C

Water

discharge temp

too hot

T0 - T1

<8°C

Refrigerant

circuit not

operational

Temperature rise across heat

exchanger smaller than 8°C

Ambient air

temp too

low

Evaporator

frozen

Sensor T0 - T4

Open or

short circuit

T3 >

T4 +15°C?

After 2 minutes

YES

Compressor discharge

temperature 15°C above ambient

Condenser inlet

temp higher than

pick up temp

T1 > S4 +7°C

T3 > 110°C

High ambient

temp or running

too long

Check every

11 minutes

Compressor recently on -

delay start

S3 - S5

Open or

short circuit

Thermostat

contacts closed?

<-3°C?

>80°C?

YES

Ambient conditions too cold

for heat pump operation

Circulator

fault

Controller de-energised

no operation

Error condition reset

Relay energised

YES

>60°C?

YES

T3 >

T4 +15°C?

YES

Compressor discharge

temperature 15°C above ambient

YES

Software

version

HPV 4.0 or higher

HPV 3.1, HPV

3.2 or no HPV identification

Relay de-

energised &

element on

S0 & S1 > 62°C?

YES

S0 & S1 < 62°C?

YES

Relay

energised &

element off

S4< 44.5°C

or S3 < 50°C

YES

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Page 2 of 2:

Boost Mode

220L heated to

approx. 60°C

Relay de-energised

Red LED Flashing

Element On

>62°C?

>53°C?

YES

Element Off

YES

Circulator On

<61°C?

>53°C?

YES

Circulator Off

YES

Sequence 0

YES

Sensor

ok?

Temp at

thermostat =

70°C?

Controller can no longer detect

lower cylinder temperature.

Water temperature will be

controlled by mechanical

thermostat to 70°C

Sensor

ok?

YES

Controller can no longer detect

upper cylinder temperature.

The circulator will not operate

preventing water below the

element level from heating

Temperature at sensor S4 will

not achieve 53°C

Heating Cycle

complete

Element On

Limp Mode

111L heated to

approx. 70°C

Element Off

YES

Power to controller off

Sensor

ok?

>62°C?

YES

Boost Mode

220L heated to

approx. 70°C

Circulator On

Temp at

thermostat =

70°C?

YES

<61°C?

Circulator Off

YES

Element On

> 2°C?

YES

Ambient temperature high enough

to resume heat pump operation

YES

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Refrigeration Terms and their Meaning

Sub Cooled Liquid – A substance below its saturation temperature at a given pressure. Super Heated Vapour – A substance above its boiling point at a given pressure. Saturated Vapour – A substance at its boiling point at a given pressure. Latent Heat – Hidden (invisible) heat removed or added to a substance that results in a

change of state (i.e. liquid to a vapour) without an increase or decrease in temperature. Heat of Compression – The additional heat added to a substance by the act of

compressing it. Low Side – Components and pipe work of a refrigeration system operating at low

pressure, generally considered to be the evaporator, suction line and accumulator. High Side – Components and pipe work of a refrigeration system operating at high

pressure, generally considered to be the condenser, discharge line, liquid receiver/filter drier and compressor case where a rotary compressor is utilized.

Boil Off – The action of a substance as it absorbs heat and changes state (evaporates) from a liquid to a vapour (gas).

Give Up Heat – The action of a substance as it releases heat and changes state (condenses) from a vapour (gas) to a liquid.

Components and their Function

Temperature and Pressure Relief Valve - 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.

Pressure Limiting Valve (P.L.V.) - A valve that controls its outlet pressure to a predetermined limit.

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.

Diffuser - A plastic device installed in the cold water inlet of the water heater cylinder to assist with stratification. It also acts as a fitting liner.

Fitting Liner - A plastic tube installed in the cold-water inlet of the water heater to provide protection against corrosion through the life of the water heater.

Anode (Sacrificial) - A metal alloy electrode installed in the water heater cylinder that by galvanic action protects the cylinder from corrosion.

Thermostat - A device responsive to temperature that controls the supply of electrical energy to the compressor, which results in the stored water being maintained at the required temperature.

Evaporator Thermistor - A device responsive to temperature that controls the active supply between the compressor circuit and the booster element circuit.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Compressor - An electro-mechanical device that adds heats to the refrigerant by compressing it, known as “heat of compression” the resulting increase in refrigerant temperature increases its pressure and causes the refrigerant to circulate through the system.

Evaporator - A finned copper coil mounted on top of the water heater. The refrigerant enters as a liquid, as it passes through the coil it absorbs heat from the surrounding atmosphere and “boils off” (evaporates) to a gas.

Condenser - An insulated housing containing stainless steel chambers where heat transfer occurs. The condenser (or heat exchanger) contains three chambers, one for refrigerant, one for water and a third separating chamber containing air. The refrigerant enters as a gas, as it passes through the condenser it transfers (“gives up”) the heat absorbed via the evaporator to the water flowing through the condenser in a separate chamber, during this process the refrigerant cools and changes state (condenses) back to a liquid.

Receiver Filter Drier - This device, fitted between the condenser and thermal expansion (TX) valve, receives and stores liquid refrigerant from the condenser for delivery to the evaporator. The receiver also incorporates a filter and drier to trap impurities and remove moisture from the sealed refrigeration system

Accumulator - This device, fitted in the suction line prior to the compressor, is designed to accumulate and prevent liquid refrigerant from entering and damaging the compressor. Any liquid refrigerant is evaporated or “boiled off” and converted to a vapour by the accumulator.

Thermal Expansion (TX) Valve - A valve, installed between the condenser and evaporator that controls (meters) the amount of refrigerant delivered to the evaporator. The TX valve has an external temperature sensor fitted to the suction line and increases or decreases the refrigerant flow to the evaporator depending on the detected suction line temperature.

Thermal Cut Out (Overload) - A manual reset temperature sensitive device that automatically cuts off the supply of electrical energy to the control board and/or boost element.

Heating Unit (Element) - A tubular device containing an electric resistance element that converts electrical energy to heat. Standard element ratings are 2.4 and 3.6kW.

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. All procedures assume there is water flowing through the water heater.

Discoloured water - This may be the result of discoloured water entering from the cold water mains. Check if the cold water is also discoloured.

Excessive hot water usage - The complaints of insufficient hot water and no hot water can on many occasions be attributed to hot water usage exceeding the capacity of the water heater to provide hot water.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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When first attending a call of this nature it is essential to establish the probable hot water usage by querying the usage habits of the household and compare this with the potential delivery of the model water heater installed. It can then be established if the usage is within or outside the capacity of the model. The areas to look at for excessive usage are:

1. Automatic washing machines.

2. Showers exceeding 12 litres/minute for mixed water and 5 minutes in duration.

3. Two or more showers operating at the same time.

4. Change of occupancy or number of persons increased.

5. High water pressure area. (Excessive pressure relief valve discharge)

6. Plumbing leaks.

7. Crossed connection. Water hammer - A water heater will not cause water hammer, however valves associated

with the water heater may be the source of the problem i.e. cold-water stopcock, nonreturn valve or relief valve.

Most water hammer problems are associated with plumbing, hot and cold or appliances i.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve parts, loose tap washers or neighbouring equipment.

High water pressure areas will have more complaints of this nature and the use of a pressure-limiting valve (PLV) to reduce the household cold-water pressure will usually solve most problems.

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. Turn on the stopcock to make up the water pressure in the cylinder, and then turn the

stopcock off again.

5. Wait approximately 5 minutes then do either of the following:

a. With your ear close to the stopcock turn it on slightly and listen for any water

passing. If there are no leaks, water should not pass.

b. Open a hot tap while listening for any pressure release. If there is a pressure

release there will be no leaks in the plumbing system.

Mixing or crossed connections - If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or thermostatic mixing valve is installed there is always the possibility that the cold water could mix with the hot water through a faulty or incorrectly installed valve. This is referred to as a cross connection. The complaints of insufficient hot water, water too cold or excessive discharge from the pressure relief valve may be attributed to a cross connection. The method of checking for a cross connection is:

1. Turn off the stopcock on the cold water supply to the water heater.

2. Open a hot tap. If water flow is persistent and cold a cross connection exists.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Wiring Diagram

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Refrigeration Sealed System Diagram

LED Indication

All 310 series Heat Pumps have LED indication. There are two variations of LED indication depending upon the version of the controllers software; however all versions utilise a red and green LED to display the operational status and/or fault condition of the appliance. Note: The software version is printed on a label on the control board.

Controller Software Version HPV 3.1, HPV 3.2 or no HPV identification

310 Series Heat Pumps with controller version HPV3.1, HPV 3.2 or no HPV identification have a green and red LED located internally on the control board in the heat pump (refrigeration) module and utilise the following LED indication:

LED Indication

LED Status Condition Details

Green Solid S4 > 53ºC or S5 > 50ºC

Standby mode (end of heating cycle, cylinder water at required temperature).

Green Flashing S4 < 44.5ºC or S3 < 50ºC Call for heat initiated. Red Flashing

Various (refer to operating sequence flow chart on page 6 for more details).

Component fault or ambient conditions too cold for heat pump operation.

No indication

Fault or system operating in limp mode.

Fault or system in limp mode with call for heat satisfied (water in cylinder @ 70ºC determined by mechanical thermostat).

Note: Refer to diagram on page 5 for control board LED location.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Controller Software Version HPV 4.0 or higher

310 series Heat Pumps with controller version HPV 4.0 or higher have a red and green LED located externally on the front of the heat pump module or internally on the control board in the heat pump (refrigeration) module depending upon date of manufacture.

LED Flashing Frequency: Different combinations of flashing red and/or green LED’s are utilised to indicate the operational status or fault condition of the Heat Pump. Each flash in a series will last 0.5 seconds and is separated by 0.5 seconds between flashes. Each series of flashes is separated by 2 sec.

Example: LED provides 2 flashes: 1) LED on for 0.5 sec.

2) LED off for 0.5 sec.

3) LED on for 0.5 sec.

4) LED off for 2 sec.

5) Return to Step 1). Operational LED Indication: If no fault is present the green LED will flash as shown

below to indicate the operational sequence number the Heat Pump is currently operating in (refer to operating sequence flow chart on page 6 for more details).

Operational LED Indication

Sequence Green LED Red LED

0 Solid 0 2 2 flashes 0 3 3 flashes 0 4 4 flashes 0

Fault Indication: If a fault is present the green and/or red LED’s will indicate the fault

condition according to the table below.

Fault Indication

Fault Error Green LED Red LED

Faulty power supply or system in limp mode

with call for heat satisfied (1)

N/A 0 0

T3 (comp dis) > 60°C in sequence 0 (2)

SerrNo 4 1 Flash 0

T4 (ambient air) < 0°C (3)

SerrNo 1 0 Solid

Any Sensor Strip Sensor Fault Any Sflag 0 1 Flash

Water circ fault T0 (water outlet) > 80°C

SerrNo 2 0 2 Flashes

T2 (evaporator) < -3°C

SerrNo 8 0 3 Flashes

Comp/refrig fault T3 > T4 + 15°C (in seq3)

SerrNo 32 0 4 Flashes

Comp/refrig fault T0 - T1 < 8°C (in seq4)

SerrNo 32 0 5 Flashes

Water circ fault T1 > S4 + 7°C

SerrNo 64 0 6 Flashes

TRIAC/refrig fault T3 > 110°C

SerrNo 128 0 7 Flashes Thermistor T0 Fault Tflag 1 1 Flash* 1 Flash* Thermistor T1 Fault Tflag 2 2 Flashes* 2 Flashes* Thermistor T2 Fault Tflag 4 3 Flashes* 3 Flashes* Thermistor T3 Fault Tflag 8 4 Flashes* 4 Flashes* Thermistor T4 Fault Tflag 16 5 Flashes* 5 Flashes*

Notes: * The green and red LED’s flash simultaneously in these cases.

(1) System may be in limp mode with call for heat satisfied (water in cylinder @ 70ºC

determined by mechanical thermostat).

(2) This condition creates a delay start for the compressor. This is not considered a fault. (3) Ambient temperature too cold for heat pump operation. This is not considered a fault.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Fault Finding

Fault Chart

Number

Page

1 16

1.1 17

1.2 21

No Hot Water

7 43

Insufficient hot water 2 23

3 24

3.1 25

3.2 25

3.3 26

3.4 27

3.5 29

3.6 30

3.7 30

8.1 44

Software version

HPV 3.1, HPV 3.2

or no HPV

identification

8.3 44 4 32

4.1 33

4.2 33

4.3 34

4.4 35

4.5 36

4.6 37

4.7 38

4.8 39

4.9 – 4.13 40

4.14 40 8 44

System in boost or limp mode

Software version

HPV 4.0 or higher

8.2 44 Leaking water heater 5 41 Noisy water heater 6 42 Blowing fuse/circuit breaker 7 43

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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General Fault Finding Chart

Fault Diagnosis

hot water?

YES

Insufficient

hot water?

YES

System

in boost or limp

mode?

YES

Leaking

water heater?

Noisy

water heater?

YES

Blowing fuse/circuit breaker

Boost or limp mode will be indicated by any of the following LED conditions: Red solid or flashing. Red & green flashing together. No LEDs (Limp mode with Robertshaw thermostat open)

HPV 3.1, HPV 3.2 or no HPV identification

HPV 4.0 or higher

What is the

controller

software version?

Note: For more information on LED indication refer to pages 12 and 13.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

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Fault Finding Chart 1

Warning: Terminals may be ‘live’.

Wear Personal Protective

Equipment to prevent risk of

electric shock.

Is 240

volts present at

the terminal

block?

Test 1

1.1

YES

the heater

connected to an

off peak

tariff?

Off peak connection is unsuitable for Heat

Pump models. Connect to continuous tariff or

‘off peak 2’ if available

YES

Is the

isolating switch

or time clock

turned off?

Restore power and advise customerYES

Is the

fuse blown at the

switchboard?

Fault in household electrical wiringNO

Reset circuit breaker

or rewire fuse

YES

Did

the fuse or

circuit breaker blow

again?

YES

1. Heat pump connected to mix ed circuit, possible excessi ve current draw or another appliance with a fault

2. Faulty circuit breaker or fatigued fuse wire

3. Unit may be short cycling due to faulty thermostat

No Hot Water

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

This document is stored and maintained electronically by

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

Fault Finding Chart 1.1

Note: Ensure you

wait the full five

minutes before

progressing from

this point.

1.1

Are the

thermostat contacts

closed?

NO Replace thermostat.

Test 2

No Hot Water

Is there

240V at the

control board &

relay?

Test 3

Wiring incorrect. Check control board wiring loom plug (lower thermostat to control

board wiring loom).

Test 4

What is the

status of the

control boards

LED’s five

minutes after

resetting?

Replace control board.

Red solid or Red and Green LED’s indicating simultaneously

Green flashing

Green solid

No indication

1.2

Replace sensor strip.

Replace control board (system should have been operating in

boost mode after five minutes

from resetting) then check

system operation as a second

fault may be present.

YES

Note: To reset heat

pump switch power off,

wait for 30 seconds

then switch back on.

Reset heat pump &

wait five minutes

before progressing

from this point.

Is the

compressor

running?

Is the

sensor strip

working?

YES

Is the

refrigeration

system

heating?

YES

To check if the refrigeration system is heating feel the braided flexible hose from the heat exchanger water out l et.

What is the

controller

software version?

HPV 3.1, HPV 3.2 or no HPV identification

HPV 4.0 or higher

sensor T3

working?

YES

Replace sensor T3.NO

Test 5

System working ok. The element ci rc u i t s h ould be checked as a temporary condition may have caused the appliance to enter boost mode. If in boost mode and the

element circuit is not operational the cylinder water will

be cold and the system cannot reset itself automatically.

Replace control board.

YES

Is the

evaporator fan

operating?

YES

3.6

1.2

Red flashing

the air flow

obstructed?

Remove obstruction or clean

evaporator.

YES

Note: For more information on LED indication refer to pages 12 and13.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

This document is stored and maintained electronically by

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

Component Tests 1, 2, 3 & 6

Tests 1 Test 2

240

Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test.

Using a multimeter on the AC voltage scale, measure between the terminals of the terminal block located behind the element access cover. The following measurements should be obtained:

Active & Neutral – 240 volts. Active & Earth – 240 volts. Neutral & Earth – 0 volts.

Warning - Ensure power is isolated before conducting this test.

Using a multimeter on the ohms scale, measure between the terminals of the mechanical thermostat. The following results should be obtained:

1L & 2T – 0 ohms. 3L & 4L – 0 ohms.

Test 3 Test 6

240

Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test.

Using a multimeter on the AC voltage scale, measure between the top 2 terminals of the heat pump module terminal block.

Normal voltage is 240 volts.

Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test.

Using a multimeter on the AC voltage scale, measure between the A return and Neutral terminals of the terminal block located behind the element access cover.

Normal voltage is 240 volts.

Note: Refer to page 19 for component test 4 and page 20 for component test 5.

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

This document is stored and maintained electronically by

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

8.49

Component Test 4

Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test.

Sensor Strip Testing: Unplug the sensor strip plug from the control board and using a multimeter on the kilo-ohms scale, measure between the pins of the sensor strip plug*. There are six individual tests to be performed as there are six individual sensors contained along the length of the sensor strip (sensors S0 – S5). As the resistance of each sensor will change according to its temperature, the resistance measurements for each sensor will need to be checked against the Temperature/Resistance Table shown below. For this reason it is best to empty the tank of hot water and then measure the cold water temperature at the T&PR so a known temperature datum can then be applied to all sensors which should then in turn all have similar resistance value when tested.

Sensor Test Points

S0 – Between Pins 1 and 9 S1 – Between Pins 2 and 9 S2 – Between Pins 4 and 9 S3 – Between Pins 6 and 9 S4 – Between Pins 3 and 8 S5 – Between Pins 3 and 10

*Note: The sensor strip plug socket test points are quite small, Fine Probe Adapters (part number WH0020082) can be utilised as probe extensions. Alternatively small pins may be used however ensure good contact is made when testing.

Sensor Strip Temperature / Resistance Table

T (°C) R (kΩ) T (°C) R (kΩ) T (°C) R (kΩ) T (°C) R (kΩ) T (°C) R (kΩ)

-10 37.45 10 15.45 30 7.037 50 3.485 70 1.853

-9 35.73 11 14.82 31 6.782 51 3.371 71 1.799

-8 34.11 12 14.22 32 6.537 52 3.262 72 1.743

-7 32.56 13 13.65 33 6.302 53 3.157 73 1.695

-6 31.10 14 13.10 34 6.076 54 3.055 74 1.646

-5 29.71 15 12.58 35 5.86 55 2.957 75 1.589

-4 28.39 16 12.09 36 5.653 56 2.863 76 1.552

-3 27.13 17 11.61 37 5.454 57 2.773 77 1.508

-2 25.94 18 11.16 38 5.264 58 2.686 78 1.465

-1 24.81 19 10.72 39 5.081 59 2.602 79 1.424 0 23.73 20 10.31 40 4.905 60 2.521 80 1.384 1 22.71 21 9.913 41 4.736 61 2.442 81 1.345 2 21.73 22 9.535 42 4.574 62 2.367 82 1.307 3 20.81 23 9.173 43 4.418 63 2.295 83 1.271 4 19.92 24 8.826 44 4.269 64 2.225 84 1.236 5 19.09 25 8.495 45 4.125 65 2.157 85 1.202 6 18.29 26 8.177 46 3.987 66 2.092 86 1.169 7 17.52 27 7.873 47 3.854 67 2.029 87 1.137 8 16.80 28 7.583 48 3.726 68 1.968 88 1.107 9 16.11 29 7.304 49 3.603 69 1.91 89 1.077

Sensor strip plug

pin configuration

Testing the

sensor strip

TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07

This document is stored and maintained electronically by

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

Component test 5

T Sensor Testing: 310 Series Heat Pumps have five independent thermistors which are

utilised to monitor temperatures at various locations around the system. These thermistors connect to and are monitored by the control board and are known as ‘T sensors’.

All five T sensors are identical and each can be tested as follows:

Warning - Ensure power is isolated before conducting this test.

Unplug the relevant T sensor from the control board and remove the T sensor from its location so its temperature will be the same as the ambient air temperature (As sensor T4 detects the ambient air temperature it may remain in position for this test). Using a multimeter on the kiloohms scale, measure between the two pins of the T sensor plug*. As the resistance of each sensor will change according to its temperature, the resistance measurements for each sensor will need to be checked against the Temperature/Resistance Table shown below and the value then compared to the ambient air temperature.

Sensor Monitors Part Number

T0 Water temperature leaving the condenser T1 Water temperature entering the condenser T2 Evaporator temperature T3 Compressor discharge temperature T4 Ambient air temperature

056006

T Sensor Temperature / Resistance Table

The table below sets out the resistance of the T sensors for a given water or air temperature.

Temperature

Degrees C

Resistance (All T Sensors)

Kilo-ohms

0 23.73 10 15.45 20 10.31 30 7.037 40 4.905 50 3.485 60 2.521 70 1.853 80 1.384

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Rheem 310 Series, 551310 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual