Rheem 310 Series, 551310 Service Instructions Manual

Page 1

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SERVICE INSTRUCTIONS

310 Series Heat Pump

TM025

551310

Page 2

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

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

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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.

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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.

Page 5

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.

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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).

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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

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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

Page 9

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.

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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.

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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.

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

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Wiring Diagram

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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.

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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.

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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

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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.

Page 17

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

Page 18

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

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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.

Page 19

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

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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.

Page 20

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

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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

Page 21

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

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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

Page 22

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

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Fault Finding - Chart 1.2

1.2

Is there

240V at the

element?

Test 6

No Hot Water

Test 8

YES

Is there

240V at the N/C

relay contact?

YES

Is there

6VDC at the relay

coil?

YES

Is the

element resistance

correct?

Test 7

Test 9

Repair faulty wiring.

Appliance operation should then

be checked to determine why the

system entered boost or limp

mode as a second fault may be

present.

Replace element.

Appliance operation should then

be checked to determine why the

system entered boost or limp

mode as a second fault may be

present.

Replace relay.

Appliance operation should then

be checked to determine why the

system entered boost or limp

mode as a second fault may be

present.

Replace control board.

Appliance operation should then

be checked to determine why the

system entered boost or limp

mode as a second fault may be

present.

Repair faulty wiring between heat

pump module electrical

connection plug and element.

Appliance operation should then

be checked to determine why the

system entered boost or limp

mode as a second fault may be

present.

Note: all faults in this chart are in the ‘boost’ or ‘limp mode’ (element) circuit. After determining the fault in the element circuit the appliance

operation should then be checked to determine why the system

entered boost or limp mode as a second fault may be present.

Page 23

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

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Component Tests 7, 8 & 9

Tests 7 Test 8

240

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

Using a multimeter on the AC voltage scale, measure between the white wire on the heat pump module electrical connection plug and the top terminal of the heat pump module terminal block (Neutral).

Normal voltage is 240 volts.

Warning - Ensure power is isolated before conducting this test.

Disconnect the element wires from the thermostat and terminal block, and using a multimeter on the ohms scale, measure between the two element wires. The following results should be obtained:

2.4kW element: 22 – 26 ohms.

3.6kW element: 15 – 17 ohms.

Test 9

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

Using a multimeter on the DC voltage scale, measure between the two wires on the control board relay plug.

Normal voltage is 6 Volts DC.

Page 24

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

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Fault Finding - Chart 2

YES

Recommend a water heater of

sufficient capacity to meet the

customers needs.

Insufficient Hot Water

Has the

supply of hot water

recently been

depleted?

Boost or limp mode may be indicated by any of the following LED conditions: Red solid or flashing. Red & green flashing together. No LED indication.

Has the

usage pattern

changed

recently?

i.e. additional applianc es or people using hot water

Depending on the ambient

temperature the water heater may

take 3 to 5 hours to recover.

Is the

heater of sufficient

size?

Recommend a hot water usage

pattern that will suit the water

heater and the custom ers needs.

YES

Is the

water supply pressure

more than 80% of the

T&PR rating?

Fit pressure limiting valve if not

already installed.

Existing pressure limiting valve

faulty - replace.

YESYES

Is the

correct T&PR

valve fitted?

YES

Check for crossed water

connection.

Replace T&PR valve.

Replace T&PR valve with one of

correct pressure rating.

Do not use reconditioned T&PR

valves.

Are there

any plumbing leaks,

crossed connections or

dripping taps?

Repair any leaks.

Isolate crossed conne c t i ons .

YES

Is the

heater operating

in boost or limp

mode?

What is the

controller

software version?

YES

HPV 3.1, HPV 3.2 or no HPV identification

HPV 4.0 or higher

Is the

T&PR valve

continuously

discharging

water?

YES

Is the

heater outlet water

temperature

> 58°C

Is a

tempering valve

fitted?

Are the filters blocked?

Clean or replace filtersYES YES

Is the

tempering valve outlet

water temperature

approx 48°C?

Replace tempering valveNO

YES

System workingYES

Is the

sensor strip

working?

YES

Replace sensor strip

Test 4

The heater outlet water temperature can be measured at the T&PR.

Is 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

Note: This assumes that

the hot water to the

tempering valve is above

52°C.

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

Page 25

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

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Fault Finding - Chart 3

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

What is the

status of the

control boards

LED’s?

Replace control board.

Red solid or Red and Green LED’s indicating simultaneously

Red flashing

Green solid

Green flashing

Test 4

System working. Check operation.

No LED Indication

3.1

YES NO

Are the

relay, circulator,

fan, sensor strip & T

sensors all firmly plugged

into the correct

sockets?

YES

Ensure plugs are firmly plugged

into correct sockets on control

board and that plug pins on

control board are clean and free

from conformal coating.

Test 5

Is the

sensor strip

working?

Replace sensor strip.

Are all

T sensors

working?

Replace faulty T sensor(s).

Ensure water in heat

pump is below 60ºC &

reset heat pump. To reset heat pump switch off, wait for 30 seconds

then switch back on.

Does

compressor

successfully start

after delay?

Note: The compressor

starts 30 seconds after

the circulator.

circulator

operating?

Does

compressor try

to start after

delay?

3.3

3.4

Circulator operation can be checked by feeling circulator brass body for vibration.

Let heat pump

run for ten

minutes or until

red LED flashes.

Does

red LED

flash?

YES

Red LED will flash if system enters boost

mode.

8.3

Has

compressor

recently been

operating?

YES

Compressor internal OTC

may have opened.

Switch off power to heat

pump, wait for ten

minutes then switch

power back on.

YES

3.5

YES

System working. Ambient air

temperature may have been too high or

low for normal operation. Heat pump

may have been too hot after operating

for an extended period due to large

volumes and/or frequent water usage.

YES

LED

Status

after 5

seconds

Green - flashing

Red solid or flashing / Red and Green indicating simultaneously / Green solid

Replace control board.

3.2

Red - flashing

3.8

Note: Refer to page 5 for T sensor plug socket location on control board.

Page 26

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

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Fault Finding – Chart 3.1

3.1

Are the

thermostat contacts

closed?

YES

Repair faulty wiring.

Replace control board.

Test 2

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

System has operated in limp mode due to a faulty sensor strip (S1 & S4 faults) and has completed a heating

cycle. Water was heated by the

electric element and controlled by

the Robertshaw thermostat to 70ºC.

Replace sensor strip.

Is the

sensor strip

working?

Replace control board.

YES

Test 4

Are the

sensor strip plug

pins clean?

Ensure sensor strip plug pins and

control board socket are clean

and free from conformal coating.

YES

Fault Finding – Chart 3.2

3.2

T0 is monitoring water out of the heat exchanger

Switch off heat pump & allow sensor T0 to cool

below 80ºC. When

sufficiently cool switch

heat pump back on.

Is red

LED flashing after

5 seconds?

Replace control board

YES

Green LED

flashing?

YES

Circulator operation can be checked by feeling circulator brass body for vibration.

Has

sensor T0 cooled

to below

80ºC?

YES

Is circulator

operating?

3.3

3.8

YES

Replace control board

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

Page 27

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

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Fault Finding – Chart 3.3

3.3

Ensure circulator is firmly plugged

into correct socket on control

board and that plug pins on

control board are clean and free

from conformal coating.

YES

Is the

circulator motor

resistance

correct?

Is 240V

present at the

circulator?

Test 10

Is the

circulator plug firmly

plugged into correct

socket?

Check circulator impellor for

restriction or siezure.

YES

Replace circulator

YES

Test 11

Replace control board

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

Component Tests 10 & 11

Test 10 Test 11

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

Using a multimeter on the AC voltage scale, measure between the circulator plug terminals at the control board.

Normal voltage is 240 volts. Note: As the control board controls the

speed of the circulator by pulsing the electrical supply to the circulator an analogue multimeter may indicate between 180 – 240V.

Warning - Ensure power is isolated before conducting this test.

Unplug the circulator connection plug from the control board and using a multimeter on the ohms scale, measure between the two circulator connection plug terminals.

A reading of approximately 75.3 ohms should be obtained.

Page 28

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

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Fault Finding – Chart 3.4

3.4

Is 240V

present at the

compressor

terminals?

NO Faulty compressor wiring.

YES

Are

the compressor

winding resistances

correct?

Test 12

Replace compressor

Faulty compressor and/or

compressor capacitor wiring.

YES

Note: Tests 12 & 13 must be performed after waiting for the 30 second delay after starting of the

circulator and cannot be performed

whilst the red LED is flashing.

Test 14

Is the

compressor

capacitor working?

Replace compressor capacitorNO

YES

Is 240V

present at the control

board compressor

terminals?

YES

Test 15

Test 13

Replace control boardNO

Is there

6VDC at the relay

coil?

Is the

relay plug plugged

into the control

board?

YES

Plug in relay plug at control board.NO

Ensure plug pins are clean of

conformal coating and are making

contact. If plug & pins are ok

replace the control board.

YES

Test 9

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

Are

the compressor

winding resistances

correct?

Compressor internal ECO

may have tripped open

circuiting the compressor

windings. Wait ten

minutes for ECO to cool

and auto reset.

Is the

compressor

temperature 150ºC

or hotter?

Reset heat pump and run

system until compressor

ECO trips again.

YES

Test 14

8.3

YES

Note: To reset heat

pump switch power off,

wait for 30 seconds

then switch back on.

Note: Compressor internal

ECO is auto trip & auto

reset & is not a replaceable

component.

ECO Opens @ 150ºC

ECO Closes @ 90ºC

Page 29

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

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Component Tests 12 – 15

Tests 12 Test 13

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

Remove the compressor electrical access cover and using a multimeter on the AC voltage scale, measure between the red and blue wires.

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 control board compressor output terminal and the top terminal of the heat pump module terminal block (Neutral).

Normal voltage is 240 volts.

Test 14 Test 15

Warning - Ensure power is isolated before conducting this test.

Remove the compressor electrical access cover and mark and disconnect terminal wiring. Using a multimeter on the ohms scale, measure between the compressor terminals. The following run and start winding results should be obtained.

(Run) Red & Blue terminals – 2.2 ohms (Start) Red & Black terminals – 3.2 ohms

Warning - Ensure power is isolated before conducting this test.

Disconnect the wiring to the compressor capacitor and using a multimeter on the capacitance (µF) scale measure between the two capacitor terminals.

Normal capacitance is 35 micro Farads (35µF).

Page 30

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

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Fault Finding – Chart 3.5

3.5

Is the

temperature at

sensor T4

< 2ºC?

System functioning correctly and

should operate in boost mode

until temperature at T4 rises

above 2ºC at which time the heat

pump will reset and start back at

sequence 0.

YES

T4 is ambient

air sensor

Is the

temperature at

sensor T2

< 2ºC?

3.6

YES

T2 is evaporator

sensor

Is the

ambient air

temperature <

ºC?

System functioning correctly and

should operate in boost mode

until evaporator temperature rises

above 2ºC at which time the heat

pump will reset and start back at

sequence 0.

YES

the ambient air

temperature above

50ºC?

System working ok. Ambient air

temperature too hot for normal

heat pump operation.

YES

T2 temperature can

be measured by

inserting thermometer

probe into evaporator

fins next to sensor T2.

Is the

circulator water

flow direction

correct?

Reinstall circulator so flow is

directed towards heat exchanger.

YESYES

Is the

water system

blocked?

YES

Clear blockage in water system at

circulator, heat exchanger,

dropper tubes or flexible hoses.

YES

Are the

refrigeration

system pressures

correct?

YES

8.1

NO NO

Tests 19 & 20

Is the

circulator impellor

functioning?

Has the

cold water dropper

tube fallen off?

Replace cold water dropper tube.

Is there

an air lock in the

water system

Repair or replace circulator

impellor.

Bleed air from water outlet at

flexible hose union.

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

Warning! Ensure water escaping from flexible hose is caught in a container and does not escape or sensor strip damage may occur.

3.7

Page 31

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

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Fault Finding – Chart 3.6

3.6

Did the

evaporator fan

come on with the

compressor?

YES

Ensure evaporator fan is firmly

plugged into correct soc ket on

control board and that pl ug p i ns

on control board are clean and

free from conformal coating.

Are the

fan motor winding

resistances

correct?

Is 240V

present at the fan

terminals?

YES

Is the

evaporator fan firmly

plugged into correct

socket?

NO NO

Replace control board.YES

Replace evaporator fan motor.NO

Is the

fan capacitor

working?

Replace capacitor.

Replace faulty contro l board.

YES NO

YES

Test 17

Test 18

Test 16

the air flow

obstructed?

Remove obstruction.YES

Clean dirty evaporator.

Appliance installe d i n enclosed

room contrary to installation

instructions.

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification. Also HPV 4.0 or higher from fault finding chart 1.1 only

Is the

fan wiring faulty

or incorrect?

Repair or replace faulty wiring.YES

Fault Finding – Chart 3.7

Note: To reset heat pump switch power off,

wait for 30 seconds then switch back on.

Note: Compressor internal

ECO is auto trip & auto

reset & is not a replaceable

component.

Opens @ 150ºC

Closes @ 90ºC

3.7

Replace compressor

Test 15

Replace faulty control board.

System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV

identification

Are

the compressor

winding resistances

correct?

Replace compressor capacitor.

Compressor internal ECO may have

tripped open circuiting the compressor

windings. Wait ten minutes for ECO

to cool and auto reset.

Is the

compressor

temperature 150ºC

or hotter?

Reset heat pump and run

system until compressor

ECO trips again.

YES

Test 14

8.3

YES

Is the

compressor

capacitor working?

Are

the compressor

winding resistances

correct?

Test 14

Replace compressor capacitorYES

Page 32

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

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Component Tests 16, 17 & 18

Tests 16 Test 17

240

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

Using a multimeter on the AC voltage scale, measure between the third and fourth terminals down from the top on the heat pump module terminal block.

Normal voltage is 240 volts.

Warning - Ensure power is isolated before conducting this test.

Mark and disconnect fan wiring at the heat pump module terminal block and using a multimeter on ohms scale, measure between the disconnected fan wires. The following run and start winding results should be obtained.

(Run) Black & Brown wires – 184 ohms (Start) Black & Blue wires – 238 ohms

Test 18

Warning - Ensure power is isolated before conducting this test.

Mark and disconnect the fan capacitor wiring at the heap pump module terminal block and using a multimeter on the capacitance (µF) scale measure between the two capacitor wires.

Normal capacitance is 2 micro Farads (2µF).

Note: Refer to page 45 for component tests 19 & 20.

Page 33

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Fault Finding – Chart 4

System in boost or limp mode - Software version 4.0 or higher

Boost or limp mode will be indicated by any of the following LED conditions:

4.3

What is the

status of the

control boards

LEDs?

4.4

4.5

4.6

4.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

4.2

Red 1 flash

Red 2 flash

Red 3 flash

Red 4 flash

Red 5 flash

Red 6 flash

Red 7 flash

Red & Green 1 flash

Red & Green 2 flash

Red & Green 3 flash

Red & Green 4 flash

Red & Green 5 flash

No LED indication

Flashing frequency: Different combinations of flashing LED’s (one Red & one Green) will indicate the status of the heat pump. Each flash in a series will last for 0.5 seconds and is separated by 0.5 seconds between flashes . Each series of flashes is separated by 2 seconds.

Notes:

Green solid - Heat pump operating in sequ enc e 0 (standb y ) Green 1 flash - Compressor delay start (T3 > 60ºC in seq 0) Green 2 flash - Heat pump operating in sequence 2

Green 3 flash - Heat pump operating in sequence 3 Green 4 flash - Heat pump operating in sequence 4

Other LED indication: If no fault is present the Green LED will flash to indicate the following:

4.1

Red solid

Red solid or flashing. Red & Green flashing simultaneously . No LED indication.

For other LED indication refer to notes below.

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

Page 34

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

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Fault Finding – Chart 4.1

4.1

sensor T4

firmly plugged

into correct

socket?

Ensure sensor T4 is firmly

plugged into correct socket on

control board and that plug pins

on control board are clean and

free from conformal coating.

Red solid

T4 < 0

ºC

YES

Is the

temperature at

sensor T4

< 2ºC?

YES

sensor T4

working?

Test 5

Replace sensor T4NO

Replace control boardYES

T4 is ambient

air sensor

Note: When T4 < -0ºC the system will enter boost mode. When in boost mode due

to this operation the system will reset and start at sequence 0 when T4 > 2ºC

System functioning correctly and

should operate in boost mode

until temperature at T4 rises

above 2ºC at which time the heat

pump will reset and start back at

sequence 0.

Note: Refer to page 5 for T sensor plug socket location on control board.

Fault Finding – Chart 4.2

4.2

Is the

sensor strip

working?

Red 1 flash

sensor strip fault

Is the

sensor strip

firmly plugged

into the correct

socket?

YES

Test 4

Replace control boardYES

Ensure sensor strip is firmly

plugged into correct socket on

control board and that plug pins

on control board are clean and

free from conformal coating.

Replace sensor strip

Page 35

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

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Fault Finding – Chart 4.3

4.3

Red 2 flash

T0 >80ºC

YES

Test 5

T0 is monitoring

water out of the heat exchanger

sensor T0

firmly plugged

into correct

socket?

sensor T0

working?

Replace sensor T0

Switch off heat pump & allow sensor T0 to cool

below 80ºC. When

sufficiently cool switch

heat pump back on.

Does red

LED immediately

go to 2 flash?

Replace control board

YES

Is circulator

operating?

Blockage of water system at

circulator, heat exchanger,

dropper tubes or flexible hoses.

Loose, damaged or jammed

circulator impellor.

YES

Circulator operation can be checked by feeling circulator brass body for vibration.

Ensure circulator is firmly plugged

into correct socket on control

board and that plug pins on

control board are clean and free

from conformal coating.

YES

Is the

circulator motor

resistance

correct?

Is 240V

present at the

circulator?

Test 10

Is the circulator plug firmly plugged into correct

socket?

Check for loose, damaged or

jammed circulator impellor.

YES

Replace circulator

YES

Test 11

Has

sensor T0 cooled

to below

80ºC?

YES

Replace control board

Ensure sensor T0 is firmly

plugged into correct socket on

control board and that plug pins

on control board are clean and

free from conformal coating.

Is there

an air lock in the

water system?

Bleed air from water outlet at

flexible hose union.

YES

Warning! Ensure water escaping from flexible hose is caught in a container and does not escape or sensor strip damage may occur.

Note: Refer to page 5 for T sensor plug socket location on control board.

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Fault Finding – Chart 4.4

4.4

sensor T2

firmly plugged

into correct

socket?

Ensure sensor T2 is firmly

plugged into correct socket on

control board and that plug pins

on control board are clean and

free from conformal coating.

Red 3 flash

T2 < -3ºC

Is the

temperature at

sensor T2

< 2ºC?

sensor T2

working?

Test 5

Replace sensor T2NO

Replace control boardYES

T2 is evaporator

sensor

System functioning correctly and

should operate in boost mode

until evaporator temperature rises

above 2ºC at which time the heat

pump will reset and start back at

sequence 0.

Did the

system reset &

operate in normal

heat pump

mode?

Is the

ambient air

temperature <

ºC?

YES

Is the

evaporator fan

running?

YES

Note: Compresor

will not start until 30 seconds after

the circulator

YES

Ensure evaporator fan is firmly

plugged into correct socket on

control board and that plug pins

on control board are clean and

free from conformal coating.

Are the

fan motor winding

resistances

correct?

Is 240V

present at the fan

terminals?

YES

Is the

evaporator fan firmly

plugged into correct

socket?

NO NO

Replace control boardYES

Replace evaporator fan motorNO

Is the

fan capacitor

working?

Replace capacitor

Repair faulty wiring

YES

Test 17

Test 18

T2 temperature can

be measured by

inserting thermometer

probe into evaporator

fins next to sensor T2.

Test 16

Note: When T2 < -3ºC the system will enter boost mode. When in boost mode due

to this operation the system will reset and start at sequence 0 when T2 > 2ºC

the air flow

obstructed?

Remove obstruction.YES

YES

Clean dirty evaporator.

Appliance installed in enclosed

room contrary to installation

instructions. Appliance is suitable

for outdoor installation only.

Raise temperature of sensor T2 to

above 2ºC by removing from

evaporator and holding probe between

thumb & fingers. Heat pump should

auto reset to sequence 0 when T2

raises above 2ºC. Ensure sensor

probe is reinserted into evaporator on

completion of testing procedure.

Note: Refer to page 5 for T sensor plug socket location on control board.

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Fault Finding – Chart 4.5

4.5

Is 240V

present at the

compressor

terminals?

NO Faulty compressor wiring.

Red 4 flash

T3 is not > T4 +

ºC in sequence 3

YES

Does

compressor start

or try to start after

delay?

YES

Are

the compressor

winding resistances

correct?

Test 12

Replace compressorNO

Faulty compressor and/or

compressor capacitor wiring.

YES

Note: T3 is compressor discharge se ns or. T4 is ambient air sensor. This check is performed in sequence 3 to

ensure that the sealed refrigerant system is operating (heating).

Are

sensors T3 & T4

firmly plugged into

the correct

sockets?

Ensure sensors T3 & T4 are firmly

plugged into correct sockets on

control board and that plug pins

on control board are clean and

free from conformal coating.

Note: Tests 12 & 13 must be

performed after waiting for the 30

second delay after starting of the

circulator and cannot be perf ormed

whilst the red LED is flashing.

Test 14

Is the

compressor

capacitor working?

Replace compressor capacitorNO

Note: The compressor starts 30

seconds after the circulator.

YES

Are

sensors T3 & T4

working?

Replace faulty sensor(s)NO

Ensure water in heat pump is below 60ºC & reset heat pump. To reset heat pump switch off, wait for 30 seconds then switch back on.

YES

Does red

LED immediately

go to 4 flash?

YES

Is 240V

present at the control

board compressor

terminals?

YES

Test 15

Test 13

Test 5

Replace control boardNO

Replace control board

Is there

6VDC at the relay

coil?

Is the

relay plug plugged

in to the control

board?

YES

Plug in relay plug at control board.NO

Ensure plug pins are clean of

conformal coating and are making

contact. If plug & pins are ok

replace the control board.

YES

Test 9

YES

Note: Refer to page 5 for T sensor plug socket location on control board.

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Fault Finding – Chart 4.6

4.6

Is 240V

present at the

compressor

terminals?

NO Faulty compressor wiring.

YES

Does

compressor start

or try to start after

delay?

YES

Are

the compressor

winding resistance s

correct?

Test 12

Replace compressorNO

Faulty compressor and/or

compressor capacitor wiring.

YES

Are

sensors T0 & T1

firmly plugged into

the correct

sockets?

Ensure sensors T0 & T1 are

plugged into correct sockets on

control board and that plug pins

on control board are clean and

free from conformal coating.

Note: Tests 12 & 13 must be

performed after waiting for the 30

second delay after s t a rting of the

circulator and cannot be performed

whilst the red LED is flashing.

Test 14

Is the

compressor

capacitor

working?

Replace compressor capacitorNO

Note: The

compressor starts 30

seconds after the

circulator.

YES

Are

sensors T0 & T1

working?

YES

Replace faulty sensor(s)NO

Ensure water in heat pump is below 60ºC & reset heat pump. To reset heat pump switch off, wait for 30 seconds then switch back on.

YES

Does red

LED immediately

go to 5 flash?

YES

Is 240V

present at the control

board compressor

terminals?

YES

Test 15

Test 13

Test 5

Replace control boardNO

Replace control board

Red 5 flash

T0 - T1 < 8ºC in

sequence 4

Note: T0 is heat exchanger water outlet sensor. T1

is heat exchanger water inlet sensor. This check is performed in sequence 4 to ensure that the sealed

refrigerant system is operating (heating).

Note: Refer to page 5 for T sensor plug socket location on control board.

Page 39

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

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Fault Finding – Chart 4.7

4.7

Is the sensor strip & sensor T1 firmly plugged into

the correct

sockets?

Ensure sensor strip & sensor T1

are both firmly plugged into the

correct sockets on control board

and that plug pins on control

board are clean and free from

conformal coating.

YES

sensor T1

working?

Replace sensor T1NO

YES

Test 5

Replace cold water dropper tube.

Red 6 flash

T1 > S4 + 7ºC in sequence 3 or 4

Note: T1 is heat exchanger water inlet sensor. S4 is thermistor sensor strip sensor.

This check is performed in sequence 3 or 4 to ensure that the circulator is operating.

sensor strip

working?

YES

Replace sensor stripNO

Is the

circulator water

flow direction

correct?

YES

Reinstall circulator so as flow is

directed towards heat exchanger.

Has the

cold water dropper

tube fallen off?

YES

Replace control board.NO

Test 4

Is there

an air lock

in the water

system?

Bleed air from water system at

water outlet flexible hose union.

YES

Warning! Ensure water escaping from flexible hose is caught in a container and does not escape or sensor strip damage may occur.

Note: Refer to page 5 for T sensor plug socket location on control board.

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Fault Finding – Chart 4.8

4.8

YES

System working ok. Ambie nt air

temperature too hot for normal

heat pump operation.

YES

Test 5

Appliance may have been

operating for an extended period

due to large volume and/or

frequent water usage.

Red 7 flash

T3 > 110ºC in

sequence 3 or 4

Note: T3 is compressor

discharge sensor.

YES

sensor T3

firmly plugged

into correct

socket?

YES

Test 19

Ensure sensor T3 is firmly

plugged into the correct socket on

control board and that plug pins

on control board are clean and

free from conformal coating.

Replace sensor T3

sensor T3

working?

the ambient air

temperature above

50ºC?

8.2

Fit pressure gauge to

high side of

refrigerant system

Is the

head pressure

excessive?

Has

sensor T3 cooled

to below

60ºC?

Switch off heat pump & allow sensor T3 to cool

below 60ºC. When

sufficiently cool switch

heat pump back on.

YES

Note: Refer to page 5 for T sensor plug socket location on control board.

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Fault Finding – Charts 4.9 to 4.13

4.9

T sensor fault

YES

Test 5

T sensor

firmly plugged

into correct

socket?

Replace T sensor.

Ensure T sensor is firmly plugged

into correct socket on control

board and that plug pins on

control board are clean and free

from conformal coa ti n g.

4.10 4.11 4.12 4.13

Replace control board.

Is T sensor working?

T0 fault.

T0 is monitoring

water out of the

heat exchanger.

T1 fault.

T1 is monitoring

water into the

heat exchanger.

T2 fault.

T2 is monitoring

the evaporator

temperature.

T3 fault.

T3 is monitoring

the compressor

discharge temp.

T4 fault.

T4 is monitoring

the ambient air

temperature.

YES

Note: Refer to page 5 for T sensor plug socket location on control board.

Fault Finding – Chart 4.14

4.14

Are the

thermostat contacts

closed?

YES

Repair faulty wiring.

Replace control board.

Test 2

System in boost or limp mode - Software version 4.0 or higher

System has operated in limp mode

due to a faulty sensor strip (S1 & S4

faults) and has completed a heating

cycle. Water was heated by the

electric element and controlled by

the Robertshaw thermostat to 70ºC.

Replace sensor strip.

Is the

sensor strip

working?

Replace control board.

YES

Test 4

Are the

sensor strip plug

pins clean?

Ensure sensor strip plug pins and

control board socket are clean

and free from conformal coating.

YES

Is there

240V at the

control board &

relay?

YES

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

board wiring loom).

Test 3

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Fault Finding – Chart 5

the T&PR

valve continuously

discharging

water?

Existing pressure limiting valve

faulty.

Fit pressure limiting valve if not

already fitted.

Replace T&PR valve if required.

Is the

leak from the

electrical access

cover?

YES

Is the

leak from

the element barrel

fitting?

YES

Check for loose element bolts.

Remove element and replace

gasket.

YES

Remove anode and repair leak

using Teflon thread tape.

YES

Is the

correct T&PR valve

fitted?

Replace T&PR valve with one of

the correct pressure rating.

Do NOT use reconditioned

T&PR valves.

Check for crossed water

connection.

Replace T&PR valve.

YES

Is the

water supply

pressure above

800kPa?

YES

the water leak

intermittent?

Leak is probably condensate draining from the evaporator

condensate tray.

Normal Operation.

YES

Are

the anode/s

leaking?

Inner Cylinder leaking

Check for hot spots on the jacket

Replace water heater.

Is the leak from the heat pump water

system?

Tighten or remake flexible hose

connection(s).

Repair or replace leaking heat

exchanger.

Replace leaking circulator.

Remake or replace dropper tube

connections.

YES

Leaking water heater

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Fault Finding – Chart 6

Fan loose on motor shaft, remove

assembly and tighten.

Fan motor faulty - Replace.

Is the

noise water

hammer?

Is the

noise only evident

when water is flowing

through the

heater?

YES

Cylinder contracting due to pressure

release when hot tap opened.

This can also be accompanied by a

creaking or cracking sound.

Normal Operation.

Check for restrictions in pipe work, faulty

valves, loose plumbing or other

appliances i.e. washing machine or

dishwasher.

Fit 600kPa pressure limiting valve.

YES

the noise

mechanical or air

related?

Normal noise level during operation is

approximately 52dB at 1.5 metres.

If this level is affecting neighbors a timer

should be fitted to prevent operation

during the affected hours or to comply

with local council regulations

AIR

Is the

noise from the

evaporator

fan?

Is the noise only evident during the heating

cycle?

Check for loose fittings or pipe work in

the refrigeration system.

Check for possible mechanical failure in

compressor

YES

Is the

water pressure

more than 80% of the

T&PR valve

rating?

Check all other appliances or valves that

can generate noise i.e. washing

machines, dishwashers, ball valves etc.

YES

Mechanical

Refer to water hammer causes in the

‘Common Complaints’ section.

Check for a faulty stop cock, non-return

valve or T&PR valve.

Is the

noise a

metallic popping

sound?

YES

Noisy water heater

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Fault Finding – Chart 7

Is the

reading below 1

Megaohm?

Replace compressor.

YES

Is the

reading below 1

Megaohm?

Replace fan motor.YES

Replace element.

Replace thermostat.

Replace circulator.

Replace control board.

Check for pinched or

damaged wiring touching

the heater jacket.

YES

Is the

reading below 0.66

Megaohms?

Is the

reading below 1

Megaohm?

Is the

reading below 1

Megaohm?

Is the

reading below 1

Megaohm?

Disconnect the power supply

wiring to the control board at

the terminal block and

megger between each control

board wire and earth.

Disconnect the wiring to the

compressor and megger

between each compressor

terminal and earth.

Disconnect the wiring to the

fan motor at the terminal

block and megger between

each fan wire and earth.

Disconnect the wiring to the

element at the thermostat

and megger between each

element wire and earth.

Disconnect the remaining

wiring from the thermostat

and megger between each

thermostat terminal and

earth.

Disconnect the wiring plug to

the circulator at the control

board and megger between

each circulator wire and

earth.

Blowing fuse/circuit breaker

Note: The control board has an internal resistor that will prov ide a Megaohm reading of

0.66 Megaohms when an insulation test is conducted on the con trol boa rd or the appliance with control board connected.

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Fault Finding – Chart 8 - 8.3

8.3

Replace compressor.

Test 19

Refrigeration system fault finding

Is the

head pressure

excessive?

Test 21

Fit pressure gauge

to high side of

refrigerant system.

Allow time for the

system to equalise.

Did

the system

equalise?

Is the system

taking too long to

equalise?

Possible restriction in system,

Locate and repair.

Possible system overcharge,

adjust refrigerant charge.

TX valve metering incorrectly ,

adjust or replace TX valve.

YES

Is the

TX valve

operating?

Locate blockage in refrigerant

system and repair.

YES

Adjust TX valve (refer to

component replacement

procedure 23 “TX valve

adjustment”) or replace if faulty.

System overcharged, adjust

refrigerant charge.

YES

8.28

Fit pressure gauges to high and low side

of refrigerant system.

Is the

Suction pressure

low/vacuum or

excessively

high?

Test 20

Locate and repair leak in

refrigerant system.

High side head pressure excessive (Test 18)

YES

High

Low

8.1

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Component Test 19

Warning – “Live” equipment. Wear Personal Protective Equipment when conducting this test.

1800 kPa

Fit gauges to the high side access pipe and observe the discharge pressure.

Typical high pressure range is 14002100 kPa depending on cylinder water temperature. The high pressure range should be within 1700-1800 kPa when heating from cold.

Component Test 20

Warning – “Live” equipment. Wear Personal Protective Equipment when conducting this test.

400 kPa

Check for persistent air bubbles through sight glass of receiver/filter drier. Fit gauges to the low side access pipe and observe the suction pressure.

The suction (low side) pressure is very dependent on ambient conditions however the low pressure range is typically between 200-600 kPa.

200 kPa @ 10°C ambient. 600 kPa @ 45°C ambient.

A suction pressure of less than 200kPa may indicate a refrigerant leak or a malfunctioning TX valve.

Note: Refer to the following section for more information on refrigerant charge and refrigerant charge fault indications.

Refrigerant Charge

Indication of correct refrigerant charge

The receiver/filter dryer sight glass should show clear liquid, a few small bubbles might be visible during initial start up of the system or when the TX valve opens quickly, however clear liquid should return shortly after. Compressor current draw should be between 5 – 6 Amps and system pressures should be within normal ranges (refer to component test 19 (above) and component test 20 (above) for typical system pressures).

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Indication of undercharged system

Bubbles persist for a significant amount of time or repeat often. Compressor current draw is low (<5 Amps) together with low system pressures. If sight glass indicates clear gas, not liquid, and current draw is very low combined with low discharge line temperature then the system is totally empty. Note: Unusual current draw or low suction pres sure can be a sign of other problems such as a blockage or malfunctioning TX valve.

Indication of overcharged system

Continuous liquid through sight glass, evaporator tends to flood, head pressure high, compressor current draw high (>6 Amps) and compressor noisy. Note: Unusual current draw or high head pressure can be a sign of other problems such as a blockage or malfunctioning TX valve.

Component Test 21

Warning – “Live” equipment. Wear Personal Protective Equipment when conducting this test.

Fit gauges to low side access pipe. Remove the insulation from the TX valve sensor on the suction line.

Hold the sensor by hand to increase the heat detected by the sensor. The TX valve should open with the following results:

1. Flow of refrigerant through sight glass of receiver/filter dryer should increase.

2. Evaporator pressure should increase.

3. Suction line should become cooler.

Remove hand and replace insulation, the TX valve should close, resulting in the reversal of the above results.

Electrical Insulation Testing

There are three basic test procedures that should be carried out when the operation and function of a heat pump water heater’s electrical system is in doubt.

Wear Personal Protective Equipment when conducting step 1 of this procedure to reduce the risk of electric shock. Refer to Rheem safety procedure on electrical testing.

Insulation resistance of the water heater Neutral Circuit. (Reading not to be below

0.66 Mega ohm).

1. Isolate power to the water heater at the isolation switch. Confirm with multi-

meter across terminal block Active and Neutral, then Active and Earth, then Neutral and Earth that voltage is not present.

2. Once satisfied, disc onnect the Active and Neutral wires from the water heater terminal block.

3. Connect megger leads to the Neutral of the water heater wiring and Earth.

4. Operate megger. A reading above 0.66 Mega ohm should be obtained.

5. If a reading below 0.66 Mega ohm is indicated, all component parts will need to be individually tested to locate the fault. Refer to Fault Finding Chart 7 on page 43.

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Insulation resistance of the water heater Active Circuit (reading not to be below 0.66 mega-ohm).

6. Connect megger leads to the Active of the water heater wiring and Earth.

7. Operate megger. A reading above 0.66 Mega ohm should be obtained.

8. If a reading below 0.66 Mega ohm is indicated, all component parts will need to be individually tested to locate the fault. Refer to Fault Finding Chart 7 on page 43.

To check “Continuity” of the Heat Pump electrical circuit.

9. Set megger to resistance scale or multimeter to x1 resistance scale.

10. Measure between the Active and Neutral terminals on the power supply terminal block located behind the electrical/element access cover. The resistance should be approximately 24 ohms. If a reading outside this resistance is measured all electrical component parts will need to be individually tested to locate the fault. Refer to Specifications table on page 3 for indicative resistance values of components.

11. Reconnect active cable to ‘A’ terminal and neutral cable to ‘N’ terminal at heater terminal block.

12. Replace fuse. Note: If continuing with any diagnostic procedures do not replace

the fuse.

Component Replacement Procedures – Water Heater

Draining the Water Heater (Procedure 1)

Elevated temperatures may be present during the draining process. Wear Personal Protective Equipment to prevent scalds or burns.

Wear Personal Protective Equipment when conducting step 3 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power and water supplies to the water heater.

2. Relieve pressure from the water heater through the T & PR valve or a hot tap.

3. Remove the lower electrical/element access cover and confirm with a multi-

meter between the Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

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. Open the temperature and pressure relief valve to allow air into the system.

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Temperature and Pressure Relief Valve (Procedure 2)

Never fit a T&PR valve with a rating higher than that indicated on the water heater rating plate. Do not use reconditioned T&PR valves.

1. Isolate the power and water supplies to the water heater.

2. Relieve pressure from the water heater through the T & PR valve or a hot tap.

3. Remove the drain line from the T&PR valve.

4. Unscrew the T&PR valve and remove.

A quantity of hot water will discharge from the tank during this process. Wear Personal Protective Equipment to prevent scalds or burns.

5. Confirm the replacement T&PR valve is the correct rating and refit using thread tape.

6. Refit the drain line.

7. Close the hot tap and restore water supply.

8. Check T&PR valve thread for leaks.

9. Operate the T&PR valve lever to reset relief drain.

10. Purge air from the system through hot taps.

11. Restore the power supply to the water heater.

Dip Tube (Procedure 3)

1. Isolate the power and water supplies to the water heater.

2. Relieve pressure from the water heater through the T & PR valve or a hot tap.

3. Disconnect the hot water line from the outlet of the water heater.

A quantity of hot water will discharge from the outlet during this process. Wear Personal Protective Equipment to prevent scalds or burns.

4. Using a flat blade screwdriver gently split the outer rim at the top and bottom of the dip

tube face and prise the dip tube out of the cylinder fitting.

5. Fit the replacement dip tube into the cylinder fitting ensuring the flat lines up with the

fitting (dip tube facing up) and gently drive the dip tube into the fitting a short distance.

6. Reconnect the plumbing; this will push the dip tube into the correct location.

7. Restore the water supply and purge air from the system through hot taps.

8. Restore the power supply.

Mechanical Thermostat (Procedure 4)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater and remove access cover.

2. Confirm with a multi-meter between Active and Neutral, then Active and Earth,

then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Disconnect the wiring to the thermostat.

4. Slide the thermostat out from under the retaining clamp.

5. Remove any scale from the cylinder surface.

6. Fit the replacement thermostat under the clamp.

7. Reconnect the wiring as per the circuit wiring diagram on page 11.

8. Conduct an electrical insulation test. Refer to page 46.

9. Refit the access cover and restore the power supply.

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Anode (Procedure 5)

Elevated temperatures may be present during anode removal process. Wear Personal Protective Equipment to prevent scalds or burns.

1. Isolate the power and water supplies to the water heater.

2. Relieve pressure from the water heater and drain approximately 10 litres of water

from the cylinder through the T & PR valve.

3. Remove the air inlet louver (Refer to Procedure 10).

4. Remove the refrigeration section jacket top.

5. Remove the anode cap(s). Access is provided through the refrigeration plant chassis.

6. Using a 27mm tube or socket spanner remove the anode(s).

7. Apply thread seal tape to replacement anode, refit and tighten. Note: It may be

necessary to cut the anode to length prior to fitting. Refer to page 3 for the correct anode length.

8. Restore water supply and check for leaks.

9. Refit the anode cap(s), jacket, air inlet louver and jacket top and restore power.

Heating Unit (Procedure 6)

Wear Personal Protective Equipment when conducting step 1 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Drain the water heater. Refer to procedure 1.

2. Remove the access cover and disconnect the wiring from the terminal block. Disconnect the wiring to the heating unit from the thermostat. Unclip the terminal block from the jacket and remove thermostat and terminal block.

3. Remove the two screws retaining the thermostat clamp.

4. Loosen the two lower screws slightly. When water is below the heating unit level, refit the cold water supply pipe.

5. Remove the two lower screws and withdraw the heating unit carefully making sure the loop does not catch and open up inside the cylinder.

6. Clean around the cylinder fitting, fit gasket to replacement heating unit and insert into water heater. Note: Ensure the element is installed in the same orientation.

7. Replace screws and thermostat clamp, and then tighten.

8. Close T&PR valv e, and open all hot taps. Restore the cold water supply and purge air through hot taps, close each hot tap as water runs freely.

9. Check heating unit for leaks.

10. Refit thermostat and terminal block and reconnect the wiring as per the circuit wiring diagram on page 11.

11. Refit the access cover.

12. Restore power supply to the water heater.

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Dropper Tube(s) (Procedure 7)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

In order to replace the dropper tube(s) the heat pump (refrigeration) module must be removed and refitted. Due to the weight of the unit (approx 45kgs) this is a two man job.

A quantity of hot water may discharge from the flexible hose(s) during this procedure. Wear Personal Protective Equipment to prevent scalds or burns and ensure all escaping water is caught in a container to prevent the sensor

strip from becoming water damaged.

1. Isolate the power and water supplies to the water heater.

2. Confirm with a multi-meter between Active and Neutral, then Active and Earth,

then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Relieve pressure from the water heater and drain approximately 10 litres of water

from the cylinder through the T & PR valve.

4. Remove the refrigeration module (refer to procedure 9 steps 4 - 9).

5. Remove the sensor strip wiring grommet from the jacket top.

6. Loosen the main power wiring cable clamp screw.

7. Carefully remove the jacket top. Note: During the foaming process the foam adheres to

the jacket top which can make it difficult to remove.

8. Clear foam from around the dropper tube(s) ¾” to ½”brass fitting(s).

9. Using an extra deep 35mm socket unscrew the dropper tube(s) brass fitting(s) in an

anticlockwise direction. Note: the 35mm socket must have a minimum internal nut clearance depth of 40mm.

10. Withdraw brass adapter(s) and dropper tube(s) from cylinder. Note: dropper tube is a

push fit into the tapered section of the brass adapter, simply pull dropper tube to remove.

11. Complete reassembly in reverse order of above using thread tape on dropper tube(s)

brass adapter(s) threaded section.

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Sensor Strip (Procedure 8)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

In order to replace the sensor strip the heat pump (refrigeration) module must be removed and refitted. Due to the weight of the unit (approx 45kgs) this is a two man job.

1. Isolate the power and water supplies to the water heater.

2. Confirm with a multi-meter between Active and Neutral, then Active and Earth,

then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the refrigeration module (refer to procedure 9).

4. Remove the sensor strip wiring grommet from the jacket top.

5. Loosen the main power wiring cable clamp screw.

6. Carefully remove the jacket top. Note: During the foaming process the foam adheres to

the jacket top which can make it difficult to remove.

7. Carefully remove the foam insulation from around the sensor strip wiring until the

sensor strip pocket can be seen (approx 150 – 200mm down), adjacent to the cylinder top. Note: Save the foam insulation for repacking in step 14 of this procedure.

8. Carefully grip the sensor strip and slide the sensor strip out, ensure that the sensor

strip pocket has also not been gripped. Note: The fitment between the sensor strip

and the pocket is quite firm, do not pull on the wires only as they will break away from the strip.

9. Carefully insert the replacement sensor strip into the pocket. Note: When reinserting

the replacement sensor strip ensure the plastic backing is facing AWAY from the

cylinder. The strip will need to be supported by hand to prevent it bending as it is inserted into the pocket and it must be fully inserted to operate correctly. Lubricants

of any kind must NOT be used.

10. Re-pack the foam removed in step 11 into the hole.

11. Complete reassembly in reverse order of above.

12. Restore water and electricity supplies and check heat pump operation.

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Component Replacement Procedures – Refrigeration Plant

Refrigeration Module (Procedure 9)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

Due to the weight of the refrigeration unit (approx 45kgs) this is a two man job.

strip from becoming water damaged.

1. Isolate the power and water supplies to the water heater.

2. Confirm with a multi-meter between Active and Neutral, then Active and Earth,

then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Relieve pressure from the water heater and drain approximately 10 litres of water

from the cylinder through the T & PR valve.

4. Remove the front and rear air louvres.

5. Undo the controller cover retaining screw, remove the c ontroller cover and disconnect

the sensor strip and power supply wiring loom plugs from the electronic controller.

6. If fitted, disconnect the condensate drain.

7. Disconnect the hot and cold flexible hoses connecting the heat pump module to the

cylinder at the cylinder fittings (refer to owners guide for location). Note: Ensure all

escaping water is caught in a container to prevent the sensor strip from becoming water damaged.

8. Remove the 3 x 6mm bolts retaining the heat pump module to the cylinder (refer to

owners guide for location).

9. Slide lifting bars (part number 080151) through the slots provided in the chassis (refer

to owners guide for location) and lift the heat pump module clear of the cylinder.

10. Complete reassembly in reverse order of above.

Air Inlet Louver (Procedure 10)

1. Isolate the power to the water heater.

2. Remove the refrigeration section jacket top.

3. Remove the 2 screws from the left and right hand sides of the air inlet louver.

4. Remove the 3 screws from the Colorbond trim directly below the air inlet louver.

5. Lift the louver clear of the jacket.

6. Complete reassembly in reverse order of above.

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Refrigeration Section Jacket (Procedure 11)

The fan motor may commence operation without warning. Failure to isolate the power may result in serious injury if the fan commences operation during the removal process.

1. Remove the air inlet louver (refer to Procedure 10).

2. Remove the air outlet cover.

3. Remove the handle.

4. Remove the screws retaining the jacket to the water heater and lift the jacket clear. Note: The refrigeration section jacket is quite flexible, care should be taken to ensure it does not kink during removal or replacement.

5. Complete reassembly in reverse order of above.

Evaporator Fan Motor (Procedure 12)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

The fan motor may commence operation without warning. Failure to isolate the power may result in serious injury if the fan commences operation during the removal process.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the refrigeration section jacket (refer to Procedure 11).

4. Undo the controller cover retaining screw, remove the controller cover and disconnect the wiring to the fan motor from the terminal block. Cut wiring loom cable ties and remove fan wiring.

5. Remove the 2 screws retaining the fan shroud to the evaporator.

6. Slide the shroud up to disengage the locating tabs and lift clear.

7. Undo the nut retaining the fan blade to the motor shaft and remove the blade.

8. Undo the 3 nuts retaining the motor to the shroud and remove the motor.

9. Complete reassembly in reverse order of above.

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Control Board (Procedure 13)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the air inlet louver (refer to Procedure 10).

4. Undo the controller cover retaining screw, remove the controller cover and unplug power supply wiring loom, T sensors, circulator, fan and sensor strip plugs from control board.

5. Mark and disconnect compressor wiring from control board.

6. Remove two screws retaining control board bracket to refrigeration base and remove control board.

7. Complete reassembly in reverse order of above.

Relay (Procedure 14)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the air inlet louver (refer to Procedure 10).

4. Undo the controller cover retaining screw, remove the controller cover and disconnect wiring to compressor capacitor.

5. Remove cable tie retaining compressor capacitor and remove compressor capacitor.

6. Mark and disconnect wiring to relay, remove two relay retaining screws and remove relay.

7. Complete reassembly in reverse order of above.

Compressor Capacitor (Procedure 15)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the air inlet louver (refer to Procedure 10).

4. Undo the controller cover retaining screw, remove the controller cover and disconnect wiring to compressor capacitor.

5. Remove cable tie retaining compressor capacitor and remove compressor capacitor.

6. Complete reassembly in reverse order of above.

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Fan Capacitor (Procedure 16)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the air inlet louver (refer to Procedure 10).

4. Undo the controller cover retaining screw, remove the controller cover and disconnect wiring to compressor capacitor

5. Remove cable tie retaining compressor capacitor and remove compressor capacitor.

6. Disconnect wiring to fan capacitor, remove two fan capacitor retaining screws and remove fan capacitor.

7. Complete reassembly in reverse order of above.

Circulator (Procedure 17)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

A quantity of hot water may discharge from the circulator flexible hoses during this procedure. Wear Personal Protective Equipment to prevent scalds or burns and ensure all escaping water is caught in a container to prevent the

sensor strip from becoming water damaged.

1. Isolate the power and water supplies to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Relieve pressure from the water heater and drain approximately 10 litres of water from the cylinder through the T & PR valve.

4. Remove the air inlet louver (refer to Procedure 10).

5. Remove circulator electrical cover, disconnect wiring and remove wiring from circulator compression gland.

6. Unscrew circulator flexible hose unions. Note: Ensure all escaping water is caught

in a container to prevent the sensor strip from becoming water damaged.

7. Unscrew circulator inlet adapter and remove circulator from supporting bracket.

8. Complete reassembly in reverse order of above.

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T sensor(s) (Procedure 18)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power supply to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the air inlet louver (refer to Procedure 10).

4. Undo the controller cover retaining screw and remove the controller cover.

5. Unplug the T sensor plug from the control board.

6. Remove insulation surrounding T sensor (if applicable).

7. Remove sensor retaining clip and withdraw sensor. Note: Ambient air sensor is held in place by a locking nut and evaporator sensor is held in place by a cable tie. Ambient air sensor retainer can be manoeuvred out of cable tie. Do not cut cable tie as it is difficult to replace.

8. Cut wiring loom cable ties and remove T sensor and wiring.

9. Complete reassembly in reverse order of above.

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Component Replacement Procedures – Sealed Refrigeration System

Personnel qualified and licensed to work with refrigerants may only carry out the following repair procedures to the sealed refrigeration system.

The following procedures assume that all work conducted conforms to the refrigeration code of good practice. During repair the refrigerant must be recovered, not vented to atmosphere.

Evaporator (Procedure 19)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the evaporator shroud and fan assembly (refer to Procedure 12 Steps 3 - 6).

4. Remove the evaporator T sensor clip from the cable tie and remove the T sensor from the evaporator finning.

5. Recover refrigerant from sealed refrigeration system.

6. Remove the pipe insulation to expose pipe work at the evaporator. Un-braze the pipework to the evaporator.

7. Remove the 4 screws retaining the evaporator to the chassis and lift evaporator clear.

8. Fit and secure the replacement evaporator and braze pipe work.

9. Replace the receiver/filter drier. (Refer to Procedure 20 – steps 4 to 7)

10. Pressurise system to 3000kPa and conduct a leak test. Refit and secure pipe work insulation.

11. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes.

12. Recharge system with the correct refrigerant. Refer to specifications table on page 3.

13. Refit the evaporator shroud and fan motor assembly and refrigeration section jacket.

14. Refit air inlet louver and jacket top.

15. Restore power. The refrigeration plant should commence operation.

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Receiver/Filter Drier (Procedure 20)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the air inlet louver (refer to Procedure 10).

4. Recover refrigerant from sealed refrigeration system.

5. Undo the compression nuts on the inlet and outlet of the receiver/filter drier.

6. Cut the cable tie and remove the receiver/filter drier.

7. Fit the replacement receiver/filter drier, secure using a cable tie and retighten the compression fittings.

8. Pressurise system to 3000kPa and conduct a leak test.

9. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes.

10. Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3.

11. Refit air inlet louver and jacket top.

12. Restore power. The refrigeration plant should commence operation after a 30 second delay.

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Compressor and Accumulator (Procedure 21)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the refrigeration section jacket (refer to Procedure 11).

4. Remove the evaporator shroud and fan motor assembly (refer to Procedure 12 Steps 3

- 6).

5. Recover refrigerant from sealed refrigeration system.

6. Disconnect the wiring to the compressor and unclip and remove the compressor T sensor from the compressor discharge pipe work.

7. Remove the pipe insulation to expose pipe work at the compressor and accumulator. Un-braze the discharge pipe-work from the compressor and the suction line from the accumulator.

8. Remove the 3 nuts retaining the compressor to the chassis and lift the compressor and accumulator clear.

9. Fit and secure the replacement compressor and accumulator, braze pipe work, reconnect wiring to the compressor and refit the discharge T sensor and retaining clip.

16. Replace the receiver/filter drier (Refer to Procedure 20 – steps 4 to 7).

10. Pressurise system to 3000kPa and conduct a leak test. Refit and secure pipe work insulation.

11. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes.

12. Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3.

13. Refit the evaporator shroud and fan motor assembly and refrigeration section jacket.

14. Refit air inlet louver and jacket top.

15. Restore power. The refrigeration plant should commence operation after a 30 second delay.

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TX Valve Replacement (Procedure 22)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

1. Isolate the power to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Remove the refrigeration section jacket (refer to Procedure 11).

4. Recover refrigerant from sealed refrigeration system.

5. Remove the pipe insulation to expose pipe- work at the TX valve assembly and the TX valve sensor.

6. Separate the TX valve sensor and capillary from the suction line.

7. Un-braze the pipe-work and remove the TX valve.

8. Braze the replacement TX valve into place and attach the sensor to the suction line. Note: Ensure the sensor bulb is in good contact with the suction line.

9. Replace the receiver/filter drier (Refer to Procedure 20 – steps 4 to 7).

10. Pressurise system to 3000kPa and conduct a leak test. Refit and secure the pipe work insulation.

11. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes.

12. Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3.

13. Restore power. The refrigeration plant should commence operation after a 30 second delay.

14. Refit air inlet louver and jacket top.

15. Adjust TX valve if required (Refer to Procedure 23).

TX Valve Adjustment (Procedure 23)

Components within the refrigeration plant section will be “live” during the adjustment process. Wear Personal Protective Equipment to reduce the risk of electric shock.

The TX valve is supplied preset and should be installed with the factory setting (6ºC) unaltered. This setting is calibrated for the lowest superheating and optimum evaporator utilization. However, should it be necessary to adjust the superheat, turn the adjusting spindle as follows: Clockwise = Reduced refrigerant flow, increase of superheat. Anticlockwise = Increased refrigerant flow, decrease in superheat.

1. Remove the air inlet louver (refer to Component Replacement - Procedure 10).

2. Remove the TX valve sealing cap (see diagram opposite).

3. Using a 4mm Allen key back the TX valve adjuster screw anticlockwise all the way out. Note: The adjuster screw is recessed approximately 8mm.

4. Screw the adjuster screw in three full turns to achieve the required superheat setting of +6ºC. Note: 1 full 360º turn of the adjuster screw = 2ºC.

5. Refit and tighten the TX valve cap to a torque of 4Nm.

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Heat Exchanger (Procedure 24)

Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.

strip from becoming water damaged.

1. Isolate the power and water supplies to the water heater.

2. Remove the access cover and confirm with a multi-meter between Active and

Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present.

3. Relieve pressure from the water heater and drain approximately 10 litres of water

from the cylinder through the T & PR valve.

4. Remove the refrigeration section jacket (refer to Procedure 11).

5. Recover refrigerant from sealed refrigeration system.

6. Undo flexible hose unions at heat exchanger. Note: Ensure all escaping water is

caught in a container to prevent the sensor strip from becoming water damaged.

7. Remove insulation from refrigeration pipe work to and from the heat exchanger and remove inlet and outlet water sensors.

8. Cut cable ties and remove heat exchanger styrene insulation.

9. Un-braze refrigeration pipe work from heat exchanger and remove heat exchanger.

10. Un-braze water system inlet and outlet pipe work from old heat exchanger and braze these components on to the new heat exchanger.

11. Braze the replacement heat exchanger (refrigeration pipe work) into place.

12. Refit inlet and outlet water sensors and replace pipe work and heat exchanger insulation.

13. Remake flexible hose connections to heat exchanger.

17. Replace the receiver/filter drier (Refer to Procedure 20 – steps 4 to 7).

14. Pressurise system to 3000kPa and conduct a leak test. Refit and secure the pipe work insulation.

15. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes.

16. Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3.

17. Restore water supply and bleed air from the heat exchanger water outlet union. Note:

Ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged.

18. Restore power. The refrigeration plant should commence operation after a 30 second delay.

19. Adjust TX valve (Refer to Procedure 23).

20. Refit refrigeration jacket (reverse procedure 11).

21. Restore water and power supplies. The refrigeration plant should commence operation after a 30 second delay.

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Exploded View - Refrigeration Plant

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Replacement Parts List – Refrigeration Plant

Item Description Part Number

1 Air Grille 104798 2 Fan Motor Assy 180027 3 Air Shield 108374 4 Fan Shroud 180026 5 Jacket Top 100659 6 Evaporator Coil 180025 7 Condenser 180032 8 Hose – Braided 088086

9 Circulator 051575 10 Capacitor – Fan Motor 890374 11 Relay 052123 12 Controller Assy 051577 13 Control Cover 051659 14 Sensor Clip 890263 15 Sensor 056006 16 Capacitor - Compressor 890373 17 Compressor 180029 18 Chassis Assy 140114 19 Receiver/Filter Drier 180021 20 TX Valve 180024 21 Drip Tray 104797 22 Side Cover 108372 23 Side Cover - Drip tray outlet 108373 24 Label – Air Grille 120513 25 Condenser Insulation 090249 26 Condenser Insulation Cover 090250 27 Pipe – Refrigerant, Low Pressure 181526 28 Pipe – Refrigerant, High Pressure 181527 29 Pipe – Refrigerant, Drier to Heat Exchanger 181528 30 Pipe – Refrigerant, Drier to TX 181529 31 Pipe – Refrigerant, TX to Evaporator 181530 32 Pipe – Condenser, Upper Water with Thermistor Holder Fitting 088096 33 Pipe – Condenser, Lower Water with Thermistor Holder Fitting 088098

NS Heat Pump Module to Water Heater Mounting Screws (pkt of 3) 080156

NS = Not shown

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Exploded View - Water Heater

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Replacement Parts List – Water Heater

Item Description Part Number

1 Jacket Bottom 100633

2 Pipe Seal – Inlet/Outlet (¾” x 38) 221418

3 Inlet Diffuser 220516

4 Name Band 120512

5 Dip Tube (Outlet) 225601

6 Wiring loom assembly N/A

Anode – Black 221904 Anode – Blue 221924

Anode – Green 222024 8 Anode Cover 221720-1 9 Dropper Tube Seal 087027

10 Dropper Tube – Short 220558 11 O-ring – Dropper Tubes 087023 12 Fitting ¾” to ½” Brass 088040 13 Pipe Seal – Dropper Tubes (30 x 16) 221233 14 Dropper Tube – Long 220559 15 Grommet - Sensor Strip 080149 16 Foam Cover 221735 17 Sensor Strip 053053 18 Jacket Top 108375 19 Pipe Seal – T & PR (½” x 38) 221420 20 Element Gasket 050704 21 Thermostat – EWT 1L2-561 051571 22 Thermostat Clamp 102501 23 Access Cover 100703-1 24 Element Bolts 051404

Element 2.4kW 050324

Element 3.6kW 050323

26 Terminal Block 051521 27 T & PR Valve HTE523/507 220641

Page 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”.

Rheem Electric Water Heater Warranty - (Australia Only)

WARRANTY CONDITIONS

1. This warranty is applicable only to water heaters

manufactured from 1

September 2006.

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 installed.

3. Where a failed component or water heater is

replaced under warranty, the balance of the original warranty period will remain effective. The replaced part or water heater does not carry a new warranty.

4. Where the water heater is installed outside the

boundaries of a metropolitan area as defined by Rheem or further than 25 km from a regional Rheem branch office, or an Accredited Service Agent, the cost of transport, insurance and travelling costs between the nearest Rheem

Accredited Service Agent’s premises and the installed site shall be the owner’s responsibility.

5. Where the water heater is installed in a position

that does not allow safe, ready access, the cost of accessing the site safely, including the cost of additional materials handling and / or safety equipment, shall be the owner’s responsibility.

6. The warranty only applies to the water heater and

original or genuine (company) component replacement parts and therefore does not cover any plumbing or electrical parts supplied by the installer and not an integral part of the water heater, e.g. pressure limiting valve; isolation valves; non-return valves; electrical switches; pumps or fuse.

7. The water heater must be sized to supply the hot

water demand in accordance with the guidelines in the Rheem water heater literature.

WARRANTY EXCLUSIONS

REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RHEEM WATER HEATER WARRANTY ABOVE HOWEVER THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO BECOME VOID AND MAY INCUR A SERVICE CHARGE AND / OR COST OF PARTS.

a) Accidental damage to the water heater or any

component, including: Acts of God; failure due to misuse; incorrect installation; attempts to repair the water heater other than by a Rheem Accredited Service Agent or the Rheem Service Department.

b) Where it is found there is nothing wrong with the

water heater; where the complaint is related to excessive discharge from the temperature and / or pressure relief valve due to high water pressure; where there is no flow of hot water due to faulty plumbing; where water leaks are related to plumbing and not the water heater or water heater components; where there is a failure of gas, electricity or water supplies; where the supply of gas, electricity or water does not comply with relevant codes or acts.

c) Where the water heater or water heater

component has failed directly or indirectly as a result of: excessive water pressure; excessive temperature and / or thermal input; blocked overflow / vent drain; corrosive

from the water heater.

d) Where the water heater is located in a position

that does not comply with the Rheem water heater installation instructions or relevant statutory requirements, causing the need for major dismantling or removal of cupboards, doors or walls, or use of special equipment to bring the water heater to floor or ground level or to a serviceable position.

e) Repair and / or replacement of the water heater

due to scale formation in the waterways or the effects of either corrosive water or water with a high chloride or low pH level when the water heater has been connected to a scaling or corrosive water supply or a water supply with a high chloride or low pH level as outlined in the Owner’s Guide and Installation Instructions booklet.

f) Breakage of collector glass for any reason

including hail damage. (We suggest that the collector glass be covered by your home insurance policy).

SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY EXCLUDES ANY AND ALL CLAIMS FOR DAMAGE TO FURNITURE, CARPETS, WALLS, FOUNDATIONS OR ANY OTHER CONSEQUENTIAL LOSS EITHER DIRECTLY OR INDIRECTLY DUE TO LEAKAGE FROM THE WATER HEATER, OR DUE TO LEAKAGE FROM FITTINGS AND / OR PIPE WORK OF METAL, PLASTIC OR OTHER MATERIALS CAUSED BY WATER TEMPERATURE, WORKMANSHIP OR OTHER MODES OF FAILURE.

Rheem Australia Pty Ltd A.B.N 21 098 823 511

FOR SERVICE TELEPHONE

131 031 AUSTRALIA

or refer local Yellow Pages

NOTE: Every care has been taken to ensure accuracy in preparation of this publication. No liability can be accepted for any

consequences, which may arise as a result of its application.

Page 68

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”.

Document Revision History

Title

Service Instructions for Rheem Heat Pump

Document Number

TM025

Revision Details of change D.O.I.

A Service Instructions issued for 310 Series Heat Pump 03/07 B Addition to flow diagram 08/07

Rheem 310 Series, 551310 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual