Rheem 52S160, 52S300 Service Instructions Manual

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52S160

52S300

SERVICE INSTRUCTIONS

Rheem Solar Hiline

TM005

Revision: D

Published: February 09

TM005 Rheem Solar Hiline Service Instructions REV D D.O.I 20/02/2009

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

Contents

Introduction .......................................................................................................................... 3

Safety Warning .................................................................................................................... 3

Heater Model Identification .................................................................................................. 4

Preventative Maintenance ................................................................................................... 5

Specifications ....................................................................................................................... 6

Solar Hiline Operation .......................................................................................................... 6

Product Changes ................................................................................................................. 7

Components & their Function .............................................................................................. 8

Hot Water Physics Related to Solar Water Heaters ............................................................. 9

Common Faults ................................................................................................................. 10

Wiring Diagram .................................................................................................................. 12

Fault Finding ...................................................................................................................... 12

Fault Finding Charts ....................................................................................................... 12

Fault Diagnosis Sequence ................................................................................................. 13

Fault Finding (Chart 1) ....................................................................................................... 14

Fault Finding (Chart 1.1) .................................................................................................... 15

Fault Finding (Chart 1.2) .................................................................................................... 16

Electrical Insulation Testing ............................................................................................ 16

Fault Finding (Chart 2) ....................................................................................................... 17

Fault Finding (Chart 2.1) .................................................................................................... 18

Component testing ............................................................................................................. 19

Fault Finding (Chart 3 & 3.1) .............................................................................................. 21

Fault Finding (Chart 4) ....................................................................................................... 22

Fault Finding (Chart 5 & 6) ................................................................................................. 23

Fault finding (Chart 7) ........................................................................................................ 24

Fault Finding (Chart 8) ....................................................................................................... 25

Component Replacement .................................................................................................. 26

Replacing CBA/CBT/SCT/SBT Collectors with NPT Collectors ......................................... 30

Exploded View 160 Litre .................................................................................................... 31

Replacement Parts List 160 Litre ................................................................................... 31

Exploded View 300 Litre .................................................................................................... 32

Replacements Parts List 300 Litre ................................................................................. 32

Solar Water Heater Warranty - Australia Only ................................................................... 33

Document Revision History ................................................................................................ 34

TM005 Rheem Solar Hiline Service Instructions REV D D.O.I 20/02/2009

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Introduction

The information provided in these service instructions is based on the Solar Hiline water heater being installed in accordance with AS/NZS 3500:4 and the Installation Instructions provided with each heater.

Should you require further technical advice on a Solar Hiline water heater, contact your nearest Rheem Service Department where genuine replacement parts are also available.

Safety Warning

The purpose of these service instructions 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 Solar Hiline solar water heater in the minimum of time.

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

“Live” testing to be conducted. Personal Protective Clothing (PPE) shall be worn to reduce the risk of electric shock.

Isolate power before conducting the indicated test

Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to reduce the risk of scalding.

General warning symbol. Observe the instructions accompanying the symbol.

Working on roofs should always be considered a hazardous activity; by law you must observe certain minimum safety precautions. These safety

precautions are outlined in the Work Cover Code of practice “Safe work on

roofs” Part 1and 2 and in the Occupation Health and Safety Act 1983.

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Heater Model Identification

The identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 6 digits and 2 letters.

Water Heater Model Number

5 2 S

160

Type

5 - Solar

Orientation

2 - Horizontal

Collector

S – NPT200

Storage Capacity

160 - 160 litres 300 - 300 litres

Element

S5 - 2.4kW S7 - 3.6kW S8 - 4.8kW

Collector Model Number

N P T 200

Type

N - Non Frost

Surface Type

P - Black Paint

Glass

T - Tempered

Collector Area

200 – Nominal Surface area 2m²

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

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

1. Check for discharge from the T&PR valve. Whilst the booster is off, and during periods

of low solar contribution there should be no discharge of water. When the booster is operating or during periods of high solar contribution, 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 the collector connectors, the hot and cold pipe, Sunstat valve and all

tank fittings.

3. Check the condition of the insulation on the hot pipe. Note: In frost prone areas the hot

and cold pipes are insulated.

4. Check the collector glass is not cracked and the absorber plate finish is not

deteriorating.

5. Clean the collector glass. Do not stand on the collectors while cleaning.

6. Check for signs of plant or tree growth that may be shading the collectors. Advise

customer to have pruned if possible.

7. Isolate power to the electric booster and check all electrical connections for signs of

overheating due to poor connection.

8. Conduct an insulation test (Refer to page 16).

9. Check for signs of roof sag or roof damage and advise customer to have rectified.

10. Check for signs of excessive corrosion on the water heater jacket, collector panels and

roof stand if fitted.

11. Confirm all supports and anchors retaining the system to the roof are present, firmly

fixed and in good condition.

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Specifications

Model

52S160

52S300

Max Water Supply Pressure kPa

With ECV

680

Without ECV

800

Maximum Thermostat Setting (ºC)

ECO Operating Temperature (ºC)

78-88

Storage Capacity (Litres)

160

300

Booster Capacity (Litres)

160

Anodes Quantity 1 1

Length (mm)

823

1616

Water Connections

Inlet

GB ½/15

Outlet

RP ¾/20

Tank

Collector

Tank

Collector

Hot pipe

GB ¾/20

M33

GB ¾/20

M33

Cold Pipe

GB ¾/20

M33

GB ¾/20

M33

T&PR Valve Diameter

RP ½/15

Rating kPa

1000

Sunstat Valve Inlet x Cylinder x Cold pipe

GB½/15 x RP1¼/32 x

GB¾/20

GB½/15 x RP1¼/32 x

GB¾/20

Weight (Kg)

Empty

103

161

Full

265

455

Solar Hiline Operation

The Hiline solar system operates on the thermosiphon principle. As water in the collector/s gains heat from solar radiation it rises to the top of the collector/s and then into the tank via the hot pipe. As the heated water from the collector/s flows to the tank, cold water from the bottom of the tank is able to return back into the collector/s, via the Sunstat valve and cold pipe, to be heated. The Sunstat valve is a temperature operated isolating valve designed to stop the flow of water back to the collectors when the water temperature in the tank reaches approximately 75ºC.

An auxiliary electric heating unit and thermostat is incorporated in the design of the storage cylinder to provide back up heating during periods of low solar contribution, cloudy weather or high hot water demand.

The Hiline solar system is not suitable for use in frost prone areas.

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Product Changes Frost Areas

The Hiline fitted with NPT collectors is not suitable for installation in frost areas. A Premier Hiline must be installed if frost is likely to occur.

Operating Thermostat

The Robertshaw EWT1L2-552 thermostat (part number 051333) was replaced by the Robertshaw ST1203133 thermostat (part number 052012) in August 2007.

It should be noted that although the ST series thermostat is a direct replacement for the EWT series thermostat, the terminal connections and wiring arrangement is different. Therefore;

Whenever an EWT series thermostat is replaced with a ST series thermostat, rewiring at the thermostat will be required. Refer to wiring diagrams in technical bulletin TB07 016 for wiring arrangements utilising the new ST series thermostat.

PPS Connectors

Failed PPS connectors used to couple SCT/SBT collector arrays can be replaced with a brass connector variant. The brass connectors are supplied in supplied in kit form with all the necessary components required to replace the corresponding PPS connector (see table below)

Connector

PPS Part Number

Brass Part Number

Collector inter-connector

195701

195701B

Hot connector

195702

195702B

End cap

195703

195703B

Cold connector

195704B

Refer to TB07 017 for further information regarding PPS connector replacement.

SCT/SBT Collector

The SCT and SBT collectors have been removed from sale. The NPT collector can be used to replace the SCT and SBT collectors in non frost areas. Contact your nearest Rheem Service Department if a SCT/SBT collector replacement is required in a frost prone area. Refer to page 30 for further information regarding superseded collector models.

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Components & their Function Temperature and Pressure Relief Valve (T&PR) - A valve designed to provide automatic

relief by discharging water in case of excessive temperature, pressure or both.

Never fit a T&PR Valve with a pressure rating greater than that indicated on the product-rating label.

Outlet Delivery Tube (Dip Tube) - A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water from the highest point to the outlet connection. It also acts as a fitting liner.

Inlet Delivery Tube (Dip Tube) - A plastic tube installed in the cold water inlet of the water heater to ensure incoming cold water is delivered to the lowest part of the cylinder and that water from the lowest point of the cylinder is returned to the collectors.

Diffuser - A plastic tube inserted in the solar flow connection of the cylinder to distribute the solar heated water evenly into the tank. The diffuser also acts as a fitting liner to prevent corrosion of the cylinder.

Cold Pipe (Solar Return) - The long pipe connecting the solar collectors to the storage water heater through which, the cooler water returns from the storage tank to the collectors.

Hot Pipe (Solar Flow) - The short pipe connecting the solar collectors to the storage tank through which, the solar heated water flows back to the storage tank from the collectors.

Sunstat Valve - A temperature limiting device fitted between the cold pipe and the storage cylinder to stop the flow of water from the collectors to the storage tank when the water temperature reaches approximately 75ºC. This device prevents the likelihood of extremely hot water being delivered at hot taps and other outlets at uncontrolled water temperatures near boiling point. It also prevents premature operation of the T&PR valve and the electrical energy cut out (ECO) and aids in extending the life of the system.

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

Thermostat (Electric) - A device, sensitive to temperature, which controls the supply of electrical energy to the heating unit to maintain the heated water at the required temperature.

Over-temperature Cut Out (ECO) - A temperature-sensing device in combination with the thermostat that automatically cuts off the energy supply to prevent excessive water temperature occurring. This device will not reset automatically, however it can be manually reset after temperatures have fallen to a safe level. CHECK CAUSE OF OPERATION.

Heating Unit (Element) - A tubular device containing an electric resistance element that converts electrical energy to heat. Standard ratings are 2.4, 3.6 and 4.8kW.

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Hot Water Physics Related to Solar Water Heaters

There are physical properties of hot water that are common to all types of heating mediums. However, with solar heating an understanding of these properties will be of assistance to servicing a solar water heater.

Stratification - The term used to describe thermal stratification within a water heater where hot water will lie above cooler water without mixing. Stratification allows the storage water heater to deliver hot water from the outlet, while refilling with cold water at the inlet.

Stagnation temperature - This is the temperature at which HEAT LOSS is equal to HEAT INPUT. In this case when water stops circulating through the solar collector the temperature will rise to the STAGNATION TEMPERATURE.

Density of water - Water is at its maximum density at 4ºC. When heated above that point up to 100ºC it expands, unequally, an average of 1/23 of its volume. However between 10ºC and 65ºC the expansion is approximately 1/50 of its volume. This is known as THERMAL EXPANSION, or expansion, and is relieved through the temperature and pressure relief valve (T&PR valve).

Note: Water will expand relative to its rise in temperature. The discharge from the T&PR valve is usually the result of thermal expansion due to heating, the quantity of the discharge will be affected by:

The amount of water being heated. The temperature rise from cold to hot. The pressure rating of the T&PR valve. The number of times a hot tap is opened during a heating cycle. The amount of water lost through dripping taps. Faulty Non-return valve fitted to cold water inlet.

It should be noted that a T&PR valve would not discharge water due to thermal expansion when the heating cycle is not on.

Boiling point of water - The temperature at which water boils is directly related to the pressure to which the water is subject to.

Water will boil at below 100ºC if the pressure is below 101kPa (atmospheric pressure at

sea level). At sea level the boiling point of water is 100ºC. Water will boil at above 100ºC if the pressure is above 101kPa (water at 1000kPa will

boil at approximately 183ºC).

Specific heat - The amount of energy required to raise 1kg of a substance by 1ºC. Measured in units of kilo-joules (kJ). i.e. 4.2kJ will raise 1 litre of water 1ºC.

Latent heat (Hidden or invisible heat) - The energy required to change the state of a substance (water) into another state without a change in temperature. i.e. Water to steam and steam to water. Water to ice and ice to water. The latent heat of steam is approximately 6 times the specific heat of water, i.e. to convert water at 100ºC to steam at 100ºC will require approximately 252 kJ/kg.

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Flash Steam - This is when water under pressure is heated to temperatures above 100ºC, and then the pressure is suddenly reduced (by opening a hot tap) allowing the excess heat to be converted to steam. This steam requires 1689 times more space than water and fights inside the system to get out, resulting in a rumbling noise commonly referred to as “elephants on the roof” by customers. The steam is dissipated when it reaches the large volume of water in the storage tank and condenses.

Freezing of water - Water cooled below 4ºC expands insignificantly until it reaches the point of its changing state into ice, at which time it expands by 1/11th of its volume. Ice contracts on further cooling. Damage to solar collectors occurs when:

1. Water trapped between two plugs of ice is compressed by the ice expansion to a point where the pressure results in a failure of the copper tube.

2. An ice plug forms in a tee or elbow and the expansion cannot be relieved resulting in a split fitting.

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.

Insufficient Hot Water - 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.

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 11 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 T&PR discharge)

6. Plumbing leaks.

Discoloured water

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

2. Brown coloured water will generally indicate that the anode has been depleted or the water heater is near the end of its useful life.

3. Milky coloured water is generally air in suspension and will disperse of its own accord. In very hard water areas where anode gassing occurs, milky water may be evident. The use of a blue anode should overcome this problem.

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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, T&PR 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 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.

Roof leaking - This complaint is usually made during or after wet weather and normally soon after commissioning a new water heater. The mass of the water heater full of water can crack roofing material if the load is borne on specific points or the roof material is brittle. Replacement and levelling of roof materials is essential. Use of a woven plastic roof sheet below the water heater will make water penetration more difficult in the future. It should also be established if water is penetrating around the pipe or conduit joints through the roof.

Moisture under the collector glass - Small amounts of condensate on the underside of the collector glass are not a sign of collector failure. The condensation is formed from humid air condensing when the collector cools down. Because of high temperatures within the collector, ambient air is transferred in and out of the collector through drain holes. Note: The collector is not hermetically sealed.

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 T&PR 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 then a cross connection exists.

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Wiring Diagram

Fault Finding

Before Servicing a Solar water heater

Working on roofs should always be considered a hazardous activity, particularly early in the morning, late in the evening or after periods of rain.

Safety precautions pertaining to working on roofs are outlined in the Work

Cover Code of Practice “Safe work on roofs” Part 1 and 2 and in the

Occupational Health and Safety Act 1983.

Water under pressure and at temperatures up to 150ºC may be present in the collector/s. Isolate water supply and relieve pressure through a hot tap or the temperature and pressure relief valve prior to opening the collector pipe work. Wear protective clothing to prevent scalding or burns.

Certain diagnostic procedures outlined in these service instructions

require “live” testing to be conducted. Caution should always be exercised

when conducting these tests to prevent the risk of electric shock.

Fault Finding Charts

Fault

Chart number

Page

No hot water

Electric booster circuit

1, 1.1, 1.2

14,15,16

Collector circuit

2, 2.1

17,18

Insufficient hot water

Excessive discharge from T&PR valve

3.1

Water too hot

Electric booster circuit

Collector circuit

High energy bills

Leaking water heater

Noisy water heater

ST Thermostat – Post 08/07

EWT Thermostat – Pre 08/07

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Fault Diagnosis Sequence

Is the complaint for no

hot water?

Have there been

periods of high solar

gain?

YES NO

Is complaint for

insufficient hot water?

No hot water-

electric booster circuit

No hot water-

Collector circuit

YES

Is complaint for water

too hot?

Does the problem only

occur during periods

of high solar gain?

YES NO

YES

Is the complaint for

high energy bills?

YES

Is the complaint

for leaking?

YES

Is the complaint

for noise?

YES

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Fault Finding (Chart 1)

Is the electric booster

connected to an off

peak tariff?

Is 240V present at

terminal block?

TEST 1

Is a switch to control

the booster installed in

the house?

Possible failure of the

off peak relay or missed

signal from energy

supplier. Continue with

diagnosis to confirm

booster circuit is

operational.

Is the booster switch

turned on?

Turn booster on.

YES

NO NO

YES

Is the fuse blown at

the switchboard?

Isolate power and continue

with diagnosis procedure.

YES

Booster switch or wiring

from switchboard to

terminal block open circuit.

Repair wiring or replace

switch.

Is 240V present at

terminal block?

TEST 1

Conduct an electrical insulation test as per

procedure on page 16.

YES

Has the weather been

conducive for good

solar gain?

2YES

YES

1.2

Reading below

1 mega-ohm

1.1

Reading above

1 mega-ohm

Advise customer that

boosting will be required

during periods of low solar

contribution.

YES

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Fault Finding (Chart 1.1)

Are the thermostat ECO

contacts closed?

TEST 5

Are the thermostat

contacts closed?

TEST 6

YES

Is the water in the tank at

least 6ºC lower than the

thermostat setting?

Slide the thermostat out from

under the retaining clamp and

allow the base of the

thermostat to cool.

Does the element have

the correct resistance?

TEST 7

Did the thermostat

contacts close?

TEST 6

YES

NO YES

NOYES

Has the weather been

conducive for good

solar gain?

YES

Water heater electrically OK.

Continue with diagnosis.

Reset the ECO or replace

thermostat.

Replace thermostat.

Replace the element.

1.1

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Fault Finding (Chart 1.2)

Electrical Insulation Testing

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

Test No.2 - Check insulation resistance of Neutral Circuit in water heater. (Reading not to be below 1 mega-ohm).

1. Isolate power to the water heater by removing fuse. Confirm with multi-meter across Active and Neutral at the terminal block that voltage is not present.

2. Once satisfied, disconnect the active and neutral wires from the water heater terminal block.

3. Connect megger leads to the neutral side of the terminal block and earth.

4. Operate megger. A reading above 1 mega-ohm should be obtained.

5. If a reading below 1 mega-ohm is indicated, all component parts will need to be individually tested to locate the fault.

Test No. 3 - Check Insulation Resistance of Active Circuit in Heater. (Reading not to be below 1 mega-ohm).

1. Connect megger leads to the active side of the terminal block and earth.

2. Operate megger. A reading above 1 mega-ohm should be obtained.

3. If a reading below 1 mega-ohm is indicated, all component parts will need to be individually tested to locate the fault.

Test No. 4 - Check “Continuity” of water heater electrical circuit.

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

2. If a reading greater than 50 ohms is indicated, all electrical component parts will need to be individually tested to locate the fault.

3. Reconnect active cable to “A” terminal and neutral cable to “N” terminal at heater terminal block.

4. Replace fuse. Note: If continuing with flow chart 2 of diagnostic procedure do not

replace fuse.

Rewire fuse if necessary

Disconnect the leads to the

heating unit from the thermostat

and megger between each

heating element wire and earth.

Reading below 1 mega-ohm

Reading above

1 mega-ohm

Disconnect remaining leads from

the thermostat and megger

between each terminal on the

thermostat and earth.

Reading below 1 mega-ohm

Reading above 1 mega-ohm

Replace heating unit

Replace thermostat

Check for pinched or

damaged wiring touching the

water heater chassis.

1.2

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Fault Finding (Chart 2)

- Reinstall on a side pitch roof stand

- Relocate to a northerly aspect.

- Add an extra collector

- Accept reduced solar gain.

YES

Are there trees or

buildings shading the

collectors at any time of the day?

Are the collectors facing

within 45º of north?

YES

Are the collectors dipping

in the centre?

Dipping of the collectors can

create an air lock or heat trap

preventing thermosiphoning.

This may be due to

insufficient roof strength

YES

The ideal collector inclination

is equal to the local latitude.

The minimum collector

inclination for the system to

operate is 10º.

Are the collectors lying

too flat?

YES

Is collector glass

broken or dirty?

YES

Is the surface coating on

the collector absorber

plate deteriorating?

Does the hot pipe have a

continuous rise to the

tank?

YES

Collectors not in optimum position.

Discuss options with client:

Advise customer to prune trees if possible or reposition heater and

collectors to shade free location.

Advise customer to have roof

strengthened or pack up the collectors

to eliminate air lock or heat trap.

Reposition heater and collectors

onto a flat roof stand.

Clean glass or replace collector.

Replace collector.

Refit the hot pipe with a continuous

rise to the tank.

2.1

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Fault Finding (Chart 2.1)

2.1

Is the hot pipe

insulation missing or

in poor condition?

Replace insulation.YES

Is the leak, discharge

from the T&PR valve?

Are there any water

leaks around the

collectors or cylinder?

Rectify leaks at connectors or

fittings. Replace collector or

tank if leaking.

YES NO

3.1YES

Are the dip tubes and

diffusers fitted and in

the correct positions?

Replace or reposition dip

tube/s or diffuser correctly.

Isolate water supply and

disconnect the cold pipe from the

collector, restore water supply.

Warning:

Water under pressure and at temperatures up to 150oC may be present in the system. Isolate water supply and relieve pressure through a hot tap prior to removing any pipe work.

YES

The tank temperature will need to be below 55oC for this test.

Does water flow freely

from the pipe?

Replace the sunstat valve.NO

Isolate water supply, reconnect cold

pipe, disconnect hot pipe from the tank

restore water supply.

Does water flow freely

from the pipe?

Blockage in collectors or hot

pipe. Replace collector or clear blockage from pipe.

YES

Is the daily water

usage exceeding the

solar heating capacity?

Is usage time not suitable to hours when solar gain is the greatest? ie. Morning usage

with west facing collectors.

Reposition heater and collectors

to northerly aspect or advice

customer that boosting will be

required more often.

NO YES

YES

Advise customer that boosting

will be required more often

during winter months.

Is the problem only

evident during winter?

YES

Advise customer on usage

pattern that will suit.

YES

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Component testing

TEST 1a – EWT Type Thermostat

TEST 1b – ST Type Thermostat

Using a multimeter on the AC voltage scale, measure between active and neutral on the terminal block.

The voltage should be approximately 240 volts.

TEST 5a – EWT Type Thermostat

TEST 5b – ST Type Thermostat

Using a multimeter on the x1 resistance scale, measure between terminals 3L and 4L on the thermostat.

The reading should be 0 ohms.

Using a multimeter on the x1 resistance scale, measure between terminals 3 and 4 on the thermostat.

The reading should be 0 ohms.

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TEST 6a & 8a – EWT Type Thermostat

TEST 6b & 8b – ST Type Thermostat

Test 6: Using a multimeter on the x1 resistance scale, measure between terminals 1L and 2T on the thermostat.

The reading should be 0 ohms. Test 8: Same test points as test 6a however the

reading should be infinity (open circuit).

Test 6: Using a multimeter on the x1 resistance scale, measure between terminals 1 and 2 on the thermostat.

The reading should be 0 ohms. Test 8: Same test points as test 6b however the

reading should be infinity (open circuit).

TEST 7a – EWT Type Thermostat

TEST 7b – ST Type Thermostat

Remove element wires from terminals 2T & 4L of the thermostat. Using a multimeter on the x1 resistance scale, measure between the element terminals.

Normal resistance for the heating unit is:

2.4kW: 22 ohms – 24 ohms +/- 10%

3.6kW: 15 ohms – 16 ohms +/- 10%

4.8kW: 11 ohms – 12 ohms +/- 10%.

Remove element wires from terminals 2 & 4 of the thermostat. Using a multimeter on the x1 resistance scale, measure between the element terminals.

Normal resistance for the heating unit is:

2.4kW: 22 ohms – 24 ohms +/- 10%

3.6kW: 15 ohms – 16 ohms +/- 10%

4.8kW: 11 ohms – 12 ohms +/- 10%

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Fault Finding (Chart 3 & 3.1)

Is the water heater of

sufficient size for the

customers needs?

Has the usage pattern

changed recently? i.e

Additional appliances or

people using hot water.

Advise customer on usage

pattern to suit solar water

heater.

Is the water heater sized

as recommended in the

Rheem sizing guide?

Is the T&PR valve

continuously discharging

water?

Are there any plumbing

leaks, crossed

connections or dripping

taps?

Does the water

temperature correspond

with the thermostat

setting?

YES

Electric Booster circuit

Collector circuit

Repair any leaks.

Isolate cross connections.

Recommend a water heater

of sufficient capacity to meet

customers needs.

Recommend a hot water

usage pattern that will suit the

water heaters capacity and

the customers needs.

YES

Is the water supply

pressure above 800kPa?

YES

Fit pressure limiting valve if

not already fitted. Existing

pressure limiting valve faulty.

YES

Is the correct T&PR

valve fitted?

Replace the T&PR valve with

one of the correct pressure

rating. Do not use

reconditioned valves.

Is the water temperature

above 75ºC

Check for crossed water

connection.

Replace the T&PR valve.

YES

3.1

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Fault Finding (Chart 4)

Does water temperature

at hot tap correspond with

or near thermostat

setting?

YES

Advise customer on operation of

solar system and benefits of

storing water at 70ºC.

Tempering valves should be considered

for ablution areas if concerns surround

small children or elderly occupants.

Has the ECO tripped?

Isolate power before continuing diagnosis

Is the water temperature

above 80ºC?

Draw water until the water

temperature drops below 60ºC.

Reset the ECO and continue

with diagnosis.

YES YES

Are thermostat contacts

open?

TEST 8

Is the thermostat in good

contact with cylinder

wall?

Remove thermostat.

Re-tension holding bracket

and refit thermostat.

Did the thermostat

contacts open?

YES

Is the heating unit

installed in the correct

orientation?

Draw water off to cool cylinder to

60ºC.

Replace the thermostat.

Refit heating unit in the correct

orientation.

YES

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Fault Finding (Chart 5 & 6)

Is the water temperature

at the hot tap above

75ºC?

Advise customer on operation of

solar system and benefits of

storing water at 70ºC.

YES

Does the customer boost

only when required?

Advise customer to operate

booster only when required or

switch to an off peak tariff.

Tempering valves should be considered

for ablution areas if concerns surround

small children or elderly occupants.

Repair plumbing leaks or dripping

taps and check ECO on

thermostat is not tripped.

Is boosting required during periods of high solar gain to meet hot

water demands?

Are there any water leaks

around the collectors or

heater?

Is the leak, discharge

from the T&PR valve?

Rectify leaks at connectors or

fittings. Replace collector or tank

if leaking.

Is the booster circuit

connected to an off peak

tariff?

Suggest a usage pattern that will

minimise depletion of hot water

supply at night.

YES NO

YES

Is there a plumbing leak

or dripping hot tap

causing inlet cold water to

open Sunstat valve?

YES

Replace Sunstat valve and check ECO on thermostat is not tripped.

Warning: Water under pressure and at temperatures up to 150ºC may be present in the collector. Isolate water supply and relieve pressure through a hot tap prior to opening the collector pipe work.

High energy bills

Water too hot - Collector Circuit

3.1

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Fault finding (Chart 7)

Is the leak from

the tank?

Replace o-rings and

connectors if damaged

or cracked.

Is the leak from the

T&PR valve?

Is the leak from a

collector connection?

YES YES

YES

Is the leak from the

anode thread?

Reseal the anode.

Is the leak from the

collector?

Is water running from

the bottom of the

collector?

Is the system in an

area that is prone to

frost?

Replace the collector.

No warranty applies if leak

is due to frost.

Is the leak from the

heating unit gasket?

Replace the heating unit

gasket.

Is the leak from a

plumbing fitting?

Reseal the plumbing

fittings.

Tank may be leaking, feel for hot spots on the jacket.

Replace tank.

YES

Condensate may be

forming in the collector.

This is a normal condition.

Leaking water

3.1

Is the leak from the

Sunstat valve?

Replace the Sunstat

valve.

YES

NOTE: All installations above 600 metres are not

covered by warranty for frost damage to the collectors

Is the cold pipe a 1"

insulated pipe?

YES

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Fault Finding (Chart 8)

Is the noise only evident

when hot water is being

drawn off during periods of

high solar gain?

Check for: Mineral build up on the heating unit loop - replace heating unit. Poor quality water supply i.e. dam water sludge - flush tank.

Is the noise only evident

when electric heating cycle

is on?

YES

Noise is caused by FLASH STEAM.

Refer to explanation in Hot Water

Physics section.

Is the noise water hammer?

Refer to water hammer explanation in

common complaints section.

YES

Is the noise only evident

when water is flowing

through the water heater?

Check all other appliances that can

generate noise i.e. washing machine,

dishwasher, ball cocks etc.

Is the water pressure above

700kPa?

Check for a faulty stop cock, nonreturn valve, ECV or T&PR valve.

Check for restrictions in pipe work, faulty valves, loose plumbing, other appliances i.e. washing machine or

dishwasher. Fit PLV if required.

YES

Noisy water heater

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Component Replacement Draining the Water Heater (Procedure 1)

1. Isolate the power supply to the electric booster circuit.

2. Isolate the water supply to the water heater.

3. Relieve pressure from the water heater through the temperature and pressure

relief valve.

4. Disconnect collector cold pipe from the collector. To prevent flooding under roof tiles drain water onto a deflection sheet of plastic or sheet metal.

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

Removing or Replacing Solar Storage Tank (Procedure 2)

Should it be necessary to remove a solar water heater from the roof, it is advisable to use a crane. This equipment will result in the least amount of damage to the roofing material and reduce the possibility of personal injury.

When the roofing material is of terracotta or cement tiles, particular care should be taken to ensure that tiles are not broken. If damage does occur, immediate repairs are

essential to prevent further water damage during periods of rain.

1. Isolate the power supply to the electric booster circuit.

2. Isolate the water supply to the water heater.

3. Relieve pressure from the water heater through the temperature and pressure relief valve.

4. Remove the access cover and disconnect the wiring from the terminal block, undo the conduit terminator lock nut and disconnect the conduit from the water heater.

5. Disconnect the water supply pipe from the Sunstat valve.

6. Disconnect the hot water outlet pipe from the water heater.

7. Disconnect the drain line and pull cord from the T&PR valve.

8. Disconnect the cold pipe from the Sunstat valve and the hot pipe from the tank.

9. Remove the Sunstat valve and the brass adapter from the hot pipe end of the tank and retain for fitting to the replacement tank.

10. Disconnect the hot and cold pipes from the collectors and relocate pipes to a safe location.

NOTE: It is strongly recommended that the hot and cold pipes be removed from the collectors. This will prevent damage to the connectors in the event the pipes are knocked, and remove the risk of tripping over the pipes during tank removal and replacement.

11. Disconnect the straps or brackets holding the tank in place and remove the tank to ground level. Ensure the tank is restrained while the straps or brackets are disconnected to prevent the tank from rolling off the roof.

12. Reassemble in the reverse order of above.

13. Once reassembly is complete, restore the water supply and open all the hot taps in the premises to allow air to be expelled from the pipe work. As the water runs freely from each tap, close it.

14. Restore the power supply to the electric booster circuit.

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Removing or Replacing a Solar Collector (Procedure 3)

NOTE: if replacing CBA/CBT/SCT/SBT collectors, go to page 30.

1. Drain the water heater. Refer to procedure 1, page 26.

2. Disconnect the hot or cold pipe at the collector and disconnect from the Sunstat valve or water heater depending on which collector requires replacement. (Note: on a single collector array it will be necessary to remove both pipes.) Remove the hot or cold pipe or both to a safe location.

NOTE: It is strongly recommended that the hot or cold pipe or both be removed from the collector. This will prevent damage to the tank in the event the pipes are knocked, and remove the risk of tripping over the pipes during collector removal and replacement.

3. Remove the inter-connectors at the top and bottom of the collector (if fitted).

4. Remove the screws retaining the collector to the angle bracket, disconnect the retaining strap at the top of the collector, slide the collector out and remove to ground level.

5. Reassemble in reverse order of above.

6. Once reassembly is complete, close the T&PR valve and restore the water supply and open all the hot taps in the premises to allow air to be expelled from the pipe work. As the water runs freely from each tap, close it.

7. Restore the power supply to the electric booster circuit.

Heating Unit (Procedure 4)

1. Drain the water heater. Refer to procedure 1, page 26.

2. Remove the access cover and disconnect the wiring between the terminal block, thermostat and heating unit and unclip the thermostat.

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 pipe to the collector and fit the spring clip into place.

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: Curve of heating unit to be horizontal.

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

8. Close T&PR valve, restore the cold water supply and purge air through hot taps.

9. Check heating unit for leaks.

10. Refit thermostat and reconnect the wiring as per the circuit diagram.

11. Refit the access cover.

12. Restore power supply to electric booster circuit.

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Thermostat (Procedure 5)

1. Isolate the power to the electric booster circuit.

2. Remove access cover and disconnect the wiring to the thermostat.

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

4. Remove any scale from the cylinder surface.

5. Fit the replacement thermostat under the clamp and set temperature at 70ºC.

6. Reconnect the wiring as per the circuit diagram.

7. Refit the access cover.

8. Restore the power supply.

Anode (Procedure 6)

Under normal conditions the anode need not be replaced. To inspect the anode or change the anode to match the water quality in the area:

1. Drain the water heater. Refer to procedure 1, page 26.

2. Unscrew the anode with a socket or tube spanner until almost out. When the water level falls below the anode level, refit the cold pipe to the collector and fit the spring clip into place.

3. Fit anode bar* to anode, completely unscrew and withdraw the anode carefully, using the bar to counter balance the anode weight.

4. Apply Teflon tape to the replacement anode, fit anode bar and insert anode carefully into the water heater using the bar to maintain a horizontal position. Ensure the tip of the anode locates in the solar flow connection and tighten.

5. Remove anode bar, close the T&PR valve, restore the cold water supply and purge air through the hot taps.

6. Check anode thread for leaks.

7. Refit access cover.

8. Restore the power supply.

*Anode bar is a 600mm piece of 15mm NB galvanised steel pipe with a socket attached.

Sunstat Valve (Procedure 7)

1. Drain the water heater. Refer to procedure 1, page 26.

2. Disconnect the cold water supply pipe.

3. Disconnect the cold pipe.

4. Unscrew the Sunstat valve from the tank.

5. Reassemble in reverse order of above using Teflon tape to seal the Sunstat valve.

6. Close the T&PR valve, restore the water supply and purge air from the system through the hot taps.

7. Check Sunstat valve connections for leaks.

8. Restore the power supply.

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Temperature and Pressure Relief Valve (Procedure 8)

This valve cannot be repaired in the field and must be replaced if it is passing excessive amounts of water.

Normally a small quantity of water will be discharged during the heating cycle. The discharge should cease shortly after heating stops.

If the mains pressure in the area is high i.e. over 1000kPa then the T&PR valve will discharge excessively. High water pressure may only occur at night.

If the water pressure is high then an 800kPa pressure-limiting valve (PLV) must be installed on the inlet supply. If the T&PR valve requires replacement ensure the new valve is of the correct pressure rating. If the discharge temperature is above 90ºC the cause must be identified.

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 supply to the electric booster circuit.

2. Isolate the water supply to the water heater.

3. Remove the pull cord and relieve pressure from the water heater through the T&PR valve.

4. Drain water from the water heater through a hot tap.

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

6. Unscrew the T&PR valve and remove.

7. Refit the replacement T&PR valve using Teflon tape. Note warnings above.

8. Refit the drain line.

9. Close the hot tap and restore water supply.

10. Check T&PR valve thread for leaks.

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

12. Reconnect the pull cord.

13. Purge air from the system through hot taps.

14. Restore the power supply.

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Replacing CBA/CBT/SCT/SBT Collectors with NPT Collectors

Under certain circumstances it may be necessary to replace CBA/CBT/SCT/SBT series collectors with NPT collectors. It is not possible to connect a C or S series collector to a NPT series collector. In this situation all collectors will require replacement.

In addition to replacing the collectors it will be also necessary to replace the pipe work from the collectors to the storage tank. For the 160 litre models the pipe kit part number is 299219, for 300 litre models the pipe kit part number is 299209.

The C series collectors are shorter and wider than the NPT collectors; this will require the collectors to be repositioned during the installation process. Full installation instructions including dimensions are provided in the pipe kit.

NPT collectors are not suitable for use in frost prone areas. When replacing collectors in a frost prone area it will be necessary to contact the nearest Rheem Service Department to determine optimal replacement product.

Collector Connectors

The NPT series collectors utilize the traditional method for connecting the collectors together and for coupling the hot and cold pipes to the collector.

An o-ring is inserted into the collector header pipe and is retained either by a blanking disc and nut, an inter-connector and nut or a hot/cold pipe which is screwed into place sealing against the o-ring.

End cap

Inter-connector

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Exploded View 160 Litre

Replacement Parts List 160 Litre

Item

Component

Part No

Item

Component

Part No

Dip Tube Hot Water Outlet

220403

Cold Pipe ¾”

193356

T&PR Valve

220614

O‟ring – 25mm

087023

Access Cover

109802

Blanking Disc

330606

Thermostat

052012

M33 Male Brass Nut

063602

Thermostat Holding Clamp

102501

Single Collector Support Angle

191614

Element – 2.4kW

050316

Collector Strap

191801

Element – 3.6kW

050317

Collector

NPT200

Element – 4.8kW

050318

Hot Pipe ¾”

193353

Element Gasket

050704

Pipe Seal ¾‟ x 30

221307

Dip Tube Cold Water Inlet

229301

¾” – M20 Adapter

063801

Sunstat Valve ¾”

223903

Diffuser – Solar flow

225701

Anode – Black

229008

Tank Strap

191701

Anode – Blue

229010

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Exploded View 300 Litre

Replacements Parts List 300 Litre

Item

Component

Part No

Item

Component

Part No

Dip Tube Hot Water Outlet

220403

Cold Pipe ¾”

193363

T & PR Valve

220614

O‟ring 25mm

330171

Access Cover

109802

Blanking Disc

330606

Thermostat

051350

M33 Brass Male Nut

063602

Thermostat Holding Clamp

102503

2 Collector support angle

191613

Element – 2.4kW

050316

Collector connector

330695

Element – 3.6kW

050317

Collector

NPT200

Element – 4.8kW

050318

Collector Strap

191801

Element Gasket

050704

Hot Pipe ¾”

193362

Dip Tube Cold Water Inlet

229301

Pipe Seal ¾” x 30

221307

Sunstat Valve ¾”

223904

¾” – M20 Adapter

063801

Anode – Black

229007

Diffuser – Solar flow

225701

Anode – Blue

229010

Tank Strap

191701

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Solar Water Heater Warranty - Australia Only

Notes: * Refer to item 4 of warranty conditions. Rheem Australia reserves the right to transfer fully functional components from the defective water heater to the

replacement water heater if required. The term “water heater” used in the Warranty Conditions and Exclusions means

both the storage tank(s), collector(s) and kit(s).

WARRANTY CONDITIONS

1. This warranty is applicable only to water heaters

manufactured from 1st July 2001.

2. The water heater must be installed in accordance with

the Rheem solar water heater installation instructions, supplied with the water heater, and in accordance with all relevant statutory and local requirements of the State in which the water heater is to be installed.

3. 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 Australia or further than 25 km from a regional Rheem Australia branch office

, or an accredited Service Agent, the cost of transport, insurance and travelling costs between the nearest Rheem Australia Accredited

Service Agent‟s premises and the installed site shall be

the owner‟s responsibility.

5. 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.

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

water demand in accordance with the guidelines in Rheem„s solar water heater literature.

WARRANTY EXCLUSIONS

1. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RHEEM SOLAR

WATER HEATER WARRANTY ABOVE, BUT THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO BECOME VOID, AND MAY INCUR A SERVICE CHARGE AND 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 Australia Accredited Service Agent or the Rheem Australia Water Heaters 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 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, temperature and/or thermal input or corrosive atmosphere; ice formation where the system is

installed at an altitude more than 600 metres above sea level; ice formation in the pipe work to and from the storage tank and solar collectors and the system has not been installed in accordance with the Rheem Australia water heater installation instructions.

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 level or to a serviceable position.

e) Repairs to the water heater due to scale formation in

the waterways when the water heater has been connected to a harmful water supply 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).

2. SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY EXCLUDES ANY AND ALL CLAIMS FOR DAMAGE TO FURNITURE, WALLS, FOUNDATIONS OR ANY OTHER CONSEQUENTIAL LOSS EITHER DIRECTLY OR INDIRECTLY DUE TO LEAKAGE FROM THE WATER HEATER

In addition to this warranty, the Trade Practices Act 1974 and similar laws in each state and territory provide the owner under certain circumstances with certain minimum statutory rights in relation to your Rheem Australia solar water heater. This warranty must be read subject to that legislation and nothing in this warranty has the effect of excluding or restricting those rights.

RHEEM AUSTRALIA

RHEEM AUSTRALIA PTY. LTD. A.B.N 21098823511

FOR SERVICE TELEPHONE

131 031 AUSTRALIA

0800 657 335 NEW ZEALAND

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.

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Document Revision History

Title:

Rheem Solar Hiline Service Instructions

Document

Number:

TM005

Revision

Details of change

D.O.I.

Service Instructions issued for 52S series Hiline

26/07/01

References to Personal Protective Equipment added

21/09/01

Format update & conversion from Southcorp to Rheem

16/02/05

Updated to reflect current product

20/02/09

Rheem 52S160, 52S300 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual