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”.
2
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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3
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.
TM005 Rheem Solar Hiline Service Instructions REV D
D.O.I 20/02/2009
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4
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
S5
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.
TM005 Rheem Solar Hiline Service Instructions REV D
D.O.I 20/02/2009
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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.
TM005 Rheem Solar Hiline Service Instructions REV D
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6
Specifications
Model
52S160
52S300
Max Water Supply
Pressure kPa
With ECV
680
680
Without ECV
800
800
Maximum Thermostat Setting (ºC)
70
70
ECO Operating Temperature (ºC)
78-88
78-88
Storage Capacity (Litres)
160
300
Booster Capacity (Litres)
80
160
Anodes
Quantity 1 1
Length (mm)
823
1616
Water Connections
Inlet
GB ½/15
GB ½/15
Outlet
RP ¾/20
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
RP ½/15
Rating kPa
1000
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.
TM005 Rheem Solar Hiline Service Instructions REV D
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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.
TM005 Rheem Solar Hiline Service Instructions REV D
D.O.I 20/02/2009
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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.
TM005 Rheem Solar Hiline Service Instructions REV D
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9
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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