Rheem 70103, 70210, 70303, 70105, 70207 Service Instructions Manual

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TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions 1

Revision D: Feb 2017

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

70103

70303

70207

70105

70305

70210

70307

70215

70225

70240

SERVICE INSTRUCTIONS

701, 702 & 703 Series

Boiling Water Units

TM063

Revision D

Published: 02/2017

701

702

703

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions 2

Revision D: Feb 2017

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

BWU Model Identification ........................................................................................................................... 4

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

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

Wiring Diagrams ......................................................................................................................................... 7

Wiring Diagram 3 – 15L Models ................................................................................................................. 7

Wiring Diagram 25 & 40L Models .............................................................................................................. 7

Plumbing Diagram ...................................................................................................................................... 8

Operation .................................................................................................................................................... 8

Operational Flow Chart – 701 & 702 Series ............................................................................................ 11

Operational Flow Chart – 703 Series ....................................................................................................... 12

Electronic Controller ................................................................................................................................. 13

Timer – 701 & 702 Series......................................................................................................................... 13

Timer Functions ........................................................................................................................................ 14

Setting the Clock ...................................................................................................................................... 15

Accessing Service Menu .......................................................................................................................... 17

Eco Timer 703 Series ............................................................................................................................... 20

Eco timer LED Indication (NZ Pre-2014 Models) ..................................................................................... 21

Activate calibration reset mode (NZ Pre-2014 Models) ........................................................................... 21

Eco timer LED Indication (Standard)........................................................................................................ 22

Activate calibration reset mode (Standard) .............................................................................................. 22

Components and their Function ............................................................................................................... 23

Common Complaints ................................................................................................................................ 24

Fault Finding ............................................................................................................................................. 24

Error Codes (701 & 702 Series Only) ...................................................................................................... 25

Error Codes (703 Series only) .................................................................................................................. 25

Testing the Boiling Water Thermistor ....................................................................................................... 26

Error Codes A, B, C, D ............................................................................................................................. 28

Error Codes E, G ...................................................................................................................................... 29

Error Codes H, J ....................................................................................................................................... 30

Error Codes K, L N ................................................................................................................................... 31

Fault Finding Chart 1 ................................................................................................................................ 32

Fault Finding Chart 1.1, 1.1a .................................................................................................................... 33

Fault Finding Chart 2, 3 ............................................................................................................................ 34

Fault Finding Chart 4, 4.1 & 4.2 ............................................................................................................... 35

Fault Finding Chart 4a, incl. (4.1 & 4.2) ................................................................................................... 36

Fault Finding Chart 5 .............................................................................................................................. 37

Fault Finding Chart 5a .............................................................................................................................. 38

Fault Finding Chart 6 ................................................................................................................................ 39

Fault Finding Chart 7 ................................................................................................................................ 40

Fault Finding Tests ................................................................................................................................... 41

Electrical Safety Testing ........................................................................................................................... 44

Component Replacement Procedures ..................................................................................................... 46

Exploded view 1: 701 series Office model 3 & 5 litre ............................................................................... 55

Exploded view 2: 702 series Commercial model 7.5 - 40 litre ................................................................. 56

Exploded view 3: 703 series Eco model 3 – 7.5 litre ............................................................................... 57

Document Revision History ...................................................................................................................... 58

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Introduction

The information provided in these instructions is based on the Boiling Water Unit (BWU) being installed in accordance with the Installation Instructions provided with each appliance.

Should you require further technical advice on a BWU, contact your distributor where genuine replacement parts are also available.

Safety Warning

The purpose of this service manual is to provide sufficient information to allow a person with the skills as required by the Regulatory Authorities to carry out effective repairs to a 701, 702 or 703 Series BWU 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 Equipment (PPE) shall be worn. An RCD shall be installed between the power point and 3-pin cord of the boiling water unit (3-15L capacity) to reduce the risk of electric shock. Hard wired units (25-40L capacity) shall only have live testing completed by a qualified electrician of appropriate class.

Isolate power before conducting the indicated test.

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

General warning symbol. Observe the instructions accompanying the symbol.

If the supply cord is damaged, it must be replaced by the manufacturer, distributor or its service agent or a similarly qualified person in order to avoid a hazard.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions 4

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BWU Model Identification

The identification numbers are designed to convey detailed information about the BWU to which it is attached. The model number consists of 5 digits and 3-5 digits and letters.

Model Number

XX or XXXX

Type

7 – Boiling Water

Model Type

01 – Office Model 02 – Commercial Model 03 – Eco Model

Capacity in Litres

03 – 3 litres 05 – 5 litres 07 – 7.5 litres 10 – 10 litres 15 – 15 litres 25 – 25 litres 40 – 40 litres

Finish

W – White S – Stainless steel

NZ or Australia Version

NZ – New Zealand Version (Plug Type I, 15mm BSPP, Rheem branded) AU – Australia Version (Plug Type I, 12mm BSPP, Rheem branded)

International Version

X X X

Plug Qty

0 – No Plug

1 – With Plug

Plug Type*

eg. E, F, G, I, L, M, N (X = None)

Plumbing Fitting Type

0 – 15mm BSPP 1 – 12mm NPT

Brand

R - Rheem E - Everhot V - Vulcan L - Lazer

*for plug type regions, see http://www.iec.ch/worldplugs/

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions 5

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Preventative Maintenance

It is suggested for peak performance that the BWU be serviced every six months.

Servicing must be performed by suitably qualified persons.

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

1. Check the inlet strainer located inside the water inlet connection to ensure it is clean and not blocked with foreign matter. If an additional auxiliary filter is fitted, such as in areas of poor water quality check to ensure it is also clean and not blocked with foreign matter.

2. Check for signs of excessive corrosion on jacket and internal panels. Corrosion can be indicative that a leak is present.

3. Check for leaks at all BWU fittings and seals.

4. Check the vent line to ensure it is not blocked with foreign matter. It is imperative that

the vent line does not become blocked as the BWU is not designed to be pressurised.

5. Isolate power and check all electrical connections for signs of overheating due to poor connection.

6. Conduct an electrical insulation test. (Refer to page 45).

7. Check tap for signs of leaking & excessive dripping after operation (clean or replace if required.

WARNING

This Boiling Water Unit contains electronic equipment and insulation tests must only be conducted between neutral and earth or between active and earth.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Specifications

Lazer Boiling Water Unit

70103 ….. 70303 …..

70105 ….. 70305 …..

70207 ….. 70307 …..

70210 …..

70215 …..

70225 …..

70240 …..

Storage capacity

3 Litres

5 Litres

7.5 Litres

10 Litres

15 Litres

25 Litres

40 Litres

Max supply pressure

(1)

1000kPa

Min supply pressure

50kPa

75kPa

100kPa

Cold water inlet connection

RP½/15

Overflow / vent connection

RP½/15

Supply voltage

230 – 240 Volts AC 50Hz

Electrical connection

10A 3 pin plug

Fixed wiring

Element kW

1.8kW

2.4kW

3.6kW

4.6kW

Resistance

32 ohms

24 ohms

16 ohms

12 ohms

Amperage

7.5A

10A

15A

20A

E.C.O. setting

Open 105ºC (manual reset)

Open 110ºC (manual reset)

Inlet solenoid

Resistance

3.5 Kilo ohms

Flow regulator

0.5 L/M (yellow regulator located in solenoid)

2.5 L/M (brown regulator located in solenoid)

Boiling thermistor resistance

Refer to table on page 26

Approx recovery

(2)

17.5 L/hr

21 L/hr

33 L/hr

41 L/hr

Approx heat time to capacity

(2)

12 min

15 min

22 min

29 min

40 min

50 min

Drain plug

Yes

Inlet strainer

(3)

Yes

(1)

If the supply pressure exceeds 1000kPa, a pressure limiting valve must be installed upstream of the BWU.

(2)

Operation based on temperature rise of 77°C

(3)

In areas with poor water quality an additional filter should be installed.

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Wiring Diagrams

Wiring Diagram 3 – 15L Models

Wiring Diagram 25 & 40L Models (Commercial 702 Series only)

(Standard)

(NZ model Pre 2014)

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Plumbing Diagram

Water Inlet and Vent Connections

Cold mains pressure water must be piped and connected to the RP½/15 inlet fitting located on the left hand side underneath the BWU.

An accessible isolating valve must be installed near the BWU.

The BWU contains an inlet strainer on the water inlet connection. Where poor water quality is present it is recommended to install an additional auxiliary filter.

The vent pipe is to be made of a material that cannot be degraded by continuous steam (i.e. copper).

Operation

701, 702 and 703 Series BWU operate on 230 - 240 volts AC and will deliver gravity fed boiling water via a lever operated tap mounted on the BWU.

Sequence of Operation

Refer to BWU Sequence of Operation Component Diagrams’ on page 10 to view components shown in brackets e.g. (1).

1. When power is supplied to the BWU the control board relay (1) is energised. If the low

level probe (2) does not detect water the inlet solenoid valve (3) is energised allowing water to enter and partially fill the boiling water tank (4) until 15 seconds after the low level probe (2) detects water. Note: Upon initial filling and calibration, the inlet solenoid valve (3) is energised until 30 seconds after the low level probe (2) senses water.

2. When the BWU is operated for the first time, or auto calibration mode is selected (5),

the unit will enter auto calibration mode. When in auto calibration mode the BWU will perform three heating operation cycles in which to determine and program the optimum boiling water temperature setting according to altitude. The optimum boiling

water temperature is termed ‘Treq’ which is the water temperature the BWU will

maintain the boiling water at after calibration. Auto calibration mode takes approximately 18 – 30 minutes to perform (depending upon model capacity) and should not be interrupted.

3. After calibration or under normal operating conditions; if the boiling water thermistor (6)

detects a temperature of less than 94ºC, or less than or equal to Treq -2ºC, the control board triac (7) allows power to the boiling water element (8) on a percentage basis of between 20% (48 volts) to 100% (230 - 240 volts) depending upon the temperature, i.e. higher temperature difference equals higher percentage basis.

All models have same pipework configuration

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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4. After first time calibration or after drawing boiling water; the control board will

incrementally fill and heat the water in the boiling water tank (4). After the first incremental fill, the water in the boiling water tank (4) is heated to Treq -2ºC at which time the control board will energise the inlet solenoid valve (3) until the water in the boiling water tank (4) is at -3 ºC of Treq which allows more water to enter the boiling water tank (4) (normally 4 – 15 seconds). This allows the boiling water to be heated in increments enabling boiling water to be available in a shorter period of time. This process is continued until the high level probe (10) detects water at which time the inlet solenoid valve (3) is de-energised and incremental filling ceases.

5. After the high level probe (10) detects water, heating is continued until the boiling

water thermistor (6) detects a temperature equal to Treq at which time the control board triac (7) switches off (de-energising the boiling water element (8)) and the control board relay (1) is de-energised.

6. When the tap (9) lever is operated, boiling water is gravity fed to the tap (9) outlet. As

the water level in the boiling water tank (4) falls below the high level probe (10) the inlet solenoid valve (3) is energised allowing water to enter the boiling water tank (4) again in 4 – 15 second incremental fills or until the high level probe (10) detects water again (depending upon the amount of boiling water drawn). It should be noted that if the water level in the boiling water tank (4) falls below the low level probe (2) at any time, the boiling water element circuit is disabled until the low level probe (2) detects water again for a period of 1 second or more.

7. When the high level probe (10) detects water again, the inlet solenoid valve (3) is de-

energised preventing water from entering the boiling water tank (4).

8. If during any stage of operation:

 The boiling water thermistor (6) becomes open or short circuited,  The low level probe (2) is shorted to earth, or  The control board triac (7) becomes short circuited,

The inlet solenoid valve (3) and control board triac (7) are de-energised (if on) and the control board relay (1) will turn off (be de-energised).

Notes:  701 & 702 series only: If the timer (5) ‘off period’ has been programmed and reached,

the boiling water Treq temperature is changed from calibrated Treq temperature to 0ºC, until the next timer ‘on period’ is reached, or the timer (5) ‘off period’ is deactivated by pressing any timer button, at which time the calibrated Treq setting will return to normal. This is an energy saving function.

 703 Series: If the Eco timer (5) has been set and reached, again, the boiling water Treq

temperature changes from calibrated Treq temperature to 0ºC. Sleep mode is deactivated by pressing and releasing the ‘ECO’ button, at which time the calibrated Treq setting will return to normal. This is an energy saving function.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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BWU Sequence of Operation Component Diagram

3 – 15L Models

LH side

Front view NZ 703 series

RH side

Control board relay

Timer

Tap 2 Low level probe

Boiling water thermistor

High level probe

Inlet solenoid valve

Control board triac

Boiling water tank

Boiling water element

25 – 40L Models

Left Hand View Front View Commercial Right Hand View

7 4 1

6 3 3

703 Display (Standard)

703 Display (NZ Pre 2014)

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Operational Flow Charts Operational Flow Chart – 701 & 702 Series

(7)

(4)

(2, 6)

Water drawn off

YES

(1)

Plug In

Power On

Fault rectified Isolate Power

Inlet solenoid off

(if on)

Control board triac (element) disabled

Control board

relay off

Inlet solenoid on Control board triac (element) off (if on)

Inlet solenoid

off after 30 seconds

Full ‘auto calibration’

cycle performed

Control board

relay on

Control board triac

(element) on 20% - 100%

Water temp (Treq)

maintained at 0ºC

(element off)

Control board triac

(element) off

YES

Inlet solenoid on

Inlet solenoid off

YES

Inlet solenoid off

YES

YESNO

NO YES

Control board triac

(element) on 20% - 100%

YES

Notes: (1) Control board relay on = Boiling water triac (element) circuit enabled. (2) The PCB monitors for faults while ever the boiling water unit is operating. (3) ‘Tb’ is the boiling point temperature detected during calibration; ‘Treq’ is the temperature the water will be maintained at; ‘T0’ is the water temperature detected by the boiling water thermistor. (4) Calibration is automatically performed by the control board on initial power up. Calibration will take approx 18 - 30 minutes (depending upon capacity) during which time 2 heating cycles will be performed. The tap should not be operated whilst calibration is being performed. (5) When measured using a conventional multimeter the voltage will be approx. 48 – 240 VAC. (6) Critical faults are; Hot Sensor O/C or S/C, Triac S/C & Level Probe shorted to earth. (7) Control board relay off = Boiling water triac (element) circuit disabled.

Critical fault

detected?

Timer

button pressed?

High level probe detecting water?

Timer ‘ON’

period reached?

Timer in ‘OFF’

period and AUTO

selected?

Sleep mode

period set?

TImer

button pressed?

High level probe

detecting water?

‘T0’ < 70°C

for 3.5 days?

High level probe

detects water?

‘T0' < ‘Tb’-3?

Low level probe

detects water?

Auto calibration

already

performed?

‘T0’ = ‘Treq’-2? ‘T0’ < ‘Treq’-3?

Error Code Displayed

Inlet solenoid off after

15 seconds (if on)

‘Treq’ value set

using ‘Temp

Override’?

(3)

Reduced ‘auto

calibration’ cycle

performed

(5)

(3)

YES

(3)

‘Treq’ becomes ‘Tb’-3

‘Treq’ becomes ‘Tb’-2

Critical fault detected?

YES

(2, 6)

(3)

‘T0' = ‘Treq’?

Control board triac

(element) off

(3)

YES

High level probe

detects water?

YES

(3)

Water drawn off

Control board triac

(element) on 20% - 100%

YES

‘T0’ = 70°C?

Control board triac

(element) off

YES

(3)

(5)

Low level probe

detects water?

YES NO

YES

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Operational Flow Chart – 703 Series

(7)

(4)

(2, 6)

YES

(1)

Plug In

Power On

Fault rectified Isolate Power

Inlet solenoid off

(if on)

Control board triac (element) disabled

Control board

relay off

Inlet solenoid on Control board triac (element) off (if on)

Inlet solenoid

off after 30 seconds

Calibration cycle

performed

Control board

relay on

Control board triac

(element) on 20% - 100%

Water temp (Treq)

maintained at 0ºC

(element off)

YES

Inlet solenoid on

Inlet solenoid off

YES

Inlet solenoid off

Control board triac

(element) on 20% - 100%

Notes: (1) Control board relay on = Boiling water triac (element) circuit enabled. (2) The PCB monitors for faults while ever the boiling water unit is operating.

(3) ‘Tb’ is the boiling point temperature detected during calibration; ‘Treq’ is the temperature the water will be maintained at; ‘T0’ is

the water temperature detected by the boiling water thermistor. (4) Calibration is automatically performed by the control board on initial power up. Calibration will take approx 18 - 30 minutes (depending upon capacity) during which time 2 heating cycles will be performed. The tap should not be operated whilst calibration is being performed. Also refer to note 8.

(5) When measured using a conventional multimeter the voltage will be approx. 48 – 240 VAC.

(6) Critical faults are; Hot Sensor O/C or S/C, Triac S/C & Level Probe shorted to earth. (7) Control board relay off = Boiling water triac (element) circuit disabled.

(8) To activate sleep delay mode: (NZ) press and release the ‘eco’ button whilst the eco circle surround is extinguished, (AU) press the ECO button whilst the green ECO LED is extinguished. When the ‘eco’ button is released: (NZ) the eco circle surround, (AU) the ECO LED will illuminate green to indicate the unit is in sleep delay mode. When the unit is asleep the ‘Press eco to heat’ text will illuminate: (NZ) green, (AU) ‘ECO’ within the text ‘PRESS ECO TO HEAT” illuminates Red. (9) To deactivate sleep delay mode press and release the ‘eco’ button: (NZ) whilst the eco circle surround is illuminated green, (AU) press the ECO button whilst the green ECO LED is illuminated. When the ‘eco’ button is released the: (NZ) eco circle surround,

(AU) ECO LED will extinguish. (10) Calibration mode can be entered by removing power supply then holding the ECO button in the depressed position whilst

restoring power supply. The ‘HEATING LED’ will illuminate and flash at which time the ECO button can be released. The unit will

now recalibrate.

Critical fault

detected?

Sleep delay

mode activated?

Sleep delay

mode

deactivated?

‘T0’ < 70°C

for 3.5 days?

High level probe

detects water?

‘T0' < ‘Tb’-3?

Low level probe

detects water?

Auto calibration

already

performed?

‘T0’ = ‘Treq’-2? ‘T0’ < ‘Treq’-3?

Inlet solenoid off after

15 seconds (if on)

(5)

(3)

‘Treq’ becomes ‘Tb’-3

‘Treq’ becomes ‘Tb’-2

Critical fault detected?

YES

(2, 6)

(3)

‘T0' = ‘Treq’?

Control board triac

(element) off

(3)

YES

High level probe

detects water?

YES

(3)

Control board triac

(element) on 20% -

100%

YES ‘T0’ = 70°C?

Control board triac

(element) off

YES

(3)

(5)

Low level probe

detects water?

YES NO

YES

Water temp (Treq)

becomes ‘Tb’ - 3

Calibration

mode entered?

YES

(10)

2 hrs since last

solenoid valve

operation?

YES

(8)

(8) (9)

(9)

Note: Refer to page 21 for timer LED indication.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Electronic Controller

The control board or electronic controller is used to control the BWU by monitoring the water temperatures in the boiling water tank (via the boiling water thermistor) and processing commands received from the timer.

The control board has a relay which when energised will switch power to the boiling water triac (boiling water element circuit). In the event of a critical fault the control board relay will de-energise and open circuit the boiling water element circuit preventing it from operating.

3 – 15L Model Electronic Controller

25 & 40L Model Electronic Controller

Timer

There are two types of timers available depending upon BWU series. Refer to ‘Timer – 701 & 702 series below or Eco Timer – 703 Series page 20.

Timer – 701 & 702 Series

701 & 702 series BWUs are supplied with a programmable 24 hour 7 day timer which can be programmed to turn the BWU ‘ON’ or ‘OFF’ at predetermined days and times.

The timer incorporates a ‘Sleep Delay Time’ function which when programmed will automatically shut the system down after a set period of time of no use i.e. after 6 hours.

The timer has a ‘Filter Life’ function which when programmed and selected will display the remaining life of the water filter in litres. Note: A water filter is optional and is not supplied as standard. The timer has a ‘Service Menu’ which can display error codes, temperature settings etc.

Front view

Rear view

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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The timer also has a key lock function which when activated prevents access to the program functions.

Timer Functions

Function

Mode

Description

Clock

N/A

Set clock time.

STD/AUTO STD

BWU ‘ON’ 24 hours 7 days.

AUTO

BWU operates according to programmed ‘Set ON/OFF Times’.

Set ON/OFF Times

N/A

Program ON/OFF times for AUTO mode.

Sleep Delay Time

N/A

Program delay-off time from last usage (operates in AUTO mode only).

Filter Life* Remaining Life

Displays remaining filter life in litres.

Filter Reset

Resets filter ‘Remaining Life’ to ‘Set Filter

Life’ setting. Utilised when replacing filter.

Set Filter Life

Program filter life start value in litres.

Service Menu

Error Codes

Displays alpha error codes (refer to page 25 for error codes and their meanings).

Boiling Temp

Displays the current boiling water temperature in ºC.

Calib. Reset

Reactivates automatic boiling point calibration operation.

Temp Override

Manually select calibrated temp setting. Selectable from 70 – 99 ºC.

Software Version

Displays Timer and Controller software versions (top = Timer, lower = Controller).

Temp Show ON/OFF

Enable/disable boiling water temperature display on timer screen (in ºC).

TB Treq

Displays boiling water temperatures in ºC. (TB = calibrated temp, Treq = maintained temp).

* 701 and 702 Series BWUs do not have a water filter however filter life functions can be utilised if the water supply to the BWU has a water filter fitted.

Timer Operation

Selecting a Timer Function

1. Press and release the (P) button until the desired function is displayed flashing on the screen (refer to table above for a list of available timer functions).

2. Press and release the (✓) button to confirm selection.

Notes:

 Pressing and releasing the (X) button at any time returns the unit to the main menu.

Any functions previously accepted will be retained.

 The display will revert back to main menu from any mode if a button has not been

pressed after 1 minute.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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Setting the Clock

1. Press and release the (P) button, ‘Clock’ is displayed flashing on the screen.

2. Press and release the (✓) button to confirm selection. ‘Set Clock Day’ will be displayed on the screen with the day selection shown flashing.

3. Press and release the (▲) button until the desired day is selected.

4. Press and release the (✓) button to confirm selection. ‘Set Clock HOUR’ will be displayed on the screen with the hours section of the time shown flashing.

5. Press and release the (▲) button until the desired hour (24 hour time) appears flashing on the screen.

6. Press and release the (✓) button to confirm selection. ‘Set Clock MIN’ will be displayed on the screen with the minutes section of the time shown flashing.

7. Press and release the (▲) button until the desired minute appears flashing on the screen.

8. Press and release the (✓) button to confirm selection. The display will revert to the main menu and the time setting will be saved.

Selecting STD or AUTO Mode

1. Press and release the (P) button until ‘Timer STD/AUTO’ is displayed flashing on the screen.

2. Press and release the (✓) button to confirm selection. ‘STD’ will be displayed flashing on the screen.

3. Pressing and releasing the (▲) button alternates between the ‘STD’ and ‘AUTO’ icons.

4. Press and release the (✓) button when the ‘STD’ or ‘AUTO’ icon is shown on the display. The display will revert to the main menu. If ‘STD’ is selected the unit will operate 24 hours a day. If ‘AUTO’ is selected the unit will operate according to the pre set times on the timer (refer to ‘Programming Set ON/ OFF Times’ below).

Note: If the timer is in ‘AUTO’ mode and is in an ‘OFF’ period, the pressing of any Timer button or drawing water will reactivate the unit. The unit will then operate normally until the next programmed ‘OFF’ time.

Programming ‘Set ON/OFF Times’ (For Use in ‘AUTO’ Mode)

Note: A highlighted numeral i.e. 7:00 indicates that the highlighted numeral 7 is flashing on the display. X:XX is your time setting.

1. Press and release the (P) button until ‘Set ON/OFF Time’ is displayed flashing on the screen.

2. Press and release the (✓) button to confirm selection. ‘SUN 7:00 – 7:00 Set ON hour’ will be displayed on the screen.

3. Press and release the (▲) button until the desired hour appears flashing on the screen.

4. Press and release the (✓) button to confirm selection. ‘SUN X:XX – X:XX Set ON minute’ will be displayed on the screen.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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5. Press and release the (▲) button until the desired minutes appear flashing on the screen.

6. Press and release the (✓) button to confirm selection. ‘SUN X:XX – X:XX Set OFF hour’ will be displayed on the screen.

7. Press and release the (▲) button until the desired hour appears flashing on the screen.

8. Press and release the (✓) button to confirm selection. ‘SUN X:XX – X:XX Set OFF Minute’ will be displayed on the screen.

9. Press and release the (▲) button until the desired minutes appear flashing on the screen.

10. Press and release the (✓) button to confirm selection. ‘MON 7:00 – 17:30 Set ON hour’ will be displayed on the screen.

11. Continue steps 3 – 8 for Monday through to Saturday. When step 8 is completed for Saturday the display will automatically revert to the main menu and the program will be saved.

Note: To program the unit to be in ‘OFF’ mode for an entire day, set the ‘ON’ and ‘OFF’

times to be the same i.e. ‘ON = 0:00 OFF = 0:00’

Programming ‘Sleep Delay Time’

1. Press and release the (P) button until ‘Sleep Delay Time’ is displayed flashing on the screen.

2. Press and release the (✓) button to confirm selection. ‘Sleep Delay Time OFF’ will be displayed on the screen with ‘OFF’ flashing.

3. Press and release the (▲) button until the desired time setting appears flashing on the screen. Each consecutive push and release of the (▲) button increases the time setting in one hour increments up to a maximum of 6 hours. If the (▲) button is pressed and released after ‘6’ is reached ‘OFF’ will be displayed and if accepted, the sleep delay timer will be turned off.

4. When the desired setting is reached press and release the (✓) button to confirm selection. The display will revert to the main menu and the setting will be saved.

Note: The sleep function puts the unit in a standby mode after a user defined period (1 – 6

hours). The unit will enter ‘Sleep’ mode if it has not been used for the programmed ‘Sleep Delay Time’ period. During ‘Sleep mode’ the unit will change the Treq boiling water temperature to 0ºC instead of the normal Treq (approximately 97ºC). To exit sleep mode, press any Timer button to reactivate the unit. The unit will then operate normally.

Selecting ‘Filter Life’ Functions

The Filter Life function has three modes to select from, ‘Remaining Life’, ‘Filter Reset’ and ‘Set Filter Life’. These modes are accessed as follows:

Accessing ‘Remaining Life’

1. Press and release the (P) button until ‘Filter Life’ is displayed flashing on the screen. Note: if ‘Remaining Life – COUNT IS OFF’ is displayed on the screen proceed directly to step 3 otherwise proceed to step 2.

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2. Press and release the (✓) button to confirm selection. ‘Remaining Life XXXX Litres’ will be displayed on the screen where XXXX is the value of remaining filter life in litres.

3. Press and release the (X) or (✓) button to revert back to the main menu.

Activating ‘Filter Reset’ & ‘Set Filter Life’

1. Press and release the (P) button until ‘Filter Life’ is displayed on the screen. Note: if ‘Remaining Life – COUNT IS OFF’ is displayed on the screen proceed directly to

step 3 otherwise proceed to step 2.

2. Press and release the (✓) button to confirm selection. ‘Remaining Life XXXX Litres’ will be displayed on the screen.

3. Press and release the (▲) button. ‘Filter Reset’ is displayed on the screen.

4. Press and release the (✓) button to confirm selection. ‘Are You Sure’ will be displayed flashing on the screen.

5. Press and release the (✓) button to confirm selection. ‘Set Filter Life YYYY Litres’ is displayed on the screen (with ‘YYYY Litres’ flashing) where YYYY is the previous preset value in litres. Note: ‘OFF’ may be displayed flashing on the screen if the previous value was set to OFF.

6. Press and release the (▲) button until the desired setting appears flashing on the screen. Each consecutive push and release of the (▲) button increases the capacity setting in 1,000 litre increments from a start value of 1,000 litres up to a maximum setting of 14,000 followed by OFF.

7. Press and release the (✓) button to confirm selection. The display will revert to the main menu and the setting will be saved.

Accessing Service Menu

The service menu has seven modes to select from (refer to ‘Timer Functions’ page 14). When service mode is entered, any existing error codes will be displayed on the screen. (Refer to page 25 for error codes and their meaning.)

Each mode is accessed as follows:-

Accessing Error Codes

1. Press and release the (P) button until ‘Service’ is displayed on the screen. Press and release the (✓) button to confirm selection.

2. Press and release the (X) or (✓) button to revert back to the main menu.

Note: An error code will be automatically cleared from the display when the fault relating to that error code is rectified and the BWU is re-powered. (Refer to page 25 for error codes and their meaning.)

Accessing Boiling Temp

1. Press and release the (P) button until ‘Service’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. Existing error codes will be displayed on the screen.

3. Press and release the (▲) button until ‘Boiling Temp XXX ºC’ is displayed on the screen where XXX is the current boiling water temperature in ºC.

4. Press and release the (X) or (✓) button to revert back to the main menu.

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Activating Calibration Reset Mode

Different altitudes will cause water to boil at different temperatures. To prevent the water in the boiling water tank from boiling continuously (which is energy inefficient) the BWU is fitted with an altitude calibration function which automatically operates when the unit is operated for the first time or if ‘calibration reset mode’ is activated. If the boiling water delivery temperature is not hot enough or the unit continuously boils, ‘calibration reset mode’ should be activated to recalibrate the unit.

When the unit is calibrating, the BWU will boil the water twice (approximately 60 seconds each time) in order to calibrate the optimum boiling point according to altitude. During this procedure steam and water droplets will be vented from the vent outlet on the tap. The entire calibration period will take approximately 18-20 minutes and

must not be interrupted; this includes operation of the tap outlet.

1. Press and release the (P) button until ‘Service’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. Existing error codes will be displayed on the screen.

3. Press and release the (▲) button until ‘Calib. Reset’ is displayed on the screen.

4. Press and release the (✓) button to confirm selection. ‘Are You Sure’ will be displayed on the screen.

5. Press and release the (✓) button to activate calibration mode. Existing error codes will be displayed on the screen.

6. Press and release the (✓) button to revert back to the main menu ‘Calibrating Do Not Interrupt’ will be displayed on the timer screen and the unit will recalibrate the boiling water temperature. When calibration is complete the timer display will automatically revert back to the main menu.

Activating Temp Override

Temperature override allows the installer to set the calibrated temperature to perform a fast calibration when the unit is operated for the first time, or to change the boiling water temperature to a selectable value from 70ºC – 99ºC.

1. Press and release the (P) button until ‘Service’ is displayed flashing on the screen.

2. Press and release the (✓) button to confirm selection. Existing error codes will be displayed on the screen.

3. Press and release the (▲) button until ‘Temp override’ is displayed on the screen.

4. Press and release the (✓) button to confirm selection. The current calibrated (or preset) boiling water temperature will be displayed flashing on the screen.

5. Press and release the (Up) button until the desired setting appears flashing on the screen. Each consecutive press and release of the (Up) button increases the boiling water temperature setting in 1ºC increments from 70ºC to a maximum of 99 ºC.

6. Press and release the (✓) button. ‘Are You Sure’ will be displayed flashing on the screen.

7. Press and release the (✓) button to confirm selection after which time the timer

screen will revert back to the main menu, ‘Calibrating Do Not Interrupt’ will be

displayed on the timer screen and the unit will recalibrate the boiling water temperature to the new selected temperature. When calibration is complete the timer display will automatically revert back to the main menu.

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Accessing Software Version

1. Press and release the (P) button until ‘Service’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. Existing error codes will be displayed on the screen.

3. Press and release the (▲) button until ‘Software Version’ is displayed on the screen.

4. Press and release the (✓) button to confirm selection. The software version will be displayed on the screen. The top digits refer to the timer software version and the lower digits refer to the controller software version.

5. Press and release the (X) or (✓) button to revert back to the service menu. Existing error codes will be displayed on the screen.

6. Press and release the (X) or (✓) button to revert back to the main menu.

Permanently Display the Boiling Water Temperature (Temp Show ON/OFF)

This function allows the temperature of the water within the BWU to be permanently displayed on the timer display screen.

1. Press and release the (P) button until ‘Service’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. Existing error codes will be displayed on the screen.

3. Press and release the (▲) button until ‘TempShow ON/OFF’ is displayed on the screen.

4. Press and release the (✓) button to confirm selection. The current setting, ‘ON’ or ‘OFF’ will be displayed flashing on the screen.

5. Press and release the (▲) button to cycle between ON and OFF.

6. Press and release the (✓) button to confirm selection. The display will revert to the service menu. Existing error codes will be displayed on the screen.

7. Press and release the (X) or (✓) button to revert back to the main menu.

Accessing Calibrated & Required Temperature (TB Treq) Information

This function allows the user to see what Temperature the unit calibrated to, and the subsequent required temperature the unit is required to be maintained at.

1. Press and release the (P) button until ‘Service’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. Existing error codes will be displayed on the screen.

3. Press and release the (▲) button until ‘TB Treq’ is displayed on the screen. Under

the letters ‘TB’ the boiling water calibration temperature will be displayed in ºC. Under the letters ‘Treq’ the temperature the unit will maintain the water at will be

displayed in ºC.

4. Press and release the (X) or (✓) button to revert back to the main menu.

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Activating Key Lock Function

This function is for extra security to prevent tampering with the unit settings. Default setting is disabled.

To activate keypad lock

1. Press and release the (P) button until ‘Keylock’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. ‘Key lock enable’ will be displayed on the screen.

3. Press and release the (✓) button to confirm selection. ‘Keypad Locked’ will be displayed on the screen when any button is pressed.

To deactivate keypad locks

1. Press (P) and (▲) buttons simultaneously for a period of approximately 5 seconds until ‘Keypad Locked’ disappears from the screen and display returns to normal.

Eco Timer 703 Series

703 series BWUs are supplied with an Eco sleep timer.

NZ model (Pre 2014)

Standard

The timer incorporates a ‘Sleep Delay Mode’ which when activated will automatically shut the system down after a set period of time of without use (2 hours).

To activate sleep delay mode press and release the ‘eco’/’ECO’ button: (NZ Pre 2014) whilst the ‘eco’ circle surround is extinguished or (Standard) whilst the green ‘ECO’ LED is extinguished. When the ‘eco’/’ECO’ button is released: (NZ Pre 2014) the eco circle surround will illuminate green to indicate the unit is in sleep delay mode or (Standard) the ECO LED will illuminate green to indicate the unit is in sleep delay mode. When the unit is asleep the: (NZ Pre 2014) ‘Press eco to heat’ text will illuminate: green, (Standard) ECO at the top of display glows red.

To deactivate sleep delay mode press and release the ‘eco’ button: (NZ Pre 2014) whilst the eco circle surround is illuminated green or (Standard) press the ‘ECO’ button whilst the green ECO LED is illuminated. When the ‘eco’/’ECO’ button is released: (NZ Pre 2014) the eco circle surround or (Standard) the ECO LED will extinguish.

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Eco timer LED Indication (NZ Pre-2014 Models)

The Eco timer has integral LED’s which indicate system status as follows:

LED

LED Status

Description

‘Heating’ text

On red flashing

Calibration cycle in progress

‘Heating’ text

On red solid

Heating in progress (T0 ≤ Tb - 7ºC)

‘Ready’ text

On green solid

Boiling water ready (T0 ≥ Tb - 7˚C)

Eco circle surround

On green solid

Sleep delay mode activated

Off

Sleep mode deactivated

‘Press eco to heat’ text

On green solid

Unit is asleep

Activate calibration reset mode (NZ Pre-2014 Models)

To activate calibration reset mode, turn off the power to the unit. Press and hold the ‘eco’ button and restore the power to the unit. Once the red heating LED is flashing, release the ‘eco’ button. When the unit has completed its calibration cycle, the red heating LED will illuminate solidly.

‘eco’ circle surround

LED glows green when Eco mode is activated

‘Press eco to heat’

LED glows green when sleep mode is activated

‘Heating’ LED glows

red when water is heated, and flashes red when unit is calibrating

‘Ready’ LED glows

green when water is ready to use

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Eco timer LED Indication (Standard)

The eco timer has integral LED’s which indicate system status as follows:

LED

LED Status

Description

‘HEATING’ text

On red flashing

Calibration cycle in progress

‘HEATING’ text

On red solid

Heating in progress

‘READY’ text

On green solid

Boiling water ready

‘ECO’ Green LED On green solid

Sleep delay mode activated

Off

Sleep mode deactivated

ECO Red LED illuminates ‘PRESS ECO TO HEAT’

On red solid

Unit is asleep

Activate calibration reset mode (Standard)

To activate calibration reset mode, turn off the power to the unit. Press and hold the ‘ECO’ button and restore the power to the unit. Once the red heating LED is flashing, release the ‘ECO’ button. When the unit has completed its calibration cycle, the red heating LED will illuminate solidly.

‘READY’ LED glows

solid green when water is ready to use

‘ECO’ Button

‘ECO’ LED glows

solid red when unit is asleep.

‘ECO’ LED glows solid

green when sleep mode is activated

‘HEATING’ LED glows

solid red whilst water is heating, and flashes red whilst calibrating

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Components and their Function Timer: An electronic device which allows the user to program the BWU operating times

and/or sleep mode function. Refer to page 14 for more information on timer operation. 701 & 702 Series have a 24 hr / 7day programmable timer. 703 series have an Eco function, refer to page 20 for Eco Sleep timer operation.

Heating Unit (Element): A tubular device containing an electric resistance element that converts electrical energy to heat which is utilised to heat water. The standard boiling water element rating is 1.8kW for 3L models, 2.4kW for 5 – 15L models, 3.6kW for 25L models and 4.6kW for 40L models. The boiling water element also has a dry well which houses the boiling water thermistor. The boiling water element in 3 – 15L models has an inbuilt E.C.O. (see below).

E.C.O. (Energy Cut Out): Also known as O.T.C. (Over Temperature Cut-out)

The boiling water element in 3 – 15L models has an inbuilt single pole E.C.O. which will open circuit the element at 105ºC. The 25-40L models have a stand-alone, dual pole E.C.O., inline between the control board and the element which will open circuit the element at 110ºC. The E.C.O.’s will not reset automatically but may be manually reset once temperatures have fallen to a safe level.

Control Board: The control board interprets signals from the timer and boiling water thermistor and controls operation of the BWU.

Boiling Water Thermistor: is a sensor which is used to detect the water tank temperature. The sensor is fitted into a pocket (dry well type) located in the boiling water element assembly, and plugs into the control board where its output is monitored. The resistance value of the boiling thermistor will change according to the water temperature detected.

Inlet Solenoid Valve: An electro-mechanical device utilised to shut off the inlet water supply to the BWU. Inlet solenoid valve operation is controlled by the low and high level probes via the control board.

The flow regulator located in the inlet of the valve has a series of holes which reduces the flow rate to 0.5 litres/ minute (3L - 10L models), or 2.5 litres/minute (15L - 40L models) to prevent turbulence within the boiling water tank which would otherwise affect stratification.

Control Board Relay: The control board relay provides protection in the case of an element triac short circuit. If an element triac short circuit is detected by the control board, the element relay will de-energise which will prevent the element triac from operating.

Level Probe: A device designed to detect the water level of the boiling water tank. The level probe contains two probes; a low level probe and a high level probe. A circuit is created when the water touches both the tank and the probe. This circuit is detected by the control board.

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Common Complaints

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. 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.

Excessive Boiling Water Usage

The complaints of insufficient and no boiling water can on many occasions be attributed to water usage exceeding the capacity of the BWU.

When first attending a call of this nature it is essential to establish the probable water usage by querying the usage habits of the inhabitants and then comparing this with the potential delivery volume of the model BWU 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. Change of occupancy or an increase in the number of persons.

2. Plumbing or BWU tap 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. Milky coloured water is generally air in suspension and will disperse of its own accord.

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 or non-return valve.

Most water hammer problems are associated with hot and/or cold plumbing 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 cold-water pressure will usually solve most problems.

Fault Finding Test Equipment

A list of test equipment which will assist in conducting diagnostic procedures is provided below. This equipment is available from your distributor.

Fine probe adapter kit

WH0020082

Probe to alligator clip kit

WH0020084

Proxy Timer Service kit

318130

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Error Codes (701 & 702 Series Only)

The Timer has a ‘Service Menu’ which can display alphanumeric error codes (refer to Error Code Table below for error codes and their descriptions).

To access ‘Error Codes’ operate the Timer in the following manner:

1. Press and release the (P) button until ‘Service’ is displayed on the screen.

2. Press and release the (✓) button to confirm selection. Error codes will be displayed on the screen with any error codes listed below.

3. Press and release the (X) or (✓) button to revert back to the main menu.

Note: An error code will be automatically cleared from the display when the fault pertaining to that error code is rectified and the BWU re-powered.

Error Code Table

Code

Error

Code

Error

Hot Thermistor O/C or S/C

Low Level Probe Fault

(1)

Chiller Unit Cold Thermistor O/C or S/C

High Level Probe Fault

Triac S/C

(2)

N/A (Compressor Fault)

(2)

N/A (Leak Detection)

Boiling Water Heating Fault

Expired Filter

Watch Dog Software Reboot

Calibration Time Out

Excessive Temperature Rise

Error code table notes: Fault codes without an asterisk (*) are informational only and the BWU will continue to

operate however the affected section may not function. Fault codes with an asterisk (*) displayed are critical faults. If detected, the BWU will shut

down and control board relay will de-energise. Refer to ‘Operational Flow Chart – 701 & 702 Series’ on page 11 for more information.

(1)

701 and 702 Series BWU’s do not have a chiller unit and therefore will display error

code B for firmware versions pre circa 2010.

(2)

Although all these error codes are available, they are not utilised by 701 and 702 Series

BWU’s.

Error Codes (703 Series only)

When the unit is performing an automatic recalibration ‘heating’ flashes on the control panel.

A 701-702 series timer can be fitted to the 703 unit for fault finding purposes. Full functionality of service mode parameters can then be utilised. It is recommended having a proxy timer for servicing purposes.

Service Timer Kit Part Number 318130 The kit contains:-

Ribbon Connector Part Number 317167 Timer Part Number 316963

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Testing the Boiling Water Thermistor

Unplug the boiling water thermistor at the thermistor wiring loom connector or control board plug socket and using a multimeter on the kilo-ohms scale, measure between the pins of the thermistor plug. As the resistance of the thermistor will change according to its temperature, the resistance measurements for the thermistor will need to be checked against the ‘Thermistor Temperature/ Resistance Table’ located below. For this reason it is best to remove the thermistor from the dry well and compare the measured value to the ambient air temperature which can be obtained using a thermometer. When refitting the thermistor, into the element well, ensure there is ample heat transfer compound on the thermistor.

Thermistor Temperature / Resistance Table

Ambient

Temperature (ºC)

Resistance (ohms)

Minimum

Typical

Maximum

868

880

893

942

953

963

980

990

1000

1017

1028

1039

1094

1107

1121

1173

1190

1206

1256

1276

1295

1341

1365

1388

1430

1458

1485

1522

1554

1585

100

1617

1653

1690

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Fault Finding Charts, Fault Diagnosis Sequence

(General Fault Finding Chart) Note:- 703 Series, if a proxy timer is not fitted, no error codes can be displayed.

Fault General Fault Finding Chart

YES

Note: This includes the complaints of BW continuously boiling or BW ECO

continuously tripping.

Note: The following abbreviations are used throughout all fault finding charts in this service manual BWU = Boiling water unit BW = Boiling water

YES

Noisy BWUNO

Is an error code

displayed on the

timer?

Refer to section

on ‘Timer’.

Refer to fault finding chart for

error code displayed.

YES

Is complaint for no

BW or BW not hot

enough?

Is complaint for

BW too hot?

Is complaint

for insufficient

BW?

Is complaint for no or low water

flow?

Is complaint for timer not functioning?

Is complaint

for leaking?

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Error Code A

YES

Is BW thermistor ok?

Is BW thermistor

wiring connector ok?

YES

Error Code A

BW thermistor

O/C or S/C

Replace BW thermistor.

Ensure connector plug & socket

is firmly connected. Replace

connector if necessary.

Refer to section on ‘Testing the

Boiling Water Thermistor’.

Is BW thermistor

firmly plugged into

control board?

Ensure BW thermistor is firmly plugged into correct socket on

control board.

Repair or replace O/C or S/C

BW thermistor wiring.

YES

Error Code B

Chiller unit cold

thermistor O/C

or S/C

701, 702 & 703 Series BWU’s

do not use a Chiller

Unit therefore error code B will

always be displayed.

This is normal operation.

Continue fault finding.

Error Code C

Error Code C Triac S/C

Check BW element circuit for

possible short circuit and

replace control board if short

circuit is not present.

Error Code D

Leak detected

(BWU or chiller unit)

701, 702 & 703 Series BWU’s do not use a leak sensor, error code D is not applicable.

Continue fault finding.

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Error Code E

Error Code E Expired filter

This error code will not affect

appliance operation. Continue

with fault diagnosis.

To reset or deactivate filter

counter refer to section on ‘Timer’

Error Code G

Calibration

time out

Successful recalibration performed. Check BWU

operation.

BWU can be reset by

disconnecting power then

restoring power after

waiting 30 seconds.

Is error code G still

displayed?

Reset BWU

BWU will attempt

recalibration

1.2

Chart 1.2 is part of and can

be located within Error code

L fault finding chart.

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Error Code H & Error Code J

NOYES

Is water supply to

BWU ok?

Is level probe ok?

(TEST 4)

YES

Error Code H

Low level

probe fault

Restore water supply to BWU.

Ensure stop cock or isolation valve is open. If an additional

water filter is installed check to

ensure it is not blocked.

Clean or replace level probe. Ensure probes are not touching each other or the probe housing

(earth).

Is level probe

wiring connector ok?

Ensure connector plug & socket

is firmly connected. Replace

connector if necessary.

Replace level probe.

YES

Error Code J

High level

probe fault

Is level probe firmly plugged into control

board?

Ensure level probe is firmly

plugged into correct socket on

control board.

Is level probe wiring

O/C or S/C?

YES

Was original error

code H or J?

YES

4.2

Is high level probe

insulation correct

length?

Replace level probe.NO

Chart 4.2 is part of and can

be located within chart 4.

Replace control board.YES

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Error Code K

Chiller Compressor

fault

701, 702 & 703 Series BWU’s do

not use compressor, error code

K is not applicable. Continue

fault finding.

Error Code L

Error Code N

YES

Is level probe ok?

(TEST 4)

Error Code N

Excessive

temperature rise

Ensure probes are not touching

each other, the tank or the

element (earth).

Repair or replace S/C

level probe wiring.

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Fault Finding Chart 1 (Proxy timer recommended for fault finding on 703 series)

Is the fuse blown at

the switchboard?

YES

Did the fuse blow

again?

YES

Is 240 volts present

at terminal block?

(TEST 2A or 2B)

Household wiring or power point

faulty. Advise customer to call

an electrician.

Is 240 volts present at the power point?

(TEST 1)

1.1

Is 240 volts present at the power point?

(TEST 1)

Faulty fuse replaced. Check

appliance operation.

YES

Test 2A for 3 – 15L models Test 2B for 25 & 40L models

Replace faulty cord set.

Is 240 volts present

at control board?

(TEST 3A or 3B)

YES

Repair O/C wiring.NO

Test 3A for 3 – 15L models Test 3B for 25 & 40L models

Does timer display an

error code other than

error code B?

YES

Refer to fault finding chart for

error code displayed.

YES

701,702 & 703 Series BWU’s do not use a Chiller,

therefore error code B will always be displayed. This

is normal operation.

Refer to section

on ‘Timer”

Is complaint for no or

low water flow?

4.1

YES

Chart 4.1 is part of and can

be located within chart 4

Is BW thermistor ok?

Replace BW thermistor.NO

Refer to section on ‘Testing the

Boiling Water Thermistor’.

Is BW thermistor

wiring connector ok?

Ensure connector plug & socket

is firmly connected. Replace

connector if necessary.

YES

1.2

Chart 1.2 is part of and can

be located within Error code

L fault finding chart.

Is BW thermistor

Firmly plugged into

control board?

Ensure BW thermistor is firmly plugged into correct socket on

control board.

YES

Note if 703 Series, with no proxy timer display, go to Fault

Finding Chart 1.1a,

on following page

Replace Fuse

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Fault Finding Chart 1.1

1.1

Is reading below

1 mega-ohm?

YES Replace BW element.

Is reading below

1 mega-ohm?

Replace inlet solenoid.YES

Is control board

shorting on backing

plate?

Check for pinched or damaged

wiring touching the water heater

chassis.

Refix control board to insulated

stand-offs.

YES

Electrical Insulation Test

Disconnect BW element

wire from control board and

megger between disconnected

wIre and earth.

Disconnect inlet solenoid

wiring and megger between

each inlet solenoid terminal

and earth.

YES

Fault Finding Chart 1.1a (703 Series with no proxy controller)

Is BW element

resistance ok?

(TEST 6A )

YES

Boiling water heating fault

Is BW element

wiring ok?

Replace control board.YES

1.2

Has BW ECO

tripped?

(TEST 5)

YES

Does BW ECO

trip again?

(TEST 5)

YES

ECO reset. Fault rectified.NO

Repair faulty wiring.

Replace boiling water element.

Reset boiling water ECO and check appliance operation. If ECO cannot be reset replace

boiling water element.

(TEST 5A & 5B)

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Fault Finding Chart 2

Fault Finding Chart 3

Recommend a BWU of sufficient

capacity to meet customers

needs.

Is BWU of sufficient

size for customers

needs?

YES

Are there any

plumbing leaks or a

dripping BWU tap?

Has the usage

pattern changed

recently?

i.e. additional people

using BWU

Recommend a usage pattern

that will suit the BWU capacity

and the customers needs.

YES

Is BW water temp at

tap outlet < 95ºC?

YES

Normal operation. Recommend

a BWU of sufficient capacity or

usage pattern to meet

customers needs.

(TEST 5A & 5B)

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Fault Finding Chart 4, 4.1 & 4.2 (Proxy Display required 703 series or use Chart 4a)

Is the fuse blown at

the switchboard?

YES

Did the fuse blow

again?

YES

Is 240 volts present

at terminal block?

(TEST 2A or 2B)

Household wiring or power

point faulty. Advise customer

to call an electrician.

Is 240 volts present

at the power point?

(TEST 1)

1.1

Is 240 volts present

at the power point?

(TEST 1)

Faulty fuse replaced. Check

appliance operation.

YESNO

Test 2A for 3 – 15L models Test 2B for 25 & 40L models

Replace faulty cord set.

Is 240 volts present

at control board? (TEST 3A or 3B)

Repair O/C wiring.NO

Test 3A for 3 – 15L models Test 3B for 25 & 40L models

Does timer display an error code other than

error code B?

Refer to fault finding chart for

error code displayed.

YES

(1) Refer to section on ‘Timer”

Is water supply

to BWU ok?

Is high level probe

insulation correct length?

Replace level probe.

Are all plugs & sockets

firmly connected?

Does water flow freely

from tap past model

capacity?

Normal operation. If original fault

was for error code J and error

code J is still displayed then

replace control board.

YES

4.1

Restore water supply to BWU.

Ensure stop cock or isolation

valve is open. If an additional

water filter is installed check to

ensure it is not blocked.

Notes: (1) 701, 702 & 703 Series BWU’s do not use a Chiller, therefore error code B will always be displayed. This is normal operation.

4.2 Firmly reconnect plug socket(s).

i.e. can 4L be drawn from

a 3L model?

Is inlet solenoid

resistance correct?

(TEST 7)

Replace inlet solenoid valve.

Is 240 volts present

at inlet solenoid?

(TEST 8)

Replace control board.NO

Is BWU inlet

strainer

blocked?

Clean or replace inlet strainer.YES

Check for blockage or restriction in pipe work, inlet solenoid valve

(including flow regulator) or

BWU tap.

Replace fuse

YES

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Fault Finding Chart 4a, incl. (4.1 & 4.2) 703 Series – No Proxy Display Timer

Is the fuse blown at

the switchboard?

YES

Did the fuse blow

again?

YES

Is 240 volts present

at terminal block?

(TEST 2A)

Household wiring or power

point faulty. Advise customer to

call an electrician.

Is 240 volts present at the power point?

(TEST 1)

1.1

Is 240 volts present

at the power point?

(TEST 1)

Faulty fuse replaced. Check

appliance operation.

YES

Test 2A for 3 – 15L models

Replace faulty cord set.

Is 240 volts present

at control board?

(TEST 3A)

Repair O/C wiring.NO

Test 3A for 3 – 15L models

YES

Replace Element

Is water supply

to BWU ok?

YES

Is high level probe

insulation correct

length?

YES

Replace level probe.

Are all plugs

& sockets firmly

connected?

YES

Does water flow

freely from tap past

model capacity?

YES

4.1

Restore water supply to BWU.

Ensure stop cock or isolation valve is open. If an additional

water filter is installed check to

ensure it is not blocked.

4.2

Firmly reconnect plug socket(s).

i.e. can 4L be drawn

from a 3L model?

Is inlet solenoid

resistance correct?

(TEST 7)

Replace inlet solenoid valve.

Is 240 volts present

at inlet solenoid?

(TEST 8)

YES

Replace control board.NO

Is BWU inlet

strainer

blocked?

YES

Clean or replace inlet strainer.YES

Check for blockage or

restriction in pipe work, inlet

solenoid valve (including flow

regulator) or BWU tap.

YES

Is there continuity across

ECO, and correct resistance

on the element?

(TEST 5 & 6A)

Replace fuse

Normal operation. If original

fault was for error code J and

error code J is still displayed

then replace control board.

(TEST 5A & 6A)

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Fault Finding Chart 5 (Proxy Display required for 703 series or use chart 5a)

Is the fuse blown at

the switchboard?

YES

Did the fuse blow

again?

YES

Is 240 volts present

at terminal block?

(TEST 2A or 2B)

Household wiring or power point

faulty. Advise customer to call

an electrician.

Is 240 volts present at the power point?

(TEST 1)

1.1

Is 240 volts present

at the power point?

(TEST 1)

Faulty fuse replaced. Check

appliance operation.

YES

Test 2A for 3 – 15L models Test 2B for 25 & 40L models

Replace faulty cord set.

Is 240 volts present

at control board? (TEST 3A or 3B)

Repair O/C wiring.NO

Test 3A for 3 – 15L models Test 3B for 25 & 40L models

Does timer display an

error code other than

error code B?

YES

Refer to fault finding chart for

error code displayed.

YES

Refer to section

on ‘Timer”

Does timer

display work?

(proxy timer display

703 series)

YES

701, 702 & 703 Series BWU’s do not use a Chiller, therefore error code B will always be displayed. This is normal operation.

Are timer ribbon

cables firmly

connected?

Replace timer.YES

Ensure timer ribbon cables are

firmly plugged into sockets on

rear of timer and socket on

control board.

Do all timer functions

operate?

Refer to section

on ‘Timer”

Are timer ribbon

cables firmly

connected?

NONO

Has timer been

operated and/or

programmed

correctly?

YES

Advise customer on timer

operation and/or how to

program timer.

Replace timer.YES

Timer ok.YES

Refer to section

on ‘Timer”

Replace fuse

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Fault Finding Chart 5a 703 series

Is the fuse blown at

the switchboard?

YES

Did the fuse blow

again?

YES

Is 240 volts present

at terminal block?

(TEST 2A)

Household wiring or power point

faulty. Advise customer to call

an electrician.

Is 240 volts present at the power point?

(TEST 1)

1.1

Is 240 volts present

at the power point?

(TEST 1)

Faulty fuse replaced. Check

appliance operation.

YES

Replace faulty cord set.

Is 240 volts present

at control board?

(TEST 3A)

Repair O/C wiring.NO

Does Eco surround

circle illuminate when

eco button pressed?

YES

Led failure.

Replace timer fascia.

Is timer ribbon cable

connected firmly?

Ensure ribbon cable is firmly plugged into sockets on rear of timer and socket

on control board.

Replace control board.

Eco timer working correctly.

Does eco function

operate?

Does eco timer

operate?

YES

Eco button failure.

Replace timer fascia.

YES

Does eco button

function correctly?

(TEST 9)

YES

Replace fuse

YES

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Fault Finding Chart 6

YES

Remake hose connection/

plumbing fitting or replace hose/

plumbing fitting.

Is leak from a hose or

plumbing fitting?

Shorten vent line or install a tundish. Remake vent line to

have continuous fall and/or

reduce number of bends.

Replace level probe o’rings or

replace level probe.

YES

Is leak from

BW element gasket?

YES

Is BWU either a 25

or 40L model?

Tighten water outlet flange bolts

or replace water outlet flange

gasket.

Is leak from drain

plug?

YES

Is leak from drain

plug flange gasket?

Tighten drain plug flange bolts

or replace drain plug flange

gasket

YES

Is leak from inlet

solenoid?

Tighten solenoid lock nut(s) or

replace solenoid.

YES

Is leak from level

probe?

Unblock or replace vent line.YES

Is vent line blocked? YES

is vent line installed

correctly?

Replace element gasket. Check

for stripped bolts.

Vent line must be no longer than 3m, have

continuous fall and have

no more than 4 bends.

Is leak at water

outlet flange?

YES

Replace leaking BWU tank.

Tighten drain plug or replace

drain plug gasket.

The boiling water tank will have to

be removed to locate the leak.

Is leak at water

outlet flange?

Tighten water outlet flange bolts

or replace water outlet flange

gasket.

YES

Replace leaking BWU tank.

The boiling water tank will have to

be removed to locate the leak.

Is leak from

BWU tap?

YES Repair or replace BWU tap.

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Fault Finding Chart 7

YES Replace Heating unit.

Is noise a creaking or cracking sound?

Is noise only

evident when electric

heating cycle is on?

Poor quality water supply i.e.

dam water. Flush tanks.

Is noise water

hammer?

YES

Is noise only evident

when water is flowing

through heater?

Is water pressure >

800kPa?

YES

Is noise an

occasional clicking

sound?

YES

Refer to ‘water hammer’ in the

common complaints section.

Check for: Restrictions in pipe work, faulty valves, loose plumbing, other appliances i.e. washing machine or dishwasher. Fit 600kPa PLV if pressure is excessive.

Check for a faulty stop cock,

non-return valve, loose

component or screws.

Is there mineral build up on BW

heating unit?

YES

Expansion & contraction noise

associated with heating. Normal

operation.

YES

Control board relay operation.

Normal operation.

Check other appliances that can

generate noise i.e. washing

machine, dishwasher, ball cocks

etc.

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Fault Finding Tests

Fault Finding Tests 1 – 3A

Test 1

Test 2A (3 – 15L models)

Ensure power point is switched on and using a multimeter on the AC voltage scale, measure between the 3 pin sockets on the power point. The following results should be obtained:

Active to Neutral – 230 - 240 Volts AC. Active to Earth – 230 - 240 Volts AC. Neutral to Earth – 0 Volts.

Using a multimeter on the AC voltage scale, measure between the Active terminal (brown wire) and Neutral terminal (blue wire) on the terminal block. The following results should be obtained:

Active to Neutral – 230 - 240 Volts AC.

Test 2B (25 – 40L models)

Test 3A (3 – 15L models)

Using a multimeter on the AC voltage scale, measure between the Active terminal (brown wire) and the Neutral terminal (blue wire) on the terminal block. The following results should be obtained:

Active to Neutral – 230 - 240 Volts AC.

Using a multimeter on the AC voltage scale, measure between the COM terminal (Active) on the control board relay and the Neutral terminal on the control board. The following results should be obtained:

Relay COM terminal to control board Neutral – 230 - 240 Volts AC.

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Fault Finding Tests 3B – 6A

Test 3B (25 & 40L models)

Test 4

Using a multimeter on the AC voltage scale, measure between the Active and Neutral terminals on the control board. The following result should be obtained:

Control board Active to Neutral – 230-240 Volts AC.

Disconnect the boiling water probe at control board and remove probe from

housing. Using a megger on the 500V scale, megger between the probes of the level probe. The following result should be obtained:

> 1 Mega-ohm.

Test 5A (3 – 15L models only)

Test 5B (25 & 40L models)

Disconnect the red wire from the boiling water element E.C.O. and using a multimeter on the ohms scale, measure between the terminals of the boiling water E.C.O. The following result should be obtained:

0 ohms (E.C.O. has not tripped).

Disconnect the red and blue wire from the E.C.O. and using a multimeter on the ohms scale, measure between the L1 and L2 terminals, and the N1 and N2 terminals of the E.C.O. The following result between should be obtained:

L1-L2: 0 ohms (E.C.O. has not tripped). N1-N2: 0 ohms (E.C.O. has not tripped).

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Fault Finding Tests 6A – 8

Test 6A (3 – 15L models)

Test 6B (25 & 40L models)

Disconnect the two wires from the boiling water element and using a multimeter on the ohms scale, measure between the two element terminals. The following result should be obtained:

3L models (1.8kW element):30 – 34 Ω. 5L–15L models (2.4kW element):22 – 26 Ω

Disconnect the two wires from the boiling water element and using a multimeter on the ohms scale, measure between the two element terminals. The following result should be obtained:

25L models (3.6kW element): 14 – 18 Ω. 40L models (4.8kW element): 10 – 14 Ω.

Test 7

Test 8

Disconnect wiring at inlet solenoid valve and using a multimeter on the ohms scale, measure between the two terminals of the solenoid. The following result should be obtained:

3.1 – 4.2 kilo ohms.

Using a multimeter on the AC voltage scale, measure between the two terminals of the inlet solenoid. The following result should be obtained:

230-240 Volts AC. (Note:- Solenoid wiring must be connected to do this test)

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Fault Finding Tests 9

Test 9

Using a multimeter on the ohms scale, measure between the orange and yellow wires. When the button is pressed the following result should be obtained:

10 – 13 ohms.

(Note:- Eco timer ribbon wiring must be connected to do this test)

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Electrical Safety Testing

There are some basic test procedures that should be carried out when the operation and function of a BWU electrical system is in doubt.

Wear Personal Protective Equipment (PPE) when conducting step 1 of these procedures to reduce the risk of electric shock. Refer to the safety warning on electrical testing on page 3.

Procedure 1: Insulation resistance test of the water heater.

1. For 3 – 15L models: Isolate power by switching off at power point and unplugging BWU 3 pin plug from power point.

For 25 & 40L models: Isolate power by turning isolation switch off and then removing fuse (or switching off circuit breaker). Disconnect Active, Neutral and Earth wires from BWU terminal block.

2. For 3 – 15L models: Connect one test meter lead to the Phase and Neutral conductors (bridging them), and the other to lead to the Earth pin of the BWU 3 pin plug.

For 25 & 40L models: Connect one test meter lead to bridge out the Phase and Neutral conductors and the other to lead to the Earth terminal of the BWU terminal block.

3. Operate insulation resistance tester. A reading above 1 mega ohm should be obtained.

4. If a reading below 1 mega ohm is indicated, all component parts will need to be individually

tested to locate the fault. Refer to Fault Finding Chart 1.1 on page 33.

Procedure 2: To check “Earth Continuity” of the water heater.

6. Set test meter to x1 Ω (ohms) resistance scale.

(3-15L models)

7. Measure between the earth pin on the 3 pin plug and the water heater jacket. The reading

should be less than 1 Ω ohms.

(25-40L models)

8. Measure between the earth terminal and the water heater jacket. The reading should be less

than 0.5 Ω ohms.

9. If a reading greater than this value is obtained the earthing connection should be checked for

corrosion/tightness and the power lead earth wire tested, if necessary replace the power lead.

Procedure 3: To check “Continuity” of the water heater electrical circuit.

Note: If continuing with any diagnostic procedures do not perform this step (3) until diagnostics are complete.

10. Set test meter to x1 Ω (ohms) resistance scale.

11. For 3 – 15L models: Measure between the Active and Neutral pins of the BWU 3 pin plug. The

resistance should be approximately 1.5 kilo ohms. For 25 & 40L models: Measure between the Active and Neutral terminals of the BWU terminal

block. The resistance should be approximately 1.4 kilo ohms.

12. If a reading outside these resistance values is obtained, all electrical component parts will

need to be individually tested to locate the fault. Refer to Specifications table on page 6 for indicative resistance values of components.

13. For 3 – 15L models: Plug BWU 3 pin plug back into power point and switch on power point. For 25 & 40L models: Reconnect Active, Neutral and Earth wires to BWU terminal block, replace fuse (or turn on circuit breaker) and turn isolation switch on.

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Component Replacement Procedures

When performing a component replacement procedure; ensure any escaping water is caught in a container and does flow onto any electrical components.

When draining water from tank using the tap, some water will remain in the tank.

 If it is necessary to remove the BWU from the wall, take care to keep the

BWU standing upright to prevent water escaping from top fittings onto electrical components.

 If replacing an element, lock the tap open, remove the wiring connector

from the water level probe and restore power. This will allow cold water to enter the tank and cool any remaining boiling water.

Isolate power before performing any component replacement procedures

When performing any component replacement procedure, water of an elevated temperature may be present. Ensure PPE is worn to prevent the risk of scalding.

All BWUs Jacket Surround (Procedure 1)

1. Isolate power supply to BWU.

2. Remove four screws retaining jacket surround and pull jacket away from BWU to

remove. Two screws are located on top of BWU and two screws are located underneath BWU

3. Complete reassembly in reverse order of above.

WARNING 701 Series: - When refitting the jacket surround, ensure that the boiling water outlet tube is positioned correctly in spout.

Tap (Procedure 2A) 702 & 703 Tap replacement

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Support tap and unscrew tap union in a clockwise direction to remove tap.

4. Complete reassembly in reverse order of above.

5. Check for leaks.

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Tap (Procedure 2B) 701 Tap, timer fascia replacement

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Follow procedure 1 to remove jacket surround

4. Lift the tap lever, remove 2 retaining screws then the complete timer fascia and

timer from the unit. Disconnect the ribbon connector and place timer fascia aside.

5. With the tap lever still raised, unscrew the tap union in an anticlockwise direction to

remove tap.

6. Complete reassembly in reverse order of above.

WARNING:- When refitting the jacket surround, ensure that boiling water outlet tube is positioned correctly in spout.

Tap components (Procedure 3A) 702 & 703 Series

Note: To replace diaphragm only; follow steps 1 – 6, fit new diaphragm, then complete reassembly in reverse order ensuring tap lever is in the up position when tightening cap.

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Leave tap lever in up position.

4. Using a pair of multigrips (Eco) or spanner (Commercial), gently

unscrew cap in an anticlockwise direction until cap thread has cleared tap body thread.

5. Pull cap away from body. Cap will come away from body with lever,

spindle, spring and tap seal attached.

6. Remove tap seal by pulling away from spindle.

7. To remove tap lever, spindle and spring; place tap spindle on

a flat surface and push down on cap to compress spring. Whilst spring is compressed hold tap lever in a horizontal position and slide out backwards from spindle.

8. To remove spindle and spring; pull spindle away from cap then pull

spring away from spindle.

9. Complete reassembly in reverse order of above.

Note: Large diameter end of spring locates in cap. Tap lever locates in slots in spindle head. Ensure tap lever is in the up position when tightening cap.

10. Check for leaks.

Tap components (Procedure 3B) 701 series

Note: To replace tap seal only, follow steps 1–6 of procedure 2B. Remove tap seal by pulling it away from spindle.

1. Fit new tap seal and refit tap. Ensure tap lever is in the up

position when tightening cap.

2. Complete reassembly in reverse order of above.

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Water Outlet Pipe, Timer fascia (Procedure 4A) 702 & 703 Series

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Remove tap by following steps 3 – 4 of procedure 2A.

5. Unplug timer ribbon cable from control board

6. Using a 10mm Allen key (Commercial), or 8mm Allen key (Eco), insert long end of

Allen key into water outlet pipe on timer fascia and unscrew water outlet pipe in an anticlockwise direction. Support timer fascia and withdraw water outlet pipe from timer fascia then lift timer fascia away from BWU.

7. Unplug both timer ribbon cables from timer PCB.

8. To remove timer; place timer fascia face down on a clean rag. Remove any silicone

from back of timer. Pull back the plastic side retaining lugs, then lift timer PCB clear of timer fascia from the top first.

Note: If the timer is not operating as buttons are faulty, the timer fascia will require replacement.

9. Complete reassembly in reverse order of above, use thread tape on water pipe outlet

thread.

10. Check for leaks.

Timer Fascia & Timer (Procedure 4B) 701 Series

1. Remove timer fascia by following steps 1 – 5 of procedure 2B. (Timer fascia is

removed prior to tap.)

2. Replace with new timer fascia assembly, (‘ECO’ button & LED’s not sold separately)

3. Reassemble in reverse order.

Inlet Strainer (Procedure 5) all models

1. Isolate power and water supplies to BWU.

2. Crack water supply union to relieve pressure then unscrew water supply union.

3. Disconnect pipe work or union from water supply inlet fitting and remove inlet strainer

from inlet fitting.

4. Complete reassembly in reverse order of above.

5. Check for leaks.

Inlet Solenoid Valve & Inlet Fitting (Procedure 6)

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Remove inlet strainer by following steps 2 – 3 of procedure 5.

5. Disconnect wiring from inlet solenoid valve.

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6. Pull silicone tube away from inlet solenoid valve ensuring any escaping water does not

flow onto electrical components. Note: Silicone tube is easier to remove if seal has been cracked first by levering with a small flat bladed screwdriver.

7. Remove inlet fitting lock nut by unscrewing locknut in an anticlockwise direction.

8. Remove inlet solenoid valve complete with inlet fitting from BWU then remove inlet

fitting from inlet solenoid valve by unscrewing inlet fitting in an anticlockwise direction.

9. If inlet sealing tube requires replacing; pull sealing tube from inlet fitting by hand. Do

not use pliers as sealing tube o’ring will be damaged. Note: Do not perform this step if sealing tube does not require replacing.

10. Complete reassembly in reverse order of above ensuring correct solenoid valve (0.5L

or 2.5L/min) is fitted, and silicone tube is not kinked. Note: if sealing tube was removed in step 9, reinstall so as arrow on sealing tube points towards inlet solenoid valve.

11. Check for leaks.

Silicone Distribution (inlet) Tubing (Procedure 7)

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Pull silicone tube away from inlet solenoid valve ensuring any escaping water does not

flow onto electrical components. Note: Silicone tube is easier to remove if seal has been cracked first by levering with a small flat bladed screwdriver.

5. Pull silicone tube away from tank inlet fitting. For 3L – 5L models the inlet tubing can

now be removed from the BWU. For 7L – 40L models also pull tubing away from top and bottom of heat sink tube to remove inlet tubing in two sections. To do this the controller will have to be unfixed from backing plate by following steps 4 – 6 of procedure 14.

6. Complete reassembly in reverse order of above ensuring silicone tubes are not kinked.

7. Check for leaks.

Vent Outlet Fitting & Vent Line Silicone Tube (Procedure 8)

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Disconnect and remove external pipe work from vent outlet fitting.

5. Pull silicone tube away from vent outlet fitting. Note: Silicone tube is easier to remove if

seal has been cracked first by levering with a small flat bladed screwdriver.

6. To remove vent line silicone tube; pull silicone tube away from tank vent outlet pipe.

7. Complete reassembly in reverse order of above ensuring silicone tube is not kinked.

8. Check for leaks.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

Cord Set (Procedure 9)

1. Follow steps 1 – 13 of procedure 17 for removal of tank & insulation

2. Once the tank is removed the cord set is exposed. With a small flat bladed screwdriver

the cord retaining tabs can be eased away from the cord to release it from the back plate.

3. Disconnect cord set wiring from terminal block.

4. Using a small flat bladed screwdriver, lever black locking section of cable gland away

from cable gland body and withdraw cord set wiring through cable gland.

5. Complete reassembly in reverse order of above. Note: To relock cable gland on to

cord set; insert black locking section into cable gland slot and depress onto cord set using a pair of pliers.

Element (Procedure 10)

1. Isolate power supply to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Disconnect element wiring from element and remove boiling thermistor from element

dry well.

5. Remove two 10mm nuts retaining element to element flange and withdraw element

from tank.

WARNING Scald hazard. Ensure remaining water is caught in a suitable heat resistant container (500ml – 2L depending upon model capacity).

6. Complete reassembly in reverse order of above. Note: Ensure element flange is clean.

Element gasket should be replaced if damaged.

7. Check for leaks.

Boiling Water E.C.O. (Procedure 11)

For 3-15L models; The boiling water E.C.O. is an integral part of the boiling water element for 3-15L models,

in this instance replace the boiling water element by following procedure 10. For 25-40L models;

1. Isolate power supply to BWU.

2. Remove jacket surround (refer to procedure 1).

3. Disconnect 4x eye terminal connections at E.C.O.

4. Remove 2x nuts retaining E.C.O. to tank bracket and remove E.C.O.

5. Complete reassembly in reverse order of above. Ensure not to over tighten the nuts.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

Boiling Water Thermistor (Procedure 12)

6. Isolate power supply to BWU.

7. Remove jacket surround (refer to procedure 1).

8. Disconnect boiling water thermistor at wiring connector.

9. Withdraw boiling water thermistor from element dry well.

10. Complete reassembly in reverse order of above. If required, apply a small amount of

heat transfer paste to the boiling water thermistor before reinserting into dry well.

Level Probe (Procedure 13)

1. Isolate power supply to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Disconnect wiring connector plug from level probe and withdraw probe from housing.

Note: level probe is a push fit o-ring seal.

5. Measure and cut the replacement probe to correct length as required

6. Complete reassembly in reverse order of above.

Control Board (Procedure 14)

3L & 5L BWU heat sinks are air cooled. 7L - 40L models heat sinks are water cooled.

1. Isolate power supply to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Disconnect all wiring / wiring plugs from controller including timer ribbon cable.

5. Using a pair of long nose pliers, compress barbs on plastic mounting spacers and

remove controller from backing plate.

6. For 7 – 40L models only: Disconnect silicone tubes from top and bottom of heat sink

pipe and remove controller from BWU. Note: Silicone tubes are easier to remove if seal has been cracked first by levering with a small flat bladed screwdriver.

7. Complete reassembly in reverse order of above ensuring silicone tubes are not kinked.

8. Check for leaks.

Terminal Block (Procedure 15)

1. Isolate power supply to BWU.

2. Remove jacket surround (refer to procedure 1).

3. Mark and disconnect wiring from terminal block.

4. Using a pair of long nose pliers, compress barbs on plastic mounting spacers located

underneath terminal block and remove terminal block.

5. Reassemble in reverse order of above.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

Water Outlet Flange (Procedure 16A) 702 & 703 Series

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Remove tap by following steps 3 – 4 of procedure 2A.

5. Remove water outlet pipe and timer fascia by following steps 5 – 6 of procedure 4A.

6. Disconnect element wiring from element and unplug boiling thermistor wiring plug at

element.

7. Undo two blue tank straps. To remove a strap; pull a strap tag end clear of strap clip

and lever tag end from strap clip using a small flat bladed screwdriver. Pay attention to how strapping is inserted into clip for later reassembly.

8. Remove tape holding element and boiling thermistor wiring in place at front and right

hand side of tank insulation and lift wiring away from insulation.

9. Lift top half of tank insulation clear of BWU.

10. Remove two 10mm nuts retaining water outlet flange to tank and remove water outlet

flange and gasket.

WARNING Scald hazard. Ensure remaining water is caught in a suitable heat resistant container (500ml – 2L depending upon model capacity).

11. Reassemble in reverse order of above. Note: Ensure water outlet flange is clean. Water

outlet flange gasket should be replaced if damaged. Rethread blue tank straps through strap clips and pull to tighten. Element and thermistor wiring goes under lower blue strap only.

12. Check for leaks.

13. Complete reassembly in reverse order.

Water Outlet Flange (Procedure 16B) 701 Series

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove tap by following steps 3 – 6 of procedure 2B.

4. Disconnect silicone tubing from tap and remove silicone tube from tank insulation.

5. Follow steps 6 – 13 of procedure 16A.

Boiling Water Storage Tank & Tank Insulation All models (Procedure 17)

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Remove tap by following procedure 2A steps 3-4 for 702 & 703 series, or procedure

2B steps 4-6 for 701 series

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

5. 702 & 703 series only: Remove water outlet pipe and timer fascia by following steps 5

– 6 of procedure 4A.

6. 701 Series: Disconnect silicone tubing from outlet tap and remove from tank insulation.

7. Remove element by following steps 5 – 6 of procedure 10.

8. Disconnect wiring connector from level probe and withdraw probe from housing. Note:

level probe is a push fit.

9. Pull silicone tubes away from tank inlet pipe and tank vent outlet pipe. Note: Silicone

tubes are easier to remove if seal has been cracked first by levering with a small flat bladed screwdriver.

10. Undo two blue tank straps. To remove a strap; pull a strap tag end clear of strap clip

and lever tag end from strap clip using a small flat bladed screwdriver. Pay attention to how strapping is inserted into clip for later reassembly.

11. Remove tape holding element and boiling thermistor wiring in place at front and right

hand side of tank insulation and lift wiring away from insulation.

12. Remove nut from Earth stud located above tank and remove Earth wires and tank

copper Earth strap from stud.

13. Remove top half of tank insulation. Lift tank including remaining half of tank insulation

clear of BWU.

14. Remove two 10mm nuts retaining water outlet flange to tank and remove water outlet

flange and gasket.

15. Reassemble in reverse order of above. Note: Ensure element and water outlet flanges

are clean. Element and water outlet flange gaskets should be replaced if damaged. Ensure silicone tubes are not kinked. Rethread blue straps through strap clips and pull to tighten. Element and thermistor wiring goes under lower blue strap only.

16. Check for leaks.

Base Assembly (Procedure 18)

1. Isolate power and water supplies to BWU.

2. Operate tap lever until water ceases to flow from tap.

3. Remove jacket surround (refer to procedure 1).

4. Remove tap by following procedure 2A steps 1-4 for 702 & 703 series, or procedure

2B steps 4-6 for 701 series.

5. 702 & 703 series: Remove water outlet pipe and timer fascia by following steps 5 – 6

of procedure 4A.

5a.701 series: Disconnect silicone tubing from outlet tap and remove from tank insulation.

6. Disconnect wiring at element and unplug boiling water thermistor at element.

7. Remove level probe and silicone tubing and undo tank straps and remove element

wiring by following steps 7 – 10 of procedure 17.

8. Remove nut from Earth stud located above tank and remove Earth wires and tank

Earth strap from stud.

9. Lift tank including tank insulation clear of BWU.

10. Remove cord set by following steps 3 – 4 of procedure 9.

11. Remove terminal block by following steps 3 – 4 of procedure 15.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

12. Remove inlet strainer by following steps 2 – 3 of procedure 5.

13. Remove inlet fitting lock nut by unscrewing locknut in an anticlockwise direction.

14. Pull silicone tube away from inlet solenoid valve and remove inlet solenoid valve

complete with inlet fitting from BWU.

15. Remove vent outlet fitting lock nut by unscrewing locknut in an anticlockwise direction

and remove vent outlet fitting complete with silicone tube.

16. Unscrew and remove M4 controller mounting nut using a 7mm socket.

17. Using a pair of long nose pliers, compress barbs on plastic mounting spacers and

remove controller complete with wiring from backing plate.

18. Remove blue tank straps from base assembly.

19. Remove screws or nuts (depending upon mounting method used) retaining base

assembly to wall and remove base assembly.

20. Reassemble in reverse order of above. Note: Ensure silicone tubes are not kinked.

Rethread blue straps through strap clips and pull to tighten. Element and thermistor wiring goes under lower blue strap only.

21. Check for leaks.

Spout Replacement (Procedure 19) 701 series only

1. Remove jacket surround procedure 1

2. Place jacket face down on a firm surface covered with a soft clean cloth. Whilst

applying a small amount of outward pressure to the inside of the spout, slide the spout toward the front of the jacket.

3. Position new spout in jacket and slide to the rear of jacket to lock in position.

4. Reassemble in reverse order

WARNING:-Ensure that silicone boiling water outlet tube is positioned correctly in spout.

Outlet Tap Silicone tube replacement (Procedure 20) 701 Series only

1. Remove tap assembly procedure 2B steps 1-6

2. Disconnect silicone tubes from top and bottom of tank outlet fitting and remove from

tank insulation. Note: Silicone tubes are easier to remove if seal has been cracked first by levering with a small flat bladed screwdriver.

3. Complete reassembly in reverse order of above

WARNING:-When refitting jacket surround, ensure that silicone boiling water outlet tube is positioned correctly in spout.

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

Exploded view 1: 701 series Office model 3 & 5 litre

Item

Description

Part Nº

Item

Description

Part Nº

Controller & Heatsink

317159

Jacket fixing screws x 4

315994

Cord set

315880

Electronic Timer

316963

Element 1.8kW 3L

317164

Tube Spout Teflon

319028

Element 2.4kW 5L

315881

Tube 13mm Silicone Kit vent (1.0m)

319027

Probe Assy Hi/Lo

312029

Fascia Screws x 2 kit

317831

Ribbon Connector Timer

317167

Valve Solenoid Assy 240V 0.5l/min

318261

Thermistor Short 150mm

310537

Jacket 3L White

319011

Gasket Silicone (Pack 5)

012142

Jacket 5L White

319012

Loom Wiring 3 & 5L

318122

Jacket 3L Stainless Steel

319013

Tank 3L

318027

Jacket 5L Stainless Steel

319014

Tank 5L

318028

Plinth 3 L 701/ 703 Series Black

317927

Upper Tap assembly

319008

Plinth 5 L 701/ 703 Series Black

317928

Fascia Panel assembly

319009

n/s

Heat Sink Compound (10g Tube)

317696

Tube 8mm Silicone Kit (1.4m)

316264

Seal Tap

310556

Spout assembly

319010

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

Exploded view 2: 702 series Commercial model 7.5 - 40 litre

Item

Description

Part Nº

Item

Description

Part Nº

Controller & Heatsink 7.5L 15L

317159

Tube 8mm Silicone Kit (1.4m)

316264

Controller & Heatsink 25L & 40L

317190

Tube 13mm Silicone Kit vent (1.0m)

319027

Cord set 7.5L - 15L

315880

Jacket fixing screws x 4

315994

Element 2.4kW 7.5L - 15L

315881

Electronic Timer

316963

Element 3.6kW 25L

319007

O-Ring Tap (114)

310497

Element 4.6kW 40L

315884

Tap Extension

317821

Probe Assy Hi/Lo

312029

Valve Solenoid Assy 7.5L – 10L models 240V 0.5l/min

318261

Ribbon Connector Timer

316955

Valve Solenoid Assy 15L – 40L Models 240V 2.5l/min

318262

Thermistor Short 150mm

310537

Jacket 7.5L White

319016

Gasket Silicone (Pack 5)

012142

Jacket 10L White

319017

Loom Wiring 7.5L

318123

Jacket 15L White

319018

Loom Wiring 10L

318124

Jacket 25L White

319019

Loom Wiring 15L

318123

Jacket 40L White

319020

Loom Wiring 25 & 40L (Manuf. prior to Mar 2017)

318125

Jacket 7.5L Stainless Steel

319021

Loom Wiring 25 & 40L

320009

Tank 7.5L

318029

Jacket 10L Stainless Steel

319022

Tank 10L

318030

Jacket 15L Stainless Steel

319023

Tank 15L

318031

Jacket 25L Stainless Steel

319024

Tank 25L

318032

Jacket 40L Stainless Steel

319025

Tank 40L

318033

n/s

E.C.O. 25L & 40L (Only applicable if Manuf. post Mar 2017)

319070

Tap assembly

317804

n/s

Seal Tap

310556

Fascia Panel (incl spring)

319015

n/s

Heat Sink Compound (10g Tube)

317696

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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

Exploded view 3: 703 series, Eco model 3 – 7.5 litre

Item

Description

Part Nº

Item

Description

Part Nº

Controller & Heatsink

318263

Tube 8mm Silicone Kit (1.4m)

316264

Cord set

315880

Tube 13mm Silicone Kit vent (1.0m)

319027

Element 3L 1.8kW

317164

Jacket fixing screws x 4

315994

Element 5L & 7.5L 2.4 kW

315881

O-Ring Tap (112)

317863

Probe Assy Hi/Lo

312029

Tap Extension Brass

317842

Thermistor Short 150mm

310537

Valve Solenoid Assy 240V 0.5l/min

318261

Gasket Silicone

012142

Jacket 3L White

319071

Loom Wiring 3L & 5L

318122

Jacket 5L White

319072

Loom Wiring 7.5L

318123

Jacket 7.5L White

319073

Tank 3L

318000

Wall Bracket Kit OB 3L

318961

Tank 5L

318001

Wall Bracket Kit OB 5L

318962

Tank 7.5L

318002

n/s

Heat Sink Compound (10g Tube)

317696

Tap assembly

317807

Seal Tap 703 series

319030

Eco Keypad & Fascia panel assembly inc. Loom & spring

318084

TM063 701, 702 & 703 Series Boiling Water Unit Service Instructions Revision D: Feb 2017

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:

701, 702 & 703 Series

Boiling Water Unit Service Instructions

Document Nº:

TM063

Revision

Details of change

D.O.I.

First issue

Service Instructions issued

11/11

Spare part number changes, and updated ‘Sleep mode - tap deactivation’ 701,702 models only

08/12

Added recalibration procedure for Eco model page 21

12/12

Australian models and warranty statement added

04/13

Add international model details, remove AU/NZ warranty statement for international use, improve wording consistency, add E.C.O. for 25/40L models

02/17

Manufactured in New Zealand www.rheem.co.nz

Rheem 70103, 70210, 70303, 70105, 70207 Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual