Rheem 871018, 871020, 871024, 871024-B, 871024-C Service Instructions Manual

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SERVICE INSTRUCTIONS

18, 20,24, 26L Integrity

Electronic Gas Continuous Flow

Water Heater

TM031

871018

871020

871024

871024-B

871024-C

871026

871026-B

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Contents

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

Water Heater Model Identification................................................................................................ 3

Preset Temperature Adjustment .................................................................................................. 4

Wiring Diagram - Models with Mechanical Bypass .................................................................... 5

Wiring Diagram - Models with Solenoid Operated Bypass ........................................................ 6

Sequence of Operation ................................................................................................................. 7

Specifications ............................................................................................................................... 8

Bypass Operation ......................................................................................................................... 9

Anti-Frost Heater Circuit ............................................................................................................ 10

Product Changes ........................................................................................................................ 10

Software Changes ................................ ........................................................................................ 10

Parts Replacement & Wiring Changes for 871024, 871024-B & 817026 Model Heaters Only ....... 10

In-series Gas Boosting ............................................................................................................... 15

Tempering Valves ....................................................................................................................... 20

Remote Controllers ..................................................................................................................... 20

How to Fault Find ........................................................................................................................ 23

Operational Flow Charts 1 & 2 ................................................................................................... 25

Error Codes ................................................................................................................................. 28

Diagnostic Test Points ............................................................................................................... 29

Maintenance Information ............................................................................................................ 30

Clearing Error Code History ....................................................................................................... 31

Resetting Error Codes ................................................................................................................ 32

Fault Diagnosis Sequence (Fault Finding Chart G) .................................................................. 33

Fault Finding Chart 1 .................................................................................................................. 34

Fault Finding Chart 2 .................................................................................................................. 36

Fault Finding Chart 3 .................................................................................................................. 38

Fault Finding Chart 3.1 ............................................................................................................... 40

Fault Finding Chart 3.2 ............................................................................................................... 41

Fault Finding Charts 3.3 and 3.5 ................................................................................................ 43

Fault Finding Chart 3.6 ............................................................................................................... 44

Fault Finding Chart 3.7 ............................................................................................................... 46

Fault Finding Chart 3.8 ............................................................................................................... 47

Fault Finding Charts 4 and 4.1 ................................................................................................... 48

Fault Finding Chart 4.2 ............................................................................................................... 49

Fault Finding Chart 4.3 ............................................................................................................... 50

Fault Finding Chart 5 .................................................................................................................. 51

Burner Gas Pressure Check....................................................................................................... 51

Component Replacement Procedures ................................ ...................................................... 52

Exploded View 1 871018 / 871020 / 871024 Replacement Parts List............................................ 61

Exploded View 2 871018 / 871020 / 871024 ................................................................................. 62

Exploded View 2 871018 / 871020 / 871024 Replacement Parts List............................................ 63

Exploded View 1 - 871024 Model ............................................................................................... 64

Exploded View 2 – 871024 Models ............................................................................................. 66

Exploded View 3 - 871024-B Model ............................................................................................ 68

Exploded View 4 - 871024-B Model ............................................................................................ 70

Exploded View 4 Replacement Parts List - 871024-B Model .................................................... 71

Exploded View 5 – 871024, 871026 & 871026-B Models ........................................................... 72

Exploded View 6 - 871024-C, 871026 & 871026-B Models ........................................................ 74

Gas Type Conversion Procedure ............................................................................................... 76

Warranty ...................................................................................................................................... 78

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Safety Warning

The purpose of this service manual is to provide sufficient information to allow a person with the skills as required by the Regulatory Authorities to carry out effective repairs to a Rheem Continuous Flow Gas Water Heater in the minimum of time.

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

Certain diagnostic procedures outlined in these Service Instructions

require “live” testing to be conducted. Personal Protective Clothing (PPE)

shall be worn and an RCD shall be installed between the power point and 3-pin cord of the water heater to reduce the risk of electric shock.

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

Introduction

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

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

Water Heater Model Identification

The identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 6 digits and up to 3 letters.

8 7 1

018 020 024 026

-B

-C

Model Number

8 – Rheem

Location

7 – External

Ignition Type

1 - Electronic 60ºC Max temp

Capacity

Nominal litres/minute @ 25 ºC rise

Gas Type

N - Natural L - LPG

F - Frost protection fitted

Version

Internal Use Only

Preset Temperature Adjustment

It is possible to choose a preset outlet water temperature setting when remote controllers are not fitted. The water heater comes factory set at 55ºC on 871 series models.

Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons.

To adjust the preset temperature:

1. Remove the front cover from the water heater.

2. Turn DIP SWITCHES 3 and 4 on (up position) on the I.C. Board. The current preset temperature is displayed on the LED.

3. Press the MIN or MAX button, located under the DIP Switches, until the desired temperature is displayed. Available temperatures are: 871 series models: 40ºC, 43ºC, 50ºC, 55ºC and 60ºC

4. Turn DIP SWITCHES 3 and 4 off (down position). The temperature display is now turned off.

5. Refit the front cover to the water heater.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Wiring Diagram - Models with Mechanical Bypass

Wiring Diagram - Models with Solenoid Operated Bypass

Sequence of Operation

Refer to „Sequence of Operation Component Diagram‟ on page 9 to view components shown in brackets e.g. (1)

1. When a hot water tap (1) is opened, cold water (or preheated water if a solar preheater

is installed) enters the water heater and passes through the Water Flow Sensor (3) and Heat Exchanger (19). Note: For 871020, 871024, 871024-B, and 871026 model heaters fitted with a comparator the inlet water temperature must be less than or equal to 57ºC and for 871020-B, 871024-C and 871026-B models the inlet water temperature must be less than or equal to 58ºC and less than or equal to the set point temperature minus 2ºC for operation to occur past this point; otherwise water will pass straight through the heat exchanger and fan and burner operation will not occur (for more information on this subject refer to the section titled „In-series Gas Boosting‟ on page

15).

2. The Water Flow Sensor (3) sends a pulse signal to the PCB (27). Once the pulse

signal reaches a pre designated frequency (at minimum flow rate) the PCB (27) activates the Fan Motor (25) and the Fan (24) starts rotating.

3. After the Fan (24) completes a pre purge, the Gas Inlet Solenoid Valve (9), Gas

Solenoid Valve 1 (10) and Gas Solenoid Valve 2 (11) open at the same time. The Proportional Gas Flow Regulating Valve (13) adjusts the gas flow rate to ensure adequate gas for ignition and gas is then supplied to the Burner (15).

4. At the same time the Gas Solenoid Valves open the Igniter (16) starts sparking

continuously and ignites the gas at the Burner (15). After the flame sensor (18) detects burner flame, the Proportional Gas Valve (13) begins to control the gas flow rate. If there is a difference between the hot water temperature detected by the Hot Water Outlet Thermistor (6) and that set on the water heater or selected on the remote controller (if fitted) the PCB (27) adjusts the hot water temperature by opening and closing the Gas Solenoid Valves 1 (10), 2 (11) and 3 (12) and adjusting the Proportional Gas Flow Regulating Valve (13). The water flow rate is also adjusted via the Water Flow Servo Motor (7) to ensure the selected temperature of hot water is delivered.

5. As the gas flow rate, controlled by the Proportional Gas Flow Regulating Valve (13)

changes the PCB (27) varies the speed of the Fan Motor (25) to maintain the correct air gas mix ratio.

6. When the hot tap (1) is closed, the pulse signal from the Water Flow Sensor (3) stops

and the burner flame is extinguished by closing Gas Solenoid Valves 1 (10), 2 (11), 3 (12) and the Gas Inlet Solenoid Valve (9). The post purge operation then commences.

7. Once the post-purge operation ends (up to 6 minutes) power to the Fan Motor (25) is

cut and the Fan (24) stops.

Specifications

Model

871018

871020

871024 871024-B 871024-C

871026

871026-B

871026

871026-B

Specification

Natural

LPG

Natural

LPG

Natural

LPG

Natural

LPG

Max hourly gas cons.-MJ/Hr

157

188

199

Min hourly gas cons.-MJ/Hr

Min inlet wtr pressure-kPa

140

Max inlet wtr pressure-kPa

1000

Min inlet gas pressure(kPa)

1.13

2.75

1.13

2.75

1.13

2.75

1.13

2.75

Max inlet gas pressure(kPa)

3.5

871024

871024-B

871024-C

871024

871024-B

871024-C

Max burner gas test pressure (kPa)

0.903

1.5

0.903

1.5

0.71

0.912

0.71

1.078

0.965

1.2

Min burner gas test pressure (kPa)

0.182

0.32

0.182

0.32

0.15

0.17

0.16

0.22

0.17

0.22

Ignition System

Continuous Spark

Power Cons. (Watts)

Standard

anti-frost*

124

146

Gas connection diam.(mm)

R¾/20

Water connection diam.(mm)

R½/15

R¾/20

Relief Valve Pressure (kPa)

1750

Accessories

Kitchen Controller

Y Y Y Y Y

Bathroom 1 Controller

Y Y Y Y Y

Bathroom 2 Controller

Y Y Y Y Y

Recess box

Y Y Y Y Y

Pipe cover

Y Y Y Y Y

* Maximum power consumption when anti-frost heaters are energised.

Sequence of Operation Component Diagram

Hot Water Tap

Bypass Control Valve

Water Flow Sensor

Inlet Water Temperature Thermistor

Combustion Chamber Thermistor

Outlet Water Temperature Thermistor

Water Flow Servo Motor

Water Filter (Strainer)

Gas Inlet Solenoid Valve

Gas Solenoid Valve 1

Gas Solenoid Valve 2

Gas Solenoid Valve 3

PGFR Valve

Nozzle

Burner

Igniter

Igniter Electrode

Flame Sensor

Heat Exchanger

Over Temperature Limiter

Exhaust (Flue) Outlet

Combustion Chamber

Anti Frost Heater (Models with F in model number only e.g. 871024NF)

Fan

Fan Motor

Drain Plug With Relief Valve.

PCB

Bypass Operation

The bypass is a section of copper pipe work connected between the water body assembly (effectively the cold water inlet) and the outlet of the heat exchanger and allows a quantity of cold water to bypass the heat exchanger. The purpose of the bypass is to ensure the heat exchanger operates at temperatures above the dew point of the combustion gases, ensuring condensate is not produced, but low enough to maximise the heat exchangers life. A valve fitted to the water body assembly controls the bypass. There are two types of bypass valve utilised in the 18, 20 and 24 models. To determine what kind of bypass is being utilized, compare the appliance to the wiring diagrams on pages 5 & 6.

Mechanical Bypass

The mechanical bypass is a small spring loaded valve located in the water body assembly. The spring is temperature sensitive, as the cold water temperature decreases the spring tension increases reducing the amount of cold water flowing through the bypass. The bypass operates at all times when water is flowing.

Solenoid Operated Bypass

The solenoid operated bypass comprises a valve (located in the water body assembly) that is controlled by a solenoid (mounted on the water body assembly). The PCB activates the solenoid at the following predetermined temperatures:

Without Touch Pads: When the unit is preset at 40 or 43 degrees. With Touch Pads: When temperatures from 37 to 46 degrees are selected. At all other times the bypass does not operate.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Anti-Frost Heater Circuit

Models with an „F‟ in the model number have an anti frost heater circuit e.g. 871024NF-B. The anti-frost heaters are wired in series and operate independently from the water heater. The 18 and 20 litre models have a 58-watt anti-frost system. The 24 and 26 litre models have an 82-watt anti-frost system.

A thermostat sensing ambient air temperature, positioned in the wiring loom near the bottom of the water heater, activates the anti-frost heaters when the ambient air temperature falls to 4ºC +4ºC/-2ºC and deactivates the anti-frost heaters when the temperature rises above 12ºC.

In the event a heater block becomes open circuit the total heater circuit is rendered inoperable. The total heater circuit measures 993.2 ohms for the 18 and 20 litre models. The total heater circuit measures 702.6 ohms for the 24 and 26 litre models.

The circuit is split into two sections with 4 heaters in total. To determine which section has failed, isolate the power to the water heater and unplug the wiring connectors at the thermostat, cord set and the water body assembly heater block. The heat exchanger and hot water outlet heater‟s resistance (3 heater blocks) is 719.2 ohms for the 18 and 20 litre models and 565.5 ohms for the 24 and 26 litre models. The resistance of the water body assembly heater is 274 ohms for the 18 and 20 litre models. The resistance of the water body assembly heater is 137.1 ohms for the 24 and 26 litre models. Refer to Procedure 10 on page 55 for replacement procedure.

Product Changes Software Changes

18 and 20 litre models manufactured after July 2006 and 24 and 26 litre models manufactured after May 2006 have a change to the software which controls the operation of the heater. When an inlet water temperature of more than 58ºC and more than the set point temperature minus 2ºC is detected by the inlet water temperature thermistor, the fan and burner will not operate.

This function has been introduced to enhance the operation of the water heater and remove the need for a Solar Bypass Valve when the Integrity is connected as an in-series gas booster to a solar water heating system (for more information refer to „In-series Gas Boosting‟ on page 15).

Models with the revised software have a –B or -C suffix added to the model number i.e. 817020NF-B or 871024NF-C.

Parts Replacement & Wiring Changes for 871024, 871024-B & 817026 Model Heaters Only

Some parts for 871024, 871024-B & 871026 model heaters have been superseded and are no longer available (refer to following tables). If any of these superseded parts are found to be faulty they must be replaced with current parts available for 871024-C and 871026-B model heaters.

Some current parts utilise different wiring connectors/connections necessitating the replacement of other interconnecting components when installed in 871024, 871024-B and 871026 model heaters (refer to „Parts Replacement Scenarios‟ on page 11). Part numbers shown in the following tables which are not marked with an asterisk (*) can be considered a direct replacement and require no additional components or modifications when installed in 871024, 871024-B and 871026 model heaters.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Note: The parts lists shown on pages 64 - 75 are for current 871026-B and 871024-C model heaters; superseded part numbers for 871024 and 871026 model heaters are not shown therein however they are listed in the following tables.

Item

Description

Superseded Model

Current Model

871024

871024-B

871026

871024-C 871026-B

115

Nozzle Plate NG

N/A

31-76238-00

Nozzle Plate LP

N/A

410

Water Body Assy

31-76285-00

31-76658-00

701

Overheat Limiter

54-02730-00

*31-79562-00

705

Anti-frost heater A

WH0020047

31-71644-00

706

Anti-frost heater B

WH0020048

31-71643-00

712

Thermistor (ambient air)

WH0020052

*Now part of item 758

713

Thermistor Outlet (B)

WH0020181

*20-64774-00

714

Anti-frost thermostat

WH0020054

20-57072-00

715

Thermistor HX

WH0020053

*Now part of item 758

717

Thermistor Inlet (A)

WH0020180

*20-64773-00

723

Hall IC Assy

31-28085-00

*20-43805-00

745

PCB

31-76604-0S

31-76623-0S

757

100V Line Cord

31-23674-00

31-76653-00

758

Signal Loom

WH0020067

*31-76655-00

773

Power Filter

WH0020079

*31-71642-00

780

Power cord

WH0020071

*31-76652-00

783

Transformer

WH0020073

*31-71646-00

784

Connecting Cord

31-23492-00

*31-71641-00

*When installed in 871024, 871024-B and 871026 model heaters these parts will require the replacement of other interconnecting components. Refer to „Parts Replacement Scenarios‟ on page 11 for more information.

Parts Replacement Scenarios for 871024, 871024-B & 871026 Model Heaters Only

When replacing any of the following parts in 871024, 871024-B or 871026 models heaters the additional components shown will also require replacing due to wiring/connection changes between superseded and current parts. In some instances electrical BP

connectors may be utilised instead of replacing the additional listed parts and in these cases this will be shown as an option. Note: Item numbers refer to the item

number on the exploded views and parts lists located on pages 64 - 75.

Power Cord (item 780) Old Part Number WH0020071 / New Part Number 31-76652-00

This part may be connected to existing wiring utilising electrical BP connectors otherwise in addition to the power cord it will also be necessary to replace:

Connecting Cord, Pt Nº 31-71641-00 (item 784) Transformer, Pt Nº 31-71646-00 (item 783) Power Filter, Pt Nº 31-71642-00 (item 773)

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Anti-frost heater A, Pt Nº 31-71644-00 (item 705) Anti-frost heater B, Pt Nº 31-71643-00 (item 706) Anti-frost thermostat, Pt Nº 20-57072-00 (item 714)

Transformer (item 783) Old Part Number WH0020073 / New Part Number 31-71646-00

This part may be connected to existing wiring utilising electrical BP connectors otherwise in addition to the transformer it will also be necessary to replace:

Connecting Cord, Pt Nº 31-71641-00 (item 784) Power Cord, Pt Nº 31-76652-00 (item 780) Power Filter, Pt Nº 31-71642-00 (item 773) Anti-frost heater A, Pt Nº 31-71644-00 (item 705) Anti-frost heater B, Pt Nº 31-71643-00 (item 706) Anti-frost thermostat, Pt Nº 20-57072-00 (item 714)

Power Filter (item 773) Old Part Number WH0020079 / New Part Number 31-71642-00

This part may be connected to existing wiring utilising electrical BP connectors otherwise in addition to the power filter it will also be necessary to replace:

Connecting Cord, Pt Nº 31-71641-00 (item 784) Power Cord, Pt Nº 31-76652-00 (item 780) Transformer, Pt Nº 31-71646-00 (item 783) Anti-frost heater A, Pt Nº 31-71644-00 (item 705) Anti-frost heater B, Pt Nº 31-71643-00 (item 706) Anti-frost thermostat, Pt Nº 20-57072-00 (item 714)

Connecting Cord (item 784) Old Part Number 31-23492-00 / New Part Number 31-71641-00

This part may be connected to existing wiring utilising electrical BP connectors otherwise in addition to the connecting cord it will also be necessary to replace:

Power Filter, Pt Nº 31-71642-00 (item 773) Power Cord, Pt Nº 31-76652-00 (item 780) Transformer, Pt Nº 31-71646-00 (item 783) Anti-frost heater A, Pt Nº 31-71644-00 (item 705) Anti-frost heater B, Pt Nº 31-71643-00 (item 706) Anti-frost thermostat, Pt Nº 20-57072-00 (item 714)

Ambient Air Thermistor (item 712) The ambient air thermistor is now part of the signal loom (item 758). In replacing the loom

the connectors on the replacement loom will now not fit any of the thermistors, water flow sensor or overheat limiter requiring replacement of those items as well.

Old Part Number WH0020052 / New Part Number 31-76655-00 (signal loom)

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In addition to the signal loom it will also be necessary to replace:

Inlet thermistor, Pt Nº 20-64773-00 (item 717) Heat Exchanger thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758) Outlet thermistor, Pt Nº 20-64774-00 (item 713) Overheat Limiter, Pt Nº 31-79562-00 (item 701)

Flow Sensor, Pt Nº 20-43805-00 (item 723) Heat Exchanger Thermistor (item 715) The heat exchanger thermistor is now part of the signal loom (item 758). In replacing the

loom the connectors on the replacement loom will now not fit any of the thermistors, water flow sensor or overheat limiter requiring replacement of those items as well.

Old Part Number WH0020053 / New Part Number 31-76655-00 (signal loom) In addition to the signal loom it will also be necessary to replace:

Inlet thermistor, Pt Nº 20-64773-00 (item 717)

Ambient air thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Outlet thermistor, Pt Nº 20-64774-00 (item 713)

Overheat Limiter, Pt Nº 31-79562-00 (item 701)

Flow Sensor, Pt Nº 20-43805-00 (item 723) Inlet thermistor (item 717) Old Part Number WH0020180 / New Part Number 20-64773-00

In addition to the inlet thermistor it will also be necessary to replace:

Signal Loom, Pt Nº 31-76655-00 (item 758)

Ambient air thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Heat Exchanger thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Outlet thermistor, Pt Nº 20-64774-00 (item 713)

Overheat Limiter, Pt Nº 31-79562-00 (item 701)

Flow Sensor, Pt Nº 20-43805-00 (item 723) Outlet Thermistor (item 713) Old Part Number WH0020181 / New Part Number 20-64774-00

In addition to the outlet thermistor it will also be necessary to replace:

Signal Loom, Pt Nº 31-76655-00 (item 758)

Ambient air thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Heat Exchanger thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Inlet thermistor, Pt Nº 20-64773-00 (item 717)

Overheat Limiter, Pt Nº 31-79562-00 (item 701)

Flow Sensor, Pt Nº 20-43805-00 (item 723)

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Overheat Limiter (item 701) Old Part Number 54-02730-00 / New Part Number 31-79562-00

In addition to the overheat limiter it will also be necessary to replace:

Signal Loom, Pt Nº 31-76655-00 (item 758)

Ambient air thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Heat Exchanger thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Inlet thermistor, Pt Nº 20-64773-00 (item 717)

Outlet thermistor, Pt Nº 20-64774-00 (item 713)

Flow Sensor, Pt Nº 20-43805-00 (item 723) Flow Sensor (item 723) Old Part Number 31-28085-00 / New Part Number 20-43805-00

This part may be connected to existing wiring utilising electrical BP connectors otherwise in addition to the flow sensor it will also be necessary to replace:

Signal Loom, Pt Nº 31-76655-00 (item 758)

Ambient air thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Heat Exchanger thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Inlet thermistor, Pt Nº 20-64773-00 (item 717)

Outlet thermistor, Pt Nº 20-64774-00 (item 713)

Overheat Limiter, Pt Nº 31-79562-00 (item 701) Signal Loom (item 758) Old Part Number WH0020067 / New Part Number 31-76655-00

In addition to the signal loom it will also be necessary to replace:

Ambient air thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Heat Exchanger thermistor, now part of the signal loom Pt Nº 31-76655-00 (item 758)

Inlet thermistor, Pt Nº 20-64773-00 (item 717)

Outlet thermistor, Pt Nº 20-64774-00 (item 713)

Flow Sensor, Pt Nº 20-43805-00 (item 723)

Overheat Limiter, Pt Nº 31-79562-00 (item 701)

In-series Gas Boosting

Temperature controllers must not be fitted if this water heater is installed as part of a solar water heater system because water at a temperature much higher than the controller setting can be delivered.

If a solar pre-heater has been installed to an existing Integrity water heater installation then a solar bypass valve or a comparator must be fitted at this water heater and any controllers, if fitted, must be disconnected and removed. Note: models 871024-C and 871026-B do not require a solar bypass valve or a comparator.

18 litre Integrity’s are NOT suitable for use as in series gas booster.

871020-B, 871024-C and 871026-B Models

Where one of the above listed model Integrity is installed to provide in-series gas boosting a solar bypass valve or a comparator is not required. These models have had a change made to the operating software which eliminates the need for either of these components.

The software now electronically mimics a bypass valve so that when the inlet water temperature is above 58°C the fan and burner will not operate despite water flowing through the heat exchanger. When the inlet water temperature is less than or equal to 58°C the burner will fire and boost the outlet temperature to 60°C provided the flow rate is greater than 3 litres per minute. 20 and 26 models with modified software can be identified by a B suffix in the model number, whereas a 24 model with modified software can be identified by a C suffix in the model number i.e. 871024NF-C.

The preset outlet temperature of the Integrity, when installed as an in-series gas booster to a solar water heater, must be set at 60 C for the system to operate correctly.

The factory preset outlet temperature of all Integrity models is 55 C; during a new installation it will be necessary to reset the outlet temperature to 60 C. Refer to page 4 for

details on checking and adjusting the outlet temperature. Note: If a 20, 24, 24B or 26 model heater is replaced with an 20B, 24C or 26B model

heater and the existing 20, 24, 24B or 26 heater is used as an in-line booster and has a solar bypass valve fitted, the solar bypass valve must be removed and the plumbing connections remade directly to the Integrity inlet and outlet water connections (refer to diagrams on pages 15 & 16).

In-series Gas Boosting Integrity Solar Loline Installation

Note: This plumbing diagram is also applicable to standard model heaters fitted with a comparator. For more information on comparators refer to page 17.

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In-series Gas Boosting Integrity Solar Hiline Installation

Note: This plumbing diagram is also applicable to standard model heaters fitted with a comparator. For more information on comparators refer to page 17.

871020, 871024, 871024-B and 871026 Models

Where one of the above listed models is installed to provide in-series gas boosting, a solar bypass valve is fitted across the Integrity inlet and outlet water connections to prevent the water heater from operating when the outlet water temperature from the solar system is above 57°C (refer to diagrams on page 17). A disconnection union must always be provided at the solar preheated water inlet and hot water outlet on the solar bypass valve to allow for removal of the valve.

The solar bypass valve has been specifically designed to work with Rheem Integrity models listed above. 20 and 26 models ending with a B do not require a bypass valve. 24 models ending with -C do not require a bypass valve. 18 litre Integrity‟s are not suitable for use as in-series boosters.

The preset outlet temperature of the Integrity, when installed as an in-series gas booster to a solar water heater, must be set at 60 C for the system to operate correctly.

The factory preset outlet temperature of all Integrity models is 55 C; during a new installation it will be necessary to reset the outlet temperature to 60 C. Refer to page 4 for details on checking and adjusting the outlet temperature.

There are two types of solar bypass valves currently in use (Paloma & RMC) and whilst both operate in the same manner the plumbing arrangement at the valve differs according to the type of solar bypass valve used (refer to diagrams on page 17). Solar bypass valves are no longer available and if faulty are to be removed and a Comparator installed. Refer to pages 17 & 18 for information on comparators.

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Note: If a 821020, 821024, 821024-B or 821026 model heater is replaced with an 821020B, 821024-C or 821026-B model heater and the existing 871020, 871024, 871024-B or 871026 heater is used as an in-line booster and has a solar bypass valve fitted, the solar bypass valve must be removed and the plumbing connections remade directly to the Integrity inlet and outlet water connections (refer to diagrams on pages 15 & 16).

Solar Bypass Valve Operation

When the water temperature entering the solar bypass valve is above 57°C a temperature sensitive mechanism moves the valve spindle preventing water from entering the Integrity and allowing the water to flow through the solar bypass valve to the hot water outlet.

If the water temperature from the solar storage tank entering the solar bypass valve is below 57°C the temperature sensitive mechanism retracts the valve allowing water to enter the Integrity and preventing flow through the solar bypass valve. The Integrity will boost the water temperature to 60°C at the hot water outlet provided the flow rate is greater than 3 litres per minute.

Replacement of Solar Bypass Valve with a Comparator

An electronic device called a Comparator (part number 052127) is now available to replace the solar bypass valve and is suitable for use on Rheem 871020, 871024, 871024-B and 871026 models heaters. NOTE: 20 and 26L models with a B suffix and 24L models with a C suffix in the model number do not require either a solar bypass valve or a comparator.

Solar bypass valves are no longer available and if faulty are to be removed and a Comparator installed. Refer to page 18 for the procedure on installing a comparator.

The purpose of the comparator is to interrupt the operation of the burner when the inlet water temperature rises above 57°C.

The comparator is connected to the water flow sensor wiring and the inlet temperature sensor (cold sensor) wiring; both these components are mounted on the water body within the gas booster. The comparator monitors the inlet water temperature and when the temperature rises above 57°C the comparator interrupts the signal from the flow sensor to the PCB causing the burner to shut down.

Paloma Solar Bypass Valve

RMC Solar Bypass Valve

Inlet water from

solar water heater

Hot water outlet

Removing a Solar Bypass Valve and Installing a Comparator

1. Ensure power and water to the water heater is isolated.

2. Remove the front cover (refer to component procedure 1 on

page 52).

3. Locate the 2 pin wiring plug in the wiring loom to the cold

sensor mounted on the water body (refer to fig 1) and disconnect.

4. Plug the 2 pin male and female connectors from the

comparator into the plugs attached to the cold sensor and the main wiring loom (refer to fig 2). NOTE: If the comparator connectors do not fit the cold sensor and main wiring loom plugs, the model is an 871020-B, 871024-C or 871026-B model which does not require a comparator.

5. Locate the 3 pin wiring plug in the wiring loom to the flow

sensor (refer to fig 3) and disconnect

6. Plug the 3 pin male and female connectors from the

comparator into the plugs attached to the flow sensor and the main wiring loom (refer to fig 4).

7. Position and secure the comparator in a safe position using

the existing wiring ties securing the wiring loom (refer to fig

5).

8. Refit the front cover.

9. Remove the bypass valve and associated fittings and connect the inlet and outlet pipe

work directly to the gas booster. NOTE: This may require the pipe work to be extended; unions must be used at the inlet and outlet to enable removal of the gas booster for serving if required (refer to diagrams on pages 15 & 16).

10. Restore water and power supplies.

Fig 1

Cold sensor

2 pin cold sensor wiring

plug disconnected

Fig 2

Comparator connected

to cold sensor wiring

Fig 3

3 pin flow sensor wiring

plug disconnected

Fig 4

Comparator connected to

flow sensor wiring

Fig 5

Comparator and wiring

secured in place

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In-series Gas Boosting 871020, 871024, 871024-B & 871026 Solar Loline Installation

Note: For 871020, 871024 & 871024-B and 871026 model heaters fitted with a comparator refer to diagram on page 15. For more information on comparators refer to page 17.

In-series Gas Boosting 871020, 871024, 871024-B & 871026 Solar Hiline Installation

Note: For 871020, 871024 & 871024-B and 871026 model heaters fitted with a comparator refer to diagram on page 15. For more information on comparators refer to page 17.

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Tempering Valves

On 871 series models where a tempering valve is fitted and there is not a separate untempered line for the kitchen or laundry areas, the Kitchen temperature controller will not be able to display temperatures above 55oC and the delivered water temperature at the tap will be that set by the tempering valve, which will be no hotter than 55oC.

To enable delivery of hot water at temperatures above 55oC a separate untempered line must be provided that supplies hot water exclusively to kitchen and laundry areas (refer to diagram below) and only where no controllers are fitted and 60°C is selected on the preset temperature adjustment.

 

Remote Controllers

The Integrity 18, 20, 24 and 26 Litre electronic continuous flow gas water heater can be fitted with optional remote controllers.

Controller

Type

Bathroom 1

Controller

Bathroom 2

Controller

Kitchen

Controller

Kitchen

Cable 20m

Bathroom

Cable 20m

Code

299854

299855

299853

299856

299857

Other manufacturers‟ controllers cannot be used.

One, two or three controllers can be installed, however if a Bathroom controller is installed without a Kitchen controller then the maximum selectable hot water temperature will be limited to 55oC when connected to an 871 series model.

When no hot water is flowing, temperatures can be selected between 37oC and 43oC by pressing and holding the temperature control buttons, to select temperatures above 43oC press the temperature control button once for each selection.

A controller must be turned on and must display the „PRIORITY‟ indicator in order to allow adjustment of water temperature.

When hot water is flowing, the temperature can be increased from 37oC to 43oC only. The water temperature can be decreased from any setting whether hot water is flowing or

not.

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Standard Controller

Note: If one or more controllers are installed, at least one must be on for the water heater to operate. If all controllers are off the water heater will only deliver cold water.

Selectable Temperatures: Kitchen Controller:

37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50, 55oC

Bathroom Controllers:

37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50oC

ON / OFF button

This button must be pressed once to turn on the controller. The light in the button will glow when the controller is on. A controller cannot be turned on if water is flowing from a hot tap. To turn off a controller, press the on / off button once. The light will go out. A controller can be turned off whilst water is flowing.

Priority light

This light will glow on a controller when that controller has priority. The Bathroom controller(s), if they are turned on, have priority over the Kitchen controller. Priority means that controller has control of the water heater temperature setting. The water temperature setting can only be adjusted by the controller that has priority.

In use light

This light will glow on all controllers, whether they are on or off, when hot water is flowing, regardless of which controller has priority.

Display panel

The current temperature setting is displayed on all controllers (whether hot water is flowing or not), when any controller is on. If all controllers are off, then the display remains blank. The water volume can also be displayed on the Kitchen controller.

The x10l symbol glows when the water volume is displayed.

Controller ON / OFF

button

Water

temperature

adjustment

buttons

Controller

display panel

(water temp or

water volume)

Controller

„priority‟ light

Controller

„In use‟ light

Water volume

button

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 (up button)

The up button increases the temperature setting.

 (down button)

The down button decreases the temperature setting.

Water volume button

(Kitchen controller only) – This feature enables an alarm to sound when a set volume of water has flowed through the water heater (refer to notes below).

Water volume notes:

The water volume function is designed to warn, by a beeping sound, that a certain

volume of water has been delivered from the water heater. It does not stop either the flow of or the heating of water.

The Kitchen controller does not require priority nor to be on in order to set the water

volume function.

The water volume function can be set whilst a hot tap is open. The water volume alarm will only sound from the kitchen controller. The factory preset water volume is 180 litres. To turn off the water volume function before the alarm sounds, press the water volume

button twice.

The water volume is measured as the water flows through the water heater. Therefore if

more than one hot tap is open, the alarm will respond to the total water volume drawn from all taps and the expected water volume from the first tap will be decreased.

If the hot tap is closed before the set water volume flows through the water heater and

the water volume button is left on, then the alarm will sound when the remaining water volume is consumed during a later operation. To prevent the alarm from sounding, press the water volume button twice to turn it off.

How to Fault Find

When conducting fault finding techniques it is important to understand that the same error code with a different sequence number can be displayed at different points during the operational sequence of the water heater. It is important to determine where the fault occurred in relationship to the operational sequence of the water heater before commencing fault finding tests, as the tests may differ even though the same error code can be displayed.

If a fault occurs the LED display will alternate between the error code for the fault and a sequence number that indicates where in the operational sequence of the water heater the fault occurred. The operational flow charts are broken into 5 sections designated by boxed numbers. The sequence number table on page 24 converts the sequence number displayed on the LED to the appropriate operational flow chart section (shown directly below where the Sequence Number falls).

The flow diagram below outlines the recommended procedure to successfully diagnose, test and rectify faults on the Integrity range of water heaters.

Identify sequence number and error

code displayed on LED.

Convert the sequence number

to an operational flow chart

section number using the

sequence number table

Locate the operational

flow chart section

identified in step 2

Locate the error code within

the operational flow chart

section identified in step 2 and

take note of where the fault

occurred during the

operational sequence.

Knowing where the fault

occurred, use the fault

diagnosis sequence chart

on Page 33 to locate the

correct fault finding flow

chart to use.

Follow the fault finding

flow chart identified in

step 5 until the error

code displayed on the

Integrity LED is located.

Conduct the necessary tests

outlined to identify and rectify

the fault.

Additional information on components, performance and past

history can be gained from the maintenance information

stored in the PCB.

About the Operational Flow Charts

The Operational Flow Charts provide information on the start up sequence and, in the event a failure occurs at any point of the start up sequence, what error code will be displayed.

When a fault occurs, an error code and sequence number will alternate in the LED display. The Sequence Number Table below indicates the section of the operational sequence (boxed numbers on the left hand side of the operational flow chart) where the fault occurred.

Sequence Number Table

Sequence Number

- 0 to -9

A0 - A9 P0 - P9

C0 - C9

E0 - E9

H0 - H9

J0 - J9

L0 - L9

U0 - U9

Operational Flow Chart Section

1 2 3 4 5

Circled numbers, adjacent to the component or function, indicate the diagnostic test point required to diagnose the fault. Refer to the table on page 29.

By locating the Error Code (displayed on the water heater or remote controller) in the diagnosis charts the component/s or fault can be quickly identified and tested using the diagnostic procedures outlined in this manual.

Notes and Abbreviations used on the Operational Flow Charts

P.G.F.R Valve

Proportional Gas Flow Regulating Valve

I.C

Integrated Circuit

G.I.S.V.

Gas Inlet solenoid Valve

S.V. 1

Solenoid Valve 1

O.H.L

Over Heat Limiter

S.V. 2

Solenoid Valve 2

C.I

Combustion Indicator

S.V. 3

Solenoid Valve 3

F.F

Flame Failure

Stepping gas rate change sequence by solenoid

Model

Step 1

Step 2

Step 3

Step 4

18/20L

S.V. 1 ON

S.V. 2 ON

S.V. 1 & 2 ON

24/26L

S.V. 1 ON

S.V. 2 ON

S.V. 1 & 2 ON

S.V. 1, 2 & 3 ON

Burner Configuration (Burner Change-Over Assembly)

Model

Burner 1

Burner 2

Burner 3

18/20L

Right Solenoid

(S.V. 1)

Left Solenoid

(S.V. 2)

24/26L

Centre Solenoid

(S.V. 1)

Left Solenoid

(S.V. 2)

Right Solenoid

(S.V. 3)

Test Equipment

A list of test equipment which will assist in conducting diagnostic procedures is provided below. This equipment is available from Rheem Service Spare Parts Department.

Flame detection simulator

WH0020080

Flame sensor current (uA) detection kit

WH0020081

Fine probe adapter kit

WH0020082

Heat exchanger fin brush

WH0020083

Probe to alligator clip kit

WH0020084

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Operational Flow Charts 1 & 2

Note: see page 24 for details on interpreting chart abbreviations.

Plug In

Power On

Operation Flow Chart

1 & 2

Initial

check

normal

Functional

problem on gas

type circuit board

Communication

problem between

remote controller

and the heater

Fan motor current

detection failure

G . I . S . V control

failure

Flashing

Error code cleared

Isolate Power

Remote controller

switched on

Remote controller

switched off

Remote controller

display off

Remote controller

display on

On / Off lamp Off

On / Off lamp On

Fan On

Fan Off

seconds later

Flashing

Over heat limiter

failure B Bath fill

operation

Water Flow Sensor

off

Hot water tap closed

Hot water tap open

Water

flow sensor

Max

Min

buttons off

YES

Flashing

seconds later

Fan On

Inlet

thermistor

? 5 31

Flashing

Heat

exchanger

thermistor

YES

Flashing

Outlet

thermistor

? 6 33

Flashing

YES

Ambient

air thermistor

YES

Flashing

Fan

speed

normal

YES

Flashing

seconds later

YES

False flame

detected

YES

Flashing

YES

seconds later

Leakage

than 0 . 1 uA

P . G . F . R Valve on

1 2 Y

Input temp

ºC or

set

temp

YES

Input temp

ºC

set temp

- 2

ºC ? YES

871024

875024

871024

875024

- B F F 1

871024-C / 871026-B

871024 / 871024-B

871018 / 871020 / 871026

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Note: see page 24 for details on interpreting chart abbreviations.

F F 1 G . I . S .

V ( SVO

)

Flashing

First

ignition

trial

Operational Flow Chart

Igniter on

P . G . F . R Valve off

S . V . 1 ( SV 1 )

on S . V .

2 ( SV 2 )

0 . 1

seconds later

14 P . G . F .

R Valve on

10 G . I . S .

V ( SVO

)

off

Igniter off

S . V

3 ( SV 3 )

off

P . G . F . R Valve off

S . V

2 ( SV 2 )

off S . V .

1 ( SV 1 )

off

C . I

Off

Flame

Detected ? Leakage

than 0 . 1 uA

seconds later

P . G . F . R Valve off

YES

G . I . S . V ( SVO

)

off S . V .

1 ( SV 1 )

off

S . V

2 ( SV 2 )

off

Igniter off

C . I

[

]

displayed

Igniter off

YES

Proportional temperature

adjustment

Gas rate change

over

done by solenoid valves

Hot water volume

adjustment

Set

temp

degrees

or lower

Solenoid bypass

valve off

YES

Low rate

combustion

Flashing

YES

Flashing

Safety

device

working

NO Z Fan motor

current

detection

failure

YES

O . H . L failure

Outlet water

temp exceeded

degrees for

more than

seconds

Flashing

Water inlet

thermistor

disconnected

Outlet water

temperature

too high

Malfunction of

water by - pass

solenoid valve

Abnormal

combustion

Heat

exchanger

thermistor

disconnected

Flame Failure

Cross light

failure

Thermistor

connections

crossed

Ambient air

thermistor

disconnected

Outlet

thermistor

disconnected

G . I . S . V control

failure

Communication

problem between

remote controller

and water heater

Abnormal fan

speed

Post purge

failure

Malfunction of

water volume

control motor

P . G . F . R

control failure

Solenoid bypass

valve o

821018, 821020, 821026, 871026-B

871024-B , 871024-C

Mechanical Bypass Models

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Hot tap closed

Operation Flow Chart

4 & 5

G . I . S . V ( SVO

)

off

or [ S . V

. 1 -

3 ( SV 1 - 3 )

off ] Flame current

detected less than

0 . 1

uA ? YES

YES

Fan

motor speed

checked during

operation

YES

Approx

minutes later

P . G . F . R Valve at

minimum

4 5 Post Purge Shut Down Function

Water flow sensor off

Check gas cut off function by

alternating the closing order of

gas valves SVO and SV

1 - 3

each shut down

Fan motor at

minimum

LED off

Fan motor at

minimum

C . I

Off S . V . 1 -

3 ( SV 1 - 3 )

failure

Flashing

seconds later

NO G . I . S .

V ( SV 0 )

failure

Flashing

G . I . S . V ( SVO

)

off

[ S . V . 1 -

3 ( SV 1 - 3 )

off

]

P . G . F . R Valve off

Fan

motor current check

ok ? Fan off

YES

Abnormal combustion

Flashing

Fan off

Isolate power

Locate and repair fault

Use procedure to

clear error code

99 S . V .

1 ( SV 1 )

off S . V .

2 ( SV 2 )

off S . V .

3 ( SV 3 )

off

Fan off

G . I . S . V ( SV 0 )

off P . G . F .

R valve off

Isolate power

Locate and repair fault

and restore power

seconds later

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Error Codes

The following table outlines the error codes, possible causes and diagnostic tests to conduct. More detailed diagnosis is outlined in the fault finding and operational flow charts.

Error

Code

Fault Condition

Items To Check

Abnormal low rate combustion

Blockage in the heat exchanger, fan, air intake or flue

Ignition failure at start up Cross light failure

P.G.F.R Valve - diagnostic point 10 G.I.S Valve - diagnostic point 11 Igniter - diagnostic point 12 Solenoid valves 1, 2 & 3 - diagnostic points 13, 14 & 15 Flame sensors 1, 2 & 3 - diagnostic points 16 &17

Flame failure during operation

P.G.F.R Valve - diagnostic point 10 G.I.S Valve - diagnostic point 11 Solenoid valves 1, 2 & 3 - diagnostic points 13, 14 & 15 Flame sensors 1, 2 & 3 - diagnostic points 16 & 17

Over heating

Over Heat Limiter - diagnostic point 2

Very high temperature

Heat exchanger thermistor - diagnostic point 6 Hot water outlet thermistor - diagnostic point 7 P.G.F.R Valve - diagnostic point 10

Outlet water temp too high

P.G.F.R Valve - diagnostic point 10

Operational switch faulty

MAX or MIN button on IC board

Inlet thermistor open circuit

Water inlet thermistor - diagnostic point 5

Heat exchanger thermistor open circuit

Heat exchanger thermistor - diagnostic point 6

Outlet thermistor open circuit

Hot water thermistor - diagnostic point 7

Ambient air thermistor open circuit

Ambient air thermistor - diagnostic point 8

Thermistor connections crossed

Connection points of thermistors

Gas cut off malfunction

G.I.S Valve - diagnostic point 11 Flame sensor 1, 2 & 3 - diagnostic points 16 & 17

P.G.F.R control failure

P.G.F.R Valve – diagnostic point 10 Gas type circuit board IC Board

Bypass solenoid failure

Water Bypass solenoid – diagnostic point 19

Abnormal fan speed

Fan motor – diagnostic point 4

Malfunction of water volume control motor

Water volume control motor - diagnostic points 18 & 19

G.I.S valve control failure

Gas. Inlet Solenoid Valve IC Board (PCB) - diagnostic point 11

Detected false flame

Flame sensors 1, 2 & 3 - diagnostic point 9

Communication problem between controller and water heater

Remote controller IC Board or cable

Fan motor current detection failure

Fan motor IC Board – diagnostic point 4

Gas cut off defective

Solenoid valve 1, 2 & 3 - diagnostic points 13, 14 & 15 Flame sensor 1, 2 & 3 - diagnostic points 16 & 17

Post purge malfunction (Solenoid valve 1 failure)

Solenoid valve 1, 2 & 3 - diagnostic points 13, 14 & 15 Flame sensor 1, 2 & 3 - diagnostic point 9

Functional problem on gas type circuit board

Gas type circuit board

Abnormal combustion

Blockage in the heat exchanger, fan, air intake or flue way

Note: see page 24 for interpretation of abbreviations.

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Diagnostic Test Points

Refer to wiring diagram, page 5, for connector and wiring positions.

Test

Point

Measuring Point

Normal Condition

Items Under Test

Connector

Wire Nº

& colour

1 A R1 – R2

AC 85V – 120V

Main Power

2 B W8 – W12

50 kilo-ohms – 500 kilo-ohms

Overheat Limiter

B BR9 – BL10 DC 2V– 5V(Pulse) *1

Water Flow Sensor pulse signal More than 1310 pulse/min

R11 – BL10

DC 7V – 15V

Water Flow Sensor

K B4 – W6

DC 120V – 170V

Fan Motor R3 – B4

DC 11V – 19V

Y1 – B4 DC 4V – 10V(Pulse) *1

Fan Motor is pulse signal More than 4800 pulse/min

5 B Y6 – BL7

@ 20ºC – 10.3 kilo-ohms

Water Inlet Thermistor @ 40ºC – 4.9 kilo-ohms

6 B W5 – BL7

@ 20ºC – 10.3 kilo-ohms

Heat Exchanger Thermistor @ 40ºC – 4.9 kilo-ohms

7 B R4 – BL7

@ 20ºC – 10.3 kilo-ohms

Hot Water Outlet Thermistor @ 40ºC – 4.9 kilo-ohms

8 B B3 – BL7

@ 25ºC – 5.0 kilo-ohms

Ambient Air Thermistor @ 5ºC – 12.7 kilo-ohms

R1 – Earth

AC 2V – 20V *2

Flame Sensor detecting flame W3 – Earth

AC 2V – 20V *2

B2 - Earth

AC 2V – 20V *2

R1 – BL2 DC 1.5V – 8.0V

Proportional Gas Flow Regulating 42 ohms – 97 ohms

Y9 – BL10 DC 70V – 110V

Gas Inlet Solenoid Valve

0.8 kilo-ohms – 2.2 kilo-ohms

R2 – R8

AC 85V – 120V

Igniter

R3 – BL10 DC 70V – 110V

Solenoid Valve 1

0.8 kilo-ohms – 2.2 kilo-ohms

W4 – BL10 DC 70V – 110V

Solenoid Valve 2

0.8 kilo-ohms – 2.2 kilo-ohms

B5 – BL10 DC 70V – 110V

Solenoid Valve 3

0.8 kilo-ohms – 2.2 kilo-ohms

R1 – Earth

AC 2V – 20V *2

Flame Sensor not detecting flame. W3 - Earth

AC 2V – 20V *2

B2 - Earth

AC 2V – 20V *2

H W2 – BL8

DC 8V – 16V

Water Volume Control Motor position switch R7 – BL8

DC 8V – 16V

GR6 – BL8 Less than DC 1V (Limiter off)

DC 4V – 6V (Limiter on)

O6 – O12

DC 70 – 110V

0.6 kilo-ohms – 2.8 kilo-ohms

Water Bypass Solenoid (models with -B or -C suffix in model number only e.g. 871024-B)

NOTES: *1: Approximate reading measured by digital multimeter on DC range. *2: Approximate reading measured by digital multimeter on AC range.

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Maintenance Information

Information relating to both the current and past operation of the water heater can be obtained from the memory; this information is referred to as the maintenance information.

The table below details the information that can be recalled from the memory i.e. to view the current temperature being measured by the outlet thermistor select 5Y, refer to page 31 for the procedure to display maintenance information.

Maintenance Table

Left digit in LED display (Numerical)

1 2 3 4 5 6 7 8 9

Right digit in LED display (Alphabetical)

Null

Error Code for the previous 8 faults

Null

Sequence number of the previous 8 faults

Null

Total combustion

starts X 10,000

Total combustion operations since last error X 10,000 hours

Null

Total combustion

starts X 100

Total combustion operations since last error X 100 hours

Null

Total combustion

period X 1000 hrs

Total combustion period since last error X 1,000 hours

Null

Total combustion

period X 10 hrs

Total combustion period since last error X 10 hours

Null

Flame sensor status (See

table below)

Water Flow Sensor

Litres / minute

Ambient Air Thermistor

temp. ºC

Water Inlet Thermistor

temp. ºC

Heat Exchanger

Thermistor temp ºC

Hot Water Outlet

Thermistor temp ºC

Fan speed X100 RPM

Power for P.G.F.R

Valve

Null

Opening angle of

Water Volume Control

motor in degrees

Fan motor current curve

(average)

Fan Motor current curve

- after tap closure

Fan Motor current curve

-present combustion

Fan Motor Current

Null

Bath fill flow volume drawn

Litres /minute X 10

Null

Sequence number

Flame Sensor Status

Model

18, 20, 24, and 26 L models

R0y Information

Flame Sensor 1

X O X O X O X O Flame Sensor 2

X X O O X X O O Flame Sensor 3

X X X X O O O

X = Flame sensor is not detecting flame. O = Flame sensor is detecting flame

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Displaying Maintenance Information

Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons.

At the Water Heater

1. Remove the front panel from the water heater.

2. Using an insulated tool, turn DIP SWITCH 1 on (refer to figure 1).

3. Use the MIN button to change the left digit (0→1etc.) in the LED display to the required maintenance code identified from the maintenance table on page 30.

4. Use the MAX button to change the right digit (E→F etc.) in the LED display to the required maintenance code identified from the maintenance table on page 30.

5. The maintenance code and the value of that code will alternate on the LED display.

6. Turn DIP SWITCH 1 off (down position) when diagnosis is complete.

7. Refit the front panel to the water heater.

NOTE: Turning on DIP SWITCH 2 will lock the display if required.

Fig 1

From a Remote Controller

1. Ensure the Remote Controller is turned off.

2. Press the temperature increase and decrease buttons simultaneously for 3 seconds

3. Use Temperature decrease button to change the left digit (0→1etc.) in the LED display to the required maintenance code identified from the maintenance table on page 30.

4. Use the Temperature increase button to change the right digit (E→F etc.) in the LED display to the required maintenance code identified from the maintenance table on page 30.

5. The maintenance code and the value of that code will alternate on the LED display of the Remote Controller.

6. Press the on/off button twice on the Remote Controller to cancel maintenance information.

Clearing Error Code History

After successfully repairing the water heater the existing Error Code history should be cleared. This will allow fresh data to be stored and reduce the risk of confusion should it be necessary to service the water heater in the future.

To clear the Error Code history:

1. Ensure all controllers (if fitted) are turned off and all hot taps are closed.

2. Remove the front panel of the water heater.

3. Turn DIP SWITCH 1 on (up position) and then off (down position) again.

4. Within 5 seconds of turning DIP SWITCH 1 off, press and hold either the MIN or MAX

button for more than 2 seconds. “CL” will flash in the LED display indicating the history

is cleared.

5. Refit the water heater front panel.

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Resetting Error Codes

Most Error Codes can be reset by shutting off the hot water flow and turning the controllers (if fitted) off and then on again. It may also be necessary to isolate and restore the power. Where controllers are not fitted it may be necessary to turn the power off at the water heater to clear the error code.

Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons.

To reset Error Code 99 it is necessary to:

1. Ensure water is not flowing through the water heater.

2. Turn off remote controllers (if fitted).

3. Ensure all DIP SWITCHES are in the off position (down position).

4. Turn DIP SWITCH 2 on (up position) and then off (down position).

5. Within 5 seconds of turning DIP SWITCH 2 off, press and hold both the MIN and MAX buttons for more than 2 seconds.

6. “UL” will flash in the LED display and then become steady.

7. Turn on a controller (if fitted) then open and close a hot water tap to complete the procedure.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Diagnosis Sequence (Fault Finding Chart G)

Turn on the

controller using the

ON/OFF button

LED

in ON/OFF

indicator

glows?

Error Code is

displayed?

YES

Open a hot water tap

Did

the burner

light?

Fan

commences

operation?

NO No error code is displayed for this fault

Close the hot water tap

Error Code is

diplayed?

End

YES

If the water heater operated normally, follow procedures 2, 3 or 5 depending on the previous error codes displayed in the maintenance history accessed from the PCB

NOTE:

If the power has been disconnected from the water heater wait 30seconds from power restoration before commencing this procedure.

Error

Code is

displayed?

YES

Error Code is

displayed?

YES

Did

ignition spark

commence?

YES

Turn on power to the

water heater

YES

Are

controllers

fitted?

YES

Are

2 bars

displayed in the

LED?

YES

Note: Bars are displayed for approx 10 seconds

If the water heater operated normally, follow flow charts 2, 3 or 5 depending on the previous error codes displayed in the maintenance history accessed from the PCB

3.5

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Chart 1

Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons.

Power Supply

Is 240

volts AC Present at

the power

point?

No power supply. Check

household wiring.

YES

Test 1

Cordset open circuit? - replace. Inline fuses open circuit – replace. Internal wiring from terminal block or transformer open circuit – repair.

YES

Test 2

Transformer failed – replace.NO

Test 3

Power filter open circuit – replace.NO

Test 4

YES

Error code

Displayed?

Remote controller failed – replace. Remote controller cable open circuit – replace.

YES

PCB failed – replace.NO

240 volts

AC Present at the

transformers primary

winding?

The transformers

output voltage 90 - 110

volts AC?

90 - 110 volts AC

Present at the

PCB?

Turn DIP

switch 1 on.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Tests 1 – 4

Components will be “Live” when conducting tests, exercise caution.

Test 1

Test 2

Measure the voltage at the connector plug to the transformer primary winding with a multimeter set on the AC voltage scale. If the voltage is between 230V and 250V the cord set and inline fuses are ok.

Measure the voltage at the connector plug from the transformer secondary winding with a multimeter set on the AC voltage scale. If the voltage is between 90V and 110V the transformer is ok.

Test 3

Test 4

Measure the voltage at connector A between R1 and R2 on the PCB with a multimeter set on the AC voltage scale. If the voltage is between 90V and 110V the power filter is ok.

Using an insulated tool, turn DIP switch 1 on

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Fault Finding Chart 2

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Fault Finding Tests 5 – 8

Isolate power before removing connector plugs

Test 5

Test 6

Unplug connector B from the PCB and measure the resistance of the Over Heat Limiter Assembly. Resistance should be between 50kilo-ohms and 500 kilo-ohms.

Unplug connector K from the PCB. Restore power and check if error code 79 is displayed within 30 seconds.

Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution

Test 7

Test 8 – Diagnostic points 5, 6, 7 & 8

Error code

Maintenance

Display

Code

Diag

Point

Test Point

Measured

Value

3y: Water

Inlet

Thermistor

6 Yellow

7 Black

20ºC –

10.3 kiloohms

40ºC –

4.9 kiloohms

4y:

Combustion

Chamber

Thermistor

5 White

7 Black

5y: Hot

Water Outlet

Thermistor

4 Red

7 Black

2y: Ambient

Air

Thermistor

3 Blue

7 Black

25ºC –

5.0 kiloohms

5ºC –

12.7 kiloohms

Use an insulated tool when operating the DIP switch or MIN and MAX buttons.

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Fault Finding Chart 3

Ignition and Temperature Control

Is error

code 24

displayed?

YES

Operation switch

malfunction

*Is error

code 31, 32, 33 or

34 displayed?

Thermistor

malfunction

Is error

code 61

displayed?

Fan speed

abnormal

YES

Test 7

Is error code 24 shown on error code display

also?

Replace the remote controller.NO

Also when

Min/Max button is

pressed?

YES

Release the Min/Max buttons and

re-open a hot tap.

YES

Replace the PCB assembly.

YES

*Is the

resistance of the

relevant thermistor

normal?

*Thermistor error codes 31 = Water inlet thermistor 32 = Heat exchanger thermistor 33 = Hot water outlet thermistor 34 = Ambient air thermistor

YES

Replace the relevant thermistor.NO

voltage being

supplied to the fan

motor?

Replace the PCB assembly.NO

Test 9

Test 8

the fan motor

rotating?

YES

Is a

pulse signal being

sent from the fan

motor?

YES

Replace the PCB assembly.YES

Test 10

3.1

Replace the fan motor assembly.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Tests 9 – 13

Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution

Tests 9 and 10 – Diagnostic Point 4

Test 11

Diagnostic Point 4

Conduct test with water flowing

Test

Check Point

Measured Value

Isolate power before removing

connector plugs

Unplug connector J from the PCB and select maintenance information 0y on the L.E.D display. If 01-07 is displayed the PCB has failed. If 00 is displayed there may be current leakage to earth

4 Blue – 6 White

DC120 -160V

3 Red – 4 Blue

DC11 -19V

1 Yellow – 4

Blue

DC4 –10V

(or measurement by

pulse counter of not

less than 4800

pulses per minute)

Test 12 - Diagnostic Point 9

Test 13 - Diagnostic Point 12

Conduct test with no water flow

Measure the voltage between terminals 1, 2 and 3 on connector J and earth. Voltage should be between AC2 – 20V

Conduct test with water flowing

When ignition sequence commences, normal voltage should be between AC 85 - 110V until flame is detected. (Note: Duration is approximately 3 seconds)

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Fault Finding Chart 3.1

Is error

code 72

displayed?

YES

False flame detection

malfunction

Ignition failure

or cross light

failure

Test 11

Is flame

detection signal in

maintenance information

00?

Replace the PCB assembly.NO

YES

Clean or replace the combustion

chamber front panel assembly.

Replace the PCB assembly.

YES

Did

the igniter

spark?

YES

voltage supplied to

the igniter?

YES

Replace the igniter assembly,

electrode or cable.

3.1

3.3

Replace the PCB assembly.

Is error

code 11

displayed?

Did

the burner

ignite?

there any voltage

at the flame

sensors?

YES

3.2

YES

Test 12

Test 13

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Fault Finding Chart 3.2

YES

Is gas available?

Test 14

Open the gas isolation valve.NO

Replace the PCB assembly.NO

Replace the proportional gas flow

regulating valve assembly.

Replace the PCB assembly.NO

Test 18

YES

Set burner pressure correctly. Replace the combustion chamber front panel assembly. Clean the burner.

YES

Test 17

3.2

Replace the proportional gas flow

regulating valve assembly.

Is the

gas pressure correct

at the burner test

point?

YES

there voltage at the

gas inlet solenoid

valve?

Is the

resistance of the gas

inlet solenoid valve

normal?

YES

Test 15

Is there

voltage at solenoid

valves 1, 2 & 3?

YES

Is there

voltage at the

proportional gas flow

regulating

valve?

Is the

resistance of the

solenoid valves 1, 2 &

3 normal?

YES

Test 19 Test 16

Is the

resistance of the

proportional gas flow

regulating valve

normal?

Replace the burner change over

assembly.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Tests 14 – 22

Isolate power when conducting resistance tests. “Live” components present

during voltage tests, exercise caution.

Tests 14, 15, 18, 19, 20 and 21

NOTE: Measure the voltage with connector L

plugged into PCB Measure the resistance with connector L

unplugged from the PCB

Test

Solenoid

Valve

Normal Voltage

Test Point

Diagnostic

Point

Test

Solenoid

Valve

Normal

Resistance

Test Point

Diagnostic

Point

GISV

DC70 to DC100V

9 Yellow 10 Black

GISV

0.8kilo-ohms

2.2kilo-ohms

9 Yellow 10 Black

3 Red

10 Black

3 Red

10 Black

4 White

10 Black

4 White

10 Black

5 Blue

10 Black

5 Blue

10 Black

Tests 16 and 17 - Diagnostic Point 10

Test 22 – Diagnostic Points 6 and 7

Test 16 – Conduct test with water flowing Measure the voltage with connector B plugged into PCB. Normal voltage is between DC1.5 and 8.0V. Test 17 – Isolate power before conducting test. Measure the resistance with connector B unplugged from the PCB. Normal resistance is between 42 ohms and 97 ohms.

Error

Code

Maintenance display code

Diagnostic

Point

Test Point

Measured

Value

4y:

Combustion

Chamber

Thermistor

5 White 7 Black

@20ºC –

10.3 kiloohms

@40ºC –

4.9 kiloohms

5y: Hot

Water Outlet

Thermistor

4 Red

7 Black

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Charts 3.3 and 3.5

Is error

code 12

displayed?

YES

Flame failure

Is error

code 35

displayed?

Is error

code 81

displayed?

Purge failure

3.3

Adjust maximum and minimum

burner pressures.

YES

Does the

flame extinguish

completely?

YES

3.5

For error code 80 or 81 replace

the burner assembly.

For error code 51 replace the

proportional gas flow regulating

valve.

Is the

flame detection

maintenance information

indicating 00?

Replace the PCB assembly.NO

YES

Test 11

Replace the combustion chamber

front panel or remove the upper

burner assembly and replace

flame sensors depending on the

model

YES

3.6

Clean the heat exchanger,

combustion chamber, fan and air intake. For error code 99 reset the PCB by following the procedure in

the section on „Error Codes‟.

YES

Are the

max and min

burner pressures

correct?

3.2

Is error

code 10 or 99

displayed?

Abnormal

combustion

YES

Is error

code 15

displayed?

*Is the

resistance of the

thermistors

correct?

Replace the relevant thermistor.

Adjust maximum and minimum

burner pressures.

YES NO

YES

*Combustion chamber

and hot water outlet

thermistors

Thermistor connections crossed. Reposition thermistor connections

correctly.

Test 22

Very high

temperature

Thermistor connection

failure

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Fault Finding Chart 3.6

Is error

code 65

displayed?

YES

Water flow

servo

malfunction

Tests 23,

24 & 25

3.6

Replace water body assembly.

3.7

Integrity temp

set below 46

degrees.

Integrity temp

set above 46

degrees.

the bypass

solenoid open

circuit?

YES

Is the

PCB supplying

power to the

solenoid?

Replace PCB assembly.

diagnostic point 18

normal?

Test 30

Note: the bypass solenoid is activated only if the set temperature is below 46 degrees.

Is the

voltage at connector

between H2 & H8 and H7

& H8 normal?

Test 31

NO NO

Replace water body assembly.

YES

Tests 23 & 24

Is the water

flow servo motor at

ON position?

YES

Isolate and

then restore

power.

Is the water

flow servo motor

functional?

Test 25

After power is restored the

water flow servo motor

limiter should move to the

fully open position

Set the hot water

temperature at 60º

and fully open a

hot water tap.

YES

*Is

maintenance

information 5y

displaying

60?

*5Y is the temperature of the

hot water outlet thermistor

YES

Is error

code 52

displayed?

Is the

resistance of the

proportional gas flow

regulating valve

normal?

YES Replace PCB assembly.YES

Test 15

Replace the proportional gas flow

regulating valve.

Mechanical bypass (models without -B or -C

suffix in model

number)

YES

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Tests 23 – 28

Test 23 - Diagnostic Point 18

Test 24 - Diagnostic Point 18

Conduct test with water flowing

Test Point

Connector H

Measured Value

Test Point

Connector H

Measured Value

2 White - 8 Black

DC8 – 16V

7 Red - 8 Black

DC8 – 16V

Components will be “Live” when conducting tests, exercise caution

Test 25 - Diagnostic Point 18

Test 28 - Diagnostic Point 3

Test Point

Connector H

Measured Value

Conduct test with water flowing

Measure the voltage between 11 Red and 10 Black on connector B. Voltage should be between DC7 – 15V

6 Green - 8 Black

On position < DC1V Off position DC4 – 6V

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Chart 3.7

3 . 7

Is error

code

displayed

Is the

Integrity inlet

water temp

ºC

YES

Is a

solar bypass valve

fitted

YES

Faulty solar bypass valve

Remove solar bypass valve

and fit a comparator

YES

Is a

Comparator

fitted

Replace the comparator

YES

Replace the PCB assembly

Is the

Integrity used as

an in

series gas

Booster

YES

Fit a comparator

the heater an

871024

- model

Is the

Integrity outlet temp

set at

ºC ?

Set the Integrity

outlet temp to

ºC

YES

Error code

will occur if the

Integrity heats the water to

above the set point

ºC

60 + 20 - 3 = 77

ºC

YES

Is the

resistance of the

proportional gas flow

regulating valve

normal

Replace the proportional gas flow

regulating valve

YES

Is error

code

displayed

Replace the PCB assembly

YES

Replace the water body

assembly

YES

3 . 8

Test

Is the

PCB supplying

power to the

solenoid

Note

the bypass solenoid is activated only

if the set temperature is below

degrees

Outlet water

temp too high

Malfunction of

water bypass

solenoid

Mechanic

al Bypass

model

871024-B

871024-C

871026

871026-B

Is the heater an

871024-C or

871026 model?

*871018, 871020

871024, 871024-B

871026

model heaters are

unsuitable for use as

in-series gas boosters

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Chart 3.8

Fan current detecting

circuit failure

3.8

Replace the PCB assembly.

Note: only replace the PCB

assembly if error code 79 is

displayed during combustion.

Was

Error code 79

displayed prior to

opening the hot

tap?

YES

Error code

79 displayed.

Fault Finding Tests 29 – 31

Test 29 - Diagnostic Point 3

Components will be “Live” when conducting

tests, exercise caution

Conduct test with water flowing

Measure the voltage between 9 Brown and 10 Black on connector B.

Voltage should be between DC2 – 5V

Test 30 and 31 - Diagnostic Point 19

Test 30

Isolate power when conducting resistance

test.

Unplug connector L from the PCB and measure the resistance between 6 Orange and 12 Orange.

Resistance should be between

0.6kilo-ohms and 2.8kilo-ohms.

Test 31

Components will be “Live” when conducting

tests, exercise caution

Conduct test with water flowing

Measure the voltage between 6 Orange and 12 Orange on connector L.

Voltage should be between DC70 – 110V

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Fault Finding Charts 4 and 4.1

1y = Water flow

detected by water

flow sensor

Test 28

Is the

Integrity used as

an in-series gas

booster?

Is the water

flow more than 3

litres/min?

Read

maintenance

information 1y

YES

Is the

voltage between

connector B10 & 11

normal?

Replace the PCB assembly.NO

Is the

voltage between

connector B9 & 10

normal?

YES

Replace the water flow sensor. If

the fault persists replace the

water body assembly.

Are

Controllers

fitted?

YES

Controllers must not be

fitted when an Integrity is used as an in-series

gas booster. Remove

controllers.

YES

Test 29

Is a

solar bypass valve

fitted?

871024-C models do not require a

solar bypass valve. Remove the

solar bypass valve and remake

water connections directly to

Integrity.

YES

871024-C

Water will flow straight through

the Integrity and the Integrity will

not operate. Normal operation.

Is the

water entering

the Integrity < or = 58ºC or

< or = the set temp

- 2ºC?

4.1

YES

4.1

Read

maintenance

information 3y

3y = Water temp

detected by water

inlet thermistor

871024 or 871024-B

875024-B or 875024-C

875024-B & 875024-C models are

not suitable for use as in-series

gas boosters.

4.2

What is the

model

number?

Is the

flow sensor turbine

jammed?

Test 33

Free the flow sensor turbine.YES

18L Model

18L Model is not suitable for use as in-series gas boosters

871024, 871024-B or 871020

871024-C or 871026-B

871026-B & 871024-C models do not require a solar bypass valve. Remove the solar bypass valve and remake water connections directly to Integrity

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Fault Finding Chart 4.2

4.2

YES

Is a

comparator

fitted?

Is a

solar bypass valve

fitted?

871024 & 871024-B models must have a solar bypass valve or a comparator fitted

when used as an in-series gas booster. If

a solar bypass valve and a comparator

are fitted, remove the solar bypass valve.

If neither is fitted fit a comparator.

Is a

comparator

fitted?

YES

4.3

YES

Read

maintenance

information 3y

3y = Water temp

detected by water

inlet thermistor

Is the

water entering

the Integrity

> 57ºC?

YES

Water will flow straight through

the Integrity and the Integrity will

not operate. Normal operation.

Is the water

flow more than 3

litres/min?

Replace the PCB assembly.

YES

Is the

voltage between

connector B10 & 11

normal?

Test 28

Is the

voltage between

connector B9 & 10

normal?

YES

Test 29

YES

Is the

water flow sensor

working?

Test 32

Replace the water flow sensor. If

the fault persists replace the

water body assembly.

Replace the comparator.

YES

Read

maintenance

information 1y

1y = Water flow

detected by water

flow sensor

Is the

flow sensor turbine

jammed?

Free the flow sensor turbine.YES

Test 33

871020 & 871026, 871024 & 871024-B models must have a solar bypass valve or a comparator fitted when used as an inseries gas booster. If a solar bypass valve and a comparator are fitted, remove the solar bypass valve. If neither is fitted, fit a comparator

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Fault Finding Chart 4.3

4.3

Replace the PCB assembly.

Is the

voltage between

connector B10 & 11

normal?

Test 28

Is the

voltage between

connector B9 & 10

normal?

YES

Test 29

YES

the preheated

water to the solar

bypass valve >

57ºC?

Read

maintenance

information 1y

1y = Water flow

detected by water

flow sensor

Water will be diverted by the

solar bypass valve. No water will

flow through the Integrity

therefore it will not operate.

Normal operation.

YES

Is the water

flow more than 3

litres/min?

Is water

flowing through the

solar bypass valve to the

Integrity water

inlet?

Remove the solar bypass valve

and fit a comparator.

YES

Replace the PCB assembly.YES

Replace the water flow sensor. If

the fault persists replace the

water body assembly.

Is the

flow sensor turbine

jammed?

Free the flow sensor turbine.

Test 33

YES

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Fault Finding Chart 5 Fault Finding Tests 32 and 33

Test 32

Components will be “Live” when

conducting test, exercise caution

Conduct test with water flowing

Measure the voltage at the 3 pin connector located between the water flow sensor and the comparator. Measure the voltage between the brown and black wires at this connector.

Voltage should be between DC2 – 5V.

Test 33

Remove flow sensor turbine by following component replacement procedure 21 on page

58. The flow sensor turbine should spin freely.

Check for wear or blockage by foreign material such as thread tape.

Burner Gas Pressure Check

Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons.

Minimum Burner Gas Pressure

1. Remove the front panel from the water heater.

2. Remove burner test point screw and fit manometer.

3. Turn on the remote controller (If fitted).

4. Open a hot tap slowly, to achieve the minimum flow rate at which the burners will ignite.

5. Press and hold the MIN button (“1L” is displayed on the LED) and observe the reading on the manometer.

6. Release the MIN button. If the reading observed in step 5 agrees with the rating label, no further adjustment is required.

Maximum Burner Gas Pressure

7. Open the hot tap fully to achieve maximum flow rate.

8. Press and hold the MAX button (“4H” is displayed on the LED) and observe the reading on the manometer.

9. Release the MAX button. If the reading observed in step 8 agrees with the rating label, no further adjustment is required.

10. Turn the hot tap off.

11. Remove manometer and refit the burner test point screw ensuring the seal is gas tight.

12. Refit the front panel to the water heater.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Adjustment

Adjustment of the burner pressure will not overcome problems associated with poor supply pressure or incorrect gas supply pipe sizing.

Minimum Burner Gas Pressure

1. Remove the front panel from the water heater.

2. Remove burner test point screw and fit manometer.

3. Turn on the remote controller (If fitted).

4. Open a hot tap slowly, to achieve the minimum flow rate at which the burners will ignite.

5. Press and hold the adjuster button (“LH” is displayed on the LED) NOTE: The adjuster button must be held down continuously through steps 5 and 6.

6. Press the MIN button and observe the reading on the manometer. NOTE: While the MIN button is pressed, the gas pressure will at first increase then

decrease, cycling between an upper gas pressure limit (39 on LED display) and a lower gas pressure limit (01 on LED display).

7. Release the MIN and adjuster buttons when the minimum test point pressure shown on the manometer agrees with the rating label.

NOTE: If the burners extinguish or an error code starts to flash on the LED display during this procedure, release the MIN and adjuster buttons close the hot tap, clear the error code, turn on the water heater and recommence the procedure from step 3. To reset an error code, follow the procedure on page 32.

Maximum Burner Gas Pressure

8. Open the hot tap fully to achieve maximum flow rate.

9. Press and hold the adjuster button (“LH” is displayed on the LED). NOTE: The adjuster button must be held down continuously through steps 10 and 11.

10. Press the MAX button and observe the reading on the manometer. NOTE: While the MAX button is pressed, the gas pressure will at first increase then

decrease, cycling between an upper gas pressure limit (39 on LED display) and a lower gas pressure limit (01 on LED display).

11. Release the MAX and adjuster buttons when the maximum test point pressure shown on the manometer agrees with the rating label.

12. Turn the hot tap off, remove manometer and refit the burner test point screw ensuring the seal is gas tight.

13. Refit the front panel to the water heater.

Component Replacement Procedures

Front Panel Removal: (Procedure 1)

1. Isolate power, gas and water supplies.

2. Remove four screws, two from the top and two from the bottom of the front panel.

3. Remove the front panel.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Burner Change-Over Assembly: (Procedure 2)

1. Remove the front panel. Refer to Procedure 1.

2. Disconnect the wiring plug from each of the solenoid valves. (Note which plug goes

to each valve)

3. Remove the screw retaining the ignition pack to the Burner Change Over Assembly.

4. Remove the six screws retaining the Burner Change Over Assembly. Four from the

Combustion Chamber Front Panel and two from the Proportional Gas Flow Regulating Valve Assembly.

5. Remove the Burner Change Over Assembly.

6. Reassemble in reverse order of above. Replace gaskets (item numbers 105 and 108) if

required.

7. Test for gas leaks using soapy water solution

Combustion Chamber Front Panel Assembly: (Procedure 3)

1. Remove the front panel and Burner Change Over Assembly. Refer to Procedures 1 and 2.

2. Remove screws (14 off) retaining the Combustion Chamber Front Panel (12 screws around perimeter and 2 screws in centre).

3. Gently remove the Combustion Chamber Front Panel Assembly.

4. Reassemble in reverse order of above. Replace gaskets (item numbers 105 and 108) if required.

5. Test for gas leaks using soapy water solution.

Lower Burner Assembly: (Procedure 4)

1. Remove the front panel, Burner Change Over Assembly and Combustion Chamber Front Panel Assembly. Refer to Procedures 1, 2 and 3.

2. Remove the 2 screws retaining the Lower Burner Assembly.

3. Reassemble in reverse order of above. Replace gaskets (item numbers 105 and 108) if required.

4. Test for gas leaks using soapy water solution.

Upper Burner Assembly: (Procedure 5)

1. Remove the front panel, Burner Change Over Assembly, Combustion Chamber Front Panel Assembly and Lower Burner Assembly. Refer to Procedures 1, 2, 3 and 4.

2. Remove the Upper Burner Assembly by sliding forward out of the heat exchanger assembly.

3. Reassemble in reverse order of above being careful not to pinch or damage wiring. Replace gaskets (item numbers 105 and 108) if required.

4. Test for gas leaks using soapy water solution.

PCB Assembly: (Procedure 6)

1. Remove the front panel. Refer to Procedure 1.

2. Remove the screw retaining the PCB Assembly in the water heater.

3. Carefully remove the PCB Assembly complete.

4. Disconnect the multi-pin connectors from the PCB Assembly.

5. Remove the Gas Type Connector IC board and fit to replacement PCB Assembly.

6. Reassemble in reverse order of above.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Proportional Gas Flow Regulating Valve: (Procedure 7)

1. Remove the front panel and Burner Change Over Assembly. Refer to Procedures 1

and 2.

2. Disconnect the gas supply pipe from the gas inlet connection.

3. Remove the three screws from the gas inlet connector and withdraw the connector and

o-ring from the base of the water heater.

4. Carefully remove the Proportional Gas Flow Regulating Valve from the water heater.

5. Disconnect the multi-pin wiring plug from the Gas Inlet Solenoid Valve and the red and

black wires from the proportioning valve. Note: The proportional valve terminals are marked + for red and – for black.

6. Reassemble in reverse order of above. Replace gaskets (item numbers 105 and 108) if

required.

7. Test for gas leaks with soapy water solution.

Water Body Assembly: (Procedure 8)

Do not attempt to dismantle the servomotor, this is factory calibrated. Adjustments will render the water heater either inoperable or cause incorrect water temperature delivery.

1. Remove the front panel, Burner Change Over Assembly and Proportional Gas Flow Regulating Valve. Refer to Procedures 1, 2 and 6.

2. Disconnect the cold water supply pipe from the cold-water inlet connection.

3. Unscrew the water drain plug (item 405) and relief valve (item 431) and drain the water heater.

4. Remove the screw/s from the flange (item 419) and remove.

5. Carefully disengage the two pipes from the Water Body Assembly.

6. Disconnect the wiring to the bypass solenoid.

7. Remove the four screws from the cold water inlet connector and withdraw the connector and o-ring from the base of the water heater.

8. Carefully remove the Water Body Assembly from the water heater.

9. Disconnect the multi-pin connectors from the motor, flow sensor and cold water thermistor.

10. Remove the retaining screw from the anti-frost heater and remove. (If fitted)

11. Reassemble in reverse order of above, replacing pipe o‟rings (item 427) if required.

12. Test for gas and water leaks.

Combustion Fan Motor: (Procedure 9)

1. Remove the front panel. Refer to Procedure 1.

2. Remove the screw retaining the Cord Connector, item 008.

3. Remove the screw retaining the Terminal Block Assembly, item 768.

4. Remove the screws retaining the mounting bracket for the transformer and the power filter to the Fan Motor Assembly and reposition the transformer and power filter temporarily.

5. Remove the remaining screw retaining the Fan Motor Assembly and lift the Fan Motor clear.

6. Disconnect the multi-pin wiring plug from the Fan Motor.

7. Reassemble in reverse order of above.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Anti-Frost Heaters: (Procedure 10)

Note: Only models with an „F‟ in the model number are fitted with anti-frost heaters e.g. 871024NF.

1. Remove the front panel. Refer to Procedure 1.

Heat Exchanger and Hot Water Outlet Connection Heaters

1. Disconnect connector plugs at the sensing thermostat and at the power cord.

2. Remove Flange (item 445) to release the Hot Water Outlet Anti-frost Heater.

3. Unclip the 2 anti-frost heaters from the heat exchanger (Note the positions of both).

4. Remove the Anti-frost Heaters and wiring (Some wiring retainers will need to be released to remove wiring).

5. Reassemble in reverse of above ensuring anti-frost heaters are fitted in correct positions.

Water Body Assembly Heater

1. Disconnect connector plugs at the cord set and at the sensing thermostat.

2. Remove the Water Body Assembly (item 410). Refer to Procedure 7.

3. Remove the Anti-frost Heater retaining clip.

4. Remove the Anti-frost Heater and wiring (Some wiring retainers will need to be

released to remove wiring).

5. Reassemble in reverse order of above.

Heat Exchanger Removal/Replacement: (Procedure 11)

1. Follow the steps in Procedure 5, Upper Burner Assembly.

2. Remove the screw/s from the Water Body Assembly flange (item 419) and remove.

3. Carefully disengage the two pipes from the Water Body Assembly.

4. Remove the two screws from the hot water outlet flange (item 445) retaining the hot

water outlet pipe and carefully disengage the pipe.

5. Undo the 2 screws retaining the heat exchanger thermistor and remove the thermistor.

6. Disconnect the wiring loom connector at the thermostat (item 714) and the hot water

outlet heater (item 705).

7. Remove 5 screws retaining the heat exchanger assembly. One from each side of the

heat exchanger, two screws from the bracket above the flue outlet and one screw from the fan case assembly (item 729).

8. Remove two screws retaining the bracket (above the flue terminal) and remove the

bracket. (Note: The bracket is glued in place; a small amount of force is required to remove it).

9. Remove Heat Exchanger Assembly by gently moving the top forward out of the water

heater then lift the assembly up and clear.

10. Disconnect the multi-pin wiring plug from the Fan Motor to completely free Heat

Exchanger Assembly from water heater.

11. Remove the Anti-Frost Heaters (if fitted) and the Fan Motor and Cowling Assembly

from the old Heat Exchanger and refit to the replacement Heat Exchanger Assembly.

12. Replace the Over Heat Limiter if damaged or open circuit.

13. Reassemble in reverse order of above.

14. Test for gas leaks using soapy water solution

15. Check for water leaks.

16. Check and if necessary adjust MIN and MAX burner gas pressures. Refer to Procedure

on page 52.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Ignition Pack Replacement: (Procedure 12) 18 - 20 Litre

1. Remove the front panel, Refer to Procedure 1.

2. Disconnect high voltage lead from spark electrode.

3. Disconnect the multi pin connector from the Ignition Pack.

4. Remove the retaining screw.

5. Remove the Ignition Pack.

6. Reassemble in reverse order of above. Test for gas leaks using soapy water solution.

Ignition Pack Replacement: (Procedure 12A) 24 - 26 Litre

1. Remove the front panel, Burner Change Over Assembly, Combustion Chamber Front Panel Assembly, Lower Burner Assembly and Upper Burner Assembly. Refer to Procedures 1, 2, 3, 4 and 5.

2. Disconnect high voltage lead from spark electrode.

3. Disconnect the multi pin connector from the Ignition Pack.

4. Remove the retaining screw.

5. Remove the Ignition Pack.

6. Reassemble in reverse order of above being careful not to pinch or damage wiring when replacing Upper Burner Assembly. Replace gaskets (item numbers 105 and 108) if required.

7. Test for gas leaks using soapy water solution.

Flow Sensor: (Procedure 13)

Note: When a flow sensor is installed as a spare part in any model heater other interconnecting components may also require replacing. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

1. Isolate cold water supply.

2. Remove the front panel. Refer to Procedure 1.

3. Disconnect the multi-pin plug to the flow sensor.

4. Remove 2 Philips head retaining screws.

5. Remove Flow Sensor (Note: Water may escape during this procedure).

6. Reassemble in reverse order of above.

Bypass Solenoid: (Procedure 14)

Note: Models with a –B or –C suffix are fitted with a bypass solenoid. For models without a suffix, compare the appliance to the wiring diagrams on pages 6 and 7 to determine whether it has a mechanical or solenoid bypass.

The bypass solenoid is only available as part of the water body assembly, follow procedure 7.

Thermistors: (Procedure 15)

Note: When a thermistor(s) is installed as a spare part in any model heater other interconnecting components may also require replacing. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

1. Remove the front Panel. Refer to Procedure 1.

2. Relieve water pressure through a hot tap.

3. Locate the Thermistor requiring replacement.

4. Disconnect the multi-pin plug from the Thermistor.

5. Remove the retaining screws and withdraw the thermistor taking care not to damage

the o‟ring (Note: With the exception of the Ambient Air Thermistor, water may escape during this procedure).

6. Reassemble in reverse order of above.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Over Heat Limiter Assembly: (Procedure 15)

Note: When an over heat limiter is installed as a spare part in any model heater other interconnecting components may also require replacing. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

Replacement of the Over Heat Limiter requires removal and possible replacement of the Heat Exchanger.

1. Follow Procedure 11 to step 10.

2. Disconnect the multi-pin plug to the Over Heat Limiter Assembly.

3. Remove the screws retaining the Over Heat Limiter Assembly to the Jacket back and

remove the Over Heat Limiter Assembly.

4. Inspect the heat exchanger for holes or combustion damage.

5. Reassemble in reverse order of above (Note: Ensure all multi-pin plugs are

reconnected and all wiring is neatly repositioned and retained to prevent damage during operation).

6. Test operation of water heater and ensure the MIN and MAX burner gas pressures are

correct. Refer to Procedure on page 52.

Remote Controller: (Procedure 16)

1. Isolate power at the water heater.

2. Remove the small Philips head screw from the bottom of the Remote Controller.

3. Gently pivot the Remote Controller up from the bottom and then lift up and off upper

retaining lugs.

4. Kitchen Controller: Disconnect the wiring from the terminals on the back of the

Controller (Note: The wiring is not polarity sensitive). Bathroom Controllers: Disconnect the multi-pin plug.

5. Reassemble in reverse order of above.

Gas Type Circuit Board: (Procedure 17)

1. Remove the front panel. Refer to Procedure 1.

2. Gently unplug the Gas Type Circuit Board from the PCB.

3. Reassemble in reverse order of above.

4. Restore power.

5. Press the MAX button. On all 871024 & 871026 models 4H should be displayed. On all

871018 & 871020 models 3H should be displayed

6. Test operation of water heater and ensure the MIN and MAX burner gas pressures are

correct. Refer to Procedure on page 52.

Transformer: (Procedure 18)

Note: When a transformer is installed as a spare part in an 871024, 871024-B or 871026 model heater other interconnecting components will also require replacing. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

1. Remove the front panel. Refer to Procedure 1.

2. Disconnect the primary and secondary winding multi-pin plugs to the Transformer.

3. Remove the 2 Philips head screws retaining the Transformer.

4. Reassemble in reverse order of above.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Power Filter: (Procedure 19)

Note: When a power filter is installed as a spare part in an 871024, 871024-B model

heater other interconnecting components will also require replacing. Refer to „Product

Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more

information.

1. Remove the front panel. Refer to Procedure 1.

2. Disconnect the incoming and outgoing wiring loom plugs.

3. Remove the 2 Philips head screws retaining the filter to the mounting bracket.

4. Remove the Power Filter.

5. Reassemble in reverse order of above.

Solar Bypass Valve: (Procedure 20)

Solar bypass valves are no longer available and if faulty are to be removed and a Comparator installed. Refer to page 18 for the procedure on installing a comparator. NOTE: 20L and 26 L models with a –B suffix and 24L models with a -C suffix in the model number do not require either a bypass valve or a comparator.

Flow Sensor Turbine: (Procedure 21)

1. Isolate cold water supply.

2. Remove the front panel. Refer to Procedure 1.

3. Unscrew the water drain plug (item 405) and relief valve (item 431) and drain the water

heater.

4. Disconnect the cold water supply pipe from the cold-water inlet connection.

5. Disconnect the bypass solenoid wiring loom plug.

6. Remove 2 Philips head retaining screws holding flow sensor to water body assembly

and remove flow sensor.

7. Using a flat bladed screwdriver lever the metal disc and o‟ring from flow sensor housing

on water body assembly. Lever the disc out by placing the shaft of the screwdriver across the disc with the tip of the screwdriver on the far inside edge of the disc.

8. Remove the four screws from the cold water inlet connector and withdraw the

connector and o‟ring from the base of the water heater.

9. Gently withdraw flow sensor turbine out from water inlet of water body assembly using

a pair of long nose pliers.

10. Reassemble in reverse order of above ensuring open slot on turbine is centred and

facing towards the face of the flow sensor.

Power cord: (Procedure 22) Note: When a power cord is installed as a spare part in any model heater other

interconnecting components may also require replacing. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

1. Switch off power at power point and unplug power cord from power point.

2. Unscrew screw on power inlet cover and remove power inlet cover.

3. Undo cord clamp screw located next to power filter and remove clamp.

4. Disconnect the power cable wiring loom plug and withdraw power cable through slot in

heater jacket.

5. Reassemble in reverse order of above.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Connecting cord: (Procedure 23) Note: When a connecting cord is installed as a spare part in any model heater other

interconnecting components may also require replacing. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

1. Isolate power at the water heater.

2. Disconnect connecting cord wiring loom plug to power cord.

3. Disconnect remaining two connecting cord wiring loom plugs and remove connecting

cord.

4. Reassemble in reverse order of above.

Nozzle Plate - NG appliances only: (Procedure 24)

1. Remove the front panel, Burner Change Over Assembly, Combustion Chamber Front

Panel Assembly and Lower Burner Assembly. Refer to Procedures 1, 2, 3 & 4.

2. Remove the three screws retaining the nozzle plate and remove nozzle plate.

3. Reassemble in reverse order of above. Replace gaskets (item numbers 105 and 108) if

required.

4. Test for gas leaks using soapy water solution.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Exploded View 1 871018 / 871020 / 871024

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 1 871018 / 871020 / 871024 Replacement Parts List

Ref.

No.

Description

871018 871020

871024

001

Front Panel Assembly

WH0020000

003

Jacket Assembly

WH0020001

004

Mounting Bracket

WH0020002

006

Reinforcing Plate

WH0020003

008

Cord Connector

WH0020004

066

Fixing Plate B

WH0020005

100

Gas Inlet Connector

WH0020006

103

Proportional Gas Flow Regulating Valve

WH0020007

104

„O‟ ring

WH0020009

105

Gasket

WH0020010

108

Gasket

WH0020012

111

Upper Burner Assembly

WH0020013

WH0020014

120

Lower Burner Assembly - NG

WH0020015

WH0020016

120

Lower Burner Assembly - LP

WH0020017

WH0020018

123

Primary Air Adjuster

WH0020085

160

Burner Change-Over Assembly

WH0020019

WH0020020

401

Water Inlet Connector Assembly (¾)

WH0020021

Water Inlet Connector Assembly (½) - 18 litre only

WH0020086

402

„O‟ ring

WH0020022

403

CS Type Snap Ring

WH0020023

405

Water Drain Valve Assembly (includes water filter)

WH0020024

407

Water Filter – use WH0020024

N/A

408

Plug Band

WH0020026

409

„O‟ ring

WH0020027

410

Water Body Assembly

WH0020028

415

Heat Exchanger and Combustion Chamber Kit

WH0020029

WH0020030

419

Flange

WH0020031

422

Combustion Chamber Front Panel Assembly

WH0020032

WH0020033

427

„O‟ ring

WH0020034

429

„O‟ ring

WH0020035

430

Hot water Outlet Connector (¾)

WH0020036

Hot water Outlet Connector (½) – 18 litre only

WH0020087

431

Relief Valve Assembly

WH0020037

433

„O‟ ring

WH0020038

434

Safety Valve Band

WH0020039

445

Flange

WH0020040

701

Over Heat Limiter Assembly

WH0020042

768

Terminal Block Assembly

WH0020043

828

Truss Gasket Screw 4 x 10

WH0020044

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Exploded View 2 871018 / 871020 / 871024

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 2 871018 / 871020 / 871024 Replacement Parts List

Ref.

No.

Description

871018 871020

871024

133

Silicone Tube (Insulator)

WH0020045

134

Silicone Tube (Insulator)

WH0020046

705

Anti-Frost Heater

WH0020047

WH0020008

706

Anti-Frost Heater Assembly

WH0020088

WH0020048

708

Anti-Frost Heater Clamp

WH0020049

710

Anti-Frost Heater “C” Clamp

WH0020050

711

Anti-Frost Heater Clamp

WH0020051

712

Ambient Air Temp Thermistor Assy

WH0020052

713

Inlet and Heat exchanger Thermistor

WH0020053

714

Thermostat Assembly

WH0020054

715

Outlet Thermistor

WH0020181

716

„O‟ ring – Thermistor

WH0020055

723

Hall Effect I.C. Assembly

WH0020056

728

Combustion Fan

WH0020057

729

Fan Case Assembly

WH0020058

735

Ignition Pack

WH0020059

737

Flame Sensor Loom

WH0020060

WH0020061

745

PCB Assembly

WH0020062

751

Gas Type Connector - NG

WH0020064

WH0020063

751

Gas Type Connector - LP

WH0020065

WH0020078

757

100 volt loom

WH0020089

WH0020066

758

Signal Loom

WH0020067

768

Terminal Block Assembly

WH0020068

771

Not Fitted (Australian Models)

N/F

773

Not Fitted (Australian Models)

N/F

775

Fuse - In line Note: PCB fuses not fitted

WH0020069

779

Power Filter

WH0020079

780

Power Cord With Clamp

WH0020071

781

Clamp – Power Cord

WH0020072

783

240-110 Volt Transformer Assembly

WH0020073

784

Not Fitted (Australian Models)

N/F

Gas Conversion Kit - LP to NG

WH0020074

WH0020075

Gas Conversion Kit - NG to LP

WH0020076

WH0020077

Kitchen Controller

299853

Bathroom 1 Controller

299854

Bathroom 2 Controller

299855

Kitchen Controller Cable (20 metres)

299856

Bathroom Controller Cable (20 metres)

299857

* - Not Illustrated

Test Equipment

Flame detection simulator

WH0020080

Flame sensor current (uA) detection kit

WH0020081

Fine probe adapter kit

WH0020082

Heat exchanger fin brush

WH0020083

Probe to alligator clip kit

WH0020084

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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Exploded View 1 - 871024 Model

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 1 Replacement Parts List – 871024 Models

Ref. No.

Description

871024

001

Front Panel Assembly

31-76496-00

003

Jacket Assembly

31-23525-00

004

Mounting Bracket

WH0020002

006

Reinforcing Plate

WH0020003

008

Cord Connector

WH0020004

066

Fixing Plate B

WH0020005

100

Gas Inlet Connector ¾”

31-76255-00

103

Proportional Gas Flow Regulating Valve

WH0020007

104

O‟ring

WH0020009

105

Gasket

WH0020010

108

Gasket

WH0020012

111

Upper Burner Assembly

WH0020014

120

Lower Burner Assembly – NG

WH0020016

120

Lower Burner Assembly – LP

WH0020018

160

Burner Change-Over Assembly

WH0020020

401

Water Inlet Connector Assembly (¾)

10-65408-00

402

O‟ring

WH0020022

403

CS Type Snap Ring

WH0020023

405

Water Drain Valve Assembly (includes water filter)

WH0020024

407

Water Filter

21-14774-00

408

Plug Band

21-35376-00

409

O‟ring

WH0020027

410

Water Body Assembly

WH0020028

415

Heat Exchanger and Combustion Chamber Kit

WH0020030

419

Flange

WH0020031

422

Combustion Chamber Front Panel Assembly

WH0020033

427

O‟ring

WH0020034

429

O‟ring

WH0020035

430

Hot water Outlet Connector (¾)

31-20192-00

431

Relief Valve Assembly

04-04764-00

433

O‟ring

WH0020038

434

Safety Valve Band

WH0020039

445

Flange

WH0020040

701

Over Heat Limiter Assembly

*31-79562-00

768

Terminal Block Assembly

WH0020043

828

Truss Gasket Screw 4 x 10

09-14144-00

*When installed in an 871024, 871024-B or 871024-C model heater these parts will require the

replacement of other interconnecting components. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 2 – 871024 Models

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 2 Replacement Parts List – 871024 Models

Ref. No.

Description

871024

133

Silicone Tube (Insulator)

20-43376-00

134

Silicone Tube (Insulator)

20-43376-00

705

Anti-Frost Heater (Heater A) (Anti-frost models only)

31-71644-00

706

Anti-Frost Heater (heater B) (Anti-frost models only)

37-71643-00

708

Anti-Frost Heater Clamp (Anti-frost models only)

WH0020049

710

Anti-Frost Heater “C” Clamp (Anti-frost models only)

WH0020050

711

Anti-Frost Heater Clamp (Anti-frost models only)

WH0020051

712

Ambient Air Temp Thermistor Assy

N/A use *37-76655-00

713

Outlet Thermistor (Thermistor B)

*20-64774-00

714

Anti-frost Thermostat Assembly (Anti-frost models only)

20-57072-00

715

Heat Exchanger (HX) Thermistor

N/A use *31-76655-00

716

O‟ring – Thermistor

WH0020055

723

Hall Effect I.C. Assembly

*20-43805-00

728

Combustion Fan

WH0020057

729

Fan Case Assembly

10-88629-00

735

Ignition Pack

31-76722-00

737

Flame Sensor Loom

31-76721-00

745

PCB Assembly

31-76623-0S

751

Gas Type Connector – NG

WH0020063

Gas Type Connector – LP

WH0020078

757

100 volt loom

31-76653-00

758

Signal Loom (inc amb air & HX thermistor)

*31-76655-00

768

Terminal Block Assembly

WH0020068

771

Noise filter holder assembly

31-23360-00

773

Power filter

*31-71642-00

775

Fuse - In line Note: PCB fuses not fitted

WH0020069

780

Power Cord With Clamp

*31-76652-00

781

Clamp – Power Cord

WH0020072

783

240 -110 Volt Transformer Assembly

*31-71646-00

784

Connecting cord

*31-71641-00

Not Shown

Gas Conversion Kit - LP to NG

WH0020075

Not Shown

Gas Conversion Kit - NG to LP

WH0020077

*When installed in an 871024, 871024-B or 871024-C model heater these parts will require the

replacement of other interconnecting components. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

Note: For controller and controller cable part numbers refer to page 20

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 3 - 871024-B Model

Fitted with solenoid operated bypass

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 3 Replacement Parts List - 871024-B Model

Fitted with solenoid operated bypass

Ref.

No.

Description

871024-B

001

Front Panel Rheem Brand (50 & 60ºC Models)

31-76496-00

Front Panel Everhot Brand (50 & 60ºC Models)

31-76498-00

003

Jacket Assembly

31-23525-00

004

Mounting Bracket

WH0020002

006

Reinforcing Plate

WH0020003

008

Cord Connector

WH0020004

066

Fixing Plate B

WH0020005

100

Gas Inlet Connector ¾”

31-76255-00

103

Proportional Gas Flow Regulating Valve

WH0020176

104

O-ring

WH0020009

105

Gasket

WH0020010

108

Gasket

WH0020012

111

Upper Burner Assembly

WH0020014

120

Lower Burner Assembly – NG

WH0020016

120

Lower Burner Assembly – LP

WH0020018

160

Burner Change-Over Assy (Including solenoids)

WH0020020

401

Water Inlet Connector Assembly (¾)

10-65408-00

402

O-ring

WH0020022

403

CS Type Snap Ring

WH0020023

405

Water Drain Valve Assy (includes water filter)

WH0020024

407

Water Filter

21-14774-00

408

Plug Band

21-35376-00

409

O-ring

WH0020027

410

Water Body Assembly including solenoid bypass

WH0020177

415

Heat Exchanger and Combustion Chamber Kit

WH0020179

419

Flange

WH0020031

422

Combustion Chamber Front Panel Assembly

WH0020033

427

O-ring

WH0020034

429

O-ring

WH0020035

430

Hot water Outlet Connector (¾)

31-20192-00

431

Relief Valve Assembly

04-04764-00

433

O-ring

WH0020038

434

Safety Valve Band

WH0020039

445

Flange

WH0020040

701

Over Heat Limiter Assembly

*31-79562-00

768

Terminal Block Assembly

WH0020043

828

Truss Gasket Screw 4 x 10

09-14144-00

*When installed in an 871024, 871024-B or 871024-C model heater these parts will require the

replacement of other interconnecting components. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 4 - 871024-B Model

Fitted with solenoid operated bypass

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 4 Replacement Parts List - 871024-B Model

Fitted with solenoid operated bypass

Ref. No.

Description

871024-B

133

Silicone Tube (Insulator)

20-43376-00

134

Silicone Tube (Insulator)

20-43376-00

705

Anti-Frost Heater (Heater A)

31-71644-00

706

Anti-Frost Heater Assembly (heater B)

37-71643-00

708

Anti-Frost Heater Clamp

WH0020049

710

Anti-Frost Heater “C” Clamp

WH0020050

711

Anti-Frost Heater Clamp

WH0020051

712

Ambient Air Temp Thermistor Assy

N/A use *37-76655-00

713

Outlet Thermistor (Thermistor B)

*20-64774-00

714

Anti-frost Thermostat Assembly

20-57072-00

715

Heat Exchanger (HX) Thermistor

N/A use *31-76655-00

716

O-ring – Thermistor

WH0020055

723

Hall Effect I.C. Assembly

*20-43805-00

728

Combustion Fan

WH0020057

729

Fan Case Assembly

10-88629-00

735

Ignition Pack

31-76722-00

737

Flame Sensor Loom

31-76721-00

745

PCB Assembly

31-76623-0S

751

Gas Type Connector – NG

WH0020186

Gas Type Connector – LP

WH0020185

757

100 volt loom

31-76653-00

758

Signal Loom (inc amb air & HX thermistor)

*31-76655-00

768

Terminal Block Assembly

WH0020068

771

Noise filter holder assembly

31-23360-00

773

Power filter

*31-71642-00

775

Fuse – In line Note: PCB fuses not fitted

WH0020069

780

Power Cord With Clamp

*31-76652-00

781

Clamp – Power Cord

WH0020072

783

240 -110 Volt Transformer Assembly

*31-71646-00

784

Connecting cord

*31-71641-00

Not Shown

Gas Conversion Kit - LP to NG

WH0020189

Not Shown

Gas Conversion Kit - NG to LP

WH0020191

*When installed in an 871024, 871024-B or 871024-C model heater these parts will require the

replacement of other interconnecting components. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

Note: For controller and controller cable part numbers refer to page 20

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 5 – 871024, 871026 & 871026-B Models Fitted with solenoid operated bypass

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View Replacement Parts List 5 - 871024-C, 871026 & 871026B Models

Fitted with solenoid operated bypass

Item No

Description

871026

871026-B

871024-C

001

Front Panel Rheem Brand (50 & 60ºC Models)

31-76496-00

003

Jacket Assembly

31-23525-00

004

Mounting Bracket

WH0020002

006

Reinforcing Plate

WH0020003

008

Cord Connector

WH0020004

066

Fixing Plate B

WH0020005

100

Gas Inlet Connector ¾”

31-76255-00

103

Proportional Gas Flow Regulating Valve

54-02340-00

104

O-ring

WH0020009

105

Gasket

WH0020010

108

Gasket

WH0020012

111

Upper Burner Assembly

31-76231-00

115

Nozzle Plate – NG

31-76238-00

Nozzle Plate – LP

N/A

120

Lower Burner Assembly – NG

31-76241-00

Lower Burner Assembly – LP

31-76240-00

131

Electrode

31-76236-00

132

Flame rod assembly (3 x flame rods)

31-76237-00

160

Burner Change-Over Assembly

WH0020020

401

Water Inlet Connector Assembly 26 L (¾)

10-65408-00

402

O-ring

WH0020022

403

CS Type Snap Ring

WH0020023

405

Water Drain Valve Assy (includes water filter)

WH0020024

407

Water Filter

21-14774-00

408

Plug Band

21-35376-00

409

O-ring

WH0020027

410

Water Body Assy including solenoid bypass

31-76658-00

415

Heat Exchanger and Combustion Chamber

31-76500-00

419

Flange

10-88332-00

422

Combustion Chamber Front Panel Assembly

10-89636-00

427

O-ring

WH0020034

429

O-ring

WH0020035

430

Hot water Outlet Connector (¾)

31-20192-00

431

Relief Valve Assembly

04-04764-00

433

O-ring

WH0020038

434

Safety Valve Band

WH0020039

445

Flange

WH0020040

701

Over Heat Limiter Assembly

*31-79562-00

768

Terminal Block Assembly

WH0020068

828

Truss Gasket Screw 4 x 10

09-14144-00

860

Nozzle Plate Bind Screw 3 x 6

09-01872-00

*When installed in 871024-C, 871026 & 871026-B model heaters these parts will require the replacement of other interconnecting components. Refer to „Product Changes‟ on page 10 and „Parts Replacement Scenarios‟ on page 11 for more information.

Note: For controller and controller cable part numbers refer to page 20.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 6 - 871024-C, 871026 & 871026-B Models

Fitted with solenoid operated bypass

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Exploded View 6 Replacement Parts List - 871024-C, 871026 & 871026-B Models

Fitted with solenoid operated bypass

Item No

Description

871026

871026-B

871024-C

133

Silicone Tube (Insulator)

20-43376-00

134

Silicone Tube (Insulator)

20-43376-00

705

Anti-Frost Heater (Heater A)

31-71644-00

706

Anti-Frost Heater Assembly (Heater B)

31-71643-00

708

Anti-Frost Heater Clamp

WH0020049

710

Anti-Frost Heater “C” Clamp (for Heater A)

WH0020050

711

Anti-Frost Heater Clamp (for Heater B)

WH0020051

712

Ambient Air Temp Thermistor Assembly

N/A use *31-76655-00

713

Outlet Thermistor (Thermistor B)

*20-64774-00

714

Anti Frost Thermostat Assembly

20-57072-00

715

Heat Exchanger (HX) Thermistor

N/A use *31-76655-00

716

O-ring – Thermistor

WH0020055

717

Inlet Thermistor (Thermistor A)

*20-64773-00

723

Hall Effect I.C. Assembly

*20-43805-00

728

Combustion Fan

WH0020057

729

Fan Case Assembly

10-88629-00

735

Ignition Pack

31-76722-00

737

Flame Sensor Loom

31-76721-00

745

PCB Assembly

31-76623-0S

751

Gas Type Connector – NG

31-76581-00

31-76592-00

Gas Type Connector - LP

31-76582-00

31-76591-00

757

100 volt loom

31-76653-00

758

Signal Loom (inc amb air & HX thermistor)

*31-76655-00

768

Terminal Block Assembly

WH0020068

771

Noise filter holder assembly

31-23360-00

773

Power filter

*31-71642-00

775

Fuse – In line Note: PCB fuses not fitted

WH0020069

780

Power Cord With Clamp

*31-76652-00

781

Clamp – Power Cord

WH0020072

783

240 -110 Volt Transformer Assembly

*31-71646-00

784

Connecting cord

*31-71641-00

Not Shown

Gas Conversion

- LP to NG

Lower Burner Assy

31-76241-00

Gas Type Connector

31-76581-00

31-76592-00

Nozzle Plate

31-01872-00

31-67238-00

Nozzle Plate Bind Screw (3 required)

09-46131-00

Not Shown

Gas Conversion

- NG to LP

Lower Burner Assy

31-76240-00

Gas Type Connector

31-76582-00

31-76591-00

Note: For controller and controller cable part numbers refer to page 20.

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Gas Type Conversion Procedure

1. Isolate the power and gas supply to the water heater.

2. Remove the front panel. (Refer to Procedure 1).

3. Remove the Burner Change Over Assembly (Refer to Figure 1 and Procedure 2).

4. Remove the Combustion Chamber Front Panel Assembly. (Refer to Figure 2 and

Procedure 3).

5. Remove the Lower Burner Assembly, (Refer to Figure 3 and Procedure 4).

NG - Propane

6. Remove and discard Nozzle Plate and nozzle plate screws – Models ending with

C suffix only (Refer to figure 3 and Procedure 23).

7. Fit replacement Propane lower burner assembly.

Propane - NG

6. Install Nozzle plate and nozzle plate screws – models ending with C suffix only

(Refer to figure 3 and Procedure 23).

7. Fit replacement NG lower burner assembly.

8. Refit the Combustion Chamber Front Panel Assembly.

9. Refit the Burner Change Over Assembly.

10. Remove the Gas Type Connector, (Refer to Figure 4 and Procedure 17) and refit

replacement for required gas type and water heater capacity.

11. Restore the power and gas supply.

12. Using an insulated tool, adjust the minimum and maximum burner gas pressures

(Figure 5) to that required for the size, model and gas type (refer to specifications table on page Error! Bookmark not defined.) following the Burner Gas Pressure Adjustment procedure on page 52.

13. Fit the correct gas type label and alter the test point pressures on the rating label

to reflect the new gas type.

Figure 1

Figure 2

TM031 Integrity 18, 20, 24, 26L Service Instructions REV: B D.O.I: February 2008

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

Figure 3

Figure 4

Figure 5

Rheem 871018, 871020, 871024, 871024-B, 871024-C Service Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual