Download Rheem Air Sourced 310 Specifications
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Rheem Australia Pty Ltd ABN 21 098 823 511 SERVICE INSTRUCTIONS 310 Series Heat Pump TM025 R Reevviissiioonn:: B B PPuubblliisshheedd:: 0088//0077 551310 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Contents Safety Warning ....................................................................................................................2 Introduction ..........................................................................................................................2 Specifications.......................................................................................................................3 Preventative Maintenance ...................................................................................................3 Operation .............................................................................................................................4 Electronic Controller ............................................................................................................5 Operating Sequence Flow Charts:.......................................................................................6 Refrigeration Terms and their Meaning................................................................................8 Components and their Function...........................................................................................8 Common Faults ...................................................................................................................9 Wiring Diagram ..................................................................................................................11 Refrigeration Sealed System Diagram...............................................................................12 LED Indication ...................................................................................................................12 Fault Finding ......................................................................................................................14 Refrigerant Charge ............................................................................................................45 Electrical Insulation Testing ...............................................................................................46 Component Replacement Procedures – Water Heater......................................................47 Component Replacement Procedures – Refrigeration Plant .............................................52 Component Replacement Procedures – Sealed Refrigeration System .............................57 Exploded View - Refrigeration Plant ..................................................................................62 Replacement Parts List – Refrigeration Plant.................................................................63 Exploded View - Water Heater...........................................................................................64 Replacement Parts List – Water Heater .........................................................................65 Rheem Electric Water Heater Warranty - (Australia Only) .................................................66 Document Revision History................................................................................................67 TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 1 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Safety Warning The purpose of this Service Manual is to provide sufficient information to allow a person with the skills as required by the controlling Regulatory Authorities to carry out effective repairs to a Rheem 310 series Heat Pump Water Heater in the minimum of time. Safety precautions or areas where extra care should be observed when conducting tests outlined in this manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended procedure. Certain diagnostic procedures outlined in these service instructions require “live” testing to be conducted. Wear Personal Protective Equipment (PPE) when conducting these tests to prevent the risk of electric shock. (Refer to the Rheem Safety Procedure on electrical testing) R134A is a controlled substance under the fair trading act. Personnel qualified and licensed to work with refrigerants may only carry out service and repair to the sealed refrigeration system. During repair the refrigerant must be recovered, not vented to atmosphere. Environmental At the end of the service life of a Rheem heat pump the refrigerant must be recovered by personnel qualified and licensed to work with refrigerants prior to the unit being disposed of. Refrigerants must not be vented to atmosphere. Introduction The information provided in these instructions is based on the water heater being installed in accordance with the Installation Instructions provided with each water heater. Should you require further technical advice on a Rheem 310 Series Heat Pump Water Heater, contact your nearest Rheem Service Department where all genuine replacement parts are also available. Heater Model Identification All identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 8 digits. 5 X X 310 0 X 5 – Renewable Energy Model 5 – Air Sourced 9 – Solar Sourced 0 – No Heating Units 1 – Booster Element Storage Capacity in Litres No Reference – System Requirement 0 – Element Not fitted 5 – 2400 watts 7 – 3600 watts Note: Model number, serial number and date of manufacture should be quoted in all correspondence. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 2 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Specifications Water Heater Model Capacity - Litres Boost Capacity - Litres Booster element rating - kW T&PR valve Rating - kPa With ECV Without ECV Inlet / Outlet Water Connections T&PR Quantity Anode Length Control board thermostat setting (fixed) Limp mode mechanical thermostat setting Mechanical thermostat ECO setting Maximum inlet pressure - kPa 551310 310 220 2.4 or 3.6 1000 680 800 RP¾/20 RP½/15 1 1153 60ºC 70ºC 88ºC Refrigeration System Parameter Sound rating Superheat setting (Factory) Refrigerant charge R134A Compressor internal OTC Compressor winding resistance Compressor Capacitor Fan winding resistance Fan Capacitor Circulator winding resistance 551310 51 dBA @1.5m +6ºC at 10ºC Evaporator temp. 1050 grams Open 150ºC. Close 90ºC (automatic reset) Run winding - Red & Blue: 2.2 ohms at 20ºC Start winding - Red & Black: 3.27 ohms at 20ºC 35µF 240 VAC 50HZ Run winding – Black & Brown: 184 ohms at 20ºC Start winding – Black & Blue: 238 ohms at 20ºC 2µF 240 VAC 50HZ 75.3 ohms @ 20ºC Preventative Maintenance It is suggested for peak performance that the water heater be serviced annually. 1. Check for discharge from the T&PR valve. When the element or heat pump is operating a small discharge of water may be evident. Operate the valve-easing lever to ensure the valve opens and resets properly. Always open and close the valve gently. The T&PR valve should be replaced at 5 yearly intervals. 2. Check for leaks at all cylinder fittings. 3. Check for signs of excessive corrosion on the water heater jacket. 4. Isolate power to the water heater and check all electrical connections for signs of overheating due to poor connection. 5. Conduct an 'Electrical insulation test' on the water heater (refer to page 46). 6. Check evaporator fins and fan blade for build up of dust or debris. 7. Check for sludge build up and if necessary drain and flush tank. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 3 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Operation Operation – Water System: The heat pump utilises a form of heating called ‘top down’ heating. The circulator (1) draws cooler water from the bottom of the cylinder via the long dropper tube (2). The water passes through the heat exchanger (condenser) (3) where it is heated by the refrigerant and is then returned to the top of the cylinder via a short dropper tube (4). 1 3 4 Operation – Heat Pump Mode: During normal operation in ‘heat pump’ mode the electronic controller (control board) holds a control relay in the energised state and power for the compressor is passed to an electronic switch (called a triac) via the normally open relay contact. The operation of the compressor causes a pressure difference within the sealed refrigeration system. This pressure difference causes the refrigerant to move around the sealed system. The refrigerant enters the evaporator (5) as a liquid, as the refrigerant absorbs heat from the atmosphere it changes state, at low pressure, from a sub cooled liquid to a super heated vapour or gas (evaporates). The vapour then enters the compressor (6) and obtains more heat, known as heat of compression, and passes into the heat exchanger as a super heated vapour at high pressure. As the refrigerant passes through the heat exchanger it gives off heat which is absorbed by the water flowing through a separate chamber inside the heat exchanger. As the refrigerant gives off heat it cools and changes state back into a liquid (condenses). The refrigerant then enters the evaporator again and the cycle is repeated. 2 5 6 3 Operation – Boost Mode: The controller will enter ‘boost’ mode when atmospheric conditions are unsuitable for heat pump operation or a possible failure of the refrigeration or water circuits has been detected. The following error conditions will initiate boost mode: 1. The temperature sensed by the ambient air sensor is below 0°C. 2. The water leaving the heat exchanger is greater than 80°C. 3. The compressor discharge temperature is greater than 110°C. 4. The evaporator temperature is less than -3°C. 5. The failure of sensors S3, S4 or S5. 6. The compressor is not running based on either of the following conditions: a. After 2 minutes in controller sequence 3 the compressor discharge temperature has not risen 15°C above ambient. b. In controller sequence 4 the water temperature rise across the heat exchanger (condenser) is less than 8°C. In boost mode the electronic controller continues to control the temperature of the water in the cylinder and the circulator however the control relay is de-energised switching the power supply from the compressor triac to the element. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 4 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Boost mode allows 220 litres of 60ºC hot water to be provided by electric boosting. During this mode the circulator will cycle on and off periodically allowing for the 220 litre boost capacity rather than just the amount of water above the element as is the case with a conventional electric boost system. Once a heating cycle is completed the error is cleared and normal operation is resumed on the next call for heat. Note: If sensor S4 fails the system will operate on boost mode however the temperature will in this case be controlled by the mechanical thermostat and 220 litres of 70ºC water will be available. Operation – Limp Mode: Limp mode will only occur due to the failure of both sensors S1 and S4. In limp mode the electronic controller no longer controls the operation of the heat pump and both ‘heat pump’ mode and ‘boost’ mode are rendered inoperable. The control relay is de-energised switching the power supply from the compressor triac to the element. Limp mode allows 111 litres of hot water to be provided by electric boosting and the water temperature is controlled by the mechanical thermostat which is set to 70°C; in this condition only the water in the zone above the element is heated as the circulator does not operate. It should be noted that if sensor S1 fails and sensor S4 is operational the system operates in boost mode however the circulator cannot operate. In this case the end result is an operation similar to limp mode in which 111 litres of water is heated by the booster and the temperature controlled to 70ºC by the Robertshaw thermostat. Electronic Controller The main features of the electronic controller (control board) are shown on the diagram opposite. The inputs to the software are shown in blue and the outputs that control the heat pump are shown in red. The connection marked “relay element” energises or de-energises a relay that switches from heat pump heating to electric element heating when the system operates in “boost” or “limp” mode. The “Compressor TRIAC” switches the power to the compressor on and off. The “Communication port” can be used in conjunction with a computer to read the inputs and outputs from the software. This information may be logged using specially designed logging software (Contact Rheem Service for more information regarding this software). The “Software loading port” is only used for loading software on to the control board. The green and red LED’s indicate the condition of the heat pump (refer to the section titled “LED Indication” on page 12). TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 5 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Operating Sequence Flow Charts: Page 1 of 2: Power to controller Error condition reset Y Tank sensors S3-S5 ok? NO YES A Sequence 0 Heat pump sensors T0-T4 ok? Thermostat contacts closed? YES NO H NO Z YES Controller de-energised no operation Relay energised Cylinder sensors S4< 44.5°C or S3 < 50°C Green LED solid System in stand by mode NO Call for heat YES B Circulator fault T0 >80°C? YES Ambient conditions too cold for heat pump operation NO T4 <0°C? NO YES YES Seq 1 T2 <-3°C? T3 >60°C? NO Compressor recently on delay start YES H Set paramaters NO Seq 2 Green LED flashing At maximum flow rate Circulator on H Compressor on 30 seconds later Evaporator fan on Circulator to minimum flow rate Sequence 3 After 2 minutes T3 > T4 +15°C? Refrigerant circuit not operational NO Compressor discharge temperature 15°C above ambient NO YES T0 = or > than 57°C? Heat exchanger outlet sensor YES Circulator to variable speed T0 - T1 Open or short circuit Open or short circuit Sensor T0 - T4 S3 - S5 Use value of T4 and T1 to set circulator flow rate to achieve 62°C at heat exchanger outlet YES <8°C Temperature rise across heat exchanger smaller than 8°C NO Sequence 4 T3 > T4 +15°C? NO Compressor discharge temperature 15°C above ambient Condenser inlet temp higher than pick up temp Water discharge temp too hot High ambient temp or running too long Ambient air temp too low Evaporator frozen T1 > S4 +7°C T0 > 80°C T3 > 110°C T4 < 0°C T2 < -3°C YES Check every 11 minutes NO T0 = 60°C? Adjust pump flow rate NO YES Fault detected? NO YES HPV 4.0 or higher NO S4 > 53°C or S5 > 50°C? YES Circulator off Compressor off Evaporator off Refrigeration Heating cycle ends TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Software version S0 & S1 < 62°C? YES Relay deenergised & element on S4< 44.5°C or S3 < 50°C NO S0 & S1 > 62°C? YES YES B HPV 3.1, HPV 3.2 or no HPV identification NO Relay energised & element off 6 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Page 2 of 2: H Red LED Flashing Relay de-energised Element On T2 > 2°C? YES Ambient temperature high enough to resume heat pump operation NO T4 > 2°C? A YES NO S4 Sensor ok? Controller can no longer detect lower cylinder temperature. Water temperature will be controlled by mechanical thermostat to 70°C NO S1 Sensor ok? NO Boost Mode 220L heated to approx. 70°C YES Sequence 0 S1 Sensor ok? NO Element On YES Controller can no longer detect upper cylinder temperature. S1 >62°C? The circulator will not operate preventing water below the element level from heating YES NO Circulator On Temperature at sensor S4 will not achieve 53°C NO NO Limp Mode 111L heated to approx. 70°C S1 <61°C? Element On YES Temp at thermostat = 70°C? YES Circulator Off NO Temp at thermostat = 70°C? YES Element Off YES Boost Mode 220L heated to approx. 60°C S1 >62°C? Power to controller off S4 >53°C? YES Y Element Off YES NO NO NO Circulator On YES Heating Cycle complete S1 <61°C? Circulator Off YES S4 >53°C? Z NO TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 7 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Refrigeration Terms and their Meaning Sub Cooled Liquid – A substance below its saturation temperature at a given pressure. Super Heated Vapour – A substance above its boiling point at a given pressure. Saturated Vapour – A substance at its boiling point at a given pressure. Latent Heat – Hidden (invisible) heat removed or added to a substance that results in a change of state (i.e. liquid to a vapour) without an increase or decrease in temperature. Heat of Compression – The additional heat added to a substance by the act of compressing it. Low Side – Components and pipe work of a refrigeration system operating at low pressure, generally considered to be the evaporator, suction line and accumulator. High Side – Components and pipe work of a refrigeration system operating at high pressure, generally considered to be the condenser, discharge line, liquid receiver/filter drier and compressor case where a rotary compressor is utilized. Boil Off – The action of a substance as it absorbs heat and changes state (evaporates) from a liquid to a vapour (gas). Give Up Heat – The action of a substance as it releases heat and changes state (condenses) from a vapour (gas) to a liquid. Components and their Function Temperature and Pressure Relief Valve - A valve designed to provide automatic relief by discharging water in case of excessive temperature, pressure or both. Never fit a T&PR Valve with a pressure rating greater than that indicated on the product-rating label. Pressure Limiting Valve (P.L.V.) - A valve that controls its outlet pressure to a predetermined limit. Outlet Delivery Tube (Dip Tube) - A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water from the highest point to the outlet connection. It also acts as a fitting liner. Diffuser - A plastic device installed in the cold water inlet of the water heater cylinder to assist with stratification. It also acts as a fitting liner. Fitting Liner - A plastic tube installed in the cold-water inlet of the water heater to provide protection against corrosion through the life of the water heater. Anode (Sacrificial) - A metal alloy electrode installed in the water heater cylinder that by galvanic action protects the cylinder from corrosion. Thermostat - A device responsive to temperature that controls the supply of electrical energy to the compressor, which results in the stored water being maintained at the required temperature. Evaporator Thermistor - A device responsive to temperature that controls the active supply between the compressor circuit and the booster element circuit. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 8 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Compressor - An electro-mechanical device that adds heats to the refrigerant by compressing it, known as “heat of compression” the resulting increase in refrigerant temperature increases its pressure and causes the refrigerant to circulate through the system. Evaporator - A finned copper coil mounted on top of the water heater. The refrigerant enters as a liquid, as it passes through the coil it absorbs heat from the surrounding atmosphere and “boils off” (evaporates) to a gas. Condenser - An insulated housing containing stainless steel chambers where heat transfer occurs. The condenser (or heat exchanger) contains three chambers, one for refrigerant, one for water and a third separating chamber containing air. The refrigerant enters as a gas, as it passes through the condenser it transfers (“gives up”) the heat absorbed via the evaporator to the water flowing through the condenser in a separate chamber, during this process the refrigerant cools and changes state (condenses) back to a liquid. Receiver Filter Drier - This device, fitted between the condenser and thermal expansion (TX) valve, receives and stores liquid refrigerant from the condenser for delivery to the evaporator. The receiver also incorporates a filter and drier to trap impurities and remove moisture from the sealed refrigeration system Accumulator - This device, fitted in the suction line prior to the compressor, is designed to accumulate and prevent liquid refrigerant from entering and damaging the compressor. Any liquid refrigerant is evaporated or “boiled off” and converted to a vapour by the accumulator. Thermal Expansion (TX) Valve - A valve, installed between the condenser and evaporator that controls (meters) the amount of refrigerant delivered to the evaporator. The TX valve has an external temperature sensor fitted to the suction line and increases or decreases the refrigerant flow to the evaporator depending on the detected suction line temperature. Thermal Cut Out (Overload) - A manual reset temperature sensitive device that automatically cuts off the supply of electrical energy to the control board and/or boost element. Heating Unit (Element) - A tubular device containing an electric resistance element that converts electrical energy to heat. Standard element ratings are 2.4 and 3.6kW. Common Faults When a complaint is lodged about the performance of a hot water system there are a number of causes that should be checked and eliminated. In an attempt to pinpoint the most likely cause it is important to discuss with the customer their reasons for the complaint, the duration of the problem, any change in circumstances or usage and recent weather conditions. This information in conjunction with the following listed common complaints will assist you in locating the most likely cause. All procedures assume there is water flowing through the water heater. Discoloured water - This may be the result of discoloured water entering from the cold water mains. Check if the cold water is also discoloured. Excessive hot water usage - The complaints of insufficient hot water and no hot water can on many occasions be attributed to hot water usage exceeding the capacity of the water heater to provide hot water. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 9 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. When first attending a call of this nature it is essential to establish the probable hot water usage by querying the usage habits of the household and compare this with the potential delivery of the model water heater installed. It can then be established if the usage is within or outside the capacity of the model. The areas to look at for excessive usage are: 1. Automatic washing machines. 2. Showers exceeding 12 litres/minute for mixed water and 5 minutes in duration. 3. Two or more showers operating at the same time. 4. Change of occupancy or number of persons increased. 5. High water pressure area. (Excessive pressure relief valve discharge) 6. Plumbing leaks. 7. Crossed connection. Water hammer - A water heater will not cause water hammer, however valves associated with the water heater may be the source of the problem i.e. cold-water stopcock, nonreturn valve or relief valve. Most water hammer problems are associated with plumbing, hot and cold or appliances i.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve parts, loose tap washers or neighbouring equipment. High water pressure areas will have more complaints of this nature and the use of a pressure-limiting valve (PLV) to reduce the household cold-water pressure will usually solve most problems. Hot water plumbing leaks - If hot water has not been used for a period of time, feeling the temperature of the hot water line may give an indication of water flow if the pipe is warm. The method of checking for plumbing leaks is: 1. Turn off the stopcock on the cold water supply to the water heater. 2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock is operating correctly. 3. Turn off the hot tap. 4. Turn on the stopcock to make up the water pressure in the cylinder, and then turn the stopcock off again. 5. Wait approximately 5 minutes then do either of the following: a. With your ear close to the stopcock turn it on slightly and listen for any water passing. If there are no leaks, water should not pass. b. Open a hot tap while listening for any pressure release. If there is a pressure release there will be no leaks in the plumbing system. Mixing or crossed connections - If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or thermostatic mixing valve is installed there is always the possibility that the cold water could mix with the hot water through a faulty or incorrectly installed valve. This is referred to as a cross connection. The complaints of insufficient hot water, water too cold or excessive discharge from the pressure relief valve may be attributed to a cross connection. The method of checking for a cross connection is: 1. Turn off the stopcock on the cold water supply to the water heater. 2. Open a hot tap. If water flow is persistent and cold a cross connection exists. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 10 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Wiring Diagram TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 11 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Refrigeration Sealed System Diagram LED Indication All 310 series Heat Pumps have LED indication. There are two variations of LED indication depending upon the version of the controllers software; however all versions utilise a red and green LED to display the operational status and/or fault condition of the appliance. Note: The software version is printed on a label on the control board. Controller Software Version HPV 3.1, HPV 3.2 or no HPV identification 310 Series Heat Pumps with controller version HPV3.1, HPV 3.2 or no HPV identification have a green and red LED located internally on the control board in the heat pump (refrigeration) module and utilise the following LED indication: LED Indication LED Status Condition Details Standby mode (end of heating cycle, Green Solid S4 > 53ºC or S5 > 50ºC cylinder water at required temperature). Green Flashing S4 < 44.5ºC or S3 < 50ºC Call for heat initiated. Various (refer to operating Component fault or ambient conditions Red Flashing sequence flow chart on too cold for heat pump operation. page 6 for more details). Fault or system in limp mode with call for Fault or system operating No indication heat satisfied (water in cylinder @ 70ºC in limp mode. determined by mechanical thermostat). Note: Refer to diagram on page 5 for control board LED location. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 12 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Controller Software Version HPV 4.0 or higher 310 series Heat Pumps with controller version HPV 4.0 or higher have a red and green LED located externally on the front of the heat pump module or internally on the control board in the heat pump (refrigeration) module depending upon date of manufacture. LED Flashing Frequency: Different combinations of flashing red and/or green LED’s are utilised to indicate the operational status or fault condition of the Heat Pump. Each flash in a series will last 0.5 seconds and is separated by 0.5 seconds between flashes. Each series of flashes is separated by 2 sec. Example: LED provides 2 flashes: 1) LED on for 0.5 sec. 2) LED off for 0.5 sec. 3) LED on for 0.5 sec. 4) LED off for 2 sec. 5) Return to Step 1). Operational LED Indication: If no fault is present the green LED will flash as shown below to indicate the operational sequence number the Heat Pump is currently operating in (refer to operating sequence flow chart on page 6 for more details). Sequence 0 2 3 4 Operational LED Indication Green LED Solid 2 flashes 3 flashes 4 flashes Red LED 0 0 0 0 Fault Indication: If a fault is present the green and/or red LED’s will indicate the fault condition according to the table below. Fault Indication Fault Error Green LED Red LED Faulty power supply or system in limp mode N/A 0 0 with call for heat satisfied (1) SerrNo 4 1 Flash 0 T3 (comp dis) > 60°C in sequence 0 (2) SerrNo 1 0 Solid T4 (ambient air) < 0°C (3) Any Sensor Strip Sensor Fault Any Sflag 0 1 Flash SerrNo 2 0 2 Flashes Water circ fault T0 (water outlet) > 80°C SerrNo 8 0 3 Flashes T2 (evaporator) < -3°C SerrNo 32 0 4 Flashes Comp/refrig fault T3 > T4 + 15°C (in seq3) SerrNo 32 0 5 Flashes Comp/refrig fault T0 - T1 < 8°C (in seq4) SerrNo 64 0 6 Flashes Water circ fault T1 > S4 + 7°C SerrNo 128 0 7 Flashes TRIAC/refrig fault T3 > 110°C Thermistor T0 Fault Tflag 1 1 Flash* 1 Flash* Thermistor T1 Fault Tflag 2 2 Flashes* 2 Flashes* Thermistor T2 Fault Tflag 4 3 Flashes* 3 Flashes* Thermistor T3 Fault Tflag 8 4 Flashes* 4 Flashes* Thermistor T4 Fault Tflag 16 5 Flashes* 5 Flashes* Notes: * The green and red LED’s flash simultaneously in these cases. (1) System may be in limp mode with call for heat satisfied (water in cylinder @ 70ºC determined by mechanical thermostat). (2) This condition creates a delay start for the compressor. This is not considered a fault. (3) Ambient temperature too cold for heat pump operation. This is not considered a fault. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding Fault No Hot Water Insufficient hot water Software version HPV 3.1, HPV 3.2 or no HPV identification System in boost or limp mode Software version HPV 4.0 or higher Leaking water heater Noisy water heater Blowing fuse/circuit breaker TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Chart Number 1 1.1 1.2 7 2 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 8.1 8.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 – 4.13 4.14 8 8.2 5 6 7 Page 16 17 21 43 23 24 25 25 26 27 29 30 30 44 44 32 33 33 34 35 36 37 38 39 40 40 44 44 41 42 43 14 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. General Fault Finding Chart Fault Diagnosis No hot water? YES 1 YES 2 NO Insufficient hot water? NO System in boost or limp mode? NO HPV 3.1, HPV 3.2 or no HPV identification 3 What is the controller software version? YES Boost or limp mode will be indicated by any of the following LED conditions: Red solid or flashing. Red & green flashing together. No LEDs (Limp mode with Robertshaw thermostat open) HPV 4.0 or higher Leaking water heater? 4 YES 5 YES 6 Blowing fuse/circuit breaker 7 NO Noisy water heater? NO Note: For more information on LED indication refer to pages 12 and 13. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 15 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding Chart 1 No Hot Water 1 Warning: Terminals may be ‘live’. Wear Personal Protective Equipment to prevent risk of electric shock. Is 240 volts present at the terminal block? YES 1.1 Test 1 NO Is the heater connected to an off peak tariff? YES Off peak connection is unsuitable for Heat Pump models. Connect to continuous tariff or ‘off peak 2’ if available YES Restore power and advise customer NO Fault in household electrical wiring NO Is the isolating switch or time clock turned off? NO Is the fuse blown at the switchboard? YES Reset circuit breaker or rewire fuse Did the fuse or circuit breaker blow again? YES 1. Heat pump connected to mixed circuit, possible excessive current draw or another appliance with a fault 2. Faulty circuit breaker or fatigued fuse wire 3. Unit may be short cycling due to faulty thermostat NO TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 7 16 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding Chart 1.1 No Hot Water 1.1 Test 2 Are the thermostat contacts closed? NO Replace thermostat. Is there Test 3 240V at the control board & relay? YES Wiring incorrect. Check control board wiring loom plug (lower thermostat to control board wiring loom). NO YES HPV 4.0 or higher Note: To reset heat Reset heat pump & pump switch power off, wait five minutes wait for 30 seconds before progressing then switch back on. from this point. Red solid or Red and Green LED’s indicating simultaneously Note: Ensure you wait the full five minutes before progressing from this point. No indication What is the status of the control boards Red flashing LED’s five minutes after Green solid resetting? Is the refrigeration system heating? YES HPV 3.1, HPV 3.2 or no HPV identification Replace control board. 1.2 Is the sensor strip working? Test 4 NO Replace sensor strip. NO Replace sensor T3. Green flashing YES Is the compressor running? YES What is the controller software version? 1.2 Is sensor T3 working? NO Test 5 YES To check if the refrigeration system is heating feel the braided flexible hose from the heat exchanger water outlet. Replace control board (system should have been operating in boost mode after five minutes from resetting) then check system operation as a second fault may be present. NO Is the evaporator fan operating? YES Replace control board. 3.6 NO Is the air flow obstructed? YES Remove obstruction or clean evaporator. System working ok. The element circuit should be checked as a temporary condition may have caused the appliance to enter boost mode. If in boost mode and the element circuit is not operational the cylinder water will be cold and the system cannot reset itself automatically. NO Note: For more information on LED indication refer to pages 12 and13. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 17 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Tests 1, 2, 3 & 6 Tests 1 Test 2 240 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Warning - Ensure power is isolated before conducting this test. Using a multimeter on the AC voltage scale, measure between the terminals of the terminal block located behind the element access cover. The following measurements should be obtained: Using a multimeter on the ohms scale, measure between the terminals of the mechanical thermostat. The following results should be obtained: 1L & 2T – 0 ohms. 3L & 4L – 0 ohms. Active & Neutral – 240 volts. Active & Earth – 240 volts. Neutral & Earth – 0 volts. Test 3 Test 6 240 240 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Using a multimeter on the AC voltage Using a multimeter on the AC voltage scale, measure between the top 2 terminals scale, measure between the A return and of the heat pump module terminal block. Neutral terminals of the terminal block located behind the element access cover. Normal voltage is 240 volts. Normal voltage is 240 volts. Note: Refer to page 19 for component test 4 and page 20 for component test 5. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 18 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Test 4 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Sensor Strip Testing: Unplug the sensor strip plug from the control board and using a multimeter on the kilo-ohms scale, measure between the pins of the sensor strip plug*. There are six individual tests to be performed as there are six individual sensors contained along the length of the sensor strip (sensors S0 – S5). As the resistance of each sensor will change according to its temperature, the resistance measurements for each sensor will need to be checked against the Temperature/Resistance Table shown below. For this reason it is best to empty the tank of hot water and then measure the cold water temperature at the T&PR so a known temperature datum can then be applied to all sensors which should then in turn all have similar resistance value when tested. Sensor Test Points 8.49 S0 – Between Pins 1 and 9 S1 – Between Pins 2 and 9 S2 – Between Pins 4 and 9 S3 – Between Pins 6 and 9 S4 – Between Pins 3 and 8 S5 – Between Pins 3 and 10 Sensor strip plug pin configuration Testing the sensor strip *Note: The sensor strip plug socket test points are quite small, Fine Probe Adapters (part number WH0020082) can be utilised as probe extensions. Alternatively small pins may be used however ensure good contact is made when testing. Sensor Strip Temperature / Resistance Table T (°C) -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 R (kΩ) 37.45 35.73 34.11 32.56 31.10 29.71 28.39 27.13 25.94 24.81 23.73 22.71 21.73 20.81 19.92 19.09 18.29 17.52 16.80 16.11 T (°C) 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 R (kΩ) 15.45 14.82 14.22 13.65 13.10 12.58 12.09 11.61 11.16 10.72 10.31 9.913 9.535 9.173 8.826 8.495 8.177 7.873 7.583 7.304 TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by T (°C) 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 R (kΩ) 7.037 6.782 6.537 6.302 6.076 5.86 5.653 5.454 5.264 5.081 4.905 4.736 4.574 4.418 4.269 4.125 3.987 3.854 3.726 3.603 T (°C) 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 R (kΩ) 3.485 3.371 3.262 3.157 3.055 2.957 2.863 2.773 2.686 2.602 2.521 2.442 2.367 2.295 2.225 2.157 2.092 2.029 1.968 1.91 T (°C) 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 R (kΩ) 1.853 1.799 1.743 1.695 1.646 1.589 1.552 1.508 1.465 1.424 1.384 1.345 1.307 1.271 1.236 1.202 1.169 1.137 1.107 1.077 19 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component test 5 T Sensor Testing: 310 Series Heat Pumps have five independent thermistors which are utilised to monitor temperatures at various locations around the system. These thermistors connect to and are monitored by the control board and are known as ‘T sensors’. All five T sensors are identical and each can be tested as follows: Warning - Ensure power is isolated before conducting this test. Unplug the relevant T sensor from the control board and remove the T sensor from its location so its temperature will be the same as the ambient air temperature (As sensor T4 detects the ambient air temperature it may remain in position for this test). Using a multimeter on the kiloohms scale, measure between the two pins of the T sensor plug*. As the resistance of each sensor will change according to its temperature, the resistance measurements for each sensor will need to be checked against the Temperature/Resistance Table shown below and the value then compared to the ambient air temperature. *Note: The sensor strip plug socket test points are quite small, Fine Probe Adapters (part number WH0020082) can be utilised as probe extensions. Alternatively small pins may be used however ensure good contact is made when testing. Sensor T0 T1 T2 T3 T4 Monitors Water temperature leaving the condenser Water temperature entering the condenser Evaporator temperature Compressor discharge temperature Ambient air temperature Part Number 056006 T Sensor Temperature / Resistance Table The table below sets out the resistance of the T sensors for a given water or air temperature. Temperature Degrees C 0 10 20 30 40 50 60 70 80 TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Resistance (All T Sensors) Kilo-ohms 23.73 15.45 10.31 7.037 4.905 3.485 2.521 1.853 1.384 20 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding - Chart 1.2 No Hot Water 1.2 Note: all faults in this chart are in the ‘boost’ or ‘limp mode’ (element) circuit. After determining the fault in the element circuit the appliance operation should then be checked to determine why the system entered boost or limp mode as a second fault may be present. Is there 240V at the element? Test 6 Is there 240V at the N/C relay contact? NO YES Repair faulty wiring between heat pump module electrical connection plug and element. Appliance operation should then be checked to determine why the system entered boost or limp mode as a second fault may be present. YES Replace control board. Appliance operation should then be checked to determine why the system entered boost or limp mode as a second fault may be present. Test 7 NO Test 9 Is there 6VDC at the relay coil? YES Replace relay. Appliance operation should then be checked to determine why the system entered boost or limp mode as a second fault may be present. NO Test 8 Is the element resistance correct? Replace element. Appliance operation should then be checked to determine why the system entered boost or limp mode as a second fault may be present. NO Repair faulty wiring. Appliance operation should then be checked to determine why the system entered boost or limp mode as a second fault may be present. YES TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 21 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Tests 7, 8 & 9 Tests 7 Test 8 240 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Warning - Ensure power is isolated before conducting this test. Using a multimeter on the AC voltage scale, measure between the white wire on the heat pump module electrical connection plug and the top terminal of the heat pump module terminal block (Neutral). Disconnect the element wires from the thermostat and terminal block, and using a multimeter on the ohms scale, measure between the two element wires. The following results should be obtained: Normal voltage is 240 volts. 2.4kW element: 22 – 26 ohms. 3.6kW element: 15 – 17 ohms. Test 9 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Using a multimeter on the DC voltage scale, measure between the two wires on the control board relay plug. Normal voltage is 6 Volts DC. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 22 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding - Chart 2 Insufficient Hot Water 2 HPV 3.1, HPV 3.2 or no HPV identification Is the What is the heater operating controller YES in boost or limp software Boost or limp mode may be mode? version? indicated by any of the following LED conditions: NO Red solid or flashing. Red & green flashing together. No LED indication. Has the Is the usage pattern YES heater of sufficient changed size? recently? i.e. additional appliances or people using hot water Is the heater connected to an off peak tariff? NO Recommend a hot water usage pattern that will suit the water heater and the customers needs. Off peak connection is unsuitable for Heat Pump models. Connect to continuous tariff or off peak 2 if available. Depending on the ambient temperature the water heater may take 3 to 5 hours to recover. YES Is the T&PR valve continuously discharging water? Is the water supply pressure more than 80% of the T&PR rating? YES Is the correct T&PR valve fitted? Are there any plumbing leaks, crossed connections or dripping taps? NO YES NO YES YES Fit pressure limiting valve if not already installed. Existing pressure limiting valve faulty - replace. YES Check for crossed water connection. Replace T&PR valve. Clean or replace filters Is the tempering valve outlet NO Replace tempering valve water temperature approx 48°C? Note: This assumes that the hot water to the tempering valve is above 52°C. NO YES NO The heater outlet water temperature can be measured at the T&PR. Replace T&PR valve with one of correct pressure rating. Do not use reconditioned T&PR valves. Repair any leaks. Isolate crossed connections. Are the filters blocked? NO Is the heater outlet water temperature > 58°C YES NO NO Is a tempering valve fitted? 4 Recommend a water heater of sufficient capacity to meet the customers needs. NO YES Has the supply of hot water recently been depleted? NO HPV 4.0 or higher YES NO 3 Is the sensor strip working? Test 4 NO Replace sensor strip YES YES System working Note: For more information on LED indication refer to pages 12 and 13. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 23 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding - Chart 3 System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification 3 Red solid or Red and Green LED’s indicating simultaneously Replace control board. Green flashing What is the status of the control boards LED’s? System working. Check operation. Green solid No LED Indication 3.1 Red flashing Are the relay, circulator, fan, sensor strip & T sensors all firmly plugged into the correct sockets? YES NO Test 4 Is the sensor strip working? NO Are all T sensors working? YES Ensure water in heat pump is below 60ºC & reset heat pump. To reset heat pump switch off, wait for 30 seconds then switch back on. Replace sensor strip. Test 5 NO Replace faulty T sensor(s). Red solid or flashing / Red and Green indicating simultaneously / Green solid YES LED Status after 5 seconds Replace control board. Red - flashing 3.2 Green - flashing Is circulator operating? 3.8 YES Note: The compressor starts 30 seconds after Does Does the circulator. compressor compressor try NO successfully start to start after after delay? delay? YES Let heat pump run for ten minutes or until red LED flashes. Red LED will flash if system enters boost mode. YES 3.3 NO Circulator operation can be checked by feeling circulator brass body for vibration. 3.4 NO Has compressor recently been operating? YES Does red LED flash? Ensure plugs are firmly plugged into correct sockets on control board and that plug pins on control board are clean and free from conformal coating. NO 8.3 Compressor internal OTC may have opened. Switch off power to heat pump, wait for ten minutes then switch power back on. 3.5 YES System working. Ambient air temperature may have been too high or low for normal operation. Heat pump may have been too hot after operating for an extended period due to large volumes and/or frequent water usage. NO Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 24 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 3.1 System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification 3.1 Test 2 Are the thermostat contacts closed? Repair faulty wiring. Replace control board. YES NO Is the sensor strip working? Test 4 NO System has operated in limp mode due to a faulty sensor strip (S1 & S4 faults) and has completed a heating cycle. Water was heated by the electric element and controlled by the Robertshaw thermostat to 70ºC. Replace sensor strip. YES Are the sensor strip plug pins clean? Ensure sensor strip plug pins and control board socket are clean and free from conformal coating. NO YES Replace control board. Fault Finding – Chart 3.2 3.2 Switch off heat pump & allow sensor T0 to cool below 80ºC. When sufficiently cool switch heat pump back on. Is red LED flashing after 5 seconds? System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification T0 is monitoring water out of the heat exchanger Has sensor T0 cooled to below 80ºC? YES NO Is Green LED flashing? NO YES Is circulator operating? YES Replace control board NO 3.3 Circulator operation can be checked by feeling circulator brass body for vibration. YES NO TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 3.8 Replace control board 25 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 3.3 3.3 Is 240V present at the circulator? System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification Test 10 NO Is the circulator plug firmly plugged into correct socket? YES Test 11 Is the circulator motor resistance correct? NO Ensure circulator is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. YES Replace control board Check circulator impellor for restriction or siezure. YES NO Replace circulator Component Tests 10 & 11 Test 10 Test 11 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Warning - Ensure power is isolated before conducting this test. Using a multimeter on the AC voltage Unplug the circulator connection plug from scale, measure between the circulator the control board and using a multimeter on plug terminals at the control board. the ohms scale, measure between the two circulator connection plug terminals. Normal voltage is 240 volts. A reading of approximately 75.3 ohms Note: As the control board controls the should be obtained. speed of the circulator by pulsing the electrical supply to the circulator an analogue multimeter may indicate between 180 – 240V. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 26 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 3.4 3.4 System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification Test 9 Is there 6VDC at the relay coil? Is the relay plug plugged into the control board? NO YES NO Ensure plug pins are clean of conformal coating and are making contact. If plug & pins are ok replace the control board. YES Test 13 Test 12 Is 240V Is 240V present at the present at the control NO compressor board compressor terminals? Note: Tests 12 & 13 must be terminals? performed after waiting for the 30 second delay after starting of the circulator and cannot be performed YES whilst the red LED is flashing. Test 14 Are the compressor winding resistances correct? NO Plug in relay plug at control board. YES Faulty compressor wiring. NO Compressor internal ECO may have tripped open circuiting the compressor windings. Wait ten minutes for ECO to cool and auto reset. Replace control board Note: Compressor internal ECO is auto trip & auto reset & is not a replaceable component. ECO Opens @ 150ºC ECO Closes @ 90ºC Test 14 Are the compressor winding resistances correct? YES Reset heat pump and run system until compressor ECO trips again. YES NO Note: To reset heat pump switch power off, wait for 30 seconds then switch back on. Replace compressor Is the compressor temperature 150ºC or hotter? NO YES Is the compressor capacitor working? 8.3 Test 15 NO Replace compressor capacitor YES TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Faulty compressor and/or compressor capacitor wiring. 27 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Tests 12 – 15 Tests 12 Test 13 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Remove the compressor electrical access cover and using a multimeter on the AC voltage scale, measure between the red and blue wires. Normal voltage is 240 volts. Using a multimeter on the AC voltage scale, measure between the control board compressor output terminal and the top terminal of the heat pump module terminal block (Neutral). Normal voltage is 240 volts. Test 14 Test 15 Warning - Ensure power is isolated before conducting this test. Warning - Ensure power is isolated before conducting this test. Remove the compressor electrical access cover and mark and disconnect terminal wiring. Using a multimeter on the ohms scale, measure between the compressor terminals. The following run and start winding results should be obtained. Disconnect the wiring to the compressor capacitor and using a multimeter on the capacitance (µF) scale measure between the two capacitor terminals. Normal capacitance is 35 micro Farads (35µF). (Run) Red & Blue terminals – 2.2 ohms (Start) Red & Black terminals – 3.2 ohms TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 28 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 3.5 System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification 3.5 Is the temperature at sensor T4 < 2ºC? System functioning correctly and should operate in boost mode until temperature at T4 rises above 2ºC at which time the heat pump will reset and start back at sequence 0. T4 is ambient air sensor YES NO T2 is evaporator sensor Is the temperature at YES sensor T2 < 2ºC? T2 temperature can be measured by inserting thermometer probe into evaporator NO fins next to sensor T2. Is the ambient air temperature < 5ºC? System working ok. Ambient air temperature too hot for normal heat pump operation. YES Is the circulator water flow direction correct? YES 3.6 System functioning correctly and should operate in boost mode until evaporator temperature rises above 2ºC at which time the heat pump will reset and start back at sequence 0. YES Is the ambient air temperature above 50ºC? NO NO Reinstall circulator so flow is directed towards heat exchanger. NO Is there an air lock in the water system Bleed air from water outlet at flexible hose union. YES Warning! Ensure water escaping from flexible hose is caught in a container and does not escape or sensor strip damage may occur. NO Is the circulator impellor functioning? NO Repair or replace circulator impellor. YES Clear blockage in water system at circulator, heat exchanger, dropper tubes or flexible hoses. YES Is the water system blocked? NO Has the cold water dropper tube fallen off? NO YES Replace cold water dropper tube. Tests 19 & 20 Are the refrigeration system pressures correct? NO YES TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 8.1 3.7 29 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 3.6 System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification. Also HPV 4.0 or higher from fault finding chart 1.1 only 3.6 Did the evaporator fan come on with the compressor? Is the air flow obstructed? YES YES Remove obstruction. Clean dirty evaporator. Appliance installed in enclosed room contrary to installation instructions. NO NO Test 16 Is 240V present at the fan NO terminals? Is the evaporator fan firmly plugged into correct socket? YES Ensure evaporator fan is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO YES Test 17 Are the fan motor winding resistances correct? Replace control board. NO Replace evaporator fan motor. Test 18 YES Is the fan capacitor working? YES NO Is the fan wiring faulty or incorrect? Replace capacitor. YES Repair or replace faulty wiring. NO Replace faulty control board. Fault Finding – Chart 3.7 System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV identification 3.7 Is the compressor capacitor working? Test 15 YES Replace faulty control board. Test 14 Are the compressor NO YES Replace compressor capacitor winding resistances correct? Note: Compressor internal ECO is auto trip & auto reset & is not a replaceable NO component. Opens @ 150ºC Replace compressor capacitor. Test 14 Are Closes @ 90ºC Compressor internal ECO may have the compressor tripped open circuiting the compressor winding resistances NO windings. Wait ten minutes for ECO correct? to cool and auto reset. YES Reset heat pump and run system until compressor ECO trips again. Is the compressor temperature 150ºC or hotter? Note: To reset heat pump switch power off, wait for 30 seconds then switch back on. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by NO YES Replace compressor 8.3 30 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Tests 16, 17 & 18 Tests 16 Test 17 240 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Warning - Ensure power is isolated before conducting this test. Using a multimeter on the AC voltage scale, measure between the third and fourth terminals down from the top on the heat pump module terminal block. Normal voltage is 240 volts. Mark and disconnect fan wiring at the heat pump module terminal block and using a multimeter on ohms scale, measure between the disconnected fan wires. The following run and start winding results should be obtained. (Run) Black & Brown wires – 184 ohms (Start) Black & Blue wires – 238 ohms Test 18 Warning - Ensure power is isolated before conducting this test. Mark and disconnect the fan capacitor wiring at the heap pump module terminal block and using a multimeter on the capacitance (µF) scale measure between the two capacitor wires. Normal capacitance is 2 micro Farads (2µF). Note: Refer to page 45 for component tests 19 & 20. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 31 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4 System in boost or limp mode - Software version 4.0 or higher 4 Boost or limp mode will be indicated by any of the following LED conditions: Red solid 4.1 Red 1 flash 4.2 Red 2 flash 4.3 Red 3 flash 4.4 Red 4 flash 4.5 Red 5 flash 4.6 Red 6 flash 4.7 Red 7 flash 4.8 Red & Green 1 flash 4.9 Red & Green 2 flash 4.10 Red & Green 3 flash 4.11 Red & Green 4 flash 4.12 Red & Green 5 flash 4.13 No LED indication 4.14 Red solid or flashing. Red & Green flashing simultaneously. No LED indication. For other LED indication refer to notes below. What is the status of the control boards LEDs? Notes: Flashing frequency: Different combinations of flashing LED’s (one Red & one Green) will indicate the status of the heat pump. Each flash in a series will last for 0.5 seconds and is separated by 0.5 seconds between flashes. Each series of flashes is separated by 2 seconds. Other LED indication: If no fault is present the Green LED will flash to indicate the following: Green solid - Heat pump operating in sequence 0 (standby) Green 1 flash - Compressor delay start (T3 > 60ºC in seq 0) Green 2 flash - Heat pump operating in sequence 2 Green 3 flash - Heat pump operating in sequence 3 Green 4 flash - Heat pump operating in sequence 4 For more information on LED indication refer to pages 12 and13. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 32 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.1 Red solid T4 < 0ºC 4.1 Note: When T4 < -0ºC the system will enter boost mode. When in boost mode due to this operation the system will reset and start at sequence 0 when T4 > 2ºC Is the temperature at sensor T4 < 2ºC? System functioning correctly and should operate in boost mode until temperature at T4 rises above 2ºC at which time the heat pump will reset and start back at sequence 0. T4 is ambient air sensor YES NO Is sensor T4 firmly plugged into correct socket? Ensure sensor T4 is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO YES Is sensor T4 working? Test 5 NO Replace sensor T4 YES Replace control board Note: Refer to page 5 for T sensor plug socket location on control board. Fault Finding – Chart 4.2 Red 1 flash sensor strip fault 4.2 Is the sensor strip firmly plugged into the correct socket? NO Ensure sensor strip is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO Replace sensor strip YES Replace control board YES Is the sensor strip working? Test 4 TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 33 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.3 Red 2 flash T0 >80ºC 4.3 T0 is monitoring water out of the heat exchanger Is sensor T0 firmly plugged into correct socket? Ensure sensor T0 is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO YES Is sensor T0 working? Test 5 NO Replace sensor T0 YES Switch off heat pump & allow sensor T0 to cool below 80ºC. When sufficiently cool switch heat pump back on. Does red LED immediately go to 2 flash? YES Has sensor T0 cooled to below 80ºC? NO YES NO Is circulator operating? Circulator operation can be checked by feeling circulator brass body for vibration. Blockage of water system at circulator, heat exchanger, dropper tubes or flexible hoses. Loose, damaged or jammed circulator impellor. YES Is there an air lock in the water system? NO Bleed air from water outlet at flexible hose union. YES Warning! Ensure water escaping from flexible hose is caught in a container and does not escape or sensor strip damage may occur. NO Test 10 Is 240V present at the circulator? Replace control board NO Is the circulator plug firmly plugged into correct socket? YES Is the Test 11 circulator motor resistance correct? NO Ensure circulator is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. YES Replace control board YES Check for loose, damaged or jammed circulator impellor. NO Replace circulator Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 34 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.4 Red 3 flash T2 < -3ºC Note: When T2 < -3ºC the system will enter boost mode. When in boost mode due to this operation the system will reset and start at sequence 0 when T2 > 2ºC 4.4 T2 is evaporator sensor Is sensor T2 firmly plugged NO into correct T2 temperature can socket? be measured by inserting thermometer YES probe into evaporator fins next to sensor T2. Test 5 Is sensor T2 working? Is the temperature at sensor T2 < 2ºC? YES Ensure sensor T2 is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO NO Replace sensor T2 YES Is the ambient air temperature < 5ºC? NO Replace control board System functioning correctly and should operate in boost mode until evaporator temperature rises above 2ºC at which time the heat pump will reset and start back at sequence 0. YES Raise temperature of sensor T2 to above 2ºC by removing from evaporator and holding probe between thumb & fingers. Heat pump should auto reset to sequence 0 when T2 raises above 2ºC. Ensure sensor probe is reinserted into evaporator on completion of testing procedure. Did the system reset & operate in normal heat pump mode? YES Is the evaporator fan running? YES Is the air flow obstructed? YES NO Note: Compresor will not start until 30 seconds after the circulator Remove obstruction. Clean dirty evaporator. Appliance installed in enclosed room contrary to installation instructions. Appliance is suitable for outdoor installation only. NO NO Test 16 Is 240V present at the fan NO terminals? Is the evaporator fan firmly plugged into correct socket? NO Ensure evaporator fan is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. YES YES Test 17 Are the fan motor winding resistances correct? YES Is the fan capacitor working? NO Replace control board Replace evaporator fan motor Test 18 NO YES Replace capacitor Repair faulty wiring Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 35 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.5 Red 4 flash T3 is not > T4 + 15ºC in sequence 3 4.5 Note: T3 is compressor discharge sensor. T4 is ambient air sensor. This check is performed in sequence 3 to ensure that the sealed refrigerant system is operating (heating). Are sensors T3 & T4 firmly plugged into the correct sockets? Ensure sensors T3 & T4 are firmly plugged into correct sockets on control board and that plug pins on control board are clean and free from conformal coating. NO Test 5 YES Are sensors T3 & T4 working? NO Replace faulty sensor(s) YES Ensure water in heat pump is below 60ºC & reset heat pum p. To reset heat pump switch off, wait for 30 seconds then switch back on. Does red LED immediately go to 4 flash? YES Replace control board NO Note: The compressor starts 30 Does seconds after the circulator. compressor start or try to start after delay? NO Test 9 Is there 6VDC at the relay NO coil? 8 YES Is the relay plug plugged in to the control board? YES NO YES Is 240V Is 240V Test 12 Test 13 present at the present at the control NO YES compressor board compressor Note: Tests 12 & 13 must be terminals? terminals? performed after waiting for the 30 second delay after starting of the circulator and cannot be performed YES NO whilst the red LED is flashing. Test 14 Are the compressor winding resistances correct? Plug in relay plug at control board. Ensure plug pins are clean of conformal coating and are making contact. If plug & pins are ok replace the control board. Faulty compressor wiring. Replace control board NO Replace compressor NO Replace compressor capacitor YES Faulty compressor and/or compressor capacitor wiring. YES Is the compressor capacitor working? Test 15 Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 36 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.6 Red 5 flash T0 - T1 < 8ºC in sequence 4 4.6 Note: T0 is heat exchanger water outlet sensor. T1 is heat exchanger water inlet sensor. This check is performed in sequence 4 to ensure that the sealed refrigerant system is operating (heating). Are sensors T0 & T1 firmly plugged into the correct sockets? YES NO Are sensors T0 & T1 working? Ensure sensors T0 & T1 are plugged into correct sockets on control board and that plug pins on control board are clean and free from conformal coating. Test 5 NO Replace faulty sensor(s) YES Ensure water in heat pump is below 60ºC & reset heat pump. To reset heat pump switch off, wait for 30 seconds then switch back on. Does red LED immediately go to 5 flash? YES Replace control board NO Does compressor start or try to start after Note: The delay? compressor starts 30 seconds after the circulator. NO Is 240V present at the compressor terminals? YES Test 12 NO Note: Tests 12 & 13 must be performed after waiting for the 30 second delay after starting of the circulator and cannot be performed whilst the red LED is flashing. Test 14 Are the compressor winding resistances correct? 8 YES Is 240V present at the control board compressor terminals? Test 13 NO YES Faulty compressor wiring. Replace control board NO Replace compressor NO Replace compressor capacitor YES Is the compressor capacitor working? Test 15 YES Faulty compressor and/or compressor capacitor wiring. Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 37 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.7 Red 6 flash T1 > S4 + 7ºC in sequence 3 or 4 4.7 Note: T1 is heat exchanger water inlet sensor. S4 is thermistor sensor strip sensor. This check is performed in sequence 3 or 4 to ensure that the circulator is operating. Is the circulator water flow direction correct? NO Reinstall circulator so as flow is directed towards heat exchanger. YES Is the sensor strip & sensor T1 firmly plugged into the correct sockets? NO Ensure sensor strip & sensor T1 are both firmly plugged into the correct sockets on control board and that plug pins on control board are clean and free from conformal coating. YES Is sensor T1 working? Test 5 NO Replace sensor T1 NO Replace sensor strip YES Bleed air from water system at water outlet flexible hose union. YES Is sensor strip working? Test 4 YES Is there an air lock in the water system? Warning! Ensure water escaping from flexible hose is caught in a container and does not escape or sensor strip damage may occur. NO Has the cold water dropper tube fallen off? YES NO Replace cold water dropper tube. Replace control board. Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 38 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 4.8 Red 7 flash T3 > 110ºC in sequence 3 or 4 4.8 Note: T3 is compressor discharge sensor. Is sensor T3 firmly plugged into correct socket? Ensure sensor T3 is firmly plugged into the correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO YES Test 5 Is sensor T3 working? NO Replace sensor T3 YES System working ok. Ambient air temperature too hot for normal heat pump operation. YES Is the ambient air temperature above 50ºC? NO Fit pressure gauge to high side of refrigerant system Has sensor T3 cooled to below 60ºC? NO Switch off heat pump & allow sensor T3 to cool below 60ºC. When sufficiently cool switch heat pump back on. YES Is the head pressure excessive? Test 19 8.2 YES Appliance may have been operating for an extended period due to large volume and/or frequent water usage. NO Note: Refer to page 5 for T sensor plug socket location on control board. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 39 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Charts 4.9 to 4.13 T sensor fault 4.9 4.10 4.11 4.12 4.13 T0 fault. T0 is monitoring water out of the heat exchanger. T1 fault. T1 is monitoring water into the heat exchanger. T2 fault. T2 is monitoring the evaporator temperature. T3 fault. T3 is monitoring the compressor discharge temp. T4 fault. T4 is monitoring the ambient air temperature. Is T sensor firmly plugged into correct socket? NO Ensure T sensor is firmly plugged into correct socket on control board and that plug pins on control board are clean and free from conformal coating. NO Replace T sensor. YES Is T sensor working? Test 5 YES Replace control board. Note: Refer to page 5 for T sensor plug socket location on control board. Fault Finding – Chart 4.14 System in boost or limp mode - Software version 4.0 or higher 4.14 Test 2 Are the thermostat contacts closed? NO Repair faulty wiring. Replace control board. YES Is there 240V at the control board & relay? Test 3 NO Wiring incorrect. Check control board wiring loom plug (lower thermostat to control board wiring loom). YES Test 4 Is the sensor strip working? YES NO System has operated in limp mode due to a faulty sensor strip (S1 & S4 faults) and has completed a heating cycle. Water was heated by the electric element and controlled by the Robertshaw thermostat to 70ºC. Are the sensor strip plug pins clean? NO YES TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Replace sensor strip. Ensure sensor strip plug pins and control board socket are clean and free from conformal coating. Replace control board. 40 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 5 Leaking water heater 5 Is the water leak intermittent? Leak is probably condensate draining from the evaporator condensate tray. Normal Operation. YES NO Is the T&PR valve continuously discharging water? Is the correct T&PR valve fitted? YES NO Replace T&PR valve with one of the correct pressure rating. Do NOT use reconditioned T&PR valves. YES Existing pressure limiting valve faulty. Fit pressure limiting valve if not already fitted. Replace T&PR valve if required. YES Is the water supply pressure above 800kPa? NO Check for crossed water connection. Replace T&PR valve. NO Is the leak from the heat pump water system? Tighten or remake flexible hose connection(s). Repair or replace leaking heat exchanger. Replace leaking circulator. Remake or replace dropper tube connections. YES NO Is the leak from the electrical access cover? Is the leak from the element barrel fitting? YES NO NO YES Are the anode/s leaking? Check for loose element bolts. Remove element and replace gasket. Inner Cylinder leaking Check for hot spots on the jacket Replace water heater. NO Remove anode and repair leak using Teflon thread tape. YES TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 41 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 6 Noisy water heater 6 Is the noise only evident during the heating cycle? Is the noise from the evaporator fan? YES NO Check for loose fittings or pipe work in the refrigeration system. Check for possible mechanical failure in compressor AIR Normal noise level during operation is approximately 52dB at 1.5 metres. If this level is affecting neighbors a timer should be fitted to prevent operation during the affected hours or to comply with local council regulations YES Is the noise mechanical or air related? NO Mechanical Is the noise water hammer? Fan loose on motor shaft, remove assembly and tighten. Fan motor faulty - Replace. Refer to water hammer causes in the ‘Common Complaints’ section. YES NO Is the noise only evident when water is flowing through the heater? Check all other appliances or valves that can generate noise i.e. washing machines, dishwashers, ball valves etc. NO YES Is the noise a metallic popping sound? Cylinder contracting due to pressure release when hot tap opened. This can also be accompanied by a creaking or cracking sound. Normal Operation. YES NO Is the water pressure more than 80% of the T&PR valve rating? Check for a faulty stop cock, non-return valve or T&PR valve. NO Check for restrictions in pipe work, faulty valves, loose plumbing or other appliances i.e. washing machine or dishwasher. Fit 600kPa pressure limiting valve. YES TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 42 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 7 Blowing fuse/circuit breaker 7 Note: The control board has an internal resistor that will provide a Megaohm reading of 0.66 Megaohms when an insulation test is conducted on the control board or the appliance with control board connected. Disconnect the wiring to the compressor and megger between each compressor terminal and earth. Is the reading below 1 Megaohm? YES Replace compressor. Is the reading below 1 Megaohm? YES Replace fan motor. Is the reading below 1 Megaohm? YES Replace element. Is the reading below 1 Megaohm? YES Replace thermostat. Is the reading below 1 Megaohm? YES Replace circulator. Is the reading below 0.66 Megaohms? YES Replace control board. NO Disconnect the wiring to the fan motor at the terminal block and megger between each fan wire and earth. NO Disconnect the wiring to the element at the thermostat and megger between each element wire and earth. NO Disconnect the remaining wiring from the thermostat and megger between each thermostat terminal and earth. NO Disconnect the wiring plug to the circulator at the control board and megger between each circulator wire and earth. NO Disconnect the power supply wiring to the control board at the terminal block and megger between each control board wire and earth. NO TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Check for pinched or damaged wiring touching the heater jacket. 43 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fault Finding – Chart 8 - 8.3 Refrigeration system fault finding 8 8.1 8.2 8.3 Fit pressure gauge to high side of refrigerant system. Test 19 Is the head pressure excessive? NO Replace compressor. NO Locate blockage in refrigerant system and repair. YES Possible restriction in system, Locate and repair. Possible system overcharge, adjust refrigerant charge. TX valve metering incorrectly, adjust or replace TX valve. NO Adjust TX valve (refer to component replacement procedure 23 “TX valve adjustment”) or replace if faulty. YES Allow time for the system to equalise. Did the system equalise? YES Is the system taking too long to equalise? NO Is the TX valve operating? Test 21 System overcharged, adjust refrigerant charge. YES Fit pressure gauges to high and low side of refrigerant system. Test 20 Is the Suction pressure YES low/vacuum or excessively high? Low Locate and repair leak in refrigerant system. High NO High side head pressure excessive (Test 18) TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 44 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Test 19 Warning – “Live” equipment. Wear Personal Protective Equipment when conducting this test. Fit gauges to the high side access pipe and observe the discharge pressure. 1800 kPa Typical high pressure range is 2100 kPa depending on cylinder temperature. The high pressure should be within 1700-1800 kPa heating from cold. 1400water range when Component Test 20 Warning – “Live” equipment. Wear Personal Protective Equipment when conducting this test. Check for persistent air bubbles through sight glass of receiver/filter drier. Fit gauges to the low side access pipe and observe the suction pressure. The suction (low side) pressure is very dependent on ambient conditions however the low pressure range is typically between 200-600 kPa. 200 kPa @ 10°C ambient. 600 kPa @ 45°C ambient. A suction pressure of less than 200kPa may indicate a refrigerant leak or a malfunctioning TX valve. 400 kPa Note: Refer to the following section for more information on refrigerant charge and refrigerant charge fault indications. Refrigerant Charge Indication of correct refrigerant charge The receiver/filter dryer sight glass should show clear liquid, a few small bubbles might be visible during initial start up of the system or when the TX valve opens quickly, however clear liquid should return shortly after. Compressor current draw should be between 5 – 6 Amps and system pressures should be within normal ranges (refer to component test 19 (above) and component test 20 (above) for typical system pressures). TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 45 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Indication of undercharged system Bubbles persist for a significant amount of time or repeat often. Compressor current draw is low (<5 Amps) together with low system pressures. If sight glass indicates clear gas, not liquid, and current draw is very low combined with low discharge line temperature then the system is totally empty. Note: Unusual current draw or low suction pressure can be a sign of other problems such as a blockage or malfunctioning TX valve. Indication of overcharged system Continuous liquid through sight glass, evaporator tends to flood, head pressure high, compressor current draw high (>6 Amps) and compressor noisy. Note: Unusual current draw or high head pressure can be a sign of other problems such as a blockage or malfunctioning TX valve. Component Test 21 Warning – “Live” equipment. Wear Personal Protective Equipment when conducting this test. Fit gauges to low side access pipe. Remove the insulation from the TX valve sensor on the suction line. Hold the sensor by hand to increase the heat detected by the sensor. The TX valve should open with the following results: 1. Flow of refrigerant through sight glass of receiver/filter dryer should increase. 2. Evaporator pressure should increase. 3. Suction line should become cooler. Remove hand and replace insulation, the TX valve should close, resulting in the reversal of the above results. Electrical Insulation Testing There are three basic test procedures that should be carried out when the operation and function of a heat pump water heater’s electrical system is in doubt. Wear Personal Protective Equipment when conducting step 1 of this procedure to reduce the risk of electric shock. Refer to Rheem safety procedure on electrical testing. Insulation resistance of the water heater Neutral Circuit. (Reading not to be below 0.66 Mega ohm). 1. Isolate power to the water heater at the isolation switch. Confirm with multimeter across terminal block Active and Neutral, then Active and Earth, then Neutral and Earth that voltage is not present. 2. Once satisfied, disconnect the Active and Neutral wires from the water heater terminal block. 3. Connect megger leads to the Neutral of the water heater wiring and Earth. 4. Operate megger. A reading above 0.66 Mega ohm should be obtained. 5. If a reading below 0.66 Mega ohm is indicated, all component parts will need to be individually tested to locate the fault. Refer to Fault Finding Chart 7 on page 43. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 46 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Insulation resistance of the water heater Active Circuit (reading not to be below 0.66 mega-ohm). 6. Connect megger leads to the Active of the water heater wiring and Earth. 7. Operate megger. A reading above 0.66 Mega ohm should be obtained. 8. If a reading below 0.66 Mega ohm is indicated, all component parts will need to be individually tested to locate the fault. Refer to Fault Finding Chart 7 on page 43. To check “Continuity” of the Heat Pump electrical circuit. 9. Set megger to resistance scale or multimeter to x1 resistance scale. 10. Measure between the Active and Neutral terminals on the power supply terminal block located behind the electrical/element access cover. The resistance should be approximately 24 ohms. If a reading outside this resistance is measured all electrical component parts will need to be individually tested to locate the fault. Refer to Specifications table on page 3 for indicative resistance values of components. 11. Reconnect active cable to ‘A’ terminal and neutral cable to ‘N’ terminal at heater terminal block. 12. Replace fuse. Note: If continuing with any diagnostic procedures do not replace the fuse. Component Replacement Procedures – Water Heater Draining the Water Heater (Procedure 1) Elevated temperatures may be present during the draining process. Wear Personal Protective Equipment to prevent scalds or burns. Wear Personal Protective Equipment when conducting step 3 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power and water supplies to the water heater. 2. Relieve pressure from the water heater through the T & PR valve or a hot tap. 3. Remove the lower electrical/element access cover and confirm with a multimeter between the Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 4. Disconnect the cold water supply pipe 5. Fit a drain hose to the cold-water connection and run the other end to a drain or safe location. 6. Open the temperature and pressure relief valve to allow air into the system. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 47 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Temperature and Pressure Relief Valve (Procedure 2) Never fit a T&PR valve with a rating higher than that indicated on the water heater rating plate. Do not use reconditioned T&PR valves. 1. 2. 3. 4. Isolate the power and water supplies to the water heater. Relieve pressure from the water heater through the T & PR valve or a hot tap. Remove the drain line from the T&PR valve. Unscrew the T&PR valve and remove. A quantity of hot water will discharge from the tank during this process. Wear Personal Protective Equipment to prevent scalds or burns. 5. Confirm the replacement T&PR valve is the correct rating and refit using thread tape. 6. Refit the drain line. 7. Close the hot tap and restore water supply. 8. Check T&PR valve thread for leaks. 9. Operate the T&PR valve lever to reset relief drain. 10. Purge air from the system through hot taps. 11. Restore the power supply to the water heater. Dip Tube (Procedure 3) 1. Isolate the power and water supplies to the water heater. 2. Relieve pressure from the water heater through the T & PR valve or a hot tap. 3. Disconnect the hot water line from the outlet of the water heater. A quantity of hot water will discharge from the outlet during this process. Wear Personal Protective Equipment to prevent scalds or burns. 4. Using a flat blade screwdriver gently split the outer rim at the top and bottom of the dip tube face and prise the dip tube out of the cylinder fitting. 5. Fit the replacement dip tube into the cylinder fitting ensuring the flat lines up with the fitting (dip tube facing up) and gently drive the dip tube into the fitting a short distance. 6. Reconnect the plumbing; this will push the dip tube into the correct location. 7. Restore the water supply and purge air from the system through hot taps. 8. Restore the power supply. Mechanical Thermostat (Procedure 4) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater and remove access cover. 2. Confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Disconnect the wiring to the thermostat. 4. Slide the thermostat out from under the retaining clamp. 5. Remove any scale from the cylinder surface. 6. Fit the replacement thermostat under the clamp. 7. Reconnect the wiring as per the circuit wiring diagram on page 11. 8. Conduct an electrical insulation test. Refer to page 46. 9. Refit the access cover and restore the power supply. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 48 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Anode (Procedure 5) Elevated temperatures may be present during anode removal process. Wear Personal Protective Equipment to prevent scalds or burns. 1. Isolate the power and water supplies to the water heater. 2. Relieve pressure from the water heater and drain approximately 10 litres of water from the cylinder through the T & PR valve. 3. Remove the air inlet louver (Refer to Procedure 10). 4. Remove the refrigeration section jacket top. 5. Remove the anode cap(s). Access is provided through the refrigeration plant chassis. 6. Using a 27mm tube or socket spanner remove the anode(s). 7. Apply thread seal tape to replacement anode, refit and tighten. Note: It may be necessary to cut the anode to length prior to fitting. Refer to page 3 for the correct anode length. 8. Restore water supply and check for leaks. 9. Refit the anode cap(s), jacket, air inlet louver and jacket top and restore power. Heating Unit (Procedure 6) Wear Personal Protective Equipment when conducting step 1 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Drain the water heater. Refer to procedure 1. 2. Remove the access cover and disconnect the wiring from the terminal block. Disconnect the wiring to the heating unit from the thermostat. Unclip the terminal block from the jacket and remove thermostat and terminal block. 3. Remove the two screws retaining the thermostat clamp. 4. Loosen the two lower screws slightly. When water is below the heating unit level, refit the cold water supply pipe. 5. Remove the two lower screws and withdraw the heating unit carefully making sure the loop does not catch and open up inside the cylinder. 6. Clean around the cylinder fitting, fit gasket to replacement heating unit and insert into water heater. Note: Ensure the element is installed in the same orientation. 7. Replace screws and thermostat clamp, and then tighten. 8. Close T&PR valve, and open all hot taps. Restore the cold water supply and purge air through hot taps, close each hot tap as water runs freely. 9. Check heating unit for leaks. 10. Refit thermostat and terminal block and reconnect the wiring as per the circuit wiring diagram on page 11. 11. Refit the access cover. 12. Restore power supply to the water heater. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 49 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Dropper Tube(s) (Procedure 7) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. In order to replace the dropper tube(s) the heat pump (refrigeration) module must be removed and refitted. Due to the weight of the unit (approx 45kgs) this is a two man job. A quantity of hot water may discharge from the flexible hose(s) during this procedure. Wear Personal Protective Equipment to prevent scalds or burns and ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 1. Isolate the power and water supplies to the water heater. 2. Confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Relieve pressure from the water heater and drain approximately 10 litres of water from the cylinder through the T & PR valve. 4. Remove the refrigeration module (refer to procedure 9 steps 4 - 9). 5. Remove the sensor strip wiring grommet from the jacket top. 6. Loosen the main power wiring cable clamp screw. 7. Carefully remove the jacket top. Note: During the foaming process the foam adheres to the jacket top which can make it difficult to remove. 8. Clear foam from around the dropper tube(s) ¾” to ½”brass fitting(s). 9. Using an extra deep 35mm socket unscrew the dropper tube(s) brass fitting(s) in an anticlockwise direction. Note: the 35mm socket must have a minimum internal nut clearance depth of 40mm. 10. Withdraw brass adapter(s) and dropper tube(s) from cylinder. Note: dropper tube is a push fit into the tapered section of the brass adapter, simply pull dropper tube to remove. 11. Complete reassembly in reverse order of above using thread tape on dropper tube(s) brass adapter(s) threaded section. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 50 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Sensor Strip (Procedure 8) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. In order to replace the sensor strip the heat pump (refrigeration) module must be removed and refitted. Due to the weight of the unit (approx 45kgs) this is a two man job. 1. Isolate the power and water supplies to the water heater. 2. Confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the refrigeration module (refer to procedure 9). 4. Remove the sensor strip wiring grommet from the jacket top. 5. Loosen the main power wiring cable clamp screw. 6. Carefully remove the jacket top. Note: During the foaming process the foam adheres to the jacket top which can make it difficult to remove. 7. Carefully remove the foam insulation from around the sensor strip wiring until the sensor strip pocket can be seen (approx 150 – 200mm down), adjacent to the cylinder top. Note: Save the foam insulation for repacking in step 14 of this procedure. 8. Carefully grip the sensor strip and slide the sensor strip out, ensure that the sensor strip pocket has also not been gripped. Note: The fitment between the sensor strip and the pocket is quite firm, do not pull on the wires only as they will break away from the strip. 9. Carefully insert the replacement sensor strip into the pocket. Note: When reinserting the replacement sensor strip ensure the plastic backing is facing AWAY from the cylinder. The strip will need to be supported by hand to prevent it bending as it is inserted into the pocket and it must be fully inserted to operate correctly. Lubricants of any kind must NOT be used. 10. Re-pack the foam removed in step 11 into the hole. 11. Complete reassembly in reverse order of above. 12. Restore water and electricity supplies and check heat pump operation. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 51 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Replacement Procedures – Refrigeration Plant Refrigeration Module (Procedure 9) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. Due to the weight of the refrigeration unit (approx 45kgs) this is a two man job. A quantity of hot water may discharge from the flexible hose(s) during this procedure. Wear Personal Protective Equipment to prevent scalds or burns and ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 1. Isolate the power and water supplies to the water heater. 2. Confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Relieve pressure from the water heater and drain approximately 10 litres of water from the cylinder through the T & PR valve. 4. Remove the front and rear air louvres. 5. Undo the controller cover retaining screw, remove the controller cover and disconnect the sensor strip and power supply wiring loom plugs from the electronic controller. 6. If fitted, disconnect the condensate drain. 7. Disconnect the hot and cold flexible hoses connecting the heat pump module to the cylinder at the cylinder fittings (refer to owners guide for location). Note: Ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 8. Remove the 3 x 6mm bolts retaining the heat pump module to the cylinder (refer to owners guide for location). 9. Slide lifting bars (part number 080151) through the slots provided in the chassis (refer to owners guide for location) and lift the heat pump module clear of the cylinder. 10. Complete reassembly in reverse order of above. Air Inlet Louver (Procedure 10) 1. Isolate the power to the water heater. 2. Remove the refrigeration section jacket top. 3. Remove the 2 screws from the left and right hand sides of the air inlet louver. 4. Remove the 3 screws from the Colorbond trim directly below the air inlet louver. 5. Lift the louver clear of the jacket. 6. Complete reassembly in reverse order of above. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 52 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Refrigeration Section Jacket (Procedure 11) The fan motor may commence operation without warning. Failure to isolate the power may result in serious injury if the fan commences operation during the removal process. 1. Remove the air inlet louver (refer to Procedure 10). 2. Remove the air outlet cover. 3. Remove the handle. 4. Remove the screws retaining the jacket to the water heater and lift the jacket clear. Note: The refrigeration section jacket is quite flexible, care should be taken to ensure it does not kink during removal or replacement. 5. Complete reassembly in reverse order of above. Evaporator Fan Motor (Procedure 12) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. The fan motor may commence operation without warning. Failure to isolate the power may result in serious injury if the fan commences operation during the removal process. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the refrigeration section jacket (refer to Procedure 11). 4. Undo the controller cover retaining screw, remove the controller cover and disconnect the wiring to the fan motor from the terminal block. Cut wiring loom cable ties and remove fan wiring. 5. Remove the 2 screws retaining the fan shroud to the evaporator. 6. Slide the shroud up to disengage the locating tabs and lift clear. 7. Undo the nut retaining the fan blade to the motor shaft and remove the blade. 8. Undo the 3 nuts retaining the motor to the shroud and remove the motor. 9. Complete reassembly in reverse order of above. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 53 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Control Board (Procedure 13) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the air inlet louver (refer to Procedure 10). 4. Undo the controller cover retaining screw, remove the controller cover and unplug power supply wiring loom, T sensors, circulator, fan and sensor strip plugs from control board. 5. Mark and disconnect compressor wiring from control board. 6. Remove two screws retaining control board bracket to refrigeration base and remove control board. 7. Complete reassembly in reverse order of above. Relay (Procedure 14) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the air inlet louver (refer to Procedure 10). 4. Undo the controller cover retaining screw, remove the controller cover and disconnect wiring to compressor capacitor. 5. Remove cable tie retaining compressor capacitor and remove compressor capacitor. 6. Mark and disconnect wiring to relay, remove two relay retaining screws and remove relay. 7. Complete reassembly in reverse order of above. Compressor Capacitor (Procedure 15) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the air inlet louver (refer to Procedure 10). 4. Undo the controller cover retaining screw, remove the controller cover and disconnect wiring to compressor capacitor. 5. Remove cable tie retaining compressor capacitor and remove compressor capacitor. 6. Complete reassembly in reverse order of above. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 54 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Fan Capacitor (Procedure 16) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the air inlet louver (refer to Procedure 10). 4. Undo the controller cover retaining screw, remove the controller cover and disconnect wiring to compressor capacitor 5. Remove cable tie retaining compressor capacitor and remove compressor capacitor. 6. Disconnect wiring to fan capacitor, remove two fan capacitor retaining screws and remove fan capacitor. 7. Complete reassembly in reverse order of above. Circulator (Procedure 17) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. A quantity of hot water may discharge from the circulator flexible hoses during this procedure. Wear Personal Protective Equipment to prevent scalds or burns and ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 1. Isolate the power and water supplies to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Relieve pressure from the water heater and drain approximately 10 litres of water from the cylinder through the T & PR valve. 4. Remove the air inlet louver (refer to Procedure 10). 5. Remove circulator electrical cover, disconnect wiring and remove wiring from circulator compression gland. 6. Unscrew circulator flexible hose unions. Note: Ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 7. Unscrew circulator inlet adapter and remove circulator from supporting bracket. 8. Complete reassembly in reverse order of above. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 55 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. T sensor(s) (Procedure 18) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power supply to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the air inlet louver (refer to Procedure 10). 4. Undo the controller cover retaining screw and remove the controller cover. 5. Unplug the T sensor plug from the control board. 6. Remove insulation surrounding T sensor (if applicable). 7. Remove sensor retaining clip and withdraw sensor. Note: Ambient air sensor is held in place by a locking nut and evaporator sensor is held in place by a cable tie. Ambient air sensor retainer can be manoeuvred out of cable tie. Do not cut cable tie as it is difficult to replace. 8. Cut wiring loom cable ties and remove T sensor and wiring. 9. Complete reassembly in reverse order of above. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 56 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Component Replacement Procedures – Sealed Refrigeration System Personnel qualified and licensed to work with refrigerants may only carry out the following repair procedures to the sealed refrigeration system. The following procedures assume that all work conducted conforms to the refrigeration code of good practice. During repair the refrigerant must be recovered, not vented to atmosphere. Evaporator (Procedure 19) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the evaporator shroud and fan assembly (refer to Procedure 12 Steps 3 - 6). 4. Remove the evaporator T sensor clip from the cable tie and remove the T sensor from the evaporator finning. 5. Recover refrigerant from sealed refrigeration system. 6. Remove the pipe insulation to expose pipe work at the evaporator. Un-braze the pipework to the evaporator. 7. Remove the 4 screws retaining the evaporator to the chassis and lift evaporator clear. 8. Fit and secure the replacement evaporator and braze pipe work. 9. Replace the receiver/filter drier. (Refer to Procedure 20 – steps 4 to 7) 10.Pressurise system to 3000kPa and conduct a leak test. Refit and secure pipe work insulation. 11.Evacuate system to 100 microbar (30”) for a period of at least 30 minutes. 12.Recharge system with the correct refrigerant. Refer to specifications table on page 3. 13.Refit the evaporator shroud and fan motor assembly and refrigeration section jacket. 14.Refit air inlet louver and jacket top. 15.Restore power. The refrigeration plant should commence operation. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 57 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Receiver/Filter Drier (Procedure 20) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the air inlet louver (refer to Procedure 10). 4. Recover refrigerant from sealed refrigeration system. 5. Undo the compression nuts on the inlet and outlet of the receiver/filter drier. 6. Cut the cable tie and remove the receiver/filter drier. 7. Fit the replacement receiver/filter drier, secure using a cable tie and retighten the compression fittings. 8. Pressurise system to 3000kPa and conduct a leak test. 9. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes. 10.Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3. 11.Refit air inlet louver and jacket top. 12.Restore power. The refrigeration plant should commence operation after a 30 second delay. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 58 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Compressor and Accumulator (Procedure 21) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the refrigeration section jacket (refer to Procedure 11). 4. Remove the evaporator shroud and fan motor assembly (refer to Procedure 12 Steps 3 - 6). 5. Recover refrigerant from sealed refrigeration system. 6. Disconnect the wiring to the compressor and unclip and remove the compressor T sensor from the compressor discharge pipe work. 7. Remove the pipe insulation to expose pipe work at the compressor and accumulator. Un-braze the discharge pipe-work from the compressor and the suction line from the accumulator. 8. Remove the 3 nuts retaining the compressor to the chassis and lift the compressor and accumulator clear. 9. Fit and secure the replacement compressor and accumulator, braze pipe work, reconnect wiring to the compressor and refit the discharge T sensor and retaining clip. 16.Replace the receiver/filter drier (Refer to Procedure 20 – steps 4 to 7). 10.Pressurise system to 3000kPa and conduct a leak test. Refit and secure pipe work insulation. 11. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes. 12.Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3. 13. Refit the evaporator shroud and fan motor assembly and refrigeration section jacket. 14.Refit air inlet louver and jacket top. 15. Restore power. The refrigeration plant should commence operation after a 30 second delay. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 59 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. TX Valve Replacement (Procedure 22) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Remove the refrigeration section jacket (refer to Procedure 11). 4. Recover refrigerant from sealed refrigeration system. 5. Remove the pipe insulation to expose pipe-work at the TX valve assembly and the TX valve sensor. 6. Separate the TX valve sensor and capillary from the suction line. 7. Un-braze the pipe-work and remove the TX valve. 8. Braze the replacement TX valve into place and attach the sensor to the suction line. Note: Ensure the sensor bulb is in good contact with the suction line. 9. Replace the receiver/filter drier (Refer to Procedure 20 – steps 4 to 7). 10. Pressurise system to 3000kPa and conduct a leak test. Refit and secure the pipe work insulation. 11. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes. 12. Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3. 13. Restore power. The refrigeration plant should commence operation after a 30 second delay. 14. Refit air inlet louver and jacket top. 15. Adjust TX valve if required (Refer to Procedure 23). TX Valve Adjustment (Procedure 23) Components within the refrigeration plant section will be “live” during the adjustment process. Wear Personal Protective Equipment to reduce the risk of electric shock. The TX valve is supplied preset and should be installed with the factory setting (6ºC) unaltered. This setting is calibrated for the lowest superheating and optimum evaporator utilization. However, should it be necessary to adjust the superheat, turn the adjusting spindle as follows: Clockwise = Reduced refrigerant flow, increase of superheat. Anticlockwise = Increased refrigerant flow, decrease in superheat. 1. Remove the air inlet louver (refer to Component Replacement - Procedure 10). 2. Remove the TX valve sealing cap (see diagram opposite). 3. Using a 4mm Allen key back the TX valve adjuster screw anticlockwise all the way out. Note: The adjuster screw is recessed approximately 8mm. 4. Screw the adjuster screw in three full turns to achieve the required superheat setting of +6ºC. Note: 1 full 360º turn of the adjuster screw = 2ºC. 5. Refit and tighten the TX valve cap to a torque of 4Nm. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 60 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Heat Exchanger (Procedure 24) Wear Personal Protective Equipment when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. A quantity of hot water may discharge from the flexible hose(s) during this procedure. Wear Personal Protective Equipment to prevent scalds or burns and ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 1. Isolate the power and water supplies to the water heater. 2. Remove the access cover and confirm with a multi-meter between Active and Neutral, then Active and Earth, then Neutral and Earth terminals of the terminal block that voltage is not present. 3. Relieve pressure from the water heater and drain approximately 10 litres of water from the cylinder through the T & PR valve. 4. Remove the refrigeration section jacket (refer to Procedure 11). 5. Recover refrigerant from sealed refrigeration system. 6. Undo flexible hose unions at heat exchanger. Note: Ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 7. Remove insulation from refrigeration pipe work to and from the heat exchanger and remove inlet and outlet water sensors. 8. Cut cable ties and remove heat exchanger styrene insulation. 9. Un-braze refrigeration pipe work from heat exchanger and remove heat exchanger. 10. Un-braze water system inlet and outlet pipe work from old heat exchanger and braze these components on to the new heat exchanger. 11. Braze the replacement heat exchanger (refrigeration pipe work) into place. 12. Refit inlet and outlet water sensors and replace pipe work and heat exchanger insulation. 13. Remake flexible hose connections to heat exchanger. 17.Replace the receiver/filter drier (Refer to Procedure 20 – steps 4 to 7). 14. Pressurise system to 3000kPa and conduct a leak test. Refit and secure the pipe work insulation. 15. Evacuate system to 100 microbar (30”) for a period of at least 30 minutes. 16. Recharge system with the correct refrigerant. Refer to “Specifications – Refrigeration System” table on page 3. 17. Restore water supply and bleed air from the heat exchanger water outlet union. Note: Ensure all escaping water is caught in a container to prevent the sensor strip from becoming water damaged. 18. Restore power. The refrigeration plant should commence operation after a 30 second delay. 19. Adjust TX valve (Refer to Procedure 23). 20. Refit refrigeration jacket (reverse procedure 11). 21. Restore water and power supplies. The refrigeration plant should commence operation after a 30 second delay. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 61 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Exploded View - Refrigeration Plant TM025 Rheem Heat Pump Service Instructions REV: A Date of Issue: 02/08/07 62 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Replacement Parts List – Refrigeration Plant Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 NS Description Air Grille Fan Motor Assy Air Shield Fan Shroud Jacket Top Evaporator Coil Condenser Hose – Braided Circulator Capacitor – Fan Motor Relay Controller Assy Control Cover Sensor Clip Sensor Capacitor - Compressor Compressor Chassis Assy Receiver/Filter Drier TX Valve Drip Tray Side Cover Side Cover - Drip tray outlet Label – Air Grille Condenser Insulation Condenser Insulation Cover Pipe – Refrigerant, Low Pressure Pipe – Refrigerant, High Pressure Pipe – Refrigerant, Drier to Heat Exchanger Pipe – Refrigerant, Drier to TX Pipe – Refrigerant, TX to Evaporator Pipe – Condenser, Upper Water with Thermistor Holder Fitting Pipe – Condenser, Lower Water with Thermistor Holder Fitting Heat Pump Module to Water Heater Mounting Screws (pkt of 3) Part Number 104798 180027 108374 180026 100659 180025 180032 088086 051575 890374 052123 051577 051659 890263 056006 890373 180029 140114 180021 180024 104797 108372 108373 120513 090249 090250 181526 181527 181528 181529 181530 088096 088098 080156 NS = Not shown TM025 Rheem Heat Pump Service Instructions REV: A Date of Issue: 02/08/07 This document is stored and maintained electronically by 63 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Exploded View - Water Heater TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 64 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Replacement Parts List – Water Heater Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Description Jacket Bottom Pipe Seal – Inlet/Outlet (¾” x 38) Inlet Diffuser Name Band Dip Tube (Outlet) Wiring loom assembly Anode – Black Anode – Blue Anode – Green Anode Cover Dropper Tube Seal Dropper Tube – Short O-ring – Dropper Tubes Fitting ¾” to ½” Brass Pipe Seal – Dropper Tubes (30 x 16) Dropper Tube – Long Grommet - Sensor Strip Foam Cover Sensor Strip Jacket Top Pipe Seal – T & PR (½” x 38) Element Gasket Thermostat – EWT 1L2-561 Thermostat Clamp Access Cover Element Bolts Element 2.4kW Element 3.6kW Terminal Block T & PR Valve HTE523/507 TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by Part Number 100633 221418 220516 120512 225601 N/A 221904 221924 222024 221720-1 087027 220558 087023 088040 221233 220559 080149 221735 053053 108375 221420 050704 051571 102501 100703-1 051404 050324 050323 051521 220641 65 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Rheem Electric Water Heater Warranty - (Australia Only) WARRANTY CONDITIONS 1. 2. 3. 4. This warranty is applicable only to water heaters manufactured from 1st September 2006. The water heater must be installed in accordance with the Rheem water heater installation instructions, supplied with the water heater, and in accordance with all relevant statutory and local requirements of the State in which the water heater is installed. Where a failed component or water heater is replaced under warranty, the balance of the original warranty period will remain effective. The replaced part or water heater does not carry a new warranty. Where the water heater is installed outside the boundaries of a metropolitan area as defined by Rheem or further than 25 km from a regional Rheem branch office, or an Accredited Service Agent, the cost of transport, insurance and travelling costs between the nearest Rheem 5. 6. 7. Accredited Service Agent’s premises and the installed site shall be the owner’s responsibility. Where the water heater is installed in a position that does not allow safe, ready access, the cost of accessing the site safely, including the cost of additional materials handling and / or safety equipment, shall be the owner’s responsibility. The warranty only applies to the water heater and original or genuine (company) component replacement parts and therefore does not cover any plumbing or electrical parts supplied by the installer and not an integral part of the water heater, e.g. pressure limiting valve; isolation valves; non-return valves; electrical switches; pumps or fuse. The water heater must be sized to supply the hot water demand in accordance with the guidelines in the Rheem water heater literature. WARRANTY EXCLUSIONS REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RHEEM WATER HEATER WARRANTY ABOVE HOWEVER THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO BECOME VOID AND MAY INCUR A SERVICE CHARGE AND / OR COST OF PARTS. a) b) c) Accidental damage to the water heater or any component, including: Acts of God; failure due to misuse; incorrect installation; attempts to repair the water heater other than by a Rheem Accredited Service Agent or the Rheem Service Department. Where it is found there is nothing wrong with the water heater; where the complaint is related to excessive discharge from the temperature and / or pressure relief valve due to high water pressure; where there is no flow of hot water due to faulty plumbing; where water leaks are related to plumbing and not the water heater or water heater components; where there is a failure of gas, electricity or water supplies; where the supply of gas, electricity or water does not comply with relevant codes or acts. Where the water heater or water heater component has failed directly or indirectly as a result of: excessive water pressure; excessive temperature and / or thermal input; blocked overflow / vent drain; corrosive d) e) f) from the water heater. Where the water heater is located in a position that does not comply with the Rheem water heater installation instructions or relevant statutory requirements, causing the need for major dismantling or removal of cupboards, doors or walls, or use of special equipment to bring the water heater to floor or ground level or to a serviceable position. Repair and / or replacement of the water heater due to scale formation in the waterways or the effects of either corrosive water or water with a high chloride or low pH level when the water heater has been connected to a scaling or corrosive water supply or a water supply with a high chloride or low pH level as outlined in the Owner’s Guide and Installation Instructions booklet. Breakage of collector glass for any reason including hail damage. (We suggest that the collector glass be covered by your home insurance policy). SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY EXCLUDES ANY AND ALL CLAIMS FOR DAMAGE TO FURNITURE, CARPETS, WALLS, FOUNDATIONS OR ANY OTHER CONSEQUENTIAL LOSS EITHER DIRECTLY OR INDIRECTLY DUE TO LEAKAGE FROM THE WATER HEATER, OR DUE TO LEAKAGE FROM FITTINGS AND / OR PIPE WORK OF METAL, PLASTIC OR OTHER MATERIALS CAUSED BY WATER TEMPERATURE, WORKMANSHIP OR OTHER MODES OF FAILURE. Rheem Australia Pty Ltd A.B.N 21 098 823 511 FOR SERVICE TELEPHONE 131 031 AUSTRALIA or refer local Yellow Pages NOTE: Every care has been taken to ensure accuracy in preparation of this publication. No liability can be accepted for any consequences, which may arise as a result of its application. TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by 66 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”. Document Revision History Title Service Instructions for Rheem Heat Pump Revision A B Document Number TM025 Details of change Service Instructions issued for 310 Series Heat Pump Addition to flow diagram TM025 Rheem Heat Pump Service Instructions REV: B Date of Issue: 02/08/07 This document is stored and maintained electronically by D.O.I. 03/07 08/07 67 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.