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Related Manuals for Rheem Premier Loline TM024
Summary of Contents for Rheem Premier Loline TM024
- Page 1 SERVICE INSTRUCTIONS Premier Loline Solar Drain Back Water Heater TM024 Revision: A Published: December 07 590270 591270 596270 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
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Page 2: Table Of Contents
Contents Safety Warning ........................3 Introduction .......................... 3 Water Heater Model Identification ..................3 Specifications ........................4 Wiring Diagrams ........................5 Operation ..........................7 Solar Circuit ........................11 Solar Circuit Plumbing Diagrams - All Models ..............12 ... -
Page 3: Safety Warning
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 Premier Loline Water Heater, contact your nearest Rheem Service Department where genuine replacement parts are also available. -
Page 4: Specifications
Specifications Specification 590, 591 & 596 Models Storage capacity 270 Litres Temperature setting 60ºC TPR valve setting 1000kPa Solar circuit relief valve 200kPa Max supply pressure 800kPa (680kPa with ECV) Min supply pressure 200kPa Water connections- tank Inlet RP¾/20, Outlet RP¾ /20 Water connections- collector Hot pipe ½”... -
Page 5: Wiring Diagrams
Wiring Diagrams Wiring Diagram - 590 & 596 Models TM024 Premier Loline Solar Drain back Service Instructions REV: A D.O.I: 12/12/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”... - Page 6 Wiring Diagram - 591 Models (Robertshaw EWT Thermostat) Wiring Diagrams - Electric Booster Circuit All 591 Models Continuous power supply to booster circuit Extended Off-Peak power supply to - All 591 Models booster circuit - All 591 Models Switchboard Switchboard Extended Off-Peak Power Supply Continuous Power Supply (no manual switch or timer)
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Page 7: Operation
Wiring Diagram - 591 Models (Robertshaw ST Thermostat) Note: Refer to page 6 for continuous or off-peak booster circuit wiring diagrams. Operation The Premier Loline is an indirect drain back solar Loline (collectors at roof level, cylinder at ground level) water heater. The fluid in the collector circuit is isolated from the potable water in the cylinder, hence the term ‘indirect’. - Page 8 Operational Flow Chart Operational Flow Chart Plug In Power On Pump relay Restore Power Rectify fault Isolate Power de-energised (if on) Self check routine normal? Software Hot sensor open Hot sensor short Cold sensor open Thermistors open Sensor strip malfunction circuit circuit or short circuit...
- Page 9 Sequence of Operation - Solar The following sequence of operation is common to 590, 591 & 596 models and pertains to the solar circuit which is a ‘closed circuit’ containing a heating fluid consisting of propylene glycol and water. For information on electric and gas booster operation refer to page 10. Refer to ‘Sequence of Operation Component Diagram’...
- Page 10 9. Once the pump (6) ceases operation the system commences to drain back. Fluid in the collectors (8) begins to fall back to the bottom of the heat exchanger (9) via the cold pipe (10) due to gravity; this creates suction on the fluid in the hot pipe (12) which is also drawn back through the collectors (8).
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Page 11: Solar Circuit
Gas Boosted Integrated Plumbing Arrangement Solar Circuit It is imperative that both the collector hot and cold pipes must fall continuously by at least 5º, or a 1 in 10 fall, to ensure proper drain back of heat exchange fluid into the storage cylinder. Each collector should be angled 10-15mm from horizontal towards the hot outlet to ensure proper drain back of heat exchange fluid and to ensure that the hot sensor is located in fluid when the pump is on. -
Page 12: Solar Circuit Plumbing Diagrams - All Models
Solar Circuit Plumbing Diagrams - All Models The solar collectors must be the highest point of the system. The maximum height of the solar installation, from the base of the solar storage tank to the top of the solar collectors, is 9 m. The pump supplied will not circulate closed circuit fluid... - Page 13 Auxiliary Pump - Solar Circuit The maximum height of the solar installation from the base of the solar storage tank to the top of the solar collectors is 9 m. The pump supplied with the solar storage tank will not circulate closed circuit fluid through heights greater than 9 m and solar gain will not be achieved.
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Page 14: Potable Water Plumbing Diagrams
Potable Water Plumbing Diagrams Plumbing Diagram - 590 & 591 Models Two temperature zones utilising temperature limiting device Plumbing Diagram - 596 Models Two temperature zones utilising temperature limiting device integrated with water heater Gas boosted integrated plumbing behind front access cover contains a tempering valve and provides both a hot... -
Page 15: Electronic Controller
Electronic Controller The control board or electronic controller is used to control the pump by monitoring the water temperatures and heat transfer temperatures at various locations within the system. By monitoring the temperature of the heat transfer fluid returning to the solar collectors (cold sensor) -
Page 16: Solar Monitor Led Indication
Solar Monitor Plug Polarity Test 1. Release water from the T&PR valve until the water temp in the cylinder is < 75ºC. 2. Switch off power for 5 seconds and then restore power. 3. If the LED flashes green (any combination) or is solid red within the first 15 seconds from restoring power, the solar monitor plug is inserted the wrong way around. - Page 17 Pump An electro-mechanical device that pumps solar transfer fluid through the collectors by centrifugal force. The control board varies the flow rate of the pump by pulsing the electrical supply to the pump motor. The flow rate is proportionate to the pulse rate. e.g. higher pulse rate = higher flow rate.
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Page 18: Product Changes
Heating Unit (Element) - 591 Models Only A tubular device containing an electric resistance element that converts electrical energy to heat. Standard element ratings are 2.4kW, 3.6kW and 4.8kW. Integral Gas Booster - 596 Models Only An Integrity 26 litre electronic gas instantaneous water heater mounted externally on the heater jacket which will boost the solar preheated water to 60ºC if required. -
Page 19: Thermostat Changes - 591 Models Only
Effective 10/08/07 – Solar Cold Connection • The cold pipe which is foamed into the heater had the large brass fitting removed so that just the pipe protrudes. • Item 2 – Union ½”C x ½”M is replaced by 088065 compression union ½”C x ½”C which is now item 2a. -
Page 20: Common Faults
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. -
Page 21: Fault Finding
2. Open a hot tap. If water flow is persistent and cold a cross connection exists. Fault Finding Test Equipment A list of test equipment which will assist in conducting diagnostic procedures is provided below. This equipment is available from Rheem Service Spare Parts Department. Fine probe adapter kit WH0020082 Probe to alligator clip kit... -
Page 22: Testing The Sensor Strip
Testing the Sensor Strip 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 –... -
Page 23: Testing The Hot And Cold Sensors
Testing the Hot and Cold Sensors Unplug the relevant sensor from the control board and remove the sensor from its location so its temperature will be the same as the ambient air temperature. Using a multimeter on the kilo-ohms scale, measure between the two pins of the 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 ‘Hot &... -
Page 24: Fault Diagnosis Sequence (General Fault Finding Chart)
Fault Diagnosis Sequence (General Fault Finding Chart) General Fault Finding Chart Fault 591 (electric boosted) Is the What is 596 (gas boosted) complaint for no the model hot water? number? 590 (solar pre-heater) Is the complaint for insufficient hot water? 591 (electric boosted) Is the What is... -
Page 25: Fault Finding Chart 1
Fault Finding Chart 1 Test 1 Is the Is 240 electric booster volts present connected to an off at the terminal peak tariff? block? Is a Possible failure of the off peak relay or switch to missed signal from energy supplier control the booster Continue diagnosis to confirm booster installed in the... -
Page 26: Fault Finding Chart 1.1
Fault Finding Chart 1.1 Water Too Hot Is the Is the water temp gas booster in the tank operating? < or = 58º? The tank water temperature No or can be determined by gently Conduct fault finding on the gas Insufficient lifting the easing lever on the booster. -
Page 27: Fault Finding Chart 1.2
Fault Finding Chart 1.2 Is a tempering valve Replace tempering valve. blocked or faulty? 590 models require an in-line Is an booster otherwise no hot water in-line booster will be available in periods of low plumbed in solar gain. Advise customer and series? continue with diagnosis to ensure solar system is operational. -
Page 28: Fault Finding Chart 1.3
Fault Finding Chart 1.3 Test 3A for EWT type thermostats or test 3B for ST type thermostats the thermostat Reset the ECO or replace ECO contacts thermostat. closed? Test 4A for EWT type thermostats or test 4B for ST type thermostats the water in the thermostat... - Page 29 Fault Finding Tests 3A – 4B Test 3A – EWT Type Thermostat Test 3B – ST Type Thermostat Warning Ensure power Warning Ensure power isolated before conducting this isolated before conducting this test. test. Using a multimeter on the ohms scale, Using a multimeter on the ohms scale, measure between the terminals of the measure between the terminals of the...
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Page 30: Fault Finding Chart 1.4
Fault Finding Chart 1.4 Electrical Insulation Test Disconnect wiring to electric 591 (electric boosted) booster at the terminal block and megger between each wire to the electric booster and earth. What is 596 (gas boosted) the model number? 590 (solar pre-heater) Is the reading below 1 mega-ohm? -
Page 31: Fault Finding Chart 1.5
Fault Finding Chart 1.5 Test 2 Is 240 Is the Restore power at the GPO if volts present fuse blown at the turned off. Locate household at the terminal switchboard? wiring or cord fault and repair. block? Reinsert solar monitor plug firmly into control board socket. -
Page 32: Fault Finding Chart 1.6
Fault Finding Chart 1.6 Pump operation Notes can be checked by (1) (2) (1) For collector heights between 9 & 18 metres an auxiliary pump (pump 2) must be feeling the pump Does installed and included in these tests. For heights < 9 metres pump 2 is not required. body for vibration the pump(s) (2) If the green LED is indicating 4 flashes, pump 2 will be off and will not operate. - Page 33 Fault Finding Tests 5 – 7B Test 5 Test 6 Warning Ensure power Warning – ‘Live’ equipment wear isolated before conducting this Personal Protective Equipment test. when conducting this test. Disconnect the element wires from the Using a multimeter on the DC voltage thermostat, and using a multimeter on the scale, measure between the two wires on ohms scale, measure between the two...
- Page 34 Fault Finding Tests 8 – 9B Test 8 Warning – ‘Live’ equipment wear Personal Protective Equipment when conducting this test. Using a multimeter on the AC voltage scale, measure between the N/O terminal of the pump relay and neutral on the control board power supply plug. Normal reading is 240 Volts.
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Page 35: Fault Finding Chart 1.7
Fault Finding Chart 1.7 Is the Is an collector height auxiliary pump Install an auxiliary pump. between 9 & 18 installed? metres high? Max allowable collector Is the height is 18 metres. System will collector height > not operate correctly at heights 18 metres? >... -
Page 36: Fault Finding Chart 1.8
Fault Finding Chart 1.8 Is the collector glass Clean the collector glass or broken or replace the collector. dirty? Is the coating on the Replace the collector. collector absorber plate deteriorating? Is the daily water No hot water usage exceeding the Solar system operational. -
Page 37: Fault Finding Chart 2 & 2.1
Fault Finding Chart 2 & 2.1 Notes (1) The T&PR may under normal operating conditions discharge up to 10 litres over a 24 hour period; therefore a small discharge may occur whilst appliance is heating – Normal operation. Is the the usage pattern water heater changed recently? i.e. -
Page 38: Fault Finding Chart 3, 3.1, 3.2 & 3.3
Fault Finding Chart 3, 3.1, 3.2 & 3.3 Is the Is a water temperature tempering valve Replace the tempering valve. at a hot tap fitted? 60 - 75º? Advise customer on operation of Premier Loline system and benefits of storing water at 60 - 75º. Tempering Test 3A for EWT valves should be considered for type thermostats or... -
Page 39: Fault Finding Chart 4
Fault Finding Chart 4 Notes (1) The T&PR may under normal operating conditions discharge up to 10 litres over a 24 hour period; therefore a small discharge may occur whilst appliance is heating – Normal operation. boosting required during periods of high solar gain to meet hot water demands? -
Page 40: Fault Finding Chart 5
Fault Finding Chart 5 Is the Is the the T&PR leak discharge leak from the valve continuously from the T&PR tank? discharging valve? water? Normal operation. Is the leak from the Reseal the anode. anode? Notes (1) The T&PR may under normal operating conditions discharge up to 10 litres over a 24 hour period;... -
Page 41: Fault Finding Chart 6
Fault Finding Chart 6 the noise only evident when there mineral build Replace heating unit. the electric heating up on the heating cycle is unit? Poor quality water supply i.e. dam water sludge. Flush Tank. Refer to water hammer causes in the the noise water ‘Common Complaints’... -
Page 42: Electrical Insulation Testing
Premier Loline water heater’s electrical system is in doubt. Wear Personal Protective Equipment when conducting step 1 of these procedures to reduce the risk of electric shock. Refer to Rheem safety procedure on electrical testing. 590 & 596 Models Procedure 1: Insulation resistance of the water heater Neutral Circuit. - Page 43 591 Models Procedure 1: Insulation resistance of the water heater Neutral Circuit. (Reading not to be below 0.66 Mega ohm). 1. Isolate power to the water heater by removing fuse(s) or switching off circuit breaker(s). Confirm with multi-meter across terminal block Active A1 and Neutral, then Active A1 and Earth, then Neutral and Earth that voltage is not present.
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Page 44: Component Replacement Procedures
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 power and water supplies to the water heater. - Page 45 Temperature and Pressure Relief Valve (Procedure 3) Never fit a T&PR valve with a rating higher than that indicated on the water heater rating plate. Do not use reconditioned T&PR valves. 1. Isolate power and water supplies to the water heater. 2.
- Page 46 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. 1. Isolate power supply to the water heater and remove pump access panel (refer to procedure 4).
- Page 47 Pump Relay (Procedure 10) 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 power supply to the water heater and remove pump access panel (refer to procedure 4).
- Page 48 Hot Sensor (Procedure 13) 1. Isolate power supply to the water heater. 2. Remove the spring clip retaining the hot sensor in the collector connector and remove the locating washer and hot sensor. 3. Fit the replacement sensor into the connector and secure with the spring clip. Ensure the clip retains the locating washer.
- Page 49 Pump Isolation Valve (Procedure 16) Ensure any escaping solar circuit fluid is contained and does not enter any part of a rainwater tank system as entry will render the water undrinkable. 1. Remove the solar circuit relief valve by following steps 1 – 6 in procedure 2. This will relieve the solar circuit pressure.
- Page 50 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 power, gas and water supplies to the water heater.
- Page 51 Heating Unit – 591 Models Only (Procedure 21) 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.
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Page 52: Exploded View 1 - 590 & 596 Models
Exploded View 1 – 590 & 596 Models TM024 Premier Loline Solar Drain back Service Instructions REV: A D.O.I: 12/12/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”... - Page 53 Replacement Parts List (Exploded View 1) Item Description 590270 596270 Item Description 590270 596270 Closed Circuit Relief Valve 200kPa 088077 088077 Fitting Liner ¾” 221001 221001 Union ½”C x ½”M 088063 088063 31a - Fitting Hot/Cold Connection ¾”C X ¾”M (pre 19/9/06) Compression Nut 1/2”...
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Page 54: Exploded View 2 - 591 Models
Exploded View 2 – 591 Models TM024 Premier Loline Solar Drain back Service Instructions REV: A D.O.I: 12/12/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”... - Page 55 Replacement Parts List (Exploded View 2) Item Description 591270 Closed Circuit Relief Valve 200kPa 088077 Union ½”C x ½”M 088063 (pre 19/9/06) Compression Nut ½” 088119 Anode Cover 221720-1 Jacket Top 108370 Extension Fitting – Relief Valve 088095 Pipe Seal – Solar Connections 221229 Foam Cover 221735...
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Page 56: Exploded View Collectors
Exploded View Collectors Replacement Parts List (Collectors) Item Description Part No Rail – 1 Collector 331847 Rail – 2 Collectors 331846 Rail – Extension (3 Panels) 331851 Strap 330847 Union 337121 Sensor Housing 340440 End Plug 337135 Hot Sensor 346080 Connector 340450 Compression Nut... -
Page 57: Commissioning Procedure
Commissioning Procedure Solar Circuit It is necessary to commission and check the operation of the solar circuit upon initial installation and whenever closed circuit fluid is lost due to leakage or when performing a closed circuit component replacement procedure i.e collector replacement. The commissioning procedure includes: •... - Page 58 The closed circuit fluid contains food grade additives (rust inhibitor, anti-freeze agent, colour) and is harmless to the environment. However, it is good practice to recover any excess closed circuit fluid and remove from site for appropriate disposal. Warning: Although non-toxic, the following first aid advice and procedures should be followed if the closed circuit fluid concentrate comes into human contact or is spilt: •...
- Page 59 2. The solar collectors will gain a high level of heat during periods of solar radiation. If the solar pump is activated during a period of high solar radiation and the solar collectors have not been covered, the initial flow of closed circuit fluid will absorb this heat and a rumbling sound may be heard.
- Page 60 6. Disconnect the drain line from the solar circuit relief valve at the top of the solar storage tank. Remove the spring clip from the solar circuit relief valve and remove the valve. Warning: The solar circuit may be under pressure. Take care when removing the solar circuit relief valve, as a sudden discharge of pressurised hot vapour may be experienced.
- Page 61 • The hot sensor lead is disconnected at the solar storage tank. If connected, disconnect the hot sensor lead at the solar storage tank (refer to step • The isolation valve in the pipe work between the outlet of the heat exchanger and the solar pump, located behind the pump access cover of the solar storage tank, is fully open.
- Page 62 15. Note the level of the closed circuit fluid in the fluid level hose. The closed circuit fluid should drain back to the original static level. If the closed circuit fluid does not drain back completely to this level, then check: •...
- Page 63 17. Determine the correct amount of water to be added to or closed circuit fluid to be drained from the heat exchanger if the dynamic level is either below the text marking “MINIMUM FLUID LEVEL WITH PUMP OPERATING” or more than 150 mm above this mark.
- Page 64 18. Add water to top up the level of the closed circuit fluid in the heat exchanger if required. To add water to the closed circuit fluid: • If not already removed, disconnect the drain line and remove the spring clip from the solar circuit relief valve at the top of the solar storage tank and remove the valve (refer to step 6).
- Page 65 Pressure Testing the Solar Circuit 21. Close the heat exchanger drain valve. 22. Refit the solar circuit relief valve, orientating the valve outlet to the rear of the solar storage tank. Secure with the spring clip. Reconnect the drain pipe to the valve. 23.
- Page 66 Remove Closed Circuit Fluid Level Hose 29. Remove the clear hose from the solar storage tank when satisfied the commissioning procedure is complete. To remove the hose: • Ensure the heat exchanger drain valve is closed. • Remove the hose from the side of the storage tank and place the end into a container to collect the closed circuit fluid remaining in the hose.
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Page 67: Warranty
Warranty Exclusions 1. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RHEEM WATER HEATER WARRANTY, HOWEVER THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER HEATER WARRANTY TO BECOME VOID AND MAY INCUR A SERVICE CHARGE AND / OR COST OF PARTS. -
Page 68: Document Revision History
Document Revision History Document Title: Premier Loline Service Instructions TM024 Number: Revision Details of change D.O.I. Service Manual Issued for Premier Loline 12/07 TM024 Premier Loline Solar Drain back Service Instructions REV: A D.O.I: 12/12/2007 This document is stored and maintained electronically by Service.