Rheem 871018 Service Instructions Manual
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Rheem 871018 Service Instructions Manual

Rheem 871018 Service Instructions Manual

18 & 20l integrity electronic gas instantaneous water heater
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SERVICE INSTRUCTIONS
Electronic Gas Instantaneous Water Heater
This document is stored and maintained electronically by
18 & 20L Integrity
Service. All printed copies not bearing this statement in RED are deemed "uncontrolled"
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  • Page 1 SERVICE INSTRUCTIONS 18 & 20L Integrity Electronic Gas Instantaneous Water Heater TM002 871018 875018 871020 875020 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 2: Table Of Contents

    Fault Finding Chart 4.3 ......................46 Burner Gas Pressure Check ....................47 Component Replacement Procedures ................48 Exploded View 1 – 871018 & 871020 Models ..............55 Exploded View 2 – 871018 & 871020 Models ..............57 Exploded View 3 – 871/875018-B & 871/875020-B Models ..........59 Exploded View 4 –...

  • 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 Integrity Water Heater, contact your nearest Rheem Service Department where genuine replacement parts are also available.

  • Page 4: Specifications

    Specifications 871018N0 871020N0 871018PF 871020PF 871018NF 871020NF 875018PF 875020PF Model 875018NF 875020NF 871018PF-B 871020PF-B 871018NF-B 871020NF-B 875018PF-B 875020PF-B 875018NF-B 875020NF-B Gas Type Natural Propane Natural Propane Specification Max hourly gas consumption (MJ/Hr) Min hourly gas consumption (MJ/Hr) Min inlet water pressure (kPa) Max inlet water pressure (kPa) 1000 1000...

  • Page 5: Preset Temperature Adjustment

    Preset Temperature Adjustment It is possible to choose a preset outlet water temperature setting when remote controllers are not fitted. The water heater comes factory set at 50ºC on 871 series models or 48ºC on 875 series models. Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals.

  • Page 6: Wiring Diagram - Models With Mechanical Bypass

    Wiring Diagram - Models with Mechanical Bypass TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 7: Wiring Diagram - Models With Solenoid Operated Bypass

    Wiring Diagram - Models with Solenoid Operated Bypass TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 8: Sequence Of Operation

    Sequence of Operation Refer to ‘Sequence of Operation Component Diagram’ on page 9 to view components shown in brackets e.g. (1) 1. When a hot water tap (1) is opened, cold water (or preheated water if a solar preheater is installed) enters the water heater and passes through the Water Flow Sensor (3) and Heat Exchanger (19).

  • Page 9: Bypass Operation

    Sequence of Operation Component Diagram Hot Water Tap Bypass Control Valve Water Flow Sensor Inlet Water Temperature Thermistor Combustion Chamber Thermistor Outlet Water Temperature Thermistor Water Flow Servo Motor Water Filter (Strainer) Gas Inlet Solenoid Valve Gas Solenoid Valve 1 Gas Solenoid Valve 2 Gas Solenoid Valve 3 (not fitted on 18 &...

  • Page 10: Anti-Frost Heater Circuit

    The solenoid operated bypass comprises a valve (located in the water body assembly) that is controlled by a solenoid (mounted on the water body assembly). The PCB activates the solenoid at the following predetermined temperatures: Without Touch Pads: When the unit is preset at 40 or 43 degrees. With Touch Pads: When temperatures from 37 to 46 degrees are selected.

  • Page 11: In-Series Gas Boosting

    In-series Gas Boosting Temperature controllers must not be fitted if this water heater is installed as part of a solar water heater system because water at a temperature much higher than the controller setting can be delivered. If a solar pre-heater has been installed to an existing Integrity water heater installation then a solar bypass valve or a comparator must be fitted at this water heater and any controllers, if fitted, must be disconnected and removed.
  • Page 12 The solar bypass valve has been specifically designed to work with Rheem Integrity 871020 models heaters. Models ending with -B do not require a bypass valve. 875 series model water heaters and 18 Litre Integrity’s are not suitable for use as in-series boosters.
  • Page 13 An electronic device called a Comparator (part number 052127) is now available to replace the solar bypass valve and is suitable for use on Rheem 871020 models heaters. NOTE: 20L models with a -B suffix in the model number do not require either a solar bypass valve or a comparator.
  • Page 14 Removing a Solar Bypass Valve and Installing a Comparator 1. Ensure power and water to the water heater is isolated. 2. Remove the front cover (refer to component procedure 1 on page 48). 3. Locate the 2 pin wiring plug in the wiring loom to the cold sensor mounted on the water body (refer to fig 1) and disconnect.
  • Page 15 In-series Gas Boosting 871020 Solar Loline Installation Note: For 871020 model heaters fitted with a comparator refer to diagram on page 11. For more information on comparators refer to page 13. In-series Gas Boosting 871020 Solar Hiline Installation Note: For 871020 model heaters fitted with a comparator refer to diagram on page 11. For more information on comparators refer to page 13.

  • Page 16: Tempering Valves

    Tempering Valves 875 series models comply with AS/NZS 3498 and therefore do not require a tempering valve. On 871 series models where a tempering valve is fitted and there is not a separate untempered line for the kitchen or laundry areas, the Kitchen temperature controller will be able to display temperatures above 50 C however the delivered water temperature at the tap will be that set by the tempering valve which will be no hotter than 50...

  • Page 17: Standard Controller

    875 series models are factory set and limited so that they cannot deliver water hotter than When no hot water is flowing, temperatures can be selected between 37 C and 43 C by pressing and holding the temperature control buttons, to select temperatures above 43 press the temperature control button once for each selection.
  • Page 18 This button must be pressed once to turn on the controller. The light in the button will glow when the controller is on. A controller cannot be turned on if water is flowing from a hot tap. ON / OFF button To turn off a controller, press the on / off button once.

  • Page 19: How To Fault Find

    How to Fault Find When conducting fault finding techniques it is important to understand that the same error code with a different sequence number can be displayed at different points during the operational sequence of the water heater. It is important to determine where the fault occurred in relationship to the operational sequence of the water heater before commencing fault finding tests, as the tests may differ even though the same error code can be displayed.
  • Page 20 Operational Flow Chart Section Test Equipment A list of test equipment which will assist in conducting diagnostic procedures is provided below. This equipment is available from Rheem Service Spare Parts Department. Flame detection simulator WH0020080 Flame sensor current (uA) detection kit...

  • Page 21: Operational Flow Charts

    Water Flow Sensor Input temp Input temp Hot water tap closed < or = 58ºC & 871018-B / 875018-B > 60ºC or > set < or = set temp 871020-B / 875020-B temp? - 2ºC? 871018 / 875018 871020 / 875020 Max &...
  • Page 22 Igniter off Igniter off Gas rate change-over Proportional temperature C.I. Off adjustment done by solenoid valves Hot water volume adjustment 871018-B / 875018-B temp. 46 degrees 871020-B / 875020-B or lower? & *solenoid bypass models *Mechanical bypass models Solenoid bypass...
  • Page 23 Operation Flow Chart 3 Hot tap closed Post Purge Shut Down Function Water flow sensor off Check gas cut off function by G.I.S.V (SVO) off alternating the closing order of gas valves SVO and SV1-2 at [S.V. 1-2 (SV1-2) off] each shut down P.G.F.R Valve at minimum...

  • Page 24: Error Codes

    Error Codes The following table outlines the error codes, possible causes and diagnostic tests to conduct. More detailed diagnosis is outlined in the fault finding and operational flow charts. Error Fault Condition Items To Check Code Abnormal low rate combustion Blockage in the heat exchanger, fan, air intake or flue P.G.F.R Valve - diagnostic point 10 G.I.S Valve - diagnostic point 11...

  • Page 25: Diagnostic Test Points

    Diagnostic Test Points Refer to wiring diagram, page 7, for connector and wiring positions. Measuring Point Test Normal Condition Items Under Test Wire Nº Point Connector & colour R1 – R2 AC 85V – 120V Main Power W8 – W12 50 kilo-ohms –...

  • Page 26: Maintenance Information

    Maintenance Information Information relating to both the current and past operation of the water heater can be obtained from the memory; this information is referred to as the maintenance information. The table below details the information that can be recalled from the memory i.e. to view the current temperature being measured by the outlet thermistor select 5Y, refer to page 27 for the procedure to display maintenance information.

  • Page 27: Displaying Maintenance Information

    Displaying Maintenance Information Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons. At the Water Heater 1.

  • Page 28: Resetting Error Codes

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

  • Page 29: Fault Diagnosis Sequence (Fault Finding Chart G)

    Fault Diagnosis Sequence (Fault Finding Chart G) General Fault Finding Chart Turn on power to the water heater NOTE: The bars are displayed for approx. 10 seconds Are 2 bars displayed on the LED? Turn on the Does controller the LED in the using the ON/ ON/OFF button OFF button...

  • Page 30: Fault Finding Chart 1

    Fault Finding Chart 1 Voltages up to 240 volts will be present within the water heater, take care not to touch wiring terminals. Use an insulated tool when operating the DIP switch or MIN and MAX buttons. Power Supply Is 240 volts AC Present at No power supply.
  • Page 31 Fault Finding Tests 1 – 4 Components will be “Live” when conducting tests, exercise caution. Test 1 Test 2 Measure the voltage at the connector plug to Measure the voltage at the connector plug transformer primary winding with from the transformer secondary winding with multimeter set on the AC voltage scale.

  • Page 32: Fault Finding Chart 2

    Fault Finding Chart 2 System Not Ready Overheating Replace over temperature limiter Test 5 Is the Is error and check for damage in the resistance of the code 14 combustion chamber. Check and over temp limiter displayed? reset minimum and maximum normal? burner pressures if required.
  • Page 33 Fault Finding Tests 5 – 8 Isolate power before removing connector plugs Test 5 Test 6 Unplug connector B from the PCB and measure Unplug connector K from the PCB. Restore resistance Over Heat Limiter power and check if error code 79 is displayed Assembly.

  • Page 34: Fault Finding Chart 3

    Fault Finding Chart 3 Ignition and Temperature Control Operation switch malfunction Is error Is error code 24 shown on code 24 Replace the remote controller. error code display displayed? also? Test 7 Also when Release the Min/Max buttons and Min/Max button is re-open a hot tap.
  • Page 35 Fault Finding Tests 9 – 13 Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution Tests 9 and 10 – Diagnostic Point 4 Test 11 Diagnostic Point 4 Conduct test with water flowing Check Point Measured Value Test Isolate power before removing...

  • Page 36: Fault Finding Chart 3.1

    Fault Finding Chart 3.1 Test 11 False flame detection malfunction Is flame Is error detection signal in code 72 Replace the PCB assembly. maintenance information displayed? Clean or replace the combustion chamber front panel assembly. Ignition failure or cross light failure Is error code 11...

  • Page 37: Fault Finding Chart 3.2

    Fault Finding Chart 3.2 Is gas available? Open the gas isolation valve. Test 14 Is the gas pressure correct there voltage at the Replace the PCB assembly. at the burner test gas inlet solenoid point? valve? Test 15 Is the resistance of the gas Replace the proportional gas flow inlet solenoid valve...
  • Page 38 Fault Finding Tests 14 – 22 Isolate power when conducting resistance tests. “Live” components present during voltage tests, exercise caution. Tests 14, 15, 18 and 19 NOTE: Measure the voltage with connector L plugged into PCB Measure the resistance with connector L unplugged from the PCB Solenoid Normal...

  • Page 39: Fault Finding Charts 3.3 And 3.5

    Fault Finding Charts 3.3 and 3.5 Flame failure Are the Is error max and min Adjust maximum and minimum code 12 burner pressures burner pressures. displayed? correct? Abnormal Clean the heat exchanger, combustion Is error combustion chamber, fan and air code 10 or 99 intake.

  • Page 40: Fault Finding Chart 3.6

    46º. circuit? code 65 Integrity Replace water body assembly. displayed? Temp set 871018-B above 46º. Note: the bypass solenoid is activated only 875018-B *For models without a if the set temperature is below 46 degrees. 871020-B -B suffix e.g.
  • Page 41 Fault Finding Tests 23 – 28 Test 23 - Diagnostic Point 18 Test 24 - Diagnostic Point 18 Conduct test with water flowing Conduct test with water flowing Test Point Test Point Measured Value Measured Value Connector H Connector H 2 White - 8 Black DC8 –...

  • Page 42: Fault Finding Chart 3.7

    Remove solar bypass valve fitted? and fit a comparator. Is a Comparator Replace the comparator. fitted? Is the heater an 871018-B Fit a comparator. or 871020-B model? Is the Test 15 resistance of the proportional gas flow Replace the PCB assembly.

  • Page 43: Fault Finding Chart 3.8

    Fault Finding Chart 3.8 Fan current detecting circuit failure Error code 79 Error code displayed prior to 79 displayed. opening the hot tap? Replace the PCB assembly. Note: only replace the PCB assembly if error code 79 is displayed during combustion. Fault Finding Tests 29 –...

  • Page 44: Fault Finding Charts 4 And 4.1

    Fault Finding Charts 4 and 4.1 Is the Read Is the water Integrity used as maintenance flow more than 3 an in-series gas information 1y litres/min? booster? 1y = Water flow detected by water flow sensor Test 28 Is the voltage between Controllers Replace the PCB assembly.

  • Page 45: Fault Finding Chart 4.2

    Fault Finding Chart 4.2 871020 models must have a solar bypass valve or a comparator fitted Is a Is a when used as an in-series gas booster. If solar bypass valve comparator a solar bypass valve and a comparator fitted? fitted? are fitted, remove the solar bypass valve.

  • Page 46: Fault Finding Chart 4.3

    Fault Finding Chart 4.3 Water will be diverted by the the preheated solar bypass valve. No water will water to the solar flow through the Integrity bypass valve > therefore it will not operate. 57ºC? Normal operation. Read 1y = Water flow maintenance detected by water information 1y...

  • Page 47: Burner Gas Pressure Check

    Fault Finding Tests 32 and 33 Test 32 Components will be “Live” when conducting test, exercise caution Conduct test with water flowing Measure the voltage at the 3 pin connector located between the water flow sensor and the comparator. Measure the voltage between the brown and black wires at this connector.

  • Page 48: Component Replacement Procedures

    Adjustment Adjustment of the burner pressure will not overcome problems associated with poor supply pressure or incorrect gas supply pipe sizing. Minimum Burner Gas Pressure 1. Remove the front panel from the water heater. 2. Remove burner test point screw and fit manometer. 3.
  • Page 49 Burner Change-Over Assembly: (Procedure 2) 1. Remove the front panel. Refer to Procedure 1. 2. Disconnect the wiring plug from each of the solenoid valves. (Note which plug goes to each valve) 3. Remove the screw retaining the ignition pack to the Burner Change Over Assembly. 4.
  • Page 50 Proportional Gas Flow Regulating Valve: (Procedure 7) 1. Remove the front panel and Burner Change Over Assembly. Refer to Procedures 1 and 2. 2. Disconnect the gas supply pipe from the gas inlet connection. 3. Remove the three screws from the gas inlet connector and withdraw the connector and o-ring from the base of the water heater.
  • Page 51 Anti-Frost Heaters: (Procedure 10) Note: Only models with an ‘F’ in the model number are fitted with anti-frost heaters e.g. 871020NF. 1. Remove the front panel. Refer to Procedure 1. Heat Exchanger and Hot Water Outlet Connection Heaters 1. Disconnect connector plugs at the sensing thermostat and at the power cord. 2.
  • Page 52 Ignition Pack Replacement: (Procedure 12) 1. Remove the front panel. Refer to Procedure 1. 2. Disconnect high voltage lead from spark electrode. 3. Disconnect the multi pin connector from the Ignition Pack. 4. Remove the retaining screw. 5. Remove the Ignition Pack. 6.
  • Page 53 Remote Controller: (Procedure 17) 1. Isolate power at the water heater. 2. Remove the small Philips head screw from the bottom of the Remote Controller. 3. Gently pivot the Remote Controller up from the bottom and then lift up and off upper retaining lugs.
  • Page 54 6. Remove 2 Philips head retaining screws holding flow sensor to water body assembly and remove flow sensor. 7. Using a flat bladed screwdriver lever the metal disc and o-ring from flow sensor housing on water body assembly. Lever the disc out by placing the shaft of the screwdriver across the disc with the tip of the screwdriver on the far inside edge of the disc.

  • Page 55: Exploded View 1 - 871018 & 871020 Models

    Exploded View 1 – 871018 & 871020 Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 56 Replacement Parts List Exploded View 1 – 871018 & 871020 Models Ref. Description 871018 871020 Front Panel Assembly (50 & 60ºC Models) WH0020000 Jacket Assembly WH0020001 Mounting Bracket WH0020002 Reinforcing Plate WH0020003 Cord Connector WH0020004 Fixing Plate B WH0020005 Gas Inlet Connector...

  • Page 57: Exploded View 2 - 871018 & 871020 Models

    Exploded View 2 – 871018 & 871020 Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 58 Replacement Parts List Exploded View 2 – 871018 & 871020 Ref. No. Description 871018/020 Silicone Tube (Insulator) WH0020045 Silicone Tube (Insulator) WH0020046 Anti-Frost Heater WH0020047 Anti-Frost Heater Assembly WH0020088 Anti-Frost Heater Clamp WH0020049 Anti-Frost Heater “C” Clamp WH0020050 Anti-Frost Heater Clamp...

  • Page 59: Exploded View 3 - 871/875018-B & 871/875020-B Models

    Exploded View 3 – 871/875018-B & 871/875020-B Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 60 Replacement Parts List Exploded View 3 – 871/875018-B & 871/875020-B Models Ref. 871018-B 871020-B Description 875018-B B875020-B Front Panel Assembly (50 & 60ºC Models) WH0020000 Jacket Assembly WH0020001 Mounting Bracket WH0020002 Reinforcing Plate WH0020003 Cord Connector WH0020004 Fixing Plate B...

  • Page 61: Exploded View 4 - 871/875018-B & 871/875020-B Models

    Exploded View 4 – 871/875018-B & 871/875020-B Models TM002 Integrity 18 & 20L Service Instructions REV: E D.O.I: 7/11/2007 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 62 Replacement Parts List Exploded View 4 – 871/875018-B & 871/875020-B Models Fitted with solenoid operated bypass 871018-B 875018-B Ref. No. Description 871020-B 875020-B Silicone Tube (Insulator) WH0020045 Silicone Tube (Insulator) WH0020046 Anti-Frost Heater WH0020047 Anti-Frost Heater Assembly WH0020088 Anti-Frost Heater Clamp WH0020049 Anti-Frost Heater “C”...

  • Page 63: Gas Type Conversion Procedure

    Gas Type Conversion Procedure 1. Isolate the power and gas supply to the water heater. 2. Remove the front panel. (Refer to Procedure 1) 3. Remove the Burner Change Over Assembly (Refer to Figure 1 and Procedure 2) 4. Remove the Combustion Chamber Front Panel Assembly. (Refer to Figure 2 and Procedure 3) 5.

  • Page 64: Warranty

    The replaced part or water heater does not carry a new warranty. 4. 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 Service branch office, or an Accredited Service Agent, the cost of transport, insurance and travelling costs between the nearest Rheem Service Accredited Service Agent’s premises and the installed site shall be the owner’s responsibility.

  • Page 65: Document Revision History

    Document Title: Integrity 18 & 20L Service Instructions TM002 Number: Revision Details of change D.O.I. Service Instructions issued for 871018, 871020, 871024 05/01 Rheem Integrity References to Southcorp Water Heaters replaced with Rheem 03/02 Australia Models with Solenoid bypass added...

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