Rheem Australia Pty Ltd ABN

Transcription

1 Rheem Australia Pty Ltd ABN SERVICE INSTRUCTIONS Lazer 701, 702 & 703 Series Boiling Water Units TM063 REV AA Issued: Jan First Issued 04/13

2 CONTENTS INTRODUCTION... 3 SAFETY WARNING... 3 BWU MODEL IDENTIFICATION... 4 PREVENTATIVE MAINTENANCE... 5 SPECIFICATIONS... 6 WIRING DIAGRAMS... 8 PLUMBING DIAGRAM... 9 OPERATION... 9 OPERATIONAL FLOW CHARTS ELECTRONIC CONTROLLER TIMER Timer 701 & 702 Series Accessing Service Menu ECO Timer 703 Series ECO Timer LED Indication COMPONENTS AND THEIR FUNCTION COMMON COMPLAINTS FAULT FINDING ERROR CODES Testing the Boiling Water Thermistor Error Code A Error Code B Error Code C Error Code D Error Code E Error Code G Error Code H & Error Code J Error Code K Error Code L Error Code N Fault Finding Chart Fault Finding Chart Fault Finding Chart 1.1a Fault Finding Chart Fault Finding Chart Fault Finding Chart 4, 4.1 & Fault Finding Chart 4a, incl. (4.1 & 4.2) 703 Series Fault Finding Chart Fault Finding Chart 5a 703 series Fault Finding Chart Fault Finding Chart Fault Finding Tests ELECTRICAL SAFETY TESTING COMPONENT REPLACEMENT PROCEDURES DOCUMENT REVISION HISTORY

3 INTRODUCTION The information provided in these instructions is based on the Boiling Water Unit (BWU) being installed in accordance with the Installation Instructions provided with each appliance. Should you require further technical advice on a Rheem BWU, contact your nearest Rheem Service Department where genuine replacement parts are also available. SAFETY WARNING The purpose of this service manual is to provide sufficient information to allow a person with the skills as required by the Regulatory Authorities to carry out effective repairs to a 701, 702 or 703 Series Boiling Water Unit in the minimum of time. Safety precautions or areas where extra care should be observed when conducting tests outlined in this service manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended procedure. Live testing to be conducted. Personal Protective Clothing (PPE) shall be worn and an RCD shall be installed between the power point and 3-pin cord of the boiling water unit to reduce the risk of electric shock. Isolate power before conducting the indicated test. Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to reduce the risk of burns or scalding. General warning symbol. Observe the instructions accompanying the symbol. If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or a similarly qualified person in order to avoid a hazard. 3

4 BWU MODEL IDENTIFICATION The identification numbers are designed to convey detailed information about the BWU to which it is attached. The model number consists of 5 digits and 3 letters. Model Number W AU Type 7 Boiling Water Model Type 01 Office Model 02 Commercial Model 03 Eco Model Capacity in Litres 03 3 Litres 05 5 Litres Litres Litres Litres Litres Litres Finish W White S Stainless steel Version AU Australia Version 4

5 PREVENTATIVE MAINTENANCE It is suggested for peak performance that the Boiling Water Unit be serviced every six months. Servicing must be performed by suitably qualified persons Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to reduce the risk of burns or scalding 1. Check the inlet strainer located inside the water inlet connection to ensure it is clean and not blocked with foreign matter. If an additional auxiliary filter is fitted, such as in areas of poor water quality check to ensure it is also clean and not blocked with foreign matter. 2. Check for signs of excessive corrosion on jacket and internal panels. Corrosion can be indicative that a leak is present. 3. Check for leaks at all BWU fittings. 4. Check the vent line to ensure it is not blocked with foreign matter. It is imperative that the vent line does not become blocked as the BWU is not designed to be pressurised. 5. Isolate power and check all electrical connections for signs of overheating due to poor connection. 6. Conduct an electrical safety test. (Refer to page 42). 7. Check tap for signs of leaking & excessive dripping after operation (clean or replace if required. 5

6 SPECIFICATIONS 3L 10L Lazer Boiling Water Unit Storage capacity 3 Litres 5 Litres 7.5 Litres 10 Litres Max supply pressure (1) 1000kPa 1000kPa 1000kPa 1000kPa Min supply pressure 50kPa 50kPa 50kPa 50kPa Cold water inlet connection RP½/15 RP½/15 RP½/15 RP½/15 Overflow / vent connection RP½/15 RP½/15 RP½/15 RP½/15 Supply voltage Volts AC 50Hz Electrical connection 10A 3 pin plug kw 1.8kW 2.4kW 2.4kW 2.4kW Element Resistance 32Ω 24Ω 24Ω 24Ω Amperage 7.5A 10A 10A 10A ECO setting Open 105ºC, close 95 ºC (manual reset) Inlet solenoid Resistance 3.5KΩ 3.5KΩ 3.5KΩ 3.5KΩ Flow regulator 0.5 L/M (yellow regulator located in solenoid) Boiling thermistor resistance Refer to table on page 25 Approx recovery (2) 17.5 L/hr 21 L/hr 21 L/hr 21 L/hr Approx heat time to capacity (2) 12 min 15 min 22 min 29 min Drain plug No No No No Inlet strainer (3) Yes Yes Yes Yes (1) If the supply pressure exceeds 1000kPa, a pressure limiting valve must be installed upstream of the BWU. (2) Operation based on an inlet water temperature of 18ºC. (3) In areas with poor water quality an additional filter should be installed. 6

7 SPECIFICATIONS (cont) 15L 40L Lazer Boiling Water Unit Storage capacity 15 Litres 25 Litres 40 Litres Max supply pressure (1) 1000kPa 1000kPa 1000kPa Min supply pressure 75kPa 75kPa 100kPa Cold water inlet connection RP½/15 RP½/15 RP½/15 Overflow / vent connection RP½/15 RP½/15 RP½/15 Supply voltage Volts AC 50Hz Electrical connection 10A 3 pin plug Fixed Wiring kw 2.4kW 3.6kW 4.6kW Resistance 24Ω 16Ω 12Ω Element Amperage 10A 15A 20A ECO setting Open 105ºC, close 95 ºC (manual reset) N/A Inlet solenoid Resistance 3.5KΩ 3.5KΩ 3.5KΩ Flow regulator 2.5 L/M (brown regulator located in solenoid) Boiling thermistor resistance Refer to table on page 25 Approx recovery (2) 21 L/hr 33 L/hr 41 L/hr Approx heat time to capacity (2) 40 min 40 min 50 min Drain plug No No Yes Inlet strainer (3) Yes Yes Yes (1) If the supply pressure exceeds 1000kPa, a pressure limiting valve must be installed upstream of the BWU. (2) Operation based on an inlet water temperature of 18ºC. (3) In areas with poor water quality an additional filter should be installed. 7

8 WIRING DIAGRAMS Wiring Diagram 3 15L Models Wiring Diagram 25 & 40L Models (Commercial 702 Series only) 8

9 PLUMBING DIAGRAM Cold mains pressure water must be piped and connected to the RP½/15 inlet fitting located on the left hand side underneath the BWU. An accessible isolating valve must be installed near the BWU. The BWU contains an inlet strainer on the water inlet connection. Where poor water quality is present it is recommended to install an additional auxiliary filter. The vent pipe is to be made of a material that cannot be degraded by continuous steam (i.e. copper). Water Inlet and Vent Connections OPERATION All models have same pipework configuration Rheem 701, 702 and 703 Series Boiling Water Units operate on volts AC and will deliver gravity fed boiling water via a lever operated tap mounted on the boiling water unit. Sequence of Operation Refer to Boiling Water Unit Sequence of Operation Component Diagrams on page 11 to view components shown in brackets e.g. (1). 1. When power is supplied to the BWU the control board relay (1) is energised. If the low level probe (2) does not detect water the inlet solenoid valve (3) is energised allowing water to enter and partially fill the boiling water tank (4) until 15 seconds after the low level probe (2) detects water. Note: Upon initial filling and calibration, the inlet solenoid valve (3) is energised until 30 seconds after the low level probe (2) senses water. 2. When the BWU is operated for the first time, or auto calibration mode is selected (5), the unit will enter auto calibration mode. When in auto calibration mode the BWU will perform three heating operation cycles in which to determine and program the optimum boiling water temperature setting according to altitude. The optimum boiling water temperature is termed Treq which is the water temperature the BWU will maintain the boiling water at after calibration. Auto calibration mode takes approximately minutes to perform (depending upon model capacity) and should not be interrupted. 3. After calibration or under normal operating conditions; if the boiling water thermistor (6) detects a temperature of less than 94ºC, or less than or equal to Treq - 2ºC, the control board triac (7) allows power to the boiling water element (8) on a percentage basis of between 20% (48 volts) to 100% ( volts) depending upon the temperature, i.e. higher temperature difference equals higher percentage basis. 9

10 4. After first time calibration or after drawing boiling water; the control board will incrementally fill and heat the water in the boiling water tank (4). After the first incremental fill, the water in the boiling water tank (4) is heated to Treq - 2ºC at which time the control board will energise the inlet solenoid valve (3) until the water in the boiling water tank (4) is at - 3 ºC of Treq which allows more water to enter the boiling water tank (4) (normally 4 15 seconds). This allows the boiling water to be heated in increments enabling boiling water to be available in a shorter period of time. This process is continued until the high level probe (10) detects water at which time the inlet solenoid valve (3) is de-energised and incremental filling ceases. 5. After the high level probe (10) detects water, heating is continued until the boiling water thermistor (6) detects a temperature equal to Treq at which time the control board triac (7) switches off (de-energising the boiling water element (8)) and the control board relay (1) is de-energised. 6. When the tap (9) lever is operated, boiling water is gravity fed to the tap (9) outlet. As the water level in the boiling water tank (4) falls below the high level probe (10) the inlet solenoid valve (3) is energised allowing water to enter the boiling water tank (4) again in 4 15 second incremental fills or until the high level probe (10) detects water again (depending upon the amount of boiling water drawn). It should be noted that if the water level in the boiling water tank (4) falls below the low level probe (2) at any time, the boiling water element circuit is disabled until the low level probe (2) detects water again for a period of 1 second or more. 7. When the high level probe (10) detects water again, the inlet solenoid valve (3) is deenergised preventing water from entering the boiling water tank (4). 8. If during any stage of operation: Notes: The boiling water thermistor (6) becomes open or short circuited, The low level probe (2) is shorted to earth, or The control board triac (7) becomes short circuited, The inlet solenoid valve (3) and control board triac (7) are de-energised (if on) and the control board relay (1) will turn off (be de-energised). 701 & 702 series only: If the timer (5) off period has been programmed and reached, the boiling water Treq temperature is changed from calibrated Treq temperature to 0ºC, until the next timer on period is reached, or the timer (5) off period is deactivated by pressing any timer button, at which time the calibrated Treq setting will return to normal. This is an energy saving function. 703 Series: If the eco timer (5) has been set and reached, again, the boiling water Treq temperature changes from calibrated Treq temperature to 0ºC. Sleep mode is deactivated by pressing and releasing the ECO button, at which time the calibrated Treq setting will return to normal. This is an energy saving function. 10

11 Boiling Water Unit Sequence of Operation Component Diagram 3 15L Models LH side Front view NZ 703 series RH side 1 Control board relay 5 Timer 9 Tap 2 Low level probe 6 Boiling water thermistor 10 High level probe 3 Inlet solenoid valve 7 Control board triac 4 Boiling water tank 8 Boiling water element 25 40L Models Left Hand View Front View Commercial Right Hand View 11

12 OPERATIONAL FLOW CHARTS Operational Flow Chart 701 & 702 Series (7) Plug In Power On Control board relay on (1) Fault rectified Critical fault detected? (2, 6) Isolate Power Error Code Displayed Control board relay off Control board triac (element) disabled Inlet solenoid off (if on) A Low level probe detects water? Inlet solenoid on Control board triac (element) off (if on) Low level probe detects water? Auto calibration already performed? High level probe detects water? (3) Treq becomes Tb -2 Inlet solenoid off after 15 seconds (if on) Inlet solenoid off after 30 seconds Full auto calibration (3) (5) (4) cycle performed Control board triac Treq becomes Tb -3 Reduced auto (element) on 20% - 100% calibration cycle performed (3) Treq value set using Temp Override? (3) (3) T0 = Treq -2? Inlet solenoid on T0 < Treq -3? (2, 6) Inlet solenoid off High level probe detects water? Critical fault detected? Inlet solenoid off T0' = Treq? Control board triac (element) off T0' < Tb -3? (3) (3) (5) Notes: (1) Control board relay on = Boiling water triac (element) circuit enabled. (2) The PCB monitors for faults while ever the boiling water unit is operating. (3) Tb is the boiling point temperature detected during calibration; Treq is the temperature the water will be maintained at; T0 is the water temperature detected by the boiling water thermistor. (4) Calibration is automatically performed by the control board on initial power up. Calibration will take approx minutes (depending upon capacity) during which time 2 heating cycles will be performed. The tap should not be operated whilst calibration is being performed. (5) When measured using a conventional multimeter the voltage will be approx VAC. (6) Critical faults are; Hot Sensor O/C or S/C, Triac S/C & Level Probe shorted to earth. (7) Control board relay off = Boiling water triac (element) circuit disabled. A Control board triac (element) on 20% - 100% Timer in OFF period and AUTO selected? Control board triac (element) off Timer ON period reached? High level probe detecting water? Timer button pressed? Water drawn off Sleep mode period set? Water temp (Treq) maintained at 0ºC (element off) High level probe detecting water? TImer button pressed? Water drawn off (3) (5) (3) T0 < 70 C for 3.5 days? Control board triac (element) on 20% - 100% T0 = 70 C? Control board triac (element) off 12

13 Operational Flow Chart 703 Series (7) Plug In Power On Control board relay on (1) Fault rectified (2, 6) Critical fault detected? Isolate Power Control board relay off Control board triac (element) disabled Inlet solenoid off (if on) A Low level probe detects water? Inlet solenoid on Control board triac (element) off (if on) Low level probe detects water? Auto calibration already performed? High level probe detects water? (3) Treq becomes Tb -2 Inlet solenoid off after 15 seconds (if on) Inlet solenoid off after 30 seconds (3) Treq becomes Tb -3 (5) Control board triac (element) on 20% - 100% Calibration cycle performed (4) (3) (3) T0 = Treq -2? Inlet solenoid on T0 < Treq -3? Inlet solenoid off High level probe detects water? (2, 6) Critical fault detected? Inlet solenoid off T0' = Treq? Control board triac (element) off T0' < Tb -3? Control board triac (element) on 20% - 100% Sleep delay mode activated? T0 < 70 C for 3.5 days? (3) (3) (5) (8) (3) A Notes: (1) Control board relay on = Boiling water triac (element) circuit enabled. (2) The PCB monitors for faults while ever the boiling water unit is operating. (3) Tb is the boiling point temperature detected during calibration; Treq is the temperature the water will be maintained at; T0 is the water temperature detected by the boiling water thermistor. (4) Calibration is automatically performed by the control board on initial power up. Calibration will take approx minutes (depending upon capacity) during which time 2 heating cycles will be performed. The tap should not be operated whilst calibration is being performed. Also refer to note 8. (5) When measured using a conventional multimeter the voltage will be approx VAC. (6) Critical faults are; Hot Sensor O/C or S/C, Triac S/C & Level Probe shorted to earth. (7) Control board relay off = Boiling water triac (element) circuit disabled. (8) To activate sleep delay mode: (NZ) press and release the eco button whilst the eco circle surround is extinguished, (AU) press the ECO button whilst the green ECO LED is extinguished. When the eco button is released: (NZ) the eco circle surround, (AU) the ECO LED will illuminate green to indicate the unit is in sleep delay mode. When the unit is asleep the Press eco to heat text will illuminate: (NZ) green, (AU) ECO within the text PRESS ECO TO HEAT illuminates Red. (9) To deactivate sleep delay mode press and release the eco button: (NZ) whilst the eco circle surround is illuminated green, (AU) press the ECO button whilst the green ECO LED is illuminated. When the eco button is released the: (NZ) eco circle surround, (AU) ECO LED will extinguish. (10) Calibration mode can be entered by removing power supply then holding the ECO button in the depressed position whilst restoring power supply. The HEATING LED will illuminate and flash at which time the ECO button can be released. The unit will now recalibrate. 2 hrs since last solenoid valve operation? (5) Control board triac (element) on 20% - 100% Water temp (Treq) maintained at 0ºC (element off) T0 = 70 C? (3) (8) (9) Sleep delay mode deactivated? Water temp (Treq) becomes Tb - 3 (9) Control board triac (element) off Calibration mode entered? (10) Note: Refer to page 21 for timer LED indication. 13

14 ELECTRONIC CONTROLLER The control board or electronic controller is used to control the boiling water unit by monitoring the water temperatures in the boiling water tank (via the boiling water thermistor) and processing commands received from the timer. The control board has a relay which when energised will switch power to the boiling water triac (boiling water element circuit). In the event of a critical fault the control board relay will de-energise and open circuit the boiling water element circuit preventing it from operating. TIMER 3 15L Model Electronic Controller 25 & 40L Model Electronic Controller There are two types of timers available depending upon boiling water unit series. Refer to Timer 701 & 702 series below or ECO Timer 703 Series page 21. Timer 701 & 702 Series 701 & 702 series boiling water units are supplied with a programmable 24 hour 7 day timer which can be programmed to turn the boiling water unit ON or OFF at predetermined days and times. The timer incorporates a Sleep Delay Time function which when programmed will automatically shut the system down after a set period of time of no use i.e. after 6 hours. The timer has a Filter Life function which when programmed and selected will display the remaining life of the water filter in litres. Note: A water filter is optional and is not supplied as standard. The timer has a Service Menu which can display error codes, temperature settings etc. The timer also has a key lock function which when activated prevents access to the program functions. Front view Rear view 14

15 Timer Functions Function Mode Description Clock N/A Set clock time. STD BWU ON 24 hours 7 days. STD/AUTO BWU operates according to programmed AUTO Set ON/OFF Times. Set ON/OFF Times N/A Program ON/OFF times for AUTO mode. Sleep Delay Time N/A Program delay-off time from last usage (operates in AUTO mode only). Remaining Life Displays remaining filter life in litres. Filter Life* Filter Reset Resets filter Remaining Life to Set Filter Life setting. Utilised when replacing filter. Set Filter Life Program filter life start value in litres. Error Codes Displays alpha error codes (refer to page 24 for error codes and their meanings). Boiling Temp Displays the current boiling water temperature in ºC. Calib. Reset Reactivates automatic boiling point calibration operation. Manually select calibrated temp setting. Temp Override Service Menu Selectable from ºC. Software Version Displays Timer and Controller software versions (top = Timer, lower = Controller). Temp Show ON/OFF Enable/disable boiling water temperature display on timer screen (in ºC). Displays boiling water temperatures in ºC. TB Treq (TB = calibrated temp, Treq = maintained temp). * 701 and 702 Series Boiling Water Units do not have a water filter however filter life functions can be utilised if the water supply to the BWU has a water filter fitted. Timer Operation Selecting a Timer Function 1. Press and release the (P) button until the desired function is displayed flashing on the screen (refer to table above for a list of available timer functions). 2. Press and release the ( ) button to confirm selection. Notes: Pressing and releasing the (X) button at any time returns the unit to the main menu. Any functions previously accepted will be retained. The display will revert back to main menu from any mode if a button has not been pressed after 1 minute. 15

16 Setting the Clock 1. Press and release the (P) button, Clock is displayed flashing on the screen. 2. Press and release the ( ) button to confirm selection. Set Clock Day will be displayed on the screen with the day selection shown flashing. 3. Press and release the ( ) button until the desired day is selected. 4. Press and release the ( ) button to confirm selection. Set Clock HOUR will be displayed on the screen with the hours section of the time shown flashing. 5. Press and release the ( ) button until the desired hour (24 hour time) appears flashing on the screen. 6. Press and release the ( ) button to confirm selection. Set Clock MIN will be displayed on the screen with the minutes section of the time shown flashing. 7. Press and release the ( ) button until the desired minute appears flashing on the screen. 8. Press and release the ( ) button to confirm selection. The display will revert to the main menu and the time setting will be saved. Selecting STD or AUTO Mode 1. Press and release the (P) button until Timer STD/AUTO is displayed flashing on the screen. 2. Press and release the ( ) button to confirm selection. STD will be displayed flashing on the screen. 3. Pressing and releasing the ( ) button alternates between the STD and AUTO icons. 4. Press and release the ( ) button when the STD or AUTO icon is shown on the display. The display will revert to the main menu. If STD is selected the unit will operate 24 hours a day. If AUTO is selected the unit will operate according to the pre set times on the timer (refer to Programming Set ON/ OFF Times below). Note: If the timer is in AUTO mode and is in an OFF period, the pressing of any Timer button or lever on the tap will reactivate the unit. The unit will then operate normally until the next programmed OFF time. Programming Set ON/OFF Times (For Use in AUTO Mode) Note: A highlighted numeral i.e. 7:00 indicates that the highlighted numeral 7 is flashing on the display. X:XX is your time setting. 1. Press and release the (P) button until Set ON/OFF Time is displayed flashing on the screen. 2. Press and release the ( ) button to confirm selection. SUN 7:00 7:00 Set ON hour will be displayed on the screen. 3. Press and release the ( ) button until the desired hour appears flashing on the screen. 4. Press and release the ( ) button to confirm selection. SUN X:XX X:XX Set ON minute will be displayed on the screen. 5. Press and release the ( ) button until the desired minutes appear flashing on the screen. 6. Press and release the ( ) button to confirm selection. SUN X:XX X:XX Set OFF hour will be displayed on the screen. 7. Press and release the ( ) button until the desired hour appears flashing on the screen. 16

17 8. Press and release the ( ) button to confirm selection. SUN X:XX X:XX Set OFF Minute will be displayed on the screen. 9. Press and release the ( ) button until the desired minutes appear flashing on the screen. 10. Press and release the ( ) button to confirm selection. MON 7:00 17:30 Set ON hour will be displayed on the screen. 11. Continue steps 3 8 for Monday through to Saturday. When step 8 is completed for Saturday the display will automatically revert to the main menu and the program will be saved. Note: To program the unit to be in OFF mode for an entire day, set the ON and OFF times to be the same i.e. ON = 0:00 OFF = 0:00 Programming Sleep Delay Time 1. Press and release the (P) button until Sleep Delay Time is displayed flashing on the screen. 2. Press and release the ( ) button to confirm selection. Sleep Delay Time OFF will be displayed on the screen with OFF flashing. 3. Press and release the ( ) button until the desired time setting appears flashing on the screen. Each consecutive push and release of the ( ) button increases the time setting in one hour increments up to a maximum of 6 hours. If the ( ) button is pressed and released after 6 is reached OFF will be displayed and if accepted, the sleep delay timer will be turned off. 4. When the desired setting is reached press and release the ( ) button to confirm selection. The display will revert to the main menu and the setting will be saved. Note: The sleep function puts the unit in a standby mode after a user defined period (1 6 hours). The unit will enter Sleep mode if it has not been used for the programmed Sleep Delay Time period. During Sleep mode the unit will change the Treq boiling water temperature to 0ºC instead of the normal Treq (approximately 97ºC). To exit sleep mode, press any Timer button to reactivate the unit. The unit will then operate normally. Selecting Filter Life Functions The Filter Life function has three modes to select from, Remaining Life, Filter Reset and Set Filter Life. These modes are accessed as follows: Accessing Remaining Life 1. Press and release the (P) button until Filter Life is displayed flashing on the screen. Note: if Remaining Life COUNT IS OFF is displayed on the screen proceed directly to step 3 otherwise proceed to step Press and release the ( ) button to confirm selection. Remaining Life XXXX Litres will be displayed on the screen where XXXX is the value of remaining filter life in litres. 3. Press and release the (X) or ( ) button to revert back to the main menu. 17

18 Activating Filter Reset & Set Filter Life 1. Press and release the (P) button until Filter Life is displayed on the screen. Note: if Remaining Life COUNT IS OFF is displayed on the screen proceed directly to step 3 otherwise proceed to step Press and release the ( ) button to confirm selection. Remaining Life XXXX Litres will be displayed on the screen. 3. Press and release the ( ) button. Filter Reset is displayed on the screen. 4. Press and release the ( ) button to confirm selection. Are You Sure will be displayed flashing on the screen. 5. Press and release the ( ) button to confirm selection. Set Filter Life YYYY Litres is displayed on the screen (with YYYY Litres flashing) where YYYY is the previous preset value in litres. Note: OFF may be displayed flashing on the screen if the previous value was set to OFF. 6. Press and release the ( ) button until the desired setting appears flashing on the screen. Each consecutive push and release of the ( ) button increases the capacity setting in 1,000 litre increments from a start value of 1,000 litres up to a maximum setting of 14,000 followed by OFF. 7. Press and release the ( ) button to confirm selection. The display will revert to the main menu and the setting will be saved. Accessing Service Menu The service menu has seven modes to select from (refer to Timer Functions page 15). When service mode is entered, any existing error codes will be displayed on the screen. (Refer to page 24 for error codes and their meaning.) Each mode is accessed as follows:- Accessing Error Codes 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. 3. Press and release the (X) or ( ) button to revert back to the main menu. Note: An error code will be automatically cleared from the display when the fault relating to that error code is rectified and the BWU is re-powered. (Refer to page 24 for error codes and their meaning.) Accessing Boiling Temp 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Existing error codes will be displayed on the screen. 3. Press and release the ( ) button until Boiling Temp XXX ºC is displayed on the screen where XXX is the current boiling water temperature in ºC. 4. Press and release the (X) or ( ) button to revert back to the main menu. 18

19 Activating Calibration Reset Mode Different altitudes will cause water to boil at different temperatures. To prevent the water in the boiling water tank from boiling continuously (which is energy inefficient) the boiling water unit is fitted with an altitude calibration function which automatically operates when the unit is operated for the first time or if calibration reset mode is activated. If the boiling water delivery temperature is not hot enough or the unit continuously boils, calibration reset mode should be activated to recalibrate the unit. When the unit is calibrating, the BWU will boil the water twice (approximately 60 seconds each time) in order to calibrate the optimum boiling point according to altitude. During this procedure steam and water droplets will be vented from the vent outlet on the tap. The entire calibration period will take approximately minutes and must not be interrupted; this includes operation of the tap outlet. 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Existing error codes will be displayed on the screen. 3. Press and release the ( ) button until Calib. Reset is displayed on the screen. 4. Press and release the ( ) button to confirm selection. Are You Sure will be displayed on the screen. 5. Press and release the ( ) button to activate calibration mode. Existing error codes will be displayed on the screen. 6. Press and release the ( ) button to revert back to the main menu Calibrating Do Not Interrupt will be displayed on the timer screen and the unit will recalibrate the boiling water temperature. When calibration is complete the timer display will automatically revert back to the main menu. Activating Temp Override Temperature override allows the installer to set the calibrated temperature to perform a fast calibration when the unit is operated for the first time, or to change the boiling water temperature to a selectable value from 70ºC 99ºC. 1. Press and release the (P) button until Service is displayed flashing on the screen. 2. Press and release the ( ) button to confirm selection. Existing error codes will be displayed on the screen. 3. Press and release the ( ) button until Temp override is displayed on the screen. 4. Press and release the ( ) button to confirm selection. The current calibrated (or preset) boiling water temperature will be displayed flashing on the screen. 5. Press and release the (Up) button until the desired setting appears flashing on the screen. Each consecutive press and release of the (Up) button increases the boiling water temperature setting in 1ºC increments from 70ºC to a maximum of 99 ºC. 6. Press and release the ( ) button. Are You Sure will be displayed flashing on the screen. 7. Press and release the ( ) button to confirm selection after which time the timer screen will revert back to the main menu, Calibrating Do Not Interrupt will be displayed on the timer screen and the unit will recalibrate the boiling water temperature to the new selected temperature. When calibration is complete the timer display will automatically revert back to the main menu. 19

20 Accessing Software Version 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Existing error codes will be displayed on the screen. 3. Press and release the ( ) button until Software Version is displayed on the screen. 4. Press and release the ( ) button to confirm selection. The software version will be displayed on the screen. The top digits refer to the timer software version and the lower digits refer to the controller software version. 5. Press and release the (X) or ( ) button to revert back to the service menu. Existing error codes will be displayed on the screen. 6. Press and release the (X) or ( ) button to revert back to the main menu. Permanently Display the Boiling Water Temperature (Temp Show ON/OFF) This function allows the temperature of the water within the boiling water unit to be permanently displayed on the timer display screen. 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Existing error codes will be displayed on the screen. 3. Press and release the ( ) button until TempShow ON/OFF is displayed on the screen. 4. Press and release the ( ) button to confirm selection. The current setting, ON or OFF will be displayed flashing on the screen. 5. Press and release the ( ) button to cycle between ON and OFF. 6. Press and release the ( ) button to confirm selection. The display will revert to the service menu. Existing error codes will be displayed on the screen. 7. Press and release the (X) or ( ) button to revert back to the main menu. Accessing Calibrated & Required Temperature (TB Treq) Information This function allows the user to see what Temperature the unit calibrated to, and the subsequent required temperature the unit is required to be maintained at. 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Existing error codes will be displayed on the screen. 3. Press and release the ( ) button until TB Treq is displayed on the screen. Under the letters TB the boiling water calibration temperature will be displayed in ºC. Under the letters Treq the temperature the unit will maintain the water at will be displayed in ºC. 4. Press and release the (X) or ( ) button to revert back to the main menu. 20

21 Activating Key Lock Function This function is for extra security to prevent tampering with the unit settings. Default setting is disabled. To activate keypad lock 1. Press and release the (P) button until Keylock is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Key lock enable will be displayed on the screen. 3. Press and release the ( ) button to confirm selection. Keypad Locked will be displayed on the screen when any button is pressed. To deactivate keypad lock 1. Press (P) and ( ) buttons simultaneously for a period of approximately 5 seconds until Keypad Locked disappears from the screen and display returns to normal. ECO Timer 703 Series 703 series boiling water units are supplied with an eco sleep timer. The timer incorporates a Sleep Delay Mode which when activated will automatically shut the system down after a set period of time of without use (2 hours). To activate sleep delay mode press and release the eco button whilst the green ECO LED is extinguished. When the eco button is released the ECO LED will illuminate green to indicate the unit is in sleep delay mode. When the unit is asleep the ECO at the top of display glows red. To deactivate sleep delay mode press and release the ECO button whilst the green ECO LED is illuminated. When the eco button is released the ECO LED will extinguish. ECO Timer LED Indication The ECO timer has integral LED s which indicate system status as follows: LED LED Status Description Heating text On red flashing Calibration cycle in progress Heating text On red solid Heating in progress Ready text On green solid Boiling water ready ECO Green LED On green solid Sleep delay mode activated ECO Red LED illuminates PRESS ECO TO HEAT Off On red solid Sleep mode deactivated Unit is asleep 21

22 ECO LED glows solid red when unit is asleep. ECO Button READY LED glows solid green when water is ready to use ECO LED glows solid green when sleep mode is activated HEATING LED glows solid red whilst water is heating, and flashes red whilst calibrating Activate calibration reset mode To activate calibration reset mode, turn off the power to the unit. Press and hold the ECO button and restore the power to the unit. Once the red heating LED is flashing, release the ECO button. When the unit has completed its calibration cycle, the red heating LED will illuminate solidly. COMPONENTS AND THEIR FUNCTION Timer: An electronic device which allows the user to program the Boiling Water Unit operating times and/or sleep mode function. Refer to page 15 for more information on timer operation. 701 & 702 Series have a 24 hr / 7day programmable timer. 703 series have eco function, refer to page 21 for eco Sleep timer operation. Heating Unit (Element): A tubular device containing an electric resistance element that converts electrical energy to heat which is utilised to heat water. The standard boiling water element rating is 1.8kW for 3L models, 2.4kW for 5 15L models, 3.6kW for 25L models and 4.6kW for 40L models. The boiling water element also has a dry well which houses the boiling water thermistor. The boiling water element in 3 15L models has an inbuilt E.C.O. which will open circuit the element at 105ºC. The E.C.O. will not reset automatically but may be manually reset once temperatures have fallen to a safe level. Control Board: The control board interprets signals from the timer and boiling water thermistor and controls operation of the boiling water unit. Boiling Water Thermistor: is a sensor which is used to detect the water tank temperature. The sensor is fitted into a pocket (dry well type) located in the boiling water element assembly, and plugs into the control board where its output is monitored. The resistance value of the boiling thermistor will change according to the water temperature detected. Inlet Solenoid Valve: An electro-mechanical device utilised to shut off the inlet water supply to the boiling water unit. Inlet solenoid valve operation is controlled by the low and high level probes via the control board. The flow regulator located in the inlet of the valve has a series of holes which reduces the flow rate to 0.5 litres/ minute (3L - 10L models), or 2.5 litres/minute (15L - 40L models) to prevent turbulence within the boiling water tank which would otherwise affect stratification. Control Board Relay: The control board relay provides protection in the case of an element triac short circuit. If an element triac short circuit is detected by the control board, the element relay will de-energise which will prevent the element triac from operating. 22

23 Level Probe: A device designed to detect the water level of the boiling water tank. The level probe contains two probes; a low level probe and a high level probe. A circuit is created when the water touches both the tank and the probe. This circuit is detected by the control board. COMMON COMPLAINTS When a complaint is lodged about the performance of a hot water system there are a number of causes that should be checked and eliminated. In an attempt to pinpoint the most likely cause it is important to discuss with the customer their reasons for the complaint, the duration of the problem, any change in circumstances or usage. This information in conjunction with the following listed common complaints will assist you in locating the most likely cause. All procedures assume there is water flowing through the water heater. Excessive Boiling Water Usage The complaints of insufficient and no boiling water can on many occasions be attributed to water usage exceeding the capacity of the BWU. When first attending a call of this nature it is essential to establish the probable water usage by querying the usage habits of the inhabitants and then comparing this with the potential delivery volume of the model BWU installed. It can then be established if the usage is within or outside the capacity of the model. The areas to look at for excessive usage are: 1. Change of occupancy or an increase in the number of persons. 2. Plumbing or BWU tap leaks. Discoloured water 1. This may be the result of discoloured water entering from the cold water mains. Check if the cold water is also discoloured. 2. Milky coloured water is generally air in suspension and will disperse of its own accord. Water hammer A water heater will not cause water hammer, however valves associated with the water heater may be the source of the problem i.e. cold-water stopcock or non-return valve. Most water hammer problems are associated with hot and/or cold plumbing or appliances i.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve parts or neighbouring equipment. High water pressure areas will have more complaints of this nature and the use of a pressure-limiting valve (PLV) to reduce the cold-water pressure will usually solve most problems. 23

24 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 WH Probe to alligator clip kit WH Proxy Timer Service kit ERROR CODES Error Codes & 702 Series Only The Timer has a Service Menu which can display alphanumeric error codes (refer to Error Code Table below for error codes and their descriptions). To access Error Codes operate the Timer in the following manner: 1. Press and release the (P) button until Service is displayed on the screen. 2. Press and release the ( ) button to confirm selection. Error codes will be displayed on the screen with any error codes listed below. 3. Press and release the (X) or ( ) button to revert back to the main menu. Note: An error code will be automatically cleared from the display when the fault pertaining to that error code is rectified and the BWU re-powered. Error Code Table Code Error Code Error A* Hot Thermistor O/C or S/C H Low Level Probe Fault B (1) Chiller Unit Cold Thermistor O/C or S/C J High Level Probe Fault C* Triac S/C K (2) N/A (Compressor Fault) D (2) N/A (Leak Detection) L Boiling Water Heating Fault E Expired Filter M Watch Dog Software Reboot G Calibration Time Out N* Excessive Temperature Rise Error code table notes: Fault codes without an asterisk (*) are informational only and the boiling water unit will continue to operate however the affected section may not function. * Critical fault. BWU unit will shut down and control board relay will de-energise. Refer to Operational Flow Chart 701 & 702 Series on page 12 for more information. (1) 701 and 702 Series BWU s do not have a chiller unit and therefore will always display error code B. This is normal operation. (2) Although all these error codes are available they are not utilised by 701 and 702 Series BWU s. 24

25 Error Codes Series only When the unit is performing an automatic recalibration heating flashes on the control panel. A series timer can be fitted to the 703 unit for fault finding purposes. Full functionality of service mode parameters can then be utilised. Rheem recommends having a proxy timer for servicing purposes. Service timer Kit Part Number The kit contains:- Ribbon Connector Part Number Timer Part Number Testing the Boiling Water Thermistor Unplug the boiling water thermistor at the thermistor wiring loom connector or control board plug socket and using a multimeter on the kilo-ohms scale, measure between the pins of the thermistor plug. As the resistance of the thermistor will change according to its temperature, the resistance measurements for the thermistor will need to be checked against the Thermistor Temperature/ Resistance Table located below. For this reason it is best to remove the thermistor from the dry well and compare the measured value to the ambient air temperature which can be obtained using a thermometer. When refitting the thermistor, into the element well, ensure there is ample heat transfer compound on the thermistor. Thermistor Temperature / Resistance Table Ambient Temperature (ºC) Resistance (ohms) Minimum Typical Maximum

26 Fault Diagnosis Sequence (General Fault Finding Chart) Note:- 703 Series, if a proxy timer is not fitted, error codes cannot be displayed. Fault Is an error code displayed on the timer? Refer to section on Timer. General Fault Finding Chart Note: The following abbreviations are used throughout all fault finding charts in this service manual BWU = Boiling water unit BW = Boiling water Refer to fault finding chart for error code displayed. Is complaint for no BW or BW not hot enough? 1 Is complaint for BW too hot? Note: This includes the complaints of BW continuously boiling or BW ECO continuously tripping. 2 Is complaint for insufficient BW? 3 Is complaint for no or low water flow? 4 Is complaint for timer not functioning? 5 Is complaint for leaking? 6 Noisy BWU 7 26

27 Error Code A Error Code A BW thermistor O/C or S/C Is BW thermistor ok? Refer to section on Testing the Boiling Water Thermistor. Replace BW thermistor. Is BW thermistor wiring connector ok? Ensure connector plug & socket is firmly connected. Replace connector if necessary. Is BW thermistor firmly plugged into control board? Ensure BW thermistor is firmly plugged into correct socket on control board. Repair or replace O/C or S/C BW thermistor wiring. Error Code B Error Code B Chiller unit cold thermistor O/C or S/C 701, 702 & 703 Series BWU s do not use a Chiller Unit therefore error code B will always be displayed. This is normal operation. Continue fault finding. Error Code C Error Code C Triac S/C Check BW element circuit for possible short circuit and replace control board if short circuit is not present. Error Code D Error Code D Leak detected (BWU or chiller unit) 701, 702 & 703 Series BWU s do not use a leak sensor, error code D is not applicable. Continue fault finding. Error Code E Error Code E Expired filter To reset or deactivate filter counter refer to section on Timer This error code will not affect appliance operation. Continue with fault diagnosis. 27

28 Error Code G Error Code G Calibration time out Reset BWU BWU will attempt recalibration Is error code G still displayed? Successful recalibration performed. Check BWU operation. BWU can be reset by disconnecting power then restoring power after waiting 30 seconds. 1.2 Chart 1.2 is part of and can be located within Error code L fault finding chart. Error Code H & Error Code J Error Code H Low level probe fault Error Code J High level probe fault Is water supply to BWU ok? Restore water supply to BWU. Ensure stop cock or isolation valve is open. If an additional water filter is installed check to ensure it is not blocked. Is level probe ok? (TEST 4) Clean or replace level probe. Ensure probes are not touching each other or the probe housing (earth). Is level probe wiring connector ok? Ensure connector plug & socket is firmly connected. Replace connector if necessary. Is level probe firmly plugged into control board? Ensure level probe is firmly plugged into correct socket on control board. Is level probe wiring O/C or S/C? Replace level probe. Was original error code H or J? H J 4.2 Chart 4.2 is part of and can be located within chart 4. Is high level probe insulation correct length? Replace level probe. Replace control board. 28

29 Error Code K Error Code K Chiller Compressor fault 701, 702 & 703 Series BWU s do not use compressor, error code K is not applicable. Continue fault finding. Error Code L Error Code L Boiling water heating fault 1.2 Is BWU either a 25 or 40L model? Has BW ECO tripped? (TEST 5) Reset boiling water ECO and check appliance operation. If ECO cannot be reset replace boiling water element. Does BW ECO trip again? (TEST 5) 2 ECO reset. Fault rectified. Is BW element resistance ok? (TEST 6A or 6B) Test 6A for 3 15L models Test 6B for 25 & 40L models Replace boiling water element. Is BW element wiring ok? Repair faulty wiring. Replace control board. Error Code N Error Code N Excessive temperature rise Is level probe ok? (TEST 4) Ensure probes are not touching each other, the tank or the element (earth). Repair or replace S/C level probe wiring. 29

30 Fault Finding Chart 1 (Proxy timer recommended for fault finding on 703 series) 1 Is 240 volts present at the power point? (TEST 1) Is the fuse blown at the switchboard? Replace Fuse Did the fuse blow again? 1.1 Is 240 volts present at the power point? (TEST 1) Faulty fuse replaced. Check appliance operation. Is 240 volts present at terminal block? (TEST 2A or 2B) Test 2A for 3 15L models Test 2B for 25 & 40L models Household wiring or power point faulty. Advise customer to call an electrician. Replace faulty cord set. Is 240 volts present at control board? (TEST 3A or 3B) Test 3A for 3 15L models Test 3B for 25 & 40L models Repair O/C wiring. Does timer display an error code other than error code B? Refer to section on Timer 701,702 & 703 Series BWU s do not use a Chiller, therefore error code B will always be displayed. This is normal operation. Refer to fault finding chart for error code displayed. Is complaint for no or low water flow? 4.1 Refer to section on Testing the Boiling Water Thermistor. Chart 4.1 is part of and can be located within chart 4 Is BW thermistor ok? Replace BW thermistor. Is BW thermistor wiring connector ok? Ensure connector plug & socket is firmly connected. Replace connector if necessary. Is BW thermistor Firmly plugged into control board? Ensure BW thermistor is firmly plugged into correct socket on control board. 1.2 Chart 1.2 is part of and can be located within Error code L fault finding chart. Note if 703 Series, with no proxy timer display, go to Fault Finding Chart 1.1a, on following page 30

31 Fault Finding Chart Electrical Insulation Test Disconnect BW element wire from control board and megger between disconnected wire and earth. Is reading below 1 mega-ohm? Replace BW element. Disconnect inlet solenoid wiring and megger between each inlet solenoid terminal and earth. Is reading below 1 mega-ohm? Replace inlet solenoid. Is control board shorting on backing plate? Refix control board to insulated stand-offs. Check for pinched or damaged wiring touching the water heater chassis. Fault Finding Chart 1.1a (703 Series with no proxy controller) 1.2 Boiling water heating fault Has BW ECO tripped? (TEST 5) Reset boiling water ECO and check appliance operation. If ECO cannot be reset replace boiling water element. Does BW ECO trip again? (TEST 5) 2 ECO reset. Fault rectified. Is BW element resistance ok? (TEST 6A ) Replace boiling water element. Is BW element wiring ok? Repair faulty wiring. Replace control board. 31

32 Fault Finding Chart 2 2 Refer to section on Testing Thermistors. Is BW thermistor ok? Replace BW thermistor. Is BWU either a 25 or 40L model? (1) Is BW ECO Does BW continuously tripping? continuously boil? (TEST 5) Normal operation. (1) Does BW continuously boil? Is BW ECO continuously tripping? (TEST 5) Is boiling water temp > 105ºC Replace BW Element (ECO is integral part of element). (2) (2) Recalibrate BWU Recalibrate BWU Notes: (1) If BW is continuously boiling, the vent line outlet will be continuously venting steam. (2) To recalibrate BWU refer to section on Timer. (1) Does BW continuously boil? Does BW ECO trip? (TEST 5) Recalibration successful. BWU operating correctly. (1) Does BW continuously boil? Replace control board. Recalibration successful. BWU operating correctly. Normal operation. Fault Finding Chart 3 3 Is BWU of sufficient size for customers needs? Has the usage pattern changed recently? i.e. additional people using BWU Recommend a BWU of sufficient capacity to meet customers needs. Recommend a usage pattern that will suit the BWU capacity and the customers needs. Are there any plumbing leaks or a dripping BWU tap? 6 Is BW water temp at tap outlet < 95ºC? 1 Normal operation. Recommend a BWU of sufficient capacity or usage pattern to meet customers needs. 32

33 Fault Finding Chart 4, 4.1 & 4.2 (Proxy Display required 703 series or use Chart 4a) 4 Is 240 volts present at the power point? (TEST 1) Is the fuse blown at the switchboard? Replace fuse Did the fuse blow again? 1.1 Household wiring or power point faulty. Advise customer to call an electrician. Is 240 volts present at the power point? (TEST 1) Faulty fuse replaced. Check appliance operation. Is 240 volts present at terminal block? (TEST 2A or 2B) Test 2A for 3 15L models Test 2B for 25 & 40L models Replace faulty cord set. Is 240 volts present at control board? (TEST 3A or 3B) Test 3A for 3 15L models Test 3B for 25 & 40L models Repair O/C wiring. Does timer display an error code other than error code B? (1) Refer to section on Timer Refer to fault finding chart for error code displayed. 4.1 Is water supply to BWU ok? Restore water supply to BWU. Ensure stop cock or isolation valve is open. If an additional water filter is installed check to ensure it is not blocked. Is high level probe insulation correct length? Replace level probe. Are all plugs & sockets 4.2 Firmly reconnect plug socket(s). firmly connected? Does water flow freely from tap past model capacity? i.e. can 4L be drawn from a 3L model? Normal operation. If original fault was for error code J and error code J is still displayed then replace control board. Is inlet solenoid resistance correct? (TEST 7) Replace inlet solenoid valve. Is 240 volts present at inlet solenoid? (TEST 8) Replace control board. Notes: (1) 701, 702 & 703 Series BWU s do not use a Chiller, therefore error code B will always be displayed. This is normal operation. Is BWU inlet strainer blocked? Clean or replace inlet strainer. Check for blockage or restriction in pipe work, inlet solenoid valve (including flow regulator) or BWU tap. 33

34 Fault Finding Chart 4a, incl. (4.1 & 4.2) 703 Series No Proxy Display Timer 4a Is 240 volts present at the power point? (TEST 1) Is the fuse blown at the switchboard? Replace fuse Did the fuse blow again? 1.1 Household wiring or power point faulty. Advise customer to call an electrician. Is 240 volts present at the power point? (TEST 1) Faulty fuse replaced. Check appliance operation. Is 240 volts present at terminal block? (TEST 2A) Test 2A for 3 15L models Replace faulty cord set. Is 240 volts present at control board? (TEST 3A) Test 3A for 3 15L models Repair O/C wiring. Is there continuity across ECO, and correct resistance on the element? (TEST 5 & 6A) Replace Element 4.1 Is water supply to BWU ok? Restore water supply to BWU. Ensure stop cock or isolation valve is open. If an additional water filter is installed check to ensure it is not blocked. Is high level probe insulation correct length? Replace level probe. Are all plugs 4.2 & sockets firmly Firmly reconnect plug socket(s). connected? Does water flow freely from tap past model capacity? i.e. can 4L be drawn from a 3L model? Normal operation. If original fault was for error code J and error code J is still displayed then replace control board. Is inlet solenoid resistance correct? (TEST 7) Is 240 volts present at inlet solenoid? (TEST 8) Replace inlet solenoid valve. Replace control board. Is BWU inlet strainer blocked? Clean or replace inlet strainer. Check for blockage or restriction in pipe work, inlet solenoid valve (including flow regulator) or BWU tap. 34

35 Fault Finding Chart 5 (Proxy Display required for 703 series or use chart 5a) 5 Is 240 volts present at the power point? (TEST 1) Is the fuse blown at the switchboard? Replace fuse Did the fuse blow again? 1.1 Is 240 volts present at the power point? (TEST 1) Faulty fuse replaced. Check appliance operation. Test 2A for 3 15L models Test 2B for 25 & 40L models Household wiring or power point faulty. Advise customer to call an electrician. Is 240 volts present at terminal block? (TEST 2A or 2B) Replace faulty cord set. Is 240 volts present at control board? (TEST 3A or 3B) Test 3A for 3 15L models Test 3B for 25 & 40L models Repair O/C wiring. Does timer display an error code other than error code B? Refer to section on Timer 701, 702 & 703 Series BWU s do not use a Chiller, therefore error code B will always be displayed. This is normal operation. Refer to fault finding chart for error code displayed. Does timer display work? (proxy timer display 703 series) Are timer ribbon cables firmly connected? Replace timer. Refer to section on Timer Do all timer functions operate? Are timer ribbon cables firmly connected? Ensure timer ribbon cables are firmly plugged into sockets on rear of timer and socket on control board. Has timer been operated and/or programmed correctly? Refer to section on Timer Advise customer on timer operation and/or how to program timer. Replace timer. Timer ok. 35

36 Fault Finding Chart 5a 703 series 5a Is 240 volts present at the power point? (TEST 1) Is the fuse blown at the switchboard? Replace fuse Did the fuse blow again? 1.1a Is 240 volts present at the power point? (TEST 1) Faulty fuse replaced. Check appliance operation. Household wiring or power point faulty. Advise customer to call an electrician. Is 240 volts present at terminal block? (TEST 2A) Replace faulty cord set. Is 240 volts present at control board? (TEST 3A) Repair O/C wiring. Does Eco surround circle illuminate when eco button pressed? Does eco function operate? Led failure. Replace timer fascia. Does eco button function correctly? (TEST 9) Eco button failure. Replace timer fascia. Does eco timer operate? Is timer ribbon cable connected firmly? Ensure ribbon cable is firmly plugged into sockets on rear of timer and socket on control board. Replace control board. Eco timer working correctly. 36

37 Fault Finding Chart 6 6 Is leak from BWU tap? Repair or replace BWU tap. Is leak from a hose or plumbing fitting? Remake hose connection/ plumbing fitting or replace hose/ plumbing fitting. Is leak from inlet solenoid? Tighten solenoid lock nut(s) or replace solenoid. Is leak from level probe? Is vent line blocked? Unblock or replace vent line. Vent line must be no longer than 3m, have continuous fall and have no more than 4 bends. is vent line installed correctly? Shorten vent line or install a tundish. Remake vent line to have continuous fall and/or reduce number of bends. Replace level probe o rings or replace level probe. Is leak from BW element gasket? Replace element gasket. Check for stripped bolts. The boiling water tank will have to be removed to locate the leak. Is BWU either a 25 or 40L model? Is leak at water outlet flange? Tighten water outlet flange bolts or replace water outlet flange gasket. Replace leaking BWU tank. Is leak from drain plug? Tighten drain plug or replace drain plug gasket. Is leak from drain plug flange gasket? Tighten drain plug flange bolts or replace drain plug flange gasket Is leak at water outlet flange? The boiling water tank will have to be removed to locate the leak. Tighten water outlet flange bolts or replace water outlet flange gasket. Replace leaking BWU tank. 37

38 Fault Finding Chart 7 7 Is noise only evident when electric heating cycle is on? Is there mineral build up on BW heating unit? Replace Heating unit. Poor quality water supply i.e. dam water. Flush tanks. Is noise a creaking or cracking sound? Expansion & contraction noise associated with heating. Normal operation. Is noise an occasional clicking sound? Control board relay operation. Normal operation. Is noise water hammer? Refer to water hammer in the common complaints section. Is noise only evident when water is flowing through heater? Check other appliances that can generate noise i.e. washing machine, dishwasher, ball cocks etc. Is water pressure > 800kPa? Check for: Restrictions in pipe work, faulty valves, loose plumbing, other appliances i.e. washing machine or dishwasher. Fit 600kPa PLV if pressure is excessive. Check for a faulty stop cock, non-return valve, loose component or screws. 38

39 Fault Finding Tests Fault Finding Tests 1 3A Test 1 Test 2A (3 10L models) Ensure power point is switched on and using a multimeter on the AC voltage scale, measure between the 3 pin sockets on the power point. The following results should be obtained: Active to Neutral Volts AC. Active to Earth Volts AC. Neutral to Earth 0 Volts. Test 2B (25 40L models) Using a multimeter on the AC voltage scale, measure between the Active terminal (brown wire) and Neutral terminal (blue wire) on the terminal block. The following results should be obtained: Active to Neutral Volts AC. Test 3A (3 15L models) Using a multimeter on the AC voltage scale, measure between the Active terminal (brown wire) and the Neutral terminal (blue wire) on the terminal block. The following results should be obtained: Active to Neutral Volts AC. Using a multimeter on the AC voltage scale, measure between the COM terminal (Active) on the control board relay and the Neutral terminal on the control board. The following results should be obtained: Relay COM terminal to control board Neutral Volts AC. 39

40 Fault Finding Tests 3B 6A Test 3B (25 & 40L models) Test 4 Using a multimeter on the AC voltage scale, measure between the Active and Neutral terminals on the control board. The following result should be obtained: Control board Active to Neutral Volts AC. Test 5 (3 15L models only) Disconnect the boiling water probe at control board and remove probe from housing. Using a megger on the 500V scale, megger between the probes of the level probe. The following result should be obtained: > 1 Mega-ohm. Test 6A (3 15L models) Disconnect the red wire from the boiling water element ECO and using a multimeter on the ohms scale, measure between the terminals of the boiling water ECO. The following result should be obtained: 0 ohms (ECO has not tripped). Disconnect the two wires from the boiling water element and using a multimeter on the ohms scale, measure between the two element terminals. The following result should be obtained: 3L models (1.8kW element):30 34 Ω. 5L 15L models (2.4kW element):22 26 Ω 40

41 Fault Finding Tests 6B 8 Test 6B (25 & 40L models) Test 7 Disconnect the two wires from the boiling water element and using a multimeter on the ohms scale, measure between the two element terminals. The following result should be obtained: 25L models (3.6kW element): Ω. 40L models (4.8kW element): Ω. Disconnect wiring at inlet solenoid valve and using a multimeter on the ohms scale, measure between the two terminals of the solenoid. The following result should be obtained: kilo ohms. Test 8 Test 9 Using a multimeter on the AC voltage scale, measure between the two terminals of the inlet solenoid. The following result should be obtained: Volts AC. (Note:- Solenoid wiring must be connected to do this test) Using a multimeter on the ohms scale, measure between the orange and yellow wires. When the button is pressed the following result should be obtained: ohms. (Note:- Eco timer ribbon wiring must be connected to do this test) 41

42 ELECTRICAL SAFETY TESTING 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. 1. For 3 15L models: Isolate power by switching off at power point and unplugging BWU 3 pin plug from power point. For 25 & 40L models: Isolate power by turning isolation switch off and then removing fuse (or switching off circuit breaker). Disconnect Active, Neutral and Earth wires from BWU terminal block. Procedure 1: To check insulation resistance of the BWU Neutral Circuit (reading not to be below 1 mega-ohm). 2. For 3 15L models: Connect megger leads to the neutral and earth pins on the 3-pin plug. For 25 & 40L models: Connect megger leads to the Neutral conductor and the Earth terminal of the BWU terminal block. 3. Operate insulation resistance tester. A reading above 1 mega ohm should be obtained. 4. If a reading below 1 mega ohm is indicated, all component parts will need to be individually tested to locate the fault. Refer to Fault Finding Chart 1.1 on page 31. Procedure 2: To check insulation resistance of the BWU Active Circuit (reading not to be below 1 mega-ohm). 5. For 3 15L models: Connect megger leads to the active and earth pins on the 3-pin plug. For 25 & 40L models: Connect megger leads to the active conductor and the earth terminal of the BWU terminal block. 6. Operate insulation resistance tester. A reading above 1 mega ohm should be obtained. 7. If a reading below 1 mega ohm is indicated, all component parts will need to be individually tested to locate the fault. Refer to Fault Finding Chart 1.1 on page 31. Procedure 3: To check Earth Continuity of the water heater. 6. Set the multimeter to x1 Ω (ohms) resistance scale. (3-15L models) 7. Measure between the earth pin on the 3 pin plug and the water heater jacket. The reading should be less than 0.5Ω. (25-40L models) 8. Measure between the earth terminal and the water heater jacket. The reading should be less than 0.5Ω. 9. If a reading greater than this value is obtained the earthing connection should be checked for corrosion/tightness and the power lead earth wire tested, if necessary replace the power lead. 42

43 COMPONENT REPLACEMENT PROCEDURES When performing a component replacement procedure; ensure any escaping water is caught in a container and does flow onto any electrical components. When draining water from tank using the tap, some water will remain in the tank. If it is necessary to remove the BWU from the wall, take care to keep the BWU standing upright to prevent water escaping from top fittings onto electrical components. If replacing an element, lock the tap open, remove the wiring connector from the water level probe and restore power. This will allow cold water to enter the tank and cool any remaining boiling water. Isolate power before performing any component replacement procedures When performing any component replacement procedure, water of an elevated temperature may be present. Ensure PPE is worn to prevent the risk of scalding. All Boiling Water Units Jacket Surround (Procedure 1) 1. Isolate power supply to BWU. 2. Remove four screws retaining jacket surround and pull jacket away from BWU to remove. Two screws are located on top of BWU and two screws are located underneath BWU 3. Complete reassembly in reverse order of above. WARNING 701 Series: - When refitting the jacket surround, ensure that the boiling water outlet tube is positioned correctly in spout. Tap (Procedure 2A) 702 & 703 Tap replacement 1. Isolate power and water supplies to BWU. 2. Operate tap lever until water ceases to flow from tap. 3. Support tap and unscrew tap union in a clockwise direction to remove tap. 4. Complete reassembly in reverse order of above. 5. Check for leaks. 43

44 Tap (Procedure 2B) 701 Tap, timer fascia replacement 1. Isolate power and water supplies to BWU. 2. Operate tap lever until water ceases to flow from tap. 3. Follow procedure 1 to remove jacket surround 4. Lift the tap lever, remove 2 retaining screws then the complete timer fascia and timer from the unit. Disconnect the ribbon connector and place timer fascia aside. 5. With the tap lever still raised, unscrew the tap union in an anticlockwise direction to remove tap. 6. Complete reassembly in reverse order of above. WARNING:- When refitting the jacket surround, ensure that boiling water outlet tube is positioned correctly in spout. Tap components (Procedure 3A) 702 & 703 Series Note: To replace diaphragm only; follow steps 1 6, fit new diaphragm, then complete reassembly in reverse order ensuring tap lever is in the up position when tightening cap. 1. Isolate power and water supplies to BWU. 2. Operate tap lever until water ceases to flow from tap. 3. Leave tap lever in up position. 4. Using a pair of multigrips (Eco) or spanner (Commercial), gently unscrew cap in an anticlockwise direction until cap thread has cleared tap body thread. 5. Pull cap away from body. Cap will come away from body with lever, spindle, spring and tap seal attached. 6. Remove tap seal by pulling away from spindle. 7. To remove tap lever, spindle and spring; place tap spindle on a flat surface and push down on cap to compress spring. Whilst spring is compressed hold tap lever in a horizontal position and slide out backwards from spindle. 8. To remove spindle and spring; pull spindle away from cap then pull spring away from spindle. 9. Complete reassembly in reverse order of above. Note: Large diameter end of spring locates in cap. Tap lever locates in slots in spindle head. Ensure tap lever is in the up position when tightening cap. 10. Check for leaks. Tap components (Procedure 3B) 701 series Note: To replace tap seal only, follow steps 1 6 of procedure 2B. Remove tap seal by pulling it away from spindle. 1. Fit new tap seal and refit tap. Ensure tap lever is in the up position when tightening cap. 2. Complete reassembly in reverse order of above. 44