TM025 Rheem 310 Series Heat Pump REV B.pdf
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SERVICE INSTRUCTIONS
310 Series Heat PumpTM025
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PPPuuubbbllliiissshhheeeddd:::000888///000777
551310
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TM025 Rheem Heat Pump Service Instructions REV: BDate of Issue: 02/08/07
This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed uncontrolled.
1
Contents
Safety Warning ....................................................................................................................2Introduction..........................................................................................................................2Specifications.......................................................................................................................3Preventative Maintenance ...................................................................................................3Operation.............................................................................................................................4
Electronic Controller ............................................................................................................5Operating Sequence Flow Charts:.......................................................................................6
Refrigeration Terms and their Meaning................................................................................8Components and their Function...........................................................................................8Common Faults ...................................................................................................................9Wiring Diagram..................................................................................................................11Refrigeration Sealed System Diagram...............................................................................12LED Indication ...................................................................................................................12Fault Finding ......................................................................................................................14Refrigerant Charge ............................................................................................................45Electrical Insulation Testing ...............................................................................................46
Component Replacement Procedures Water Heater......................................................47
Component Replacement Procedures Refrigeration Plant .............................................52Component Replacement Procedures Sealed Refrigeration System .............................57Exploded View - Refrigeration Plant ..................................................................................62
Replacement Parts List Refrigeration Plant.................................................................63Exploded View - Water Heater...........................................................................................64
Replacement Parts List Water Heater .........................................................................65Rheem Electric Water Heater Warranty - (Australia Only) .................................................66Document Revision History................................................................................................67
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Safety Warning
The purpose of this Service Manual is to provide sufficient information to allow a personwith the skills as required by the controlling Regulatory Authorities to carry out effectiverepairs to a Rheem 310 series Heat Pump Water Heater in the minimum of time.
Safety precautions or areas where extra care should be observed when conducting testsoutlined in this manual are indicated by print in bold italics and/or a warning symbol.Take
care to observe the recommended procedure.
Certain diagnostic procedures outlined in these service instructions require live testing to be conducted. Wear Personal Protective Equipment (PPE)when conducting these tests to prevent the risk of electric shock. (Refer tothe Rheem Safety Procedure on electr ical testing)
R134A is a controlled substance under the fair trading act. Personnelqualified and licensed to work with refrigerants may only carry out serviceand repair to the sealed refrigeration system. During repair the refrigerantmust be recovered, not vented to atmosphere.
Environmental
At the end of the service li fe o f a Rheem heat pump the refr igerant must berecovered by personnel qualified and licensed to work with refrigerantsprior to the unit being disposed of. Refrigerants must not be vented toatmosphere.
Introduction
The information provided in these instructions is based on the water heater being installedin accordance with the Installation Instructions provided with each water heater.
Should you require further technical advice on a Rheem 310 Series Heat Pump WaterHeater, contact your nearest Rheem Service Department where all genuine replacementparts are also available.
Heater Model Identification
All identification numbers are designed to convey detailed information about the waterheater to which it is attached. The model number consists of 8 digits.
5 X X 310 0 X
5 Renewable Energy Model
5 Air Sourced9 Solar Sourced
0 No Heating Units1 Booster Element
Storage Capacity in Litres
No Reference System Requirement
0 Element Not fitted5 2400 watts7 3600 watts
Note: Model number, serial number and date of manufacture should be quoted in allcorrespondence.
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Specifications
Water Heater
Model 551310Capacity - Litres 310
Boost Capacity - Litres 220
Booster element rating - kW 2.4 or 3.6T&PR valve Rating - kPa 1000
With ECV 680Maximum inlet pressure - kPa
Without ECV 800
Inlet / Outlet RP/20Water Connections
T&PR RP/15Quantity 1
AnodeLength 1153
Control board thermostat setting (fixed) 60C
Limp mode mechanical thermostat setting 70C
Mechanical thermostat ECO setting 88C
Refrigeration System
Parameter 551310
Sound rating 51 dBA @1.5mSuperheat setting (Factory) +6C at 10C Evaporator temp.Refrigerant charge R134A 1050 gramsCompressor internal OTC Open 150C. Close 90C (automatic reset)
Compressor winding resistanceRun winding - Red & Blue: 2.2 ohms at 20C
Start winding - Red & Black: 3.27 ohms at 20C
Compressor Capacitor 35F240 VAC 50HZ
Fan winding resistanceRun winding Black & Brown: 184 ohms at 20CStart winding Black & Blue: 238 ohms at 20C
Fan Capacitor 2F240 VAC 50HZ
Circulator winding resistance 75.3 ohms @ 20C
Preventative Maintenance
It is suggested for peak performance that the water heater be serviced annually.
1. Check for discharge from the T&PR valve. When the element or heat pump isoperating a small discharge of water may be evident. Operate the valve-easing lever toensure the valve opens and resets properly. Always open and close the valve gently.The T&PR valve should be replaced at 5 yearly intervals.
2. Check for leaks at all cylinder fittings.
3. Check for signs of excessive corrosion on the water heater jacket.
4. Isolate power to the water heater and check all electrical connections for signs ofoverheating due to poor connection.
5. Conduct an 'Electrical insulation test' on the water heater (refer to page 46).
6. Check evaporator fins and fan blade for build up of dust or debris.
7. Check for sludge build up and if necessary drain and flush tank.
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Operation
Operation Water System:
The heat pump utilises a form of heating called top down heating.The circulator (1)draws cooler water from the bottom of the cylindervia the long dropper tube (2). The water passes through the heatexchanger (condenser) (3)where it is heated by the refrigerant and isthen returned to the top of the cylinder via a short dropper tube (4).
Operation Heat Pump Mode:
During normal operation in heat pumpmode the electronic controller(control board) holds a control relay in the energised state and powerfor the compressor is passed to an electronic switch (called a triac) viathe normally open relay contact.
The operation of the compressor causes a pressure difference withinthe sealed refrigeration system. This pressure difference causes the
refrigerant to move around the sealed system. The refrigerant entersthe evaporator (5)as a liquid, as the refrigerant absorbs heat from theatmosphere it changes state, at low pressure, from a sub cooled liquidto a super heated vapour or gas (evaporates). The vapour then entersthe compressor (6) and obtains more heat, known as heat ofcompression, and passes into the heat exchanger as a super heatedvapour at high pressure.
As the refrigerant passes through the heat exchanger it gives offheat which is absorbed by the water flowing through a separatechamber inside the heat exchanger. As the refrigerant gives offheat it cools and changes state back into a liquid (condenses). Therefrigerant then enters the evaporator again and the cycle isrepeated.
Operation Boost Mode:
The controller will enter boostmode when atmospheric conditions are unsuitable for heatpump operation or a possible failure of the refrigeration or water circuits has beendetected. The following error conditions will initiate boostmode:
1. The temperature sensed by the ambient air sensor is below 0C.
2. The water leaving the heat exchanger is greater than 80C.
3. The compressor discharge temperature is greater than 110C.
4. The evaporator temperature is less than -3C.
5. The failure of sensors S3, S4 or S5.
6. The compressor is not running based on either of the following conditions:
a. After 2 minutes in controller sequence 3 the compressor discharge temperature hasnot risen 15C above ambient.
b. In controller sequence 4 the water temperature rise across the heat exchanger(condenser) is less than 8C.
Inboost
mode the electronic controller continues to control the temperature of the water inthe cylinder and the circulator however the control relay is de-energised switching thepower supply from the compressor triac to the element.
1
2
3
4
3
6
5
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Boostmode allows 220 litres of 60C hot water to be provided by electric boosting. Duringthis mode the circulator will cycle on and off periodically allowing for the 220 litre boostcapacity rather than just the amount of water above the element as is the case with aconventional electric boost system.
Once a heating cycle is completed the error is cleared and normal operation is resumed onthe next call for heat.
Note: If sensor S4 fails the system will operate on boost mode however the temperaturewill in this case be controlled by the mechanical thermostat and 220 litres of 70C waterwill be available.
Operation Limp Mode:
Limpmode will only occur due to the failure of both sensors S1 and S4.
In limpmode the electronic controller no longer controls the operation of the heat pumpand both heat pump mode and boostmode are rendered inoperable. The control relay isde-energised switching the power supply from the compressor triac to the element.
Limpmode allows 111 litres of hot water to be provided by electric boosting and the water
temperature is controlled by the mechanical thermostat which is set to 70C; in thiscondition only the water in the zone above the element is heated as the circulator does notoperate.
It should be noted that if sensor S1 fails and sensor S4 is operational the system operatesin boost mode however the circulator cannot operate. In this case the end result is anoperation similar to limp mode in which 111 litres of water is heated by the booster and thetemperature controlled to 70C by the Robertshaw thermostat.
Electronic Controller
The main features of the electronic controller(control board) are shown on the diagram opposite.The inputs to the software are shown in blue andthe outputs that control the heat pump are shown inred.
The connection marked relay element energisesor de-energises a relay that switches from heatpump heating to electric element heating when thesystem operates in boost or limp mode.
The Compressor TRIAC switches the power to the
compressor on and off.The Communication port can be used inconjunction with a computer to read the inputs andoutputs from the software. This information may belogged using specially designed logging software(Contact Rheem Service for more informationregarding this software).
The Software loading port is only used for loadingsoftware on to the control board.
The green and red LEDs indicate the condition ofthe heat pump (refer to the section titled LEDIndication on page 12).
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Page 2 of 2:
NO
Boost Mode
220L heated toapprox. 60C
H
Relay de-energised
Red LED Flashing
Element On
S1>62C?
S4>53C?
YES
NO
Element OffYES
Z
Circulator On
NO
S153C?
YES Circulator Off
YES
NO
Sequence
0
YES
S4Sensor
ok?
Temp atthermostat =
70C?
Controller can no longer detect
lower cylinder temperature.Water temperature will becontrolled by mechanical
thermostat to 70C
S1Sensor
ok?
NO
YES
Controller can no longer detect
upper cylinder temperature.
The circulator will not operatepreventing water below theelement level from heating
Temperature at sensor S4 willnot achieve 53C
NO
Heating Cycle
complete
Element On
Limp Mode
111L heated to
approx. 70C
NO
Element Off
YES
Power to controller offY
S1Sensor
ok?
S1>62C?
YES
Boost Mode
220L heated to
approx. 70C
Circulator On
Temp atthermostat =
70C?
YES
S1 2C?
T4> 2C?
A
YES
NO
NO Ambient temperature high enoughto resume heat pump operation
YES
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Refrigeration Terms and their Meaning
Sub Cooled Liquid A substance below its saturation temperature at a given pressure.
Super Heated VapourA substance above its boiling point at a given pressure.
Saturated Vapour A substance at its boiling point at a given pressure.
Latent Heat Hidden (invisible) heat removed or added to a substance that results in achange of state (i.e. liquid to a vapour) without an increase or decrease in temperature.
Heat of Compression The additional heat added to a substance by the act ofcompressing it.
Low Side Components and pipe work of a refrigeration system operating at lowpressure, generally considered to be the evaporator, suction line and accumulator.
High Side Components and pipe work of a refrigeration system operating at highpressure, generally considered to be the condenser, discharge line, liquid receiver/filterdrier and compressor case where a rotary compressor is utilized.
Boil Off The action of a substance as it absorbs heat and changes state (evaporates)from a liquid to a vapour (gas).
Give Up Heat The action of a substance as it releases heat and changes state(condenses) from a vapour (gas) to a liquid.
Components and their Function
Temperature and Pressure Relief Valve - A valve designed to provide automatic relief bydischarging water in case of excessive temperature, pressure or both.
Never fit a T&PR Valve with a pressure rating greater than that indicated onthe product-rating label.
Pressure Limiting Valve (P.L.V.) - A valve that controls its outlet pressure to apredetermined limit.
Outlet Delivery Tube (Dip Tube) - A plastic tube installed in the hot water outlet of thewater heater cylinder to conduct water from the highest point to the outlet connection. Italso acts as a fitting liner.
Diffuser- A plastic device installed in the cold water inlet of the water heater cylinder toassist with stratification. It also acts as a fitting liner.
Fitting Liner - A plastic tube installed in the cold-water inlet of the water heater to provideprotection against corrosion through the life of the water heater.
Anode (Sacrificial)- A metal alloy electrode installed in the water heater cylinder that bygalvanic action protects the cylinder from corrosion.
Thermostat - A device responsive to temperature that controls the supply of electricalenergy to the compressor, which results in the stored water being maintained at therequired temperature.
Evaporator Thermistor - A device responsive to temperature that controls the active
supply between the compressor circuit and the booster element circuit.
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Compressor - An electro-mechanical device that adds heats to the refrigerant bycompressing it, known as heat of compression the resulting increase in refrigeranttemperature increases its pressure and causes the refrigerant to circulate through thesystem.
Evaporator - A finned copper coil mounted on top of the water heater. The refrigerantenters as a liquid, as it passes through the coil it absorbs heat from the surroundingatmosphere and boils off (evaporates) to a gas.
Condenser - An insulated housing containing stainless steel chambers where heattransfer occurs. The condenser (or heat exchanger) contains three chambers, one forrefrigerant, one for water and a third separating chamber containing air. The refrigerantenters as a gas, as it passes through the condenser it transfers (gives up) the heatabsorbed via the evaporator to the water flowing through the condenser in a separatechamber, during this process the refrigerant cools and changes state (condenses) back toa liquid.
Receiver Filter Drier- This device, fitted between the condenser and thermal expansion(TX) valve, receives and stores liquid refrigerant from the condenser for delivery to the
evaporator. The receiver also incorporates a filter and drier to trap impurities and removemoisture from the sealed refrigeration system
Accumulator- This device, fitted in the suction line prior to the compressor, is designed toaccumulate and prevent liquid refrigerant from entering and damaging the compressor.
Any liquid refrigerant is evaporated or boiled off and converted to a vapour by theaccumulator.
Thermal Expansion (TX) Valve - A valve, installed between the condenser andevaporator that controls (meters) the amount of refrigerant delivered to the evaporator.The TX valve has an external temperature sensor fitted to the suction line and increases ordecreases the refrigerant flow to the evaporator depending on the detected suction line
temperature.
Thermal Cut Out (Overload) - A manual reset temperature sensitive device thatautomatically cuts off the supply of electrical energy to the control board and/or boostelement.
Heating Unit (Element)- A tubular device containing an electric resistance element thatconverts electrical energy to heat. Standard element ratings are 2.4 and 3.6kW.
Common Faults
When a complaint is lodged about the performance of a hot water system there are anumber of causes that should be checked and eliminated. In an attempt to pinpoint themost likely cause it is important to discuss with the customer their reasons for thecomplaint, the duration of the problem, any change in circumstances or usage and recentweather conditions. This information in conjunction with the following listed commoncomplaints will assist you in locating the most likely cause. All procedures assume there iswater flowing through the water heater.
Discoloured water- This may be the result of discoloured water entering from the coldwater mains. Check if the cold water is also discoloured.
Excessive hot water usage- The complaints of insufficient hot water and no hot water
can on many occasions be attributed to hot water usage exceeding the capacity of thewater heater to provide hot water.
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When first attending a call of this nature it is essential to establish the probable hot waterusage by querying the usage habits of the household and compare this with the potentialdelivery of the model water heater installed. It can then be established if the usage iswithin or outside the capacity of the model. The areas to look at for excessive usage are:
1. Automatic washing machines.
2. Showers exceeding 12 litres/minute for mixed water and 5 minutes in duration.
3. Two or more showers operating at the same time.
4. Change of occupancy or number of persons increased.
5. High water pressure area. (Excessive pressure relief valve discharge)
6. Plumbing leaks.
7. Crossed connection.
Water hammer- A water heater will not cause water hammer, however valves associatedwith the water heater may be the source of the problem i.e. cold-water stopcock, non-return valve or relief valve.
Most water hammer problems are associated with plumbing, hot and cold or appliancesi.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valveparts, loose tap washers or neighbouring equipment.
High water pressure areas will have more complaints of this nature and the use of apressure-limiting valve (PLV) to reduce the household cold-water pressure will usuallysolve most problems.
Hot water plumbing leaks- If hot water has not been used for a period of time, feelingthe temperature of the hot water line may give an indication of water flow if the pipe iswarm. The method of checking for plumbing leaks is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock isoperating correctly.
3. Turn off the hot tap.
4. Turn on the stopcock to make up the water pressure in the cylinder, and then turn thestopcock off again.
5. Wait approximately 5 minutes then do either of the following:
a. With your ear close to the stopcock turn it on slightly and listen for any waterpassing. If there are no leaks, water should not pass.
b. Open a hot tap while listening for any pressure release. If there is a pressurerelease there will be no leaks in the plumbing system.
Mixing or crossed connections - If an automatic dishwasher, washing machine, flickmixer tap, tempering valve or thermostatic mixing valve is installed there is always thepossibility that the cold water could mix with the hot water through a faulty or incorrectlyinstalled valve. This is referred to as a cross connection. The complaints of insufficient hotwater, water too cold or excessive discharge from the pressure relief valve may beattributed to a cross connection. The method of checking for a cross connection is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap. If water flow is persistent and cold a cross connection exists.
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Wiring Diagram
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Refrigeration Sealed System Diagram
LED Indication
All 310 series Heat Pumps have LED indication. There are two variations of LED indicationdepending upon the version of the controllers software; however all versions utilise a redand green LED to display the operational status and/or fault condition of the appliance.Note: The software version is printed on a label on the control board.
Controller Software Version HPV 3.1, HPV 3.2 or no HPV identification
310 Series Heat Pumps with controller version HPV3.1, HPV 3.2 or no HPV identificationhave a green and red LED located internally on the control board in the heat pump(refrigeration) module and utilise the following LED indication:
LED IndicationLED Status Condition Details
Green Solid S4 > 53C or S5 > 50CStandby mode (end of heating cycle,cylinder water at required temperature).
Green Flashing S4 < 44.5C or S3 < 50C Call for heat initiated.
Red FlashingVarious (refer to operatingsequence flow chart onpage 6 for more details).
Component fault or ambient conditionstoo cold for heat pump operation.
No indicationFault or system operatingin limp mode.
Fault or system in limp mode with call forheat satisfied (water in cylinder @ 70C
determined by mechanical thermostat).Note: Refer to diagram on page 5 for control board LED location.
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Controller Software Version HPV 4.0 or higher
310 series Heat Pumps with controller version HPV 4.0 or higherhave a red and greenLED located externally on the front of the heat pump module or internally on the controlboard in the heat pump (refrigeration) module depending upon date of manufacture.
LED Flashing Frequency:Different combinations of flashing red and/or green LEDs areutilised to indicate the operational status or fault condition of the Heat Pump. Each flash in
a series will last 0.5 seconds and is separated by 0.5 seconds between flashes. Eachseries of flashes is separated by 2 sec.
Example: LED provides 2 flashes: 1) LED on for 0.5 sec.2) LED off for 0.5 sec.3) LED on for 0.5 sec.4) LED off for 2 sec.5) Return to Step 1).
Operational LED Indication: If no fault is present the green LED will flash as shownbelow to indicate the operational sequence number the Heat Pump is currently operatingin (refer to operating sequence flow chart on page 6 for more details).
Operational LED Indication
Sequence Green LED Red LED0 Solid 0
2 2 flashes 03 3 flashes 0
4 4 flashes 0
Fault Indication:If a fault is present the green and/or red LEDs will indicate the faultcondition according to the table below.
Fault Indication
Fault Error Green LED Red LEDFaulty power supply or system in limp mode
with call for heat satisfied (1)N/A 0 0
T3 (comp dis) > 60C in sequence 0(2) SerrNo 4 1 Flash 0
T4 (ambient air) < 0C (3) SerrNo 1 0 Solid
Any Sensor Strip Sensor Fault Any Sflag 0 1 Flash
Water circ fault T0 (water outlet) > 80C SerrNo 2 0 2 Flashes
T2 (evaporator) < -3C SerrNo 8 0 3 Flashes
Comp/refrig fault T3 > T4 + 15C (in seq3) SerrNo 32 0 4 Flashes
Comp/refrig fault T0 - T1 < 8C (in seq4) SerrNo 32 0 5 Flashes
Water circ fault T1 > S4 + 7C SerrNo 64 0 6 Flashes
TRIAC/refrig fault T3 > 110C SerrNo 128 0 7 Flashes
Thermistor T0 Fault Tflag 1 1 Flash* 1 Flash*
Thermistor T1 Fault Tflag 2 2 Flashes* 2 Flashes*Thermistor T2 Fault Tflag 4 3 Flashes* 3 Flashes*Thermistor T3 Fault Tflag 8 4 Flashes* 4 Flashes*
Thermistor T4 Fault Tflag 16 5 Flashes* 5 Flashes*
Notes:* The green and red LEDs flash simultaneously in these cases.(1) System may be in limp mode with call for heat satisfied (water in cylinder @ 70C
determined by mechanical thermostat).(2) This condition creates a delay start for the compressor. This is not considered a fault.(3)Ambient temperature too cold for heat pump operation. This is not considered a fault.
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Fault Finding
Fault ChartNumber
Page
1 161.1 171.2 21
No Hot Water
7 43Insufficient hot water 2 23
3 243.1 25
3.2 253.3 263.4 27
3.5 293.6 303.7 30
8.1 44
Software versionHPV 3.1, HPV 3.2
or no HPVidentification
8.3 444 32
4.1 334.2 33
4.3 344.4 35
4.5 364.6 374.7 38
4.8 394.9 4.13 40
4.14 408 44
System in boost or limp mode
Software versionHPV 4.0 or higher
8.2 44Leaking water heater 5 41
Noisy water heater 6 42Blowing fuse/circuit breaker 7 43
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General Fault Finding Chart
Fault Diagnosis
No
hot water?YES 1
Insufficienthot water?
NO
2YES
System
in boost or limp
mode?
NO
3
YES
NO
5YES
6
NO
Leaking
water heater?
Noisy
water heater?
7
YES
NO
Blowing fuse/circuit breaker
Boost or limp mode will be
indicated by any of the followingLED conditions:
Red solid or flashing.
Red & green flashing together.
No LEDs (Limp mode with
Robertshaw thermostat open)
4
HPV 3.1, HPV 3.2 or
no HPV identification
HPV 4.0 or higher
What is the
controller
software
version?
Note: For more information on LED indication refer to pages 12 and 13.
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Fault Finding Chart 1
1
Warning: Terminals may be live.
Wear Personal Protecti ve
Equipment to prevent risk of
electric shock.Is 240
volts present at
the terminal
block? Test 1
1.1YES
Is
the heater
connected to an
off peak
tariff?
NO
Off peak connection is unsuitable for Heat
Pump models. Connect to continuous tariff or
off peak 2 if available
YES
Is the
isolating switch
or time clock
turned off?
NO
Restore power and advise customerYES
Is the
fuse blown at the
switchboard?
NO
Fault in household electrical wiringNO
Reset circuit breaker
or rewire fuse
YES
Did
the fuse or
circuit breaker blow
again?
7YES
1. Heat pump connected to mixed circuit,
possible excessive current draw or another
appliance with a fault
2. Faulty circuit breaker or fatigued fuse wire
3. Unit may be short cycling due to faultythermostat
NO
No Hot Water
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Fault Finding Chart 1.1
Note: Ensure you
wait the full five
minutes before
progressing from
this point.
1.1
Are the
thermostat contacts
closed?
NO Replace thermostat.
Test 2
No Hot Water
Is there
240V at the
control board &
relay?
Test 3 Wiring incorrect.
Check control board wiring loom
plug (lower thermostat to control
board wiring loom).
NO
Test 4
What is the
status of the
control boards
LEDs five
minutes after
resetting?
Replace control board.
Red solid or Red and
Green LEDs indicatingsimultaneously
Green flashing
Green solid
No indication
1.2
Replace sensor strip.
Replace control board (system
should have been operating in
boost mode after five minutes
from resetting) then check
system operation as a second
fault may be present.
YES
Note: To reset heat
pump switch power off,
wait for 30 seconds
then switch back on.
Reset heat pump &
wait five minutes
before progressing
from this point.
Is the
compressor
running?
Is the
sensor strip
working?
NO
YES
Is the
refrigeration
system
heating?
YES
NO
YES
NO
To check if the refrigeration system is
heating feel the braided flexible hose
from the heat exchanger water outlet.
What is the
controller
software
version? HPV 3.1, HPV 3.2 or
no HPV identification
HPV 4.0 or higher
Is
sensor T3
working?
YES
Replace sensor T3.NO
Test 5
System working ok. The element circuit should be
checked as a temporary condition may have caused the
appliance to enter boost mode. If in boost mode and the
element circuit is not operational the cylinder water will
be cold and the system cannot reset itself automatically.
Replace control board.
YES
Is the
evaporator fan
operating?
YES
3.6NO
1.2Red flashing
Is
the air flow
obstructed?
NO
Remove obstruction or clean
evaporator.YES
Note: For more information on LED indication refer to pages 12 and13.
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18
Component Tests 1, 2, 3 & 6
Tests 1 Test 2
240
Warning Live equipment wearPersonal Protective Equipmentwhen conducting th is test.
Using a multimeter on the AC voltagescale, measure between the terminals ofthe terminal block located behind theelement access cover. The followingmeasurements should be obtained:
Active & Neutral 240 volts.Active & Earth 240 volts.Neutral & Earth 0 volts.
Warning - Ensure power isisolated before conducting thistest.
Using a multimeter on the ohms scale,measure between the terminals of themechanical thermostat. The followingresults should be obtained:
1L & 2T 0 ohms.3L & 4L 0 ohms.
Test 3 Test 6
240
240
Warning Live equipment wearPersonal Protective Equipmentwhen conducting this test.
Using a multimeter on the AC voltagescale, measure between the top 2 terminalsof the heat pump module terminal block.
Normal voltage is 240 volts.
Warning Live equipment wearPersonal Protective Equipmentwhen conducting th is test.
Using a multimeter on the AC voltagescale, measure between the A return andNeutral terminals of the terminal blocklocated behind the element access cover.
Normal voltage is 240 volts.
Note:Refer to page 19 for component test 4 and page 20 for component test 5.
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19
8.49
Component Test 4
Warning Live equipment wear Personal Protective Equipment whenconducting this test.
Sensor Strip Testing:Unplug the sensor strip plug from the control board and using amultimeter on the kilo-ohms scale, measure between the pins of the sensor strip plug*.There are six individual tests to be performed as there are six individual sensors contained
along the length of the sensor strip (sensors S0 S5). As the resistance of each sensorwill change according to its temperature, the resistance measurements for each sensor willneed to be checked against the Temperature/Resistance Table shown below. For thisreason it is best to empty the tank of hot water and then measure the cold watertemperature at the T&PR so a known temperature datum can then be applied to allsensors which should then in turn all have similar resistance value when tested.
Sensor Test Points
S0 Between Pins 1 and 9
S1 Between Pins 2 and 9
S2 Between Pins 4 and 9
S3 Between Pins 6 and 9
S4 Between Pins 3 and 8
S5 Between Pins 3 and 10
*Note: The sensor strip plug socket test points are quite small, Fine Probe Adapters (partnumber WH0020082) can be utilised as probe extensions. Alternatively small pins may beused however ensure good contact is made when testing.
Sensor Strip Temperature / Resistance Table
T (C) R (k) T (C) R (k) T (C) R (k) T (C) R (k) T (C) R (k)-10 37.45 10 15.45 30 7.037 50 3.485 70 1.853
-9 35.73 11 14.82 31 6.782 51 3.371 71 1.799-8 34.11 12 14.22 32 6.537 52 3.262 72 1.743
-7 32.56 13 13.65 33 6.302 53 3.157 73 1.695-6 31.10 14 13.10 34 6.076 54 3.055 74 1.646
-5 29.71 15 12.58 35 5.86 55 2.957 75 1.589-4 28.39 16 12.09 36 5.653 56 2.863 76 1.552
-3 27.13 17 11.61 37 5.454 57 2.773 77 1.508-2 25.94 18 11.16 38 5.264 58 2.686 78 1.465-1 24.81 19 10.72 39 5.081 59 2.602 79 1.424
0 23.73 20 10.31 40 4.905 60 2.521 80 1.3841 22.71 21 9.913 41 4.736 61 2.442 81 1.3452 21.73 22 9.535 42 4.574 62 2.367 82 1.3073 20.81 23 9.173 43 4.418 63 2.295 83 1.271
4 19.92 24 8.826 44 4.269 64 2.225 84 1.2365 19.09 25 8.495 45 4.125 65 2.157 85 1.202
6 18.29 26 8.177 46 3.987 66 2.092 86 1.1697 17.52 27 7.873 47 3.854 67 2.029 87 1.1378 16.80 28 7.583 48 3.726 68 1.968 88 1.107
9 16.11 29 7.304 49 3.603 69 1.91 89 1.077
Sensor strip plugpin configuration
Testing thesensor strip
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Component test 5
T Sensor Testing:310 Series Heat Pumps have five independent thermistors which areutilised to monitor temperatures at various locations around the system. These thermistorsconnect to and are monitored by the control board and are known as T sensors.
All five T sensors are identical and each can be tested as follows:
Warning - Ensure power is isolated before conducting this test.
Unplug the relevant T sensor from thecontrol board and remove the T sensorfrom its location so its temperature will bethe same as the ambient air temperature(As sensor T4 detects the ambient airtemperature it may remain in position forthis test). Using a multimeter on the kilo-ohms scale, measure between the two pins
of the T sensor plug*. As the resistance ofeach sensor will change according to itstemperature, the resistance measurementsfor each sensor will need to be checkedagainst the Temperature/Resistance Tableshown below and the value then comparedto the ambient air temperature.
*Note: The sensor strip plug socket test points are quite small, Fine Probe Adapters (partnumber WH0020082) can be utilised as probe extensions. Alternatively small pins may beused however ensure good contact is made when testing.
Sensor Monitors Part NumberT0 Water temperature leaving the condenserT1 Water temperature entering the condenser
T2 Evaporator temperatureT3 Compressor discharge temperatureT4 Ambient air temperature
056006
T Sensor Temperature / Resistance Table
The table below sets out the resistance of the T sensors for a given water or air
temperature.
TemperatureDegrees C
Resistance (All T Sensors)Kilo-ohms
0 23.7310 15.4520 10.31
30 7.03740 4.90550 3.485
60 2.521
70 1.85380 1.384
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Fault Finding - Chart 1.2
1.2
Is there
240V at the
element?
NO
Test 6
No Hot Water
Test 8
YES
YES
Is there
240V at the N/C
relay contact?
YES
Is there
6VDC at the relaycoil?
NO
YES
NO
Is the
element resistancecorrect?
NO
Test 7
Test 9
Repair faulty wiring.Appliance operation should then
be checked to determine why thesystem entered boost or limp
mode as a second fault may bepresent.
Replace element.Appliance operation should then
be checked to determine why thesystem entered boost or limp
mode as a second fault may bepresent.
Replace relay.
Appliance operation should thenbe checked to determine why thesystem entered boost or limp
mode as a second fault may be
present.
Replace control board.
Appliance operation should thenbe checked to determine why the
system entered boost or limpmode as a second fault may be
present.
Repair faulty wiring between heatpump module electrical
connection plug and element.Appliance operation should thenbe checked to determine why the
system entered boost or limp
mode as a second fault may bepresent.
Note: all faults in this chart are in the boost or limp mode (element)
circuit. After determining the fault in the element circuit the applianceoperation should then be checked to determine why the system
entered boost or limp mode as a second fault may be present.
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Component Tests 7, 8 & 9
Tests 7 Test 8
240
Warning Live equipment wearPersonal Protective Equipment
when conducting this test.Using a multimeter on the AC voltagescale, measure between the white wire onthe heat pump module electricalconnection plug and the top terminal of theheat pump module terminal block(Neutral).
Normal voltage is 240 volts.
Warning - Ensure power isisolated before conducting this
test.Disconnect the element wires from thethermostat and terminal block, and using amultimeter on the ohms scale, measurebetween the two element wires. Thefollowing results should be obtained:
2.4kW element: 22 26 ohms.3.6kW element: 15 17 ohms.
Test 9
Warning Live equipment wear Personal Protective Equipment whenconducting this test.
Using a multimeter on the DC voltage scale, measure between the two wires on thecontrol board relay plug.
Normal voltage is 6 Volts DC.
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23
Fault Finding - Chart 2
2
YESRecommend a water heater ofsufficient capacity to meet the
customers needs.
Insufficient Hot Water
NO
Has the
supply of hot water
recently been
depleted?
Boost or limp mode may beindicated by any of the following
LED conditions:Red solid or flashing.
Red & green flashing together.
No LED indication.Has the
usage pattern
changed
recently? i.e. additional appliances
or people using hot water
Depending on the ambient
temperature the water heater may
take 3 to 5 hours to recover.
Is theheater of sufficient
size?
NO
Recommend a hot water usage
pattern that will suit the water
heater and the customers needs.
YES
Is the
water supply pressuremore than 80% of the
T&PR rating?
Fit pressure limiting valve if not
already installed.
Existing pressure limiting valve
faulty - replace.
YESYES
Is thecorrect T&PR
valve fitted?
NO
NO
YES
Check for crossed water
connection.
Replace T&PR valve.
Replace T&PR valve with one ofcorrect pressure rating.
Do not use reconditioned T&PR
valves.
Are there
any plumbing leaks,
crossed connections or
dripping taps?
NO
Repair any leaks.
Isolate crossed connections.
YES
Is theheater operating
in boost or limp
mode?
NO
What is the
controller
software
version?
YES
3
4
HPV 3.1, HPV 3.2 or
no HPV identification
HPV 4.0 or higher
Is the
T&PR valve
continuously
discharging
water?
YES
NO
Is theheater outlet water
temperature> 58C
Is atempering valve
fitted?
Arethe filtersblocked?
NO
Clean or replace filtersYES YES
Is thetempering valve outlet
water temperatureapprox 48C?
NO
NO
Replace tempering valveNO
YES
System workingYES
NO
Is the
sensor strip
working?
NO
YES
Replace sensor strip
Test 4
The heater outletwater temperature
can be measured at
the T&PR.
Is the heater
connected to anoff peak tariff?NO
Off peak connection is unsuitablefor Heat Pump models. Connect
to continuous tariff or off peak 2 ifavailable.
YES
Note: This assumes thatthe hot water to the
tempering valve is above52C.
Note: For more information on LED indication refer to pages 12 and 13.
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24
Fault Finding - Chart 3
3
System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV
identification
What is the
status of thecontrol boards
LEDs?
Replace control board.
Red solid or Red and Green LEDs
indicating simultaneously
Red flashing
Green solid
Green flashing
Test 4
System working. Check operation.
No LED Indication 3.1
NO
YES NO
Are therelay, circulator,
fan, sensor strip & Tsensors all firmly plugged
into the correctsockets?
YES
Ensure plugs are firmly plugged
into correct sockets on control
board and that plug pins on
control board are clean and free
from conformal coating.
NO
Test 5
Is the
sensor stripworking?
Replace sensor strip.
Are all
T sensors
working?
Replace faulty T sensor(s).
Ensure water in heatpump is below 60C&
reset heat pump. Toreset heat pump switchoff, wait for 30 seconds
then switch back on.
Does
compressor
successfully start
after delay?
Note: The compressor
starts 30 seconds after
the circulator.
NO
NO
Is
circulatoroperating?
Does
compressor try
to start after
delay?
NO
3.3
3.4
Circulator operation can be
checked by feeling circulator
brass body for vibration.
Let heat pumprun for ten
minutes or untilred LED flashes.
Does
red LED
flash?
YES
Red LED will flash if
system enters boost
mode.
8.3
Has
compressor
recently beenoperating?
YES
Compressor internal OTCmay have opened.
Switch off power to heatpump, wait for ten
minutes then switchpower back on.
YES
NO
3.5YES
System working. Ambient air
temperature may have been too high or
low for normal operation. Heat pump
may have been too hot after operating
for an extended period due to large
volumes and/or frequent water usage.
NO
YES
YES
LED
Status
after5
seconds
Green - flashing
Red solid or flashing / Red and Green
indicating simultaneously / Green solidReplace control board.
3.2Red - flashing
3.8
Note: Refer to page 5 for T sensor plug socket location on control board.
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Fault Finding Chart 3.1
3.1
Are the
thermostat contactsclosed?
YESRepair faulty wiring.
Replace control board.
Test 2
System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV
identification
NO
System has operated in limp mode
due to a faulty sensor strip (S1 & S4
faults) and has completed a heatingcycle. Water was heated by the
electric element and controlled bythe Robertshaw thermostat to 70C.
Replace sensor strip.
Is the
sensor strip
working?
NO
Replace control board.
YES
Test 4
Are thesensor strip plug
pins clean?
Ensure sensor strip plug pins andcontrol board socket are clean
and free from conformal coating.
NO
YES
Fault Finding Chart 3.2
3.2
T0 is monitoring
water out of the
heat exchanger
Switch off heat pump &allow sensor T0 to cool
below 80C. Whensufficiently cool switchheat pump back on.
Is redLED flashing after
5 seconds?
Replace control board
YES
Is
Green LEDflashing?
NO
YES
Circulator operation can bechecked by feeling circulator
brass body for vibration.
NO
Hassensor T0 cooled
to below80C?
YES
NO
Is circulator
operating?3.3NO
3.8YES
Replace control board
System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV
identification
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Fault Finding Chart 3.3
3.3
Ensure circulator is firmly plugged
into correct socket on control
board and that plug pins on
control board are clean and free
from conformal coating.
NO
YES
Is the
circulator motor
resistance
correct?
Is 240V
present at the
circulator?
Test 10 Is the
circulator plug firmly
plugged into correctsocket?
NO
Check circulator impellor for
restriction or siezure.
YES
Replace circulator
YES
NO
Test 11
Replace control board
System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV
identification
Component Tests 10 & 11
Test 10 Test 11
Warning Live equipment wear
Personal Protective Equipmentwhen conducting this test.
Using a multimeter on the AC voltagescale, measure between the circulatorplug terminals at the control board.
Normal voltage is 240 volts.
Note: As the control board controls thespeed of the circulator by pulsing theelectrical supply to the circulator ananalogue multimeter may indicatebetween 180 240V.
Warning - Ensure power is
isolated before conducting thistest.
Unplug the circulator connection plug fromthe control board and using a multimeter onthe ohms scale, measure between the twocirculator connection plug terminals.
A reading of approximately 75.3 ohmsshould be obtained.
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Fault Finding Chart 3.4
3.4
Is 240V
present at the
compressor
terminals?
NO Faulty compressor wiring.
YES
Are
the compressor
winding resistances
correct?
Test 12
Replace compressor
NO
Faulty compressor and/orcompressor capacitor wiring.
YES
Note: Tests 12 & 13 must be
performed after waiting for the 30second delay after starting of the
circulator and cannot be performed
whilst the red LED is flashing.
Test 14
Is the
compressor
capacitor
working?
Replace compressor capacitorNO
YES
Is 240V
present at the control
board compressor
terminals?
YES
Test 15
Test 13
Replace control boardNO
Is there
6VDC at the relay
coil?
Is the
relay plug pluggedinto the control
board?
NO
YES
Plug in relay plug at control board.NO
Ensure plug pins are clean of
conformal coating and are making
contact. If plug & pins are ok
replace the control board.
YES
Test 9
System in boost or limp mode - Software version HPV 3.1, HPV 3.2 or no HPV
identification
Are
the compressor
winding resistancescorrect?
Compressor internal ECOmay have tripped open
circuiting the compressor
windings. Wait ten
minutes for ECO to cool
and auto reset.
NO
Is the
compressortemperature 150C
or hotter?
Reset heat pump and run
system until compressor
ECO trips again.
YES
Test 14
8.3YES
NO
Note: To reset heat
pump switch power off,
wait for 30 seconds
then switch back on.
Note: Compressor internalECO is auto trip & auto
reset & is not a replaceable
component.
ECO Opens @ 150C
ECO Closes @ 90C
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Component Tests 12 15
Tests 12 Test 13
Warning Live equipment wearPersonal Protective Equipment
when conducting th is test.
Remove the compressor electrical accesscover and using a multimeter on the ACvoltage scale, measure between the redand blue wires.
Normal voltage is 240 volts.
Warning Live equipment wearPersonal Protective Equipment
when conducting this test.
Using a multimeter on the AC voltagescale, measure between the control boardcompressor output terminal and the topterminal of the heat pump module terminalblock (Neutral).
Normal voltage is 240 volts.
Test 14 Test 15
Warning - Ensure power isisolated before conducting thistest.
Remove the compressor electrical accesscover and mark and disconnect terminalwiring. Using a multimeter on the ohmsscale, measure between the compressorterminals. The following run and startwinding results should be obtained.
(Run) Red & Blue terminals 2.2 ohms(Start) Red & Black terminals 3.2 ohms
Warning - Ensure power isisolated before conducting thistest.
Disconnect the wiring to the compressorcapacitor and using a multimeter on thecapacitance (F) scale measure betweenthe two capacitor terminals.
Normal capacitance is 35 micro Farads(35F).
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Fault Finding Chart 3.5
3.5
Is the
temperature atsensor T4< 2C?
System functioning correctly andshould operate in boost mode
until temperature at T4 risesabove 2C at which time the heat
pump will reset and start back at
sequence 0.
YES
T4 is ambientair sensor
Is thetemperature at
sensor T2< 2C?
NO
3.6YES
T2 is evaporator
sensor Is theambient air
temperature 60C in seq 0)Green 2 flash - Heat pump operating in sequence 2
Green 3 flash - Heat pump operating in sequence 3
Green 4 flash - Heat pump operating in sequence 4
Other LED indication:If no fault is present the Green LED
will flash to indicate the following:
4.1Red solidRed solid or flashing.
Red & Green flashing simultaneously.
No LED indication.
For other LED indication refer to notes
below.
For more information on LED indication refer to pages 12 and13.
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33
Fault Finding Chart 4.1
4.1
Is
sensor T4firmly plugged
into correctsocket?
NO
Ensure sensor T4 is firmly
plugged into correct socket oncontrol board and that plug pins
on control board are clean andfree from conformal coating.
Red solid
T4 < 0C
YES
Is thetemperature atsensor T4
< 2C?
NO
YES
Issensor T4
working?
Test 5
Replace sensor T4NO
Replace control boardYES
T4 is ambient
air sensor
Note: When T4 < -0C the system will enter boost mode. When in boost mode dueto this operation the system will reset and start at sequence 0 when T4 > 2C
System functioning correctly and
should operate in boost modeuntil temperature at T4 rises
above 2C at which time the heatpump will reset and start back at
sequence 0.
Note: Refer to page 5 for T sensor plug socket location on control board.
Fault Finding Chart 4.2
4.2
Is thesensor strip
working?
NO
Red 1 flash
sensor strip fault
Is thesensor strip
firmly pluggedinto the correct
socket?
YES
NO
Test 4
Replace control boardYES
Ensure sensor strip is firmly
plugged into correct socket oncontrol board and that plug pinson control board are clean and
free from conformal coating.
Replace sensor strip
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Fault Finding Chart 4.3
4.3
NO
Red 2 flashT0 >80C
YES
YES
NO
Test 5
T0 is monitoring
water out of the
heat exchangerIs
sensor T0
firmly pluggedinto correct
socket?
Is
sensor T0
working?
Replace sensor T0
Switch off heat pump &allow sensor T0 to cool
below 80C. Whensufficiently cool switchheat pump back on.
Does red
LED immediately
go to 2 flash?
Replace control board
YES
Is circulator
operating?
NO
Blockage of water system atcirculator, heat exchanger,
dropper tubes or flexible hoses.
Loose, damaged or jammed
circulator impellor.
YES
Circulator operation can be
checked by feeling circulatorbrass body for vibration.
NO
Ensure circulator is firmly pluggedinto correct socket on control
board and that plug pins on
control board are clean and free
from conformal coating.
NO
YES
Is the
circulator motor
resistance
correct?
Is 240V
present at the
circulator?
Test 10 Is the
circulator plug firmly
plugged into correct
socket?
NO
Check for loose, damaged or
jammed circulator impellor.
YES
Replace circulator
YES
NO
Test 11
Hassensor T0 cooled
to below80C?
YES
NO
Replace control board
Ensure sensor T0 is firmly
plugged into correct socket on
control board and that plug pinson control board are clean and
free from conformal coating.
Is there
an air lock in the
water system?
NO
Bleed air from water outlet at
flexible hose union.YES
Warning! Ensure water escaping
from flexible hose is caught in a
container and does not escape or
sensor strip damage may occur.
Note: Refer to page 5 for T sensor plug socket location on control board.
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35
Fault Finding Chart 4.4
4.4
Is
sensor T2firmly plugged
into correctsocket?
NO
Ensure sensor T2 is firmly
plugged into correct socket oncontrol board and that plug pins
on control board are clean andfree from conformal coating.
Red 3 flash
T2 < -3C
Is thetemperature atsensor T2
< 2C?
NO
Issensor T2
working?
Test 5
Replace sensor T2NO
Replace control boardYES
T2 is evaporatorsensor
System functioning correctly andshould operate in boost mode
until evaporator temperature rises
above 2C at which time the heatpump will reset and start back at
sequence 0.
Did the
system reset &operate in normal
heat pumpmode?
Is theambient air
temperature 2C
Is
the air flowobstructed?
NO
Remove obstruction.YES
YES
Clean dirty evaporator.
Appliance installed in enclosedroom contrary to installation
instructions. Appliance is suitablefor outdoor installation only.
Raise temperature of sensor T2 to
above 2C by removing fromevaporator and holding probe between
thumb & fingers. Heat pump shouldauto reset to sequence 0 when T2raises above 2C. Ensure sensor
probe is reinserted into evaporator on
completion of testing procedure.
Note: Refer to page 5 for T sensor plug socket location on control board.
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Fault Finding Chart 4.5
4.5
Is 240V
present at the
compressor
terminals?
NO Faulty compressor wiring.
Red 4 flash
T3 is not > T4 +
15C in sequence 3
YES
Does
compressor start
or try to start after
delay?
YES
Are
the compressor
winding resistances
correct?
Test 12
Replace compressorNO
Faulty compressor and/or
compressor capacitor wiring.
YES
Note: T3 is compressor discharge sensor. T4 is ambient air sensor. This check is performed in sequence 3 to
ensure that the sealed refrigerant system is operating (heating).
8
Are
sensors T3 & T4
firmly plugged into
the correct
sockets?
Ensure sensors T3 & T4 are firmly
plugged into correct sockets on
control board and that plug pins
on control board are clean and
free from conformal coating.
NO
Note: Tests 12 & 13 must be
performed after waiting for the 30
second delay after starting of the
circulator and cannot be performed
whilst the red LED is flashing.
Test 14
NO
Is the
compressor
capacitor
working?
Replace compressor capacitorNO
Note: The compressor starts 30
seconds after the circulator.
YES
Are
sensors T3 & T4
working?
Replace faulty sensor(s)NO
Ensure water in heatpump is below 60C &reset heat pump. Toreset heat pump switch
off, wait for 30 secondsthen switch back on.
YES
Does red
LED immediately
go to 4 flash?
NO
YES
Is 240V
present at the control
board compressor
terminals?
YES
Test 15
Test 13
Test 5
Replace control boardNO
Replace control board
Is there
6VDC at the relay
coil?
Is the
relay plug plugged
in to the control
board?
NO
YES
Plug in relay plug at control board.NO
Ensure plug pins are clean of
conformal coating and are makingcontact. If plug & pins are ok
replace the control board.
YES
Test 9
YES
Note: Refer to page 5 for T sensor plug socket location on control board.
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Fault Finding Chart 4.6
4.6
Is 240V
present at the
compressor
terminals?
NO Faulty compressor wiring.
YES
Does
compressor start
or try to start after
delay?
NO
YES
Are
the compressor
winding resistancescorrect?
Test 12
Replace compressorNO
Faulty compressor and/or
compressor capacitor wiring.
YES
8
Are
sensors T0 & T1
firmly plugged into
the correct
sockets?
Ensure sensors T0 & T1 are
plugged into correct sockets on
control board and that plug pins
on control board are clean and
free from conformal coating.
NO
Note: Tests 12 & 13 must be
performed after waiting for the 30
second delay after starting of the
circulator and cannot be performed
whilst the red LED is flashing.
Test 14
Is the
compressor
capacitor
working?
Replace compressor capacitorNO
Note: The
compressor starts 30
seconds after the
circulator.
YES
Are
sensors T0 & T1
working?
YES
Replace faulty sensor(s)NO
Ensure water in heatpump is below 60C &reset heat pump. Toreset heat pump switch
off, wait for 30 secondsthen switch back on.
YES
Does red
LED immediately
go to 5 flash?
NO
YES
Is 240V
present at the control
board compressor
terminals?
YES
Test 15
Test 13
Test 5
Replace control boardNO
Replace control board
Red 5 flashT0 - T1 < 8Cin
sequence 4
Note: T0 is heat exchanger water outlet sensor. T1
is heat exchanger water inlet sensor. This check is
performed in sequence 4 to ensure that the sealed
refrigerant system is operating (heating).
Note: Refer to page 5 for T sensor plug socket location on control board.
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38
Fault Finding Chart 4.7
4.7
Is thesensor strip & sensor
T1 firmly plugged intothe correct
sockets?
Ensure sensor strip & sensor T1
are both firmly plugged into the
correct sockets on control boardand that plug pins on control
board are clean and free from
conformal coating.
NO
YES
Is
sensor T1working?
Replace sensor T1NO
YES
Test 5
Replace cold water dropper tube.
Red 6 flashT1 > S4 + 7Cinsequence 3 or 4
Note: T1 is heat exchanger water inlet sensor. S4 is thermistor sensor strip sensor.
This check is performed in sequence 3 or 4 to ensure that the circulator is operating.
Is
sensor stripworking?
YES
Replace sensor stripNO
Is thecirculator water
flow directioncorrect?
YES
NOReinstall circulator so as flow is
directed towards heat exchanger.
Has thecold water dropper
tube fallen off?
YES
Replace control board.NO
Test 4
Is there
an air lock
in the watersystem?
Bleed air from water system at
water outlet flexible hose union.YES
NO
Warning! Ensure water escaping
from flexible hose is caught in a
container and does not escape or
sensor strip damage may occur.
Note: Refer to page 5 for T sensor plug socket location on control board.
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39
Fault Finding Chart 4.8
4.8
NO
YES
System working ok. Ambient air
temperature too hot for normal
heat pump operation.
YES
Test 5
Appliance may have been
operating for an extended period
due to large volume and/or
frequent water usage.
Red 7 flashT3 > 110Cin
sequence 3 or 4
Note: T3 is compressor
discharge sensor.
NO
YES
Is
sensor T3firmly plugged
into correct
socket?
YES
NO
NO
Test 19
Ensure sensor T3 is firmly
plugged into the correct socket oncontrol board and that plug pins
on control board are clean and
free from conformal coating.
Replace sensor T3
Is
sensor T3
working?
Isthe ambient air
temperature above50C?
8.2
Fit pressure gauge to
high side of
refrigerant system
Is the
head pressure
excessive?
Hassensor T3 cooled
to below60C?
Switch off heat pump &allow sensor T3 to cool
below 60C. Whensufficiently cool switchheat pump back on.
NO
YES
Note: Refer to page 5 for T sensor plug socket location on control board.
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40
Fault Finding Charts 4.9 to 4.13
4.9
NO
T sensor fault
YES
NO
Test 5
Is
T sensorfirmly plugged
into correct
socket?
Replace T sensor.
Ensure T sensor is firmly plugged
into correct socket on controlboard and that plug pins on
control board are clean and free
from conformal coating.
4.10 4.11 4.12 4.13
Replace control board.
IsT sensor
working?
T0 fault.
T0 is monitoringwater out of the
heat exchanger.
T1 fault.
T1 is monitoringwater into the
heat exchanger.
T2 fault.
T2 is monitoringthe evaporator
temperature.
T3 fault.
T3 is monitoringthe compressor
discharge temp.
T4 fault.
T4 is monitoringthe ambient air
temperature.
YES
Note: Refer to page 5 for T sensor plug socket location on control board.
Fault Finding Chart 4.14
4.14
Are the
thermostat contactsclosed?
YESRepair faulty wiring.
Replace control board.
Test 2
System in boost or limp mode - Software version 4.0 or higher
NO
System has operated in limp modedue to a faulty sensor strip (S1 & S4
faults) and has completed a heatingcycle. Water was heated by the
electric element and controlled by
the Robertshaw thermostat to 70C.
Replace sensor strip.Is the
sensor strip
working?
NO
Replace control board.
YES
Test 4
Are thesensor strip plug
pins clean?
Ensure sensor strip plug pins andcontrol board socket are clean
and free from conformal coating.
NO
YES
Is there
240V at thecontrol board &
relay?
YES
Wiring incorrect.
Check control board wiring loomplug (lower thermostat to control
board wiring loom).
NO
Test 3
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Fault Finding Chart 5
5
Isthe T&PR
valve continuouslydischarging
water?
Existing pressure limiting valve
faulty.Fit pressure limiting valve if not
already fitted.
Replace T&PR valve if required.
Is theleak from the
electrical accesscover?
NO
YES
NO
Is theleak from
the element barrelfitting?
YESCheck for loose element bolts.Remove element and replace
gasket.
YES
NO
Remove anode and repair leakusing Teflon thread tape.YES
Is the
correct T&PR valvefitted?
Replace T&PR valve with one ofthe correct pressure rating.
Do NOT use reconditioned
T&PR valves.
NO
Check for crossed waterconnection.
Replace T&PR valve.
YES
Is thewater supply
pressure above800kPa?
YES
NO
Isthe water leak
intermittent?
NO
Leak is probably condensatedraining from the evaporatorcondensate tray.
Normal Operation.
YES
Arethe anode/s
leaking?
Inner Cylinder leakingCheck for hot spots on the jacket
Replace water heater.
NO
Isthe leak from theheat pump water
system?
NO
Tighten or remake flexible hose
connection(s).
Repair or replace leaking heatexchanger.
Replace leaking circulator.
Remake or replace dropper tubeconnections.
YES
Leaking water heater
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42
Fault Finding Chart 6
6
Fan loose on motor shaft, remove
assembly and tighten.Fan motor faulty - Replace.
Is the
noise water
hammer?
NO
NO
Is thenoise only evident
when water is flowing
through the
heater?
YES
Cylinder contracting due to pressure
release when hot tap opened.
This can also be accompanied by a
creaking or cracking sound.
Normal Operation.
NO
Check for restrictions in pipe work, faulty
valves, loose plumbing or other
appliances i.e. washing machine or
dishwasher.
Fit 600kPa pressure limiting valve.
YES
Is
the noise
mechanical or air
related?
Normal noise level during operation is
approximately 52dB at 1.5 metres.
If this level is affecting neighbors a timer
should be fitted to prevent operation
during the affected hours or to comply
with local council regulations
AIR
Is the
noise from the
evaporator
fan?
Is the
noise only evident
during the heating
cycle?
Check for loose fittings or pipe work in
the refrigeration system.
Check for possible mechanical failure in
compressor
YES
Is the
water pressuremore than 80% of the
T&PR valve
rating?
Check all other appliances or valves that
can generate noise i.e. washing
machines, dishwashers, ball valves etc.
NO
YES
Mechanical
Refer to water hammer causes in the
Common Complaints section.
Check for a faulty stop cock, non-return
valve or T&PR valve.NO
Is the
noise a
metallic popping
sound?
YES
NO
YES
Noisy water heater
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44
Fault Finding Chart 8 - 8.3
8.3
Replace compressor.
Test 19
Refrigeration system fault finding
Is the
head pressure
excessive?
Test 21
NO
Fit pressure gauge
to high side of
refrigerant system.
Allow time for the
system to equalise.
Did
the system
equalise?
Is the system
taking too long to
equalise?
Possible restriction in system,
Locate and repair.
Possible system overcharge,
adjust refrigerant charge.
TX valve metering incorrectly,
adjust or replace TX valve.
NO
YES
Is theTX valve
operating?
NO
Locate blockage in refrigerant
system and repair.
YES
Adjust TX valve (refer to
component replacement
procedure 23 TX valve
adjustment) or replace if faulty.
NO
System overcharged, adjust
refrigerant charge.YES
YES
8.28
Fit pressure gauges
to high and low side
of refrigerant system.
Is the
Suction pressure
low/vacuum or
excessively
high?
Test 20Locate and repair leak in
refrigerant system.
High side head pressure excessive (Test 18)
YES
High
Low
NO
8.1
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Component Test 19
Warning Live equipment. Wear Personal Protective Equipment whenconducting this test.
1800 kPa
Fit gauges to the high side access pipeand observe the discharge pressure.
Typical high pressure range is 1400-2100 kPa depending on cylinder watertemperature. The high pressure rangeshould be within 1700-1800 kPa whenheating from cold.
Component Test 20
Warning Live equipment. Wear Personal Protective Equipment whenconducting this test.
400 kPa
Check for persistent air bubbles throughsight glass of receiver/filter drier. Fitgauges to the low side access pipe and
observe the suction pressure.
The suction (low side) pressure is verydependent on ambient conditionshowever the low pressure range istypically between 200-600 kPa.
200 kPa @ 10C ambient.600 kPa @ 45C ambient.
A suction pressure of less than 200kPamay indicate a refrigerant leak or a
malfunctioning TX valve.
Note: Refer to the following section formore information on refrigerant chargeand refrigerant charge fault indications.
Refrigerant Charge
Indication of correct refrigerant chargeThe receiver/filter dryer sight glass should show clear liquid, a few small bubbles might bevisible during initial start up of the system or when the TX valve opens quickly, howeverclear liquid should return shortly after. Compressor current draw should be between 5 6
Amps and system pressures should be within normal ranges (refer to component test 19(above) and component test 20 (above) for typical system pressures).
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Indication of undercharged systemBubbles persist for a significant amount of time or repeat often. Compressor current drawis low (6 Amps) and compressor noisy. Note:Unusual currentdraw or high head pressure can be a sign of other problems such as a blockage ormalfunctioning TX valve.
Component Test 21
Warning Live equipment. Wear Personal Protective Equipment whenconducting this test.
Fit gauges to low side access pipe.
Remove the insulation from the TX valvesensor on the suction line.
Hold the sensor by hand to increase theheat detected by the sensor. The TXvalve should open with the followingresults:
1. Flow of refrigerant through sight glassof receiver/filter dryer should increase.
2. Evaporator pressure should increase.3. Suction line should become cooler.
Remove hand and replace insulation, theTX valve should close, resulting in thereversal of the above results.
Electrical Insulation Testing
There are three basic test procedures that should be carried out when the operation andfunction of a heat pump water heaters electrical system is in doubt.
Wear Personal Protective Equipment when conducting step 1 of thisprocedure to reduce the risk of electric shock. Refer to Rheem safety
procedure on electrical testing.Insulation resistance of the water heater Neutral Circuit. (Reading not to be below0.66 Mega ohm).
1. Isolate power to the water heater at the isolation swi tch. Confirm with multi-meter across terminal block Active and Neutral, then Active and Earth , thenNeutral and Earth that vol tage is not present.
2. Once satisfied, disconnect the Active and Neutral wires from the water heater terminalblock.
3. Connect megger leads to the Neutral of the water heater wiring and Earth.
4. Operate megger. A reading above 0.66 Mega ohm should be obtained.
5. If a reading below 0.66 Mega ohm is indicated, all component parts will need to beindividually tested to locate the fault. Refer to Fault Finding Chart 7 on page 43.
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Insulation resistance of the water heater Active Circuit (reading not to be below 0.66mega-ohm).
6. Connect megger leads to the Active of the water heater wiring and Earth.
7. Operate megger. A reading above 0.66 Mega ohm should be obtained.
8. If a reading below 0.66 Mega ohm is indicated, all component parts will need to be
individually tested to locate the fault. Refer to Fault Finding Chart 7 on page 43.
To check Continuity of the Heat Pump electrical circuit.
9. Set megger to resistance scale or multimeter to x1 resistance scale.
10. Measure between the Active and Neutral terminals on the power supply terminal blocklocated behind the electrical/element access cover. The resistance should beapproximately 24 ohms. If a reading outside this resistance is measured all electricalcomponent parts will need to be individually tested to locate the fault. Refer toSpecifications table on page 3 for indicative resistance values of components.
11. Reconnect active cable