Rheem Premier Loline TM024 Operating instructions

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SER
V
ICE INSTRUCTIONS
Premier Loline
Solar Drain Back Water Heater
TM024
Revision: A
Published: December 07
590270
591270
596270

TM024 Premier Loline Solar Drain back Service Instructions REV: A
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Contents
Safety Warning....................................................................................................................3
Introduction..........................................................................................................................3
Water Heater Model Identification........................................................................................3
Specifications.......................................................................................................................4
Wiring Diagrams..................................................................................................................5
Operation.............................................................................................................................7
Solar Circuit.......................................................................................................................11
Solar Circuit Plumbing Diagrams - All Models................................................................12
Potable Water Plumbing Diagrams....................................................................................14
Tempering Valves..............................................................................................................14
Electronic Controller ..........................................................................................................15
Solar Monitor .....................................................................................................................15
Solar Monitor LED Indication..........................................................................................16
Components and Their Function........................................................................................16
Product Changes...............................................................................................................18
Solar Monitor Changes – All Models..............................................................................18
Gas Booster Integral Plumbing Changes – 596 Models Only ........................................18
Minor Plumbing Changes – All Models...........................................................................18
Thermostat Changes – 591 Models Only.......................................................................19
Preventative Maintenance .................................................................................................19
Common Faults .................................................................................................................20
Fault Finding......................................................................................................................21
Testing the Sensor Strip.................................................................................................22
Testing the Hot and Cold Sensors .................................................................................23
Fault Diagnosis Sequence (General Fault Finding Chart)..............................................24
Fault Finding Chart 1......................................................................................................25
Fault Finding Chart 1.1...................................................................................................26
Fault Finding Chart 1.2...................................................................................................27
Fault Finding Chart 1.3...................................................................................................28
Fault Finding Chart 1.4...................................................................................................30
Fault Finding Chart 1.5...................................................................................................31
Fault Finding Chart 1.6...................................................................................................32
Fault Finding Chart 1.7...................................................................................................35
Fault Finding Chart 1.8...................................................................................................36
Fault Finding Chart 2 & 2.1 ............................................................................................37
Fault Finding Chart 3, 3.1, 3.2 & 3.3 ..............................................................................38
Fault Finding Chart 4......................................................................................................39
Fault Finding Chart 5......................................................................................................40
Fault Finding Chart 6......................................................................................................41
Gas Booster Flow Rate and Outlet Temperature – 596 Models Only................................41
Electrical Insulation Testing...............................................................................................42
Component Replacement Procedures...............................................................................44
Exploded View 1 – 590 & 596 Models...............................................................................52
Exploded View 2 – 591 Models..........................................................................................54
Exploded View Collectors..................................................................................................56
Commissioning Procedure.................................................................................................57
Warranty............................................................................................................................67
Document Revision History................................................................................................68

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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
Rheem Premier Loline Water Heater 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.
Certain diagnostic procedures outlined in these Service Instructions require
“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 water heater to reduce the risk of electric shock.
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.
Introduction
The information provided in these instructions is based on the water heater being installed
in accordance with the Installation Instructions provided with each water heater.
Should you require further technical advice on a Rheem Premier Loline Water Heater,
contact your nearest Rheem Service Department where genuine replacement parts are
also available.
Water Heater Model Identification
The identification numbers are designed to convey detailed information about the water
heater to which it is attached. The model number consists of 7 digits and 1 letter.
Model Number 5 9 0 270 N5
Type
5 - Solar
Operation
9 - Heat exchange
Booster Type
0 - Solar Preheater Only
1 - Electric Boosted
6 - Gas Boosted
Capacity
Storage Capacity in Litres
Booster Capacity
00 - No boost
05 - 2.4kW Element
07 - 3.6kW Element
08 - 4.8kW Element
N5 - Natural Gas
P5 - Propane gas

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Specifications
Specification 590, 591 & 596 Models
Storage capacity 270 Litres
Temperature setting 60ºC
TPR valve setting 1000kPa
Solar circuit relief valve 200kPa
Max supply pressure 800kPa (680kPa with ECV)
Min supply pressure 200kPa
Water connections- tank Inlet RP¾/20, Outlet RP¾ /20
Water connections- collector Hot pipe ½” BSP, Cold pipe ½” BSP
Collector(s) type S200 or T200
Supply voltage 220 – 250 Volts AC 50Hz
Solar circuit fluid *4.5 Litres propylene glycol / 11.5 Litres water
Anodes 2 X 1153mm
Solar circuit pump 127.8 ohms
Solar circuit aux pump (optional) 127.8 ohms
* Approximate propylene glycol / water ratio. Refer to ‘Commissioning Procedure’ on page
57 for more information.
Power Consumption
Solar controller 3 Watts Constant load
Solar pump 165 Watts Maximum load at solar heating cycle start up
(for approximately two (2) minutes)
50 Watts Average load during the solar heating cycle
Heating unit
(591 models only) 2.4kW, 3.6kW
or 4.8kW Consumption when booster heating unit is operating depending upon model
Gas Booster
(596 models only) 146W When anti frost device is activated
Electric Booster Specifications (591 models only)
Heating unit rating depending upon model 2.4kW 3.6kW 4.8kW
Amps 10 15 20
Element circuit resistance (ohms) 22 – 26 15 – 17 11 - 13
Booster capacity 125 litres
Booster temperature setting 60ºC
Gas Booster Specifications (596 models only)
Input 199mJ
Booster capacity 26L/min
Booster temperature setting 60ºC
For complete gas booster specifications refer to Integrity 26 Service Manual TM023.

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Wiring Diagrams
Wiring Diagram - 590 & 596 Models

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Wiring Diagram - 591 Models (Robertshaw EWT Thermostat)
Wiring Diagrams - Electric Booster Circuit All 591 Models
Continuous power supply to booster circuit
- All 591 Models Extended Off-Peak power supply to booster circuit - All 591 Models
Continuous Power Supply
(no manual switch or timer)
Continuous Power Supply
(with manual switch or timer)
Continuous
Power Supply
Switchboard
Extended Off-Peak Power Supply
(no manual switch or timer)
Extended Off-Peak Power Supply
(with manual switch or timer)
Switchboard
Extended Off-Peak
Power Supply

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Wiring Diagram - 591 Models (Robertshaw ST Thermostat)
Note: Refer to page 6 for continuous or off-peak booster circuit wiring diagrams.
Operation
The Premier Loline is an indirect drain back solar Loline (collectors at roof level, cylinder at
ground level) water heater. The fluid in the collector circuit is isolated from the potable
water in the cylinder, hence the term ‘indirect’.
When there is insufficient solar gain or the cylinder is fully heated the pump is turned off
allowing the heating fluid in the collectors and pipe work to ‘drain back’ to the central heat
exchanger within the water heater.

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Operational Flow Chart
Plug In
Power On
Operational Flow Chart
Self
check routine
normal?
Red LED 1 flash
Rectify fault Isolate Power
YES Software
malfunction Hot sensor open circuit Hot sensor short circuit
Red LED 2 flash
Cold sensor open
or short circuit
Red LED 3 flash
Thermistors open
or short circuit
Red LED 4 flash
Sensor strip
unplugged
Red LED 5 flash
NO
Is hot
sensor temp
> or = tank temp
+ 12ºC?
YES
Green LED
5 flash
NO
Green LED
4 flash
Notes
(1) Self check routine is
performed every 20 milliseconds
regardless of stage of operation.
(2) Tank temp = average temp of
sensor strip top 3 thermistors.
(3) Pump 2 (auxiliary pump) is
optional and is utilised only if
collector heights are between 9
& 18 metres high.
Is hot
sensor temp <
5ºC above tank
temp?
Is cold
sensor temp >
75ºC?
Is hot
sensor temp >
95ºC?
Is hot
sensor temp
< 20ºC?
Is hot
sensor temp < 4ºC
above cold sensor
temp?
YES
NO
NO
NO
NO
NO
A
Restore Power
A
Pump 1 off
YES
YES
YES
YES
Is tank
temperature > or
= 75ºC?
The pump(s) speed is pulse
controlled by the control board
to limit the temperature rise of
the fluid across the collectors
to 10ºC. For pump 1 this will
occur from this period onwards
until pump 1 is switched off by
the control board.
NO
YES
Is hot
sensor temp < 4ºC
above cold sensor
temp?
Is hot
sensor temp <
5ºC above tank
temp?
Is cold
sensor temp >
75ºC?
Is hot
sensor temp >
95ºC?
Is hot
sensor temp <
20ºC?
NO NO NO
YES YES YES YES
Pump relay
energised
NO
YES
Pump 1 & 2 on
Is tank
temperature > or
= 75ºC?
Green LED
on (solid)
YES
Pump 1 off
YES
NO
NO
Pump relay
de-energised (if on)
Green LED
2 flash
Green LED
3 flash
Pump 1 & 2 on low
(pulse controlled)
Pump 2 off
15sec
2 min
1 min
0 sec
30 sec
Pump 1 & 2 speed
pulse controlled
(1)
(2)
(2)
(2)
(2)
(2)
(3)
(3)
(3)
(3)

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Sequence of Operation - Solar
The following sequence of operation is common to 590, 591 & 596 models and pertains to
the solar circuit which is a ‘closed circuit’ containing a heating fluid consisting of propylene
glycol and water. For information on electric and gas booster operation refer to page 10.
Refer to ‘Sequence of Operation Component Diagram’ on page 10 to view components
shown in brackets e.g. (1).
1. When power is supplied to the appliance the controller (1) performs a self check routine.
If the software, sensor strip (2), hot sensor (3) and cold sensor (4) are all functional the
control board will energise the pump relay (5). The pump relay (5) supplies power to the
control boards internal pump switch. If any of the aforementioned components are faulty
the pump relay will not be energised preventing pump (6) operation.
2. The cylinder (7) temperature is monitored by a sensor strip (2) containing 6 thermistors
spaced at equal intervals along the strip. The sensor strip (2) is attached to the outer
cylinder wall. The water temperature is derived by averaging the readings from the top 3
sensors.
3. As the vapour in the collector(s) (8) gains heat from solar radiation a sensor mounted in
the collector (hot sensor) (3) senses the temperature increase.
4. The controller (1) will turn the pump (6) on when the temperature in the collector(s) is
greater than or equal to 12°C above the average cylinder top temperature provided the
cylinder top temperature is less than or equal to 75°C.
5. Heating fluid consisting of propylene glycol and water is pumped from the central heat
exchanger (9) up to the collector(s) via the cold pipe (10).
6. The fluid gains heat as it passes through the collectors (8) and returns to the top of the
heat exchanger (9) where it passes through a distributor (11) which forces the fluid to
run down the heat exchanger (9) walls in a film (‘falling film’). The heating fluid gives off
its heat through the heat exchanger (9) wall to the water in the cylinder (7).
7. 15 seconds after the pump (6) commences operation the controller (1) limits the pump
(6) speed to ensure the temperature rise of the fluid across the collector(s) (8) is limited
to 10°C to prevent unnecessary cycling of the pump (6) and draining of the system.
8. The pump (6) is turned off when:
•The Temperature rise across the collector(s) (8) (i.e. difference between the hot
sensor (3) and cold sensor (4)) is less than 4°C, or:
•The average cylinder (7) top temperature is greater than 75°C, or:
•The temperature of the heating fluid leaving the heat exchanger (9) is greater than
75°C (detected by cold sensor (4)), or:
•The temperature of the heating fluid leaving the collector(s) (8) is greater than 95°C
(detected by hot sensor (3)), or:
•The collector (8) temperature is less than 20°C (detected by hot sensor (3)), or:
•The temperature of the heating fluid leaving the collector(s) (8) (detected by hot
sensor (3)) is less than 5°C above the average cylinder (7) top temperature
(detected by sensor strip (2)).

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9. Once the pump (6) ceases operation the system commences to drain back. Fluid in the
collectors (8) begins to fall back to the bottom of the heat exchanger (9) via the cold
pipe (10) due to gravity; this creates suction on the fluid in the hot pipe (12) which is
also drawn back through the collectors (8).
At the same time the heated vapour in the heat exchanger (9) is rising up through the
distributor (11) and into the hot pipe (12) also forcing the fluid back through the
collectors (8). At the end of the process all the heating fluid is stored in the central heat
exchanger (9) leaving the collectors (8) and connecting pipe work empty of heating fluid.
Sequence of Operation Component Diagram
1 Controller
2 Sensor Strip
3 Hot Sensor
4 Cold Sensor
5 Pump Relay
6 Pump
7 Cylinder
8 Collector(s)
9 Heat Exchanger
10 Cold Pipe
11 Distributer
12 Hot Pipe (not
shown)
Electric Booster Operation - 591 Models
Electric boosted models are fitted with either a 2.4kW, 3.6kW or 4.8kW electric immersion
type heating element depending upon model (refer to water heater model identification
table on page 3). The element will heat the volume of water in the storage cylinder directly
above the level of the element providing a 125 litre boost capacity.
Electric boosted models are fitted with a Robertshaw mechanical thermostat set at 60ºC.
This thermostat controls the electric boost element only. The electric boost circuit operates
simultaneously with the solar system and will heat the 125 litre boost volume to 60ºC
regardless of whether the solar circuit is heating or not. Simultaneous operation can be
prevented by the installation of a switch in the electric booster circuit.
The element & mechanical thermostat are located behind the top electrical access cover.
Gas Booster Operation - 596 Models
Gas boosted models have an integral in-line gas booster (Integrity 26 electronic gas
instantaneous water heater) mounted externally on the jacket of the heater. The in-line gas
booster will only operate provided the flow is greater than 3 litres per minute and the inlet
water temperature to the booster is less than or equal to 58ºC.
Gas boosted models have additional integrated plumbing connections which are located
behind the front access cover (refer to ‘Gas Boosted Integrated Plumbing Arrangement’ on
page 11).
Two hot water outlets are available on gas boosted models; a tempered water outlet (50ºC
max) and an optional hot water outlet (65 - 75ºC). Gas boosted models do not require an
external tempering valve to comply with AS3500.4 Clause 1.9.2(b) provided the tempered
water plumbing is connected to the tempered water outlet. The tempered water outlet from
this water heater will not deliver temperatures exceeding 50°C in accordance with
AS 4032.2. For more information refer to ‘Tempering Valves’ on page 14.

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Gas Boosted Integrated Plumbing Arrangement
Solar Circuit
It is imperative that both the collector hot and cold pipes must fall
continuously by at least 5º, or a 1 in 10 fall, to ensure proper drain back of
heat exchange fluid into the storage cylinder.
Each collector should be angled 10-15mm from horizontal towards the hot
outlet to ensure proper drain back of heat exchange fluid and to ensure that
the hot sensor is located in fluid when the pump is on. Likewise it is
essential that the collector connections are angled slightly downwards.
Failure to provide correct fall for the hot and/or cold pipes, collector(s) and
collector connections will result in incorrect operation of this appliance.
The solar hot and solar cold pipes between the solar storage tank and the
solar collectors MUST BE of copper and fully insulated with closed cell
polymer insulation or similar (minimum thickness 13 mm). Thicker insulation
may be required to comply with the requirements of AS/NZS 3500.4. The
insulation must be weatherproof and UV resistant if exposed. All
compression fittings must use brass or copper olives.
Plastic pipe MUST NOT be used, as it will not withstand the temperature of
the closed circuit fluid generated by the solar collectors.
Solar pipe work which is oversized or is too long can result in the drain back
system not operating effectively.

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Solar Circuit Plumbing Diagrams - All Models
The solar collectors must be the
highest point of the system. The
maximum height of the solar
installation, from the base of the
solar storage tank to the top of the
solar collectors, is 9 m. The pump
supplied will not circulate closed
circuit fluid through heights
greater than 9 m and solar gain
will not be achieved.
For heights greater than 9m, an
auxiliary pump kit (PN 299914)
must be installed. Refer to
‘Auxiliary Pump - Solar Circuit’ on
page 13 for more information. The
installation of an auxiliary pump
will enable a maximum height of
18 m to be achieved.
Maximum Total Pipe Length (solar cold + solar hot) & Number of 90°Bends
Pipe Size 1 or 2 Collectors 3 Collectors
Pipe Length 90°Bends Pipe Length 90°Bends
DN15 40 metres 20 30 metres 20
Notes:
•For each additional 90°bend, reduce the maximum total pipe length by 0.5 metres.
•For each additional metre of pipe length, reduce the number of 90°bends by two.
•One 90°elbow is equal to two 90°bends.

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Auxiliary Pump - Solar Circuit
The maximum height of the solar installation from the base of the solar storage tank to the
top of the solar collectors is 9 m. The pump supplied with the solar storage tank will not
circulate closed circuit fluid through heights greater than 9 m and solar gain will not be
achieved.
For heights greater than 9 m, an auxiliary pump kit (kit PN 299914) must be installed
above and within 1 m of the solar storage tank. The installation of an auxiliary pump will
enable a maximum height of 18 m to be achieved. Note: The installation of an auxiliary
pump does not allow for an increase in total pipe length of the system. The maximum pipe
lengths shown in the table on page 12 must still be observed.
The arrows on the rear face of the pump indicate the direction of flow and should be
pointing upwards when the pump is in the installed position.
The auxiliary pump speed setting must be set on 3. The solar control unit automatically
controls and adjusts the speed of the pump to maximise solar contribution. Manual
adjustment of the speed dial setting on a setting other than 3 may result in the system not
operating correctly or efficiently. Note: If an auxiliary pump is utilised it will switch on with
pump 1, run for 3 minutes to establish circulation then switch off. After this period pump 1
maintains circulation.
The two wire plug from the auxiliary pump connects to the terminals marked “PUMP 2” on
the control board (refer to wiring diagrams on pages 5 & 6) and the earth wire spade
connector from the auxiliary pump connects to a terminal on the earth connector strip
located on the bracket adjacent to the control board. For information on installing an
auxiliary pump refer to ‘Installation Instructions – Auxiliary Pump Kit Solar Drain Back
Water Heater’.
Auxiliary Pump Kit Part Number 299914 Contents
Part No Description Quantity
121994 Installation instructions auxiliary pump 1
299998 Pump Salmson HXL63-15P RU15/21 Union 1
108381 Bracket pump wall mount 1
108380 Cover pump wall mount 1
080031 Screw phillips pan head no 8 x 13 4
088063 Union fitting assembly ½” x ½” male (includes union ½”
x ½” male, copper olive, compression nut) 2
080138 Cable tie black 200 mm long 10
N/A Cable tie mount adhesive backed 4 way 4

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Potable Water Plumbing Diagrams
Plumbing Diagram - 590 & 591 Models
Two temperature zones utilising temperature limiting device
Plumbing Diagram - 596 Models
Two temperature zones utilising temperature limiting device integrated with water heater
Note: Refer to page 11 for gas boosted integrated plumbing arrangement.
Tempering Valves
590 and 591 models require the installation of a tempering valve to comply with the
requirements of AS3500.4 (refer to plumbing diagram on top of page).
Gas boosted (596) models do not require an external tempering valve to comply with
AS3500.4 Clause 1.9.2(b) provided the tempered water plumbing is connected to the
tempered water outlet. The tempered water outlet from this water heater will not deliver
temperatures exceeding 50ºC in accordance with AS 4032.2.
To enable delivery of hot water at temperatures above 50ºC a separate untempered line
must be provided that supplies hot water exclusively to kitchen and laundry areas (refer to
plumbing diagrams above). Note: Gas boosted (596) models have an integrated tempering
valve and provide both a tempered and untempered hot water outlet.
Gas boosted integrated
plumbing behind front
access cover contains
a tempering valve and
provides both a hot
(75ºC) and tempered
(50ºC) water outlet.

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Electronic Controller
The control board or electronic controller
is used to control the pump by monitoring
the water temperatures and heat transfer
temperatures at various locations within
the system.
By monitoring the temperature of the
heat transfer fluid returning to the solar
collectors (cold sensor) and the
temperature of the fluid at the outlet of
the collectors (hot sensor), the controller
adjusts the pump speed to regulate the
temperature rise through the collectors to
10ºC.
The controller also monitors the water
temperatures within the storage cylinder
and regulates when solar heating should
occur.
Solar Monitor
A remote solar monitor is located on the
front of the cylinder pump access cover.
The remote solar monitor plugs into the
control board display socket and has two
LED’s which indicate the operational mode
or fault status of the system. The green
LED (marked solar) is used to indicate the
present operating mode of the controller
whilst the red LED (marked attention) is
used to indicate a fault condition.
590 and 596 models manufactured before
01/11/2006 do not have a remote solar
monitor however the control board has an
inbuilt solar monitor (green and red LED
mounted on the control board) which can
be viewed by removing the pump access
cover.
It should be noted that on early versions the solar monitor connection plug is not polaritive
sensitive and may be inserted into the control board plug socket either way. If unusual fault
codes are occurring, such as a solid red LED when in standby mode (instead of green), or
a flashing red LED whilst the pump is operating (instead of flashing green), the solar
monitor plug polarity should be tested by performing the following procedure:

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Solar Monitor Plug Polarity Test
1. Release water from the T&PR valve until the water temp in the cylinder is < 75ºC.
2. Switch off power for 5 seconds and then restore power.
3. If the LED flashes green (any combination) or is solid red within the first 15 seconds
from restoring power, the solar monitor plug is inserted the wrong way around.
Solar Monitor LED Indication
Each flash lasts for 0.5 seconds and each series of flashes is separated by a two second
interval.
Green LED - Operational Status Red LED - Fault Condition
Flash Sequence Indicates Flash Sequence Indicates
Solid green (on) Standby mode 1 Flash Hot sensor open circuit
2 Flash Flooding solar circuit period 2 Flash Hot sensor short circuit
3 Flash Pump(s) flow control period 3 Flash Cold sensor open / short circuit
4 Flash *Pump flow established. 4 Flash Open or short circuit of any top
3 thermistor on sensor strip
5 Flash Cylinder at maximum temp. 5 Flash Sensor strip unplugged
* When pump flow is established auxiliary pump 2 is turned off by the control board (if
fitted) whilst pump 1 continues to operate.
Components and Their Function
Temperature and Pressure Relief Valve (T&PR)
A valve designed to provide automatic relief by discharging water in case of excessive
temperature and/or pressure.
Never fit a T&PR Valve with a pressure rating greater than that indicated on
the product-rating label.
Storage Cylinder
A fully welded steel cylinder incorporating a convex (plus) top, concave (minus) bottom
and central tube (heat exchanger). The cylinder is lined with vitreous enamel to provide
protection against corrosion throughout the life of the water heater.
Outlet Delivery Tube (Dip Tube)
A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water
from the highest point to the outlet connection. It also acts as a fitting liner.
Fitting Liner
A plastic tube installed in the cold-water inlet of the water heater to provide protection
against corrosion throughout the life of the water heater.
Cold Pipe (Solar Return)
The pipe connecting the solar collectors to the storage water heater through which the
cooler solar transfer fluid returns from the storage cylinder to the collectors.
Hot Pipe (Solar Flow)
The pipe connecting the solar collectors to the storage cylinder through which the solar
heated solar transfer fluid flows back to the storage cylinder from the collectors.
Electronic Controller
An electronic control unit that interprets low voltage signals indicating water temperature
from the hot and cold sensors to switch on and off the 240 volt circulating pump circuit.
The unit is factory set and cannot be adjusted or mega-ohm tested. Refer to page 15 for
more information.

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Pump
An electro-mechanical device that pumps solar transfer fluid through the collectors by
centrifugal force. The control board varies the flow rate of the pump by pulsing the
electrical supply to the pump motor. The flow rate is proportionate to the pulse rate. e.g.
higher pulse rate = higher flow rate.
Pump Relay
The pump is controlled and switched by the control board however the pump power supply
may be interrupted by the relay in the event of a software malfunction or over temperature
condition. If a fault develops in the controller software or the cylinder reaches over
temperature (95ºC) the controller will de-energise the pump relay. This will open circuit the
pump wiring and prevent the pump from operating.
Hot Sensor
A thermistor type sensor utilised to sense the air/fluid temperature in the collector(s). The
hot sensor is fitted into the unused connection at the top of the collector array on the
opposite side to the hot pipe connection. The hot sensor plugs into and is monitored by the
control board.
Cold Sensor
A thermistor type sensor utilised to sense the fluid temperature leaving the heat
exchanger. The cold sensor is fitted into a pocket in the pipe work between the heat
exchanger outlet and the pump. The cold sensor plugs into and is monitored by the control
board.
Anode (Sacrificial)
A metal alloy electrode (magnesium) installed in the water heater cylinder that by galvanic
action protects the cylinder from corrosion. All Premier Loline models are fitted with two
anodes both of which are located in the potable water section of the storage cylinder.
Thermistor Strip (Sensor Strip)
A thermistor type sensor strip mounted down the external face of the storage cylinder
between the cylinder jacket and storage cylinder. The sensor strip has 6 equally spaced
thermistors however the water temperature of the cylinder is derived by averaging the
readings from the top 3 sensors only. It should be noted that the lower three sensors are
not used. The thermistor strip plugs into and is monitored by the control board.
Heat exchanger
Heat exchange from the solar heated transfer fluid to the water in the storage tank is by
means of a ‘falling film’ on the inside wall of the heat exchanger. The fluid entering the
heat exchanger top is diverted through an internal four channel distributor which creates
the falling film.
Mechanical Thermostat - 591 Models Only
A device responsive to temperature which controls the supply of electrical energy to the
element to maintain the heater water at the required temperature. The mechanical
thermostat controls the electric boost element only.
Over Temperature Energy Cut-out (E.C.O.) - 591 Models Only
A temperature-sensing device integral to the mechanical thermostat that automatically cuts
off the supply of electrical energy to prevent excessive water temperature occurring. This
device will not reset automatically but may be manually reset once temperatures have
fallen to a safe level.

TM024 Premier Loline Solar Drain back Service Instructions REV: A
D.O.I: 12/12/2007
This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”
18
Heating Unit (Element) - 591 Models Only
A tubular device containing an electric resistance element that converts electrical energy
to heat. Standard element ratings are 2.4kW, 3.6kW and 4.8kW.
Integral Gas Booster - 596 Models Only
An Integrity 26 litre electronic gas instantaneous water heater mounted externally on the
heater jacket which will boost the solar preheated water to 60ºC if required. Refer to page
10 for more information.
Product Changes
Solar Monitor Changes – All Models
A remote solar monitor was introduced to 590 and 596 models on the 01/11/2006. 590 and
596 models manufactured before 01/11/2006 do not have a remote solar monitor however
the control board has an inbuilt solar monitor (green and red LED mounted on the control
board) which can be viewed by removing the pump access cover.
All 591 models have a remote solar monitor regardless of date of manufacture. Refer to
page 15 for more information on solar monitors. For solar monitor LED indication modes
and their meaning refer to the table on page 16.
Gas Booster Integral Plumbing Changes – 596 Models Only
The gas booster insulated copper hot and cold pipes (items 32a & 33a) have been
replaced with insulated flexible hoses (items 32b & 33b) effective 17/09/2007. Note: Refer
to replacement parts list on page 53 for ‘a’ and ‘b’ items and exploded view 1 on page 52.
To replace an existing copper hot pipe (item 32a) with a flexible hose (item 32b):
•Obtain 1 x 088137 Flexible hose insulated 440 x ¾” (item 32b).
•Discard the nut and olive on the elbow at the heater hot outlet (item 31b) and screw
the flexible hose directly to the elbow.
•Remove union from Integrity inlet (item 41a) and replace with elbow part number
088117 (item 41b).
•Connect remaining end of flexible hose to elbow (item 41b).
To replace an existing cold pipe (item 33a) with a flexible hose (item 33b):
•Obtain 1 x 088138 Flexible hose insulated 450 x ¾” (item 33b).
•Discard the nut and olive on the elbow at the heater cold inlet (item 31b) and screw
the flexible hose (item 33b) directly to the elbow.
•Remove union from tee (item 43a) and replace with elbow part number 088117
(item 43b).
•Connect remaining end of flexible hose to elbow (item 43b).
Minor Plumbing Changes – All Models
Effective 19/09/06 –Solar Hot Connection
•Item 12 - 088092 brass extension fitting replaced by 088118 brass extension fitting
•Item 2 – 088063 Union ½”C x ½”M replaced by 088119 compression nut
•Item 11 – 080163 washer replaced by 088027 compression olive
Note: This means the solar hot connection is different although the installing plumber still
makes to two ½” copper connections.

TM024 Premier Loline Solar Drain back Service Instructions REV: A
D.O.I: 12/12/2007
This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”
19
Effective 10/08/07 – Solar Cold Connection
•The cold pipe which is foamed into the heater had the large brass fitting removed so
that just the pipe protrudes.
•Item 2 – Union ½”C x ½”M is replaced by 088065 compression union ½”C x ½”C
which is now item 2a.
•Item 10 - 087035 Rubber disc is replaced by 221754 Kelvindale plug which is now
item 10a.
Note: This means the solar cold connection is different although the installing plumber still
makes to two ½” copper connections.
Thermostat Changes – 591 Models Only
The Robertshaw ST thermostat was introduced to 591 models on 14/08/2007 and replaces
the Robertshaw EWT thermostat used previously.
It should be noted that although ST series thermostat is a direct replacement for the EWT
series thermostat the terminal connections and wiring arrangement is different, therefore;
Whenever an EWT series thermostat is replaced with a ST series
thermostat as a spare part, each appliance will require rewiring at the
thermostat. Refer to wiring diagrams on pages 6 & 7 for wiring
arrangements for EWT and ST series thermostats.
Preventative Maintenance
It is suggested for peak performance that the water heater be serviced annually.
Servicing is to be performed by qualified persons.
1. Check for discharge from the T&PR valve. Whilst the electric booster (if fitted) is off,
and during periods of low solar contribution there should be no discharge of water.
When the electric booster (if fitted) is operating or during periods of high solar
contribution, a small discharge of water may be evident. Operate the valve-easing lever
to ensure the valve opens and resets properly. Always open and close the valve gently.
The T&PR valve should be replaced at 5 yearly intervals.
2. Check for leaks at the collector connectors, hot and cold pipes and all tank fittings.
3. Check the collector glass is not cracked and the absorber plate finish is not
deteriorating.
4. Confirm all supports and anchors retaining the collector(s) to the roof are present, firmly
fixed and in good condition.
5. Clean the collector glass. Do not stand on the collectors while cleaning.
6. Check for signs of plant or tree growth that may be shading the collectors. Advise
customer to have pruned if possible.
7. Check for signs of excessive corrosion on the water heater jacket, collector panels and
roof stand if fitted.
8. Isolate power and check all electrical connections for signs of overheating due to poor
connection.
9. 591 Models Only
Conduct an electrical insulation test on the electric booster circuit only (refer to page
42). Note: Do not Megger test the electronic controller.
596 Models Only - Refer to TM023 Integrity 26 Litre Service Instructions for
preventative maintenance information on the Integrity 26 litre gas booster.

TM024 Premier Loline Solar Drain back Service Instructions REV: A
D.O.I: 12/12/2007
This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”
20
Common Faults
When a complaint is lodged about the performance of a hot water system there are a
number of causes that should be checked and eliminated. In an attempt to pinpoint the
most likely cause it is important to discuss with the customer their reasons for the
complaint, the duration of the problem, any change in circumstances or usage and recent
weather conditions. This information in conjunction with the following listed common
complaints will assist you in locating the most likely cause. All procedures assume there is
water flowing through the water heater.
Excessive hot water usage
The complaints of insufficient hot water and no hot water can on many occasions be
attributed to hot water usage exceeding the capacity of the water heater to provide hot
water.
When first attending a call of this nature it is essential to establish the probable hot water
usage by querying the usage habits of the household and then comparing this with the
potential delivery of the model water heater installed. It can then be established if the
usage is within or outside the capacity of the model. The areas to look at for excessive
usage are:
1. Automatic washing machines.
2. Showers exceeding 11 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 an increase in the number of persons.
5. High water pressure area (Excessive T&PR discharge).
6. Plumbing 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. Brown coloured water will generally indicate that the anode has been depleted or the
water heater is near the end of its useful life.
3. Milky coloured water is generally air in suspension and will disperse of its own accord.
In very hard water areas where anode gassing occurs, milky water may be evident. The
use of a blue anode should overcome this problem.
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, non-return valve, T&PR
valve or relief 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 household cold-water pressure will usually
solve most problems.