Rheem Australia Pty Ltd ABN 21 098 823 511 SERVICE INSTRUCTIONS Rheem Gas Permanent Pilot Water Heaters TM016 R Reevviissiioonn:: C C PPuubblliisshheedd:: JJaannuuaarryy 0066 300 Series - Indoor 311 Series - Outdoor 314 Series - Rheem Plus 811 Series - Optima 620 Series - Indoor 630 Series - Outdoor This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Contents Safety Warning ....................................................................................................................3 Introduction ..........................................................................................................................3 Heater Model Identification ..................................................................................................3 Preventative Maintenance ................................................................................
Safety Warning The purpose of these service instructions is to provide sufficient information to allow a person with the skills as required by the controlling Regulatory Authorities to carry out effective repairs to a Rheem Gas 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.
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 burner is off there should be no discharge of water. When the burner is operating, 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.
Specifications 300, 311, 314** & 811 Series With ECV Maximum Water Supply Pressure (kPa) Without ECV Maximum Thermostat Setting (ºC) Cut Out Temperature (Water ºC) Hourly Recovery @ 45ºC Rise (Litres) Water Connections Gas Connection Butane Gas Natural Gas Thermal Input (MJ) Propane Gas TLP Gas Connection T & PR Valve Rating (kPa) Quantity Anodes Length (mm) Blades Flue Baffle Length (mm) Model 90L 135L 170L Indoor Outdoor Indoor Outdoor Indoor Outdoor 960 960 960 1120 1120 1120 66 66 66 82 82 82 100 125
TLP Gas Propane Gas Natural Gas Butane Gas Gas Specifications Min Gas Pressure (kPa) Max Gas Pressure (kPa) Pilot Injector (mm) Main Injector (mm) Burner Pressure (kPa) Min Gas Pressure (kPa) Max Gas Pressure (kPa) Pilot Injector (mm) Main Injector (mm) Burner Pressure (kPa) Min Gas Pressure (kPa) Max Gas Pressure (kPa) Pilot Injector (mm) Main Injector (mm) Burner Pressure (kPa) Min Gas Pressure (kPa) Max Gas Pressure (kPa) Pilot Injector (mm) Main Injector (mm) Burner Pressure (kPa) 300, 311, 314* &
Lighting Instructions Eurosit Gas Control (Old Style) 1. Ensure the gas control knob is in the “●” position (the off position). 2. Wait five (5) minutes so any build up of gas can escape. 3. Depress and turn the gas control knob to the “ pilot position). ” position (the 4. Depress the knob fully (until the “ ” disappears below the housing) and after thirty (30) seconds, whilst keeping the gas control knob depressed, press the igniter button several times to ignite the pilot flame.
Eurosit Gas Control (New Style) 1. Ensure the gas control knob is in the “●” position (the off position). 2. Wait five (5) minutes so any build up of gas can escape. 3. Turn the gas control knob to the “ position). ” position (the pilot 4. Depress the knob fully (until the “” disappears below the housing) and after thirty (30) seconds, whilst keeping the gas control knob depressed, press the igniter button several times to ignite the pilot flame.
Operation When the gas control knob is depressed in the pilot position, it allows gas to flow to the pilot head where it can be ignited by a spark from the piezo igniter. The pilot flame heats the thermocouple, which creates an electrical current to energise the magnetic safety valve. This electrical current holds the magnetic valve in the open position when the gas control knob is released allowing the pilot to remain alight.
Tempering Valve – Rheem Plus Models A non adjustable valve that mixes hot and cold water to provide an outlet water temperature of 48ºC +/- 1.5ºC. Cold Water connector – Rheem Plus models A three way fitting which the plumber connects the cold water supply to. This fitting then diverts water to both the storage cylinder and to the cold water inlet of the tempering valve. Eurosit 630 Gas Control The gas control is a multi-functional single knob gas control.
Magnetic Valve A solenoid type gas isolating valve held in the open position by a small electric current generated by the thermocouple. This valve will completely isolate the supply of gas to the burner and pilot in the event of a pilot flame failure. Thermal Switch A one-shot safety device mounted in the thermocouple near the gas control that senses excessive heat outside the combustion chamber. This device cannot be reset and must not be bypassed.
Product Changes Main burner assembly Gas storage water heaters have been manufactured with two (2) types of main burner assembly. The original production featured a Eurosit gas control with a 2BL Robertshaw pilot assembly (refer to figure 1). Current production features a Eurosit gas control with a S.I.T pilot assembly (refer to figure 2). Figure 1 Figure 2 Eurosit gas control with 2 BL pilot manufactured from inception to the end of March 2000 Eurosit gas control with S.I.
Insulation During 2001 the insulation material used in domestic outdoor gas water heaters was changed from a wool glass blanket wrapped around the cylinder to moulded styrene. The moulded styrene is fitted around the cylinder in two (2) halves on 90L and 135L models and in four (4) sections on the 170L models (see diagrams opposite).
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 in locating the most likely cause.
Mixed or crossed plumbing connections If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or thermostatic mixing valve is installed there is always the possibility that the cold water could mix with the hot water through a faulty or incorrectly installed valve. This is referred to as a crossed connection. The complaints of insufficient hot water, water too cold or excessive discharge from the T&PR valve may be attributed to a cross connection.
Conventional fluing (Indoor models) Below are some examples of the correct and incorrect positions for flue cowls to terminate at roof level. Where the flue cowl terminates in a pressurized zone, a severe down draught can be excerpted during windy conditions. This down draught can result in flame roll out from the combustion chamber, sooting of the primary flue and/or flame failure problems. Fault Finding Chart Index Fault Pilot fault No hot water Main burner fault Leaking water heater Chart Number 1, 1.
General Fault Finding chart Attempt to light the pilot Refer to lighting instructions on access cover. Ensure the correct lighting procedure is followed.
Fault Finding Chart 1 1 Ensure the gas control is in the off position when conducting test Is a pilot flame established? Is a spark generated at the pilot head when the piezo is pressed? NO NO 1.1 YES YES 1.2 Check the gas supply pressure is between the minimum and maximum limit for the gas type Is the gas supply pressure ok? If possible adjust gas supply pressure or refer to installer or gas utility.
Component tests 1 – 4 TEST 1 TEST 2 Using a multimeter set on the x1 resistance scale measure across the terminals of the interrupter block on the gas control. The reading should be less than 1 ohm. Disconnect the thermocouple from the gas control and using a multimeter on the DC millivolt scale measure the voltage being generated by the thermocouple. Normal voltage should be approximately 20mV. Note: It will be necessary to hold the gas control knob down to maintain pilot flame during this test.
Fault Finding Chart 1.1 1.1 Does the piezo make a loud click when pressed NO Replace the piezo YES Check the high tension lead terminals are tight and that the HT lead is not open circuit, damaged, or shorting to metal components TEST 4 Is the HT lead ok? NO Replace the HT lead NO Replace the spark plug NO Replace the pilot assembly YES Check the spark plug ceramic is not damaged (cracked) or contaminated with soot.
Fault Finding Chart 1.2 1.
Fault Finding Chart 2 2 Fit manometer to burner pressure test point Ensure the gas control is in the pilot position when fitting the manometer Turn gas control knob to position “6” Is a pressure reading indicated? NO YES Replace the gas control YES Refer to specifications table Is the burner NO pressure reading correct? TEST 6 Is the gas supply pressure within the minimum and maximum limit for the gas TEST 7 type? YES Turn the gas control to the off position and remove the burner assembly NO If
Component Tests 5 – 7 TEST 5 TEST 6 The gap between the pilot hood and Fit manometer to burner test point. The electrode tip should be between 4 and burner gas pressure reading should be as 5mm. Gently bend the pilot hood to adjust per the specifications table on page 6. the spark gap. TEST 7 Fit manometer to inlet pressure test point.
Fault Finding Chart 3 3 Is the water leak intermittent? Leak is probably condensate formed in the combustion chamber during the heating cycle. Large quantities of condensate can be produced during cold weather or after large draw offs. May also be evident on initial lighting. Normal operation YES NO Is the T&PR valve continuously discharging water? YES NO 3.
Fault Finding Chart 4 4 Is the water heater of sufficient size for the customers needs? Has the usage pattern changed recently? i.e. additional appliances or people using hot water NO Recommend a water heater of sufficient capacity to meet customers needs NO YES 3.
Fault Finding Charts 4.1 & 4.2 4.1 Does the water temperature at the T&PR correspond with the thermostat setting? YES 4.2 Has there been a recent large draw off of hot water? NO YES Tempering Valve Refer to manufacturers instructions Rheem Plus Refer to the ‘Annual Servicing Procedure’ Are the filters blocked? NO NO Typically the hot inlet temperature to the tempering valve must be 10 degrees higher than the required outlet temperature.
Fault Finding Chart 5 5 Is the T&PR valve continuously discharging water? Is the water supply pressure above 1120kPa? YES YES Existing pressure limiting valve faulty - Replace. Fit a pressure limiting valve if not already installed NO Refer to NO specifications table Is the correct NO T&PR valve fitted? Is the customer drawing small but frequent amounts of hot water? NO YES YES 5.3 Replace the T&PR valve with one of the correct pressure rating. Do not use reconditioned T&PR valves 5.
Fault Finding Charts 5.1 & 5.2 5.2 5.1 Is the flue baffle missing? YES Replace the flue baffle NO Fit the correct size flue baffle NO Is the flue baffle the correct length? YES The continuous addition of cold water will cause the burner to operate more frequently and can result in excessive water temperature at the top of the cylinder while reducing the temperature in the mid and lower sections of the cylinder. This condition is known as stacking. 5.1 5.
Fault Finding Chart 6 6 Is the noise only evident when the pilot is burning? Is the inlet gas pressure exceeding the specified limit? YES NO NO YES Is the noise only evident when the main burner is on? Incorrect pilot injector fitted: Replace with correct injector Pilot injector dirty: Remove and clean pilot injector Refer to gas installer or gas utility Check for: Noisy burner operation due to incorrect gas pressure or aeration. Poor quality water supply i.
Fault Finding Chart 7 7 Outdoor Models Only Is the water heater installed against an external wall? The balanced flue terminal will not operate correctly unless the water NO heater is installed against an external wall. See section on “Fluing Principals” Reposition the water heater against an external wall or install a blade behind the water heater extending 500mm either side and to the height of the water heater.
Component Replacement Draining the Water Heater – 90L to 170L models (Procedure 1) Elevated temperatures may be present during the draining process. Personal Protective Equipment should be worn to prevent the risk of scalding. 1. 2. 3. 4. Isolate the gas and water supplies to the water heater. Relieve pressure from the water heater through T&PR valve or a hot tap. Disconnect the cold water supply pipe. Fit a drain hose to the cold water connection and run the other end to a drain or safe location. 5.
Gas Control and Burner Assembly Removal (Procedure 4) 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove the access door (outdoor models) or the pipe cover (indoor models). Note the current setting on the gas control. Turn the gas control to the off position. Isolate the gas supply. Disconnect the gas line at the gas control. Indoor Models Only: Remove the plastic trim from the front of the gas control. Remove holding screw from the burner-mounting bracket. Disconnect the igniter lead from the piezo igniter.
T&PR Valve Replacement (Procedure 7) Never fit a T&PR valve with a rating higher than that indicated on the water heater rating label. Do not use reconditioned T&PR valves. 1. 2. 3. 4. Isolate the gas and water supplies to the water heater. Relieve pressure from the water heater through the T&PR valve or a hot tap. Remove the drain line from the T&PR valve. Unscrew the T&PR valve and remove. A quantity of hot water will discharge from the tank during this process.
Pilot Injector Replacement (Procedure 10) 1. Remove the gas control and burner assembly (Refer to procedure 4). 2. Disconnect the pilot pipe at the pilot assembly and draw the pilot feed pipe from the pilot assembly. Note: The injector is clipped to the end of the pilot feed pipe and will be removed as the pipe is withdrawn from the pilot assembly. 3.
Burner Feed Pipe Replacement (Procedure 13) 1. 2. 3. 4. Remove the gas control and burner assembly (Refer to procedure 4). Disconnect the burner feed pipe from the gas control. Remove the retaining clip holding the burner feed pipe to the burner air duct. Hinge the burner feed pipe down to disengage the tongue from the end of the burner air duct. 5. Remove the injector. 6. Fit the injector to the replacement burner feed pipe using gas paste or similar to ensure a gas tight seal.
Cold Water Connector – Rheem Plus Models (Procedure 16) Elevated temperatures may be present during the draining process. Personal Protective Equipment should be worn to prevent the risk of scalding. 1. 2. 3. 4. 5. Isolate gas and water supplies. Relieve pressure from water heater through the T & PR valve or a hot tap. Drain the water heater. Refer to procedure 1 on page 31. Remove cold water and cold pipe access covers.
Rheem Plus Tempering Valve Annual Service Procedure A quantity of hot water will discharge from the tank during this process. Personal Protective Equipment should be worn to prevent scalds or burns. 1. Remove the tempering valve. Follow steps 1 to 5 in Procedure 17 on page 36. 2. Dismantle and clean or replace hot water inlet filter. The “C” clip and filter can be removed by gently prising out with a small flat bladed screwdriver. When clean reassemble by inserting filter then the “C” clip. 3.
Exploded View – 90L to 170L Indoor Heater TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by 38 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Replacement Parts List (Indoor Models) 90L - 170L Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Pilot viewing mirror Front cover – Metal Front cover – Plastic Burner assembly Adapter Pipe seal - Inlet / Outlet Pipe seal - T & PR T & PR valve Dip Tube Draught diverter Baffle (90L) Baffle (130 & 135L) Baffle (170L) Anode – Black (300090) Anode – Black (300135) Anode – Black (300170) Anode – Black (620130) Anode – Blue (300090) Anode – Blue (300135 & 620130) Anode – Blue (300170) Anode – Green
Exploded View – 90L to 170L Outdoor Heater TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by 40 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Replacement Parts List – Outdoor Models 90L - 170L Item 1 2 3 4 5 6 7 8 Description Foot Burner assembly Access door Adapter Grommet Pipe seal – Inlet/Outlet Dip tube Wall bracket Name Band (311, 314 & 811 series) 9 Name Band (630 series) 10 Pipe seal - T & PR 11 T & PR valve Anode - Black (90L) Anode - Black (135L) Anode - Black (170L) Anode - Black (630130) Anode - Blue (90L) 12 Anode - Blue (90L) Anode - Blue (170L) Anode - Green (90L) Anode - Green (135L) Anode - Green (170L) Baffle (90L) 13 Baffle (1
Exploded View – Gas Control and Burner Assembly 90L - 170L TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by 42 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Replacement Parts List - Gas Control and Burner Assembly 90L - 170L Item Description 1 Gas Control Cover 2 Piezo Igniter Gas Control 60ºC - Natural (300/311/314/811 series) Gas Control 60ºC – LP/Butane (300/311/314/811 series) 3 Gas Control 60ºC - TLP (300/311/314/811 series) Gas Control 80ºC - Natural (620/630 series) Gas Control 80ºC - LP Gas (620/630 series) Burner Feed Pipe – Natural/TLP Gas 4 Burner Feed Pipe – LP/Butane Gas 5 Pilot Feed Pipe Burner Assy – Natural Gas (90L) Burner Assy – Natural Gas (1
Exploded View – 620260 Indoor Heater TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by 44 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Exploded View – 630260 Outdoor Heater TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by 45 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Replacement Parts List 620260 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Description Pilot viewing mirror Front cover - metal Front cover - plastic Burner Assembly Adapter Pipe Seal – Inlet/Outlet Pipe Seal – T & PR valve T & PR valve Dip Tube Draught Diverter Baffle Anode – Black Anode – Blue Anode – Green Anode Cover Name Band Drain Cock Foot Jacket Top 620260 103805 101312-1 226930 Refer to page 47 079411 221406-1 221398-1 220604 220511 102809-1 071835 221909 221924 222014 221391-1 120627 224813 10
Exploded View – 620/630260 Gas Control and Burner Assembly TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by 47 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Replacement Parts List - 620/630260 Gas Control and Burner Assembly Item Description 1 Gas Control Cover 2 Piezo Igniter Gas Control – Natural Gas 3 Gas Control – Propane & Butane Gas Gas Control – TLP Gas Burner Feed Pipe – Natural & TLP Gas 4 Burner Feed Pipe – Propane & Butane Gas 5 Pilot Feed Pipe Burner Assy – Natural Gas Burner Assy – Propane Gas 6 Burner Assy – Butane Gas Burner Assy – TLP Gas Main Burner Injector – Natural Gas Main Burner Injector – Propane Gas 7 Main Burner Injector – Butane Gas M
Exploded View & Parts List – Rheem Plus Components Replacement Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Cold Connector Tempering Valve 50ºC Plastic Cold Pipe (135 litre) Plastic Cold Pipe (170 litre) Duct Lower Cover & Insulation Duct & Insulation (135 litre) Duct & Insulation (170 litre) Duct Top Cover & Insulation Quick Connect Fitting. Comes with item 2.
Gas Type Conversion Procedure The 620130 & 630130 are approved for Natural and LP gas types only. Conversions to Butane or TLP gas are illegal. For warehouse gas type conversions the burner operation and gas tightness testing must be completed by dry firing the water heater or fully assembled burner/gas control assembly. Do NOT leave the main burner on for more than 30 seconds if dry firing. Where gas is unavailable for testing gas type conversions must NOT be conducted. 1.
Conversion Tables 300, 311, 314 & 811 Series – Components Required 90L - Natural to LP Component Part Number Gas Control LP Red (60°) 079424 Indoor 070800 Burner Feed Pipe Outdoor 070858 Pilot Injector 890197 Indoor 073355 Burner Injector Outdoor 073352 Aeration Shutter 071201 Gas Type Label - Propane 121805 90L - Natural to TLP Component Part Number Gas Control TWN Blue (60°) 079422 Indoor 073342 Burner Injector Outdoor 073347 Aeration Shutter 071201 Pilot Injector 890198 Gas Type Label - Towns 121801 135L
Conversion Tables 620 & 630 Series – Components Required 620130 & 630130 - Natural to LP Component Part Number Gas Control LP Red (80°) 079429 620130 070800 Burner Feed Pipe 630130 070858 Pilot Injector 890197 620130 073352 Burner Injector 630130 073370 Aeration Shutter 071201 Gas Type Label - Propane 121805 620130 & 630130 - LP to Natural Component Part Number Gas Control NAT Blk (80°) 079428 620130 070801 Burner Feed Pipe 630130 070859 Pilot Injector 890181 620130 073327 Burner Injector 630130 073328 Gas
Rheem Mains Pressure Water Heater Warranty – Australia Only WARRANTY CONDITIONS nearest Rheem Australia Accredited Service Agent’s st premises and the installed site shall be the owner’s heaters manufactured from 1 November 2004. responsibility. 2. The water heater must be installed in accordance with the Rheem water heater installation instructions, 5.
Document Revision History Title: Rheem Gas Permanent Pilot Water Heaters Revision A B C Document Number: Details of change Service Instructions issued for Permanent Pilot Gas Models Format update. Addition of Rheem Plus models. Gas conversion parts corrected for towns gas TM016 Rheem Gas Permanent Pilot Service Instructions D.O.I: 01/2006 This document is stored and maintained electronically by TM016 D.O.I. 05/02 11/05 01/06 54 Service.