Rheem Australia Pty Ltd Title: - Service Instructions for Rheem Heavy Duty Electric Water Heaters Document control header Document Number: - TM014 Revision Details of change D.O.I.
ELECTRIC RHEEM AUSTRALIA PTY LTD SERVICE INSTRUCTIONS TM014 HEAVY DUTY ELECTRIC WATER HEATERS MODELS 613050 613315 616315 610340 – Storage Tank Rheem Australia Pty Ltd Revision: A TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 ABN 21 098 823 511 Published: July 2002 1
SAFETY WARNING The purpose of this Service Manual 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 Heavy Duty Electric Water Heater in the minimum of time. Safety precautions or areas where extra care should be observed when conducting tests outlined in this manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended procedure.
HEATER MODEL IDENTIFICATION All identification numbers are designed to convey detailed information about the water heater to which it is attached. The model number consists of 8 digits. 6 1 6 315 0 8 6 – Heavy Duty 1 – MEPS Compliant 0 – No Heating Units 3 – Three Heating Units 6 – Six Heating Units Rated Capacity in Litres No Reference – System Requirement 0 – Element Not fitted 7 – 3600w 8 – 4800w 9 – 6000w Note: Model number, serial number and date of manufacture should be quoted in all correspondence.
COMPONENTS AND THEIR FUNCTION Temperature and Pressure Relief Valve A valve designed to provide automatic relief by discharging water in case of excessive temperature, pressure or both. Never fit a T&PR Valve with a pressure rating greater than that indicated on the product-rating label. Pressure Limiting Valve (P.L.V.) A valve that controls its outlet pressure to a predetermined limit.
WIRING DIAGRAMS THREE ELEMENT MODELS TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 5
WIRING DIAGRAMS SIX ELEMENT MODELS TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 6
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.
COMMON FAULTS Mixing or crossed 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 cross connection. The complaints of insufficient hot water, water too cold or excessive discharge from the pressure relief valve may be attributed to a cross connection.
COMMON FAULTS Manifolding 3. All the water heaters must be of the same size and capacity. 4. The first heater supplied from the cold (inlet) manifold must be the last heater supplying the hot (outlet) manifold (see examples below).
FAULT FINDING Fault Diagnosis Is the complaint for no hot water? YES 1 NO Is the complaint for insufficient hot water? YES 2 YES 3 YES 4 NO Is the complaint for leaking water heater? NO Is the complaint for water too hot ? NO Noisy water heater TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 10 5
FAULT FINDING No hot water 1 Warning: Terminals may be live, Personal Protective Equipment should be worn. Is 240/415 volts present at the terminal NO block? Test 1 & Test 2 Restore power and advise customer YES YES Is the isolating switch turned off? NO Possible fault in building electrical wiring, continue with diagnosis to confirm water heater is operational NO Is the fuse(s) blown at the switchboard? YES Isolate power and reconnect correctly.
FAULT FINDING With multi -element water heaters very often more than one fault may have occurred before the user feels the effect. When servicing a multi-element water heater each thermostat - element combination should be checked to ensure correct operation. In manifolded installations a complaint for insufficient hot water may be due to faults in more than 1 heater or may be a result of poor manifolding.
COMPONENT TESTING Warning – “Live” equipment Personal Protective Equipment should be worn when conducting these tests. TEST 1 – 3 Element Models TEST 1 – 6 Element Models Using a multimeter on the AC voltage scale, measure between each active and neutral on the terminal block. Normal voltage is 240 volts Warning – “Live” equipment Personal Protective Equipment should be worn when conducting these tests.
COMPONENT TESTING Warning: Ensure power is isolated before conducting these tests TEST 6 TEST 7 Using a multimeter on the x1 resistance scale, Using a multimeter on the x1 resistance scale, measure between terminals 3L and 4L on the measure between terminals 1L and 2T on the thermostat. The reading should be less than 1 ohm thermostat. The reading should be less than 1 ohm.
FAULT FINDING Leaking Water Heater 3 Is the leak from or near the top? NO Is the leak from the electrical access cover? Remove anode and reseal with thread tape YES YES YES NO Is the leak from the T & PR valve? YES Replace water heater NO Is the leak from the anode? Is the leak from the anode cylinder fitting? NO Is the leak from the element barrel fitting? Remove anode cap YES YES NO Remove element and replace gasket YES Is the leak from the T & PR cylinder fitting? NO NO YES YES Is th
FAULT FINDING Water too hot 4 Does the water temperature at the T&PR valve correspond with or near the thermostat setting? NO Is the thermostat in good contact with the cylinder? YES NO Remove the thermostat and clean any scale from the cylinder wall. Re-tension bracket and refit thermostat YES Explain to customer the reasons for storing water hotter than they may desire i.e. (A) When mixed with cold water more hot water delivery is possible.
FAULT FINDING Noisy Water Heater 5 NO Is the noise only evident during the heating cycle? Is the noise water hammer? NO Is the noise only evident when water is flowing through the water heater? YES Check for: (A) Mineral build up on the element (B) Mineral or sludge build up in the cylinder (C) Normal noises associated with heating water YES Refer to water hammer causes on page 7, common complaints NO Check all other appliances that can generate noise i.e.
FAULT FINDING Electrical Insulation Test 6 Test 9 Is the reading below 1 mega-ohm? Disconnect the leads to the element from the thermostat and megger between each element lead and earth YES Rewire fuse if necessary NO Disconnect remaining leads from the thermostat and megger between each terminal on the thermostat and earth Replace element Is the reading below 1 mega-ohm? YES Replace thermostat Rewire fuse if necessary NO Check for pinched or damaged wiring touching the water heater chassis ELE
COMPONENT REPLACEMENT DRAINING THE WATER HEATER (PROCEDURE 1) Elevated temperatures may be present during the draining process. Personal Protective Equipment should be worn to prevent the risk of scalding. Personal Protective Equipment should be worn when conducting step 3 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power and water supplies to the water heater. 2.
COMPONENT REPLACEMENT THERMOSTAT (PROCEDURE 3) Personal Protective Equipment should be worn when conducting step 2 of this procedure to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. 1. Isolate the power to the water heater and remove access cover. 2. Confirm with multi-meter between each Active and Neutral at the terminal block that voltage is not present. 3. Remove the thermostat protective cover and disconnect the wiring from the thermostat. 4.
COMPONENT REPLACEMENT ANODE (PROCEDURE 5) Elevated temperatures may be present during anode removal process. Personal Protective Equipment should be worn to prevent the risk of scalding. 1. Isolate the power and water supplies to the water heater. 2. Relieve pressure from the water heater through the T & PR valve or a hot tap. 3. Remove the anode cap. 4. Using a 27mm tube or socket spanner remove the anode. 5. Apply thread seal tape to replacement anode, refit and tighten.
EXPLODED VIEW – THREE ELEMENT MODELS TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 22
EXPLODED VIEW – SIX ELEMENT MODELS TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 23
EXPLODED VIEW – STORAGE CYLINDER TM014 Rheem Heavy Duty Electric Service Instructions REV: A Date of Issue: 10/7/2002 24
REPLACEMENT PARTS LIST Item 1 2 3 4 5 6 Description Fitting Liner – Inlet Pipe Seal – Inlet/Outlet Access Cover Adaptor Flange and Pipe Element Screw Element Blanking Plate Element (Incoloy)* - 3.6kW 7 Element (Incoloy)* - 4.8kW Element (Incoloy)* - 6.0kW 8 Thermostat Clamp 9 Element Gasket 10 Thermostat 11 Terminal Block 12 Jacket Bottom 13 T & PR Valve (H.T.
RHEEM ELECTRIC WATER HEATER WARRANTY - (AUSTRALIA ONLY) Rheem Australia will: a) Repair or, if necessary replace any Rheem water heater; or b) Replace any component (or, if necessary, arrange the installation of a new water heater), which falls within the Warranty Periods specified below, in accordance with and subject to the following table, conditions and exclusions.
