Rheem Australia Pty Ltd ABN 21 098 823 511 SERVICE INSTRUCTIONS Rheem Stellar TM009 R Reevviissiioonn:: D D PPuubblliisshheedd:: SSeepptteem mbbeerr 0077 850330 850360 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 WATER HEATER MODEL IDENTIFICATION...............................................................................................................3 OPERATION ...........
SAFETY WARNING The purpose of these instructions is to provide sufficient information to allow a person with the skills required by the 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.
SPECIFICATIONS Model 850330 960 1120 1.13 2.75 3.5 66 82+/-3 130 200 2 1153 20 1214 RP¾/20 RP½/15 1400 RP½/15 0.18 0.27 LP gas only Natural gas 1.60 2.
PREVENTATIVE MAINTENANCE TO BE DONE BY QUALIFIED PERSONS It is suggested for peak performance that the water heater be serviced annually. 1. Check for discharge from the T&PR valve. Whilst 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.
Gas Control In January 2001 a new generation Eurosit gas control was introduced to Stellar 850330 and 850360. The replacement gas control features a more positive interlock between the pilot and main burner position and, on Natural Gas types, an internal regulated pilot gas supply. The new gas control can be easily identified by the larger control knob (see diagram below).
LIGHTING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE LIGHTING WARNING Gas water heaters are designed to operate reliably and safely as long as the operating instructions are followed EXACTLY. You must comply with these lighting instructions at every stage A. This water heater is equipped with an igniter button that position and then turn off the isolation valve on the gas supply lights the pilot. When lighting the pilot follow these pipe to the water heater. instructions exactly.
COMPONENTS AND THEIR FUNCTION EUROSIT 630 GAS CONTROL The gas control is a multi functional single knob gas control. It is gas type specific and designed for either Natural Gas or LPG. The control is factory set and not field serviceable or gas type convertible. The gas control is manufactured without the temperature sensor and over temperature switch (ECO) enclosed in a sheath. The sheath is a separate item and is screwed into the cylinder during manufacture.
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 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.
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.
HIGH EFFICIENCY WATER HEATERS When the water heater is first lit, or after a large usage of hot water, condensation may form on the burner and flue terminal. This is quite normal, especially in winter months, and will dry off as the water is heated. NOTE: During heating cycles it is not unusual to see water vapour clouds streaming from the flue terminal. This is normal operation of the water heater.
FAULT FINDING Fault Diagnosis Sequence Attempt to light the pilot Refer to lighting instructions on access cover. Ensure the correct lighting procedure is followed. Did the pilot light and hold? NO Pilot Fault YES Is the water temperature above 60 degrees? Turn the gas control knob to main burner position number "6".
FAULT FINDING – CHART 1 Pilot Fault 1 Ensure the gas control is in the off position when conducting test Is a pilot flame established? NO Is a spark generated at the pilot head when the piezo is pressed? NO 1.1 YES 1.2 YES Check the gas supply pressure is between the minimum and maximum limit for the gas type Is the gas supply pressure ok? NO If possible adjust supply pressure or refer to installer or gas utility. Advise customer.
FAULT FINDING – CHART 1.1 Pilot Fault 1.1 Does the piezo make a loud click when pressed? NO Replace the piezo NO Replace the HT lead NO Replace the spark plug YES Replace the pilot assembly 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 1 Is the HT Lead ok? YES Check the spark plug ceramic is not damaged (cracked) or contaminated with soot.
FAULT FINDING – CHART 1.2 Pilot Fault 1.
FAULT FINDING – CHART 2 Main Burner Fault 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? Replace the gas control NO YES YES Refer to the specifications table Is Is the gas supply the burner pressure within the minimum NO pressure reading and maximum limit correct? for the gas TEST 6 TEST 7 type? YES NO If possible adjust the supply pressure or refer to in
FAULT FINDING – TESTS 1-4 TEST 1 TEST 2 Disconnect the thermocouple from the gas control and Using a multimeter set on the x1 resistance scale, using a multimeter set on the DC millivolt scale measure measure across the terminals of the interrupter block on the voltage being generated by the thermocouple. the gas control. The reading should be 0 ohms (dead Normal voltage should be approximately 20 millivolts. short).
FAULT FINDING – TESTS 5-7 TEST 5 TEST 6 The gap between the pilot hood and electrode tip should Burner gas pressure reading should be 1kPA for natural be between 4 and 5 mm. Gently bend the pilot hood to gas and2.75kPa for propane gas +/- 20% adjust the spark gap. TEST 7 Fit manometer to static pressure test point. With all gas burning appliances lit, including the water heater, the static test point pressure should be a minimum of 1.13kPa for natural gas and 2.75kPa for LP gas.
FAULT FINDING – CHART 3 Leaking Water Heater 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 drawoffs. May also be evident on initial lighting.
FAULT FINDING - CHART 4 Insufficient Hot Water 4 Is the water heater of sufficient size for the customers needs? Has the usage pattern changed recently? i.e.
FAULT FINDING – CHART 5 Water Too Hot 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 NO Refer to specifications table Is the correct NO T & PR valve fitted? Is the customer drawing small but frequent amounts of hot water? Replace the T & PR valve with one of the correct pressure rating.
FAULT FINDING – CHART 5.1 & 5.2 Stacking Water Heater 5.1 Replace the flue baffle 5.2 Is the flue baffle missing? YES NO Fit the correct size flue baffle Is the flue baffle the correct length? YES NO 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 Noisy Water Heater 6 Is the noise only evident when the pilot is burning? YES Is the inlet gas pressure exceeding the specified limit? NO Is the noise only evident when the main burner is on? NO Incorrect pilot injector fitted: Replace with correct injector Pilot injector dirty: Remove and clean pilot injector YES Refer to installer or gas utility YES Check for: Noisy burner operation due to incorrect gas pressure or aeration. Poor quality water supply i.
FAULT FINDING – CHART 7 Intermittent Operation 7 Is the water heater installed against an external wall? NO The balanced flue terminal will not operated correctly unless the water heater is installed against an external wall. Refer to page 5 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 Gas Control Only (Procedure 1) 1. Note the current setting on the gas control. 2. Isolate the gas supply. 3. Disconnect the gas line at the gas control. 4. Disconnect the pilot feed pipe, burner feed pipe, igniter lead and thermocouple. 5. Remove the screw retaining the plastic cover, remove the plastic cover, release the spring clip and withdraw the control from the sheath. 6. Reassemble in reverse order of above. 7. Restore gas supply. 8. Relight the pilot.
Pilot Assembly (Procedure 4) 1. Remove the gas control and burner assembly. (Refer to procedure 2) 2. Disconnect the pilot feed pipe and thermocouple from the gas control and disconnect the high-tension lead from the piezo igniter. 3. Remove the screw retaining the pilot assembly to the burner air channel. 4. Reassemble in the reverse order of above. 5. Restore gas supply. 6. Relight the pilot. Lighting instructions are provided on the access door, follow the instructions carefully.
Anodes (Procedure 7) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Remove the access cover and turn gas control knob to pilot position. Note number to which knob was set. Isolate water supply at the stopcock. Relieve pressure through a hot tap or the temperature and pressure relief valve. Remove holding screw from recess in rear of jacket top. Remove jacket top - gently lever top from jacket. Remove flue liner lid using handle provided.
EXPLODED VIEW (MODELS MANUFACTURED UP TO 30/08/02) Stellar Service Instructions REV: D Date of Issue: 14/09/2007 This document is stored and maintained electronically by 28 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
REPLACEMENT PARTS LIST (MODELS MANUFACTURED UP TO 30/08/02) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 NI Description Access Cover Flue Terminal Burner Assembly Adapter (Sheath) Flue Liner Seal Flue Liner Flange Jacket - 850330 Jacket - 850360 Spacer 26.
EXPLODED VIEW (MODELS MANUFACTURED AFTER 30/08/02) Stellar Service Instructions REV: D Date of Issue: 14/09/2007 This document is stored and maintained electronically by 30 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
REPLACEMENT PARTS LIST (MODELS MANUFACTURED AFTER 30/08/02) Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 NI Description Access Cover Flue Terminal Burner Assembly Adapter (Sheath) Flue Liner Seal Flue Liner Flange Jacket - 850330 Jacket - 850360 Spacer 26.
BURNER ASSEMBLY EXPODED VIEW REPLACEMENT PARTS LIST ITEM 1 2 3 4 COMPONENT Top Cover – Old Style Top Cover – New Style Piezo Igniter Gas Control Eurosit NG Gas Control Eurosit LPG Burner Feed Pipe – See next page Stellar Service Instructions REV: D Date of Issue: 14/09/2007 This document is stored and maintained electronically by PART No 890176 890263 890202 079421 079424 ITEM 5 6 7/9 8 NI COMPONENT Pilot Feed Pipe S.I.T. Thermocouple TS S.I.T.
BURNER EXPLODED VIEW Natural Gas LP Gas REPLACEMENT PARTS LIST ITEM 1 2 3 4/9 5 COMPONENT Thermocouple TS S.I.T. Burner Feed Pipe NG Burner Feed Pipe LPG Pilot Feed Pipe S.I.T.
GAS TYPE CONVERSION PROCEDURE NOTE: Stellar is approved for Natural and LP gas types only. Conversions to butane or towns 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.
RHEEM WATER HEATER WARRANTY (EXCLUDING SOLAR) - (AUSTRALIA AND NEW ZEALAND ONLY) Rheem Australia will: a) Repair, or if necessary replace any Rheem water heater or; b) Replace any failed component or, if necessary, arrange the installation of a new water heater for the period shown in the following table and terms and conditions.
DOCUMENT REVISION HISTORY Title: Rheem Stellar Revision A B C D Document Number: Details of change Service Instructions issued for 850 series Rheem Stellar All references to Southcorp replaced with Rheem Manual updated to include changes to jacket and injector sizes Gas Conversion Procedure Updated Stellar Service Instructions REV: D Date of Issue: 14/09/2007 This document is stored and maintained electronically by TM009 D.O.I. 14/08/2001 30/07/2002 9/05/2003 14/09/2007 36 Service.