Rheem Australia Pty Ltd ABN 21 098 823 511 SERVICE INSTRUCTIONS Rheem Electric Water Heaters TM012 R Reevviissiioonn:: B B PPuubblliisshheedd:: M Maarrcchh 0066 111 Series - Rheemglas 162 Series - Rheemglas 171 Series - Rheemglas 191 Series - Rheemglas 121 Series - Rheem Plus 411 Series - Optima 462 Series - Optima This document is stored and maintained electronically by Service.
Contents Safety Warning ....................................................................................................................3 Introduction ..........................................................................................................................3 Heater Model Identification ..................................................................................................3 Specifications...........................................................................................
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 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.
Specifications Without ECV Bottom T/stat setting (ºC) 960 1120 70 RP¾/20 RP½/15 053 50 1400 960 1120 75 RP¾/20 RP½/15 090 80 1400 960 1120 70 RP¾/20 RP½/15 135 125 1400 960 1120 70 RP¾/20 RP½/15 170 160 1400 960 1120 70 RP¾/20 RP½/15 270 250 1000 680 800 70 RP¾/20 RP½/15 340 315 1000 680 800 70 RP¾/20 RP½/15 425 400 1000 680 800 70 RP¾/20 RP½/15 270 250 1000 680 800 60 RP¾/20 RP½/15 411 340 462 315 1000 680 800 60 RP¾/20 RP½/15 425 400
Operation Single Element Models Water temperature is maintained via a thermostat switching the active conductor to an electric immersion element positioned towards the bottom of the cylinder. When the water temperature within the cylinder falls sufficiently the thermostat contacts close suppling power to the element. Once the water temperature reaches the set point of the thermostat, the contacts open cutting power to the element.
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 Single Element Models Twin Element Models Product Changes Diameter and Height Changes In April 2003 the jacket diameter on all 80 -160L models was reduced from 492mm to 478mm. In January 2004 the overall height of single and twin element 400L models (excluding solar) was reduced by 40mm. As part of this change the inlet fitting was raised 40mm to maximise delivery and the height of the booster element was dropped 40mm to retain the same boost volume.
In May 2004 the 111050 (LH connections) and 171050 (RH connections) models were replaced with the 191050 dual handed model. The dimensions remained unchanged. In October 2005 the 191050 was superseded by the 191G50 to meet new MEPS requirements. As part of this change the diameter increased from 393mm to 437mm and the height increased from 670mm to 673mm In March 2006 the 191G50 (dual handed) models were superseded by the 111050F (LH connections) and 171050F (RH connections).
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.
Hot water plumbing leaks If hot water has not been used for a period of time, feeling the temperature of the hot water line may give an indication of water flow if the pipe is warm. 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 is operating correctly. 3. Turn off the hot tap. 4.
General Fault Finding Chart Fault Diagnosis 1 Is the complaint for no hot water? Single element models YES Twin element models 2 NO Is the complaint for insufficient hot water? YES 3 YES 4 YES 5 NO Is the complaint for leaking water heater? NO Is the complaint for water too hot ? NO Noisy water heater TM012 Rheem Electric Water Heaters Service Instructions REV: B Date of Issue: 03/06 This document is stored and maintained electronically by 6 11 Service.
Fault Finding Chart 1 No hot water - single element models 1 Warning: Terminals may be live, Personal Protective Equipment should be worn. Is 240 volts present at the terminal block? Is the water heater connected to an off peak tariff? NO NO Test 1 YES YES Possible failure of the off peak relay or missed signal from energy supplier. Continue with diagnosis to confirm water heater is operational.
Fault Finding Chart 1.1 No hot water - Single element models 1.
Component Tests 1, 5, & 6 Test 1 Live equipment Personal Protective Equipment should be worn when conducting this test. Using a multimeter on the AC voltage scale, measure between active and neutral on the terminal block. Normal voltage is 240 volts Test 5 Ensure power is isolated before conducting test Using a multimeter on the x1 resistance scale, measure between terminals 3L and 4L on the thermostat. The reading should be less than 1 ohm.
Component Tests 7 - 9 Test 7 Ensure power is isolated before conducting test Using a multimeter on the x1 resistance scale, measure between terminals 2T and 4L of the thermostat. Normal resistance for the heating unit is: 1.2kW: 43-53 ohms 1.5kW: 35-42 ohms 1.8kW: 29-35 ohms 2.4kW: 22-26 ohms 3.0kW: 17-21 ohms 3.6kW: 15-17 ohms 4.8kW: 11-13 ohms 6.
Fault Finding Chart 2 No hot water - Twin element models 2 Warning: Terminals may be live, Personal Protective Equipment should be worn. Is 240 volts present at the terminal block supplying the upper and lower elements? Test 9 Is either element circuit connected to an off peak tariff? NO YES NO YES Possible failure of the off peak relay or missed signal from energy supplier. Continue with diagnosis to confirm water heater is operational.
Fault Finding Chart 2.1 No hot water - Twin element models 2.1 Test 10 Are the top thermostat ECO contacts closed ? NO Is the top element installed in the correct orientation? NO Install the element correctly and reset the ECO YES Replace upper thermostat NO Install the element correctly and reset the ECO YES Replace upper thermostat NO Replace upper thermostat YES 2.2 NO Replace the upper element YES Break in upper circuit wiring loom.
Component Tests 10 - 12 Test 10 Ensure power is isolated before conducting test Using a multimeter on the x1 resistance scale, measure between terminals 3L and 4L of the upper thermostat. The reading should be less than 1 ohm. Test 11 Ensure power is isolated before conducting test Using a multimeter on the x1 resistance scale, measure between terminals 1L and 2T of the upper thermostat. If the reading is less than 1 ohm the neutral to the top element is closed.
Fault Finding Chart 2.2 No hot water - Twin element models 2.
Fault Finding Chart 3 Insufficient Hot Water 3 Refer to Rheem sizing guide Has the usage pattern changed recently? i.e.
Fault Finding Chart 3.1 & 3.2 3.1 Does the water temperature at the T&PR correspond with the thermostat setting? YES 3.2 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 Single element models 2 Twin element models Typically the hot inlet temperature to the tempering valve must be 10 degrees higher than the required outlet temperature.
Fault Finding Chart 4 Leaking Water Heater 4 Is the leak from or near the top? YES Remove anode cap YES Remove anode and reseal with thread tape Is the leak from the element barrel weld? NO YES YES NO NO Replace water heater Is the leak from the element gasket? YES Remove element and replace gasket YES Is the leak from the inlet extension fitting? NO Remove the extension fitting and reseal with thread tape YES Is the leak from the anode cylinder fitting? NO YES Is the leak from the outle
Fault Finding Chart 5 Noisy Water Heater 2 NO Is the noise only evident during the heating cycle? 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 Is the noise water hammer? NO YES Refer to water hammer causes on page 9, common faults Is the noise only evident when water is flowing through the water heater NO Check all other appliances that can generate noise i.e.
Fault Finding Chart 6 Water too hot 6 Is the temperature at the hot tap similar to the thermostat setting? Explain to customer the reasons for storing water hotter than they may desire i.e. 1. When mixed with cold water more hot water delivery is possible 2. Prohibit bacteria growth YES Tempering devices should be suggested as a solution NO Is a tempering valve fitted? YES Is the model a Rheem Plus? YES 3.1 NO NO Is the thermostat in good contact with the cylinder? 3.
Fault Finding Chart 7 Electrical Insulation Test 7 Disconnect the wires to the element from the thermostat and megger between each element wire and earth Is the reading below 1 mega-ohm? YES Replace element Rewire fuse or reset circuit breaker if necessary NO Disconnect remaining wires from the thermostat and megger between each thermostat terminal and earth Is the reading below 1 mega-ohm? YES Replace thermostat Rewire fuse or reset circuit breaker if necessary NO Check for pinched or damaged wi
Component Replacement Procedures 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 and remove lower access cover. 2.
Dip Tube (Procedure 3) 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. Disconnect the hot water line from the outlet of the water heater. A quantity of hot water will discharge from the outlet during this process. Personal Protective Equipment should be worn to prevent scalds or burns. 4. Remove the extension fitting (80L– 400L models). 5.
Top Thermostat – Non-simultaneous (Procedure 5) 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 electrical supply and remove upper and lower front covers. 2. Confirm with multi-meter between each Active and Neutral at the terminal block that voltage is not present. 3. Remove the protective cover and disconnect wiring from the thermostat (Note wiring positions). 4.
Bottom Thermostat – Consumer Adjustable (Procedure 7) 1. Follow procedure 6 to step 5 2. Slide the replacement thermostat under the clamp. 3. Reconnect the wiring as per the circuit diagram on page 7 and refit the thermostat protective cover. 4. Conduct an electrical insulation test. (Refer to page 25) 5. Rotate the thermostat pointer to the middle position and fit the tee connector to the thermostat. 6. Gently disengage the knob from the access cover by compressing the 4 retaining fingers. 11.
Tempering Valve – Rheem Plus Models (Procedure 9) 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. Isolate the electricity and water supplies to the water heater. 2. Relieve pressure from the water heater through the T&PR valve or a hot tap. 3. Drain the water heater. Refer to procedure 1 on page 26. 4. Remove the tempering valve and cold pipe access covers. 5.
Element – Top and Bottom (Procedure 10) Elevated temperatures may be present during element removal process. Personal Protective Equipment should be worn to prevent the risk of scalding. 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.
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 9 on page 30. 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 – Single Element Models TM012 Rheem Electric Water Heaters Service Instructions REV: B Date of Issue: 03/06 This document is stored and maintained electronically by 33 Service.
Exploded View – Twin Element Models TM012 Rheem Electric Water Heaters Service Instructions REV: B Date of Issue: 03/06 This document is stored and maintained electronically by 34 Service.
Replacement Parts List - 25L and 50L Item Description 111025 2 3 4 5 7 9 10 Inlet Diffuser Dip Tube (Inlet) Extension Fitting Pipe Seal – Inlet/Outlet Access Cover Thermostat Cover Element Screw Element (Copper) - 1.2kW Element (Incoloy)* - 1.2kW Element (Copper) - 1.8kW Element (Incoloy)* - 1.8kW Element (Copper) - 2.4kW Element (Incoloy)* - 2.4kW 11 Element (Copper) - 3.0kW Element (Incoloy) - 3.0kW Element (Copper) - 3.6kW Element (Incoloy)* - 3.6kW Element (Copper) - 4.8kW Element (Incoloy)* - 4.
Replacement Parts List - 80L, 125L and 160L Item Description 1 Fitting Liner 4 Extension Fitting Pipe Seal – Inlet/Outlet (Pre April 03) 5 Pipe Seal – Inlet/Outlet (After April 03) Access Cover (Bottom – 111 series) 7 Access Cover (Bottom – Rheem Plus) Access Cover (Bottom – 162 series) 9 Thermostat Cover – Bottom 10 Element Screw Element (Copper) - 1.2kW Element (Copper) - 1.8kW Element (Copper) - 2.4kW 11 Element (Copper -3.0kW Element (Copper) - 3.6kW Element (Copper) - 4.8kW Element (Copper) - 6.
Replacement Parts List - 250L, 315L and 400L Item 1 2 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Description Fitting Liner Inlet Diffuser (After January 2004) Extension Fitting Pipe Seal – Inlet/Outlet Temp Adjustment Knob (411 & 462 series) Access Cover (Bottom – 111 series) Access Cover (Bottom – 162 series) Access Cover (Bottom – Rheem Plus) Access Cover (Bottom – 411 series) Access Cover (Bottom – 462 series) Tee Connector (411 and 462 series) Thermostat Cover – Bottom (Trade
Exploded View – Rheem Plus Components 11 12 2 2 13 6 10 9 8 { 14 5 7 4 15 1 3 16 Replacement Parts List Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Description Cold Connector Tempering Valve 50ºC Plastic Cold Pipe Duct Lower Cover & Insulation Duct & Insulation Duct Top Cover & Insulation Quick Connect Fitting.
Rheem Electric Water Heater Warranty - (Australia Only) WARRANTY CONDITIONS 1. 2. 3. 4. This warranty is applicable only to Rheem water heaters manufactured from 1st January 2001. The water heater must be installed in accordance with the Rheem water heater installation instructions, supplied with the water heater, and in accordance with all relevant statutory and local requirements of the 5. State in which the water heater is to be installed.
Document Revision History Title: Service Instructions - Rheem Electric Water Heaters Document Number: Revision Details of change A Service Instructions issued for Rheem Electric Models B Format revised, Dual handed and Rheem Plus models added TM012 Rheem Electric Water Heaters Service Instructions REV: B Date of Issue: 03/06 This document is stored and maintained electronically by TM012 D.O.I. 11/02 03/06 40 Service.