Rheem Australia Pty Ltd ABN 21 098 823 511 SERVICE INSTRUCTIONS Vulcan Electric Water Heaters TM013 Revision: D Published: May 09 661 Series 671 Series 691 Series 662 Series This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”.
Contents Introduction .......................................................................................................................... 3 Safety Warning .................................................................................................................... 3 Heater Model Identification .................................................................................................. 4 Specifications........................................................................................
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 Vulcan Electric Water Heater, contact your nearest Rheem Service Department where all genuine replacement parts are also available.
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.
Specifications T&PR Valve Rating (kPa) With ECV Without ECV Bottom T/stat Setting (ºC) 1400 960 1120 65 RP¾/20 RP½/15 540 053 50 1400 960 1120 75 RP¾/20 RP½/15 490 / 540* 090 80 1400 960 1120 70 RP¾/20 RP½/15 1400 960 1120 70 RP¾/20 RP½/15 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 T&PR Tradesperson Adjustable Series 661 135 125 671 691 170 16
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 TM013 Vulcan Electric Service Instructions REV: D D.O.I.: 05/09 This document is stored and maintained electronically by 8 Service.
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 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.
The new design cylinder element barrels do not have an earthing tab and require the earth bond to be connected to the earthing tab on the thermostat clamp (refer to fig. 4). When installing an early or new type element on a cylinder barrel that has an earth tab, this earth tab must be used (refer to fig.3). When installing an early or new type element on a new type cylinder barrel that does not have an earth tab, the earth tab on the thermostat clamp must be used (refer to 4). Fig.3.
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 Preliminary fault diagnosis What is the complaint? No hot water No hot water diagnostic Insufficient hot water Insufficient hot water diagnostic Leaking water heater Leaking water heater diagnostic Water too hot Water too hot diagnostic Noisy water heater Noisy water heater diagnostic TM013 Vulcan Electric Service Instructions REV: D D.O.I.: 05/09 This document is stored and maintained electronically by 13 Service.
Power Supply No Hot Water Power Diagnostic Is 240 volts present at the terminal block? TERMINAL BLOCK TEST NO Is the water heater connected to an off peak tariff? YES TWIN ELEMENT MODELS Complaint may be due to the booster circuit also being controlled by the off peak relay. Connect to continuous tariff NO Is the isolating switch turned off? Possible failure of the off peak relay or missed signal from energy supplier.
Single Element Single Element Diagnostic Are the thermostat ECO contacts closed? ECO TEST 1 NO Is the element installed in the correct orientation? NO YES Install the element correctly and reset the ECO Replace thermostat YES Are the thermostat contacts closed? THERMOSTAT TEST 1 Is the tank water 8°C less than the thermostat temperature setting? NO YES Replace thermostat NO Slide out the thermostat and allow the contact base to cool.
Twin Element – Upper Element Twin Element Diagnostic Are the top thermostat ECO contacts closed? ECO TEST 2 NO Is the top element installed in the correct orientation? NO Install the top element correctly and reset the ECO YES Replace top thermostat YES Is the bottom element installed in the correct orientation? YES Install the bottom element correctly and reset the ECO NO Is the neutral contact to the upper element closes? THERMOSTAT TEST 2 NO Is the tank water 8°C less than the thermostat t
Twin Element – Lower Element Twin Element Lower Element Diagnostic Are the bottom thermostat ECO contacts closed? ECO TEST 1 Is the bottom element installed in the correct orientation? NO YES Replace bottom thermostat Install the bottom element correctly and reset the ECO NO YES Are the bottom thermostat contacts closed? THERMOSTAT TEST 1 Is the tank water 8°C less than the thermostat temperature setting? NO YES Replace bottom thermostat NO Replace bottom thermostat NO Slide out the thermos
Insufficient Hot Water Insufficient hot water diagnostic Has the usage pattern changed recently? i.e. additional appliances or people using hot water YES Is the heater of sufficient size for the customers ongoing needs? Refer to Vulcan sizing guide.
Tempering Valve Diagnostic Tempering value diagnostic Clean or replace: Are the filters blocked? YES Refer to manufacturers instructions for Tempering Valve NO Normal Operation Tempering valves are generally set to deliver water at 48 50 degrees Is the outlet water temp approx.
Leaking Water Heater Leaking water heater diagnostic NO Is the leak from the upper part of the tank? YES Remove anode cap Remove anode and reseal with thread tape YES Is the leak from the anode? NO Is the leak from the element barrel weld? YES Replace water heater YES Remove element and replace gasket YES Remove the extension fitting and reseal with thread tape YES Is the leak from the anode cylinder fitting? NO Is the leak from the element gasket? NO NO Is the leak from the inlet exte
Water Too Hot Water too hot diagnostic Does the temperature at the hot tap correspond with or near the thermostat setting? Is a tempering valve installed? YES NO 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. Tempering devices should be suggested as a solution. NO Tempering valve faulty. Clean filters or replace.
Noisy Water Heater Noisy water heater diagnostic Check for: Is the noise only evident during the heating cycle? (A) Mineral build up on the element YES (B) Mineral or sludge build up in the cylinder (C) Normal noises associated with heating water NO Is the noise water hammer? YES Consult water hammer in Chapter Common Faults NO Is the noise only evident when water is flowing through the water heater? Check all other appliances that can generate noise i.e.
Electrical Insulation Testing There are three basic test procedures that should be carried out when the operation and function of a water heater‟s electrical system is in doubt. Personal Protective Equipment should be worn when conducting step 1 of this procedure to reduce the risk of electric shock. Refer to Rheem safety procedure on electrical testing To check insulation resistance of the water heater Neutral Circuit (reading not to be below 1 mega-ohm). 1.
Component Tests Terminal Block Test Twin Element Single Element Using a multimeter on the AC voltage scale, measure between each active and neutral on the terminal block. Normal voltage is 240 volts ECO Test 1 ST12 Thermostat EWT1 Thermostat Using a multimeter on the x1 resistance scale, measure between terminals indicated above on the thermostat. The reading should be less than 1 ohm.
Thermostat Test 1 ST22 Thermostat EWT2 Thermostat Using a multimeter on the resistance scale, measure between the terminals indicated above on the thermostat. The reading should be less than 1 ohm. Thermostat Test 2 EWT2 Thermostat ST22 Thermostat Using a multimeter set on the resistance scale, measure between the terminals indicated above on the upper thermostat. If the reading is less than 1 ohm the neutral to the top element is closed.
Element Test ST Thermostat EWT Thermostat Using a multimeter set on the resistance scale, measure across the element wires. Normal resistance for the heating unit is: 1.2kW: 43-53Ω; 1.5kW: 35-42Ω; 1.8kW: 29-35Ω; 2.4kW: 22-26Ω; 3.0kW: 17-21Ω; 3.6kW: 15-17Ω; 4.8kW: 11-13Ω; 6.0kW: 9-11Ω. Resistance Test Using a multimeter set on the x1 resistance scale, measure between active and neutral on the terminal block. Normal resistance when the thermostat contacts are closed is: 1.2kW: 43-53Ω; 1.5kW: 35-42Ω; 1.
Component Replacement Draining the Water Heater 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 2 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 1. Partially drain the water heater. Refer to „Draining the Water Heater‟ procedure on page 27. 2. Disconnect the hot water line from the outlet of the water heater. 3. Remove the extension fitting. 4. Using a flat blade screwdriver gently split the outer rim at the top and bottom of the dip tube face and prise the dip tube out of the cylinder fitting. 5.
Top Thermostat - Non-Simultaneous 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.
Element – Top and Bottom Elevated temperatures may be present during element removal process. Personal Protective Equipment should be worn to prevent the risk of scalding. When replacing an element on a heater with a cylinder barrel that does not have an earth tab (refer to page 10) ensure that the metal surround of the element flange is in direct contact with the cylinder barrel flange thus ensuring a good Earthing contact and conduct an earth continuity test as required by AS/NZS 3000 6.3.3.2.
Exploded View - Single Element Models TM013 Vulcan Electric Service Instructions REV: D D.O.I.: 05/09 This document is stored and maintained electronically by 31 Service.
Exploded View - Twin Element Models TM013 Vulcan Electric Service Instructions REV: D D.O.I.: 05/09 This document is stored and maintained electronically by 32 Service.
Replacement Parts List – 45L & 50L Item Description 1 2 4 661045 Fitting Liner Inlet Diffuser Extension Fitting Pipe Seal (Pre April 03) 5 Pipe Seal (From April 03) 7 Access Cover 9 Thermostat Cover 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.
Replacement Parts List – 80L, 125L & 160L Item Description 1 Fitting Liner 4 Extension Fitting Pipe Seal – Inlet/Outlet (Pre April 03) 5 Pipe Seal – Inlet/Outlet (From April 03) 7 Access Cover 9 Thermostat Cover 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 & 400L Item 1 2 4 5 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Description Fitting Liner (Pre Jan 2004) Inlet Diffuser (From Jan 2004) Extension Fitting Pipe Seal – Inlet/Outlet Access Cover (Bottom – 661 Series) Access Cover (Bottom – 662 Series) Thermostat Cover – Bottom Element Screw Element (Copper) - 1.2kW Element (Copper) - 1.8kW Element (Copper) - 2.4kW Element (Copper) - 3.0kW Element (Copper) - 3.6kW Element (Copper) - 4.8kW Element (Copper) - 6.
Vulcan Water Heater Warranty Australia Only WARRANTY CONDITIONS 1. This warranty is applicable only to Vulcan water from a regional Rheem Australia branch office, st heaters manufactured from 1 January 2001. or an Accredited Service Agent, the cost of 2.
Document Revision History Document Number: Title: Vulcan Electric Service Instructions Revision A B C D Details of change Service Instructions issued for Vulcan Electric Models Format update & conversion from Southcorp to Rheem 50L F models added 45L model added TM013 Vulcan Electric Service Instructions REV: D D.O.I.: 05/09 This document is stored and maintained electronically by TM013 D.O.I. 14/11/01 21/2/05 3/3/06 25/5/09 37 Service.
