Rheem 613050 Operating instructions

Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue: 10/7/2002

Rheem Australia Pty Ltd Document control header

Title: -Service Instructions for Rheem Heavy Duty Electric Water Heaters Document Number: -TM014

Revision Details of change D.O.I.

AService Instructions issued for Rheem Heavy Duty Electric

Models 07/02

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

RHEEM AUSTRALIA PTY LTD

SERVICE INSTRUCTIONS

TM014

HEAVY DUTY

ELECTRIC WATER HEATERS

MODELS

613050

613315

616315

610340 –Storage Tank

Rheem Australia Pty Ltd ABN 21 098 823 511

Revision: A Published: July2002

ELECTRIC

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

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.

Certain diagnostic procedures outlined in these service instructions require “live” testing to

be conducted. Personal Protective Equipment (PPE) should be worn when conducting these

tests to prevent the risk of electric shock.

WARNING: Voltages up to 415 volts AC may be present (Refer to the Rheem Safety

Procedure on electrical testing)

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 Rheem Heavy Duty Electric Water Heater, contact your

nearest Rheem Service Department where all genuine replacement parts are also available.

CONTENTS

Page

Safety Warning 2

Model Identification 3

Specifications 3

Operation 3

Components And Their Function 4

Preventative Maintenance 4

Wiring Diagrams

5 -6

Common Faults 7 -8

Manifolding 8 -9

Fault Finding

10 -18

Component Tests 13 -14

Electrical Insulation Tests 18

Component Replacement Procedures

19 -21

Exploded View -Three Element 22

Exploded View -Six Element 23

Exploded View –Storage Tank 24

Replacement Parts List 25

Warranty Statement 26

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

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.

616315 08

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.

SPECIFICATIONS

Model Maximum Inlet

Pressure (kPa) Water Connections

Series Capacity

Rated

Capacity

(Litres)

T & PR

Valve

Rating

(kPa) With ECV Without

ECV

T/stat

Setting

(ºC) Inlet

Outlet T&PR

T/stat

Type

Anode

Length

(mm)

613 060 50 1000 680 800 75 RP1¼/32 RP¾/20 485

613

616 340 315 1000 680 800 75 RP1¼/32 RP¾/20

Tradesperson

Adjustable

1400

HEAVYDUTY

610 340 340 1000 680 800 N/A RP1¼/32 RP¾/20 N/A 1400

OPERATION

The 613 and 616 series heavy duty electric water heaters are designed for connection to a 3 phase AC supply

incorporating a neutral.

On 3 element models the wiring is configured for one element and thermostat combination to be supplied

between each active conductor (phase) and neutral. On six element models the wiring is configured for two

element and thermostat combinations to be supplied between each active conductor (phase) and neutral.

Water temperature is maintained via the thermostat switching the active conductor to an electric immersion

element. The thermostat and corresponding element are mounted at intervals up the side of the cylinder.

As the water temperature within the cylinder falls the thermostat contacts close suppling power to the element.

Each element is switched on sequentially from the bottom up, as cold water enters the cylinder.

Once the water temperature reaches the set point of the thermostat, the contacts open cutting power to the

corresponding element.

A double pole “manual reset” over temperature cut out is incorporated into each thermostat to provide

additional protection in the event the controlling thermostat contacts fail. The ECO contacts open between

87ºC and 93ºC.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

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 itsoutlet pressure to a predetermined limit.

Outlet Delivery Tube (Dip Tube)

A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water from the highest

point to the outlet connection. It also acts as a fitting liner.

Diffuser

A plastic device installed in the cold water inlet of the water heater cylinder to assist with stratification. It also

acts as a fitting liner.

Fitting Liner

A plastic tube installed in the cold-water inlet of the water heater to provide protection against corrosion

through the life of the water heater.

Anode (Sacrificial)

A metal alloy electrode installed in the water heater cylinder that by galvanic action protects the cylinder from

corrosion.

Thermostat

A device, responsive to temperature, which controls the supply of electrical energy to the element to maintain

the stored water at the required temperature.

Over Temperature Energy Cutout (E.C.O.)

A temperature-sensing device in combination with the thermostat that automatically cuts off the supply of

electrical energy to prevent excessive water temperature occurring. This device will not reset automatically

but may be manually reset once temperatures have fallen to a safe level. DETERMINE CAUSE OF

OPERATION.

Heating Unit (Element)

A tubular device containing an electric resistance element that converts electrical energy to heat. Standard

ratings are 3.6, 4.8 and 6.0kW

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 elements are 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. Check for leaks at all cylinder fittings.

3. Check for signs of excessive corrosion on the water heater jacket.

4. Isolate power to the water heater and check all electrical connections for signs of overheating due to poor

connection.

5. Conduct an electrical insulation test on the water heater. (Refer to page 18)

6. Check for sludge build up and if necessary drain and flush tank.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

WIRING DIAGRAMS

THREE ELEMENT MODELS

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

WIRING DIAGRAMS

SIX ELEMENT MODELS

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

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. All procedures assume there is water flowing

through the water heater.

Excessive hot water usage

The complaints of insufficient hot water and no hot water can on many occasions be attributed to hot water

usage exceeding the capacityof the water heater to provide hot water.

When first attending a call of this nature it is essential to establish the probable hot water usage by querying

the usage habits of the household and compare this with the potential delivery of the model water heater

installed. It can then be established if the usage is within or outside the capacity of the model. The areas to

look at for excessive usage are:

1. Automatic washing machines.

2. Showers exceeding 12 litres/minute for mixed water and 5 minutes in duration.

3. Two or more showers operating at the same time.

4. Change of occupancy or number of persons increased.

5. High water pressure area. (Excessive pressure relief valve discharge)

6. Plumbing leaks

7. Thermostat temperature setting

8. Crossedconnection

Discoloured water

This may be the result of discoloured water entering from the cold water mains. Check if the cold water is also

discoloured.

Water hammer

A water heater will not cause water hammer, however valves associated with the water heater may be the

sourceof the problem i.e. cold-water stopcock, non-return valve or relief valve.

Most water hammer problems are associated with plumbing, hot and cold or appliances i.e. solenoid valves,

ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve parts, loose tap washers or

neighbouringequipment.

High water pressure areas will have more complaints of this nature and the use of a pressure-limiting valve

(PLV) to reduce the household cold-water pressure will usually solve most problems.

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. Turn on the stopcock to make up the water pressure in the cylinder, and then turn the stopcock off again.

5. Wait approximately 5 minutes then do either of the following:

a. With your ear close to the stopcock turn it on slightly and listen for any water passing. If there are no

leaks, water should not pass.

b. Open a hot tap while listening for any pressure release. If there is a pressure release there will be no

leaks in the plumbing system.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

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.

The method of checking for a cross connection is:

1. Turn off the stopcock on the cold water supply to the water heater.

2. Open a hot tap. If water flow is persistent and cold a cross connection exists.

Manifolding

Very often complaints surrounding insufficient hot water in commercial installations can be attributed to poor

manifolding. In order for the water heaters to operate simultaneously the water flow through all the tanks must

be the same to ensure the temperature drop is equal across the tanks. In a worst-case scenario it is possible

for 2 or 3 of the water heaters in a bank to almost never operate. This results in an overall loss of heat input to

the water moving through the building and can be confused as the installation being undersized or a

malfunction of the water heaters. The principle of Equa-Flow is to ensure the demand on each water heater in

the bank is the same as any other. To achieve this, the following are necessary:

1. The cold water manifold must be designed to balance the flow to each unit i.e. each branch line must be

the same diameter and length and be fitted with identical ball or gate valves.

2. The hot water manifold must be designed to balance the flow from each unit i.e.

each branch line must

be the same diameter and length and be fitted with identical ball or gate valves.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A

DateofIssue:10/7/2002

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).

In Line Manifold

Back to Back Manifold Angle Manifold

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