Rheem TM039 Operating instructions

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

SERVICE

INSTRUCTIONS

Rheem Water Star

TM039

Revision: A

Published: January 09

W8100401

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

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 Number ....................................................................................3

Specifications.......................................................................................................................4

Preventative Maintenance ...................................................................................................4

Operation.............................................................................................................................5

Components and their Function...........................................................................................6

Wiring Diagram....................................................................................................................6

Common Faults ...................................................................................................................7

Fault Finding Chart Index.....................................................................................................8

General Fault Finding Chart.................................................................................................9

Fault Finding Chart 1 .........................................................................................................10

Fault Finding Chart 1.1 ......................................................................................................11

Fault Finding Chart 2 .........................................................................................................14

Fault Finding Chart 3 .........................................................................................................15

Fault Finding Chart 4 .........................................................................................................16

Fault Finding Chart 5 .........................................................................................................17

Fault Finding Chart 6 .........................................................................................................18

Electrical Insulation Testing...............................................................................................18

Component Replacement Procedures...............................................................................19

Exploded View...................................................................................................................24

Replacement Parts List......................................................................................................24

Rheem Electric Water Heater Warranty - (Australia Only).................................................25

Document Revision History................................................................................................26

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

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 Water Star, contact your nearest

Rheem Australia Service Department where all genuine replacement parts are also

available.

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 Water Star 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.

“Live” testing to be conducted. Personal Protective Clothing (PPE) shall

be worn and an RCD shall be installed between the power point and 3-pin

cord of the water heater to reduce the risk of electric shock.

Isolate power before conducting the indicated test

Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to

reduce the risk of scalding.

General warning symbol. Observe the instructions accompanying the

symbol.

If the supply cord is damaged, it must be replaced by the manufacturer or

its service agent or a similarly qualified person in order to avoid a hazard.

When handling pipe work attached to the Rheem Water Star, assume that

all pipes are carrying hot water. Personal Protective Equipment should be

worn to prevent scalds or burns.

Heater Model Identification Number

The identification number is designed to convey detailed information about the water

heater to which it is attached. The model number consists of 8 digits.

004

W –Water Star

8 - 70°C temperature limited

1 –Single Heating Unit

Rated Capacity in Litres

0 –Not fitted

Top Element Rating

1 –800 Watts

Bottom Element Rating

Note: Model number, serial number and date of manufacture should be quoted in all correspondence.

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Specifications

Model

Rated Capacity

(Litres)

T & PR Valve

Rating (kPa)

Maximum Inlet

Pressure (kPa)

T/stat setting

(ºC)

Water Connections

T/stat Type

Element Rating

(w)

Series

Capacity

With ECV

Without

ECV

Inlet

Outlet

T&PR

W81

004

1000

680

800

RP¾/20

RP½/15

Fixed

800

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 element is operating a small

discharge of water may be evident. Direct access to the valve is via the circular plastic

cover at the top of the unit. 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 tank 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 insulation test on the water heater. (Refer to page 18)

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Operation

The Rheem Water Star is designed to work in conjunction (in series) with a continuous

flow gas water heater, e.g. Rheem Continuous Flow models. It works as a booster water

heater to ensure immediate availability of hot water. As such the inlet pipe to the Rheem

Water Star is referred to as an inlet pipe, NOT a cold water pipe, as water flowing through

this pipe could have a temperature as high as 60ºC.

The Rheem Water Star is designed for use with continuous flow water heaters that have

an outlet temperature of 60°C.

Continuous flow gas water heaters pass several litres of water before the temperature

reaches a useable temperature. The Rheem Water Star stores 4 litres of water at 70°C

which is delivered immediately to the household plumbing saving on water usage each

time a hot tap is opened.

The Rheem Water Star is available in a 70ºC model only. To meet the requirements of

AS/NZS 3500.4, this model may require an additional tempering valve set at a maximum

of 50°C (depending on the application), to be installed in pipe work to ablution areas.

When a hot tap is opened, water passes through the continuous

flow gas water heater, which commences operation, into the

Rheem Water Star via a transfer valve. The hot water stored in the

cylinder (4 litres @ 70ºC) is immediately supplied to the household

plumbing (refer to Figure 1).

When the outlet temperature of the continuous flow gas water

heater (inlet temperature to the Rheem Water Star) has risen to

between 52°C and 56°C the transfer valve shuts off the water flow

to the storage cylinder and transfers the flow of hot water to the

Rheem Water Star‟s outlet pipe, effectively bypassing the Rheem

Water Star (refer to figure 2).

The water temperature in the Rheem Water Star storage cylinder is

maintained via a thermostat switching the active conductor to an

electric immersion element.

When the water temperature within the cylinder falls sufficiently the

thermostat contacts close supplying power to the element. Once the

water temperature reaches the set point of the thermostat (70°C),

the contacts open cutting power to the element.

A double pole „manual reset‟over temperature cut out is

incorporated into the thermostat to provide additional protection in

the event the controlling thermostat contacts fail. The ECO contacts

open at a water temperature of between 80ºC and 88ºC

Figure 1

Figure 2

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Components and their Function

Temperature and Pressure Relief Valve: A T&PR valve is designed to provide automatic

relief to the water heater 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.

Over Temperature Energy Cut Out (E.C.O.): An ECO is 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.

Thermostat: A thermostat is a device, responsive to temperature, which controls the

supply of electrical energy to the element to maintain the stored water at the required

temperature.

Heating Unit (Element): An element is a tubular device containing an electric resistance

that converts electrical energy into heat. The maximum rating of the Rheem Water Star is

800 watts.

Transfer Valve: A 3 way valve, sensitive to temperature that simultaneously opens one

outlet and closes the other transferring the direction of water flow.

Wiring Diagram

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

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 capacity of 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 comparing 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. Shower output rate exceeding 12 litres/minute for mixed water and being 5 minutes or

more, 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. Crossed connection.

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.

Water hammer

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

heater may be the source of 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 neighbouring equipment.

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.

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

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 water heater, 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 any leaks, the sound of water flowing would be audible.

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.

Discoloured water

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

the cold water is also discoloured.

Fault Finding Chart Index

Fault

Chart number

Page

No hot water

1, 1.1

10, 11

High energy bill / Insufficient hot water

Leaking water heater

Water too hot

Noisy water heater

Electrical insulation test

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

General Fault Finding Chart

Fault Diagnosis

Is the complaint for

no hot water?

Is the complaint for a

high energy bill or

insufficient hot water?

Is the complaint for a

leaking water heater?

Is the complaint for

water too hot?

YES

Noisy Water Heater

TM039 Rheem Water Star Service Instructions REV: A

Date of Issue: 02/09

This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

Fault Finding Chart 1

Is 240 volts present at the

terminal block?

Is the isolating switch

turned off?

Is the fuse blown at the

switchboard?

Is the reading below 1

Megaohm?

Restore power and advise

customer

Possible fault in household

electrical wiring. Continue with

diagnosis to confirm water heater

is operational.

Isolate power and continue

with diagnosis procedure

Conduct an electrical

insulation test (refer to section

on insulation testing)

No hot water

Warning: Terminals may be live.

Personal Protective Equipment

must be worn.

YES

Test 1

Tests 2, 3 & 4

1.1 6

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