Rheem 613050, 613315, 616315, 610340 Service Instructions Manual
Rheem Heavy Duty Electric Service Instructions REV: A
Date of Issue: 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.
A
Service Instructions issued for Rheem Heavy Duty Electric
Models
07/02
TM014 Rheem Heavy Duty Electric Service Instructions REV: A
Date of Issue: 10/7/2002
1
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: July 2002
ELECTRIC
TM014 Rheem Heavy Duty Electric Service Instructions REV: A
Date of Issue: 10/7/2002
2
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
Date of Issue: 10/7/2002
3
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.
6 1 6 315 0 8
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
HEAVY DUTY
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
Date of Issue: 10/7/2002
4
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.
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 disc harge 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
Date of Issue: 10/7/2002
5
WIRING DIAGRAMS
THREE ELEMENT MODELS
TM014 Rheem Heavy Duty Electric Service Instructions REV: A
Date of Issue: 10/7/2002
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WIRING DIAGRAMS
SIX ELEMENT MODELS
TM014 Rheem Heavy Duty Electric Service Instructions REV: A
Date of Issue: 10/7/2002
7
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 discus s
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 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. Crossed connection
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
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.
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 releas e. If there is a pressure release there will be no
leaks in the plumbing system.
TM014 Rheem Heavy Duty Electric Service Instructions REV: A
Date of Issue: 10/7/2002
8
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.
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