Rheem Crossflow RD200, Crossflow Series, Crossflow RD400, Crossflow RD600, Crossflow RD800 Owner's Manual And Installation Instructions
Owner’s Guide
and
Installation Instructions
Rheem Crossflow ™
Instantaneous Heat Exchange
Delivery System
This water heater must be installed and serviced by a qualified person.
Please leave this guide with a responsible officer.
CONTENTS
CONTENTS ....................................................................................................................................................... 2
DESCRIPTION .................................................................................................................................................. 4
SYSTEM INSTALLATION ................................................................................................................................. 9
CROSSFLOW PRIMARY CONNECTIONS ...................................................................................................... 9
POTABLE WATER CONNECTIONS TO CROSSFLOW SYSTEM ................................................................ 11
COLD WATER SUPPLY.................................................................................................................................. 11
HOT WATER SUPPLY .................................................................................................................................... 11
MULTIPLE INSTALLATIONS .......................................................................................................................... 11
ELECTRICAL CONNECTIONS ....................................................................................................................... 12
WATER SUPPLIES ......................................................................................................................................... 13
COMMISSIONING OF THE CROSSFLOW SYSTEM .................................................................................... 15
SETTING THE DELIVERY TEMPERATURE .................................................................................................. 15
SETTING THE GLOBE VALVE ....................................................................................................................... 16
CLEANING THE HEAT EXCHANGER ............................................................................................................ 17
TROUBLE SHOOTING .................................................................................................................................... 17
THE RHEEM WARRANTY - GENERAL ......................................................................................................... 19
Copyright Rheem Australia PTY LTD 2016 2 Dec 2016 AQ0901085 Rev C
Notice to Victorian Customers from the
Victorian Building Authority.
This heat exchange system must be installed by a licensed person as required by the Victorian
Building Act 1993.
Only a licensed person will give you a Compliance Certificate, showing that the work complies with all the
relevant standards. Only a licensed person will have insurance protecting their workmanship for 6 years.
Make sure you use a licensed person to install this water heater and ask for your Compliance Certificate.
PATENTS
This water heater may be protected by one or more patents or registered designs.
TRADEMARKS
®
Registered trademark of Rheem Australia Pty Ltd.
TM
Trademark of Rheem Australia Pty Ltd.
NOTE: Every care has been taken to ensure accuracy in preparation of this publication.
No liability can be accepted for any consequences, which may arise as a result of its application
Copyright Rheem Australia PTY LTD 2016 3 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
THIS HEAT EXCHANGE SYSTEM IS NOT SUITABLE FOR APPLICATIONS
WHERE REFRIGERANTS ARE USED AS THE HEATING SOURCE, OR
WHERE THE PRESSURE IN THE NON-POTABLE SIDE OF THE HEAT
EXCHANGER IS LIKELY TO EXCEED THE PRESSURE IN THE POTABLE SIDE.
DESCRIPTION
The Rheem CrossflowTM Delivery Skid is used to instantaneously
transfer heat from the primary circuit to the secondary or domestic hot
water circuit without the need for further storage. A temperature
controlled variable speed circulator for the primary fluid circuit is used to
regulate the rate of energy transfer to the potable water. The Rheem
Crossflow controls allow heat input up to 90°c to be supplied on the
primary side and accurate, reduced temperature to be delivered on the
potable side. The temperature setting is factory set but can be adjusted
on site as required. The system is factory assembled and furnished with
316L stainless steel manifolds and fittings, the steel frame is fully
welded and hot dip galvanised for superior corrosion resistance. The
Rheem Crossflow is available in four sizes and two of the same size
unit can be connected where further redundancy or greater capacity is
required.
PUMP
The Rheem Crossflow is fitted with a temperature controlled variable
speed pump. There are two options available, these being a single
head pump or a dual head pump to provide duty/standby redundancy.
HEAT EXCHANGE
Each system is supplied with two WaterMark certified, 316L stainless
steel single wall brazed plate-type heat exchangers. Each heat exchanger can be separately isolated and
removed for individual maintenance, thus providing redundancy capability. The heat exchangers exhibit
extremely low pressure loss and are insulated to maximise efficiency.
Copyright Rheem Australia PTY LTD 2016 4 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
Model
RD200
RD400
RD600
RD800
Nominal Capacity
kW
200
400
600
800
Parameters for
Nominal Capacity
Rating
Primary Side (non-potable)
Inlet Temp
o
C
80
80
80
80
Flow Rate
L/min
48
114
144
186
Pressure Drop
kPa
24
47
36
36
Secondary Side (potable)
Inlet/Outlet Temp
o
C
15/65
15/65
15/65
15/65
Flow Rate
L/min
57
115
172
223
Pressure Drop
kPa
37
47
51
48
Dimensions
H x W x D
mm
1364 x 761 x 700
Weight
kg
130
138
147
156
Pipe Connections Primary Circuit
BSPF
RP1¼
Pipe Connections Secondary Circuit
DN50 ISO EN 1092-1 11B PN40 Flange
Max Operating Pressure Primary Circuit
kPa
1400*
Max Operating Pressure Secondary
Circuit
kPa
1400*
Electrical Supply
230-240V 50/60Hz Hard Wired By Electrician
Min Recommended Circuit Size
Amps
10
Table 1 – Crossflow System Specifications
*The maximum working pressure of each side of the system will be governed by the lowest operating pressure appliance
connected to it. The potable water side (secondary side) must be higher than the non-potable side (primary side).
Copyright Rheem Australia PTY LTD 2016 5 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
Crossflow System Dimensions (Dual head pump model shown)
Copyright Rheem Australia PTY LTD 2016 6 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
0
10
20
30
40
50
60
0 0.5 1 1.5 2 2.5 3 3.5 4
Pressure Drop KPa
Flow Rate L/s
Secondary Side Pressure Drop
vs Flow Rate
200kW 400kW 600kW 800kW
200
400
600
800
200
400
600
800
Table 2 – Crossflow System Output
Table 3 – Crossflow System Pressure Drop (Secondary Side)
Copyright Rheem Australia PTY LTD 2016 7 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
200kW
400kW
Primary Temp
85
80
75
70
65 Primary Temp
85
80
75
70
65
Output (kW)
215
200
190
160
100 Output (kW)
450
400
365
300
200
Temp Rise
Secondary Side Flow Rate (L/min)
Temp Rise
Secondary Side Flow Rate (L/min)
65
47
44
42
35
22 65
99
88
80
66
44
60
51
48
45
38
24 60
108
96
87
72
48
55
56
52
50
42
26 55
117
104
95
78
52
50
62
57
54
46
29 50
129
115
105
86
57
45
68
64
61
51
32 45
143
127
116
96
64
40
77
72
68
57
36 40
161
143
131
108
72
35
88
82
78
66
41 35
184
164
149
123
82
600kW
800kW
Primary Temp
85
80
75
70
65 Primary Temp
85
80
75
70
65
Output (kW)
785
600
535
450
300 Output (kW)
870
800
695
580
400
Temp Rise
Secondary Side Flow Rate (L/min)
Temp Rise
Secondary Side Flow Rate (L/min)
65
173
132
118
99
66 65
192
176
153
128
88
60
188
143
128
108
72 60
208
191
166
139
96
55
205
156
139
117
78 55
227
208
181
151
104
50
225
172
153
129
86 50
249
229
199
166
115
45
250
191
170
143
96 45
277
255
221
185
127
40
281
215
192
161
108 40
312
287
249
208
143
35
321
246
219
184
123 35
356
328
285
238
164
2 x 600kW
2 x 800kW
Primary Temp
85
80
75
70
65 Primary Temp
85
80
75
70
65
Output (kW)
1570
1200
1070
900
600 Output (kW)
1740
1600
1390
1260
800
Temp Rise
Secondary Side Flow Rate (L/min)
Temp Rise
Secondary Side Flow Rate (L/min)
65
346
265
236
198
132 65
384
353
307
256
176
60
375
287
256
215
143 60
416
382
332
277
191
55
409
313
279
235
156 55
453
417
362
302
208
50
450
344
307
258
172 50
499
459
398
333
229
45
500
382
341
287
191 45
554
510
443
369
255
40
563
430
383
323
215 40
624
573
498
416
287
35
643
491
438
369
246 35
713
655
569
475
328
Delivery Skid Secondary Side Flow Rate
for Varying Primary Supply Temperatures and Secondary Side Temperature Rise
Copyright Rheem Australia PTY LTD 2016 8 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
IMPORTANT:
It is the responsibility of the plumber/installer that all installations are made in accordance with the
building, electrical, and plumbing codes applicable in the installation region.
SYSTEM INSTALLATION
GENERAL REQUIREMENTS
Codes and Regulations
Besides these instructions, all installations of the Rheem Crossflow system shall be carried out in accordance
with:
Local Regulations
Municipal Building Codes
Occupational Health, Safety & Welfare Regulations
All plumbing work must be carried out by a qualified person and in accordance with the National
Plumbing Standard AS/NZS 3500.4 and local authority requirements.
All electrical work must be carried out by a qualified person and in accordance with AS/NZS 3000, as
applicable under local regulations, and all local codes and regulatory authority requirements.
In New Zealand the installation must also conform to the New Zealand Building Code.
Permits
All correct permits shall be obtained from the appropriate regulatory authorities.
Safety
Safety is the first priority in all installations. Please observe the safety warnings in this manual and other safety
information provided on the HS Series system. Common safety precautions are:
System must only be installed, commissioned or serviced by a qualified person.
Depending on the model selected, the Crossflow system can be programmed by the installer to supply
hot water at a temperature in excess of 50°C. We recommend that a temperature limiting device be
fitted between the Crossflow system and the hot water outlets in any ablution and public areas such as
bathrooms, ensuites or public amenities, to reduce the risk of scalding. A tempering valve may be
required to comply with local requirements. Refer to the plumbing codes applicable in your area to
determine if a temperature limiting device is required to minimize the risk of scalding.
SYSTEM CONFIGURATION
Refer to the Application Guide for specific system layouts.
CROSSFLOW PRIMARY CONNECTIONS
Position the Crossflow in the required location, as close to the heat source as possible and secure to the
ground if required. Access to the Crossflow and removal of components is from the front, however sufficient
clearance should be left on either side to allow for wrench access.
The Crossflow system is suitable for indoor or outdoor installation. In extreme climatic regions where ambient
temperatures regularly exceed 40oC, it is recommended to install the Crossflow system out of direct sunlight.
Copyright Rheem Australia PTY LTD 2016 9 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
Cold Water
Supply
Ring Main
Return
Hot Water
Supply
Primary Flow
Primary Return
The Crossflow requires a minimum of 1m head in order for the pump to function to specification. This
requirement can be met in most situations. Minimum head may need to be considered when used with the
primary circuit located in open vented or drain back systems.
Install a line strainer on the primary flow to the Crossflow marked “Heating Source In”. Pipe work must be
cleared of foreign matter before connection and purged before attempting to operate the system. All olive
compression fittings must use brass or copper olives.
Refer to Delivery Skid Primary Side Pipe Sizing Chart on page 10 for pipe sizing between the heating source
and the Crossflow. If more than 2 Crossflows are to be manifolded, or the pipe run exceeds a total of 10m
flow and return between the Crossflow and the closest tank, or pipe material other than copper is being
used, consult Rheem for appropriate pipe sizing.
Connect hot supply from heating source to the fitting marked “Heating Source In” on the Crossflow.
Install the globe valve (not required with 800kW model) at the connection marked “Heating Source Out” on
the Crossflow.
Connect from the fitting marked “Heating Source Out” on the Crossflow to the heating source return. Refer to
the Application Guide for specific system layouts.
Provision for expansion of the primary side circuit must be included in the primary circuit. This may be in the
form of pressure relief in the storage tank or primary flow and return circuit or via an expansion tank or
vessel.
If multiple Delivery Skids are to be manifolded together to provide greater flow rate capability, follow the
diagram on page 10. Ensure equal-friction method is used when making the plumbing connections. If more
than 2 Delivery skids are to be manifolded, or the pipe run exceeds a total of 10m flow and return, consult
Rheem for appropriate pipe sizing.
Refer to Potable Water Connections to Crossflow System on page 10 for potable water connection details.
Multiple Crossflow System Manifolding
Copyright Rheem Australia PTY LTD 2016 10 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
Crossflow
system Model
Output
(kW)
Pipe Size
(copper)
DN
200
200
40
400
400
50
600
600
65
800
800
80
2 x 600
1200
100
2 x 800
1600
100
Table 4 - Crossflow System Primary Side Pipe Sizing
POTABLE WATER CONNECTIONS TO CROSSFLOW SYSTEM
Refer to the diagram on page 10 for potable water connections.
All pipe work must be cleared of foreign matter before connection and purged before attempting to operate
the system.
COLD WATER SUPPLY
Install an isolation valve, non-return valve, line strainer and expansion control valve (ECV) (not supplied) on
the cold water supply to the Crossflow.
The pressure relief setting of the ECV should be no greater than the maximum operating pressure of the
lowest pressure rated component of the plumbing system, eg, taps, valves, water heaters, other appliances,
but MUST NOT exceed 1400kPa. The cold water supply pressure should be 20% below the ECV setting.
An acceptable arrangement is shown in the diagram on page 10.
Connect the cold water supply at the flange marked “Potable In”. The Crossflow system is supplied such that
cold water enters on the right and leaves on the left. It is important that it remains this way to ensure
accurate temperature reading at the hot water outlet.
HOT WATER SUPPLY
Depending on the model selected, the Crossflow system can be programmed by the installer to supply hot
water at a temperature in excess of 50°C. We recommend that a temperature limiting device be fitted between
the Crossflow system and the hot water outlets in any ablution and public areas such as bathrooms, ensuites
or public amenities, to reduce the risk of scalding. A tempering valve may be required to comply with local
requirements. Refer to the plumbing codes applicable in your area to determine if a temperature limiting device
is required to minimize the risk of scalding.
Connect the hot water flow at the flange marked “Potable Out”.
MULTIPLE INSTALLATIONS
If multiple Crossflows are to be manifolded together to provide greater flow rate capability, follow the diagram
on page 10. Ensure equal-friction method is used when making the plumbing connections. The potable water
flanges may be joined together for up to two Crossflows. Systems greater than this require the potable water
to be connected via a common header.
Copyright Rheem Australia PTY LTD 2016 11 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
Warning! Do not connect the power supply cable to the mains voltage power
supply until all connections have been made and the system has been charged
with water. Failure to do so can lead to electric shock and/or failure of the pump.
Model
Power Supply
Max Current
(Amps)
Min Circuit
Size
(Amps)
RD200
220 -240V AC
/ 50-60Hz
5
10
RD400
RD600
RD800
PIPE INSULATION
All hot water pipework shall be insulated to minimise heat losses. Use a minimum of 13 mm thick closed-cell
polymer preformed pipe insulation or similar. Additionally, where temperatures reach -4ºC for periods of greater
than 8 hours, the potable cold water supply pipes shall be adequately insulated with at least 13 mm of closedcell polymer insulation or equivalent. All insulation used shall be weatherproof and UV resistant if exposed,
and protected from water ingress by tape, painting or sheathing.
ELECTRICAL CONNECTIONS
The Crossflow system is supplied pre-assembled and wired, however, requires connection of a correctly sized
single phase power supply (including neutral ‘N’ and protective earth ‘PE’). This power supply SHALL BE
supplied from a distribution board (not supplied) that contains a circuit breaker and a main isolation switch to
cut power to the control unit for servicing purposes. If the distribution board is not located close to the
Crossflow, then a separate isolation switch SHALL BE installed in the power supply directly before it.
All electrical work and permanent wiring must be carried out by a qualified person and in accordance with the
Wiring Rules AS/NZS 3000 and all local codes and regulatory authority requirements.
Table 5 - Crossflow system Electrical Requirements
Wire the power supply to terminals L, N, Earth within the Crossflow system pump controller housing.
Crossflow System Wiring
Copyright Rheem Australia PTY LTD 2016 12 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
CHLORIDE
CONTENT
MAXIMUM TEMPERATURE
60°C
80°C
120°C
130°C
= 10 ppm
SS 304
SS 304
SS 304
SS 316
= 25 ppm
SS 304
SS 304
SS 316
SS 316
= 50 ppm
SS 304
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
= 80 ppm
SS 316
SS 316
SS 316
= 150 ppm
SS 316
SS 316
Ti / 254 SMO
Ti / 254 SMO
= 300 ppm
SS 316
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
> 300 ppm
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
Ti / 254 SMO
WATER SUPPLIES
This Crossflow system must be installed in accordance with this advice to be covered by the Rheem
warranty.
The Crossflow system is manufactured to suit the water conditions of most public reticulated water supplies.
However, there are some known water chemistries which can have detrimental effects on the heat
exchanger system and its operation and / or life expectancy. If you are unsure of your water chemistry, you
may be able to obtain information from your local water supply authority. This heat exchanger system should
only be connected to a water supply which complies with these guidelines for the Rheem warranty to apply.
CHANGE OF WATER SUPPLY
The changing or alternating from one water supply to another can have a detrimental effect on the operation
and / or life expectation of a number of components in this heat exchanger system.
Where there is a changeover from one water supply to another, e.g. a rainwater tank supply, bore water
supply, desalinated water supply, public reticulated water supply or water brought in from another supply,
then water chemistry information should be sought from the supplier or it should be tested to ensure the
water supply meets the requirements given in these guidelines for the Rheem warranty to apply.
SATURATION INDEX
The saturation index (SI) is used as a measure of the water’s corrosive or scaling properties.
Where the saturation index is less than –1.0, the water is very corrosive and the Rheem warranty does not
apply to the heat exchanger system. In a corrosive water supply, the water can attack copper parts and
cause them to fail.
Where the saturation index exceeds +0.40, the water is very scaling and an expansion control valve* must
be fitted on the cold water line after the non-return valve for the Rheem warranty to apply to a Rheem
storage tank. The Rheem warranty does not apply to the heat exchanger.
Water which is scaling may be treated with a water softening device to reduce the saturation index.
CHLORIDE AND PH
In a high chloride water supply, the water can corrode stainless steel parts and cause them to fail. Where the
chloride level exceeds the limits shown in the table below the Rheem warranty does not apply to the
Crossflow system.
pH is a measure of whether the water is alkaline or acid. In an acidic water supply, the water can attack
stainless steel parts and cause them to fail. Where the pH is less than the recommended level shown in the
table of water content below, the Rheem warranty does not apply to the heat exchanger system.
Water with a low pH may be treated to raise the pH. The water supply from a rainwater tank in a metropolitan
area is likely to be corrosive due to the dissolution of atmospheric contaminants.
Copyright Rheem Australia PTY LTD 2016 13 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
WATER CONTENT
CONCENTRATION (mg/l
or ppm)
TIME LIMITS
Analyze before
AISI 316
COPPER
Alkalinity (HCO -)
< 70
Within 24 h
+
0
70-300 + +
> 300 +
0/+
Sulphate
[1]
(SO
4
2-
)
< 70
No limit
+
+
70-300 + 0/+
> 300 + -
HCO
3
-
/ SO
4
2-
> 1.0
No limit
+
+
< 1.0 +
0/-
Electrical conductivity
< 10 µS/cm
No limit
+
0
10-500 µS/cm
+
+
> 500 µS/cm
+
0
pH
[2]
< 6.0 Within 24 h
0
0
6.0-7.5 +
0
7.5-9.0 +
+
>9.0 +
0
Ammonium (NH
4
+
)
< 2 Within 24 h
+
+
2-20 +
0
>20 +
-
Chlorides (Cl-) Please also
see table above
<100 +
+
100 - 200
+
+
200 – 300
+
+
>300 -
0/+
Free chlorine (Cl2)
<1
Within 5 h
+
+
1 – 5 -
0
>5 -
0/-
Hydrogen sulphide (H2S)
<0.05 +
+
>0.05
No limit
+
0/-
Free (aggressive) carbon
dioxide (CO2)
<5
No limit
+
+
5 – 20 +
0
>20 +
-
Total hardness (°dH)
4.0 – 8.5
No limit
+
+
Nitrate
[1]
(NO
3
-
)
<100
No limit
+
+
>100 +
0
Iron
[3]
(Fe)
<0.2
No limit
+
+
>0.2 +
0
Aluminium (Al)
<0.2
No limit
+
+
>0.2 +
0
Manganese
[3]
(Mn)
<0.1
No limit
+
+
>0.1 +
0
SUMMARY OF WATER CHEMISTRY ADVICE AFFECTING THE RHEEM WARRANTY
The Crossflow system is not suitable for certain water chemistries. The following table is to be considered a
guide to the corrosion resistance of stainless steels and brazing materials in tap water at room temperature.
In the table a number of important chemical components are listed, however the actual corrosion is a very
complex process influenced by many different components in combination.
Rheem's warranty will not cover any resultant faults if the water heater is connected at any time to a water
supply that exceeds the limits listed in the table.
EXPLANATIONS:
+ Good resistance under normal conditions
0 Corrosion problems may occur especially when more factors are valued 0
- Use is not recommended
[1] Sulfate and nitrate work as inhibitors for pitting corrosion caused by chlorides in pH neutral environments
[2] Low pH (below 6) increases corrosion risk and high pH (above 7.5) decreases the corrosion risk
[3] Fe and Mn are strong oxidants and may increase the risk for localised corrosion on stainless steels.
SiO2 above 150ppm increases the risk of scaling
Copyright Rheem Australia PTY LTD 2016 14 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
Model
ECO Setting
Factory Setting
Max Recommended Temp Setting
70
70
65
65
COMMISSIONING OF THE CROSSFLOW SYSTEM
Potable and Non-Potable Water Circuit
All lines must be flushed of debris prior to filling the system. Failure to observe this requirement may lead to
system blockage and/or underperformance. Check and clean the line strainers after flushing.
Fill the potable water circuit by opening the isolation valve at the cold water inlet connection on the potable
water side of the Crossflow. Open a hot tap so air may be purged from within the system whilst filling. Close
hot tap when all air has been expelled.
Fill the non-potable water circuit by opening the isolation valve at the “Heating Source In” and “Heating
Source Out” connections on the non-potable water side of the Crossflow. Ensure air is purged from within
the system whilst filling.
When full operational pressure is reached, ensure that all connections on both circuits are free of leaks. The
non-potable water circuit MUST BE full and pressurised before any other tests are conducted to avoid
potentially damaging the Crossflow pump. Failure to observe this precaution will result in warranty being
void.
Switch on the electrical power to the Crossflow and follow the instructions below to set the temperature.
SETTING THE DELIVERY TEMPERATURE
The temperature entering the primary side of the Crossflow should
be at least 5oC higher than the set temperature of the Crossflow in
order for the Crossflow to perform to specification.
The Crossflow set point temperature should be at least 5oC below
the ECO setting for the given model. Refer to table below for ECO
temperature settings.
The Crossflow is supplied from the factory at the temperature
described in the table below. If adjustment is required:
Go to Home screen on the pump.
Press OK. The setpoint box will be highlighted.
Press OK. The temperature will be highlighted
Press OK. The first digit will be highlighted. Use the Up/Down
and Side keys to select the desired setpoint.
Press the Return key to go back through the pages or the
Home key to return to the home page.
Delivery Skid Temperature Settings
Refer to Grundfos Magna manual supplied with Crossflow for other system options.
Copyright Rheem Australia PTY LTD 2016 15 Dec 2016 AQ0901085 Rev C
Chapter 3 – Commissioning Procedures
SETTING THE GLOBE VALVE
Before testing the system, the water heating plant must be at the set temperature.
If installed, and connected to the inlet of the Crossflow (refer to Application Guide), turn on the building
recirculation pumps. If the Crossflow is connected on a dead leg circuit, open some taps to represent the
design minimum flow rate. The Crossflow will automatically activate to heat the water in the secondary circuit
to the set temperature.
If the pump does not activate, or shuts down soon afterwards, this is an indication the flow rate is at the
lower end of the Crossflow pump operating range. This will be the case typically with 200 to 600kW Delivery
Skids, with a high heating source temperature and a high return water temperature (ie small temperature
rise).
Adjusting the globe valve on the Crossflow primary side outlet towards the closed position will allow the
Crossflow pump to operate at a lower flow rate and maintain better temperature control (not supplied with
800kW Crossflow).
Adjust the globe valve so that the pump remains on for a longer period of time.
CROSSFLOW PARAMETER SETTINGS
The Dual Head Pump Crossflow system is factory set to automatically switch pump operation in duty/standby
mode and switch pumps in the event of pump failure. No further adjustments are required to the system.
The system is now completely commissioned. Explain operation and hand over to a responsible officer.
Copyright Rheem Australia PTY LTD 2016 16 Dec 2016 AQ0901085 Rev C
CLEANING THE HEAT EXCHANGER
Should the heat exchanger require cleaning, e.g. due to operation in hard water at high temperatures, it is possible
to clean the heat exchanger. Use a tank with weak acid, 5% phosphoric acid or, if the heat exchanger is frequently
cleaned, 5% oxalic acid. Remove from the system and circulate cleaning fluid through the heat exchanger, ideally at
1.5 times the normal flow rate and in reverse flow.
Flush the heat exchanger water ways with clean water and then before the final rinse with water, rinse with a
solution of 1-2% sodium hydroxide (NaOH) or sodium bicarbonate (NaHCO3) to neutralise all acid.
TROUBLE SHOOTING
Check the items below before making a service call. You will be charged for attending to any condition or fault that is
not related to manufacture or failure of a part.
“Insufficient Water Temperature”
Check for blown fuses or tripped circuit breakers.
Has over-temperature lock-out occurred on the operating thermostats of the heating source?
Temperature setting on the Crossflow incorrect.
“Insufficient Water Pressure”
Check line strainers for blockage (if fitted).
Check water pressure before and after pressure limiting valve (if fitted). If possible, adjust pressure setting if too
low. Replace valve if necessary.
Ensure pressure limiting valve is of sufficient capacity to meet the requirements of the application.
Is pipe sizing adequate to suit the application?
Check all valves, heat exchangers and pipework for fouling or blockage.
Copyright Rheem Australia PTY LTD 2016 17 Dec 2016 AQ0901085 Rev C
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Copyright Rheem Australia PTY LTD 2016 18 Dec 2016 AQ0901085 Rev C
RHEEM CROSSFLOW WARRANTY – AUSTRALIA ONLY
1. CROSSFLOW MODELS RD200, RD400, RD600 & RD800
THE RHEEM WARRANTY - GENERAL
1.1 This warranty is given by Rheem Australia Pty Limited ABN 21 098 823 511 of 1 Alan Street, Rydalmere New South
Wales.
1.2 Rheem offer a trained and qualified national service network who will repair or replace components at the address of the
water heater subject to the terms of the Rheem warranty. Rheem Service, in addition can provide preventative
maintenance and advice on the operation of your water heater. The Rheem Service contact number is available 7 days a
week on 131 031 with Service personnel available to take your call from 8am to 8pm daily (hours subject to change).
1.3 For details about this warranty, you can contact us on 131 031 or by email at warrantyenquiry@rheem.com.au (not for
service bookings).
1.4 The terms of this warranty and what is covered by it are set out in section 2 and 3 and apply to water heaters manufactured
after 1st March 2016.
1.5 If a subsequent version of this warranty is published, the terms of that warranty and what is covered by it will apply to
water heaters manufactured after the date specified in the subsequent version.
2. TERMS OF THE RHEEM WARRANTY AND EXCLUSIONS TO IT
2.1 The decision of whether to repair or replace a faulty component is at Rheem’s sole discretion.
2.2 Where a failed component or cylinder is replaced under this warranty, the balance of the original warranty period will
remain effective. The replacement does not carry a new Rheem warranty.
2.3 Where the water heater is installed outside the boundaries of a metropolitan area as defined by Rheem or further than
25 km from either a regional Rheem branch office or an Accredited Rheem Service Agent's office, the cost of transport,
insurance and travelling between the nearest branch office or Rheem Accredited Service Agent’s office and the installed
site shall be the owner’s responsibility.
2.4 Where the water heater is installed in a position that does not allow safe or ready access, the cost of that access, including
the cost of additional materials handling and/or safety equipment, shall be the owner’s responsibility. In other words, the
cost of dismantling or removing cupboards, doors or walls and the cost of any special equipment to bring the water heater
to floor or ground level or to a serviceable position is not covered by this warranty.
2.5 This warranty only applies to the original and genuine Rheem water heater in its original installed location and any genuine
Rheem replacement parts.
2.6 If the water heater is not sized to supply the hot water demand in accordance with the guidelines in Rheem’s water heater
literature, any resultant fault will not be covered by the Rheem warranty.
2.7 The Rheem warranty does not cover faults that are a result of:
a) Accidental damage to the water heater or any component (for example: (i) Acts of God such as floods, storms, fires,
lightning strikes and the like; and (ii) third party acts or omissions).
b) Misuse or abnormal use of the water heater.
c) Installation not in accordance with the Owner’s Guide and Installation Instructions or with relevant statutory and local
requirements in the State or Territory in which the water heater is installed.
d) Connection at any time to a water supply that does not comply with the water supply guidelines as outlined in the Owner’s
Guide and Installation Instructions.
e) Repairs, attempts to repair or modifications to the water heater by a person other than Rheem Service or a Rheem
Accredited Service Agent.
f) Faulty plumbing or faulty gas or power supply.
g) Failure to maintain the water heater in accordance with the Owner's Guide and Installation Instructions.
h) Transport damage.
i) Fair wear and tear from adverse conditions (for example, corrosion).
j) Cosmetic defects.
k) Ice formation in the waterways of a water heater: where the electricity supply has been switched off or has failed and the
water heater has not been drained in accordance with the instructions; or due to an ambient temperature below -20°C
(including wind chill factor).
2.8 If you require a call out and we find that the fault is not covered by the Rheem warranty, you are responsible for our
standard call out charge. If you wish to have the relevant component repaired or replaced by Rheem, that service will be
at your cost.
2.9 Subject to any statutory provisions to the contrary, this warranty excludes any and all claims for damage to furniture,
carpet, walls, foundations or any other consequential loss either directly or indirectly due to leakage from the water heater,
or due to leakage from fittings and/ or pipe work of metal, plastic or other materials caused by water temperature,
workmanship or other modes of failure.
Copyright Rheem Australia PTY LTD 2016 19 Dec 2016 AQ0901085 Rev C
What components
are covered
The period in which the fault must
appear in order to be covered
What coverage you receive
All components
Year 1
Repair and/or replacement of the faulty
component, free of charge, including
labour.
Heat exchanger
Years 2 to 5
New parts, free of charge, with installation
and labour costs being the responsibility of
the owner.
RHEEM AUSTRALIA PTY LTD
A.B.N. 21 098 823 511
www.rheem.com.au
FOR SERVICE TELEPHONE
131 031 AUSTRALIA
0800 657 335 NEW ZEALAND
3. WHAT IS COVERED BY THE RHEEM WARRANTY FOR THE CROSSFLOW IS DETAILED IN THIS
DOCUMENT
3.1 Rheem will repair or replace a faulty component of your Crossflow Delivery Skid if it fails to operate in accordance with its
specifications as follows:
4. ENTITLEMENT TO MAKE A CLAIM UNDER THIS WARRANTY
4.1 To be entitled to make a claim under this warranty you need to:
a) Be the owner of the water heater or have consent of the owner to act on their behalf.
b) Contact Rheem Service without undue delay after detection of the defect and, in any event, within the applicable
warranty period.
4.2 You are not entitled to make a claim under this warranty if your water heater:
a) Does not have its original serial numbers or rating labels.
b) Is not installed in Australia.
5. HOW TO MAKE A CLAIM UNDER THIS WARRANTY
5.1 If you wish to make a claim under this warranty, you need to:
a) Contact Rheem on 131031 and provide owner’s details, address of the water heater, a contact number and date of
installation of the water heater or if that’s unavailable, the date of manufacture and serial number (from the rating label
on the water heater).
b) Rheem will arrange for the water heater to be tested and assessed on-site.
c) If Rheem determines that you have a valid warranty claim, Rheem will repair or replace the faulty component in
accordance with this warranty.
d) Any expenses incurred in the making of a claim under this warranty will be borne by you.
6. THE AUSTRALIAN CONSUMER LAW
6.1 Our goods come with guarantees that cannot be excluded under the Australian Consumer Law. You are entitled to a
replacement or refund for a major failure and for compensation for any other reasonably foreseeable loss or damage. You
are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does
not amount to a major failure.
6.2 The Rheem warranty (set out above) is in addition to any rights and remedies that you may have under the Australian
Consumer Law.
Copyright Rheem Australia PTY LTD 2016 20 Dec 2016 AQ0901085 Rev C
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