Page 1
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RRhheeeem
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AABBNN 2211 009988 882233 551111
SERVICE
INSTRUCTIONS
Rheem Water Star
TM039
Revision: A
Published: January 09
W8100401
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TM039 Rheem Water Star Service Instructions REV: A
Date of Issue: 02/09
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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
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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.
W 8 1
004 0 1
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.
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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
4
1000
680
800
70
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)
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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
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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
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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.
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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
2
14
Leaking water heater
3
15
Water too hot
4
16
Noisy water heater
5
17
Electrical insulation test
6
18
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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?
NO
NO
NO
YES
YES
YES
1.
2.
3.
4.
5.
YES
Noisy Water Heater
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Fault Finding Chart 1
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
YES
NO
YES
YES
NO
Test 1
Tests 2, 3 & 4
NO
1.1 6
NO
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Fault Finding Chart 1.1
No hot water
Replace thermostat
Replace thermostat
Replace thermostat
Replace element
Locate wiring failure
and repair
Are the
thermostat ECO
contacts closed?
Are the
thermostat
contacts closed?
Is the overall
resistance of the
water heater
correct?
Does the element
have the correct
resistance?
Did the thermostat
contacts close?
Is the water in the tank at
least 6 degrees lower
than the thermostat
setting?
NO
NO
YES
NO YES
Water heater electrically OK.
Slide the thermostat out from
under the retaining clamp and
allow base to cool.
YES
Test 5
Test 6
Test 7
Test 8
NO
Test 6
NO
YES
YES
2.
YES
1.1
NO
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Component Tests 1, 5, & 6
Test 1
With the water heater plugged in and
switched on, use a multimeter on the AC
volts scale and measure between active
and neutral on the terminal block.
Normal voltage is 240 volts
Test 5
Using a multimeter on the x1 resistance
scale, measure between terminals 3 and
4 on the thermostat.
The reading should be less than 1Ω.
Test 6
Using a multimeter on the x1 resistance
scale, measure between terminals 1 and
2 on the thermostat.
The reading should be less than 1Ω.
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Component Tests 7 & 8
Test 7
Using a multimeter on the x1 resistance
scale, measure the resistance of the
element across the wires that connect to
terminals 2 and 4 of the thermostat.
Normal resistance for the element is 6879 ohms.
Test 8
Using a multimeter on the x1 resistance
scale, measure between active and
neutral on the terminal block.
Normal resistance when the thermostat
contacts are closed is 68 - 79 ohms
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Fault Finding Chart 2
2
High energy bill/ Insufficient hot water
NO
Refer to Rheem sizing guide
Recommend a water heater
of sufficient capacity to meet
the customer‟s needs.
Fit pressure limiting valve
(PLV), if not already installed.
Replace faulty PLV. Replace
faulty T&PR valve.
Recommend a hot water
usage pattern that will suit
the water heater and the
customer‟s needs.
Check for cross water
connection. Replace the
T&PR valve (if required.).
Repair any leaks. Isolate
cross connections.
Replace the thermostat
Is the heater of
sufficient size for the
customer‟s ongoing
needs?
Has the usage
pattern changed
recently, ie.additional
appliances or people
using hot water?
Is the T&PR
valve continuously
discharging
water?
Does the cylinder
water temperature
correspond with the
thermostat setting?
Are there any plumbing
leaks,
crossed connections
or dripping taps?
Is the correct T&PR valve
fitted?
Is the water supply
pressure more than 80%
of the T&PR
valve rating?
YES NO
YES
NO
NO
NO
NO
YES
YES
Is a tempering valve
installed?
NO
YES
YES YES
Replace T&PR valve with one
with the correct pressure
rating. Do not use
reconditioned T&PR valves.
Measure the water temperature at the T&PR
valve drain by gently lifting the easing lever
Water Star OK. Possible fault
with continuous flow gas water
heater. (Refer to relevant
service instructions).
Has there been a recent
large draw off of hot
water
NO NO
Allow heater time to recoverYES
Possible fault with tempering
valve
YES
AS/NZS 3500 Part 4 only requires
fixtures used for ablution purposes to
be tempered. If practical a 2-zone
plumbing solution may be offered.
Replace the transfer valve
Is the transfer valve
allowing water to pass in
both directions?
NO
YES
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2 Zone Plumbing Option
Fault Finding Chart 3
3.
Leaking Water Heater
Replace the
cylinder
Remove pipe and
replace contite
olives
Remove element
and replace
gasket
Replace the
cylinder
Remove the T&PR
valve and reseal with
thread tape
Is the
leak from or near
the top?
Is the
leak from the
element barrel
weld?
Is the
leak from the
element
gasket?
Is the
leak from the
T&PR valve?
Is the
leak from the
T&PR valve fitting
weld?
Is the
leak from the
outlet pipe?
Is the
leak from the inlet
tee weld?
YES
NO
Is the
leak from the
drain pipe?
YES
NO
NO
YES
NO
YES
YES
NO
YES
YES
NO
YES
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Fault Finding Chart 4
4
Water too hot
Is the outlet water
temperature approx. 70
degrees?
Water heater operating
normally
YES
Is the thermostat in good
contact with the cylinder?
NO
Remove the thermostat, retension the bracket and refit
the thermostat
Allow the water heater to
recover and re-check the
water temperature
Is the water temperature
in the cylinder > 80°C?
NO
Replace the thermostat
YESYES
NO
An external tempering valve
should be considered if concerns
surround children or elderly
occupants
Water temperature can be
measured at the T&PR
valve drain by gently lifting
the easing lever
Has the correct
continuous flow gas water
heater been installed?
Is the water temperature
in the cylinder < 80°C?
NO
Fault rectified
The continuous flow gas water heater
connected to a Rheem Water Star MUST have
a maximum outlet temperature of 60 degrees
Reset the outlet
temperature of the
continuous flow water
heater or replace with a
suitable model
NO
Possible fault with
continuous flow gas water
heater. Refer to service
instructions on relevant
model for fault finding
YES
YES
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Fault Finding Chart 5
5.
Noisy Water Heater
Check for:
(A) Mineral build-up on the element.
(B) Mineral or sludge build-up inm the
cylinder
(C) Normal noises associated with heating
water.
Check for faulty stop cock, non-return
valve or T&PR valve.
Refer to water hammer causes, under
Common Faults
Check all other appliances that can
generate noise, eg. washing machine,
dishwasher, etc.
Cylinder contracting due to pressure
release when hot tap is opened. This can
be accompanied by a creaking or cracking
sound from the insulation. This noise is
normal operation.
Is the
noise only evident
during the heating
cycle?
Is the
noise water hammer?
Is the
noise only evident
when water is flowing
through the water
heater?
Is the
noise a metallic
popping sound?
Is the
water pressure more
than 80% of the
T&PR valve rating?
YES
NO
NO
YES
NO
YES
NO
Check for restrictionsin pipe work, faulty
valves, loose plumbing or other
appliances, eg. Washing machine or
dishwasher. Fit a 600kPa PLV if pressure
is excessive.
YES
YES
NO
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Fault Finding Chart 6
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.
Test 2 - To check insulation resistance of the water heater Neutral Circuit (reading
not to be below 1 MΩ).
1. Switch off power at GPO and unplug power cord from GPO (unplug continuous
flow water heater).
2. Connect megger leads to the neutral of the water heater wiring and earth.
3. Operate megger. A reading above 1 MΩ should be obtained.
4. If a reading below 1 MΩ is indicated, all component parts will need to be individually
tested to locate the fault. Refer to flow diagram chart 6, above.
Test 3 - To check insulation resistance of the water heater Active Circuit (reading
not to be below 1 MΩ).
1. Connect megger leads to the active of the water heater wiring and earth.
2. Operate megger. A reading above 1 MΩ should be obtained.
3. If a reading below 1 MΩ is indicated, all component parts will need to be individually
tested to locate the fault. Refer to flow diagram chart 6, above.
Test 4 - To check “Continuity” of water heater electrical circuit.
1. Set megger to resistance scale or multimeter to x1 resistance scale.
2. Measure between the active and the neutral of the water heater. If a reading between
68-79 ohms is not indicated, all electrical component parts will need to be individually
tested to locate the fault.
3. Reconnect the power cord. Note: If continuing with diagnostic procedure flow
chart 1.1 do not reconnect the power cord.
6
Disconnect the remaining wires
from the thermostat and megger
between each thermostat terminal
and earth.
Check for:
Faulty 3 pin outlet socket
Pinched or damaged wiring
touching the heater chassis
Replace thermostat
Is the reading below 1
Megaohm?
Is the reading below 1
Megaohm?
YES
Disconnect the wires to the
element from the thermostat and
megger between each element
wire and earth.
Replace elementYES
NO
NO
Rewire fuse or reset circuit
breaker, if necessary
Rewire fuse or reset circuit
breaker, if necessary
Electrical Insulation Test
NOTE: Unplug continuous flow water heater
prior to commencing insulation testing
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Component Replacement Procedures
Draining the Water Heater (Procedure 1)
1. Switch off power at GPO, unplug power cord from GPO and isolate the water
supply to the water heater
2. Relieve pressure from the water heater by easing the T&PR valve or through a
hot tap.
3. Disconnect the inlet water supply pipe
4. Fit a drain hose to the inlet water connection and run the other end to a drain or safe
location.
5. Open the temperature and pressure relief valve to allow air into the system.
NOTE: A small amount of water will be left in the cylinder.
Transfer Valve (Procedure 2)
1. Drain the water heater (refer to procedure 1 above)
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Disconnect the inlet pipe from the transfer valve by undoing the ¾” brass nut.
5. Disconnect the outlet pipe from the transfer valve by undoing the ¾” brass nut.
Remove the old transfer valve.
6. Fit the replacement transfer valve and assemble in reverse order.
7. Restore the water supply and check for leaks.
8. Purge air from the system through hot taps.
9. Refit the front polystyrene insulation and outer jacket.
10. Restore the power supply to the water heater.
Temperature and Pressure Relief Valve (Procedure 3)
Never fit a T&PR valve with a rating higher than that indicated on the water
heater rating plate. Do not use reconditioned T&PR valves.
1. Partially drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Disconnect the outlet pipe from the T&PR valve by undoing the ¾” brass nut.
5. Disconnect the drain line fitting from the T&PR valve
6. Unscrew the T&PR valve from the top of the cylinder.
7. Confirm the replacement T&PR valve is the correct rating and refit using thread tape.
8. Reassemble in the reverse order of above
9. Restore the water supply.
10. Check the T&PR valve thread and connections for leaks.
11. Operate the T&PR valve lever to reset relief drain.
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12. Purge air from the system through hot taps.
13. Refit the front polystyrene insulation and outer jacket.
14. Restore the power supply to the water heater.
Thermostat (Procedure 4)
1. Switch off power at GPO and unplug power cord from GPO.
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Confirm the wiring is as per the wiring diagram on page 6.
5. Disconnect the wiring to the thermostat.
6. Slide the thermostat out from under the retaining clamp.
7. Slide the replacement thermostat under the clamp ensuring the thermostat is held firmly
against the cylinder.
8. Reconnect the wiring as per the wiring diagram on page 6.
9. Check water heater internal wiring insulation for cracking.
10. Refit the front polystyrene insulation and outer jacket.
11. Conduct an electrical insulation test. Refer to page 18.
12. Restore power to the water heater.
Inlet Water Connector (Procedure 5)
1. Drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Undo the brass nuts retaining the inlet pipe to the inlet fitting and the transfer valve.
5. Loosen the remaining two brass nuts retaining the transfer valve.
6. Remove the two (2) screws retaining the inlet fitting to the bottom chassis.
7. Rotate the bottom of the transfer valve towards the front of the water heater so the inlet
water pipe could be manoeuvred free.
8. Fit the replacement inlet connector into place.
9. Reassemble in reverse order of above.
10. Restore the water supply.
11. Purge air from the system through hot taps and check for leaks.
12. Refit front polystyrene insulation and outer jacket.
13. Restore the power supply to the water heater.
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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”
21
Outlet Water Connector (Procedure 6)
1. Drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Disconnect the outlet water pipe from the T&PR valve, transfer valve and outlet water
connector by undoing the ¾” brass nuts.
5. Remove the outlet pipe.
6. Remove the two (2) screws retaining the outlet water connector fitting to the bottom
chassis.
7. Fit the replacement outlet water connector
8. Reassemble in reverse order.
9. Restore the water supply.
10. Purge air from the system through hot taps and check for leaks.
11. Refit front polystyrene insulation and outer jacket.
12. Restore the power supply to the water heater.
T&PR Valve Drain Connector (Procedure 6)
1. Drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Disconnect the T&PR drain pipe from the T&PR valve and drain connector by undoing
the brass nuts.
5. Remove the drain pipe.
6. Remove the two (2) screws retaining the connector to the water heater chassis.
7. Fit the replacement drain connector
8. Reassemble in reverse order of above.
9. Restore the water supply.
10. Purge air from the system through hot taps and check for leaks.
11. Refit front polystyrene insulation and outer jacket.
12. Restore the power supply to the water heater.
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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”
22
Element (Procedure 9)
1. Drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Slide the thermostat out of the retaining clamp
5. Disconnect the T&PR valve drain line and outlet water pipe from the T&PR valve.
6. Disconnect the transfer valve from the cylinder by undoing the ¾” brass nut.
7. Remove the cylinder from the water heater and invert it.
8. Unscrew the element using a 42mm spanner or tube socket.
9. Withdraw the element. Care must be taken to ensure the loop of the element does not
catch in the cylinder opening and open out inside the cylinder.
NOTE: Do not “cut off” the element and leave a portion inside the cylinder
10. Clean around the cylinder fitting. Ensure that the replacement element is of the correct
rating and carefully insert and screw into the cylinder.
11. Reassemble in reverse order of above.
12. Restore the water supply.
13. Purge air from the system through hot taps and check for leaks.
14. Refit front polystyrene insulation and outer jacket.
15. Conduct an electrical insulation test (refer to page 18).
16. Restore the power supply to the water heater.
Cylinder Replacement (Procedure 10)
1. Drain the water heater (refer to Procedure 1 on page 19).
2. Remove the T&PR valve (follow steps 2-6 of Procedure 3 on page 19).
3. Remove the element (follow steps 2-9 of Procedure 9 on page 22).
4. Refit the element & T&PR valve to the replacement cylinder. NOTE: Depending on the
age of the water heater consideration should be given to fitting a new T&PR valve.
5. Fit the replacement cylinder into the rear polystyrene housing. Note: The cylinder will
need to be supported until the T&PR valve drain line and outlet pipe are
connected.
6. Reassemble in reverse order of above.
7. Restore the water supply.
8. Operate the T&PR valve lever to reset relief drain.
9. Purge air from the system through hot taps and check the entire water heater for leaks.
10. Refit front polystyrene insulation and outer jacket.
11. Conduct an electrical insulation test. (Refer to page 18).
12. Restore the power supply to the water heater.
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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”
23
3 Pin Outlet Socket
1. Switch off power at GPO and unplug power cord from GPO.
2. Unplug the continuous flow water heater 3 pin plug from the socket.
3. Remove the outer jacket screws.
4. Remove the outer jacket and front polystyrene insulation to expose the water heater.
5. Confirm the wiring is as per the wiring diagram on page 6.
6. Disconnect the wiring from the active, neutral and earth connectors.
7. Remove the screw from the centre of the 3 pin socket outlet and remove the bottom
half of the 3 pin outlet socket.
8. Remove the upper half of the 3 pin outlet socket from the water heater.
9. Reassemble in reverse order of above. NOTE: When fitting the replacement 3 pin
outlet socket ensure the bottom half is orientated correctly so the earth pin entry aligns
with the earth socket in the top half of the plug.
10. Refit front polystyrene insulation and outer jacket.
11. Conduct an electrical insulation test. (Refer to page 18).
12. Restore the power supply to the water heater.
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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”
24
Exploded View
Replacement Parts List
Item
Description
Part Nº
Item
Description
Part Nº
1
Base – cabinet
140003
16
Name band-Rheem Water Star
125996
2
Insulation - rear
090160
17
Front cover – cabinet
140001
3
T&PR valve
220350
18
Cover – T&PR valve
221720-1
4
Valve connection kit
220371
19
Insulation - front
090159
5
T&PR valve drain pipe ½”
220366
20
Pipe – Outlet ¾”
220373
6
Nut – M4
080406
21
Transfer valve
220370
7
Wiring ass earth (GPO socket)
080402
22
Pipe – Inlet ¾”
220372
8
Wiring loom & cord set
080403
23
Nut – ¾” contite
220357
9
Wiring loom – thermostat
080400
24
Cone fitting ¾”
220358
10
Washer – flat
080405
25
Cylinder assembly unit
050032
11
Nut – ½” contite
220359
26
Thermostat R/S – ST1203133
052075
12
Washer – tooth lock
080404
27
Clamp – thermostat assy.
102501
13
Cone fitting ½”
220360
28
Heating unit – 800 watt
050022
14
T&PR valve drain fitting
220362
29
GPO socket
080410
15
Inlet/Outlet fitting
220361
Page 25
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”
25
Rheem Electric Water Heater Warranty - (Australia Only)
WARRANTY CONDITIONS
1. This warranty is applicable only to water heaters
manufactured from 1st June 2008.
2. The water heater must be installed in accordance with
the Rheem water heater installation instructions,
supplied with the water heater, and in accordance
with all relevant statutory and local requirements of
the State in which the water heater is to be installed.
3. Where a failed component or water heater is replaced
under warranty, the balance of the original warranty
period will remain effective. The replaced part or
water heater does not carry a new warranty.
4. Where the water heater is installed outside the
boundaries of a metropolitan area as defined by
Rheem or further than 25 km from a regional Rheem
branch office, or an Accredited Service Agent, the
cost of transport, insurance and travelling costs
between the nearest Rheem Accredited Service
Agent‟s premises and the installed site shall be the
owner‟s responsibility.
5. Where the water heater is installed in a position that
does not allow safe, ready access, the cost of
accessing the site safely, including the cost of
additional materials handling and / or safety
equipment, shall be the owner‟s responsibility.
6. The warranty only applies to the water heater and
original or genuine (company) component
replacement parts and therefore does not cover any
plumbing or electrical parts supplied by the installer
and not an integral part of the water heater, e.g.
pressure limiting valve; isolation valves; non-return
valves; electrical switches; pumps or fuse.
7. The water heater must be sized to supply the hot
water demand in accordance with the guidelines in
Rheem water heater literature.
WARRANTY EXCLUSIONS
A). REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RHEEM WATER
HEATER WARRANTY , HOWEVER THE FOLLOWING EXCLUSIONS MAY CAUSE THE WATER
HEATER WARRANTY TO BECOME VOID AND MAY INCUR A SERVICE CHARGE AND / OR COST
OF PARTS.
1. Accidental damage to the water heater or any
component, including: Acts of God; failure due to
misuse; incorrect installation; attempts to repair the
water heater other than by a Rheem Accredited
Service Agent or the Rheem Service Department.
2. Where it is found there is nothing wrong with the
water heater; where the complaint is related to
excessive discharge from the temperature and / or
pressure relief valve due to high water pressure;
where there is no flow of hot water due to faulty
plumbing; where water leaks are related to plumbing
and not the water heater or water heater
components; where there is a failure of gas,
electricity or water supplies; where the supply of
gas, electricity or water does not comply with
relevant codes or acts.
3. Where the water heater or water heater component
has failed directly or indirectly as a result of:
excessive water pressure, excessive temperature
and / or thermal input; blocked overflow / vent drain;
corrosive atmosphere; ice formation in the pipe work
to or from the water heater.
4. Where the water heater is located in a position that
does not comply with the Rheem water heater
installation instructions or relevant statutory
requirements, causing the need for major
dismantling or removal of cupboards, doors or walls,
or use of special equipment to bring the water
heater to floor or ground level or to a serviceable
position.
5. Repair and / or replacement to the water heater due
to scale formation in the waterways or the effects of
either corrosive water or water with a high chloride
or low pH level when the water heater has been
connected to a scaling or corrosive water supply or
a water supply with a high chloride or low pH level
as outlined in the Owner‟s Guide and Installation
Instructions booklet.
B) SUBJECT TO ANY STATUTORY PROVISIONS TO THE CONTRARY, THIS WARRANTY EXCLUDES
ANY AND ALL CLAIMS FOR DAMAGE TO FURNITURE, 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.
In addition to this warranty, the Trade Practices Act 1974 and similar laws in each state and territory provide the owner under certain
circumstances with certain minimum statutory rights in relation to your Rheem water heater. This warranty must be read subject to that
legislation and nothing in this warranty has the effect of excluding or restricting those rights.
RHEEM WATER HEATERS AUSTRALIA
RHEEM AUSTRALIA PTY. LTD.
A.B.N 21 098 823 511
FOR SERVICE TELEPHONE
131 031 AUSTRALIA
or refer local Yellow Pages
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.
Page 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”
26
Document Revision History
Title:
Service Instructions - Rheem Water Star
Document Nº:
TM039
Revision
Details of change
D.O.I.
A
Service Instructions issued for Rheem Water Star
2/09
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