Rheem TM039 Service Instructions Manual
This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”
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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”
2
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”
3
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.
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”
4
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)
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”
5
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”
6
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”
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 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”
8
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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