EverHot Rheem 613050 Operating instructions

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Rheem Australia Pty Ltd ABN 21 098 823 511
Rheem and Everhot Heavy Duty
Electric Water Heaters
TM014
Issued: Jul 02
Revision: AC
Issued: Aug 2016
Rheem
Everhot
613050
623050
613315
623315
616315
610340
610430

TM014 Rheem & Everhot Heavy Duty Electric Service Instructions.
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CONTENTS
INTRODUCTION .................................................................................................................3
SAFETY WARNING.............................................................................................................3
HEATER MODEL IDENTIFICATION...................................................................................3
SPECIFICATIONS...............................................................................................................4
OPERATION........................................................................................................................4
COMPONENTS AND THEIR FUNCTION ...........................................................................5
PREVENTATIVE MAINTENANCE ......................................................................................6
WIRING DIAGRAMS ...........................................................................................................7
Three Element Models.....................................................................................................7
Six Element Models..........................................................................................................7
PRODUCT CHANGES ........................................................................................................8
COMMON FAULTS .............................................................................................................9
FAULT FINDING................................................................................................................12
No Hot Water .................................................................................................................13
Insufficient Hot Water.....................................................................................................14
Component Testing........................................................................................................15
Leaking Water Heater ....................................................................................................18
Water Too Hot................................................................................................................19
Noisy Water Heater........................................................................................................20
Electrical Insulation Test ................................................................................................20
ELECTRICAL INSULATION TESTING..........................................................................21
COMPONENT REPLACEMENT........................................................................................22
DOCUMENT REVISION HISTORY...................................................................................25

TM014 Rheem & Everhot Heavy Duty Electric Service Instructions.
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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 or Everhot Heavy Duty Electric
Water Heater, contact your nearest Rheem 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 or Everhot Heavy Duty Electric Water Heater in the minimum of time.
Safety precautions or areas where extra care should be observed when conducting tests
outlined in this manual are indicated by print in bold italics and/or a warning symbol. Take
care to observe the recommended procedure.
Certain diagnostic procedures outlined in these service instructions
require “live” testing to be conducted. Personal Protective Equipment
(PPE) should be worn when conducting these tests to prevent the risk of
electric shock.
WARNING: Voltages up to 415 volts AC may be present (Refer to the Rheem
Safety Procedure on electrical testing)
HEATER MODEL IDENTIFICATION
All identification numbers are designed to convey detailed information about the water
heater to which it is attached.
6
1
6
315
0
8
6 –Heavy Duty
1 - Rheem
2 - Everhot
0 –No Heating Units
3 –Three Heating Units
6 –Six Heating Units
Rated Capacity in Litres
No Reference –System Requirement
0 –Element Not fitted
7 –3600w
8 –4800w
9 –6000w
Note: Model number, serial number and date of manufacture should be quoted in all
correspondence.

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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
Anode
Length
(mm)
Series
Capacity
With ECV
Without
ECV
Inlet
Outlet
T&PR
HEAVY DUTY
613
623
060
50
1000
680
800
75
RP1¼/32
RP¾/20
Tradesperson
Adjustable
485
613
623
616
340
315
1000
680
800
75
RP1¼/32
RP¾/20
1400
610
340
340
1000
680
800
N/A
RP1¼/32
RP¾/20
N/A
1400
OPERATION
The 613, 623 and 616 series heavy duty electric water heaters are designed for connection
to a 3 phase AC supply incorporating a neutral.
On 3 element models the wiring is configured for one element and thermostat combination
to be supplied between each active conductor (phase) and neutral. On six element models
the wiring is configured for two element and thermostat combinations to be supplied between
each active conductor (phase) and neutral.
Water temperature is maintained via the thermostat switching the active conductor to an
electric immersion element. The thermostat and corresponding element are mounted at
intervals up the side of the cylinder.
As the water temperature within the cylinder falls the thermostat contacts close suppling
power to the element. Each element is switched on sequentially from the bottom up, as cold
water enters the cylinder.
Once the water temperature reaches the set point of the thermostat, the contacts open
cutting power to the corresponding element.
A double pole “manual reset” over temperature cut out is incorporated into each thermostat
to provide additional protection in the event the controlling thermostat contacts fail. The ECO
contacts open between 87ºC and 93ºC.

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COMPONENTS AND THEIR FUNCTION
Temperature and Pressure Relief Valve
A valve designed to provide automatic relief by discharging water in case of excessive
temperature, pressure or both.
Never fit a T&PR Valve with a pressure rating greater than that indicated on the
product-rating label.
Pressure Limiting Valve (P.L.V.)
A valve that controls its outlet pressure to a predetermined limit.
Outlet Delivery Tube (Dip Tube)
A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water
from the highest point to the outlet connection. It also acts as a fitting liner.
Diffuser
A plastic device installed in the cold water inlet of the water heater cylinder to assist with
stratification. It also acts as a fitting liner.
Fitting Liner
A plastic tube installed in the cold-water inlet of the water heater to provide protection against
corrosion through the life of the water heater.
Anode (Sacrificial)
A metal alloy electrode installed in the water heater cylinder that by galvanic action protects
the cylinder from corrosion.
Thermostat
A device, responsive to temperature, which controls the supply of electrical energy to the
element to maintain the stored water at the required temperature.
Over Temperature Energy Cutout (E.C.O.)
A temperature-sensing device in combination with the thermostat that automatically cuts off
the supply of electrical energy to prevent excessive water temperature occurring. This
device will not reset automatically but may be manually reset once temperatures have fallen
to a safe level. DETERMINE CAUSE OF OPERATION.
Heating Unit (Element)
A tubular device containing an electric resistance element that converts electrical energy to
heat. Standard ratings are 3.6, 4.8 and 6.0kW

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PREVENTATIVE MAINTENANCE
It is suggested for peak performance that the water heater be serviced annually.
Annual Service
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. Operate the valve-easing lever to ensure the valve
opens and resets properly. Always open and close the valve gently.
2. Check for discharge from the ECV if fitted. When the element is operating a small
discharge of water may be evident. Operate the valve-easing lever to ensure the valve
opens and resets properly. Always open and close the valve gently.
3. Check for leaks at all tank fittings.
4. Check for signs of excessive corrosion on the water heater jacket.
5. If an overflow tray is installed, check to ensure the overflow tray drain pipe is not blocked.
6. Isolate power to the water heater and check all electrical connections for signs of
overheating due to poor connection.
7. Conduct an electrical insulation test on the water heater (refer to “Electrical Insulation
Testing” on page 20).
Major Five Year Service
It is recommended that a major five year service be conducted on the water heater.
1. Replace pressure temperature relief valve.
2. Inspect and flush expansion control valve (if ECV fitted) and replace expansion control
valve if required.
3. Inspect anode and replace anode if required. If the anode is not replaced, it should be
replaced within three years of this service.
4. Check electric heating units for excessive calcium build up or corrosion and replace
heating unit if required.
5. Visually check water heater for any potential problems.
6. Inspect all plumbing and electrical connections

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WIRING DIAGRAMS
Three Element Models
EWT Thermostat
ST Thermostat
Six Element Models
EWT Thermostat
ST Thermostat

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PRODUCT CHANGES
Element Changes
In November 2005 a newdesign electric element and cylinder element barrel was introduced
to all Vulcan electric storage water heaters (refer to Fig. 1A & 1B). The new design elements
utilise a new flange, gasket and earthing arrangement and are a direct replacement for
earlier model elements and as such part numbers remain unchanged.
The new type gaskets (refer to Fig. 2) will also fit earlier model elements and are now
supplied with the element. These new gaskets have a radius on the top internal edge
allowing a better seal against the element, are shorter overall by 2mm, and have a flange
thickness of 2.15mm instead of 2.25mm.
Fig. 1A
New design front
view
Fig. 1B
New design
side view
Fig. 2
New design
gasket
Fig. 3.
Cylinder barrel
Earth tab
Fig. 4.
Thermostat clamp
Earth tab
The new design cylinder element barrels do not have an earthing tab and require the earth
bond to be connected to the earthing tab on the thermostat clamp (refer to Fig. 4).
When installing an early or new type element on a cylinder barrel that
has an earth tab, this earth tab must be used (refer to Fig. 3).
When installing an early or new type element on a new type cylinder
barrel that does not have an earth tab, the earth tab on the thermostat
clamp must be used (refer to Fig. 4).
Refer also to Technical Bulletins TB05 019 and TB05 020.
Thermostat changes
Robertshaw EWT series thermostats have been
replaced by Robertshaw ST series thermostats. This
change applies to all electric water heaters
manufactured from 14/08/2007.
It should be noted that although the ST series
thermostat is a direct replacement for the EWT series
thermostat, the terminal connections and wiring
arrangement is different. Therefore;
Whenever an EWT series thermostat is replaced with a ST series thermostat
as a spare part, the water heater will require rewiring at the thermostat. Refer
to “Wiring Diagrams” section on page 7 for wiring arrangements utilising the
ST series thermostat.

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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 compare this with the potential
delivery of the model water heater installed. It can then be established if the usage is within
or outside the capacity of the model. The areas to look at for excessive usage are:
1. Automatic washing machines.
2. Showers exceeding 12 litres/minute for mixed water and 5 minutes in duration.
3. Two or more showers operating at the same time.
4. Change of occupancy or number of persons increased.
5. High water pressure area. (Excessive pressure relief valve discharge)
6. Plumbing leaks
7. Thermostat temperature setting
8. Crossed connection
Discoloured water
This may be the result of discoloured water entering from the cold water mains. Check if the
cold water is also discoloured.
Water hammer
A water heater will not cause water hammer, however valves associated with the water
heater may be the source of the problem i.e. cold-water stopcock, non-return valve or relief
valve.
Most water hammer problems are associated with plumbing, hot and cold or appliances i.e.
solenoid valves, ballcocks, loose pipes, sharpangles 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 cylinder, and then turn the
stopcock off again.
5. Wait approximately 5 minutes then do either of the following:
a. With your ear close to the stopcock turn it on slightly and listen for any water passing.
If there are no leaks, water should not pass.
b. Open a hot tap while listening for any pressure release. If there is a pressure release
there will be no leaks in the plumbing system.
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.

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Manifolding
Very often complaints surrounding insufficient hot water in commercial installations can be
attributed to poor manifolding.
In order for the water heaters to operate simultaneously the water flow through all the tanks
must be the same to ensure the temperature drop is equal across the tanks.
In a worst-case scenario it is possible for 2 or 3 of the water heaters in a bank to almost
never operate. This results in an overall loss of heat input to the water moving through the
building and can be confused as the installation being undersized or a malfunction of the
water heaters.
The principle of Equa-Flow is to ensure the demand on each water heater in the bank is the
same as any other. To achieve this, the following are necessary:
1. The cold water manifold must be designed to balance the flow to each unit i.e. each
branch line must be the same diameter and length and be fitted with identical ball or
gate valves.
2. The hot water manifold must be designed to balance the flow from each unit i.e. each
branch line must be the same diameter and length and be fitted with identical ball or
gate valves.
3. All the water heaters must be of the same size and capacity.
4. The first heater supplied from the cold (inlet) manifold must be the last heater supplying
the hot (outlet) manifold (see examples on next page).

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In Line Manifold
Back to Back Manifold
Angle Manifold
FAULT FINDING
Fault diagnosis
YES
Is the complaint for no hot water? YES 1
Is the complaint for insufficient hot water?
NO
Is the complaint for a leaking water
heater?
NO
YES
Is the complaint for a leaking water
heater?
NO
YES
Noisy Water Heater
2
3
4
5

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No Hot Water
Restore power and
advise customer
NO
YES
NO
YES
Is 240/415 volts present
at the terminal block?
Is the isolating switch
turned off?
Are the fuse(s) blown at
the switchboard?
Has the heater been
connected incorrectly?
i.e. active connected to neutral terminal
YES
NO
1
Possible fault in building
electrical wiring, continue with
diagnosis to confirm water
heater is operational
Test 1 & Test 2
NO
2
YES
Test 1
Isolate power and reconnect
correctly. Follow flow chart 2 to
diagnose any damaged
components.
YES
Carry out electrical insulation
and continuity test.
6
Is the reading
below 1 megaohm? Isolate power and continue with diagnosis procedure
NO

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Insufficient Hot Water
With multi-element water heaters very often more than one fault may have occurred before
the user feels the effect.
When servicing a multi-element water heater each thermostat - element combination should
be checked to ensure correct operation.
In manifolded installations a complaint for insufficient hot water may be due to faults in more
than 1 heater or may be a result of poor manifolding.
NO
YES
Install the element correctly and reset
the ECO
NO
YES
NO
NO
YES
Replace Element
NO
YES
Are the thermostat ECO
contacts closed? Is the element installed in the correct orientation?
Are the thermostat
contacts closed?
Is the temperature at
the TPR valve at least 12
degrees lower than the
thermostat setting?
Does the element have
the correct resistance?
2
Test 6
Test 7
Replace the thermostatYES
Slide the thermostat out from
under the retaining clamp and
allow base to cool
Did the thermostat contacts
close? Replace the thermostatNO
Test 8
YES
Repeat diagnosis for each
thermostat element
combination
Is more than 1
water heater installed? 2
YES
Water heater electrically ok
Refer to manifolding section
NO

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Component Testing
Tests 1 & 2
Warning –“Live” equipment
Personal Protective Equipment should be worn when conducting these tests.
TEST 1 –3 Element Models
TEST 1 –6 Element Models
Using a multimeter on the AC voltage scale, measure between each active and neutral
on the terminal block. Normal voltage is 240 volts
Warning –“Live” equipment
Personal Protective Equipment should be worn when conducting these tests.
TEST 2 –3 Element Models
TEST 2 –6 Element Models
Using a multimeter on the AC voltage scale, measure between each active on the
terminal block.
Normal voltage is 415 volts when connected to a 3-phase supply.

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Tests 6 & 7
Warning: Ensure power is isolated before conducting these tests
Test 6
EWT Thermostat
ST Thermostat
Using a multimeter set on the resistance
scale, measure between terminals 3L and 4L
on the thermostat.
The reading should be less than 1 ohm.
Using a multimeter set on the resistance
scale, measure between terminals ‘3’ and ‘4’
The reading should be less than 1 ohm.
Test 7
EWT Thermostat
ST Thermostat
Using a multimeter on the resistance scale,
measure between terminals 1L and 2T on
the thermostat.
The reading should be less than 1 ohm.
Using a multimeter set on the resistance
scale, measure between terminals ‘1’ and
‘2’.
The reading should be less than 1 ohm.

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Tests 8 & 9
Warning: Ensure power is isolated before conducting these tests
Test 8
EWT Thermostat
ST Thermostat
Using a multimeter on the resistance scale,
measure between terminals 2T and 4L of
the thermostat. Normal resistance for the
heating unit is:
3.6kW: 15 - 17 ohms
4.8kW: 11 - 13 ohms
6.0kW: 9 –11 ohms
Disconnect both element wires from the
thermostat and using a multimeter set on
the resistance scale, measure between the
two disconnected element wires. Normal
resistance is as follows:
3.6kW: 15 ~ 17Ω.
4.8kW: 11~ 13Ω.
6.0kW: 9 –11 ohms
Test 9
EWT Thermostat Shown
Using a megger on the 500V DC setting, measure between each element wire and earth.
The resistance should be greater than 1 mega ohm.

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Leaking Water Heater
Remove anode capYES
NO
NO
Remove anode and
reseal with thread tape YES
Replace water heater
Remove the extension fitting and
reseal with thread tape
Check for hot spots on the jacket. If any are
detected conduct a pressure test.
Replace heater if pressure will not hold.
NOTE: For Rheem Plus models, additional cold
water tee fitting and tempering valve need
checking before the pressure test.
YES
NO
YES
NO
Remove element and replace
gasket
YES
YES
YES
NO
NO
Remove T&PR valve and reseal
with thread tape YES
YES
Replace water heater YES
YES
NO
NO
NO
NO
Is the leak from or near the
top of the tank?
Is the leak from the anode?
Is the leak from the
element barrel weld? Is the leak from the anode cylinder fitting?
Is the leak from the element
gasket?
Is the leak from the inlet
extension fitting?
Is the leak from the inlet fitting
weld?
Is the leak from the outlet
extension fitting?
Is the leak from the outlet
fitting weld?
Is the leak from the T&PR
fitting weld?
Is the leak from the T&PR
valve?
NO
3

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Water Too Hot
Explain to customer the reasons for
storing water hotter than they may
desire i.e.
1. When mixed with cold water more
hot water delivery is possible
2. Prohibit bacteria growth
Tempering devices should be
suggested as a solution
YES
Remove the thermostat and clean any
scale from the cylinder wall.
Re-tension bracket and refit
thermostat.
NO
YES
Refit element correctlyNO
Replace thermostatYES
Reset the ECO
YES
NO
Are the thermostat contacts closed?
NO
Does the water temperature at
the T&PR valve correspond with
or near the thermostat setting?
Are the thermostats in good
contact with the cylinder?
Is the element installed in the
correct orientation?
4
Test 6
Are the thermostat
ECO contacts closed? NO
Repeat test for each
thermostat and element
combination
Replace thermostatYES
Test 7

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Noisy Water Heater
Check for:
(A) Mineral build up on the element
(B) Mineral or sludge build up in the cylinder
(C) Normal noises associated with heating water
Check for restrictions in pipe work, faulty valves,
loose plumbing or other appliances i.e washing
machine or dishwasher.
Fit 600kPa PLV if pressure excessive
NO
YES
Check for faulty stop cock, non-return valve or
T&PR valve
NO
YES
NO
YES
NO
Cylinder contracting due to pressure release
when hot tap opened.
This can also be accompanied by a creaking or
cracking sound from the insulation.
This noise is normal operation
YES
Check all other appliances that can generate
noise i.e. washing machine, dishwasher, ball
cocks etc.
NO
YES Refer to water hammer
causes in Common Faults Chapter
Is the noise water
hammer?
Is the noise only evident
when water is flowing
through the water heater?
Is the noise a metallic
dropping sound?
Is the water pressure more
than 80% of the T&PR
valve rating?
5
Is the noise only evident
during the heating cycle?
Electrical Insulation Test
Replace element
Disconnect the leads to the element
from the thermostat and meggar
between each element lead and earth
NO
6
Is the reading below 1 megaohm? YES
Rewire fuse / reset
breaker if necessary
Disconnect remaining leads from the
thermostat and meggar between each
terminal on the thermostat and earth Is the reading below 1 megaohm? Replace thermostat
Rewire fuse / reset
breaker if necessary
YES
Check for pinched or
damaged wiring touching the
water heater chassis
NO
Test 9