Rheem 613050 Operating instructions

Rheem Heavy Duty Electric Service Instructions REV: A
DateofIssue: 10/7/2002
Rheem Australia Pty Ltd Document control header
Title: -Service Instructions for Rheem Heavy Duty Electric Water Heaters Document Number: -TM014
Revision Details of change D.O.I.
AService Instructions issued for Rheem Heavy Duty Electric
Models 07/02

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
DateofIssue:10/7/2002
1
RHEEM AUSTRALIA PTY LTD
SERVICE INSTRUCTIONS
TM014
HEAVY DUTY
ELECTRIC WATER HEATERS
MODELS
613050
613315
616315
610340 –Storage Tank
Rheem Australia Pty Ltd ABN 21 098 823 511
Revision: A Published: July2002
ELECTRIC

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
DateofIssue:10/7/2002
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SAFETY WARNING
The purpose of this Service Manual is to provide sufficient information to allow a person with the skills as
required by the controlling Regulatory Authorities to carry out effective repairs to a Rheem Heavy Duty Electric
Water Heater in the minimum of time.
Safety precautions or areas where extra care should be observed when conducting tests outlined in this
manual are indicated by print in bold italics and/or a warning symbol. Take care to observe the recommended
procedure.
Certain diagnostic procedures outlined in these service instructions require “live” testing to
be conducted. Personal Protective Equipment (PPE) should be worn when conducting these
tests to prevent the risk of electric shock.
WARNING: Voltages up to 415 volts AC may be present (Refer to the Rheem Safety
Procedure on electrical testing)
INTRODUCTION
The information provided in these instructions is based on the water heater being installed in accordance with
the Installation Instructions provided with each water heater.
Should you require further technical advice on a Rheem Heavy Duty Electric Water Heater, contact your
nearest Rheem Service Department where all genuine replacement parts are also available.
CONTENTS
Page
Safety Warning 2
Model Identification 3
Specifications 3
Operation 3
Components And Their Function 4
Preventative Maintenance 4
Wiring Diagrams
5 -6
Common Faults 7 -8
Manifolding 8 -9
Fault Finding
10 -18
Component Tests 13 -14
Electrical Insulation Tests 18
Component Replacement Procedures
19 -21
Exploded View -Three Element 22
Exploded View -Six Element 23
Exploded View –Storage Tank 24
Replacement Parts List 25
Warranty Statement 26

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
DateofIssue:10/7/2002
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HEATER MODEL IDENTIFICATION
All identification numbers are designed to convey detailed information about the water heater to which it is
attached. The model number consists of 8 digits.
616315 08
6 –Heavy Duty
1 –MEPS Compliant
0 –No Heating Units
3 –Three Heating Units
6 –Six Heating Units
Rated Capacity in Litres
No Reference –System Requirement
0 –Element Not fitted
7 –3600w
8 –4800w
9 –6000w
Note: Model number, serial number and date of manufacture should be quoted in all correspondence.
SPECIFICATIONS
Model Maximum Inlet
Pressure (kPa) Water Connections
Series Capacity
Rated
Capacity
(Litres)
T & PR
Valve
Rating
(kPa) With ECV Without ECV
T/stat
Setting
(ºC) Inlet
Outlet T&PR
T/stat
Type
Anode
Length
(mm)
613 060 50 1000 680 800 75 RP1¼/32 RP¾/20 485
613
616 340 315 1000 680 800 75 RP1¼/32 RP¾/20
Tradesperson
Adjustable
1400
HEAVYDUTY
610 340 340 1000 680 800 N/A RP1¼/32 RP¾/20 N/A 1400
OPERATION
The 613 and 616 series heavy duty electric water heaters are designed for connection to a 3 phase AC supply
incorporating a neutral.
On 3 element models the wiring is configured for one element and thermostat combination to be supplied
between each active conductor (phase) and neutral. On six element models the wiring is configured for two
element and thermostat combinations to be supplied between each active conductor (phase) and neutral.
Water temperature is maintained via the thermostat switching the active conductor to an electric immersion
element. The thermostat and corresponding element are mounted at intervals up the side of the cylinder.
As the water temperature within the cylinder falls the thermostat contacts close suppling power to the element.
Each element is switched on sequentially from the bottom up, as cold water enters the cylinder.
Once the water temperature reaches the set point of the thermostat, the contacts open cutting power to the
corresponding element.
A double pole “manual reset” over temperature cut out is incorporated into each thermostat to provide
additional protection in the event the controlling thermostat contacts fail. The ECO contacts open between
87ºC and 93ºC.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
DateofIssue:10/7/2002
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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 itsoutlet pressure to a predetermined limit.
Outlet Delivery Tube (Dip Tube)
A plastic tube installed in the hot water outlet of the water heater cylinder to conduct water from the highest
point to the outlet connection. It also acts as a fitting liner.
Diffuser
A plastic device installed in the cold water inlet of the water heater cylinder to assist with stratification. It also
acts as a fitting liner.
Fitting Liner
A plastic tube installed in the cold-water inlet of the water heater to provide protection against corrosion
through the life of the water heater.
Anode (Sacrificial)
A metal alloy electrode installed in the water heater cylinder that by galvanic action protects the cylinder from
corrosion.
Thermostat
A device, responsive to temperature, which controls the supply of electrical energy to the element to maintain
the stored water at the required temperature.
Over Temperature Energy Cutout (E.C.O.)
A temperature-sensing device in combination with the thermostat that automatically cuts off the supply of
electrical energy to prevent excessive water temperature occurring. This device will not reset automatically
but may be manually reset once temperatures have fallen to a safe level. DETERMINE CAUSE OF
OPERATION.
Heating Unit (Element)
A tubular device containing an electric resistance element that converts electrical energy to heat. Standard
ratings are 3.6, 4.8 and 6.0kW
PREVENTATIVE MAINTENANCE
It is suggested for peak performance that the water heater be serviced annually.
1. Check for discharge from the T&PR valve. When the elements are operating a small discharge of water
may be evident. Operate the valve-easing lever to ensure the valve opens and resets properly. Always
open and close the valve gently. The T& PR valve should be replaced at 5 yearly intervals.
2. Check for leaks at all cylinder fittings.
3. Check for signs of excessive corrosion on the water heater jacket.
4. Isolate power to the water heater and check all electrical connections for signs of overheating due to poor
connection.
5. Conduct an electrical insulation test on the water heater. (Refer to page 18)
6. Check for sludge build up and if necessary drain and flush tank.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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WIRING DIAGRAMS
THREE ELEMENT MODELS

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WIRING DIAGRAMS
SIX ELEMENT MODELS

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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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 capacityof 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. Crossedconnection
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
sourceof 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
neighbouringequipment.
High water pressure areas will have more complaints of this nature and the use of a pressure-limiting valve
(PLV) to reduce the household cold-water pressure will usually solve most problems.
Hot water plumbing leaks
If hot water has not been used for a period of time, feeling the temperature of the hot water line may give an
indication of water flow if the pipe is warm. The method of checking for plumbing leaks is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock is operating correctly.
3. Turn off the hot tap.
4. Turn on the stopcock to make up the water pressure in the cylinder, and then turn the stopcock off again.
5. Wait approximately 5 minutes then do either of the following:
a. With your ear close to the stopcock turn it on slightly and listen for any water passing. If there are no
leaks, water should not pass.
b. Open a hot tap while listening for any pressure release. If there is a pressure release there will be no
leaks in the plumbing system.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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COMMON FAULTS
Mixing or crossed connections
If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or thermostatic mixing valve is
installed there is always the possibility that the cold water could mix with the hot water through a faulty or
incorrectly installed valve. This is referred to as a cross connection. The complaints of insufficient hot water,
water too cold or excessive discharge from the pressure relief valve may be attributed to a cross connection.
The method of checking for a cross connection is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap. If water flow is persistent and cold a cross connection exists.
Manifolding
Very often complaints surrounding insufficient hot water in commercial installations can be attributed to poor
manifolding. In order for the water heaters to operate simultaneously the water flow through all the tanks must
be the same to ensure the temperature drop is equal across the tanks. In a worst-case scenario it is possible
for 2 or 3 of the water heaters in a bank to almost never operate. This results in an overall loss of heat input to
the water moving through the building and can be confused as the installation being undersized or a
malfunction of the water heaters. The principle of Equa-Flow is to ensure the demand on each water heater in
the bank is the same as any other. To achieve this, the following are necessary:
1. The cold water manifold must be designed to balance the flow to each unit i.e. each branch line must be
the same diameter and length and be fitted with identical ball or gate valves.
2. The hot water manifold must be designed to balance the flow from each unit i.e.
each branch line must
be the same diameter and length and be fitted with identical ball or gate valves.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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COMMON FAULTS
Manifolding
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 below).
In Line Manifold
Back to Back Manifold Angle Manifold

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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FAULT FINDING
Is
thecomplaint
for no hot
water?
Fault Diagnosis
YES 1
Is
thecomplaint
forinsufficienthot
water?
NO
2YES
Is
thecomplaint
for leaking water
heater?
NO
3YES
Is
thecomplaint
for water too
hot?
NO
4
YES
5
NO
Noisy water heater

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
DateofIssue:10/7/2002
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FAULT FINDING
1No hot water
Is
240/415 volts
present at the terminal
block?
Warning: Terminals may be live,
Personal Protective Equipment
should be worn.
Test 1 & Test 2
Isolate power and
continue with diagnosis
procedure
YES
2
Restore power and
advisecustomer
Is
the isolating switch
turnedoff?
YES
Is the
fuse(s) blown at the
switchboard?
NO
Possible fault in building
electricalwiring,continue
with diagnosis to confirm
water heater is operational
NO
Is the
reading below 1
mega-ohm?
6
YES
NO
Using the procedure on
page 18 conduct an
electricalinsulationtest
YES
Test 3, 4 and 5
NO
Has
the heater
beenconnected
incorrectly?
i.e. Active connected to Neutral terminal
Test1
YES
NO
Isolate power and reconnect correctly.
Follow flow chart 2 to diagnose any
damagedcomponents

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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FAULT FINDING
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.
2Insufficient Hot Water
Are
thethermostat
contacts
closed ?
Test 7 Is
the temperature
at the T&PR valve at
least 6 degrees lower than
the thermostat
setting?
NO
Slide the thermostat out from under the
retaining clamp and allow base to cool
NO
YES
Replace thermostat
YES
Did
the thermostat
contacts
close?
Test 7
ReplacethermostatNO
Does
the element
have the correct
resistance?
YES
Are
thethermostat
ECO contacts
closed ?
Test6
Install the element
correctly and reset the
ECO
YES
Test8
Replace element
NO
Waterheater
electrically ok.
Refer to manifolding
section
Is
the element
installed in the correct
orientation?
NO NO
Replace thermostatYES
Note: Depending on the stratification some
thermostats may be open and some closed.
Ensure the next step is followed to correctly
diagnose a faulty thermostat.
Is
more than
1 water heater
installed?
NO
YES 2
Repeatdiagnoses
for each water heater
Repeat diagnoses for each
thermostatelement
combination
YES

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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COMPONENT TESTING
Warning –“Live” equipment
Personal Protective Equipment should be worn when conducting these tests.
TEST 1–3ElementModels TEST 1–6ElementModels
Using a multimeter on the AC voltage scale, measure betweeneachactive 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.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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COMPONENT TESTING
Warning: Ensure power is isolated before conducting these tests
TEST6 TEST7
Using a multimeter on the x1 resistance scale,
measure between terminals 3L and 4L on the
thermostat. The reading should be less than 1 ohm
Using a multimeter on the x1 resistance scale,
measure between terminals 1L and 2T on the
thermostat. The reading should be less than 1 ohm.
Warning: Ensure power is isolated before conducting these tests
TEST 8 TEST9
Using a multimeter on the x1 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
Using a megger on the 500V DC setting, measure
between each element wire and earth.
The resistance should be greater than 1 mega ohm

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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FAULT FINDING
LeakingWaterHeater
3
Is
theleak
from or near the
top?
Isthe
leak from the
anode?
Remove anode and
reseal with thread tape
Remove anode
cap
YES
Is
the leak from
theanodecylinder
fitting?
Replace water heater
Is
the leak from
the T & PR
valve?
Remove the
T & PR valve and
reseal with thread
tape
NO
Check for hot spots on
the jacket. If any are
detected conduct a
pressure test.
Replace water heater if
pressure will not hold
Is the
leak from the
electrical access
cover?
NO
Is
the leak from
the element barrel
fitting?
YES
Remove element and
replace gasket
NO
YES YES
NO
Is
the leak from
the T & PR cylinder
fitting?
YES
NO
YES
YES
NO NO
Is
theleakfrom
theoutletcylinder
fitting?
Is
the leak from
theinletcylinder
fitting?
NO NO
YES YES

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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FAULT FINDING
Water too hot
4
Does
thewater
temperature at
the T&PR valve correspond
with or near the
thermostat
setting? Explain to customer the reasons for
storing water hotter than they may desire
i.e.
(A) When mixed with cold water more hot
water delivery is possible.
(B) Prohibit bacteria growth
Tempering limiting devices should be
suggested as a solution
YES
Is
the thermostat
in good contact with the
cylinder?
Are
thethermostat
contacts
closed?
NO
Is
the element
installed in the correct
orientation?
Refit element correctly
NO
Replacethermostat
YES
Remove the thermostat and clean
any scale from the cylinder wall.
Re-tension bracket and refit
thermostat
NO
YES
YES Replacethermostat
Are
thethermostat
ECO contacts
closed?
YES
ResettheECO
NO
NO
Test6 Test 7
Repeat test for each thermostat
and element combination

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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FAULT FINDING
Noisy Water Heater
5
Is
the noise water
hammer?
Refer to water hammer causes on page
7,commoncomplaints
Isthe
noise only
evidentwhenwater
is flowing through
the water
heater?
NO
Check all other appliances that can
generate noise i.e. washing machine,
dishwasher, ball cocks etc.
Is
thewater
pressure more than 80%
of the T & PR valve
rating?
YES
Check for a faulty stop cock, non-return
valve or T&PR valve
NO
Check for restrictions in pipe work,
faulty valves, loose plumbing or other
appliances i.e washing machine or
dishwasher.
Fit 600kPa pressure limiting valve
YES
Is
the noise
only evident during
the heating
cycle? Checkfor:
(A) Mineral build up on the element
(B)Mineral or sludgebuildup in the
cylinder
(C) Normal noises associated with
heating water
YESNO
YES
NO
Is
thenoise
a metallic popping
sound?
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
NO

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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FAULT FINDING
Electrical Insulation Test
Disconnecttheleadstotheelement
fromthethermostatandmegger
between each element lead and earth
Is the
reading below 1
mega-ohm? ReplaceelementYES
Rewire fuse if necessary
Is the
reading below 1
mega-ohm? ReplacethermostatYES
Rewirefuseifnecessary
Disconnect remaining leads from the
thermostat and megger between each
terminalonthethermostatandearth
NO
Check for pinched or
damagedwiring
touchingthewater
heaterchassis
NO
6
Test9
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.
Personal Protective Equipment should be worn when conducting step 1 of this procedure to
reduce the risk of electric shock. Refer to Rheem safety procedure on electrical testing.
Test No.3
Insulation resistance of the water heater Neutral Circuit. (Reading not to be below 1 mega-ohm).
1. Isolate power to the water heater at the isolation switch. Confirm with multi-meter across each
Active and Neutral at the terminal block that voltage is not present.
2. Once satisfied, disconnect the active and neutral wires from the water heater terminal block.
3. Connect megger leads to the neutral of the water heater wiring and earth.
4. Operate megger. A reading above 1 mega-ohm shouldbe obtained.
5. If a reading below 1 mega-ohm is indicated, all component parts will need to be individually tested to
locate the fault. Refer to flow diagram 6.
Test No.4
Insulation resistance of the water heater Active Circuit. (Reading not to be below 1 mega-ohm).
6. Connect megger leads to the active of the water heater wiring and earth.
7. Operate megger. A reading above 1 mega-ohm shouldbeobtained.
8. If a reading below 1 mega-ohm is indicated, all component parts will need to be individually tested to
locate the fault. Refer to flow diagram 6.
Test No.5
“Continuity” of water heater electrical circuit.
9. Set megger to resistance scaleor multimeter to x1 resistance scale.
10. The reading should correspond with resistances indicated in test 8, page 14. If the reading varies by more
than 2 ohms, all electrical component parts will need to be individually tested to locate the fault.
11. Reconnect active cables to ”A” terminal and neutral cable to “N” terminal at heater terminal block.
12. Replace fuse. Note: If continuing with flow chart 2 of diagnostic procedure do not restore power.

TM014 Rheem Heavy Duty Electric Service Instructions REV: A
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COMPONENT REPLACEMENT
DRAINING THE WATER HEATER (PROCEDURE 1)
Elevated temperatures may be present during the draining process. Personal Protective
Equipment should be worn to prevent the risk of scalding.
Personal Protective Equipment should be worn when conducting step 3 of this procedure to
reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing.
1. Isolate the power and water supplies to the water heater.
2. Relieve pressure from the water heater through the T & PR valve or a hot tap.
3. Remove the access cover and confirm with a multi-meter between each Active and Neutral at the
terminal block that voltage is not present.
4. Disconnect the cold water supply pipe
5. Fit a drain hose to the cold-water connection and run the other end to a drain or safe location.
6. Open the temperature and pressure relief valve to allow air into the system.
TEMPERATURE AND PRESSURE RELIEF VALVE (PROCEDURE 2)
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. Isolate the power and water supplies to the water heater.
2. Relieve pressure from the water heater through the T & PR valve or a hot tap.
3. Remove the drain line from the T&PR valve.
4. Unscrew the T&PR valve and remove.
A quantity of hot water will discharge from the tank during this process. Personal Protective
Equipment should be worn to prevent scalds or burns.
5. Confirm the replacement T&PR valve is the correct rating and refit using thread tape.
6. Refit the drain line.
7. Close the hot tap and restore water supply.
8. Check T&PR valve thread for leaks.
9. Operate the T&PR valve lever to reset relief drain.
10. Purge air from the system through hot taps.
11. Restore the power supply to the water heater.