Rheem Everhot 2A1050M7 Operating instructions

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Rheem Australia Pty Ltd ABN 21 098 823 511
SERVICE INSTRUCTIONS
Stainless Steel
Electric Water Heaters
TM074
Issued: November 13
Revision: AB
Issued: July 16
Rheem Stellar
Everhot
AquaMax
4A1050
2A1050
E50S
4A1080
4A1125
4A1160
4A1250
4A2250
2A1250
4A1315
4A2315
2A1315

TM074: Stainless Steel Electric Water Heater Service Instructions
REV AB Issued: 07/16
This document is stored and maintained electronically by Rheem Technical Support. All printed copies are deemed “uncontrolled”
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CONTENTS
INTRODUCTION .................................................................................................................3
SAFETY WARNING.............................................................................................................3
RHEEM & EVERHOT MODEL IDENTIFICATION...............................................................4
AQUAMAX MODEL IDENTIFICATION................................................................................4
SPECIFICATIONS...............................................................................................................5
PREVENTATIVE MAINTENANCE ......................................................................................6
OPERATION........................................................................................................................7
COMPONENTS AND THEIR FUNCTION ...........................................................................7
WIRING DIAGRAMS ...........................................................................................................8
PLUMBING DIAGRAMS......................................................................................................9
PRODUCT CHANGES ......................................................................................................11
FAULT FINDING................................................................................................................12
General Fault Finding Chart.......................................................................................14
Fault Finding Chart 1 –No Hot Water........................................................................15
Fault Finding Chart 2 –Insufficient Hot Water / Water Not Hot Enough.....................18
Fault Finding Chart 3 –Water Too Hot.......................................................................19
Fault Finding Chart 4 –Leaking Water Heater...........................................................20
Fault Finding Chart 5 –Noisy Water Heater...............................................................20
COMPONENT ADJUSTMENT PROCEDURES ................................................................25
COMPONENT REPLACEMENT PROCEDURES .............................................................26
DOCUMENT REVISION HISTORY...................................................................................29
Common Faults..............................................................................................................12
Fault Finding Charts.......................................................................................................14
Fault Finding Tests ........................................................................................................21
Electrical Insulation Testing ...........................................................................................24
Thermostat Adjustment..................................................................................................25
Draining the Water Heater (Procedure 1) ......................................................................26
Pressure & Temperature Relief Valve (Procedure 2).....................................................26
Thermostat (Procedure 3)..............................................................................................27
Element (Procedure 4)...................................................................................................27

TM074: Stainless Steel Electric Water Heater Service Instructions
REV AB Issued: 07/16
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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, Everhot or Aquamax 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 Stellar, Everhot or Aquamax SS Electric Water Heater 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) must
be worn to prevent the risk of electric shock.
Isolate power before conducting the indicated test
Hot surface or liquid. Personal Protective Clothing (PPE) must be worn to
reduce the risk of scalding.
General warning symbol. Observe the instructions accompanying the
symbol.

TM074: Stainless Steel Electric Water Heater Service Instructions
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RHEEM & EVERHOT MODEL IDENTIFICATION
All identification numbers are designed to convey detailed information about the water
heater to which it is attached.
4
A
1
250
M
5
P
Cylinder Warranty
2 –Everhot
4 –Rheem
A –Stainless Steel
Heating Units
1 –Single Heating Unit
2 –Two Heating Units
Rated Delivery
Plant of Manufacture
Heating Unit Rating
4 –1800W
5 –2400W
7 –3600W
8 –4800W
P –Lead & Plug
Model number, serial number and date of manufacture should be quoted in all correspondence.
AQUAMAX MODEL IDENTIFICATION
E
50
S
24
SS
L
Cylinder Warranty
E –Aquamax
Rated Delivery
Heating Units
S –Single Heating Unit
T –Two Heating Units
24 –2400W
36 –3600W
SS –Stainless Steel
L –Lead & Plug

TM074: Stainless Steel Electric Water Heater Service Instructions
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SPECIFICATIONS
Model
Rated Capacity
(Litres)
TPR Valve
Rating (kPa)
Max Inlet
Pressure (kPa)
Bottom T/stat
Setting (ºC)
Top T/stat
Setting (ºC)
Water Connections
With ECV
Without
ECV
Inlet
Outlet
TPR
2A1050M7
4A1050Mx
E50SxSS
50
1400
960
1120
60 ~ 80
-
RP¾/20
RP½/15
4A1080Mx
80
1400
960
1120
60 ~ 70
-
RP¾/20
RP½/15
4A1125Mx
125
1400
960
1120
60 ~ 70
-
RP¾/20
RP½/15
4A1160Mx
160
1400
960
1120
60 ~ 70
-
RP¾/20
RP½/15
2A1250M7
4A1250Mx
250
1000
680
800
60 ~ 70
-
RP¾/20
RP½/15
4A2250Mx
250
1000
680
800
60 ~ 70
60
RP¾/20
RP½/15
2A1315M7
4A1315Mx
315
1000
680
800
60 ~ 70
-
RP¾/20
RP½/15
4A2315Mx
315
1000
680
800
60 ~ 70
60
RP¾/20
RP½/15
x –Substitutes for element rating

TM074: Stainless Steel Electric Water Heater Service Instructions
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PREVENTATIVE MAINTENANCE
Annual Service
It is suggested for peak performance that the water heater be serviced annually.
1. Check for discharge from the TPR 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 24).
Major Five Year Service
It is recommended that a major five year service be conducted on the water heater.
1. Replace Temperature & Pressure Relief (TPR) valve.
2. Inspect and flush expansion control valve (if ECV fitted) and replace if required.
3. Check electric heating unit for excessive calcium build up or corrosion and replace
heating unit if required.
4. Visually check water heater for any potential problems.
5. Inspect all plumbing and electrical connections.

TM074: Stainless Steel Electric Water Heater Service Instructions
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OPERATION
Water temperature is maintained via a thermostat switching the active conductor to an
electric immersion element positioned towards the bottom of the cylinder.
When the water temperature within the cylinder falls sufficiently, the thermostat contacts
close suppling power to the element.
Once the water temperature reaches the set point of the thermostat, 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 between 80ºC and 88ºC.
COMPONENTS AND THEIR FUNCTION
Temperature and Pressure Relief (TPR) Valve: A valve designed to provide automatic
relief by discharging water in case of excessive temperature, pressure or both.
Never fit a TPR 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.
Inlet Delivery Tube (Dip Tube)
A stainless steel tube installed in the cold water inlet of the water heater cylinder to assist
with stratification.
Diffuser
A device installed in the cold water inlet of the water heater cylinder to assist with
stratification.
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 Cut Out (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 1.8, 2.4, 3.6, and 4.8 kW.

TM074: Stainless Steel Electric Water Heater Service Instructions
REV AB Issued: 07/16
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WIRING DIAGRAMS
Single Element
Twin Element

TM074: Stainless Steel Electric Water Heater Service Instructions
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PLUMBING DIAGRAMS
The following information and plumbing diagrams are provided as a guide only. For more
information refer to the relevant Installation Instructions.
Two Temperature Zone Plumbing Diagram
Circulated Flow & Return Plumbing Diagrams
For circulated hot water flow and return systems, a temperature limiting device can only be
installed on a dead leg which branches off the circulated hot water flow and return pipe.
Installing a temperature limiting device in the circulated flow and return
pipe work, or circulating tempered water from a temperature limiting device
may cause water to be delivered to ablution areas at a temperature
exceeding the requirements of AS/NZS 3500.4.

TM074: Stainless Steel Electric Water Heater Service Instructions
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Circulated Flow & Return Plumbing Diagrams (continued)

TM074: Stainless Steel Electric Water Heater Service Instructions
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PRODUCT CHANGES
There are no product changes at date of issue

TM074: Stainless Steel Electric Water Heater Service Instructions
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FAULT FINDING
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 twelve (12) litres/minute for mixed water and five (5) minutes in
duration.
3. Two (2) 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, 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.

TM074: Stainless Steel Electric Water Heater Service Instructions
REV AB Issued: 07/16
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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 five (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 not hot enough 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 then a cross connection exists.

TM074: Stainless Steel Electric Water Heater Service Instructions
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Fault Finding Charts
General Fault Finding Chart
What is complaint?
No hot water
GENERAL FAULT
FINDING CHART
1
2
3
4
5
Insufficient hot water / Water not hot enough
Water too hot
Leaking water heater
Noisy water heater
Chart
Complaint
Page
1
No hot water –Power supply fault finding
15
1.1
Electrical Insulation Fault
15
1.2
No hot water –Single element fault finding
16
1.3
No hot water –Twin element fault finding
16
1.4
No hot water –Twin element fault finding (continued)
17
2
Insufficient hot water / Water not hot enough
18
3
Water too hot
19
4
Leaking water heater
20
5
Noisy water heater
20

TM074: Stainless Steel Electric Water Heater Service Instructions
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Fault Finding Chart 1 –No Hot Water
NO HOT WATER
1
Is 240 volts present
at the terminal block
(TEST 1)
Possible failure of off peak relay
or missed signal from energy
supplier.
Continue with diagnosis to
confirm water heater is
operational.
NO
YES
Is the water heater
connected to an off
peak tariff? YES
Is the isolating switch
turned off?
NO
Restore power by turning
isolating switch on and advise
customer.
YES
Has the fuse blown at
the switchboard or
has the CB tripped?
NO
YES Conduct an electrical insulation test. Refer to the section on
‘Electrical Insulation Testing’.
Is reading below 1 mega
ohm?
1.1
YES
Isolate power and
continue fault finding NO
Fault in premises
electrical wiring. Isolate
power and continue fault
finding to confirm water
heater is operational.
NO
1.2
Electrical insulation fault
Isolate power and
continue fault finding
Fault Finding Chart 1.1
ELECTRICAL INSULATION FAULT
1.1
Is reading below 1
mega ohm? YES
NO
Replace element. Rewire fuse or
reset circuit breaker if
necessary.
Isolate power to the water
heater.
Disconnect remaining wires from
thermostat and megger between
each thermostat terminal and
earth.
Is reading below 1
mega ohm?
Replace thermostat. Rewire fuse
or reset circuit breaker if
necessary.
Check for pinched or damaged
wiring touching water heater
chassis. Rewire fuse or reset
circuit breaker if necessary.
YES
NO
Disconnect element wires from
thermostat and megger between
each element wire and earth.

TM074: Stainless Steel Electric Water Heater Service Instructions
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Fault Finding Chart 1.2
Single element model
1.2
Are the thermostat
ECO contacts
closed? (TEST 2) NO
YES
Is the element
installed in the correct
orientation? NO
YES
Install element in correct
orientation and reset ECO.
Replace thermostat.
Are the thermostat
contacts closed?
(TEST 3)
Is cylinder water temp
12ºC less than the
thermostat setting?
NO YES
Slide thermostat out from
retaining bracket and allow
thermostat base to cool
NO
Did the thermostat
contacts close?
(TEST 3)
NO
Does the element
have the correct
resistance? (TEST 4)
YES
Replace element.NO
Is the overall
resistance of the
water heater correct?
(TEST 5)
YES Locate wiring failure and repair.NO
Water heater electrically ok.
YES
YES
Fault Finding Chart 1.3
Twin element model
1.3
Are the top
thermostat ECO
contacts closed?
(TEST 6)
NO
YES
Is the top element
installed in the correct
orientation? NO
YES
Install top element in correct
orientation and reset ECO.
Replace top thermostat.
Is the top thermostats
neutral contact to the
top element closed?
(TEST 7)
NO YES
NO
YES
Does the top element
have the correct
resistance? (TEST 4)
YES
Replace top element.
NO
Is the overall
resistance of the
water heater correct?
(TEST 5)
YES Locate wiring failure and repair. NO
Water heater electrically ok.
YES
Is the bottom element
installed in the correct
orientation? Replace top thermostat.YES
Install bottom element in correct
orientation and reset ECO.
NO
1.4
NO
Is cylinder water temp
48ºC or less?
Is the top thermostats
neutral contact to the
bottom element
closed? (TEST 8)

TM074: Stainless Steel Electric Water Heater Service Instructions
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Fault Finding Chart 1.4
Twin element model
(continued)
1.4
Are the bottom
thermostat ECO
contacts closed?
(TEST 2)
NO
YES
Is the bottom element
installed in the correct
orientation? NO
YES
Install element in correct
orientation and reset ECO.
Replace bottom thermostat.
Are the bottom
thermostat contacts
closed? (TEST 3)
Is cylinder water temp
12ºC less than the
bottom thermostat
setting?
NO YES
Slide bottom thermostat
out from bracket and allow
thermostat base to cool
NO
Did the bottom
thermostat contacts
close? (TEST 3)
NO
Does the bottom
element have the
correct resistance?
(TEST 4)
YES
Replace bottom element.NO
Is the overall
resistance of the
water heater correct?
(TEST 5)
YES
Locate wiring failure and repair.NO
Water heater electrically ok.YES
YES

TM074: Stainless Steel Electric Water Heater Service Instructions
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Fault Finding Chart 2 –Insufficient Hot Water / Water Not Hot Enough
INSUFFICIENT HOT WATER / WATER NOT HOT ENOUGH
2
Has the usage pattern
changed recently? i.e.
additional appliances or
people using hot water.
YES
NO
YES
NO
Recommend a hot water usage
pattern that will suit the water
heater and the customers needs
YES
NO
Is the heater of sufficient
size for the customers
on going needs?
Refer to sizing guide. Recommend a water heater of
sufficient capacity to meet the
customers needs.
Is the water supply
pressure more than
80% of the TPR valve
rating?
Fit pressure limiting valve if not
already installed.
Existing pressure limiting valve
faulty –Replace.
Faulty TPR valve –Replace.
YES
Is the TPR valve
continuously
discharging water?
Is the correct TPR valve
fitted?
NO
Check for crossed water
connection. Replace TPR valve.
YES
Replace TPR valve with one of
the correct pressure rating.
NOTE: Do not use
reconditioned PTR valves
NO
Are there any plumbing
leaks, crossed
connections or dripping
taps?
Repair any leaks.
Isolate crossed connections.
YES
NO
Is cylinder water temp
8ºC less than the
thermostat setting? YES
NO
1.2
Has there been a recent
large draw off of hot
water?
NO
YES
Is a tempering valve
installed?
YES
Are tempering valve
filters blocked?
Check inlet diffuser is not
restricted, missing or damaged.
NO
YES
Clean or replace tempering
valve filters. Refer to
manufacturers instructions for
tempering valve.
YES
Is tempering valve outlet
water temp approx
48ºC?
NO
Replace tempering valve. Refer
to manufacturers instructions for
tempering valve.
NO
Normal Operation of tempering valve
Tempering valves are generally set to deliver water at 48 - 50ºC.
Depending on the length of pipe work and insulation to the
fixture(s), water temperature can be lower due to heat loss.
NOTE: 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.
YES
Is the element
installed in the correct
orientation?
Install element in correct
orientation.
NO
Check inlet diffuser is not
restricted, missing or damaged.
Confirm a recent large draw off of hot water has
not depleted the hot water supply temp. Allow time
for the heater to recover (Note: for models on off
peak tariffs this may not occur until the next day).
If water heater has a tempering valve installed:
Typically the hot inlet temperature to the tempering
valve must be 10º higher than the required outlet
temperature.

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Fault Finding Chart 3 –Water Too Hot
WATER TOO HOT
3
Does the temperature at
the hot tap correspond
with or near the
thermostat setting?
YES
NO
NO
YES
Normal operation.
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. To prohibit bacteria growth.
Tempering devices should be suggested as a
solution.
Is a tempering valve
installed? Faulty tempering valve. Clean filters or replace
tempering valve.
Is the temperature at the
hot tap higher than the
thermostat setting?
NO
YES
YES
Is the thermostat in
good contact with the
cylinder wall? NO
Replace thermostat.
Remove thermostat and clean any impurities
from the cylinder wall. Re-tension bracket and
refit thermostat.
Install element in correct orientation.NO
Is the element
installed in the correct
orientation?
YES

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Fault Finding Chart 4 –Leaking Water Heater
LEAKING WATER HEATER
4
Is leak from the
outlet? YES
Is leak from TPR
valve or TPR valve
fitting weld?
NO Remove TPR valve and reseal
with thread tape.
YES
NO
Redo connection to water
heater.
Replace water heater
Plumbing fitting
Outlet fitting weld
TPR valve
Replace water heaterTPR valve fitting weld
Is leak from an
element gasket or
element barrel weld?
Remove element and replace
gasket.
Replace water heater
YES
Element gasket
Element barrel weld
Is leak from the inlet?
NO
Redo connection to water heater
Replace water heater
YES
Plumbing fitting
Inlet fitting weld
Check for hot spots on the
jacket. If any are detected
conduct a pressure test.
Replace heater if pressure will
not hold.
NO
Fault Finding Chart 5 –Noisy Water Heater
NOISY WATER HEATER
5
Is noise only evident
during heating cycle? YES
NO
Check for:
(1) Mineral build up on the element
(2) Mineral or sludge build up in the cylinder.
(3) Normal expansion and contraction noises
associated with heating water.
Is noise water
hammer? YES
Is noise only evident
when water is flowing
through the water
heater?
NO
YES
NO
Refer to “Water Hammer” in “Common Faults”
section.
Check all other appliances that can generate
noise i.e. washing machine, dishwasher, ball
cocks etc.
Is noise a creaking,
cracking or popping
sound?
Cylinder contracting due to pressure release
when a hot tap is opened. This can be
accompanied by a creaking or cracking sound
from the insulation –Normal operation
YES
Is water pressure
more than 80% of
TPR valve rating?
NO
Check for faulty stop cock, non return valve or
TPR valve.
YES
Check for restrictions in pipe work, faulty
valves, loose plumbing or other appliances i.e.
washing machine or dishwasher.
Fit 600 kPa PLV if excessive
NO