Rheem TM039 Operating instructions

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R
Rh he ee em m A Au us st tr ra al li ia a P Pt ty y L Lt td d A AB BN N 2 21 1 0 09 98 8 8 82 23 3 5 51 11 1
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
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Contents
Introduction..........................................................................................................................3
Safety Warning....................................................................................................................3
Heater Model Identification Number ....................................................................................3
Specifications.......................................................................................................................4
Preventative Maintenance ...................................................................................................4
Operation.............................................................................................................................5
Components and their Function...........................................................................................6
Wiring Diagram....................................................................................................................6
Common Faults ...................................................................................................................7
Fault Finding Chart Index.....................................................................................................8
General Fault Finding Chart.................................................................................................9
Fault Finding Chart 1 .........................................................................................................10
Fault Finding Chart 1.1 ......................................................................................................11
Fault Finding Chart 2 .........................................................................................................14
Fault Finding Chart 3 .........................................................................................................15
Fault Finding Chart 4 .........................................................................................................16
Fault Finding Chart 5 .........................................................................................................17
Fault Finding Chart 6 .........................................................................................................18
Electrical Insulation Testing...............................................................................................18
Component Replacement Procedures...............................................................................19
Exploded View...................................................................................................................24
Replacement Parts List......................................................................................................24
Rheem Electric Water Heater Warranty - (Australia Only).................................................25
Document Revision History................................................................................................26

TM039 Rheem Water Star Service Instructions REV: A
Date of Issue: 02/09
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Introduction
The information provided in these instructions is based on the water heater being installed
in accordance with the Installation Instructions provided with each water heater
Should you require further technical advice on a Rheem Water Star, contact your nearest
Rheem Australia Service Department where all genuine replacement parts are also
available.
Safety Warning
The purpose of this Service Manual is to provide sufficient information to allow a person
with the skills as required by the controlling Regulatory Authorities to carry out effective
repairs to a Rheem Water Star in the minimum of time.
Safety precautions or areas where extra care should be observed when conducting tests
outlined in this service manual are indicated by print in bold italics and/or a warning
symbol. Take care to observe the recommended procedure.
“Live” testing to be conducted. Personal Protective Clothing (PPE) shall
be worn and an RCD shall be installed between the power point and 3-pin
cord of the water heater to reduce the risk of electric shock.
Isolate power before conducting the indicated test
Hot surface or liquid. Personal Protective Clothing (PPE) shall be worn to
reduce the risk of scalding.
General warning symbol. Observe the instructions accompanying the
symbol.
If the supply cord is damaged, it must be replaced by the manufacturer or
its service agent or a similarly qualified person in order to avoid a hazard.
When handling pipe work attached to the Rheem Water Star, assume that
all pipes are carrying hot water. Personal Protective Equipment should be
worn to prevent scalds or burns.
Heater Model Identification Number
The identification number is designed to convey detailed information about the water
heater to which it is attached. The model number consists of 8 digits.
W
8
1
004
0
1
W –Water Star
8 - 70°C temperature limited
1 –Single Heating Unit
Rated Capacity in Litres
0 –Not fitted
Top Element Rating
1 –800 Watts
Bottom Element Rating
Note: Model number, serial number and date of manufacture should be quoted in all correspondence.

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Specifications
Model
Rated Capacity
(Litres)
T & PR Valve
Rating (kPa)
Maximum Inlet
Pressure (kPa)
T/stat setting
(ºC)
Water Connections
T/stat Type
Element Rating
(w)
Series
Capacity
With ECV
Without
ECV
Inlet
Outlet
T&PR
W81
004
4
1000
680
800
70
RP¾/20
RP½/15
Fixed
800
Preventative Maintenance
It is suggested for peak performance that the water heater be serviced annually.
1. Check for discharge from the T&PR valve. When the element is operating a small
discharge of water may be evident. Direct access to the valve is via the circular plastic
cover at the top of the unit. Operate the valve-easing lever to ensure the valve opens
and resets properly. Always open and close the valve gently. The T&PR valve should
be replaced at 5-yearly intervals.
2. Check for leaks at all tank fittings.
3. Check for signs of excessive corrosion on the water heater jacket.
4. Isolate power to the water heater and check all electrical connections for signs of
overheating due to poor connection.
5. Conduct an insulation test on the water heater. (Refer to page 18)

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Operation
The Rheem Water Star is designed to work in conjunction (in series) with a continuous
flow gas water heater, e.g. Rheem Continuous Flow models. It works as a booster water
heater to ensure immediate availability of hot water. As such the inlet pipe to the Rheem
Water Star is referred to as an inlet pipe, NOT a cold water pipe, as water flowing through
this pipe could have a temperature as high as 60ºC.
The Rheem Water Star is designed for use with continuous flow water heaters that have
an outlet temperature of 60°C.
Continuous flow gas water heaters pass several litres of water before the temperature
reaches a useable temperature. The Rheem Water Star stores 4 litres of water at 70°C
which is delivered immediately to the household plumbing saving on water usage each
time a hot tap is opened.
The Rheem Water Star is available in a 70ºC model only. To meet the requirements of
AS/NZS 3500.4, this model may require an additional tempering valve set at a maximum
of 50°C (depending on the application), to be installed in pipe work to ablution areas.
When a hot tap is opened, water passes through the continuous
flow gas water heater, which commences operation, into the
Rheem Water Star via a transfer valve. The hot water stored in the
cylinder (4 litres @ 70ºC) is immediately supplied to the household
plumbing (refer to Figure 1).
When the outlet temperature of the continuous flow gas water
heater (inlet temperature to the Rheem Water Star) has risen to
between 52°C and 56°C the transfer valve shuts off the water flow
to the storage cylinder and transfers the flow of hot water to the
Rheem Water Star‟s outlet pipe, effectively bypassing the Rheem
Water Star (refer to figure 2).
The water temperature in the Rheem Water Star storage cylinder is
maintained via a thermostat switching the active conductor to an
electric immersion element.
When the water temperature within the cylinder falls sufficiently the
thermostat contacts close supplying power to the element. Once the
water temperature reaches the set point of the thermostat (70°C),
the contacts open cutting power to the element.
A double pole „manual reset‟over temperature cut out is
incorporated into the thermostat to provide additional protection in
the event the controlling thermostat contacts fail. The ECO contacts
open at a water temperature of between 80ºC and 88ºC
Figure 1
Figure 2
Figure 2

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Components and their Function
Temperature and Pressure Relief Valve: A T&PR valve is designed to provide automatic
relief to the water heater by discharging water in case of excessive temperature, pressure
or both.
Never fit a T&PR Valve with a pressure rating greater than that indicated on
the product-rating label.
Over Temperature Energy Cut Out (E.C.O.): An ECO is a temperature-sensing device in
combination with the thermostat that automatically cuts off the supply of electrical energy
to prevent excessive water temperature occurring. This device will not reset automatically
but may be manually reset once temperatures have fallen to a safe level.
Thermostat: A thermostat is a device, responsive to temperature, which controls the
supply of electrical energy to the element to maintain the stored water at the required
temperature.
Heating Unit (Element): An element is a tubular device containing an electric resistance
that converts electrical energy into heat. The maximum rating of the Rheem Water Star is
800 watts.
Transfer Valve: A 3 way valve, sensitive to temperature that simultaneously opens one
outlet and closes the other transferring the direction of water flow.
Wiring Diagram

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Common Faults
When a complaint is lodged about the performance of a hot water system there are a
number of causes that should be checked and eliminated. In an attempt to pinpoint the
most likely cause it is important to discuss with the customer their reasons for the
complaint, the duration of the problem, any change in circumstances or usage and recent
weather conditions. This information in conjunction with the following listed common
complaints will assist you in locating the most likely cause. All procedures assume there is
water flowing through the water heater.
Excessive hot water usage
The complaints of insufficient hot water and no hot water can on many occasions be
attributed to hot water usage exceeding the capacity of the water heater to provide hot
water.
When first attending a call of this nature it is essential to establish the probable hot water
usage by querying the usage habits of the household and comparing this with the potential
delivery of the model water heater installed. It can then be established if the usage is
within or outside the capacity of the model. The areas to look at for excessive usage are:
1. Automatic washing machines.
2. Shower output rate exceeding 12 litres/minute for mixed water and being 5 minutes or
more, in duration.
3. Two or more showers operating at the same time.
4. Change of occupancy or number of persons increased.
5. High water pressure area. (Excessive pressure relief valve discharge).
6. Plumbing leaks.
7. Thermostat temperature setting.
8. Crossed connection.
Mixing or crossed connections
If an automatic dishwasher, washing machine, flick mixer tap, tempering valve or
thermostatic mixing valve is installed there is always the possibility that the cold water
could mix with the hot water through a faulty or incorrectly installed valve. This is referred
to as a cross connection. The complaints of insufficient hot water, water too cold or
excessive discharge from the pressure relief valve may be attributed to a cross
connection. The method of checking for a cross connection is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap. If water flow is persistent and cold a cross connection exists.
Water hammer
A water heater will not cause water hammer, however valves associated with the water
heater may be the source of the problem i.e. cold-water stopcock, non-return valve or relief
valve.
Most water hammer problems are associated with plumbing, hot and cold or appliances
i.e. solenoid valves, ballcocks, loose pipes, sharp angles in pipe work, faulty or worn valve
parts, loose tap washers or neighbouring equipment.
High water pressure areas will have more complaints of this nature and the use of a
pressure-limiting valve (PLV) to reduce the household cold-water pressure will usually
solve most problems.

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Hot water plumbing leaks
If hot water has not been used for a period of time, feeling the temperature of the hot water
line may give an indication of water flow if the pipe is warm. The method of checking for
plumbing leaks is:
1. Turn off the stopcock on the cold water supply to the water heater.
2. Open a hot tap to ensure the flow of water stops. This will confirm the stopcock is
operating correctly.
3. Turn off the hot tap.
4. Turn on the stopcock to make up the water pressure in the water heater, and then turn
the stopcock off again.
5. Wait approximately 5 minutes then do either of the following:
a. With your ear close to the stopcock turn it on slightly and listen for any water
passing. If there are any leaks, the sound of water flowing would be audible.
b. Open a hot tap while listening for any pressure release. If there is a pressure
release there will be no leaks in the plumbing system.
Discoloured water
This may be the result of discoloured water entering from the cold water mains. Check if
the cold water is also discoloured.
Fault Finding Chart Index
Fault
Chart number
Page
No hot water
1, 1.1
10, 11
High energy bill / Insufficient hot water
2
14
Leaking water heater
3
15
Water too hot
4
16
Noisy water heater
5
17
Electrical insulation test
6
18

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General Fault Finding Chart
Fault Diagnosis
Is the complaint for
no hot water?
Is the complaint for a
high energy bill or
insufficient hot water?
Is the complaint for a
leaking water heater?
Is the complaint for
water too hot?
NO
NO
NO
YES
YES
YES
1.
2.
3.
4.
5.
YES
Noisy Water Heater

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Fault Finding Chart 1
1.
Is 240 volts present at the
terminal block?
Is the isolating switch
turned off?
Is the fuse blown at the
switchboard?
Is the reading below 1
Megaohm?
Restore power and advise
customer
Possible fault in household
electrical wiring. Continue with
diagnosis to confirm water heater
is operational.
Isolate power and continue
with diagnosis procedure
Conduct an electrical
insulation test (refer to section
on insulation testing)
No hot water
Warning: Terminals may be live.
Personal Protective Equipment
must be worn.
YES
YES
NO
YES
YES
NO
Test 1
Tests 2, 3 & 4
NO
1.1 6
NO

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Fault Finding Chart 1.1
No hot water
Replace thermostat
Replace thermostat
Replace thermostat
Replace element
Locate wiring failure
and repair
Are the
thermostat ECO
contacts closed?
Are the
thermostat
contacts closed?
Is the overall
resistance of the
water heater
correct?
Does the element
have the correct
resistance?
Did the thermostat
contacts close?
Is the water in the tank at
least 6 degrees lower
than the thermostat
setting?
NO
NO
YES
NO YES
Water heater electrically OK.
Slide the thermostat out from
under the retaining clamp and
allow base to cool.
YES
Test 5
Test 6
Test 7
Test 8
NO
Test 6
NO
YES
YES
2.
YES
1.1
NO

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Component Tests 1, 5, & 6
Test 1
With the water heater plugged in and
switched on, use a multimeter on the AC
volts scale and measure between active
and neutral on the terminal block.
Normal voltage is 240 volts
Test 5
Using a multimeter on the x1 resistance
scale, measure between terminals 3 and
4 on the thermostat.
The reading should be less than 1Ω.
Test 6
Using a multimeter on the x1 resistance
scale, measure between terminals 1 and
2 on the thermostat.
The reading should be less than 1Ω.

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Component Tests 7 & 8
Test 7
Using a multimeter on the x1 resistance
scale, measure the resistance of the
element across the wires that connect to
terminals 2 and 4 of the thermostat.
Normal resistance for the element is 68-
79 ohms.
Test 8
Using a multimeter on the x1 resistance
scale, measure between active and
neutral on the terminal block.
Normal resistance when the thermostat
contacts are closed is 68 - 79 ohms

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Fault Finding Chart 2
2High energy bill/ Insufficient hot water
NO
Refer to Rheem sizing guide
Recommend a water heater
of sufficient capacity to meet
the customer‟s needs.
Fit pressure limiting valve
(PLV), if not already installed.
Replace faulty PLV. Replace
faulty T&PR valve.
Recommend a hot water
usage pattern that will suit
the water heater and the
customer‟s needs.
Check for cross water
connection. Replace the
T&PR valve (if required.).
Repair any leaks. Isolate
cross connections.
Replace the thermostat
Is the heater of
sufficient size for the
customer‟s ongoing
needs?
Has the usage
pattern changed
recently, ie.additional
appliances or people
using hot water?
Is the T&PR
valve continuously
discharging
water?
Does the cylinder
water temperature
correspond with the
thermostat setting?
Are there any plumbing
leaks,
crossed connections
or dripping taps?
Is the correct T&PR valve
fitted?
Is the water supply
pressure more than 80%
of the T&PR
valve rating?
YES NO
YES
NO
NO
NO
NO
YES
YES
Is a tempering valve
installed?
NO
YES
YES YES
Replace T&PR valve with one
with the correct pressure
rating. Do not use
reconditioned T&PR valves.
Measure the water temperature at the T&PR
valve drain by gently lifting the easing lever
Water Star OK. Possible fault
with continuous flow gas water
heater. (Refer to relevant
service instructions).
Has there been a recent
large draw off of hot
water
NO NO
Allow heater time to recoverYES
Possible fault with tempering
valve
YES
AS/NZS 3500 Part 4 only requires
fixtures used for ablution purposes to
be tempered. If practical a 2-zone
plumbing solution may be offered.
Replace the transfer valve
Is the transfer valve
allowing water to pass in
both directions?
NO
YES

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2 Zone Plumbing Option


Fault Finding Chart 3
3. Leaking Water Heater
Replace the
cylinder
Remove pipe and
replace contite
olives
Remove element
and replace
gasket
Replace the
cylinder
Remove the T&PR
valve and reseal with
thread tape
Is the
leak from or near
the top?
Is the
leak from the
element barrel
weld?
Is the
leak from the
element
gasket?
Is the
leak from the
T&PR valve?
Is the
leak from the
T&PR valve fitting
weld?
Is the
leak from the
outlet pipe?
Is the
leak from the inlet
tee weld?
YES
NO
Is the
leak from the
drain pipe?
YES
NO
NO
YES
NO
YES
YES
NO
YES
YES
NO
YES

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Fault Finding Chart 4
4Water too hot
Is the outlet water
temperature approx. 70
degrees?
Water heater operating
normally
YES
Is the thermostat in good
contact with the cylinder?
NO
Remove the thermostat, re-
tension the bracket and refit
the thermostat
Allow the water heater to
recover and re-check the
water temperature
Is the water temperature
in the cylinder > 80°C?
NO
Replace the thermostat
YESYES
NO
An external tempering valve
should be considered if concerns
surround children or elderly
occupants
Water temperature can be
measured at the T&PR
valve drain by gently lifting
the easing lever
Has the correct
continuous flow gas water
heater been installed?
Is the water temperature
in the cylinder < 80°C? NO
Fault rectified
The continuous flow gas water heater
connected to a Rheem Water Star MUST have
a maximum outlet temperature of 60 degrees
Reset the outlet
temperature of the
continuous flow water
heater or replace with a
suitable model
NO
Possible fault with
continuous flow gas water
heater. Refer to service
instructions on relevant
model for fault finding
YES
YES

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Fault Finding Chart 5
5. Noisy Water Heater
Check for:
(A) Mineral build-up on the element.
(B) Mineral or sludge build-up inm the
cylinder
(C) Normal noises associated with heating
water.
Check for faulty stop cock, non-return
valve or T&PR valve.
Refer to water hammer causes, under
Common Faults
Check all other appliances that can
generate noise, eg. washing machine,
dishwasher, etc.
Cylinder contracting due to pressure
release when hot tap is opened. This can
be accompanied by a creaking or cracking
sound from the insulation. This noise is
normal operation.
Is the
noise only evident
during the heating
cycle?
Is the
noise water hammer?
Is the
noise only evident
when water is flowing
through the water
heater?
Is the
noise a metallic
popping sound?
Is the
water pressure more
than 80% of the
T&PR valve rating?
YES
NO
NO
YES
NO
YES
NO
Check for restrictionsin pipe work, faulty
valves, loose plumbing or other
appliances, eg. Washing machine or
dishwasher. Fit a 600kPa PLV if pressure
is excessive.
YES
YES
NO

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Fault Finding Chart 6
Electrical Insulation Testing
There are three basic test procedures that should be carried out when the operation and
function of a water heater‟s electrical system is in doubt.
Test 2 - To check insulation resistance of the water heater Neutral Circuit (reading
not to be below 1 MΩ).
1. Switch off power at GPO and unplug power cord from GPO (unplug continuous
flow water heater).
2. Connect megger leads to the neutral of the water heater wiring and earth.
3. Operate megger. A reading above 1 MΩ should be obtained.
4. If a reading below 1 MΩ is indicated, all component parts will need to be individually
tested to locate the fault. Refer to flow diagram chart 6, above.
Test 3 - To check insulation resistance of the water heater Active Circuit (reading
not to be below 1 MΩ).
1. Connect megger leads to the active of the water heater wiring and earth.
2. Operate megger. A reading above 1 MΩ should be obtained.
3. If a reading below 1 MΩ is indicated, all component parts will need to be individually
tested to locate the fault. Refer to flow diagram chart 6, above.
Test 4 - To check “Continuity” of water heater electrical circuit.
1. Set megger to resistance scale or multimeter to x1 resistance scale.
2. Measure between the active and the neutral of the water heater. If a reading between
68-79 ohms is not indicated, all electrical component parts will need to be individually
tested to locate the fault.
3. Reconnect the power cord. Note: If continuing with diagnostic procedure flow
chart 1.1 do not reconnect the power cord.
6
Disconnect the remaining wires
from the thermostat and megger
between each thermostat terminal
and earth.
Check for:
Faulty 3 pin outlet socket
Pinched or damaged wiring
touching the heater chassis
Replace thermostat
Is the reading below 1
Megaohm?
Is the reading below 1
Megaohm? YES
Disconnect the wires to the
element from the thermostat and
megger between each element
wire and earth.
Replace elementYES
NO
NO
Rewire fuse or reset circuit
breaker, if necessary
Rewire fuse or reset circuit
breaker, if necessary
Electrical Insulation Test
NOTE: Unplug continuous flow water heater
prior to commencing insulation testing

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Component Replacement Procedures
Draining the Water Heater (Procedure 1)
1. Switch off power at GPO, unplug power cord from GPO and isolate the water
supply to the water heater
2. Relieve pressure from the water heater by easing the T&PR valve or through a
hot tap.
3. Disconnect the inlet water supply pipe
4. Fit a drain hose to the inlet water connection and run the other end to a drain or safe
location.
5. Open the temperature and pressure relief valve to allow air into the system.
NOTE: A small amount of water will be left in the cylinder.
Transfer Valve (Procedure 2)
1. Drain the water heater (refer to procedure 1 above)
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Disconnect the inlet pipe from the transfer valve by undoing the ¾” brass nut.
5. Disconnect the outlet pipe from the transfer valve by undoing the ¾” brass nut.
Remove the old transfer valve.
6. Fit the replacement transfer valve and assemble in reverse order.
7. Restore the water supply and check for leaks.
8. Purge air from the system through hot taps.
9. Refit the front polystyrene insulation and outer jacket.
10.Restore the power supply to the water heater.
Temperature and Pressure Relief Valve (Procedure 3)
Never fit a T&PR valve with a rating higher than that indicated on the water
heater rating plate. Do not use reconditioned T&PR valves.
1. Partially drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Disconnect the outlet pipe from the T&PR valve by undoing the ¾” brass nut.
5. Disconnect the drain line fitting from the T&PR valve
6. Unscrew the T&PR valve from the top of the cylinder.
7. Confirm the replacement T&PR valve is the correct rating and refit using thread tape.
8. Reassemble in the reverse order of above
9. Restore the water supply.
10.Check the T&PR valve thread and connections for leaks.
11.Operate the T&PR valve lever to reset relief drain.

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12.Purge air from the system through hot taps.
13.Refit the front polystyrene insulation and outer jacket.
14.Restore the power supply to the water heater.
Thermostat (Procedure 4)
1. Switch off power at GPO and unplug power cord from GPO.
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Confirm the wiring is as per the wiring diagram on page 6.
5. Disconnect the wiring to the thermostat.
6. Slide the thermostat out from under the retaining clamp.
7. Slide the replacement thermostat under the clamp ensuring the thermostat is held firmly
against the cylinder.
8. Reconnect the wiring as per the wiring diagram on page 6.
9. Check water heater internal wiring insulation for cracking.
10.Refit the front polystyrene insulation and outer jacket.
11.Conduct an electrical insulation test. Refer to page 18.
12.Restore power to the water heater.
Inlet Water Connector (Procedure 5)
1. Drain the water heater (refer to procedure 1 on page 19).
2. Remove the outer jacket screws.
3. Remove the outer jacket and front polystyrene insulation to expose the water heater.
4. Undo the brass nuts retaining the inlet pipe to the inlet fitting and the transfer valve.
5. Loosen the remaining two brass nuts retaining the transfer valve.
6. Remove the two (2) screws retaining the inlet fitting to the bottom chassis.
7. Rotate the bottom of the transfer valve towards the front of the water heater so the inlet
water pipe could be manoeuvred free.
8. Fit the replacement inlet connector into place.
9. Reassemble in reverse order of above.
10.Restore the water supply.
11.Purge air from the system through hot taps and check for leaks.
12.Refit front polystyrene insulation and outer jacket.
13.Restore the power supply to the water heater.