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TM039 Rheem Water Star Service Instructions REV: A 
Date of Issue: 02/09 

This document is stored and maintained electronically by 

 

Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”

 

25 

Rheem Electric Water Heater Warranty - (Australia Only) 

 

WARRANTY CONDITIONS 

 

1.  This  warranty  is  applicable  only  to  water  heaters 

manufactured from 1

st

 June 2008. 

2.  The water heater must be installed in accordance with 

the  Rheem  water  heater  installation  instructions, 
supplied  with  the  water  heater,  and  in  accordance 
with  all  relevant  statutory  and  local  requirements  of 
the State in which the water heater is to be installed. 

3.  Where a failed component or water heater is replaced 

under  warranty,  the  balance  of  the  original  warranty 
period  will  remain  effective.  The  replaced  part  or 
water heater does not carry a new warranty.  

4.  Where  the  water  heater  is  installed  outside  the 

boundaries  of  a  metropolitan  area  as  defined  by 
Rheem or further than 25 km from a regional Rheem  
branch  office,  or  an  Accredited  Service  Agent,  the 
cost  of  transport,  insurance  and  travelling  costs 
between the nearest Rheem Accredited Service  

Agent‟s  premises  and  the  installed  site  shall  be  the 
owner‟s responsibility. 

5.  Where  the  water  heater  is  installed  in  a  position  that 

does  not  allow  safe,  ready  access,  the  cost  of 
accessing  the  site  safely,  including  the  cost  of 
additional  materials  handling  and  /  or  safety 
equipment, shall be the owne

r‟s responsibility. 

6.  The  warranty  only  applies  to  the  water  heater  and 

original 

or 

genuine 

(company) 

component 

replacement  parts  and  therefore  does  not  cover  any 
plumbing  or  electrical  parts  supplied  by  the  installer 
and  not  an  integral  part  of  the  water  heater,  e.g. 
pressure  limiting  valve;  isolation  valves;  non-return 
valves; electrical switches; pumps or fuse. 

7.  The  water  heater  must  be  sized  to  supply  the  hot 

water  demand  in  accordance  with  the  guidelines  in 
Rheem water heater literature. 

 

WARRANTY EXCLUSIONS 

 

A)

. REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE RHEEM WATER 

HEATER  WARRANTY  ,  HOWEVER  THE  FOLLOWING  EXCLUSIONS  MAY  CAUSE  THE  WATER 
HEATER WARRANTY  TO  BECOME  VOID  AND  MAY  INCUR  A  SERVICE  CHARGE  AND  /  OR  COST 
OF PARTS. 

 

1. 

Accidental  damage  to  the  water  heater  or  any 
component,  including:  Acts  of  God;  failure  due  to 
misuse;  incorrect  installation;  attempts  to  repair  the 
water  heater  other  than  by  a  Rheem  Accredited 
Service Agent or the Rheem Service Department. 

2. 

Where  it  is  found  there  is  nothing  wrong  with  the 
water  heater;  where  the  complaint  is  related  to 
excessive  discharge  from  the  temperature  and  /  or 
pressure  relief  valve  due  to  high  water  pressure; 
where  there  is  no  flow  of  hot  water  due  to  faulty 
plumbing; where water leaks are related to plumbing 
and  not  the  water  heater  or  water  heater 
components;  where  there  is  a  failure  of  gas, 
electricity  or  water  supplies;  where  the  supply  of 
gas,  electricity  or  water  does  not  comply  with 
relevant codes or acts.  

3. 

Where the water heater or water heater component 
has  failed  directly  or  indirectly  as  a  result  of: 
excessive water pressure, excessive temperature 

and / or thermal input; blocked overflow / vent drain; 
corrosive atmosphere; ice formation in the pipe work 
to or from the water heater. 

4. 

Where the water heater is located in a position that 
does  not  comply  with  the  Rheem  water  heater 
installation 

instructions 

or 

relevant 

statutory 

requirements, 

causing 

the 

need 

for 

major 

dismantling or removal of cupboards, doors or walls, 
or  use  of  special  equipment  to  bring  the  water 
heater  to  floor  or  ground  level  or  to  a  serviceable 
position. 

5. 

Repair and / or replacement to the water heater due 
to scale formation in the waterways or the effects of 
either  corrosive  water  or  water  with  a  high  chloride 
or  low  pH  level  when  the  water  heater  has  been 
connected to a scaling  or  corrosive  water supply  or 
a  water  supply  with  a  high  chloride  or  low  pH  level 
as  outlined  in  the  Owner‟s  Guide  and  Installation 
Instructions booklet.     

 

B)

  SUBJECT  TO  ANY  STATUTORY  PROVISIONS  TO  THE  CONTRARY,  THIS WARRANTY  EXCLUDES 

ANY  AND  ALL  CLAIMS  FOR  DAMAGE  TO  FURNITURE,  WALLS,  FOUNDATIONS  OR  ANY  OTHER 
CONSEQUENTIAL  LOSS  EITHER  DIRECTLY  OR  INDIRECTLY  DUE  TO  LEAKAGE  FROM  THE 
WATER  HEATER  OR  DUE  TO  LEAKAGE  FROM  FITTINGS  AND  /  OR  PIPE  WORK  OF  METAL, 
PLASTIC  OR  OTHER  MATERIALS  CAUSED  BY  WATER  TEMPERATURE,  WORKMANSHIP  OR 
OTHER MODES OF FAILURE. 

 

In addition to this warranty, the Trade Practices Act 1974 and similar laws in each state and territory provide the owner under certain 
circumstances with certain minimum statutory rights in relation to your Rheem water heater. This warranty must be read subject to that 
legislation and nothing in this warranty has the effect of excluding or restricting those rights. 

 

 

RHEEM WATER HEATERS AUSTRALIA 

RHEEM AUSTRALIA PTY. LTD. 
A.B.N 21 098 823 511 

FOR SERVICE TELEPHONE 

131 031 AUSTRALIA 

or refer local Yellow Pages  

 
NOTE:  Every  care  has  been  taken  to  ensure  accuracy  in  preparation  of  this  publication.  No  liability  can  be  accepted  for  any 
consequences, which may arise as a result of its application. 

 
 

Summary of Contents for TM039

Page 1: ... printed copies not bearing this statement in RED are deemed uncontrolled 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 ...

Page 2: ... 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 Expl...

Page 3: ...ve 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 sy...

Page 4: ...eak 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 re...

Page 5: ... 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 conti...

Page 6: ...g 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 maintai...

Page 7: ...e 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 ...

Page 8: ... 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 the...

Page 9: ...ed copies not bearing this statement in RED are deemed uncontrolled 9 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 ...

Page 10: ...g 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 li...

Page 11: ... 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 fr...

Page 12: ...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 o...

Page 13: ... 13 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 ...

Page 14: ...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 ...

Page 15: ...he 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 inl...

Page 16: ...er temperature in the cylinder 80 C NO Replace the thermostat YES YES 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 c...

Page 17: ... 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 wa...

Page 18: ...erate 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...

Page 19: ...ng the brass nut 5 Disconnect the outlet pipe from the transfer valve by undoing the 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 Temperatur...

Page 20: ...am 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 ...

Page 21: ...8 Reassemble in reverse order 9 Restore the water supply 10 Purge air from the system through hot taps and check for leaks 11 Refit front polystyrene insulation and outer jacket 12 Restore the power supply to the water heater T PR Valve Drain Connector Procedure 6 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 polystyre...

Page 22: ...fully insert and screw into the cylinder 11 Reassemble in reverse order of above 12 Restore the water supply 13 Purge air from the system through hot taps and check for leaks 14 Refit front polystyrene insulation and outer jacket 15 Conduct an electrical insulation test refer to page 18 16 Restore the power supply to the water heater Cylinder Replacement Procedure 10 1 Drain the water heater refer...

Page 23: ...m the wiring is as per the wiring diagram on page 6 6 Disconnect the wiring from the active neutral and earth connectors 7 Remove the screw from the centre of the 3 pin socket outlet and remove the bottom half of the 3 pin outlet socket 8 Remove the upper half of the 3 pin outlet socket from the water heater 9 Reassemble in reverse order of above NOTE When fitting the replacement 3 pin outlet sock...

Page 24: ... PR valve 221720 1 4 Valve connection kit 220371 19 Insulation front 090159 5 T PR valve drain pipe 220366 20 Pipe Outlet 220373 6 Nut M4 080406 21 Transfer valve 220370 7 Wiring ass earth GPO socket 080402 22 Pipe Inlet 220372 8 Wiring loom cord set 080403 23 Nut contite 220357 9 Wiring loom thermostat 080400 24 Cone fitting 220358 10 Washer flat 080405 25 Cylinder assembly unit 050032 11 Nut con...

Page 25: ...Department 2 Where it is found there is nothing wrong with the water heater where the complaint is related to excessive discharge from the temperature and or pressure relief valve due to high water pressure where there is no flow of hot water due to faulty plumbing where water leaks are related to plumbing and not the water heater or water heater components where there is a failure of gas electric...

Page 26: ...nd maintained electronically by Service All printed copies not bearing this statement in RED are deemed uncontrolled 26 Document Revision History Title Service Instructions Rheem Water Star Document Nº TM039 Revision Details of change D O I A Service Instructions issued for Rheem Water Star 2 09 ...

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