Page 2 - Contents
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 1 Contents Safety Warning .......................................................................
Page 3 - Safety Warning; bold italics; Introduction; – Heavy Duty
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 2 Safety Warning The purpose of these instructions is to provide sufficient information to all...
Page 4 - Specifications
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 3 Specifications Model 621265 631265 621275 631275 With ECV 680 680 680 680 Maximum Water Supp...
Page 5 - Lighting Instructions
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 4 Lighting Instructions The water heater incorporates an automatic ignition system. Switch on ...
Page 6 - The ignition control module will enter “retry lock out”,
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 5 Retry Mode If flame is not sensed during the Ignition Activation Period (2.5 seconds) 1. The...
Page 9 - Burner Extinction Cycle Flow Chart
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 8 Burner Extinction Cycle Flow Chart Ignition module de-energized Thermostat contacts open 621...
Page 14 - Components and their Function
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 13 Components and their Function Gas Control Valve: The gas valve is a White Rodgers model 36C...
Page 15 - Temperature and Pressure Relief Valve:
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 14 Temperature and Pressure Relief Valve: A valve designed to provide automatic relief by disc...
Page 16 - re-ignition attempts, with a 5-minute delay between each attempt; Limit Thermostat
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 15 Ignition Module (All Models Except 631275 Manufactured After 09/02/05) The 50A72-298 igniti...
Page 17 - Common Faults; if the cold water is also discoloured.
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 16 Common Faults When a complaint is lodged about the performance of a hot water system there ...
Page 18 - Hot water plumbing leaks; operating correctly.; Mixing or crossed connections
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 17 Hot water plumbing leaks If hot water has not been used for a period of time, feeling the t...
Page 19 - cold; hot; water manifold must be; In Line Manifold; same size and capacity.; Back to Back Manifold
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 18 1. The cold water manifold must be designed to balance the flow to each unit i.e. each bran...
Page 20 - Fault Finding - Chart 1
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 19 Fault Finding - Chart 1 Is the thermostat display blank? Power Supply Is there power at the...
Page 21 - Component Tests 1- 3; Test 1
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 20 Component Tests 1- 3 Test 1 Components will be “live”. Personal Protective Equipment should...
Page 22 - Component Tests 4 - 6; Test 4
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 21 Component Tests 4 - 6 Test 4 60 Hot water capable of scalding may discharge from the T&...
Page 23 - Fault Finding - Chart 2
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 22 Fault Finding - Chart 2 1 Disconnect power and test ECO Is the ECO open circuit? Test 7 Is ...
Page 24 - Component Tests 7- 9; Test 7
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 23 Component Tests 7- 9 Test 7 Ensure power is isolated prior to conducting this test. Using a...
Page 27 - current setting for “C0” will be displayed. Release the buttons.
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 26 To adjust the thermostat setting and offset 1. Press the “down” button for 5 seconds. The c...
Page 28 - To adjust the maximum set point; setting for “C2” will be displayed. Release the buttons.; To adjust the “minimum set point”; setting for “C3” will be displayed. Release the buttons.; To adjust the “type of operation”; setting for “P0” will be displayed. Release the buttons.; must be
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 27 To adjust the maximum set point 1. Press and hold the “down” button and the “up” button sim...
Page 29 - setting for “P2” will be displayed. Release the buttons.
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 28 To unblock parameters 1. Press and hold the “down” button and the “up” button simultaneousl...
Page 30 - Temperature Sensor Set
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 29 Temperature Sensor Set The temperature sensor set consists of 2 NTC (negative temperature c...
Page 31 - Fault Finding – Chart 3
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 30 Fault Finding – Chart 3 2 Is the thermostat displaying an error code? EE? YES E1? AL? AH? N...
Page 32 - Ignition Module; Auto reset when fault is rectified; Steady
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 31 Ignition Module The ignition module continuously performs a self-check routine. Any time a ...
Page 34 - Using a multimeter set on the AC micro-
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 33 Component Tests 10 - 12 Test 10 Components will be “live”. Personal Protective Equipment sh...
Page 35 - It will be necessary to strip a small
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 34 Component Tests 13 – 14A Test 13 Isolate power before conducting this test. Using a multime...
Page 37 - Component Test 17; Normal resistance should be infinity.; Flashes – Active and Neutral wiring reversed; Check for incorrectly wired power point.
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 36 5 Flashes (Flame sensed with gas valve de-energised) - Chart 6 Isolate power to the heater ...
Page 39 - Note: Wiring and plug not shown for clarity
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 38 Component Tests 18 - 20 Test 18 Note: Wiring and plug not shown for clarity Isolate power b...
Page 40 - The butterfly flap is secured in the closed; Damper Closed
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 39 Flue Damper - 621275 ONLY The flue damper is screwed to the jacket top of the water heater....
Page 41 - Flue Damper Fault Finding - Chart 8
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 40 Flue Damper Fault Finding - Chart 8 Is the flue damper open? Is the flue damper fuse blown?...
Page 42 - Normal resistance is less than 1 ohm.; Components will be “live”. Personal; Remove the green cover from
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 41 Component Tests 21 - 23 Test 21 Isolate power before conducting this test Using a flat blad...
Page 43 - Component Test 24
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 42 Component Test 24 Test 24 Isolate power before conducting this test Remove the flue damper ...
Page 45 - Flue Damper - Bypass; Isolate the power and remove the 3-pin plug from the power point.
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 44 Flue Damper - Bypass In the event the flue damper has failed, and a replacement is not on h...
Page 46 - Combustion Fan, Pressure Switch and Relay - 631275 ONLY
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 45 Combustion Fan, Pressure Switch and Relay - 631275 ONLY The combustion fan, relay (models m...
Page 49 - duct and placed on a stable work area.
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 48 Component Tests 28 – 30 NOTE: In order to conduct tests 28 - 30 the fan module should be re...
Page 57 - Fluing Principals
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 56 Fluing Principals Indoor Models Reverse flow (down draught) in the flue occurs when pressur...
Page 58 - Power Fluing / Mechanical Ventilation; 4 hour Fan Operation; individual; water heater must be
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 57 Power Fluing / Mechanical Ventilation Where a fan is used to assist with the fluing (power ...
Page 60 - Component Replacement; WARNING; heater
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 59 Component Replacement WARNING H.S.I models are fitted with a 3 plug. All procedures relatin...
Page 61 - Outdoor Models; Main Burner Injector Replacement (Procedure 4); Both
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 60 Burner Replacement (Procedure 3) 1. Remove 3-pin plug from GPO & isolate gas supply to ...
Page 62 - Ignition Module Replacement (Procedure 6)
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 61 Igniter/Flame Rod replacement (Procedure 5) Use Procedure 3 (Burner Replacement) Ignition M...
Page 63 - Temperature Sensor Replacement (Procedure 9); Apply thread-sealing tape to the sheath thread and tighten
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 62 Temperature Sensor Replacement (Procedure 9) The temperature sensors must be replaced as a ...
Page 64 - Limit Thermostat Replacement (Procedure 11); Note; Relieve pressure through a hot tap or the T&PR valve.; Temperature & Pressure Relief Valve Replacement (Procedure 13)
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 63 Limit Thermostat Replacement (Procedure 11) 1. Remove 3-pin plug from GPO (note warning on ...
Page 65 - Flue Damper Assembly Replacement (Procedure 15)
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 64 Dip Tube Replacement (Procedure 14) 1. Remove 3-pin plug from GPO & isolate water suppl...
Page 69 - Item Description
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 68 Replacement Parts List – 621265 Item Description Part Number 1 Draught diverter 108113 2 Fl...
Page 72 - Burner Assembly Exploded View – 265L
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 71 Burner Assembly Exploded View – 265L 3 1 4 13 1 2 1 1 10 9 8 7 6 5 2 Replacement Burner Par...
Page 76 - Replacement Parts List – 631275 (Heater)
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 75 Replacement Parts List – 631275 (Heater) Item Description Part Number 1 Black 221914 Blue 2...
Page 77 - 31275 Exploded View – Air Duct & Flue Terminal
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 76 631275 Exploded View – Air Duct & Flue Terminal 1 28 20 21 2 9 1 2 24 26 17 9 1 8 6 5 4...
Page 79 - Burner Assembly Exploded View – 275L
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 78 Burner Assembly Exploded View – 275L 10 5 7 4 2 3 8 1 6 9 Replacement Burner Parts List – 2...
Page 80 - Gas Type Conversion Procedure; Isolate the gas and power supplies to the water heater.; test all unions with soapy
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 79 Gas Type Conversion Procedure For warehouse gas type conversions the burner operation and g...
Page 81 - 65 Gas Conversion Replacement Parts List
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 80 265 Gas Conversion Replacement Parts List Conversion components Component Component Part Nu...
Page 82 - Rheem Water Heater (Excluding Solar) Warranty; WARRANTY CONDITIONS; WARRANTY EXCLUSIONS; REPAIR AND REPLACEMENT WORK WILL BE CARRIED OUT AS SET OUT IN THE
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 81 Rheem Water Heater (Excluding Solar) Warranty - Australia Only - WARRANTY CONDITIONS 1. Thi...
Page 83 - Document Revision History; Title: - Service Instructions For Rheem Heavy Duty Gas; Details of change; Service Instructions issued for H.S.I Heavy Duty Gas models
TM011 H.S.I Heavy Duty Gas Service Instructions D.O.I: 03/06 This document is stored and maintained electronically by Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” 82 Document Revision History Title: - Service Instructions For Rheem Heavy Duty Gas Document N...