Rheem 874W27NF Service Manual
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Rheem 874W27NF Service Manual

27 water star. continuous flow water heater with auxiliary hot water storage tank
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SERVICE INSTRUCTIONS

Rheem 27 Water Star
Continuous Flow Water Heater with Auxiliary Hot
Water Storage Tank
TM061
First Issued: Nov 10
Revision A
Issued: Aug 13
Rheem
874W27
Service. All printed copies not bearing this statement in RED are deemed "uncontrolled"
This document is stored and maintained electronically by

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Summary of Contents for Rheem 874W27NF

  • Page 1: Service Instructions

    SERVICE INSTRUCTIONS Rheem 27 Water Star Continuous Flow Water Heater with Auxiliary Hot Water Storage Tank TM061 First Issued: Nov 10 Revision A Issued: Aug 13 Rheem 874W27 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 2: Table Of Contents

    BURNER GAS PRESSURE CHECK ................. 48 COMPONENT REPLACEMENT PROCEDURE ..............49 DOCUMENT REVISION HISTORY ................... 61 TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 3: Introduction

    AS/NZS 5601 and the Installation Instructions provided with each water heater. Should you require further technical advice on any Rheem Water Heater, contact your nearest Rheem Service Department where genuine replacement parts are also available. SAFETY WARNING...

  • Page 4: Water Heater Model Identification

    F – Frost protection fitted The model number, serial number and date of manufacture should be quoted in all correspondence. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 5: Specifications

    Maximum power consumption with heater running and anti-frost heaters energized. Maximum power consumption with element operating. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 6: Wiring Diagram

    WIRING DIAGRAM A wiring diagram is also located on the inside of the front cover panel. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 7: Preset Temperature Adjustment

    50°C the water saving function of the water heater will not operate, resulting in added energy costs and nil water saving. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service.

  • Page 8: Sequence Of Operation

    500W booster element (31) to boost the storage water temperature to 70ºC. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 9: Bypass Operation

    There are six anti-frost heaters in total. Refer to „Anti-Frost Heaters‟ on page 55 for replacement procedure. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 10: Components And Their Function

    Burner Assembly - Burner component that ignites the fuel-air mixture and provides heat for the heat exchanger. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 11 The factory set temperature range is in the vicinity of 42-46ºC. The transfer valve is not user adjustable. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 12: In-Series Gas Boosting

    50°C a separate untempered line must be provided that supplies hot water exclusively to kitchen and laundry areas (refer to diagram). TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 LEGEND Service.

  • Page 13: Maintenance Information

    X = Not detecting flame O = Is detecting flame Flame Rod 1 TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 14 5) Verify clearing of fault history by entering Maintenance Mode and check the code at location 1E; it should read -- (no record). TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 15 Operational Flow Chart Section Test Equipment A list of test equipment which will assist in conducting diagnostic procedures is provided below. This equipment is available from Rheem Service Spare Parts Department. Flame detection simulator WH0020080 Flame sensor current (uA) detection kit...

  • Page 16: Operational Flow Charts

    Igniter on P.G.F.R Valve off S.V.3 (SV3) on TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...
  • Page 17 Operational Flow Chart 2 Igniter off S.V. 3 (SV3) off S.V. 2 (SV2) on S.V. 2 (SV2) off S.V. 1 (SV1) off S.V. 1 (SV1) on G.I.S.V (SVO) off P.G.F.R Valve on P.G.F.R Valve off First ignition Flame Detected? trial? 3 seconds later S.V.
  • Page 18 Operational Flow Chart 3 Hot water tap closed Post Purge Shut Down Function Water flow sensor off G.I.S.V (SVO) off [S.V. 1-3 (SV1-3) off] P.G.F.R Valve at minimum Fan motor at minimum I.U.I off Flame current detected less than 0.1uA? 8 seconds later S.V.

  • Page 19: Error Codes

    Connection PCB. Ensure the hot and cold plumbing to the heater is not reversed. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 20 Check transfer valve, element and thermostat operation. code arrive once hot tap opened. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 21 GR6 – BK8 4 – 6VDC (Limiter Off) switch is normal. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 22: Thermistor Resistance Chart

    “Live” testing to be conducted. Personal Protective Clothing (PPE) shall be worn to reduce the risk of electric shock. Refer to Rheem Safety Procedure on electrical testing. All Molex connections only go to one location and fit one way. You do not need to force a connection.

  • Page 23: Fault Diagnosis Sequence

    Heater operation appears to be normal TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 24: Power Supply Fault-Finding

    LED1? Rectify wiring and fully insert all multi-pin connectors. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...
  • Page 25 Normal voltage is between 144V and 192V DC. Resistance should be 0 ohms. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 26: No Error Code Fault Finding

    874W Series models are not suitable for use as in-series gas boosters. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...
  • Page 27 Check for excessive wear of turbine or blockage by foreign material such as thread tape. The power must be isolated during water flow sensor removal. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 28: Error Code 11

    Replace ignition electrode. damaged? Replace ignition module. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...
  • Page 29 Clean the flame rod electrode and main burner. Replace if necessary. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...
  • Page 30 6 Blue 8 Black 8 Black TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...
  • Page 31 Normal resistance should be between 50 - 500 Normal voltage should be 1 - 100VAC. kilo-ohms. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 32: Error Code 12

    Check flame sensor positioning and wiring for breaks. Adjust or replace flame sensor or lead. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 33: Error Code 14

    TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 34: Error Code 16

    TEST 12 Replace the gas valve assembly. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 35: Error Code 24

    Refer to section on burner clear and free of debris pressure adjustment TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 36: Error Code 35

    Rectify thermistor connections. connector correctly fitted? Replace control PCB. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 37: Error Code 51

    01? Replace the control PCB. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 38: Error Code 52

    Replace the control PCB. supply. Isolate power to clear error code. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 39: Error Code 65

    TEST 23 Replace water bypass control assembly. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 40: Fault Finding Tests

    DC8 – 16V 2 White - 8 Black 2 White - 8 Black TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 41: Error Code 71

    Replace control PCB. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 42: Error Code 79

    Error Code 80 Follow the same procedure as used in Error Code 51. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 43: Error Code 82

    The appliance seems to be normal. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 44: Error Code 99

    1 Check for blockage of heat exchanger fins. This warning code is followed by failure Error Code 99. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 45: Water Saving Fault Finding

    70ºC. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 46 1 and 2 on the thermostat. The reading should be less than 1Ω. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 47 Normal resistance for the element is 110-130 ohms. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled” This document is stored and maintained electronically by...

  • Page 48: Burner Gas Pressure Check

    NOTE: If the burners extinguish or an error code appears during this procedure, release the buttons, close the hot tap, clear the error code and recommence the procedure from step 5. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service.

  • Page 49: Component Replacement Procedure

    5. Undo the two wiring harnesses to free wires and remove LED display. 6. Reassembly in reverse order of above. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 50 7. Test for gas leaks using soapy water solution. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 51 (replace gaskets if required). 8. Test for gas leaks with soapy water solution. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 52 9. Reassemble in reverse order of above. Ensure an o‟ring is fitted to each of the three connections on the water bypass control assembly. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 53 8. Reassemble in reverse order of above. Ensure turbine is correctly centred and all o‟rings are fitted. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 54 6. Disconnect the hot outlet thermistor lead from the black cable connector. 7. Reassemble in reverse order of above. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 55 5. Remove screw from the bottom left hand side of the fan housing. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 56 5. Reassemble in reverse order of above. NOTE: Ensure wiring to igniter and flame sensors is not pinched during reassembly. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 57 TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 58 10. Purge air from the system through hot taps. 11. Restore the power supply to the water heater. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 59 11. Reassemble in the reverse order of above. 12. Check the element connections for leaks. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...
  • Page 60 3. Remove hot water storage tank from rear insulation and replace. 4. Reassemble in reverse order of above. 5. Check for water leaks. TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

  • Page 61: Document Revision History

    Rheem Australia Pty Ltd ABN 21 098 823 511 TM061 Rheem 27 Water Star Service Instructions – Issued: 11/10 REV A Issued 08/13 Service. All printed copies not bearing this statement in RED are deemed “uncontrolled”...

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