AquaMAX G270VE User Manual
Owner’s Guide
and
Installation Instructions
Outdoor Domestic Mains Pressure
Gas Storage Water Heater
G270VE Series
This water heater must be installed and serviced by a qualified person.
Please leave this guide with the householder.
Warning: Upon completion of the installation and commissioning of the
water heater, leave this guide with the householder or responsible officer.
DO NOT leave this guide inside the cover of the water heater, as it may
interfere with the safe operation of the water heater or ignite when the
water heater is turned on.
Patents
This water heater may be protected by one or more patents or registered
designs in the name of Aquamax Australia Pty Ltd.
Trademarks
®
Registered trademark of Aquamax Australia Pty Ltd.
TM
Trademark of Aquamax Australia Pty Ltd.
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CONTENTS
Householder: Read the section ‘About Your Water Heater’ (pages 3 to
19). The ‘Installation’ section is intended for the installer but may be of
interest.
ABOUT YOUR WATER HEATER ................................................................ 3
Model Type ................................................................................................ 3
Lighting the Water Heater ......................................................................... 5
Shut Down Procedure ............................................................................... 8
Temperature Adjustment ........................................................................... 8
Other Important Information ...................................................................... 9
Periodic Maintenance .............................................................................. 11
Water Chemistry...................................................................................... 14
Troubleshooting ...................................................................................... 17
INSTALLATION .......................................................................................... 20
Installation Overview ............................................................................... 20
Water Supplies ........................................................................................ 23
Plumbing & Plumbing Diagrams ............................................................. 24
Plumbing Connections ......................................................................... 24
Two Temperature Zones Using a Temperature Limiting Device......... 28
Circulated Hot Water Flow & Return Systems .................................... 29
Commissioning ........................................................................................ 31
To Fill, Turn ON and Commission the Water Heater .......................... 31
Testing Inlet Gas Pressure .................................................................. 32
Draining the Water Heater ...................................................................... 35
Dimensions & Technical Data ................................................................. 36
WARRANTY ............................................................................................... 39
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Model Number
Legend
G
270
VE
NG
LP
ABOUT YOUR WATER HEATER
Product Application
This water heater is designed for use in a single family domestic dwelling
for the purpose of heating potable water. Its use in an application other
than this may shorten its life.
Warning: This water heater is only intended to be operated by persons
who have the experience or knowledge and capabilities to do so. This
water heater is not intended to be operated by persons with reduced
physical, sensory or mental capabilities i.e. the infirm, or by children.
Children should be supervised to ensure they do not interfere with the
water heater.
Model Type
This Aquamax® water heater is a 5 star permanent pilot gas storage water
heater suitable for outdoor installation only. This water heater is not to be
used as a pool heater.
Water is stored in a vitreous enamel storage cylinder and heated by a gas
burner located under the cylinder. The heat produced by the burner is
transferred to the water through the base, top and side walls of the storage
cylinder with flue baffle rings capturing heat to improve efficiency. The gas
supply to the burner is controlled by a thermostat so that the water in the
storage cylinder is heated and then maintained at a constant temperature.
Automatic safety controls are fitted to the water heater to provide safe and
efficient operation.
Model Selection Chart
Model Name
G270VE-NG G270VE-LP
Note: All models can be supplied with a ‘Hard Water Anode’. These models
have the suffix ‘HWA’ at the end of the model number.
Gas Series
Rated first hour hot water delivery in Litres
Vitreous enamel storage cylinder
Natural gas
Propane gas
G270VE
(without mixing valve)
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Mains Pressure Operation
This water heater is designed to operate at mains pressure by connecting
directly to the mains water supply. If the mains supply pressure in your area
exceeds that shown in ‘Mains Water Supply’ on page 23, a pressure
limiting valve must be fitted. The supply pressure should be greater than
350 kPa for true mains pressure operation to be achieved.
Hot Water Temperature
This water heater features a user adjustable thermostat located behind the
front access panel which controls the temperature of the stored water in
the storage cylinder. The thermostat is adjustable between 30 ~ 70°C
(factory setting approximately 60°C). Refer to ‘Temperature Adjustment’ on
page 8.
To meet the requirements of the National Plumbing Standard, the
temperature of the stored water must not be below 60°C.
Note: AS 3498 requires that a water heater provides the means to inhibit
the growth of legionella bacteria in stored potable water. This water heater
can satisfy this AS 3498 requirement provided it is operating and the
thermostat setting is set at 60°C or higher.
High Hot Water Temperature Increases the Risk of Scald Injury
Warning: This water heater can deliver water at temperatures which
can cause scalding. Always check the water temperature before use, such
as when entering a shower or filling a bath or basin, to ensure it is suitable
for the application and will not cause a scald injury. Aquamax recommends
monthly temperature checks to ensure the appropriate temperature is
maintained within the hot water heater.
Aquamax recommends, and it may also be required by regulations, that a
secondary device such as an approved temperature limiting device or antiscald water shut off valve be fitted into the hot water pipe work to the
bathroom(s) and ensuite(s) if persons living in the house require additional
safety protection from potential scalding. This will keep the hot water supply
temperature to the bathroom(s) and ensuite(s) below 50°C which will
reduce the risk of scald injury whilst still allowing hotter water (60°C+) to the
kitchen and laundry.
For new hot water installations, all sanitary outlet fixtures used primarily for
personal hygiene purpose must deliver hot water not exceeding 50°C. This
temperature limit is not mandatory for kitchen sinks and laundry tubs and
the preferable temperature setting for these outlets should be 60°C.
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To minimise scalding, especially for those people in high scald risk
categories i.e. young children, people with potentially incapacitating
medical conditions, elderly people etc, this water heater must be installed in
accordance with AS/NZS 3500.4.
For early childhood centres, primary and secondary schools, nursing
homes or similar facilities for young, aged, sick or disabled persons, please
consult your local health authority for the correct temperature setting.
Lighting the Water Heater
Safety Warnings
For your safety, read the following warnings before attempting to light the
water heater:
Warning: This water heater is designed to operate reliably and safely
as long as the operating instructions are followed exactly. You must comply
with these lighting instructions at every stage.
Warning: Ensure the water heater is filled with water and the water
supply is turned on otherwise serious damage to the storage cylinder and
water heater components may occur.
Warning: After installation and before lighting the water heater, the
qualified installer must check all gas connections for leaks. The qualified
installer must also test the gas inlet (supply) pressure and burner gas
pressure.
Warning: Use only your hand to turn the gas knob, never use tools. If
the gas knob will not turn by hand, do not try to repair it, call a qualified
service technician. Force or attempted repair may cause a fire or
dangerous situation.
Warning: Do not attempt to operate this water heater if it has been
damaged. Call a qualified service technician.
Warning: This water heater is equipped with a ‘Piezo’ push button
igniter which lights the pilot. There is no need for matches to light the water
heater. When lighting the pilot, follow these instructions exactly.
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Lighting Instructions
1. Stop. Read ‘Safety Warnings’ on
page 5.
2. Remove single screw retaining
access panel and lift out access
panel.
3. Slightly depress gas knob and rotate
fully clockwise so that the white dot
‘‘ aligns with the gas knob position
indicator on the gas control body (off
position).
4. Before lighting: Ensure there is no
smell of gas around vicinity of water
heater and burner opening. Be sure
to smell next to ground level as
some gases can settle there.
If you do not smell gas proceed to step 5.
If you do smell gas do not try to light the water heater. If the gas smell
is still present after five (5) minutes, turn off the isolation valve on the
gas supply line to the water heater, leave the area and call Aquamax
Service or a qualified service technician.
5. Depress gas knob slightly and rotate anticlockwise to the red star ‘ ’
(pilot) position.
6. Depress gas knob fully (until red star disappears below housing) and
hold in the depressed position. After twenty (20) seconds, whilst
keeping gas knob depressed, repeatedly press and release the igniter
button for up to forty (40) seconds or until the pilot flame ignites (igniter
is a red button located below and to the right of the gas control).
Warning: Keep your face clear of combustion chamber opening
while operating igniter button.
If pilot ignites, proceed to step 7.
If pilot does not ignite, release gas knob, wait five (5) minutes for any
unburnt gas to escape then begin again from the beginning of step 6.
Note: It is not possible to depress the gas knob fully if the gas control
has activated its safety shut off feature. In this case, wait five
(5) minutes for the gas control to reset (this allows for any unburnt gas
to escape).
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7. Hold gas knob in depressed position for a further twenty (20) seconds
and then release.
8. Depress gas knob slightly and rotate anticlockwise to the red line ‘l’
(ignition) position and hold in this position for five (5) seconds.
9. Release gas knob (gas knob will return to the red flame ‘ ’ (on)
position automatically) and listen for burner noise.
10. If burner ignites, proceed to step 11.
If burner fails to ignite, depress gas knob slightly and rotate gas knob
to the white dot ‘‘ (off) position. Wait five (5) minutes for any unburnt
gas to escape and then begin again from step 5.
Warning: Failure to wait five (5) minutes may result in a fire or
dangerous situation.
11. When the burner remains alight with the gas knob released, rotate
temperature adjustment dial so that ‘4’ aligns with the temperature dial
position indicator on the gas control body. This is the recommended
(and factory default) setting which will provide a water temperature of
approximately 60°C. Rotate adjusting dial past this position if a higher
temperature is required. Refer to ‘Temperature Adjustment’ on page 8
for dial position indicative temperatures.
Note: To comply with the requirements of AS 3498 and to inhibit the
growth of Legionella bacteria, the thermostat setting must be set at
60°C or higher.
Warning: Hotter water increases the risk of scald injury.
12. Replace front access panel.
The main burner will now automatically ignite when heating is required and
extinguish when the water in the storage cylinder has been heated to the
set temperature. If the main burner does not light at the selected setting,
the water may already be at the selected temperature.
Note: Never press igniter button whilst gas knob is in other than the red
star ‘ ’ (pilot) position.
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Shut Down Procedure
To view the gas control components described in this procedure refer to the
‘Lighting Instructions’ diagram on page 6.
1. Remove front access panel by following step 2 of ‘Lighting
Instructions’ on page 6.
2. Depress gas knob slightly and rotate gas knob clockwise so that the
red star ‘ ’ aligns with the gas knob position indicator on the gas
control body (pilot position). This setting will leave the pilot flame
alight, however the main burner will not be able to ignite.
Note: To reinstate the burner from the red star ‘ ’ (pilot) position,
depress gas knob slightly and rotate anticlockwise to the red line ‘l’
(ignition) position. Hold in this position for five (5) seconds then
release the gas knob. The gas knob will return to the red flame ‘ ’ (on)
position automatically and the burner will ignite when heating is
required and extinguish when the water in the storage cylinder has
been heated to the set temperature. If the main burner does not light
at the selected setting, the water may already be at the selected
temperature.
3. Replace front access panel or to completely shut down the gas
control, perform steps 4 and 5.
4. Depress gas knob slightly and rotate clockwise to the white dot ‘‘
(off) position. This setting shuts the gas control down completely.
Note: To reinstate the gas control and burner from the white dot ‘‘
(off) position, follow the ‘Lighting Instructions’ on page 6.
5. Replace front access panel.
Note: When switched back on from the red star ‘ ’ (pilot) position or white
dot ‘‘ (off) position, the water heater may take up to an hour to reheat.
Temperature Adjustment
Warning: AS 3498 requires that a water heater provides the means to
inhibit the growth of Legionella bacteria in potable water. This water heater
can satisfy this AS 3498 requirement provided it is operating and the
thermostat setting is 60°C or higher.
Thermostat Adjustment – All Models
The thermostat controls the stored water temperature.
The thermostat automatically controls the gas supply to the burner so that a
constant water temperature is maintained within the storage cylinder. The
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thermostat is fully automatic and the burner only operates when the water
in the storage cylinder requires heating. There is no need to switch the
water heater off when it is not in use, except when you are going away for
an extended period.
The temperature adjustment dial is on the front of the gas control located
behind the front access panel of the water heater (refer to the diagram in
‘Lighting Instructions’ on page 6). The adjustment dial is marked with
numerals with each number representing a temperature difference of
approximately 10°C. When aligned with the temperature dial position
indicator on the gas control body, the dial setting corresponds
approximately to the following temperatures:
Dial Setting 1 2 3 4 5
Temperature
30°C 40°C 50°C 60°C 70°C
To adjust the thermostat:
1. Remove front access panel by following step 2 of ‘Lighting
Instructions’ on page 6.
2. Rotate temperature adjustment dial anticlockwise to increase or
clockwise to decrease the stored water temperature.
Warning: Hotter water increases the risk of scald injury.
3. Replace front access panel.
Other Important Information
Going Away?
If you plan to be away from home for one or two nights, we suggest you
leave the water heater switched on. However, if you plan to stay away
more than a few nights, the gas knob can be set to the red star ‘ ’ (pilot)
position to conserve energy (follow steps 1~ 3 of ‘Shut Down Procedure’ on
page 8).
Note: When switched back on, the water heater may take up to an hour to
reheat.
Safety
This water heater is supplied with a thermostat, an over temperature cut
out, a thermocouple and a combination pressure temperature relief valve.
These devices must not be tampered with or removed. The water heater
must not be operated unless each of these devices are fitted and are in
working order.
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The Aquamax warranty may not cover faults if relief valves or other safety
devices are tampered with or if the installation is not in accordance with
these instructions.
Warning: For continued safety of this water heater, it must be installed,
operated and maintained in accordance with the Owner’s Guide and
Installation Instructions. These instructions must be read in conjunction with
all other instructions affixed to the appliance.
Warning: Do not store flammable or combustible materials near the
water heater. Flammable liquids (such as petrol), newspapers and similar
articles must be kept well away from the water heater and the flue terminal.
Warning: Do not use aerosols, stain removers and household
chemicals near the water heater whilst it is operating. Gases from some
aerosol sprays, stain removers and household chemicals are flammable
and/or become corrosive when drawn into a flame.
Warning: Do not store swimming pool chemicals, household
cleaners, etc., near the water heater.
Warning: Do not place anything in contact with the flue terminal.
Ensure the flue terminal is not obstructed in any way at any time.
How Long Will the Water Heater Last
The water heater is supported by a manufacturer’s warranty (refer to page
39). There are a number of factors that will affect the length of service the
water heater will provide. These include but are not limited to the water
chemistry, the water pressure, the water temperature (inlet and outlet) and
the water usage pattern.
Precautions
Where damage to property can occur in the event of the water heater
leaking, the water heater must be installed in a safe tray. Construction,
installation and draining of a safe tray must comply with AS/NZS 3500.4
and all local codes and regulatory authority requirements.
The water heater must be maintained in accordance with the Owner’s
Guide and Installation Instructions. Refer to ‘Periodic Maintenance’ on page
11.
If this water heater is to be used where an uninterrupted hot water supply is
necessary for your application or business, you should ensure that you
have back up redundancy within the hot water system design. This should
ensure the continuity of hot water supply in the event that this water heater
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was to become inoperable for any reason. We recommend you seek advice
from your plumber or specifier about your needs and building back up
redundancy into your hot water supply system.
Periodic Maintenance
Minor Six Monthly Maintenance
It is recommended minor maintenance be performed every six months by
the dwelling occupant.
Warning: Exercise care when operating easing levers as water
discharged from the water heater may be of a very high temperature.
Minor maintenance actions:
1. Operate easing lever on pressure temperature relief valve (refer to
‘Pressure Temperature Relief Valve’ on page 12).
2. Operate easing lever on expansion control valve (if ECV fitted) (refer
to ‘Expansion Control Valve’ on page 13).
3. If a safety tray is installed, check to ensure the safety tray drain pipe is
not blocked.
Annual Service
It is recommended an annual service be conducted on the water heater.
Servicing must be performed by a qualified person. Phone Aquamax
Service or their nearest Accredited Service Agent.
Annual service actions:
1. Inspect and flush temperature pressure relief valve.
2. Inspect and flush expansion control valve (if ECV fitted).
3. Check and if necessary adjust burner gas pressure.
4. Check piezo igniter, gas control and thermocouple condition and
operation.
5. Check operation of and clean pilot and main burner.
6. Visually check the water heater for any potential problems.
7. Inspect all plumbing, gas and electrical connections.
Note: The water heater may need to be drained during this service and
may take up to an hour to reheat the water after servicing has been
completed.
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Major Five (5) Year Service
It is recommended a major five (5) year service be conducted on the water
heater. Servicing must be performed by a qualified person. Phone
Aquamax Service or their nearest Accredited Service Agent.
Note: The five (5) year service and routine replacement of any
components, such as the relief valve(s), are not included in the Aquamax
warranty. A charge will be made for this work.
Major five (5) year service actions:
1. Replace pressure temperature relief valve.
2. Inspect and flush expansion control valve (if ECV fitted) and replace
expansion control valve if required.
3. Inspect anode and replace anode if required. If the anode is not
replaced, it should be replaced within three (3) years of this service.
Refer to ‘Anode’ on page 13.
4. Check and if necessary adjust burner gas pressure.
5. Check piezo igniter, gas control and thermocouple condition and
operation.
6. Check operation of and clean pilot and main burner.
7. Visually check the water heater for any potential problems.
8. Inspect all plumbing and gas connections.
Note: The water heater may need to be drained during this service and
may take up to an hour to reheat the water after servicing has been
completed.
Pressure Temperature Relief Valve (PTR valve)
The PTR valve is near the top of the water heater and is essential for safe
water heater operation. It is possible for the PTR valve to release a little
water through the drain line during each heating period. This occurs as the
water is heated and expands by approximately 1/50 of its volume.
Continuous leakage of water from the PTR valve and its
drain line may indicate a problem with the water heater
(refer to ‘Pressure Temperature Relief Valve Running’
on page 18).
Warning: Never block the outlet of the PTR valve
or its drain line for any reason.
Operate the easing lever on the PTR valve once every six months. It is
very important you raise and lower the lever gently.
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Warning: Exercise care when operating easing lever as water
discharged from the water heater may be of a very high temperature.
Warning: Exercise care to avoid any splashing of water, as water
discharged from the drain line will be hot. Stand clear of the drain line’s
point of discharge when operating the valve’s lever.
Danger: Failure to perform this procedure may result in the water
heater storage cylinder failing.
If water does not flow freely from the drain line when the lever is lifted, then
the water heater must be checked. Phone Aquamax Service or their
nearest Accredited Service Agent to arrange for an inspection.
The pressure temperature relief valve should be replaced at intervals not
exceeding five (5) years, or more frequently in areas where there is a high
incidence of water deposits (refer to ‘Water Chemistry’ on page 14).
Expansion Control Valve (ECV)
In many areas, including South Australia, Western Australia and scaling
water areas, an ECV is fitted to the cold water supply line to the water
heater (refer to the ‘Cold Water Supply Plumbing Arrangement’ diagram on
page 25). The ECV may discharge a small quantity of water from its drain
line during the heating period instead of the PTR valve on the water heater.
Operate the easing lever on the expansion control valve once every six
months. It is very important that you raise and lower the lever gently.
The expansion control valve should be checked for performance or
replaced at intervals not exceeding five (5) years, or more frequently in
areas where there is a high incidence of water deposits (refer to ‘Water
Chemistry’ on page 14).
Anode
The anode installed in your water heater has been designed to slowly
dissipate whilst protecting the storage cylinder. If the hot water heater is not
used for two (2) weeks or more, a quantity of hydrogen gas, which is highly
flammable, may accumulate in the water heater. To dissipate this gas
safely, it is recommended that a hot tap be turned on for several minutes or
until discharge of gas ceases. Use a sink, basin, or bath outlet, but not a
dishwasher, clothes washer or other appliance. During this procedure,
there must be no smoking, open flame, or any electrical appliances
operating nearby. If hydrogen is discharged through the tap, it will probably
make an unusual sound similar to air escaping.
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