FLOWMAX 170 Instruction Manual
Installation, operating, commissioning and maintenance instructions.
Water heaters for other than recreational vehicle installation
Instruction Manual
for model
FLOWMAX - 170
Condensing water heater
174,000 BTU
WARNING
If the information in these instructions is not followed exactly, a fi re or explosion may result, causing p roperty damage, personal injury or death.
-Do not store or use gasoline or other flammable va pours and liq uids in the vicinity o f t his or any other applianc e.
-WHAT TO DO IF YOU SMELL GAS
●Do not try t o light any applia nce.
●Do not touch any elect rical switch; do not use any phone in your building.
●Immediately ca ll yo ur gas supplier from a neighbour ’s phone. Follow the gas supplie r ’s instruc tions.
●If you cannot reach your gas supplier, call the fire department.
-Installation and service must be performed by a qualified installer, service agency or the gas supplier.
CONTENTS
Pages
1. General information
1.1 General warnings 1
1.2 Product conformity 9
2. Technical characteristics
2.1 Technical data 10
2.2 Dimensions 11
2.3 Internal parts of the water heater 12
2.4 Water cir cuit 13
2.5 Circulation pump head/flow graph 14
2.6 Printed circuit board – Technical characterist ics 15
2.7 Control panel 15
3. Installation (authorized personnel)
3.1 Reference standard 16
3.2 Unpacking 17
3.3 Installation water heater 18
3.4 Fixing the water heater 19
3.5 Water connections 20
3.6 Domestic Hot Wat er Circuit/Hard W at er Warning/ Condensat e Dr ain 21
3.7 Schematic of Piping Installation 23
3.8 Gas connection 25
3.9 Electrical connections
26
3.10 Venting connections 29
4. Commissioning the appliance (authorized personnel)
4.1 General warnings 36
4.2 Filling the system 37
4.3 Flushing the system 38
4.4 Filling the condensate trap 38
4.5 Starting up the water heater 39
5. Regulating the appliance (authorized personnel)
5.1 Parameters table 40
5.2 Setting the parameters 41
5.3 Gas Data 48
5.4 Regulating the Gas Valve Offset 49
CONTENTS
Pages
6. Maintenance (authorized personnel)
6.1 General warnings 50
6.2 Maintenance 50
6.3 Water heat er inspection 50
6.4 Accessing the water heater 52
6.5 Flushing out the primary side 52
6.6 Draining the central heating and domestic hot water s ystem 53
6.7 Maintenance operations 54
6.8 Wiring diag r ams 60
6.9 D.H.W Sensor Connect ion 66
6.10 Troubleshooting 67
6.11 Diagnostics 68
6.12 Parts list 78
7. Warranty
7.1 Terms and Condition of Sale 79
7.2 Warranty Registrat ion For m 81
7.3 Warranty Parts Request Form 82
GENERAL INFORMATION
1
1. GENERAL INFORMATION
1.1 General warnings – Installation
Read all s afety warnings in the “Instruction Manual”. The additional safety issues outlined below must also be
followed completely when installing this FLOWMAX Combination Water heater.
Failure to remove or maintain the area free of combustible material, gasoline and other flammable liquids or
vapours can result in severe personal injury, death or substantial property damage.
All applicable local, state, national and provincial codes, ordinances, regulations and laws must be observed.
For installations in Massachusetts – code requires the units to be installed by a licensed plumbing or gas fitter.
The appliance cannot operate without the correct amount of air for combustion. Please make sure there is
sufficient inflow and outf low of air for ventilation; never obstruct the flow of ventilation air. Failure to provide the
proper amount of combustion air can result in a fire or explosion and cause death, serious bodily injury or
property damage.
If an external electrical source is utilized, the appliance, when installed, must be electrically grounded in
accordance with local codes or, in the absence of local codes, with the National Electrical Codes ANSI/NFPA 70
and or the CSA C22.1 Canadian Electrical Code.
Follow all local codes and/or the most recent edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in
the USA or the Natural Gas and Propane Installation Code in Canada (CAN/CSA B149.1).
This unit is designed for indoor installations. DO NOT operate this unit without the vent piping connected.
Exhaust gases must be completely expelled out of the building.
Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to
inspect the appliance and replace any part of the control system and any gas control which has been
underwater.
Be sure not to reverse the water and gas connections as this may damage the gas valves.
Water temperatures over 125⁰F can cause severe burns instantly or death from scalding. If the proposed water
heater outlet temperature is above 125⁰F, a thermostatically controlled mixing valve (or a temperature limiting
valve) for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a
licensed plumber or the local plumbing authority for further information.
The appliance s hould be located in an area where leakage within the unit or at its connecti ons will not result in
damage to the area adjacent to the appliance or to lower floors of the structure. FLOWMAX will not be
responsible for any damage resulting from leaking if adequate drainage is not provided. W hen such locations
cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the
appliance.
Do not use this combination water heater for any purpose other than water heating and space heating.
The fl ow of combustion air and ventilation to the water heater must not be obstructed. The water heater area
must be kept clear and free from combustible materials, gasoline and other flammable vapours and liquids.
If the water quality is known to be highly acidic and/or extremely hard, water treatments (ie water softeners and
filtration) are recommended to maintain full warranty. Consult the local water authority.
DO NOT over-tighten fittings, as pipe and/or fitting damage may occur causing leakage.
DO NOT install water heater where subject to vibrations.
For other than a direct vent appliance, the appliance must be loc ated as close as possible to a c himney or gas
vent.
Should overheating occur or the gas supply fails to shut off , turn the manual gas control valve to the appliance.
Contact a Service Technician immediately.
Clearance must be in accordance with the local installation codes and the requirements of the gas supplier.
GENERAL INFORMATION
2
Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of
improper operation, fire, explosion or asphyxiation.
DO NOT ins tall this water heater directly on a carpeted floor. A f ire hazard may result. The water heater shall
be installed on a metal or wood panel extending beyond the full width and depth of the water heater by at least 3
inches (76.2mm) in any direction or, if the water heater is installed in an alcove or closet, the entire floor shall be
covered by the panel.
For safe operation, an ample supply of air must be provided for proper combustion and ventilation in accordance
with the National Fuel Gas Code ANSI Z223.1/NFPA 54 National Fuel Gas Code CSA/B149.1 Natural Gas and
Propane Installation Codes or applicable provisions of the local buil ding codes. An insuffic ient supply of air may
result in a yellow, luminous burner flame, carboning or sooting of the heat exchanger, or create a risk of
asphyxiation. Do not obstruct the flow of combustion and ventilation air.
This unit is not intended to operate at gas supply pressures other than those shown on the rating plate.
Exposure to higher gas supply pressure may cause damage to gas valves, which can result in fi re or explosion.
If over-pressure has occurred, such as through improper testing of gas lines or emergency malfunction of the
supply system, the gas valves must be checked for safe operation.
A thermostatic mixing valve must be added to this system to prevent scalding, if regulated by local codes and
authorities.
Check the Rating Plate
FLOW MAX units come from the factory configured for use with natural gas. Prior to installation, check the
rating plate of the water heater to ensure the unit matches gas type, gas pressure, water pressure and electrical
supply. If the unit does not match the requirements, do not install.
Be sure the gas type and electricity voltage match the rating plate.
There is a risk i n using fuel burning appliances in rooms or areas where gasoline, other flammable liquids or
engine-driven equipment or vehicles are stored, operate or are repaired. Flammable vapours are heavy and
travel along the floor and may be ignited by the igniter or main burner flames causing fire or explosion. Some
local codes permit operation of gas appliances if ins talled 18 inches or more above the floor. This may reduce
the risk if loc ation in such an area cannot be avoided. Flammable items, pressurized containers or any other
potential fire hazardous articles must never be placed on or adjacent to the water heater. Open containers of
flammable materials should not be stored or used in the same room with the water heater.
Do not install the FLOWMAX water heater in areas with excessive high humidity.
Do not install the unit in location where there is excessive humidity, such as a bathroom, damp crawl space and
other areas with high levels of humidity. This may cause the unit to malfunction.
To avoid possible electrical s hock, DO NOT touch the internal components of the water heater or the power
cord with wet hands.
DO NOT splash excessive water on the water heater when cleaning, as they are water resistant, not water
proof.
Professionally qualified personnel in accordance with current laws and standards and in line with the
manufacturer’s instructions must install the appliance.
The commissioning of the water heater and any subsequent works carried out on the appliance must be
effected by an appropriately qualified technician.
The appl iance must be used solely for the purpose f or which it has been designed and manufactured: central
heating and domestic hot water production. Any other use is deemed as improper and as such dangerous.
Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals
caused by errors in the installation and/or use of the appliance, or through non-compliance with current local
and national standards and/or the manufacturer’s instructions.
The install ation, operation and maintenance manual forms are an integral and essential part of the product and
must be kept with the appliance always.
The warnings contained i n this chapter have been written for the appliance user, the installer and the service
technician.
GENERAL INFORMATION
3
The “operating instructions” chapter of this manual must be read carefully as it provides information on the
operation and the operating limits of the appliance.
• After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not
attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden crate, nails, staples,
plastic bags, polystyrene, etc.) must not be left within reach of children in that these items represent a potential
hazard and must be disposed of in a responsible manner.
• Before carrying out any cleaning or maintenance operations, disconnect the appliance from the mains electricity
supply by switching off at the main switch and/or any other isolating device.
• In the case of a fault and/or malfunction in the appliance, shut down the s ystem. Do not interfere with or attempt any
repairs. Call for professionally qualified technical assistance only.
• Any warranty repairs to the appliance must be carried out exclusively by the manufacturer’s authorized service
dealers using original spare parts. Non-compliance with the above requirements may compromise the safety of the
appliance and invalidate the warranty. In order to guarantee the efficiency of the appliance and its c orrect operation, it
must be serviced regularly by professionally qualified personnel in line with the manufacturer’s instructions .
• Only original accessories or optional extras (including electrical parts) must be used with the applianc e.
• Should there be a smell of gas present in the room where the appliance is i nstalled, DO NOT attempt to activate any
electric switches, telephones or any other equipment that may cause sparks. Open doors and windows immediately to
create a current of air and ventilate the room. Shut-off the main gas supply valve (at the meter), or on the cylinder in
the case of bottled gas, and call an authorized service centre.
• Do not attempt to interfere with the appliance in any way.
• As dictated by current legislation, this appliance must be installed exclusively by qualified personnel. Before
starting the water heater for the first time, make sure that it is connected to a water supply and central heating system
compatible with its performance characteristics.
• Prior to start-up, the central heating pipes should be flushed to remove any residues that could compromise the
operation of the appliance.
• The domestic power supply must be checked by a qualified electrician to ensure that it can support the maximum
power absorption of the appliance, as indicated on the appliance rating plate (positioned on the casi ng). In particular,
make sure that the cable ratings are adequate for the power absorbed.
• Do not use adapters; multiple sockets or extension leads to connect the appliance to the power supply.
• The appliance must be connected to the mains power supply through an appropriate electrical isol ator in accordance
with the current wiring regulations.
• If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified
technician.
• When the appliance is no longer required for use, switch off the main power supply, to switch all electrical
components off (circulating pump, burner, etc).
GENERAL INFORMATION
4
Important: Carbon Monoxide Detectors
Many jurisdictions require the installation of carbon monoxide detectors in building where a side wall vented fuel burning
appliance is installed. Installers must abide by local code requirements regarding the installation of CO detectors. The
use of a certified carbon monoxide detector is recommended but not required by FLOWMAX.
“In the State of Massachusetts only”
(a)For all horizontally vented gas fuelled equipment installed in every dwelling, building or structure used in whole or in
part for residential purposes, including those owned and operated by the Commonwealth and where the side wall
exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not
limited to decks and porches, the following requirements shall be satisfied:
1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the si de wall
horizontal vented gas fuelled equipment, the installing plumber or gas fitter shall observe that a hard wired
carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas
equipment is to be installed and on each additional level of the dwelling, building or structure served by the
equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed
professionals for the installation of hard wired carbon monoxide detectors.
a. In the event that the side wall horizontally vented gas fuelled equipment is installed in a crawl space
or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be
installed on the next adjacent floor level.
b. In the event that the requirements of this subdivision cannot be met at the time of completion of
installation, the owner shall have a period of 30 days to comply with the above requirements;
provided, however, that during said 30 day period a battery operated carbon monoxide detector with
alarm shall be installed.
2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in
accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS
certified.
3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building
at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the
horizontally vented gas fuelled heating appliance or equipment. The sign shall read, in print size no less than
one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.
4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fuelled equipment
shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors
and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.
GENERAL INFORMATION
5
GENERAL INFORMATION
6
GENERAL INFORMATION
7
GENERAL INFORMATION
8
GENERAL INFORMATION
9
1.2 Product conformity
All FLOWMAX water heaters are ETL certified and possess technical and functional characteristics that comply with
the following standards:
Gas fired water heaters also comply with the following directives:
American National Standard/CSA Standard for Gas Water Heaters Volume III, Storage W ater Heaters with input
Ratings above 75,000 Btu per Hour, Circulating and Instantaneous. Conform s to ANSI STD Z21.10.3, certified to
CSA STD 4.3.
The materials used suc h as copper, brass, stainless steel, etc. form a compact, homogeneous, highly functional
unit that is easy to install and simple to operate. In its simplic ity, the wall-mounted appliance is equipped with all the
appropriate accessories required to m ake it a fully independent water heater capable of satisfying domestic hot
water production and central heating needs. All water heaters are fully inspected and are accompanied by a quality
certificate, signed by the inspec tor, and a guarantee c ertific ate. T his m anual m us t be k ept in a safe plac e and must
accompany the water heater at all times.
FLOWMAX will not be held responsible for any misinterpretation of this manual resulting from the
inaccurate translation of same.
FLOWMAX will not be held responsible for the consequences in the case of non-observance of the
instructions contained in thi s manual or in the case where actions not specifically described herein are
undertaken.
TECHNICAL CHARACTERISTCS
10
2. TECHNICAL CHARACTERISTICS
2.1 Technical data
Model FLOWMAX 170
Heat Input max
kW - BTU/hr
51 - 174019
Heat Input min
kW - BTU/hr
12 – 40946
Heat Output max - 122/86°F
kW - BTU/hr
54.5 – 185859
Heat Output max - 167/140°F
kW - BTU/hr
49.9 – 170198
Heat Output min - 167/140°F
kW - BTU/hr
11.65 - 39758
Efficiency 100% (full load 167/140°F)
%
97.8
Central Heating circuit
Central Heating water temperature setting (min-max)
°C – °F
30-75 / 25-40 – 86-167 / 77-104
Max. heating working temperature
°C – °F
75/167
Expansion vessel capacity
gal
1.58
Max. working pressure (heating)
bar - psi
2.1 - 30
Min. working pressure (heating)
bar - psi
0.3 - 4.29
Domestic Hot Water circuit
D.H.W. temperature setting (min-max)
°C – °F
35-60 – 95-140
Max. Hot water working pressure
bar - psi
6 - 86
Min. Hot water working pressure
bar - psi
0.5 - 7.16
D.H.W. flow rate at ∆T 45°F (25°C)
l/min - gal/min
30 - 7.93
D.H.W. flow rate at ∆T 72°F (40°C)
l/min - gal/min
18.8 – 4.95
Dimensions (Water heater casing size)
Width
in
19.3
Height
in
27.6
Depth
in
18.5
Weight (net)
lb
120
Hydraulic connections
Central Heating Flow connection
NPT
3/4"
Central heating Return connection
NPT
3/4"
Cold water mains connection
NPT
1/2"
D. Hot water connection
NPT
3/4"
Gas connection
NPT
3/4"
Gas Supply
Natural gas G 20
Inlet pressure
mbar - psi
20 - 0.29
Gas consumption
m3/h - ft3/h
5.40 – 190.7
Electrical specifications
Power supply
V/Hz
120/60
Electrical power consumption
W
225
TECHNICAL CHARACTERISTCS
11
18.5
18.5
5.313.2
19.3
27.6
8.3
8.3
2.7
HWO G
CWI
HI
HO
2.2 Dimensions
LEGEND
HI
HEATING INTAKE
Ø 3/4"
HO
HEATING OUTLET
Ø 3/4"
G
GAS
Ø 3/4"
CWI
COLD WATER INLET
Ø 1/2"
HWO
HOT WATER OUTLET
Ø 3/4"
SC
CONDENSATE DRAIN
Ø 0.98 in
TECHNICAL CHARACTERISTCS
12
2.3 Internal parts of the wat er heater
LEGEND
1. AIR PRESSURE SWITCH
2. SAFETY THERMOFUSE
3. HEATING SENSOR
4. HEATING SAFETY THERMOSTAT
5. IONIZATION ELECTRODE
6. EXPANSION TANK
7. IGNITION TRANSFORMER
8. FLOWMAX BURNE R UNIT (GAS MANIFOLD + BURNER)
9. AUTOMATIC AIR VENT VALVE
10. FAN
11. PUMP
12. CONDENSATE TRAP
13. AIR VENT VALVE 1/4
14. SAFETY VALVE 3/4
15. D.H.W. SENSOR
16. EXHAUST HOOD
17. PRIMARY CONDENSING HEAT EXCHANGER
18. D.H.W. EXCHANGER
19. IGNITION ELECTRODE
20. VENTURI
21. DIVERTER ACTUATOR VALVE
22. ELECTRONIC GAS VALVE
23. WATER PRESSURE SWITCH
24. NO-RETURN VALVE
25. WATER PRESSURE GAUGE
26. FILLING TAP
27. ELECTRONIC FLOWSWITCH
1
2
4
5
6
7
8
9
10
11
13
14
15
16
3
12
1
3
4
13
13
17
18
19
20
21
22
23
24
25
26
21
27
23
24
TECHNICAL CHARACTERISTCS
13
2.4 Water circuit
LEGEND
1. SAFETY THERMOFUSE
2. AIR PRESSURE
SWITCH
3. HEATING SAFETY THERMOSTAT
4. HEATING SENSOR
5. FLOWMAX BURNE R UNIT (GAS MANIFOLD+BURNER)
6. P RIMARY CONDENSING HEAT EXCHANGER
7. EXPANSION VESSEL
8. FAN
9. ELECTRONIC GAS VALVE
10. AUTOMATIC AIR VENT VALVE
11. PUMP
12. AIR VENT VALVE 1/4
13. PRESSURE RELIEF VALVE
14. EXHAUST HOOD
15. IGNITION TRANSFORMER
16. IGNITION ELECTRODE
17. IONIZATION ELECTRODE
18. DIVERTER ACTUATOR VALVE
19. D.H.W. SENSOR
20. VENTURI
21. D.H.W. EXCHANGER
22. CONDENSATE TRAP
23. ELECTRONIC FLOWSWITCH
24. WATER PRESSURE SWITCH
25. CONDENSATE DRAIN PIPE
26. FLOW LIMITER
27. FILLING TAP
28. WATER PRESSURE GAUGE
29. NO-RETURN VALVE
LEGEND
HI
HEATING INTAKE
HO
HEATING OUTLET
G
GAS
CWI
COLD WATER INLET
HWO
HOT WATER OUTLET
SC
CONDENSATE DRAIN
3
6
4
11
10
9
8
14
5
1
G CWIHWO
SC
12
15
16
17
18
19
20
21
22
23
25
7
2
13
26
27
28
29
HI
TECHNICAL CHARACTERISTCS
14
2.5 Circulati on pum p he a d/flow gr a ph
Pump head
I, II, III Pump speed
Water heater
losses
I
II
III
0
5
10
15
20
25
30
0 2 4 6 8 10
Water flow (US gpm)
Head (ft)
TECHNICAL CHARACTERISTCS
15
2.6 DIGITECH® printed circ uit board – SM 20021
Technical characteristics
Adjustments possible by service personnel only
• Standard (86-167°F) / reduced (77-104°F) central heating temperature
• Water hammer prevention function
• Central Heating timer - (adjustable from 0 to 7,5 minutes)
• Central Heating pump overrun timer
• Domestic Hot Water pump overrun timer
• Minimum Gas pressure setting
• Maximum Heating Load
• D.H.W. temperature setting 95-160°F
User settings
• On/Off
• Heating Temperature setting (86-167°F) – (77-104°F)
• D.H.W. temperature setting (95-140°F) – (95-160°F)
• Summer only mode / Winter only mode / Summer + Winter mode selection
Operation/Functions display
• Lock-Out
• Water deficiency indicator
• Temperature display
When the water heater is switched off at the switch on the control panel, the word OFF appears on the
display. The D.H.W and central heating frost protec tion system, nevertheless, remain enabled. If the
water heater was previously on, it is switched off and the post-ventilation, pump overrun , circulation
pump and three-way valve inactivity protection functions are enabled.
The remote control, where fi tted, remains active and illuminated.
2.7 Control panel
LEGEND
1. ON/OFF SWITCH
2. HEATING TEMPERATURE CONTROL KNOB
3. D.H.W TEMPERATURE CONTROL KNOB.
4. D.H.W TEMPERATURE BUTTON. KEEP
PRESSED FOR 5 SECONDS TO DISPLAY
OUTSIDE TEMPERATURE (ONLY WITH
OPTIONAL OUTDOOR SENSOR)
5. SERVICE BUTTON.
6. SUMMER, WINTER OR SUMMER/WINTER
MODE SELECTION BUTTON.
7. TERMINAL BOARD FOR EXTERNAL WIRING.
8. TEMPERATURE, ERROR CODE AND
OPERATING STATUS DISPLAY
6 7543
21
8
120V 60Hz
INSTALLATION INSTRUCTIONS
16
3. INSTALLATION (authorized personnel)
3.1 Reference standard
Install in accordance with CEC and NEC. All wiring shall conform to CEC , NEC and local building and electrical
codes.
This appliance meets the requirements of:
American National Standard/CSA Standard for Gas Water Heaters Volume III, Storage W ater Heaters with input
Ratings above 75,000 Btu per Hour, Circulating and Instantaneous. Conform s to ANSI STD Z21.10.3, certif ied to
CSA STD 4.3.
Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution. It is in
the interest of the installer and safety that the law is complied with.
The manufacturer’s instructions form an integral part of the installation and should be left with the appliance but do
not over ride in anyway statutory obligations.
Installation requirements
Please refer to local and national standards in force with the Country of destination of the product.
INSTALLATION INSTRUCTIONS
17
3.2 Unpacking
■ The materials (cardboard) used for packing the appliance are fully recyclable.
■ It is recommended that the packing material is only removed prior to installing the water heater. The
manufacturer will not be held responsible for damage caused by incorrect storage of the product.
■ Packing materials (plastic bags, polystyrene, nails, etc.) must not be left within reach of children, in that
these items represent a potential hazard.
A. Place the packed appliance on the f loor
(see fig. 1) m aking sure that the "up” arrow
is facing down. Remove the staples and
open out the four flaps of the box.
B. Rotate the water heater 90° while
manually supporting it from underneath
C. Lif t the box and remove the protections.
Lift the water heater by grasping the rear
part and proceed with the installation.
STORAGE & HANDLING
Please note that prior to installation the
Radiant water heaters should be stored in
the horizontal position with no more than
three water heaters to a stack;
Ensure that the water heaters are stored in
dry conditions and be aware that the carton
is a tow-man lift;
B
C
A
Fig. 1
INSTALLATION INSTRUCTIONS
18
3.3 Installing the water heater
The appliance must be installed
exclusively on a vertical solid wall capable
of supporting its weight. The
water heater should be fitted within the
building unless otherwise protected by a
suitable enclosure i.e. garage or
outhouse. (The water heater may be fitted
inside a cupboard)
■ If the water heater is sited in an
unheated enclosure then it is
recommended to leave the ON/OFF
switch always in ON position to give
frost protection.
In order to allow access to the interior of
the water heater for maintenance
purposes, it is important that the
minimum
distances
indicated in figure 2 are
respected
. To make the installation
easier, the water heater is s upplied with a
template to enable the pipe connections
to be positioned prior to fixing the
appliance to the wall.
To install the water heater, proceed as follows (see fig. 2):
a. Use a s pirit level (of not less than 25 m m long) to m ark a horizontal line on the wall where the water heater is to
be fitted.
b. Position the top of the tem plate along the line drawn with the level, respecting the distances indicated. Then
mark the centr es of the positions of the two wall-plugs or anchor s. Finally, mark the positions of the water and
gas pipes.
c. Rem ove the template and install the supplied bracket sec urely to the wall. Once the water heater is securely
installed, connect the domestic hot and cold water pipes, the gas supply pipe and the central heating pipes
using the fittings supplied with the water heater.
d. Clearance to Combustibles-
Front –0 inches
Sides – 0 inches
Rear – 0 inches
Top – 0 inches from jacket cover
MINIMUM DISTANCE [INCHES]
H
A
X
L
Y
X Y L H
24200
FLOWMAX-170
B
A B
12 12
0
Model
Fig. 2
INSTALLATION INSTRUCTIONS
19
3.4 Fixing the water heater to wall
1
2
3
Instructions as follows:
1) Fix the external part of mounting bracket to wall using proper screw anchors.
2) Insert the inner guide of mounting bracket
3) Hang the water heater onto the opposite hooks.
INSTALLATION INSTRUCTIONS
20
G
CWI
4.3 2.75 3.85
4.4
1.25
4.3 3.25 3.25
HWO
HI
HO
3.5 Water connecti ons
In order to safeguard the heat exchanger
and circulation pum p, especially in case
of water heater replacement, it is
recommended that the system is hotflushed to remove any impurities
(especially oil and grease) from the pipes
and radiators.
Make sure that the domestic water and
central heating pipes are not used to
ground the electrical system. The pipes
are totally unsuitab le for this purpose.
Isolation Valves must be installed on the
heating and D.H.W circuits. This will
facilitate all maintenance and service
operations where the water heater needs
to be drained.
■ To prevent vibration and noise coming from
the system, do not use pipes of reduced
diameter, short radius elbows or severe
reductions in the cross sec tions of the water
passages.
In order to guarantee the reliability of the
water heater and prevent permanent damage
in areas with high water inlet pressure too, a
36.3 psi (2.5 bar) pressure reducing valve
should be fitted.
■ The water flowing out of the pressure/relief
valve during its operation may be extremely
hot. Before operating relief valve, make sure
drain line is installed to direct discharge to a
safe location such as an open drain. Avoid
scalding and/or water damage.
A pressure relief valve is installed in this dual purpose water heater that is rated in accordance with and com plying
with either The Standard for relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI
Z21.22 CSA 4.4 Code.
The relief valve must be installed such that the dis charge will be conducted to a suitable place for disposal when
relief occurs and that no reducing coupling or other restriction be installed in the dischar ge line. The discharge line
must be installed to allow complete drainage of both the valve and the line. If this unit is inst alled with a separate
storage vessel, the separate vessel must have its own temperature and pressure r elief valve. No valve is to be
placed between the relief valve and the tank. This valve must also com ply with The Standard for Relief Valves and
Automatic Shutoff Devices for Hot W ater Supply Sys tems. ANSI Z21.22 or CSA 4.4. If a relief valve discharges
periodically, this may be due to the thermal expansion in a closed water system.
Contact the water supplier or local plumbing inspector on how to correct this situation. Do not unplug relief valve.
LEGEND
HI
HEATING INTAKE
Ø 3/4
HO
HEATING OUTLET
Ø 3/4
G
GAS
Ø 3/4
CWI
COLD WATER INLET
Ø 1/2
HWO
HOT WATER OUTLET
Ø 3/4
Fig. 1
INSTALLATION INSTRUCTIONS
21
3.6 Domestic hot water circuit/ Condensate Drain
Warning/ Hard Water
If this water heater is installed in an application where the supply water is hard, it must be treated with either
a water softener and filtration, which removes the hardness, or by using sequestering agents that reduce
the amount of scale deposits.
Damage to the water heater as a result of water in excess of 14.5 gpg (250mg/L) of hardness is not
covered by FLOWMAX Limited warranty. If there a problem with the water quality, contact your local water
conditioning company for equipment to condition the water supply to this appliance
The cold water supply pressure at the inlet to the water heater must be between 7.25 psi (0.5 bar) and 87 psi
(6 bar).
In areas with higher water inlet pressure a pressure reducing valve must be fitted before the water heater.
The frequency of the heat exchanger coil cleaning depends on the har dness of the mains water supply and the
presence of residual solids or impurities, which are often present in the case of a new installation. If the
characteristics of the mains water supply are such that require it to be treated, then the appropriate treatment
devices must be installed, while in the case of residues, an in-line filter should be sufficient.
Central heating circuit
In order t o prevent scaling or deposits in the primar y heat exchanger, the mains supply water to the heating circuit
must be treated according to the requirements of local standards.
This treatment is indispensable in the c ase where the circuit is frequently topped-up or when the system is often
either partially or fully drained.
Condensate Drain
■ FLOWMAX water heater is a high efficient gas appliance that creates condensation when it operates. A
condensate trap and flexible drain pipe comes factory installed inside each water tank.
The condensate trap must be primed before operation to prevent exhaust gases from entering the building.
■ Follow your local code with regards to the disposal of condensation
■ Here are several options for disposal of condensate
o From combination water heater direct to drain
o From combination water heater to neutralizer to drain
o From combination water heater to laundry tub (bottom of water heater must be above the height of
the laundry tub; must have a negative slope to properly drain)
o From combination water heater to condensate pump to laundry tub (for long distances between
water heater and laundry tub or when bottom of the water heater is installed below height of the
laundry tub)
■ Failure to install the condensate discharge properly will affect the reliability of the water heater.
For all units installed with vertical exhaust, must have an additional approved condensate drain. Fittings
must be ULC S636 approved.
Failure to properly connect the condensate line will cause combustion gases to enter the room, possibly
causing serious injury to occupants or death.
Note: Check with your municipality, local codes, or local gas company to determine if disposal of
combustion condensate is permitted. In the State of Massachusetts the condensate must be
neutralized prior to entering a drain
■ Use only PVC, Vinyl or CPVC pipe for the condensate drain line, metal pipe work is not suitable for
condensate discharge system.
■ The condensate drain line should be a minimum of 1/2” diameter that connects to the 7/8” supplied hose
and must be supported to prevent sagging. Manufacturer will supply a ¾” to ½” reducer for connection.
■ Keep the length of the condensate drain as short as possible. Long runs or applications where the nearest
drain is above the water heater will require the use of a condensate pump. Size the pump to allow for a
maximum condensate discharge of 2 gpm from the water heater. The end drain pipe must not be
submerged in water or blocked in any way.
INSTALLATION INSTRUCTIONS
22
■ The condensate pump must be installed with an overflow safety switch that detects downstream clogs and
shuts off the water heater before flooding occurs. See condensate pump manufacture for installation
instructions.
■ Be sure to check that condensate is freely flowing from the drain piping after the system has been installed.
Condensate will begin flowing out of the water heater within 15 minutes after operation has started.
■ Do not run condensate line outside and take measures to prevent the condensate drain lines from freezing
(insulation, heat tape, electric heaters, etc.)
■ Be sure to clean the condensate trap at least once per year to prevent any problems, and after cleaning be
sure to check for any leaks of condensed water or flue gas.
Space Heating
This water heater is suitable for water (potable) heating and space heating.
Piping and components connected to the water heater f or t he spac e heating application s hall be suitable for
use with potable water.
Toxic chem icals, such as used for water heater treatm ent, shall not be introduced into the potable water
used for space heating.
A water heater which will be us ed to supply potable water shall not be connected to any heating system of
component(s) previously used with nonpotable water heating appliance.
W hen the system requires water for the space heating at temperat ures higher than r equired for other uses ,
a means suc h as a mixing valve shall be installed to temper the water for those uses in order to reduce
scald hazard potential.
The water heater can be used for potable hot water heating and combination space heating applications.
Note: the following illustrations are c onc eptual designs only. There are many design variations of the equipment
presented. Designers m ust add all necessary saf ety and auxiliary equipment to conform to Code requirement
and proper design practice. For more details, contact the manufacturer or distributors of the products.
INSTALLATION INSTRUCTIONS
23
3.6 Schematic of Piping Installation
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