FLOWMAX 90 Instruction Manual
Instruction Manual
for model
FLOWMAX – 90
Nordgas Version
Condensing water heater
85,000 BTU
WARNING
If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury or death.
-Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance.
-WHAT TO DO IF YOU SMELL GAS
●Do not try to light any appliance.
●Do not touch any elect rica l switc h; do not use any phone in your building.
●Immediately call yo ur gas supplier fro m a neighbour’s pho ne. Fo llow the gas s upplier’s instructions.
●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.
Installation, operating, commissioning and maintenance instructions.
Water heaters for other than recreational vehicle installation
CONTENTS
Pages
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 circuit 13
2.5 Circulation pump head/flow graph 14
2.6 Printed circuit board – Technical characteristics 15
2.7 Control panel 16
3. Installation (authorized personnel)
3.1 Reference standard 18
3.2 Unpacking 19
3.3 Installing the water heater 20
3.4 Water connections 21
3.5 Domestic Hot Water Circuit/Hard Water Warning/ Condensate Drain 22
3.6 Schematic of Piping Installation 24
3.7 Gas connection 26
3.8 Electrical connections
27
3.9 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 42
5.3 Gas Data 51
CONTENTS
6. Maintenance (authorized personnel)
6.1 General warnings 52
6.2 Maintenance 52
6.3 Water heater inspection 52
6.4 Accessing the water heater 54
6.5 Flushing out the primary side 54
6.6 Draining the central heating and domestic hot water system 55
6.7 Maintenance operations 56
6.8 Wiring diagrams 63
6.9 D.H.W Sensor Connection 66
6.10 Troubleshooting 67
6.11 Diagnostics 68
6.12 Parts list 82
7. Warranty
Pages
7.1 Terms and Condition of Sale 84
7.2 Warranty Registration Form 86
7.3 Warranty Part Request Form 87
GENERAL INFORMATION
1. GENERAL INFORMATION
1.1 General warnings – Installation
Read all safety 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 outflow 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 should be located in an area where leakage within the unit or at its connections 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. When 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 flow 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 located as close as possible to a chimney 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.
1
GENERAL INFORMATION
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 install this water heater directly on a carpeted floor. A fire 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 building codes. An insufficient 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 fire 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
FLOWMAX 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 in 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 installed 18 inches or more above the floor. This may reduce the risk if location 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 shock, 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 appliance must be used solely for the purpose for 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 installation, operation and maintenance manual forms are an integral and essential part of the product and must
be kept with the appliance always.
2
GENERAL INFORMATION
The warnings contained in this chapter have been written for the appliance user, the installer and the service
technician.
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 system. 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 correct 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 appliance.
• Should there be a smell of gas present in the room where the appliance is installed, 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 casing). 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 isolator 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.).
3
GENERAL INFORMATION
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 side wall horizontal
vented gas fuelled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon
monoxide detector
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,
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”.
however, that during said 30 day period a battery operated carbon monoxide detector with alarm shall
be installed.
with an alarm and battery back-up is installed on the floor level where the gas equipment
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.
4
GENERAL INFORMATION
5
GENERAL INFORMATION
6
GENERAL INFORMATION
7
GENERAL INFORMATION
8
GENERAL INFORMATION
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 standards:
American National Standard/CSA Standard for Gas Water Heaters Volume III, Storage Water Heaters with input
Ratings above 75,000 Btu per Hour, Circulating and Instantaneous. Conforms to ANSI STD Z21.10.3, certified to CSA
STD 4.3.
The materials used such as copper, brass, stainless steel, etc. form a compact, uniform, highly functional unit that is
easy to install and simple to operate. In its simplicity, the wall-mounted appliance is equipped with all the appropriate
accessories required to make 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 inspector, and a guarantee certificate. This manual must be kept in a safe place 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 this manual or in the case where actions not specifically described herein are
undertaken.
9
GENERAL INFORMATION
Model FLOWMAX - 90
Heat Input max
kW - BTU/hr
25 – 90 000
Heat Input min
kW - BTU/hr
9 – 35 000
Heat Output max - 122/86°F
kW - BTU/hr
26.7 – 91 019
Heat Output max - 167/140°F
kW - BTU/hr
24.6 – 83 939
Heat Output min - 167/140°F
kW - BTU/hr
8.73 – 29 788
Efficiency 100% (full load 167/140°F)
%
98.4
Central Heating circuit
Central Heating water temperature setting (min-max)
°C – °F
25–40 / 30-75 - 77–104 / 86-167
Max. heating working temperature
°C – °F
75/167
Expansion vessel capacity
ltrs - gal
6 - 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
35-72 – 95-160
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
14.10 - 3.72
D.H.W. flow rate at ∆T 72°F (40°C)
l/min - gal/min
8.7 - 2.30
Dimensions (Water heater casing size)
Width
in
16.1
Height
in
28.7
Depth
in
11.2
Weight (net)
lb
84
Hydraulic connections
Central Heating Flow connection
BSPP
3/4"
Central heating Return connection
BSPP
3/4"
Cold water mains connection
BSPP
1/2"
D. Hot water connection
BSPP
1/2"
Gas connection
NPT
1/2"
Gas Supply
Natural Gas (Ng)
Inlet pressure
mbar – in wc
20 - 7
Gas consumption
m3/h - ft3/h
2.65 - 93.58
Liquid Propane (Lp)
Inlet pressure
mbar – in wc
37 – 14
Gas Consumption
m3/h - ft3/h
1.01 – 35.67
Electrical specifications
Power supply
V/Hz
120/60
Electrical power consumption
W
180
2. TECHNICAL CHARACTERISTICS
2.1 Technical data
10
4.3
5.4
6.4
11.2
5.2
28.7
HO
CWI
G
HI
HWO
1.9 3.1
4
1.2
11.2
28.7
4.4
7.3
4.4
1.9
12.3
1.9
4.1
2.7
3.2
LEGEND
HI
HEATING INLET
3/4" BSPP
HO
HEATING OUTLET
3/4" BSPP
G
GAS
1/2" BSPP
CWI
COLD WATER INLET
1/2" BSPP
HWO
HOT WATER OUTLET
1/2" BSPP
SC
CONDENSATE DRAIN
0.98 in
2.2 Dimensions
GENERAL INFORMATION
11
GENERAL INFORMATION
13
24
17
3
2
16
19
20
1
12
7
6
10
14
22
11
4
29
25
5
15
9
18
28
26
27
21
30
8
23
2.3 Internal parts of the water heater
LEGEND
1. PRIMARY CONDENSING HEAT EXCHANGER
2. PREMIX BURNER UNIT (GAS MANIFOLD + BURNER)
3. CONDENSATE DRAIN PIPE
4. IONIZATION ELECTRODE
5. IGNITION ELECTRODE
6. FAN
7. VENTURI
8. IGNITION TRANSFORMER
9. ELECTRONIC GAS VALVE
10. PRESSURE RELIEF VALVE
11. AUTOMATIC AIR VENT VALVE
12. HEATING SAFETY THERMOSTAT
13. HEATING SENSOR
14. PUMP WITH AIR VENT
15. WATER PRESSURE SWITCH
16. EXHAUST HOOD
17. SAFETY THERMOFUSE
18. EXPANSION TANK
19. D.H.W. SENSOR
20. CONDENSATE TRAP
21. WATER PRESSURE GAUGE
22. AUTOMATIC BY-PASS
23. AIR PRESSURE SWITCH
24. SYSTEM DRAIN VALVE
25. ROOM SEAL CHAMBER BACK SIDE
26. DIVERTER ACTUATOR VALVE
27. ELECTRONIC FLOWSWITCH
28. DHW EXCHANGER
29. HEATING LOOP FILL TAP
30. NO-RETURN VALVE
12
LEGEND
HI
HEATING INLET
HO
HEATING OUTLET
G
GAS
CWI
COLD WATER INLET
HWO
HOT WATER OUTLET
SC
CONDENSATE DRAIN
3
19
22
21
SC
23
25
18
17
2
16
19
5
4
6
9
20
11
10
24
14
15
27
29
28
13
1
12
7
30
32
26
HWO CWIG
31
8
HI HO
GENERAL INFORMATION
2.4 Water circuit
LEGEND
1. PRIMARY CONDENSING HEAT EXCHANGER
2. PREMIX BURNER UNIT (GAS
MANIFOLD+BURNER)
3. CONDENSATE DRAIN PIPE
4. IONIZATION ELECTRODE
5. IGNITION ELECTRODE
6. FAN
7. VENTURI
8. IGNITION TRANSFORMER
9. ELECTRONIC GAS VALVE
10. PRESSURE RELIEF VALVE
11. AUTOMATIC AIR VENT VALVE
12. HEATING SAFETY THERMOSTAT
13. HEATING SENSOR
14. PUMP WITH AIR VENT
15. WATER PRESSURE SWITCH
16. EXHAUST HOOD
17. SAFETY THERMO FUSE
18. EXPANSION TANK
19. D.H.W. SENSOR
20. CONDENSATE TRAP
21. WATER PRESSURE GAUGE
22. AUTOMATIC BY-PASS
23. CONDENSATE DRAIN PIPE
24. SYSTEM DRAIN VALVE
25. ROOM SEAL CHAMBER BACK SIDE
26. FLOW LIMITER
27. ELECTRONIC FLOWSWITCH
28. DHW EXCHANGER
29. DIVERTER ACTUATOR VALVE
30. HEATING LOOP FILL TAP
31. AIR PRESSURE SWITCH
32. NO-RETURN VALVE
13
GENERAL INFORMATION
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)
2.5 Circulation pump head/flow graph
14
GENERAL INFORMATION
2.6
DIGITECH CS MIAH4 COD.40-0007
MAIN NEWS
The new electronic board Digitech CS is now installed on all condensing boiler models, from the 13kW output
model to the 100kw output model.
At the first ignition of the boiler, the function F33 (System purging function) is enable for a period of 5 minutes;
pump is enabled while the burner ignition is disable. This cycle eliminates any residual air contained in the system.
The same function is automatically enabled every time the E04 error (no water in the system) appears
display, activated by the water pressure switch, in this case for a period of 2 minutes.
Other news:
•
•
•
•
•
Here below a list of possible settings to be performed, according to the specific need, by the authorized
personnel:
•
•
•
•
With boiler in ON position, through the INFO button “i” (Info), it is now possible to display the following
information:
•
•
•
•
•
•
The chimney-sweeper function (or test function) is enabled by keeping the button "R" (Reset) pressed for 7
seconds.
on the
White backlit LCD Display;
Improved icons graphic for an easy reading and setting of the electronic board
The electronic board manages the zone control PCB from the boiler control panel (only with zone PCB
in
stalled)
The flame presence signal is completed by the power level expressed in 3 steps.
Through the INFO button “i”, with boiler in OFF position, it is possible to display the last 5 errors (to reset
press "R " button).
technical
Central heating temperature minimum and maximum set point adjustment from min 25°C to max 88°C
(factory set as 30-80°C).
Domestic Hot water temperature minimum and maximum set point adjustment from a min. 35°C to a max
75°C (factory set at 35-60°C) ;
∆t set point flow I return (only if a modulating pump and sensor on the return circuit are installed);
Minimum and maximum speed of modulating pump (if installed);
Outdoor temperature (if the outdoor temperature sensor is installed);
Kd value of outdoor temperature sensor (if installed);
Low temperature circuit temperature (if optional CRAD board for the 2 temperature circuits is
connected);
Solar panel sensor temperature (if installed);
Solar storage cylinder sensor temperature (if installed);
Fan speed.
the
15
GENERAL INFORMATION
>33% >33%<66% >66%<100%
120v 60Hz
2.7 Control panel
Control panel Key
1.
HEATING TEMPERATURE SETTING BUTTONS
2.
INFO BUTTON: PRESS ONCE TO DISPLAY
TEMPERATURES AND INFO (see 2.8 INFO menu
display). KEEP INFO BUTTON PRESSED FOR 5
SECONDS (in OFF MODE) TO DISPLAY
LAST 5 ERRORS.
3.
MODE SELECTION BUTTON
WINTER ONLY I SUMMER-WINTER I OFF.
4.
RESET BUTTON:
FUNCTION ACTIVATION (CHIMNEY-SWEEPER
- KEEP IT PRESSED FOR 7 SECONDS).
5.
DOMESTIC HOT WATER TEMPERATURE
SETTING BUTTONS.
PRESSED FOR 5 SECONDS TO ACTIVATE
DISPLAY BACKLIT MODE FOR A
PERIOD OF 10 MINUTES.
6. TERMINAL BLOCK FOR EXTERNAL WIRING.
7.
LCD DISPLAY.
THE
SUMMER ONLY I
ERROR RESET - FLUE TEST
KEEP BUTTONS
'+'
AND '-'
CONTINUOUS
THE
LCD DISPLAY ICONS' KEY
1. PARAMETER NUMBER INFORMATION
2.
PARAMETERS PROGRAMMING MODE ON
3.
SOLAR PCB CONNECTION INFORMATION I
SOLAR PANEL TEMPERATURE DISPLAY (d6)
4.
SOLAR PUMP ON
5.
STORAGE CYLINDER LOW LEVEL
TEMPERATURE VISUALIZATION (d7)
CYLINDER HIGH LEVEL TEMPERATURE
VISUALIZATION (dB)
6. OUTDOOR TEMPERATURE SENSOR
CONNECTED I OUTDOOR SENSOR
TEMPERATURE DISPLAY (d2)
7.
TEMPERATURE I SET POINT I PARAMETER
VALUE INFORMATION
8.
OPEN THERM COMPONENTS COMMUNICATION
CONNECTED (REMOTE
MANAGEMENT CONTROL BOX)
9. W ATER LOW PRESSURE INFORMATION
10.
(*) FLAME PRESENCE ON (3 POWER STEPS)
11.
D.H.W. MODE ENABLED
12.
RESETTABLE ERROR DISPLAY
13.
OFF MODE
14.
NOT RESETTABLE ERROR DISPLAY
15.
HEATING MODE ENABLED
(*) -
10
can show 3 different power levels according to
the flame modulation
icon/power % images
During the boiler operation the display
I STORAGE
CONTROL I ZONE
of the boiler. (See flame
16
GENERAL INFORMATION
d00
DHW sensor temperature
d01
d02
d03
d04
d05
d06
d07
d08
INFO Menu display
Press the
Once pressed, the parameter number will appear on the left side of the display and the associated
parameter value will appear on the center of the display . Use “
temperature setting to scroll the list of available data.
“ ”
INFO button to display the boiler data.
”
and “ ” buttons of the heating
Press the
The list of available display data is the following:
Parameter Icon
“ ”
INFO button to exit the display mode.
Outdoor sensor temperature
Kd
Thermoregulation value
Fan speed
Low temperature circuit sensor (only with Zone PCB connected)
Heating return sensor temperature
Solar panel sensor temperature (only with Solar PCB connected)
Solar storage cylinder temperature (
Solar storage cylinder temperature (
Description
low level
high level
)
(only with Solar PCB
) (only w ith Solar PCB
17
GENERAL INFORMATION
3. INSTALLATION (authorized personnel)
3.1 Reference standard
Install in accordance with local building and electrical codes.
This appliance meets the requirements of:
American National Standard/CSA Standard for Gas Water Heaters Volume III, Storage Water Heaters with input
Ratings above 75,000 Btu per Hour, Circulating and Instantaneous Conforms to ANSI STD Z21.10.3, certified 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 codes are 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.
18
B
C
A
Fig. 1
GENERAL INFORMATION
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
floor (see fig. 1) making 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 180° while
manually supporting it from underneath
C. Lift 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
FLOWMAX 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 two-man lift;
19
GENERAL INFORMATION
MINIMUM DISTANCES [INCHES]
H
A
X
L
Y
X Y L H
24
16
00
B
A B
18 12
FLOWMAX - 90
Model
Fig. 2
Fig. 1
3.3 Installing the water heater
■ The appliance must be installed
exclusively on a flat 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 power on to give frost protection (frost
protection is active even with On/Off switch
in Off position).
■ If a water heater is installed in a closed water
supply system, such as one having a back
flow preventer in the cold water supply line,
means shall be provided to control thermal
expansion. Contact the water supplier or
local plumbing inspector on how to control
this situation.
In order to allow access to the interior of the
water heater for maintenance purposes, it is
important that the necessary clearances
indicated in figure 1 are respected. To make the
installation easier, the water heater is supplied
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 spirit level (of not less than 1” long) to
mark a horizontal line on the wall where the
water heater is to be fitted.
b. Position the top of the template along the line
drawn with the level, respecting the
distances indicated. Then mark the centres
of the positions of the two wall-plugs or
anchors. Finally, mark the positions of the
water and gas pipes.
c. Remove the template and install the supplied
bracket securely to the wall. Once the
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 the jacket cover
20
1.9
3.1
4
1.2
HI
HWO G
CWI HO
4.9
2.7
3.2
LEGEND
HI
HEATING INLET
3/4" BSPP
HO
HEATING OUTLET
3/4" BSPP
G
GAS
1/2" NPT
CWI
COLD WATER INLET
1/2" BSPP
HWO
HOT WATER OUTLET
1/2" BSPP
Fig. 1
3.4 Water connections
In order to safeguard the heat exchanger
and circulation pump, 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 unsuitable 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 hot water needs to
be drained.
Water connection tail pieces / unions are
supplied with every unit and must be
used. These are the only fittings that
must be installed on to the unit. They are
designed to be tightened on to the
appropriate male thread along with the
fiber washer.
GENERAL INFORMATION
Failure to use these tail pieces will cause
the unit to leak and will VOID the
warranty.
To prevent vibration and noise coming from the system the system, do not use pipes of reduced diameter,
short radius elbows or severe reductions in the cross sections 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 30 psi (2 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 complying 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 discharge will be conducted to a suitable place for disposal when relief
occurs and that no reducing coupling or other restriction be installed in the discharge line. The discharge line must be
installed to allow complete drainage of both the valve and the line. If this unit is installed with a separate storage
vessel, the separate vessel must have its own temperature and pressure relief valve. No valve is to be placed between
the relief valve and the tank. This valve must also comply with The Standard for Relief Valves and Automatic Shutoff
Devices for Hot Water Supply Systems. ANSI Z21.22 or CSA 4.4. If a relief valve discharges periodically, this may be
due to 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.
21
GENERAL INFORMATION
3.5 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 hardness 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 to prevent scaling or deposits in the primary 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 case 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.
22
GENERAL INFORMATION
■ 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.
■ 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
Suitable for combination water (potable) heating and space heating and not suitable for space heating
applications only.
Piping and components connected to the water heater for the space heating application shall be suitable for
use with potable water.
Toxic chemicals used for water heater treatment shall not be introduced into the potable water.
A water heater which will be used to supply potable water shall not be connected to any heating system of
component(s) previously used with nonpotable water heating appliance.
When the system requires water for the space heating at temperatures higher than required for other uses, a
means such 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 conceptual designs only. There are many design variations of the equipment
presented. Designers must add all necessary safety and auxiliary equipment to conform to Code requirement and
proper design practice. For more details, contact the manufacturer or distributors of the products.
23
GENERAL INFORMATION
3.6 Schematic of Piping Installation
24
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