Vulcan-Hart 244 series, 627, 244 627 Owner's Manual And Installation Instructions
This water heater must be installed and serviced by a qualified person.
Please leave this guide with the householder.
Owner’s Guide
and
Installation Instructions
Continuous Flow
Gas Water Heater
244 series
627 models
PATENTS
This water heater may be protected by one or more patents or registered designs in the name of
Rheem Australia Pty Ltd or Paloma Co., Ltd.
Rheem Australia Pty Ltd is the supplier of the Vulcan range of continuous flow gas water heaters,
manufactured by Paloma Co., Ltd., a world leader in water heater technology and manufacture.
TRADEMARKS
®
Registered trademark of Rheem Australia Pty Ltd.
™ Trademark of Rheem Australia Pty Ltd.
Note: Every care has been taken to ensure accuracy in preparation of this publication.
No liability can be accepted for any consequences, which may arise as a result of its application.
Warning: Upon completion of the installation and commissioning of the water heater, leave this guide
with the householder or a responsible officer. DO NOT leave this guide inside of 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.
3
CONTENTS
HOUSEHOLDER - We recommend you read pages 4 to 13.
The other pages are intended for the installer but may be of interest.
About Your Water Heater ............................................................................................................ 4
Water Supplies ........................................................................................................................... 10
Save A Service Call ................................................................................................................... 11
Installation – Water Heater ....................................................................................................... 14
Connections – Plumbing .......................................................................................................... 22
Connections – Electrical ........................................................................................................... 24
Commissioning .......................................................................................................................... 25
Draining The Water Heater ....................................................................................................... 30
Warranty ..................................................................................................................................... 31
4
ABOUT YOUR WATER HEATER
WATER HEATER 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.
MODEL TYPE
The Vulcan® continuous flow water heater model you have chosen is for outdoor installation only.
This water heater has been installed as an in-series gas booster to a solar water heater. For information
relating to the function and operation of the solar water heater, refer to the Owner‟s Guide and Installation
Instructions supplied with the solar water heater.
MAINS PRESSURE
The water heater is designed for direct connection to the mains water
supply. If the mains supply pressure in your area exceeds that shown on
page 16, a pressure limiting valve must be fitted. The supply pressure
should be greater than 140 kPa for the rated flow and performance to be
achieved.
WATER HEATER OPERATION
The water heater operates automatically if heating of the water is required.
When a hot tap is opened and the solar heated water temperature is below
58°C, the gas burners ignite to provide immediate heating of the water to
its preset outlet temperature setting as the water passes through the water
heater. The heat produced by the burner is transferred to the water through
the heat exchanger. The water is heated to a constant temperature by the
automatic adjustment of the gas supply to the burner to suit the water flow
rate. The gas burners extinguish when the hot tap is closed.
Automatic safety controls are fitted to the water heater to provide safe and
efficient operation.
REDUCED HOT WATER FLOW WHEN HEAT EXCHANGER IS COLD
At a cold start-up, i.e. when the water heater has not operated for some time (which is most often first thing
in the morning), the initial flow of hot water may be reduced for a period of 5-10 seconds while the heat
exchanger warms up. This is both an energy and water saving feature of this water heater. Once the
heat exchanger has warmed up the hot water flow will increase and remain at normal flow levels. This
feature will only occur at a cold start-up and not when the heat exchanger is already warm from a recent use
of hot water.
GAS BOOSTING FOR A SOLAR WATER HEATER
Water stored in the solar storage tank passes through the in-series gas booster when a hot tap is opened.
The in-series gas booster is for heating water at times of low solar energy gain, such as during cloudy or
rainy weather, or during colder months.
Solar heated water can reach temperatures up to 70°C to 80°C for a Vulcan solar direct or indirect pumped
system and possibly higher for some other models of solar water heaters. The in-series gas booster operates
automatically. When the solar heated water temperature is 58°C or higher, the flow passes through the inseries gas booster without boosting. When the solar heated water temperature is below 58°C, the in-series
gas booster heats the water to its preset outlet temperature setting.
ABOUT YOUR WATER HEATER
5
HOW HOT SHOULD THE WATER BE?
The solar water heater will deliver water at temperatures up to 70°C to
80°C for a Vulcan solar direct or indirect pumped system and possibly
higher for some other models of solar water heaters.
During periods of low solar energy gain, the in-series gas booster will boost
the water temperature automatically to its preset outlet temperature setting.
The factory preset outlet temperature setting is 60°C.
Note: The preset outlet temperature setting of this water heater cannot be
adjusted by the householder. The setting can only be adjusted by the
installer, Rheem Service or their nearest Accredited Service Agent.
Note: AS 3498 requires that a water heater provides the means to inhibit
the growth of Legionella bacteria in potable water. When this water heater
is used as an in-series booster for a solar water heater it can satisfy this
AS 3498 requirement provided it is energised, the booster preset outlet
temperature setting is 70°C or higher, and that a remote temperature
controller is not used.
Warning: Temperature controllers must not be fitted to this water heater as part of a solar water heater
system because water at a temperature much higher than the controller setting can be delivered.
HOTTER WATER INCREASES THE RISK OF SCALD INJURY
This water heater can deliver water at temperatures which can cause scalding. 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 scald injury.
We recommend and it may be required by regulations that an approved temperature limiting device be fitted
into the hot water piping to the bathroom and ensuite when this water heater is installed. This will keep the
water temperature below 50°C at the bathroom and ensuite. The risk of scald injury will be reduced and still
allow hotter water to the kitchen and laundry.
factory preset outlet
temperature setting
maximum
recommended supply
temperature to
bathrooms and
ensuites
maximum preset outlet
temperature setting
244 627 models
ABOUT YOUR WATER HEATER
6
WARNING
This water heater is only intended to be operated by persons who have the experience or the knowledge and
the 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.
The water heater uses 240 Volt AC electrical power for operation of the control systems and the combustion
fan. The removal of the front panel will expose 240 V wiring. It must only be removed by a qualified person.
The power lead from the water heater must be plugged into a weatherproof electrical outlet. Take care not to
touch the power plug with wet hands.
SAFETY
This water heater is supplied with temperature sensors, a FlameSafe® protection system and a pressure
relief valve. These devices must not be tampered with or removed. The water heater must not be operated
unless each of these devices is fitted and is in working order.
If the power supply cord or plug is damaged, it must be replaced by a qualified person in order to avoid a
hazard. The power supply cord and plug must be replaced with a genuine replacement part available from
Rheem. Phone Rheem Service or their nearest Accredited Service Agent to arrange for an inspection.
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.
The Vulcan 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.
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.
Do not use aerosols, stain removers and household
chemicals near the water heater whilst it is working. Gases
from some aerosol sprays, stain removers and household
chemicals become corrosive when drawn into a flame.
Do not store swimming pool chemicals, household
cleaners, etc., near the water heater.
Do not place anything on top of the water heater or in contact
with the flue terminal. Ensure the flue terminal is not
obstructed in any way at any time.
Do not use Propane / Butane gas mixtures in a Propane model. A Propane model is designed to operate
on Propane only. The use of Propane / Butane mixture, such as automotive LPG fuel, in a Propane
model is unsafe and can cause damage to the water heater.
PRECAUTIONS
Where damage to property can occur in the event of the water heater leaking, the water heater must be
installed over 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 “General Maintenance” on page 7, “Minor Six Month Maintenance” on page 7 and “Major Five Year
Service” on page 7.
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 were 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.
ABOUT YOUR WATER HEATER
7
GENERAL MAINTENANCE
The jacket of the water heater can be cleaned with a soft cloth and warm mild soapy water. Under no
circumstances should abrasive materials or powders be used.
The area around the water heater can be sprayed with insecticide to rid the area of insects. Insects
encroaching into or nesting in the water heater can interfere with the operation of the water heater and also
damage components.
MINOR SIX MONTH MAINTENANCE
It is recommended minor maintenance be performed every six months by the dwelling occupant.
The minor maintenance includes:
Inspect around the air inlet, flue terminal and the water heater in general for plant growth.
Trim back any shrubs, bushes or other plants which have encroached around the water heater.
Plant growth across the air inlet and flue terminal can interfere with the performance of the water
heater.
Inspect around the water heater for insect infestations, such as ants.
Spray insecticide around the water heater if necessary to rid the area of insects. Do not spray the
surface or into the air inlet or flue terminal of the water heater.
Insects encroaching into or nesting in the water heater can interfere with the operation of the water
heater and also damage components.
Check the drain line from the safe tray (if one is installed) is not blocked.
MAJOR FIVE YEAR SERVICE
For safe and efficient operation, it is recommended a five year service be conducted on the water heater.
Warning: Servicing of a water heater must only be carried out by qualified personnel. Phone Rheem
Service or their nearest Accredited Service Agent.
Note: The five year service and routine replacement of any components, if required, are not included in the
Vulcan warranty. A charge will be made for this work. Only genuine replacement parts should be used on
this water heater.
The five year service includes the following actions:
Check and if necessary adjust the gas pressure.
Check the operation of and clean the burner.
Visually check the unit for any potential problems.
Inspect all connections.
Check the drain line from the safe tray (if one is installed) is not blocked.
ABOUT YOUR WATER HEATER
8
CIRCULATED HOT WATER FLOW AND RETURN SYSTEM
A Vulcan 244 627 model continuous flow water heater can be installed as part of a circulated hot water flow
and return system in a building. Refer to “Circulated Hot Water Flow and Return System” on page 19 for
further information and notes on this type of installation.
GOING ON HOLIDAYS
If you are going on holidays, it is not necessary to turn the water heater off. If it is necessary to turn off the
water heater, refer to “To Turn Off The Water Heater” on page 8.
TO TURN OFF THE WATER HEATER
If it is necessary to turn off the water heater:
Switch off the electrical supply at the power outlet to the water heater if there is no risk of freezing
conditions occurring (refer to note below).
Close the gas isolation valve at the inlet to the water heater.
Close the solar preheat water isolation valve at the inlet to the water heater.
Note: If there is a risk of freezing conditions, the electrical supply to the water heater should not be switched
off unless the water heater is drained, otherwise damage could result (refer to “Frost Protection” on page 8
and “Draining the Water Heater” on page 9).
TO TURN ON THE WATER HEATER
Screw in the drain plugs at the solar heated water inlet and hot water outlet of the water heater if the
water heater has been drained.
Open all of the hot taps in the house (don‟t forget the shower).
Open the cold water isolation valve fully at the inlet to the solar water heater.
Open the solar heated water isolation valve fully at the inlet to the in-series gas booster.
Air will be forced out of the taps.
Close each tap as water flows freely from it.
Open the gas isolation valve fully at the inlet to the water heater.
Plug in the power supply cord at the power outlet.
Switch on the electrical supply at the power outlet to the water heater.
The water heater will operate automatically when you open a hot tap if boosting is required.
FROST PROTECTION
The in-series gas booster has a frost protection system. The frost protection system will protect the in-series
gas booster from damage, by preventing ice forming in the waterways of the in-series gas booster, in the
event of freezing conditions occurring.
Notes:
The frost protection system will be rendered inoperable if electrical power is not available at the water
heater. Damage caused by freezing due to the unavailability of power at the water heater is not covered
by the Vulcan warranty (refer to “Terms of the Vulcan Warranty” on page 31).
If it is necessary to switch the power off to the water heater and there is a risk of freezing, then it is
necessary to drain the water heater (refer to “Draining the Water Heater” on page 9).
Pipe work to and from the water heater must be adequately insulated to prevent freezing.
The water heater is not suitable for installation in areas where the ambient temperature falls below -20°C
(including wind chill factor).
Refer to “Terms of the Vulcan Warranty” on page 31.
ABOUT YOUR WATER HEATER
9
DRAINING THE WATER HEATER
Turn off the water heater (refer to “Turn Off The Water Heater” on page 8).
Open a hot tap (preferably the shower outlet).
Unscrew the two drain plugs, one each at the solar heated water inlet and hot water outlet, on the
underside of the water heater.
Water will drain from the water heater.
When water stops flowing from the water heater, close the hot tap.
Note: It is recommended not to screw the drain plugs back in, until the water heater is to be turned on again.
HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY?
Installation requirements are shown on pages 14 to 21. The water heater must be installed:
by a qualified person, and
in accordance with the installation instructions, and
in compliance with Standards AS/NZS 3500.4, AS 5601 or AS/NZS 5601.1, as applicable under local
regulations, and all local codes and regulatory authority requirements.
Warning: Temperature controllers must not be fitted to this water heater as part of a solar water heater
system because water at a temperature much higher than the controller setting can be delivered.
The pipe work between the solar storage tank and the in-series gas booster has a minimum recommended
pipe size of DN20, MUST BE of copper and be fully insulated in accordance with the requirements of
AS/NZS 3500.4. The insulation must be weatherproof and UV resistant if exposed. The insulation must be
fitted up to the connections on both the solar storage tank and the in-series gas booster.
VICTORIAN CUSTOMERS
Notice to Victorian Customers from the Victorian Plumbing Industry Commission. This water heater must be
installed by a licensed person as required by the Victorian Building Act 1993.
Only a licensed person will give you a Compliance Certificate, showing that the work complies with all the
relevant Standards. Only a licensed person will have insurance protecting their workmanship for 6 years.
Make sure you use a licensed person to install this water heater and ask for your Compliance Certificate.
DOES THE WATER CHEMISTRY AFFECT THE WATER HEATER?
The water heater is suitable for most public water supplies, however some water chemistries may have
detrimental effects on the water heater, its components and fittings. Refer to “Water Supplies” on page 10.
If you are in a known harsh water area or you are not sure of your water chemistry, have your water checked
against the conditions described on page 10.
HOW LONG WILL THE WATER HEATER LAST?
The water heater is supported by a manufacturer‟s warranty (refer to page 31). 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. Refer to “Precautions” on page 6.
10
WATER SUPPLIES
This water heater must be installed in accordance with this advice to be covered by the Vulcan
warranty.
This water heater is manufactured to suit the water conditions of most public reticulated water supplies.
However, there are some known water chemistries which can have detrimental effects on the water heater
and its operation and / or life expectancy. If you are unsure of your water chemistry, you may be able to
obtain information from your local water supply authority. This water heater should only be connected to a
water supply which complies with these guidelines for the Vulcan warranty to apply.
CHANGE OF WATER SUPPLY
The changing or alternating from one water supply to another can have a detrimental effect on the operation
and / or life expectation of a heat exchanger in a continuous flow water heater.
Where there is a changeover from one water supply to another, e.g. a rainwater tank supply, bore water
supply, desalinated water supply, public reticulated water supply or water brought in from another supply,
then water chemistry information should be sought from the supplier or it should be tested to ensure the
water supply meets the requirements given in these guidelines for the Vulcan warranty to apply.
SATURATION INDEX
The saturation index (SI) is used as a measure of the water‟s corrosive or scaling properties.
In a corrosive water supply, the water can attack copper parts and cause them to fail. Where the saturation
index is less than –1.0, the water is very corrosive and the Vulcan warranty does not apply to a copper heat
exchanger in a continuous flow water heater.
In a scaling water supply calcium carbonate is deposited out of the water onto any hot metallic surface.
Where the saturation index exceeds +0.80, the Vulcan warranty does not apply to a copper heat exchanger
in a continuous flow water heater.
Water which is scaling may be treated with a water softening device to reduce the saturation index of the
water.
Refer to the Saturation Index chart on page 10.
-1.0
no warranty applies to a:
-continuous flow copper heat exchanger
SATURATION INDEX (SI)
GAS CONTINUOUS FLOW WATER HEATERS
WITHIN WARRANTY
SPECIFICATION
SATURATION INDEX
(calculated @ 80°C water temperature)
no warranty applies to a:
-continuous flow copper heat exchanger
+0.4 +0.80
very corrosive very scaling
scaling
corrosive
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