Vulcan-Hart 648 Series Technical Document

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
Gas Domestic Outdoor
Water Heater
648 Series

PATENTS
This water heater may be protected by one or more patents or registered designs
in the name of Rheem Australia Pty Ltd.
TRADEMARKS
®Registered trademark of Rheem Australia Pty Ltd.
TM Trademark of Rheem Australia Pty Ltd.
Note: Every care has been taken to ensure the 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 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 19.
The other pages are intended for the installer
but may be of interest.
About Your Water Heater............................................................4
Regular Care ................................................................................9
Water Supplies...........................................................................13
Save A Service Call ...................................................................17
Installation..................................................................................20
Connections –Plumbing ..........................................................29
Commissioning..........................................................................33
Lighting The Water Heater........................................................34
Draining The Water Heater .......................................................37
Warranty.....................................................................................38

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®Freeloader®4 water heater
model you have chosen is suitable for outdoor
installation only. The model is a 648 series
4 star gas water heater.
Water is stored in a vitreous enamel lined
steel cylinder and heated by a gas burner
located under the cylinder. The heat produced
by the burner is transferred to the water
through the base of the cylinder and through
the wall of a flue pipe which passes through
the centre of the cylinder. A flue baffle in this
flue ensures the efficiency of the water heater
is correct. The gas supply to the burner is
controlled by the thermostat so the water is
heated to a constant temperature.
Automatic safety controls are fitted to the
water heater to provide safe and efficient
operation.
HOW HOT SHOULD THE WATER BE?
The water heater features a user adjustable
thermostat, which allows you to personally
choose the most suitable temperature for your
hot water needs. Refer to “Temperature
Adjustment” on page 5.
To meet the requirements of the National
Plumbing Standard the temperature of the
stored water must not be below 60°C.
Note: AS 3498 requires that a water heater provides the means to inhibit the
growth of Legionella bacteria in potable water. This water heater can satisfy
this AS 3498 requirement provided it is operating and the thermostat setting is
60°C or higher, including when it is used as an in-series booster water heater
for a solar water heater.
maximum thermostat
setting
maximum
recommended supply
temperature to
bathrooms and
ensuites
minimum
recommended stored
water temperature

ABOUT YOUR WATER HEATER
5
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 also be required by regulations that an approved
temperature limiting device be fitted into the hot water pipe work 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.
TEMPERATURE ADJUSTMENT
The temperature adjusting dial is on the
gas valve, located behind the access cover
on the lower front of the water heater. A
setting of „5‟will normally maintain the
water temperature at about 60°C. Each
number represents a temperature
difference of approximately 6°C.
To increase the water temperature to 66°C
or 73°C, turn the gas control knob
anticlockwise to a setting of „6‟ or „7‟
respectively. Refer to “Hotter Water
Increases the Risk of Scald Injury” on
page 5.
PIEZO IGNITION
The “Piezo” push button igniter makes
lighting the pilot flame of your water heater
very easy. Simply follow the instructions on
the label attached to the back of the access
door. There is no need for matches to light
the water heater.
PILOT IGNITER
A permanent pilot flame burns to ignite the
main burner automatically. Heat from the
pilot is absorbed by the water.

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.
SAFETY
This water heater is supplied with a thermostat, an over-temperature cut-out,
and a combination temperature 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.
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.

ABOUT YOUR WATER HEATER
7
MAINS PRESSURE
The water heater is designed to operate at mains pressure by connecting
directly to the mains water supply. If the mains supply pressure in your area
exceeds that shown on page 22, a pressure limiting valve must be fitted. The
supply pressure should be greater than 350 kPa for true mains pressure
operation to be achieved.
PRECAUTIONS
Where damage to property can occur in the event of the water heater leaking,
the water heater must be installed in a safe tray. Construction, installation and
draining of a safe tray must comply with AS/NZS 3500.4 and all local codes
and regulatory authority requirements.
The water heater must be maintained in accordance with the Owner‟s Guide
and Installation Instructions. Refer to “Regular Care” on page 9 and to “Anode
Inspection and Replacement” on page 14.
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.
TO TURN OFF THE WATER HEATER
If it is necessary to turn off the water heater:
Shut down the gas control (refer to “Close Down Procedure” on page 36).
Close the gas isolation valve at the inlet to the gas control.
Close the cold water isolation valve at the inlet to the water heater.
TO TURN ON THE WATER HEATER
Open the cold water isolation valve fully at the inlet to the water heater.
Open the gas isolation valve fully at the inlet to the gas control.
Light the water heater (refer to “Lighting the Water Heater” on page 34).
GOING ON HOLIDAYS
If you are going on holiday for more than a few days the thermostat can be set
to the “” (pilot) position to conserve energy (refer to point 1 of “Close Down
Procedure” on page 36). If it is necessary to turn off the water heater, refer to
“To Turn Off The Water Heater” on page 7.

ABOUT YOUR WATER HEATER
8
HOW DO I KNOW IF THE WATER HEATER IS INSTALLED CORRECTLY?
Installation requirements are shown on pages 20 to 27. 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.
In New Zealand, the installation must also conform with the New Zealand
Building Code.
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 13.
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
pages 13 to 16.
HOW LONG WILL THE WATER HEATER LAST?
The water heater is supported by a manufacturer‟s warranty (refer to page 38).
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 7.

9
REGULAR CARE
ANNUAL SERVICE
For safe and efficient operation, it is recommended an annual 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 annual 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 annual service includes the following actions:
Inspect and flush the temperature pressure relief valve.
Inspect and flush the expansion control valve (if fitted).
Check and if necessary adjust the inlet gas pressure.
Check the piezo igniter, gas control and thermocouple.
Check the operation of and clean the pilot light and main 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.
Note: The water heater may need to be drained during this service. After the
completion of the service, the water heater will take some time to reheat the
water. Hot water may not be available for a while.

REGULAR CARE
10
MAJOR FIVE YEAR SERVICE
It is recommended a major 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, such
as the anode and relief valve(s), 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 major service includes the following actions:
Replace the temperature pressure relief valve.
Inspect and flush the expansion control valve (if fitted). If required, replace
the valve.
Inspect and if required, replace the anode.
If the anode is not replaced, it should be replaced within three years of this
service (refer to “Anode Inspection and Replacement” on page 14).
Check and if necessary adjust the inlet gas pressure.
Check the piezo igniter, gas control and thermocouple.
Check the operation of and clean the pilot light and main 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.
Note: The water heater may need to be drained during this service. After the
completion of the service, the water heater will take some time to reheat the
water. Hot water may not be available for a while.