Vulcan gas hot water system troubleshooting guide

Have you been experiencing problems with your Vulcan gas hot water system? Using the various manuals, we've put together this guide to help identify issues you might be having and get things working again.

If you need expert help with Vulcan hot water system problems or repairs in Southern Sydney & Sutherland Shire contact Everyday Plumbing & Gas today.

Not enough hot water (or no hot water)

Are you using more hot water than you think?

Is one outlet (especially the shower) using more hot water than you think?

Very often it is not realised the amount of hot water used, particularly when showering. Carefully review the family’s hot water usage. Have your plumber fit a flow control

valve to each shower outlet to reduce water usage.

Is pilot flame alight?

Check the pilot flame is burning by removing the access cover. Relight the pilot flame using the following instructions:

Remove the access cover
Turn the gas control knob fully clockwise to the ‘off’ position
Wait 5 minutes so any build-up of unburnt gas can escape. If you then smell gas, stop and follow ‘C’ in the safety information. If you do not smell gas: Do not try to light the water heater. If the gas smell is throughout the area, turn the gas control knob clockwise to the ‘off’ position and then turn off the isolation valve on the gas line to the water heater. Leave the area and call Everyday Plumbing & Gas immediately.
Turn the knob to the ‘pilot’ position
Depress the knob fully (until the star disappears below the housing) and after 30 seconds, whilst keeping the knob depressed, repeatedly press the igniter button (for up to 40 seconds) until the pilot flame ignites.
Warning: Keep your face clear of the combustion chamber opening while pressing the igniter.
Keep the knob depressed for 20 seconds after the pilot flame lights.
Release the knob and check the pilot is still alight. The pilot can be checked by looking through the large opening below the gas control.
If the pilot has failed to light or has not remained alight, turn the gas control knob to the ‘off’ position. Wait 5 minutes for any unburnt gas to escape and then begin again at step 3. Warning: Failure to wait 5 minutes may result in a fire or explosion.
When the pilot flame remains alight with the gas control knob released, turn the knob anticlockwise to the setting of ‘6’. This will give a water temperature of about 60°C.
Replace the access cover. The main burner will now automatically ignite when heating is required and extinguish when the water has been heated to the set temperature. If the main burner does not light at the selected setting, the water may already be at the selected temperature. Note: Never press the igniter button while the top knob is in a numbered position.

Temperature pressure relief valve running

Is the relief valve discharging too much water?

See the Temperature Pressure Relief Valve Running section below.

Thermostat setting

Ensure the thermostat setting is appropriate. You may choose to adjust the thermostat upwards to gain additional hot water capacity.

Warning: Hotter water increases the risk of scald injury.

Water heater size

Do you have the correct size water heater for your requirements?

The sizing guides in the sales literature suggest average sizes that may be needed.

The water is not hot enough

You may find that due to heavy hot water usage, the water temperature may be lower than normally expected.

Temperature pressure relief valve running

Normal Operation

It is normal and desirable this valve allows a small quantity of water to escape during the heating cycle. However, if it discharges more than a bucket full of water in 24 hours, there may be another problem.

Continuous dribble

Try gently raising the easing lever on the relief valve for a few seconds. This may dislodge a small particle of foreign matter and clear the fault. Release the lever gently.

Steady flows for a long period (often at night)

This may indicate the mains water pressure sometimes rises above the designed pressure of the water heater. Ask your plumber to fit a pressure limiting valve.

Heavy flows of hot water until the water heater is cold - then stops until water reheats

The gas control must be turned off using the knob on top of the gas control thermostat.

Expansion control valve running

If an expansion control valve is fitted in the cold water line to the water heater, it may discharge a small quantity of water instead of the temperature pressure relief valve on the water heater. The benefit is that energy is conserved as the discharged water is cooler.

Can’t light the pilot flame

Is there gas to the water heater?

Check the gas isolation valve on the gas supply line is open.

Is there a normal gas supply to the rest of the house?

Try lighting another gas appliance to check. If there is no gas, call the gas supplier.

The water heater appears to be leaking

When the water heater is first lit, or after a large usage of hot water, condensation may form on the burner of the water heater. This is quite normal, especially in the winter months and will dry off as the water is heated.

Higher than expected gas bills

Should you at any time, feel your gas account is higher than expected, we suggest you check the following points:

Is the relief valve running excessively?
Is one outlet (especially the shower) using more hot water than you think?
Is there a leaking hot water pipe, dripping hot water tap, etc? Even a small leak will waste a surprising quantity of hot water and gas. Replace faulty tap washers, and have your plumber rectify any leaking pipe work.
Has there been an increase in hot water usage? An increase in hot water usage will result in an increase in water heater operation.
Has your water heating tariff rate been increased by your gas retailer since your previous account?

All troubleshooting information and instructions can be found in the Vulcan Owner’s Guide and Instructions.

Reference: https://www.vulcan.com.au/warranty/

Your local gas hot water system in Southern Sydney & Sutherland Shire

If you have checked all of the aforementioned and still need help with your Vulcan gas hot water system, call Everyday Plumbing & Gas for assistance on 0488 801 008 or complete our online enquiry form.