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Dorchester DR-RS Range
of Hot Water Storage Heaters
Room Sealed, Direct Gas Fired Hot Water Storage
Heaters with Automatic Ignition
for Domestic Hot Water Installations
Installation, Commissioning
and Servicing Instructions
DORCHESTER DR-RS 25, 40, 65, 85, 105 Models
NATURAL GAS I
LPG I
2H
3+
NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
ND
THIS WATER HEATER IS FOR USE ON GROUP H NATURAL GAS (2
FAMILY) I
OR
2H
RD
LPG (3
FAMILY) I
(DR-RS 105 I
). PLEASE ENSURE RELEVANT INFORMATION
3+
3P
REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED
BEFORE FIRING HEATER.
THIS WATER HEATER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
PUBLICATION NO. 500001138
ISSUE 'A'
OCTOBER 2013
1
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Table of Contents
Troubleshooting
Related Manuals for DORCHESTER DR-RS Series
Summary of Contents for DORCHESTER DR-RS Series
- Page 1 Heaters with Automatic Ignition for Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions DORCHESTER DR-RS 25, 40, 65, 85, 105 Models NATURAL GAS I LPG I NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
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Page 3: Table Of Contents
Table of contents Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 About the water heater - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 What to do if you smell gas - - - - - - - - - - - - - - - - - - - - - - - - - 7 Regulations and documents - - - - - - - - - - - - - - - - - - - - - - - - 7 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 8... - Page 4 Gas connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 27 Air supply and flue gas discharge - - - - - - - - - - - - - - - - - - - - - 27 3.9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 27 3.9.2...
- Page 5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - 59 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59 Preparing for maintenance - - - - - - - - - - - - - - - - - - - - - - - - 59 Water-side maintenance - - - - - - - - - - - - - - - - - - - - - - - - - 60 9.3.1...
- Page 6 Instruction manual DR-RS...
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Page 7: Introduction
Introduction About the water This manual describes how to install, service and use the DR-RS water heater. heater A DR-RS water heater is a gas-fired closed water heater with a fan in the air supply. Depending on the water heater type, the chimney connections are parallel or concentric. -
Page 8: Target Groups
Introduction British Standards • BS 6891: Specification for installation of low pressure gas pipework of up to 28 mm (R1) in domestic premises (2nd family gas). For larger installations see IGE/UP/2 below. • BS 6798: Specification for installation of gas-fired boilers of rated input not exceeding 70 kW net. -
Page 9: Maintenance
Maintenance Maintenance A service should be carried out at least once a year, both on the water side and on the gas side. Maintenance frequency depends, among other things, on the water quality, the average burning time per day and the set water temperature. Remark To determine the correct maintenance frequency, it is recommended to arrange for the service and maintenance engineer to check the water heater... -
Page 10: Overview Of This Document
Introduction Overview of this Table 1.2 provides an overview of the contents of this document. document Table 1.2 Contents of document Chapter Target groups Description 2 Functioning of the water This chapter describes how the water heater functions. heater 3 Installation This chapter describes the installation activity to be completed before you actually start up the water heater. -
Page 11: Functioning Of The Water Heater
Functioning of the water heater Introduction Topics covered in this chapter: • Functional description of the water heater; • The water heater’s heating cycle; • Protection for the water heater; • Safety of the installation. Instruction manual DR-RS... -
Page 12: Functional Description Of The Water Heater
Functioning of the water heater Functional Figure 2.1 shows a cut-away view of the water heater. description of the water heater IMD-0240 Legend: (10) air restrictor (20) high-limit thermostat sensor (1) flue gas discharge (11) cleaning opening (21) safety thermostat (2) air supply (12) cold water inlet (22) safety thermostat sensor... -
Page 13: The Water Heater's Heating Cycle
The water heater’s heating cycle In this water heater, the cold water enters the bottom of the it via the cold water inlet (12). The heat of combustion is transferred to the water through the combustion chamber (14) and flue tubes (6). The heated tap water leaves the heater via the hot water outlet (16). -
Page 14: Water Temperature Protection
Functioning of the water heater 2.4.1 Water temperature protection By means of the frost, high-limit and safety thermostats, the burner control monitors three temperatures related to safety. Table 2.1 explains the operation of the thermostats with sensors. Table 2.1 Temperature protection Protection Description Frost thermostat... -
Page 15: Safety Of The Installation
Safety of the installation Safety of the instal- lation 2.5.1 Unvented installation With an unvented installation, an expension valve and expansion vessel prevent excessive pressure in the water heather. This prevents damage of the water heater. A non-return valve prevents excessive pressure in the water supply system. -
Page 16: Top To Bottom Circulation
Functioning of the water heater 2.7.3 Top to Bottom Circulation In order to give enhanced temperature control to aid compliance with the HSE guidance and the DHss Code of Practice for 'The Control of Legionellae in Health Care Premises', a pump circulation kit can be supplied comprising 230 volt single phase pump, non-return valve, pipe work and sufficient fittings to contact between the hot water flow and the bottom connection. -
Page 17: Installation
Installation Warning The installation should be carried out by an approved installer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service. The water heater may only be installed in a room which complies with the requirements stated in national and local ventilation regulations. -
Page 18: Humidity And Ambient Temperature
Installation 3.3.1 Humidity and ambient temperature The boiler room must be frost-free or be protected against frost. Table 3.1 shows the environmental conditions that must be adhered to, for correct functioning of the electronics present in the water heater to be guaranteed. Table 3.1 Humidity and ambient temperature specifications ambient Humidity and... - Page 19 Environmental conditions If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered from Hamworthy, the installer / supplier. Remark When installing the water heater, be aware that any leakage from the it and/or connections can cause damage to the immediate environment or floors below the level of the boiler room.
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Page 20: Technical Specifications
Installation Technical specifica- The water heater is supplied without accessories. Check the dimensions and tions other specifications for the accessories to be used, based on Figure 3.2 Table 3.3. DR-RS 25, 40, 65 DR-RS 85, 105 IMD-0057 Figure 3.2 Plan and elevation of the water heater Instruction manual DR-RS... - Page 21 Technical specifications Table 3.3 Dimensions Description Unit DR-RS 25 DR-RS 40 DR-RS 65 DR-RS 85 DR-RS sion 2000 2000 2020 2020 2020 Total height 1800 1820 1820 1820 Height water heater top 1800 surface Appliance diameter Depth 1000 1000 1000 1000 1000 Width...
- Page 22 Installation Table 3.4 General and electrical specifications (Continued) DESCRIPTION Unit DR-RS DR-RS DR-RS DR-RS DR-RS Number of bar burners/orifices Number of flue tubes/flue baffles Diameter of air restrictor Electrical power consumption Supply voltage 230 (-15% +10%) Mains frequency Table 3.5 Gas data Gas category data Unit DR-RS...
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Page 23: Installation Diagram
Installation diagram Table 3.5 Gas data Gas category data Unit DR-RS DR-RS DR-RS DR-RS DR-RS G31 - 37 mbar (propane)(butane) Nominal heat input (gross) 29.9 47.0 75.7 108.7 122.5 62.6 89.0 100.3 Nominal output 25.0 38.9 Supply pressure mbar Burner pressure mbar 22.0 Gas consumption... - Page 24 Installation Legend a pressure-reducing valve UNVENTED (mandatory whenever the mains water pressure exceeds 8 bar) b expansion vessel (mandatory) c T&P valve (mandatory) ca) safety valve d stop valve (recommended) e non-return valve (mandatory) ea) non-return valve f circulation pump (optional) g drain valve h gas valve (mandatory) i stop valve (mandatory)
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Page 25: Water Connections, Unvented
Water connections, Unvented Water connections, Unvented 3.6.1 Cold water side See a in Figure 3.3. 1. Fit an approved stop valve i on the cold water side as required by regulations. Refer also to paragraph 1.3 Regulations and documents. 2. Fit an approved pressure-reducing valve a. 3. -
Page 26: Condensation Drainage
Installation 3.6.6 Condensation drainage Fit a small drainpipe with fall to the appropriate connection for condensation drainage at the rear of the water heater and connect this further to the water drainage pipe. Note All piping behind the siphon must be condensation-resistant. Water connections, Vented 3.7.1... -
Page 27: Gas Connection
Gas connection Gas connection Warning Gas installation may only be carried out by an authorised installer in compliance with the general regulations imposed by the gas company. Refer also to paragraph 1.3 Regulations and documents. Note Make sure that the diameter and length of the gas supply pipe are large enough to supply sufficient capacity to the water heater. - Page 28 Installation 3.9.2.1 Concentric wall flue terminal DR-RS 25, 40,65 Table 3.6 shows the wall flue terminal prescribed by Hamworthy (installation type C IMD-0060 Figure 3.5 Wall flue terminal Table 3.6 Concentric wall flue terminal specifications Item Description Wall flue terminal Part No.
- Page 29 Air supply and flue gas discharge 3.9.2.2 Concentric roof flue terminal for DR-RS 25, 40, 65 Hamworthy heating limited prescribes the roof flue terminal (installation type ) as specified in Table 3.7. IMD-0061 Figure 3.6 Roof flue terminal Table 3.7 Concentric roof flue terminal specifications Item Description Roof flue terminal...
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Page 30: Fitting Flue Gas Discharge And Air Supply For Dr-Rs 85 And 105
Installation 3.9.3 Fitting flue gas discharge and air supply for DR-RS 85 and 105 The air supply duct a and flue gas discharge duct b of the DR-RS 85 and 105 emerge separately from the top box, as shown in Figure 3.7. - Page 31 Air supply and flue gas discharge 3.9.3.1 Concentric wall flue terminal for DR-RS 85 and 105 Table 3.8 shows the wall flue terminal prescribed by Hamworthy (installation type C IMD-0226 Figure 3.8 Wall flue terminal Table 3.8 Specifications for transition piece and concentric wall flue terminal Item Description Wall flue terminal and transition...
- Page 32 Installation 3.9.3.2 Concentric roof flue terminal for DR-RS 85 and 105 Hamworthy heating limited prescribes the roof flue terminal (installation type ) as specified in Table 3.9. IMD-0239 Figure 3.9 Roof flue terminal Table 3.9 Specifications for transition piece and concentric roof flue terminal Item Description Roof flue terminal and...
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Page 33: Electrical Connections
Electrical connections 3.10 Electrical connec- tions Warning The installation should be carried out by an approved installer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire service. Refer also to paragraph 1.3 Regulations and documents. -
Page 34: Mains
Installation IMD-0362 Figure 3.10 Connection block (connections 1 through 10 explained in Table 3.10) In preparation, first remove the protective cover from the control column: • Undo the 4 screws 1 and remove the protective cover 2 from the electrical section. -
Page 35: Checking The Supply Pressure And Burner Pressure
Checking the supply pressure and burner pressure 5. Connect the power cable to the isolator. Warning Leave the water heater disconnected until you are ready to start it up. 3.11 Checking the supply pressure and burner Note pressure Before you start up the water heater and/or begin to check the supply pressure and burner pressure, you must first fill the water heater. - Page 36 Installation Gas control valve for DR-RS 105 IMD-0257 Figure 3.11 Gas control valve(Continued) To check the supply pressure and burner pressure, proceed as follows: 1. Disconnect the water heater from the power supply. See paragraph 7.3.2 Isolate the water heater from the power supply.
- Page 37 Checking the supply pressure and burner pressure 11. Use the pressure gauge to read the burner pressure at test nipple g. Refer Table 3.5. Remark If the burner pressure is not correct and the water heater is fitted with a blank plate, you will not be able to adjust the pressure.
- Page 38 Installation Instruction manual DR-RS...
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Page 39: Conversion To A Different Gas Category
Conversion to a different gas category 3.12 Conversion to a different gas category 3.12.1 Introduction If the water heater must operate on a family of gas (LP gas or natural gas) or other gas category than that for which the water heater has been set up at the factory, the water heater will have to be adapted using a special conversion kit. -
Page 40: Replacing Orifices
3.12.3 Replacing orifices Legend: a strain relief b lead for spark electrode c lead for flame probe d burner control e gas control connector(s) f gas control g gas coupling h burner tray IMD-0254 Figure 3.12 Disassembled gas control 1. Detach the protective cap van the control column: Loosen the 4 screws and remove the protective cap by lifting it upwards. - Page 41 Conversion to a different gas category Legend: spark electrode flame probe pilot flame orifice socket pilot flame orifice main orifice IMD-0255 Figure 3.13 Gas control 7. If Table 3.5 Gas data indicates that the pilot flame orifice must be replaced: a.
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Page 42: Replacing Burner Pressure Regulator Or Flat Plate (Dr-Rs 25-40-65-85)
14. Refit the protective cover. Remark Refer to A Electrical diagram DR-RS for the connection of electrical components. 3.12.4 Replacing burner pressure regulator or flat plate (DR-RS 25-40-65-85) Referring to Table 3.5 Gas data, ascertain whether the gas control needs to be fitted with a burner pressure regulator or blank plate. -
Page 43: Filling And Draining
Filling and draining Introduction Topics covered in this chapter: • Filling the water heater. • Draining the water heater. Instruction manual DR-RS... -
Page 44: Filling The Water Heater
Filling and draining The components referred to in these paragraphs are illustrated in Figure 4.1. Legend a pressure-reducing valve UNVENTED (mandatory if the mains water pressure exceeds 8 bar) b expansion vessel (mandatory) c T&P valve (mandatory) ca) safety valve d stop valve (recommended) e non-return valve (mandatory) ea) non-return valve... -
Page 45: Filling Vented Installations
Draining the water heater 3. Open the nearest hot water draw-off point m. 4. Open the supply valve i on the cold water side a so that cold water flows into the water heater. 5. Completely fill the water heater (when cold water flows at normal pressure from the nearest hot water draw-off point, the water heater is full). - Page 46 Filling and draining 4. Close the stop valve i in the hot water pipe. 5. Close the stop valve between the water tank and the cold water inlet. 6. Open the drain valve g. Instruction manual DR-RS...
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Page 47: Controls
Controls Introduction Topics covered in this chapter: • 5.2 Control panel; • 5.3 Explanation of the symbols; • 5.4 ON/OFF switch; • 5.5 Control thermostat; • 5.6 Burner control reset button; Control panel Figure 5.1 shows the control panel The panel consists of: •... -
Page 48: Explanation Of The Symbols
Controls Explanation of the Table 5.1 shows the meanings of the symbols on the control panel. symbols Table 5.1 Icons and their meaning Symbol Name Explanation ON/OFF switch ’ON mode’ / ’OFF mode’ Reset button with error Reset burner control indicator Temperature control To set water temperature (T... -
Page 49: Status Of The Water Heater
Status of the water heater Introduction Topics covered in this chapter: • 6.2 Operating modes; • 6.3 Error conditions; Operating modes When running, the water heater has three basic operating modes, namely: • DISCONNECTED In this mode the water heater is off and all components are electrically dead. The isolator (switch between the water heater and the power supply) is turned off. - Page 50 Status of the water heater If, as end-user, you find the water heater in an error condition, you may attempt to re-start the water heater by pressing the reset button once. However, should the error return or become persistent, you should contact your service and maintenance engineer.
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Page 51: Starting Up And Shutting Down
Starting up and shutting down Introduction Topics covered in this chapter: • Starting • Shutting down; • The water heater’s heating cycle. Starting up Start-up the water heater as follows: 1. Fill the water heater. See chapter 4 Filling and draining. -
Page 52: The Water Heater's Heating Cycle
Starting up and shutting down The water heater’s The water heater’s heating cycle is activated as soon as the measured water heating cycle temperature (T ) falls below the threshold value (T ). This threshold value water depends on the currently selected water heater operating mode. For example, if the water heater is in the ’OFF mode’... -
Page 53: Troubleshooting
Troubleshooting Introduction This chapter covers the following errors: • smell. • Water leakage. • Explosive ignition. • Poor flame profile. • No hot water • Insufficient hot water. If the water heater has gone into an error condition, then the heat demand will be (temporarily) ignored and no hot water will be supplied. -
Page 59: Maintenance
Maintenance Introduction Note Maintenance may only by carried out by an approved service and maintenance engineer. At each service, the water heater undergoes maintenance both on the water side and on the gas side. The maintenance should be carried out in the following order. -
Page 60: Water-Side Maintenance
Maintenance Water-side mainte- nance 9.3.1 Introduction The following steps should be carried out on the water side: Checking the anodes. Descaling and cleaning the heater. 9.3.2 Checking the anodes Timely replacement of the anodes extends the service life of the water heater. The water heater’s anodes must be replaced as soon as they are 60% or more used up (take this into consideration when determining the maintenance frequency). -
Page 61: Gas-Side Maintenance
Gas-side maintenance To simplify descaling and cleaning of the tank, the appliance is equipped with two cleaning openings. Figure 9.1 Cleaning opening 1. Remove the cover plate a on the outer jacket. See Figure 9.1. 2. Carefully remove the insulation b and set it to one side. This will be needed again later. -
Page 62: Cleaning The Orifices
Maintenance 9.4.3 Cleaning the orifices 1. Remove the orifices. 2. Remove any contamination present in the orifices. 3. Re-attach the orifices. 9.4.4 Checking the flue baffles Take care 1. Complete steps through of paragraph 9.3.2 Checking the anodes. The flue baffles may 2. -
Page 63: A Electrical Diagram Dr-Rs
Electrical diagram DR-RS Instruction manual DR-RS...
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