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DORCHESTER DR-FC 25 Installation, Commissioning And Maintenance Instructions

Hot water storage heaters
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Condensing, Closed Combustion, Direct Gas Fired Hot Water Storage Heaters
NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
THIS WATER HEATER IS FOR USE ON GROUP H NATURAL GAS (2
RD
LPG (3
FAMILY) I
DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING
HEATER.
THIS WATER HEATER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES
PUBLICATION NO. 500001153
ISSUE 'A'
FEBRUARY 2006
DORCHESTER
DR-FC 25 to DR-FC 60

HOT WATER

STORAGE HEATERS
Installation, Commissioning
and Maintenance Instructions
DORCHESTER MODELS: DR-FC 25, 30, 45, 60
with Automatic Ignition for
Domestic Hot Water Installations
. PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN
3+
1
ND
FAMILY) I
OR
2H
.

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  • Page 1: Hot Water

    HOT WATER STORAGE HEATERS Installation, Commissioning and Maintenance Instructions DORCHESTER MODELS: DR-FC 25, 30, 45, 60 Condensing, Closed Combustion, Direct Gas Fired Hot Water Storage Heaters with Automatic Ignition for Domestic Hot Water Installations NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

  • 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 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 25 Air supply and flue gas discharge - - - - - - - - - - - - - - - - - - - - - 26 3.9.1 Concentric wall flue terminal - - - - - - - - - - - - - - - - - - 28 3.9.2...
  • Page 5 Setting the water temperature - - - - - - - - - - - - - - - - - - - - - - 58 8.4.1 Setting the water temperature via SETPOINT MENU - - - - - - 58 8.4.2 Setting water temperature during ON mode - - - - - - - - - - 58 Week programme - - - - - - - - - - - - - - - - - - - - - - - - - - - - 59...
  • Page 6 Appendices - - - - - - - - - - - - - - - - - - - - - - - - - - - 95 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 95 Electrical diagram DR-FC - - - - - - - - - - - - - - - - - - - - - - - - - 96 Instruction Manual DR-FC...

  • Page 7: Introduction

    Alternatively, the water heater can be connected using a parallel system. Installation types possible with this water heater are B23, C13, C33, C43, C53 and C63. The information in this manual is applicable to types: DR-FC 25, DR- FC 30, DR-FC 45 and DR-FC 60.

  • 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 Tabel 1.2 provides an overview of the contents of this document. document Tabel 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

    Introduction 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. Functional Figure 2.1 shows a cut-away view of the water heater. description of the water heater Legend...

  • Page 12: The Water Heater's Heating Cycle

    Functioning of the water heater In this water heater the cold water enters the bottom of the heater via the cold water inlet n. The tap water, heated by the combustion chamber h and heat exchanger k, leaves the heater through the hot water outlet b. Once the water heater is completely filled with water, it remains constantly under water supply pressure.

  • Page 13: Water Temperature Protection

    Protection for the water heater 2.4.1 Water temperature protection With temperature sensor T g and temperature sensor T m, the control panel monitors three temperatures which are important for safety. Tabel 2.1 explains the functioning of the temperature sensors. Tabel 2.1 Temperature protection Protection Description Against frost...

  • Page 14: Flame Probe

    Functioning of the water heater Tabel 2.2 shows the trip point per water heater. Tabel 2.2 Pressure switch trip points [Pa] Water Pressure differential heater Closing Opening DR-FC > 635 < 605 DR-FC > 855 < 825 DR-FC > 885 <...

  • Page 15: Options

    Options heater is under water supply pressure, cold water will automatically flow into it. The valve remains open until the unsafe situation has been averted. A connecting point for a T&P valve is standard on the water heater. See paragraph ’3.6.3 Hot water side’.
  • Page 16 Functioning of the water heater Instruction Manual DR-FC...

  • Page 17: Installation

    Introduction 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

    In connection with the water heater’s weight, take account of the maximum floor loading, see Table 3.2. Table 3.2 Weight specifications related to maximum floor loading Weight of the water heater filled with water DR-FC 25 402 kg DR-FC 30, DR-FC 45, DR- 606 kg FC 60 3.3.3...
  • 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 heater and/or connections can cause damage to the immediate environment or floors below the level of the boiler room.

  • Page 20: Technical Specifications

    Figure 3.2 Tabel 3.5. IMD-0394 Figure 3.2 Plan and elevation of the water heater Table 3.3 Dimensions Dime Description DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 nsion Total height (mm) 1370 1900 1900...
  • Page 21 Technical specifications Table 3.3 Dimensions Dime Description DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 nsion Height of drain valve (mm) Height of T&P valve (mm) 1415 1415 1415 Height of condensation drainage (mm) Height of air supply connection (mm)

  • Page 22: Installation Diagram

    Installation Tabel 3.5 Gas data Gas category data Unit DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 2H3+ Data for natural gas 2H: G20-20 mbar Orifice diameter 4.90 5.10 7.00 7.10 (1) = flat sealing plate 1 or 2 (2) = burner pressure regulator Nominal load (gross) 31.5...
  • Page 23 Installation diagram Legend a pressure-reducing valve UNVENTED (mandatory ) b T&P valve (mandatory) ba) safety valve c stop valve (recommended) d non-return valve (mandatory) da) non-return valve e circulation pump (optional) f drain valve g manual gas valve (mandatory) h stop valve (mandatory) i temperature gauge (optional) j condensation drainage (mandatory)

  • Page 24: Water Connections, Unvented

    Installation Water connections, Unvented 3.6.1 Cold water side See a in Figure 3.3. 1. Fit an approved stop valve c on the cold water side as required by regulations. Refer also to paragraph ’1.3 Regulations and documents’. 2. The maximum working pressure of the water heater is 8 bar. Because the pressure in the water pipe at times can exceed 8 bar, you must fit an approved pressure-reducing valve a.

  • Page 25: Water Connections, Vented

    Water connections, Vented Water connections, Vented 3.7.1 Cold water side See a in Figure 3.3. 1. Fit an approved stop valve h on the cold water side between the water tank o and the water heater, as required by regulations. Refer also to paragraph ’1.3 Regulations and documents’.

  • Page 26: Air Supply And Flue Gas Discharge

    Installation See d in Figure 3.3. 1. Fit a gas valve g in the gas supply pipe. 2. Blow the gas pipe through before use, to be sure it is clean. 3. Close the gas valve. 4. Fit the gas supply pipe to the gas control. Warning Check for leaks after fitting.
  • Page 27 Air supply and flue gas discharge • The maximum permitted number of 45° or 90° bends is four. Table 3.6 Chimney configurations for concentric wall and roof termination. Dimension DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 0-15 m 0-15 m...

  • Page 28: Concentric Wall Flue Terminal

    Pipe diameter Concentric • DR-FC 25: Ø 80/125 mm. • DR-FC 30, 45 and 60: Ø 100/150 mm. The M2000 MDV SE model is a special version of the Mugro 3000 series. No other wall flue terminal may be used, as the DR-FC-water heater is approved exclusively for this model of wall flue terminal.

  • Page 29: Concentric Roof Flue Terminal

    Thin-walled galvanised sheet steel Pipe diameter Concentric • DR-FC 25: 80/125 mm. • DR-FC 30, 45 and 60: Ø 100/150 mm. The model M2000 DDV SEC HR is a special version of the Mugro 3000 series. No other roof flue terminal may be used, as the DR-FC- water heater is approved exclusively for this model of roof flue terminal.

  • Page 30: Preparation

    Installation • 3.10.6 program-controlled pump; • 3.10.7 Extra ON mode switch (“Heater ON”); • 3.10.8 Connecting extra error signal (“Alarm OUT”). Remark The optional components are not included in the rating for electrical power consumption (see tables in paragraph 3.4). 3.10.2 Preparation Note...

  • Page 31: Mains Voltage

    Electrical connection In preparation you should first remove the two covers and the protective cap of the electrical section. The covers are attached to the water heater by 4 screws and fastenings. The covers are also joined to each other with fastenings.

  • Page 32: Continuous Pump

    Installation 3.10.5 Continuous pump The continuous pump will start up as soon as mains power is connected to the water heater. 1. Connect phase (L), neutral (N) and earth ( ) to terminals 7, 8 and 9 as indicated in Table 3.9.

  • Page 33: Checking The Supply Pressure And Burner Pressure

    Checking the supply pressure and burner pressure 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. Please refer to paragraph ’4.2 Filling the water heater’...
  • Page 34 Installation The display will now show for about 10 seconds, and INTERNAL CHECK will then go to the main menu. INTERNAL CHECK Figure 3.8 Internal check 10. Activate the “ON mode” by going through the following steps: Press once on the blue arrow (L) to bring the pointer ( ) to »...

  • Page 35: Conversion To A Different Gas Category

    Conversion to a different gas category 20. Disconnect the two pressure gauges and re-tighten the sealing screws in the test nipples. 21. Replace the covers. 3.12 Conversion to a Note different gas The conversion may only by carried out by an authorised installer. category If the water heater must operate on a family of gas (LP gas or natural gas) other than the category of gas for which the water heater has been set up at...
  • Page 36 Installation 8. Remove the burner as complete assembly. Legend a connector b gas coupling c air supply hose d pressure switch hose e distribution plate f orifice Figuur 3.12 Orifice assembly 9. Place and fit the burner with parts from the conversion kit. Remark The burner for LP gases can be recognised by the letter ‘P’...
  • Page 37 Conversion to a different gas category Legend g burner pressure regulator h burner pressure control cap i burner pressure control adjusting screw jJconnector k flat sealing plate l supply pressure test nipple m burner pressure test nipple IMD-0079 Figure 3.13 Conversion of gas control Remark In the event the supply pressure for a gas category is the same as the burner pressure (see the gas tables in paragraph 3.4) then the gas control must be...
  • Page 38 Installation 17. Remove the sticker showing the new gas category from the conversion kit, and attach it below the water heater’s rating plate. This clearly indicates that the water heater may no longer be run on the gas for which it was originally supplied.

  • Page 39: Filling And Draining

    Introduction Filling and draining Introduction Topics covered in this chapter: • Filling the water heater. • Draining the water heater. The components referred to in these paragraphs are illustrated in Figure 4.1. Filling the water heater 4.2.1 Filling unvented installations To fill the water heater, proceed as follows.
  • Page 40 Filling and draining Legend a pressure-reducing valve UNVENTED (mandatory ) b T&P valve (mandatory) ba) safety valve c stop valve (recommended) d non-return valve (mandatory) da) non-return valve e circulation pump (optional) f drain valve g manual gas valve (mandatory) h stop valve (mandatory) i temperature gauge (optional) j condensation drainage...

  • Page 41: Draining The Water Heater

    Draining the water heater Draining the water heater 4.3.1 Draining unvented installations Some service activities require the water heater to be drained. The procedure is as follows: 1. Activate the with B. MENU MENU 2. Use H and L to place the cursor beside .
  • Page 42 Filling and draining Instruction Manual DR-FC...

  • Page 43: The Control Panel

    Introduction The control panel Introduction Topics covered in this chapter: • Operating; • 5.3 Explanation of the icons; • 5.4 ON/OFF switch of control panel; • 5.5 Navigation buttons; • 5.6 PC connection.. Operating Figure 5.1 shows the control panel. The control panel is completely menu- driven.

  • Page 44: Explanation Of The Icons

    The control panel In this manual, the display of the control panel is shown as in Figure 5.2, both with and without icons. ^»START OPERATION È CHANGE SETPOINT Tset=70ÉC Figure 5.2 The display Explanation of the Table 5.1 gives an explanation of the icons. icons Table 5.1 Icons and their meaning Icon...

  • Page 45: Pc Connection

    PC connection. The cursor » points to the option to be activated. In the display as shown in Figure 5.4 you can scroll through the main menu. MENU The main menu consists of: WEEK PROGRAM EXTRA PERIOD . The options only become visible SETTINGS EXTRA PERIOD...
  • Page 46 The control panel Instruction Manual DR-FC...

  • Page 47: Status Of The Water Heater

    Introduction Status of the water heater Introduction Topics covered in this chapter: • 6.2 Operating modes; • 6.3 Error conditions; • 6.4 Service condition. Operating modes When running, the water heater has four basic operating modes, namely: In this mode, the frost protection is activated. Figure 6.1 shows the display with the following information:...

  • Page 48: Error Conditions

    Status of the water heater 1) The current time falls within a set time period of the week program. PROG Figure 6.4 shows the display in this situation: 10:00 Monday 76ÉC line one: the text PROG MO 11:15 Tset 75ÉC line two: the time, the day and alternately T and T .

  • Page 49: Service Condition

    Service condition Service condition Figure 6.7 shows the message . Should this message SERVICE REQUIRED appear, then the water heater is in need of a service and maintenance inspection. In that case, contact your service and maintenance engineer. WARNING Remark MAX.
  • Page 50 Status of the water heater Instruction Manual DR-FC...

  • Page 51: Starting Up And Shutting Down

    Introduction Starting up and shutting down Introduction Topics covered in this chapter: • Starting • Shutting down. Starting up Start-up the water heater as follows: 1. Fill the water heater. See chapter ’4 Filling and draining’ 2. Open the gas valve (see ’Figure 4.1 Installation diagrams’).

  • Page 52: Shutting Down

    Starting up and shutting down Confirm with E the option START OPERATION. The water heater will now enter “ON mode”. If there is a heat demand, the water heater will run through a heating cycle. See paragraph »START OPERATION ’7.4 The water heater’s heating cycle’.

  • Page 53: Shut The Water Heater Down For A Longer Period

    The water heater’s heating cycle 5. Turn the appliance OFF (position 0) using the ON/OFF switch on the control panel. See Figure 7.7. 6. Disconnect the appliance by putting the mains switch between the appliance and the mains power supply to position 0. Figure 7.7 control panel 7.3.3 Shut the water heater down for a longer period...
  • Page 54 Starting up and shutting down 1. The water temperature drops below the set temperature of (for example) 65°C. The control panel detects a heat demand and starts the heating cycle. Ê icon is activated. 13:45 Thursday 63ÉC The message HEAT DEMAND appears. Tset 65ÉC HEAT DEMAND Figure 7.8 Frost protection cuts...
  • Page 55 The water heater’s heating cycle 8. Following the post-purge, the fan stops and the pressure switch opens: icons are dimmed. The message POST PURGE disappears. 14:05 Thursday 65ÉC At the first subsequent heat demand, the heating cycle will resume from step Figure 7.15 Running Instruction Manual DR-FC...
  • Page 56 Starting up and shutting down Instruction Manual DR-FC...

  • Page 57: Main Menu

    Introduction Main menu Introduction is reached by pressing button B of thecontrol panel. The options MENU MENU are: »OFF ^ ON • È WEEK PROGRAM Select this option if you wish to shut the water heater down for a brief period, EXTRA PERIOD but do not wish to drain it.

  • Page 58: Switching Into "On Mode

    Main menu This means: 1. B: Activate the main menu with B. : Using button H and/or L go to and press E. SETTINGS SETTINGS : Using button H and/or L go to LANGUAGE LANGUAGE. 4. Confirm with E: After pressing E, the sub-menu LANGUAGE activated.

  • Page 59: Week Programme

    Week programme Week programme 8.5.1 Introduction Using the week program, you can set the water temperature for the days and times you wish. If the water heater is running under a week program, then this is indicated on PROG the display by the text on the first line (see Figure 8.5).
  • Page 60 Main menu The display now shows the menu for the week program, see Figure 8.7. With DAY TIME Tset the default setting, the program switches on and off every day at 00:00 and ON »SU 00:00 65ÉC P 23:59 hours respectively, the water temperature is 65ºc and the pump is OFF SU 23:59 switched on (...

  • Page 61: Adding Times To A Week Program

    Week programme The cursor moves to the minute digits, which will blink. See Figure 8.12. SU 08:15 7. Use H and L to select the minutes. In the example this is SU 12»15 Tset 65ÉC Confirm with E. PUMP ON SAVE The cursor moves to the water temperature.

  • Page 62: Deleting Times From A Week Program

    Main menu The display shows the menu for the week program, see Figure 8.18. The DAY TIME Tset cursor points to the active period. »SU 08:15 75ÉC P 2. Scroll L to OFF SU 12:45 INSERT 00:00 65ÉC P Confirm with E.....
  • Page 63 Week programme 2. Scroll with L to PROGRAM OVERVIEW WEEK PROGRAM Confirm with E. START OPERATION ^»PROGRAM OVERVIEW The display will show the week program sub-menu, see Figure 8.21. È 3. Scroll with L to DELETE Figure 8.23 week program Confirm with E.

  • Page 64: Extra Period

    Main menu Extra period 8.6.1 Introduction Use an extra period when you either want to have the water heater switch on and off for a certain period, either without modifying the active week program, or without taking the water heater out of OFF mode (frost protection active). If the water heater is running under an ‘extra period’, then this is indicated in the EXTRA display with the text...

  • Page 65: Settings

    Settings The cursor moves to the water temperature. See Figure 8.34. SU 08:15 Setting the water temperature SU 12:45 Tset»65ÉC 7. Use H and L to select the water temperature. In the example this is 75. PUMP ON SAVE Confirm with E. Figure 8.34 Setting water The cursor moves to .

  • Page 66: Setting Day And Time

    Main menu 3. Scroll with L to the desired language. LANGUAGE Confirm with E. ENGLISH ^ NEDERLANDS The language is set. ȻDEUTSCH FRANCAIS ITALIANO Figure 8.39 Language selection 8.7.3 Setting day and time Bring up the menu for entering the day and time via: MENU 1.
  • Page 67 Table 8.2 Water heater specifications Water Ignition speed of fan Running speed of Regulation heater interval DR-FC 25 4500 rpm 4980 rpm 40-80 °C DR-FC 30 4500 rpm 5400 rpm 40-80 °C DR-FC 45...
  • Page 68 Main menu Instruction Manual DR-FC...

  • Page 69: Service Program

    Introduction Service program Introduction The service program is used by the installer or service and maintenance SERVICE MENU engineer for: »HYSTERESE • Setting the hysteresis; ^ HISTORIE OF ERRORS È APPLIANCE HISTORY • Displaying the error history; SELECT APPLIANCE • Displaying the water heater history;...

  • Page 70: Displaying The Water Heater History

    Service program Figure 9.3 shows an example of ‘Blocking errors’. In this case, the text HISTORIE OF ERRORS(B) is followed by HISTORIE OF ERRORS S04 SENSOR ERROR F06 IONIZATION È CO2 50 HZ ERROR Figure 9.3 Blocking errors Figure 9.4 shows an example of the ‘Lock out errors’.

  • Page 71: Setting The Display Contrast

    Setting the display contrast The service interval is based on the number of burning hours. This can be set to 500, 1000 and 1500 hours. The standard setting for number of hours is 500. Once the preset number of hours is reached, a message to this effect will appear.
  • Page 72 Service program Instruction Manual DR-FC...

  • Page 73: Troubleshooting

    Troubleshooting 10.1 Introduction A distinction is made between: • General errors General errors are not reported on the display. General errors are: Gas smell Display does not light up Insufficient or no hot water. Water leakage Explosive ignition Table 10.1 gives a troubleshooting overview for general errors.
  • Page 88 Troubleshooting Instruction Manual DR-FC...

  • Page 89: Maintenance Frequency

    Introduction Maintenance frequency 11.1 Introduction 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 Regular maintenance extends the service life of the water heater.
  • Page 90 Maintenance frequency Instruction Manual DR-FC...

  • Page 91: Maintenance

    Introduction Maintenance 12.1 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 92 See paragraph ’12.5 Finalising maintenance’. Table 12.1 Pressure switch differential Water Observed pressure differential across the pressure switch heater (Pa) DR-FC 25 > 635 DR-FC 30 > 885 DR-FC 45 > 885 DR-FC 60 > 1085 15.

  • Page 93: Water-Side Maintenance

    Water-side maintenance 12.3 Water-side mainte- nance 12.3.1 Introduction The following steps should be carried out on the water side: Checking the anodes. Descaling and cleaning the heater. Cleaning condensate discharge. 12.3.2 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 94: Cleaning Heat Exchanger

    Maintenance 3. Fit the orifice. 12.4.4 Cleaning heat exchanger 1. Detach the burner. 2. Clean the combustion chamber of the heat exchanger using a vacuum cleaner and a soft brush. 3. Detach the flue gas discharge. 4. Clean the end of the heat exchanger using tap water. 5.
  • Page 95 Appendices Introduction This appendix contains: • Electrical diagram DR-FC. • Week program card. Instruction Manual DR-FC...

  • Page 96: Electrical Diagram Dr-Fc

    Appendices Electrical diagram DR-FC = brown = brown = blue = yellow/green = black = white (flat cable) = grey/beige TERMINAL STRIP CONNECTIONS: Earth Temperature sensor (T2 - bottom of heater) Neutral Dummy Phase input of controller Temperature sensor (T1 - top of heater) Phase input of isolating transformer (primary side) Selection resistor Phase output of isolating transformer (secondary side)
  • Page 98 Appendices Instruction Manual DR-FC...

This manual is also suitable for:

Dr-fc 45Dr-fc 30Dr-fc 60

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