Page 1 DORCHESTER DR-TC 40 and DR-TC 60 SOLAR HOT WATER STORAGE HEATERS Installation, Commissioning and Maintenance Instructions DORCHESTER MODELS: DR-TC 40, 60 Room Sealed or Open Flue, Direct Gas Fired Hot Water Storage Heaters with Intergrated Solar Coil and with Automatic Ignition for...
Page 3 Errata The amendments below apply to:  the preparation of the electrical connection of the solar heating control (3.12.1 "Preparation");  finishing maintenance (15.6 "Finalizing maintenance");  the electrical diagram of the solar heating control (17.4 "Electrical diagram solar heating system"). These instructions supersede the previous instructions of the solar heating control.
Page 4 17.3 Electrical diagram Electrical diagram solar heating system 0309686b R2.0 1 = brown, 2 = blue, 3 = yellow / green, 4 = black, 5 = white, 6 = grey / beige, 7 = green, 8 = yellow...
Page 5 TERMINAL BLOCK CONNECTIONS Earth Neutral Live input of the controller Live input for the solar heating system modulating pump PWM+ PWM+ stuursignaal t.b.v. aansturing pomp zonnesysteem PWM- PWM- stuursignaal t.b.v. aansturing pomp zonnesysteem COMPONENTS Controller Solar heating system pump (modulating) (230 VAC) [VAC] Solar heating system pump (modulating) (PWM-signal) [PWM]...
Page 7 Read this manual carefully Warning Read this manual carefully before starting the water heater. Failure to read the manual and to follow the printed instructions may lead to personal injury and damage to the water heater. Copyright © 2013 All rights reserved. Nothing from this publication may be copied, reproduced and/or published by means of printing, photocopying or by whatsoever means, without the prior written approval of the supplier.
Page 8 Instruction manual DR-TC...
Page 9: Table Of Contents
Contents Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 About the water heater - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10...
Page 10 Contents The control panel - - - - - - - - - - - - - - - - - - - - - - - - 57 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 Explanation of icons- - - - - - - - - - - - - - - - - - - - - - - - - - - - 57 ON/OFF switch on controller - - - - - - - - - - - - - - - - - - - - - - - 57...
Page 11 Errors- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81 13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - 82 13.3...
Page 12 Contents Instruction manual DR-TC...
Page 13: Introduction
The possible installation types are B23, C13, C33, C43, C53 and C63. The information in this manual applies to the: DR-TC 40 and DR-TC 60. The water heater has been manufactured and equipped in accordance with the European standard for gas-fired storage water heaters for the production of domestic hot water (EN 89).
Page 14: Target Groups
Introduction British and European Standards • BS 6891: Installation of low pressure gas pipework of up to 35 mm (R1¼) in domestic premises (2nd family gas) - Specification. Note: for lager installations see IGE/UP/2 below. • BS 6798: Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net.
Page 15: Maintenance
Target group symbols Symbol Target Group (End) user Installation engineer Service and maintenance engineer Caution This water heater is not intended for use by persons with reduced physical, sensory or mental capacities, or who lack the necessary experience or knowledge, unless the person responsible for their safety is supervising them or has explained to them how the water heater should be used.
Page 16: Overview Of This Document
Introduction Overview of this document Chapter Target groups Description Working principle of the water This chapter describes the working principle of the water heater heater. Installation This chapter describes the installation activities to be carried out before final commissioning. Conversion to a different gas This chapter describes the activities required to convert category the water heater to a different gas category.
Page 17: Working Principle Of The Water Heater
Working principle of the water heater Introduction This chapter covers the following topics: • General working principle of the water heater; • Water heater operating cycle; • Protection for the water heater; • Safety of the installation; • Protection for the solar heating system; •...
Page 18: Water Heater Operating Cycle
Working principle of the water heater Cut-away view of the water heater Legend Unused numbers are not applicable cover hot water outlet electrical connector block controller pressure switch control panel temperature sensor T combustion chamber anode tank heat exchanger inspection and cleaning opening temperature sensor T cold water inlet...
Page 19: Protection For The Water Heater
• Hysteresis The moment that T falls below (T - hysteresis), the controller solar diff registers such a heat demand that the gas burner and the solar heating system jointly heat the water. The solar heating system is only employed when the temperature measured by S is a certain (adjustable) value grater than that of S...
Page 20: Safety Of The Installation
Working principle of the water heater Temperature protection protection Description Against frost: The frost protection cuts in. The water is heated to 20°C. < 5°C < 5°C Against overheating of water: The high-limit safeguard serves to prevent overheating and/or excessive >...
Page 21 2.5.1 Unvented installation With an unvented installation, an expansion valve and expansion vessel prevent the buildup of excessive pressure in the tank. This prevents damage being caused to the enamel coating (in the water heater) or to the tank. A non-return valve prevents excessive pressure build-up in the water supply system.
Page 22: Protection For The Solar Heating System
Working principle of the water heater Protection for the solar heating system 2.6.1 Drain-back tank The solar heating system may optionally be equipped with a drain-back tank. The tank fills itself with the heating fluid when there is no heat demand. This avoids overheating of the solar heating system.
Page 23: Installation
Installation Warning The installation must be carried out by an approved installation engineer in compliance with the general and local regulations imposed by the gas, water and power supply companies and the fire brigade. The appliance may only be installed in a room that complies with the requirements stated in national and local ventilation regulations (1.3 "Regulations").
Page 24 Installation 3.3.1 Air humidity and ambient temperature The boiler room must be frost-free, or be protected against frost. The table shows the ambient conditions that must be adhered to for correct functioning of the electronics present in the appliance to be guaranteed. Air humidity and ambient temperature specifications Air humidity and ambient temperature Air humidity...
Page 25: Technical Specifications
Working clearances IMD-0767 R0 Technical The water heater is supplied without accessories. Check the dimensions (3.4 "Technical specifications"), gas data (3.4.3 "Gas data") and specifications other specifications (3.4.2 "General and electrical specifications") of any accessories you plan to use. 3.4.1 Dimensions of the water heater Plan and elevation of the water heater Legend...
Page 26 Installation Size Description Unit DR-TC 40 DR-TC 60 Overall height 2055 2055 Position on pallet Appliance diameter Depth Width Diameter of flue gas discharge 100 / 150 100 / 150 2020 2020 Height of chimney flue x position flue gas outlet...
Page 27 3.4.2 General and electrical specifications General and electrical specifications Description Unit DR-TC 40 DR-TC 60 Contents litres Empty weight Maximum floor load Maximum operating pressure (vented) kPa (bar) 800 (8) 800 (8) Maximum operating pressure, unvented kPa (bar) 550 (5,5)
Page 28 Installation 3.4.3 Gas data Gas data description Unit DR-TC 40 DR-TC 60 2H3P Gas category 2H: G20 - 20 mbar Venturi injector diameter 43,5 62,1 Nominal load (gross) Nominal output 41,9 59,3 Supply pressure mbar (full load) Vol% 9,0 + 1,0...
Page 29: Installation Diagram
Installation diagram The figure shows the Installation diagram. This diagram is referred to in the sections describing the actual connection procedure. Installation diagram Legend Vented and unvented UNVENTED Unused numbers are not applicable pressure reducing valve (mandatory) T&P valve stop valve (recommended in pipe C and mandatory in pipe non-return valve (mandatory) circulation pump (optional)
Page 30: Unvented Water Connections
Installation Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems.
Page 31: Vented Water Connections
Vented water Warning The installation should be carried out by a competent person, in compliance connections with general and locally applicable regulations (1.3 "Regulations"). 3.7.1 Cold water side See (A) in the installation diagram (3.5 "Installation diagram"). 1. Fit an approved stop valve (4) on the cold water side between the cold water head tank (18) and the water heater, as required by applicable regulations.
Page 32: Gas Connection
Installation Gas connection Warning The installation should be carried out by a competent person, in compliance with general and locally applicable regulations (1.3 "Regulations"). Caution Make sure that the diameter and length of the gas supply pipe are large enough to supply sufficient capacity to the water heater. See (D) in the installation diagram (3.5 "Installation diagram").
Page 33: Air Supply And Chimney Flue Discharge
3.10 Air supply and chimney flue discharge 3.10.1 Introduction This section covers the following topics: • Requirements for flue gas discharge materials • Concentric connections • Parallel connections 3.10.2 Requirements for flue gas discharge materials Warning The installation should be carried out by a competent person, in compliance with general and locally applicable regulations (1.3 "Regulations").
Page 34 Installation Installation types Instruction manual DR-TC...
Page 35 Flue gas discharge requirements for concentric systems (C13, C33) Appliance Diameter Maximum length Maximum number of 90 bends DR-TC 40 100/150 mm 40 m DR-TC 60 100/150 mm 40 m Caution Both conditions stated in the table must be fulfilled.
Page 36 Installation Water heater with concentric flue gas discharge material IMD-0792 R0 According to the table, the maximum permitted length is 40 metres, and 4 x 90 degree bends are permitted. Both requirements are fulfilled. Specifications Caution For type C13 and C33 installations,Hamworthy prescribes the use of a roof or wall flue terminal, exclusively of a type approved for the water heater.
Page 37 Chimney flue requirements for parallel systems Appliance Diameter Maximum equivalent equivalent total bend bend length DR-TC 40 55 m 4.6 m 1.2 m DR-TC 60 55 m 4.6 m 1.2 m DR-TC 40 100 m 2.4 m 1.4 m...
Page 38: Electrically Connecting The Water Heater
Installation Appliance with parallel flue gas discharge material IMD-0794 R0 The longest pipe must be used to check the maximum length. In this case, the chimney pipe is the longest. This is 4 metres. This 4 metres is the sum of pipe sections 1 and 2.
Page 39 3.11.2 Preparation Caution The water heater is phase-sensitive. It is absolutely essential to connect the mains live (L) to the live of the water heater, and the mains neutral (N) to the neutral of the water heater. Caution There must be no potential difference between neutral (N) and earth ( ). If this is the case, then an isolating transformer (3.11.4 "Isolating transformer") must be used in the supply circuit.
Page 40 Installation Terminal block Mains Isolating transformer Alarm Out Program- External Bus-link voltage controlled ON/OFF primary secondary pump 16 to 20 3.11.3 Connecting the mains power The water heater is supplied without a power cable and isolator. Note In order to receive electrical power, the water heater has to be connected to the mains power by means of a permanent electrical connection.
Page 41 3.11.5 Connecting a program-controlled pump Note The maximum power capacity for a pump regulated by the controller is 100W. 1. Connect neutral (N), live (L) and earth ( ) to terminals 13, 14 and 15 as indicated in the table (3.11.2 "Preparation"). 2.
Page 42: Electrical Connection Of The Solar Heating System
Installation 3.12 Electrical connection of the This section covers the following topics: solar heating system • Preparation • Connecting the mains power • Connecting pump station - modulating pump • Connecting solar collector • Connecting tank sensor • Connecting communication cable Optionally you can connect an extra head pump and Q/T sensor: •...
Page 43 3.12.4 Connecting solar collector Note This sensor must be mounted in the solar collector;refer to the solar collector installation manual. Connect the sensor (S ) to the water heater as follows: 1. Connect the sensor to terminal 2 and 4 of J13. 2.
Page 44: Check The Supply Pressure, Gas Control Valve Pressure, Co 2 Value And Switching Pressure
Installation 3.12.7 Connecting extra head pump Note This pump is essential if a greater head is required. When the system has such a high resistance (>66 kPa) that the pump in the pump station is insufficient, you can connect a second (ON/OFF) pump to the solar heating system controller.
Page 45 This test nipple has a sealing screw. Loosen the sealing screw by a few turns. Do not completely loosen it as it can be difficult to retighten. IMD-1095a R0 IMD-1096a R0 5. Open the gas supply and vent the gas supply line via the test nipple. 6.
Page 46 Installation 12. Use the pressure gauge to read the supply pressure and compare it against the value from the gas table (3.4.3 "Gas data"). Note Consult the mains gas supply company if the supply pressure is not correct. You cannot yet start using the appliance. You must now take the appliance out of service (10.3 "Isolating the water heater from the mains").
Page 47 10. Confirm with The display shown here will appear. SERVICE OPERATION FULL LOAD »PARTIAL LOAD The appliance is now in "PARTIAL LOAD" mode and will ignite. 11. You must wait about 1 minute after the display shows the text RUNNING before reading the dynamic pressures (the fan needs this time to get up to full speed, so that a reliable reading can be obtained).
Page 48 Installation Full-load measurement 10. From the service menu, select: SERVICE OPERATION | FULL LOAD Confirm with The appliance is now in "FULL LOAD mode" and will ignite. SERVICE Ê Ê FULL LOAD 65ÉC Tset 70ÉC RUNNING 11. The appliance is now running at FULL LOAD. Read the value from the CO meter and wait until this measured value has remained stable for some time.
Page 49 Partial load measurement 16. From the service menu, select: SERVICE OPERATION | PARTIAL LOAD Confirm with The appliance is now in "PARTIAL LOAD" mode and will ignite. SERVICE Ê Ê PARTIAL LOAD 65ÉC Tset 70ÉC RUNNING 17. The appliance is now running at PARTIAL LOAD. Read the value from the meter and wait until this measured value has remained stable for some time.
Page 50 Installation 3.13.4 Switching pressure measurement To measure the switching pressure, proceed as follows: 1. Isolate (10.3 "Isolating the water heater from the mains") the appliance from the power supply. 2. Carefully remove the covers from the appliance. 3. The electrical section is now visible. 4.
Page 51: Conversion To A Different Gas Category
Conversion to a different gas category Introduction Caution The conversion may only by carried out by a competent person. If the appliance has to operate on a different family of gases (liquid petroleum gas or natural gas) or gas category other than that for which the appliance has been configured at the factory, then the appliance will have be adapted using a special conversion kit.
Page 52 Conversion to a different gas category Instruction manual DR-TC...
Page 53: Filling
Filling Installation diagram Legend Vented and unvented UNVENTED Unused numbers are not applicable pressure reducing valve (mandatory) T&P valve stop valve (recommended in pipe C and mandatory in pipe non-return valve (mandatory) circulation pump (optional) drain valve (mandatory) manual gas valve (mandatory) pressure valve (mandatory) air bleed (mandatory)
Page 54: Filling Unvented Installations
Filling Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems.
Page 55: Filling Solar Heating System
Filling solar heating system Note No special safety measures are required when working with the diluted glycol solution specified by the manufacturer. For more information about the fluid, please contact the manufacturer. Warning Before filling the solar heating system to replenish the heating fluid, make certain that: •...
Page 56 Filling 5.3.2 Filling met glycol 1. Insert the hose of the glycol pump into the jerry can containing the glycol. 2. Connect the pump to the jerry can. 3. Connect the hose of the glycol pump to the inlet combination of the pump station.
Page 57: Draining
Draining Installation diagram Legend Vented and unvented UNVENTED Unused numbers are not applicable pressure reducing valve (mandatory) T&P valve stop valve (recommended in pipe C and mandatory in pipe non-return valve (mandatory) circulation pump (optional) drain valve (mandatory) manual gas valve (mandatory) pressure valve (mandatory) air bleed (mandatory)
Page 58: Draining Unvented Installations
Draining Caution The installation diagram shows a pump station with an integrated non-return valve. This type of pump unit may only be used with closed systems. In systems with drain-back, installation of a pump unit with non-return valve is prohibited. There are special pump units for these systems.
Page 59: Draining Solar Heating System
Draining solar Note No special safety measures are required when working with the diluted heating system glycol solution specified by the manufacturer. For more information about the fluid, please contact the manufacturer. 1. Activate the MENU with MENU »OFF ^ ON È...
Page 60 Draining Instruction manual DR-TC...
Page 61: The Control Panel
The control panel Introduction Explanation of icons This chapter covers the following topics: The table explains the meanings of the icons. • Control; Icons and their meaning • Explanation of icons; Name Explanation • ON/OFF switch on controller; • Navigation buttons; Heat demand Heat demand detected...
Page 62: Navigation Buttons
The control panel Navigation buttons The use of these buttons is explained with the help of the figure showing the main menu (11 "Main menu"). The navigation buttons are: • Buttons for UP , and DOWN • Enter: • Reset button: The arrows ^ and È...
Page 63: Status Of The Water Heater
Status of the water heater Introduction 8.2.2 This chapter covers the following topics: In this mode, the water heater continually responds to the hot water demand. The figure shows the display • Operating modes; with the following information: • Error conditions; •...
Page 64: Error Conditions
Status of the water heater 8.2.4 Error conditions PROG In this mode a preset week program is active, and the The figure shows an example of an error condition. If water heater responds continually to demand within the water heater enters this condition, the display will the time periods set in the week program.
Page 65: Service Condition
Service condition Collector temperature warning The figure shows the message This message appears whenever the collector temperature is too high. This message disappears WARNING automatically. If the message does not disappear, you must contact your service and maintenance engineer. MAX. BURNING HOURS: SERVICE REQUIRED WARNING TEMPERATURE...
Page 66 Status of the water heater Instruction manual DR-TC...
Page 67: Starting The Water Heater
Starting the water heater Introduction 5. Press once on the blue arrow ( ) to position the cursor beside ON, then press . The This chapter covers the following topics: display shown in the figure will appear. • Starting the appliance. •...
Page 68 Starting the water heater When the water heater starts, it will run through the 5. After a number of seconds pre-glow, the gas following steps: control valve is opened and ignition takes place. 1. The water temperature drops below the set The icon is activated.
Page 69: Shutting Down
Shutting down 10.1 Introduction 10.3 Isolating the water heater from the mains This chapter describes: The water heater may only be isolated from mains • Decommissioning the water heater for a short power in the correct way. The correct procedure is as period.
Page 70 Shutting down Instruction manual DR-TC...
Page 71: Main Menu
Main menu 11.1 Introduction 11.2 Notation convention for menu-related instructions The MENU is reached by pressing the button on the controller. The MENU ( ) of the controller is divided into sub- menus. For example, SETTINGS is one of the MENU functions reached from the main menu.
Page 72: Week Program
Main menu 2. Use: 11.6 Starting and stopping the week program • to increase the value; The week program can be started up from any other • to decrease the value. operating mode, as follows: • Confirm with .After confirming, the water heater enters "ONmode".
Page 73 The display shows the menu for the week program, 3. Use to set the hours. In the example, this see the figure below. With the default setting, the is 08. program switches on and off every day at 00:00 and Confirm with 23:59 respectively, the water temperature is 65ºC and The cursor moves to the minute digits, which will...
Page 74: Adding Times To A Week Program
Main menu 11.7.3 Week program: setting the water 11.8 Adding times to a week program temperature Call up the menu to INSERT switch-on and switch-off times into a week program as follows: 1. Use to set the water temperature. In the example this is 75°C.
Page 75: Deleting Times From A Week Program
3. Proceed as follows: 3. Scroll with to DELETE. a. Set the switch-on time (11.7.1 "Week program: Confirm with setting the switch-on time"). To warn you that you are now working in the delete sub-menu, the cursor is replaced with an b.
Page 76: Extra Period
Main menu The switching period has been deleted. You will return Setting the switch-on time now to the week program menu. The cursor points to 1. Use to set the day. In the example this is the first programmed period. Confirm with DAY TIME Tset...
Page 77: Settings
2. Use to set the minutes. In the example, 11.11 Settings this is 45. Using the option SETTINGS you can adjust certain Confirm with settings, and display certain water heater specifications: The cursor moves to the water temperature. See the figure •...
Page 78 Main menu 11.11.2 Setting day and time 6. The cursor moves to the minute digits, which will blink. To enter the time and day: Scroll with to the next minute, for example MENU WEEK PROGRAM Confirm the minute setting with ^ EXTRA PERIOD È»SETTINGS TIME...
Page 79: Service Program
Service program 12.1 Introduction 12.2 Setting the hysteresis The service program is used by the installation Call up the menu to set the hysteresis as follows: engineer or service and maintenance engineer for: : HYSTERESIS DOWN • Displaying the water heater history •...
Page 80: Displaying The Water Heater History
Service program 12.4 Displaying the water heater history 12.7 Setting the service interval The water heater history sub-menu is used to display The service interval is a feature of the controller to help the burning hours, the number of ignitions, the number the service and maintenance engineer set the of flame errors and the number of ignition errors.
Page 81: Setting Legionella Prevention
Temporarily raising the setpoint during 12.9.1 Switching legionella prevention on FULL and off LOAD PARTIAL LOAD :>:SERVICE OPERATION. To switch legionella prevention on or off, select: • : ANTI LEGIONELLA SERVICE OPERATION »FULL LOAD ANTI LEGIONELLA PARTIAL LOAD »YES 2. Select FULL LOAD or PARTIAL LOAD. The example below describes the situation for •...
Page 82: Solar Heating System Configuration
Service program 12.10 Solar heating system configuration actually generating heat. This makes use of the difference between the temperature at the top of the Use the solar heating system settings menu to reach solar collector (S ) and that in the appliance the menus shown here: (measured by S SETTINGS SOLAR...
Page 83: Setting The Central Heating Configuration
12.10.6 Displaying contribution This option enables you to read out how much energy the solar heating system supplies. For this data to be displayed, the installation must be equipped with a Q/T sensor (12.10.5 "Setting the Q/T sensor"). Three values are reported on the display: •...
Page 84 Service program Instruction manual DR-TC...
Page 85: Errors
Errors 13.1 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. The manual includes (13.2 "Troubleshooting table for general errors") a table with general errors.
Page 86: Troubleshooting Table For General Errors
13.2 Troubleshooting table for general errors Warning Maintenance may only be performed by a qualified service and maintenance engineer. General errors Indication Cause Measure Remark Gas smell Gas leak Warning Warning Close the main gas valve at once. Immediately contact your installation engineer or local gas company.
Page 87 Indication Cause Measure Remark Water leakage Leakage from a water Tighten the threaded connection If the leak persists, consult your installation engineer connection (threaded) Condensate leakage Check that the condensation water discharge is working properly. Rectify if necessary Leakage from another Trace the leak nearby water water heater or pipe segment...
Page 88 Indication Cause Measure Remark Glycol leakage Leakage from a fluid Tighten the threaded connection. If the leak persists or a component needs replacement, consult connection (threaded) your installation engineer Leakage from a 1. Tighten component joints component 2. Any defective components must be replaced Leakage from solar Consult the supplier and/or manufacturer heating system...
Page 89: Troubleshooting Table For Displayed Errors
13.3 Troubleshooting table for displayed errors Displayed errors Code + description Cause Measure Remark S01 (blocking error) Sensor is not (correctly) Connect the sensor lead to JP3 See the electrical diagram (17 "Appendices"). connected Open circuit from Damaged cable and/or Replace the cable and/or sensor.
Page 90 Code + description Cause Measure Remark S07 (blocking error) Sensor is not (correctly) Connect the sensor lead to J14 (ports 2 and 4) of the solar See the electrical diagram (17 "Appendices"). connected controller Open circuit from Damaged cable and/or Replace the cable and/or sensor.
Page 91 Code + description Cause Measure Remark S15 (blocking error) Short circuit in sensor Replace the dummy sensor To replace the necessary parts, you must contact your installation circuit engineer Short circuit from dummy 2 S17 (blocking error) Short circuit in sensor Replace the cable and/or sensor.
Page 92 Code + description Cause Measure Remark Damaged wiring 1. Check the wiring between the fan and the controller. 2. If any wires are damaged, the wiring harness must be replaced. 3. Reset controller Contaminated or 1. Check if the fan is dirty and repair it if necessary. If the error cannot be resolved or is persistent, contact your blocked fan installation engineer...
Page 93 Code + description Cause Measure Remark F03 (lock out error) Damaged wiring/Open 1. Check the wiring between the pressure switch and the If the error cannot be resolved or is persistent, contact your circuit installation engineer controller The pressure switch To replace the necessary parts, you must contact your installation 2.
Page 94 Code + description Cause Measure Remark F04 (lock out error) No gas 1. Open the main gas supply valve and/or the manual gas supply To restore the gas supply, contact your installation engineer valve before the gas control valve Three unsuccessful 2.
Page 95 Code + description Cause Measure Remark F06 (blocking error) Damaged cable in Check the wiring and the flame probe. Replace the wiring and/or If the error persists, contact your installation engineer. contact with metal flame probe if necessary. To replace the necessary parts, you must contact your installation surface or bent flame Short circuit between engineer...
Page 96 Code + description Cause Measure Remark F19 (blocking error) There is not enough 1. Check that there is power to the controller See the electrical diagram (17 "Appendices"). supply voltage. If the error persists, consult your installation engineer 2. The measured voltage must be 230 V (-15%, +10%) Power supply voltage is too low.
Page 97 Code + description Cause Measure Remark C04 (blocking error) Incorrect water heater 1. Check whether the correct water heater is If the error cannot be resolved or is persistent, contact your selection/Incorrect installation engineer selected (3.4.2 "General and electrical specifications"). selection resistor Appliance selection To replace the necessary parts, you must contact your installation...
Page 98: Warnings On The Display
13.4 Warnings on the display Warnings on the display Situation Cause Measure Note Maximum burning The actual burning Appliance runs, but displays a warning For maintenance to your appliance, please contact your installation hours: Servicing hours have exceeded engineer. required. the preset burning hours.
Page 99 Situation Cause Measure Note The anode protection is • The cables Appliance runs, but displays a warning. 1. Connect the wiring up properly and the warning will disappear. not working. between the 2. If the wiring is correct but the warning remains, check that the potentiostat and earth connection is good and whether the tank is filled with Note...
Page 100 Instruction manual DR-TC...
Page 101: Service Interval
Service interval 14.1 Introduction A service should be carried out at least once a year, both on the water side and on the gas side. Among other things, the service interval depends on the water quality, the average burning time per day and the set water temperature. Note Regular maintenance extends the service life of the water heater.
Page 102 Service interval Instruction manual DR-TC...
Page 103: Performing Maintenance
Performing maintenance 15.1 Introduction Caution Maintenance may only by carried out by an approved service and maintenance engineer. At each service, the water heater undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in the following order.
Page 104: Water-Side Maintenance
Performing maintenance 6. Switch the controller ON by setting the ON/OFF switch to position I. INTERNAL CHECK The display will now show INTERNAL CHECK for about 10 seconds, and will then go to the main menu. MENU »OFF ^ ON È...
Page 105: Gas-Side Maintenance
Take the rate of scale formation into account when deciding on the service interval. Scale formation depends on the local water composition, the water consumption and the water temperature setting. A water temperature setting of maximum 60°C is recommended for the prevention of excessive scale build-up. To guarantee a good, watertight seal around the cleaning opening, replace the gasket, washers, bolts and, if necessary, the lid with new parts before reassembly (see the figure).
Page 106: Solar Collector Maintenance
Performing maintenance 15.4.3 Clean 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 chimney flue. 4. Clean the end of the heat exchanger using tap water. 5.
Page 107: Warranty
Warranty Please contact your supplier for the warranty conditions. Instruction manual DR-TC...
Page 108 Warranty Instruction manual DR-TC...
Page 109: Appendices
Appendices 17.1 Introduction This appendix contains: • Menu structure of the main menu (17.2 "Menu structure") • Appliance electrical diagram (17.3 "Electrical diagram for the appliance") • Electrical diagram, solar heating system (17.4 "Electrical diagram, solar heating system") • Declaration of conformity (17.5 "Declaration of conformity") •...
Page 110: Menu Structure
Appendices 17.2 Menu structure CONTROL SERVICE MAIN MENU PROGRAM HYSTERESE HYSTERESE DOWN HISTORY OF ERRORS START OPERATION APPLIANCE HISTORY CHANGE SETPOINT SELECT WEEK- APPLIANCE PROGRAMMA START OPERATION PUMP RELAY PROGRAM OVERVIEW SERVICE INTERVAL EXTRA PERIOD SERVICE OPERATION FULL LOAD SETTINGS PARTIAL LOAD LANGUAGE ANTI LEGIONELLA...
Page 111 Instruction manual DR-TC...
Page 112: Electrical Diagram For The Appliance
Appendices 17.3 Electrical diagram Electrical diagram for the appliance X J2 JP11 JP12 21 22 23 Primair Secundair 230VAC 50Hz 0309 686a R0 230VAC 50Hz 1 = brown, 2 = blue, 3 = green, 4 = black, 5 = white, 6 = grey / beige, 7 = green, 8 = yellow Instruction manual DR-TC...
Page 113 TERMINAL STRIP CONNECTIONS CONTROLLER CONNECTIONS Earth Power connection for controller Neutral Extra error signal connection Live input of controller Gas control valve connection Live input of isolating transformer (primary Program-controlled pump connection side) Power connection for the fan Live output of isolating transformer Controller display connection (secondary side) Regulator connection for the fan...
Page 114: Electrical Diagram, Solar Heating System
Appendices Electrical diagram, see Errata. 17.4 Electrical diagram, solar heating system DD EE 230VAC 50Hz 0309 686b R0 1 = brown, 2 = blue, 3 = green, 4 = black, 5 = white, 6 = grey / beige, 7 = green, 8 = yellow Instruction manual DR-TC...
Page 115 CONTROLLER CONNECTIONS Earth Neutral Live input of controller Live input for the solar heating system pump ON/OFF. Live input for the solar heating system modulating pump. Neutral input for the solar heating system modulating pump. Modulation output of the solar heating system modulating pump COMPONENTS Control...
Page 116: Declaration Of Conformity
Appendices 17.5 Declaration of Declaration of conformity conformity Instruction manual DR-TC...
Page 117: Week Program Card
17.6 Week program card You can cut the week program card out and keep it near the water heater. Period TIME Tset Pump Period TIME Tset Pump ..°C ON / OFF ..°C ON / OFF ..°C ON / OFF ..°C ON / OFF ..°C ON / OFF...
Page 118 Instruction manual DR-TC...
Page 119 Index actuation 67 maintenance ambient conditions 19 condensation water discharge 101 ambient temperature 20 descaling 100 gas-side 101 heat exchanger 102 preparation 99 connecting the air supply 29 scale 100 connecting the chimney flue 29 mode connecting the circulation pipe 26, 27 ERROR 60 connecting the cold water side 26, 27 SERVICE REQUIRED 61...
Page 120 Index symbol installation engineer 10 user 10 service engineer 10 user 10 warranty 103 water target groups 10 composition 20 terminal block 35 water heater ThermoControl displaying history 76 ON/OFF switch 57 displaying the selection 76 trademarks 3 types 9, 19 Instruction manual DR-TC 0311 179 1.2 UK...

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DORCHESTER DR-TC 40 Installation, Commissioning And Maintenance Instructions

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