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DORCHESTER DR-LA 30 User Manual

Dr-la series of hot water storage heaters, open flue, direct gas fired hot water storage heaters for domestic hot water installations, natural gas & lpg
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Dorchester DR-LA Range
of Hot Water Storage Heaters
Open Flue, Direct Gas Fired Hot Water Storage Heaters
with Automatic Ignition
for Domestic Hot Water Installations
Installation, Commissioning
and Servicing Instructions
DORCHESTER DR-LA 30, 40, 45, 60, 75, 95, 110 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
. PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN
3+
DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING
HEATER.
THIS WATER HEATER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
PUBLICATION NO. 500001137
ISSUE 'A'
SEPTEMBER 2005
1

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  • Page 1 Automatic Ignition for Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions DORCHESTER DR-LA 30, 40, 45, 60, 75, 95, 110 Models NATURAL GAS I LPG I 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 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - 33 3.12.2 Conversion to a different gas category DR-LA 30 through 95 - - 34 3.12.3...
  • Page 5 Electrical diagram DR-LA - - - - - - - - - - - - - - - - - - - - - - - - 62 1.2.1 Electrical diagram DR-LA 30 through 95 and 110 (natural gas) - 62 1.2.2...
  • Page 6 Instruction manual DR-LA...

  • Page 7: Introduction

    . The information in this 11BS manual is applicable to types: DR-LA 30, DR-LA 40, DR-LA 45, DR-LA 60, DR- LA 75, DR-LA 95 and DR-LA 110. The manner of construction and features of the water heater are in conformance with the European standard for gas-fired storage water heaters for the production of domestic hot water (EN 89).

  • 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. Caution 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

    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. Instruction manual DR-LA...

  • 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 Legend a flue gas discharge b draught diverter c anodes d flue tubes e flue baffles f flue gas thermostat g flue gas thermostat sensor h insulation layer i hot water tank...

  • Page 13: The Water Heater's Heating Cycle

    The water heater’s heating cycle hot surface igniter z ensures the ignition of the gas/air mixture. The flue gases generated by this combustion are led through the flue tubes d. There are flue baffles e located in the flue tubes. These slow down the flue gas exhaust, improving the heat transfer efficiency.

  • Page 14: Combustion Products Discharge Safety Device

    Functioning of the water heater 2.4.2 Combustion products discharge safety device The flue gases are channelled to the outside via the draught diverter b and the flue gas discharge a. To prevent the flue gases from flowing back into the boiler room, the discharge ducting is monitored by a feature called the combustion products discharge safety device.

  • Page 15: Options

    Options Options The heaters can be supplied with the following additional variations, either ready fitted or for site fitting: 2.7.1 The heaters can be supplied adjusted for use on propane or butane, see section 3.12. It is most important that the heater is correctly adjusted for the gas to be fired.
  • Page 16 Functioning of the water heater Instruction manual DR-LA...

  • Page 17: Installation

    Introduction Installation Warning The installation should 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 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-LA 30 DR-LA 40 DR-LA 45 DR-LA 60 DR-LA 75 DR-LA 95...
  • Page 19 Environmental conditions If the available clearance is less than 100 cm, flexible magnesium anodes may be ordered from Hamworthy, the installation engineer / supplier. Caution 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.

  • 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 Tabel 3.5. 10” 37” 45” IMD-0135 Figure 3.2 Plan and elevation of the water heater Instruction manual DR-LA...
  • Page 21 Technical specifications Table 3.3 Dimensions Dimension Description DR-LA DR-LA DR-LA DR-LA DR-LA DR-LA DR-LA A Height including draught diverter (mm) 1900 2105 1900 2105 2010 2085 2085 B Height excluding draught diverter (mm) 1750 1960 1750 1960 1795 1870 1870 D Diameter of the water heater (mm) E Width of water heater incl.
  • Page 22 Installation Table 3.4 General and electrical data (Continued) DESCRIPTION Unit DR-LA DR-LA DR-LA DR-LA DR-LA DR-LA DR-LA Electrical power consumption Supply voltage 230 (-15% +10%) Mains frequency 50 (±1 Hz) Instruction manual DR-LA...
  • Page 23 Technical specifications Tabel 3.5 Gas data Gas category data Unit DR-LA DR-LA DR-LA DR-LA DR-LA DR-LA DR-LA 2H3+ Data for natural gas 2H: G20-20 mbar Orifice diameter 3.20 3.20 3.10 2.95 3.20 3.20 3.90 (1) = Blanking plate 1, 2 or 3 (2) = Burner pressure regulator (3) = High Low control Nominal load (gross)

  • Page 24: Installation Diagram

    Installation Installation diagram Figure 3.3 shows the water and gas connection diagrams for unvented and vented installations. The following paragraphs, describing the connections in detail, make reference to these diagrams Legend UNVENTED pressure-reducing valve (mandatory ) expansion vessel (mandatory) T&P valve (mandatory) a) safety valve stop valve (recommended) non-return valve (mandatory)

  • 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 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. The expansion valve regulates the pressure to 5.5 bar.

  • Page 26: Water Connections, Vented

    Installation Water connections, Vented 3.7.1 Cold water side See a in Figure 3.3. • Fit an approved stop valve on the cold water side between the water tank and the water heater, as required by regulations. Ideally the vent pipe should be linked to a separate tundish/drain or else to the cold water storage tank.

  • Page 27: Flue Gas Discharge

    Flue gas discharge See d in Figure 3.3. 1. Fit a gas valve 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 28: Flue Gas Thermostat Assembly

    Installation 5. Place the draught diverter in the support bracket and mark the centres for the two drill holes on the top surface of the water heater. Remove the draught diverter from the water heater. 6. Now drill two holes into the top of the water heater (3.2 mm drill).

  • Page 29: Electrical Connection

    Electrical connection 4. Screw the cable clips 3 in place in the draught diverter and the water heater. 3.10 Electrical Warning connection The installation should 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 service.

  • Page 30: Mains Power

    Installation IMD-0134 Figure 3.7 Connection block (connections 1 through 6 explained in Table 3.6) 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 31: Checking The Supply Pressure And Burner Pressure

    IMD-0127 Figure 3.8 Gas control valve for DR-LA 30 through 95 and DR-LA 110 Instruction manual DR-LA...
  • Page 32 Gas control valve for DR-LA 110 IMD-0129 Figure 3.8 Gas control valve for DR-LA 30 through 95 and DR-LA 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...

  • Page 33: Conversion To A Different Gas Category

    There are differences between the conversions for the DR-LA 110 and the DR- LA 30 through 95. The conversion procedures are described in paragraphs: • 3.12.2 Conversion to a different gas category DR-LA 30 through 95 • 3.12.3 Conversion to a different gas category, DR-LA110.

  • Page 34: Conversion To A Different Gas Category Dr-La 30 Through 95

    IMD-0126 Figure 3.9 Exchanging orifices 3.12.2 Conversion to a different gas category DR-LA 30 through 95 1. Disconnect the water heater from the power supply. See paragraph 7.3.2 Isolate the water heater from the power supply.
  • Page 35 Conversion to a different gas category Legend Figure 3.9 through burner pressure regulator gas control connector blank plate supply pressure test nipple gas control valve IMD-0131 Figure 3.10 Conversion of gas control 12. Check whether there is a burner pressure regulator fitted to the gas control or simply a blank plate Caution...

  • Page 36: Conversion To A Different Gas Category, Dr-La110

    Conversion from LP gas to natural gas 1. Perform steps 1 through 9 of paragraph 3.12.2 Conversion to a different gas category DR-LA 30 through 2. Detach the high-low control 3. Fit the burner pressure regulator including the sealing gasket from the conversion kit.
  • Page 37 8. Connect the cables of the gas control valve, the hot surface igniter and flame probe to the 6-terminal connector strip as shown in the electrical diagram. See appendices 1.2.1 Electrical diagram DR-LA 30 through 95 and 110 (natural gas) 1.2.2 Electrical diagram DR-LA 110 (LP gas).
  • Page 38 Conversion from natural gas to LP gas 1. Perform steps 1 through 9 of paragraph 3.12.2 Conversion to a different gas category DR-LA 30 through 2. Detach the burner pressure regulator 3. Fit the high-low control including the sealing gasket from the conversion kit.

  • 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. Legend UNVENTED a pressure-reducing valve (mandatory ) b expansion vessel (mandatory) c T&P valve (mandatory) ca) safety valve d stop valve (recommended)

  • Page 40: Filling The Water Heater

    Filling and draining Filling the water heater 4.2.1 Filling unvented installations To fill the water heater, proceed as follows. 1. Open the stop valve i in the hot water pipe and, if present, the stop valves d for the circulation pump. 2.

  • Page 41: Draining Vented Installations

    Draining the water heater 7. Vent the water heater (or installation) so that it drains completely. 4.3.2 Draining vented installations Some service activities require the water heater to be drained. The procedure is as follows: 1. Shut the water heater down by putting the On/Off switch to position 0. 2.
  • Page 42 Filling and draining Instruction manual DR-LA...

  • Page 43: Controls

    Introduction 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; • 5.7 Flue gas thermostat reset button. Control panel Figure 5.1 shows the control panel The panel consists of: •...

  • Page 44: Explanation Of The Symbols

    Controls Explanation of the Table 5.1 shows the meanings of thesymbol s on the control panel. symbols Table 5.1 Icons and their meaning Symbol Name Explanation ON/OFF switch 'ON mode' / 'OFF mode' Reset button Reset burner control Power LED Indicates power to burner control Error LED Burner control lockout...
  • Page 45 Flue gas thermostat reset button button to reset (if the sensor is not sufficiently cooled down, the flue gas thermostat will immediately lock out again). The water heater will then automatically start up again, if there is a demand. If this does not happen, refer to chapter 8 Troubleshooting for a complete troubleshooting guide.
  • Page 46 Controls Instruction manual DR-LA...

  • Page 47: Status Of The Water Heater

    Introduction Status of the water heater Introduction Topics covered in this chapter: • 6.2 Operating states; • 6.3 Error states; Operating states The water heater has three operating states, namely: • ISOLATED In this state 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 48 Status of the water heater The cause of the error cannot be seen on the control panel. For a detailed overview of error states, please refer to chapter Troubleshooting. If, as end-user, you find the water heater in an error status, you may attempt to re-start the water heater by pressing the reset button once.

  • Page 49: Starting Up And Shutting Down

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

  • Page 50: Heating Cycle

    Starting up and shutting down Heating cycle The heating cycle is activated as soon as the measured water temperature ) falls below the threshold value (T ). This threshold value depends on water the state in which you want to place the water heater. For example, if the water heater is in the "OFF mode"...

  • Page 51: 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 should go into an "error" state, you will be unable to draw hot water.

  • Page 52: Troubleshooting Table For General Errors

    Warning Maintenance may only be performed by a qualified service and maintenance engineer. Troubleshooting table for general errors Table 8.1 General errors Page 1 of 2 Symptom Cause Solution Remark Gas smell Gas leak Warning Caution Immediately close the main gas valve. Immediately contact your installer or local gas company.

  • Page 53: Troubleshooting Table "No Hot Water

    Warning Maintenance may only be performed by a qualified service and maintenance engineer. Table 8.1 General errors Page 2 of 2 Symptom Cause Solution Remark Explosive ignition Incorrect supply Set the correct supply pressure and/or burner pressure, see If ignition is not improved, consult your installer. pressure and/or burner 3.11 Checking the supply pressure and burner pressure.
  • Page 54 Warning Maintenance may only be performed by a qualified service and maintenance engineer. Table 8.2 No hot water Page 2 of 2 Symptom Cause Solution Remark Green LED ON There are three possible causes for this error. To determine the cause, the error must be made to recur: Red LED ON.

  • Page 55: Troubleshooting Table "Insufficient Hot Water

    Warning Maintenance may only be performed by a qualified service and maintenance engineer. Troubleshooting table "insufficient hot water’" If the water heater fails to supply any hot water, there are several possible causes. Refer to Table 8.3 Insufficient hot water Table 8.3 Insufficient hot water Symptom Cause...
  • Page 56 Warning Maintenance may only be performed by a qualified service and maintenance engineer. Instruction manual DR-LA...

  • Page 57: Maintenance

    Introduction 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 58: 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 anodes that are present must be replaced as soon as they are 60% or more used up (take this into consideration when determining the maintenance frequency).

  • Page 59: Gas-Side Maintenance

    Gas-side maintenance To simplify descaling and cleaning of the tank, the appliance is equipped with two cleaning openings. IMD-0235 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 60: Cleaning The Orifices

    Maintenance 3. Re-attach the burners. 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.

  • Page 61: A Appendices

    Appendices Introduction This appendix contains: • Electrical diagram DR-LA. Instruction manual DR-LA...

  • Page 62: Electrical Diagram Dr-La

    Week timer Phase input of hot surface igniter Ionisatiion detection = output Normally open Phase input alarm Normally closed Fuse (T5A) Relay (Max. 250V, 10A) Figure 1.1 Electrical diagram DR-LA 30 through 95 and 110 (natural gas) Instruction manual DR-LA...

  • Page 63: Electrical Diagram Dr-La 110 (Lp Gas)

    Electrical diagram DR-LA 1.2.2 Electrical diagram DR-LA 110 (LP gas) 230V AC 50Hz 1 = brown 2 = blue 3 = yel./green 4 = black 5 = white 19 20 21 22 23 FUSE SUR- FACE L’ L" N H N 1 4 4 4 25 26 28 29...
  • Page 64 Appendices Instruction manual DR-LA...

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