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DORCHESTER DR-FC 120, Installation, Comissioning And Maintenance Instructions

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DORCHESTER DR-FC 120 Installation, Comissioning And Maintenance Instructions Download Page 1

DORCHESTER

DR-FC 25 to DR-FC 120

CONDENSING HOT WATER

STORAGE HEATERS

Installation, Commissioning

and Maintenance Instructions

DORCHESTER MODELS: DR-FC 25, 30, 45, 60, 80, 95, 120

Room Sealed or Open Flue, Direct Gas Fired Condensing Hot Water

Storage Heaters with Premix Burner and Automatic Ignition for

Domestic Hot Water Installations

NOTE:
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

PUBLICATION NO. 50001195

ISSUE: “A”.

FEBRUARY 2010

THIS WATER HEATER IS FOR USE ON GROUP H NATURAL GAS (2

FAMILY) I ,

OR PROPANE (3

FAMILY) I . PLEASE ENSURE RELEVANT INFORMATION

REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO GAS TO BE FIRED
BEFORE FIRING HEATER.

ND

RD

2H

3P

THIS WATER HEATER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.

0309429

Summary of Contents for DR-FC 120

Page 1: ...on for Domestic Hot Water Installations NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT PUBLICATION NO 50001195 ISSUE A FEBRUARY 20...

Page 2: ......

Page 3: ...he service interval is a feature of the controller to help the service and maintenance engineer set the maintenance frequency based on the number of months that the appliance has been running The serv...

Page 4: ......

Page 5: ...parties arising from unauthorised use use other than that stated in this manual and use other than in accordance with the General Conditions registered at the Chamber of Commerce Refer further to the...

Page 6: ...4 Instruction manual DR FC gis...

Page 7: ...cifications 19 3 5 Installation diagram 24 3 6 Unvented water connections 25 3 7 Vented water connections 26 3 8 Gas connection 26 3 9 Air supply and chimney flue discharge 27 3 10 Electrical connecti...

Page 8: ...ing the water temperature 57 11 5 Week program 58 11 6 Starting and stopping the week program 58 11 7 Changing the water heater s standard week program 58 11 8 Adding times to a week program 60 11 9 D...

Page 9: ...duction 83 15 2 Preparation for maintenance 83 15 3 Water side maintenance 84 15 4 Gas side maintenance 85 15 5 Finalizing maintenance 86 16 Warranty 87 17 Appendices 89 17 1 Introduction 89 17 2 Menu...

Page 10: ...Table of contents 8 Instruction manual DR FC...

Page 11: ...CE mark 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 heate...

Page 12: ...or human consumption Part 2 Design BS 5546 Specification for installation of hot water supplies for domestic purposes using gas fired appliances of rated input not exceeding 70 kW BS 5440 Flueing and...

Page 13: ...and the set water temperature Note To determine the correct service interval it is recommended to arrange for the service and maintenance engineer to check the water heater on both the water and gas...

Page 14: ...water heater for a brief or long period of time Main menu This chapter describes the main menu of the display This is the actual menu for the user However the installation engineer and service and ma...

Page 15: ...tank through the hot water outlet 2 Once the water heater is completely filled with water it will constantly be under mains water pressure As hot water is drawn from the water heater cold water is im...

Page 16: ...tank 11 heat exchanger 12 inspection and cleaning opening 13 temperature sensor T2 14 cold water inlet 15 drain valve 16 gas control valve 17 burner 18 fan 19 air supply hose 20 hot surface igniter 21...

Page 17: ...oller monitors three temperatures that are important for safety The table explains the functioning of the temperature sensors Temperature protection 2 4 3 Gas control valve The controller opens the ga...

Page 18: ...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 This valve also prevents water from flowing backwards...

Page 19: ...he water heater remove the packaging carefully We recommend unpacking the water heater at or near its intended location Caution The water heater may only be manoeuvred in an upright position Take care...

Page 20: ...ith the regulations governing drinking water for human consumption The table gives an overview of the specifications Water specifications Note If the water specifications deviate from those stated in...

Page 21: ...a suitable metal leak tray The leak tray must have an appropriate waste water drain and must be at least 5 cm deep with a length and width at least 5 cm greater than the diameter of the water heater 3...

Page 22: ...Top and front view of the water heater Legend See the table DR FC 25 30 45 60 DR FC 80 95 120 IMD 0771 R0 45 18 45 3 5 4 F E 2 6 6 5 Hy Hx C Ny D 2 5 P M 6 1 4 R S N A G 7 K W H 3 5 P M 6 4 R S K N A...

Page 23: ...ter inlet mm 265 255 255 255 225 225 225 N Height of hot water outlet mm 1485 2005 2005 2005 2060 2060 2060 Ny y position of hot water outlet mm 205 205 205 205 205 205 205 P Height of cleaning openin...

Page 24: ...erval hysteresis down o C 0 10 0 10 0 10 0 10 0 10 0 10 0 10 Default value hysteresis down oC 5 5 5 5 5 5 5 Number of power anodes 1 2 2 2 2 2 2 Measured pressure differential across pressure switch P...

Page 25: ...20 20 20 20 20 20 20 CO2 Vol 9 0 1 0 9 0 1 0 9 0 1 0 9 0 1 0 8 9 1 0 8 9 1 0 8 9 1 0 Gas consumption m3 h 3 1 3 2 5 0 6 0 8 3 10 1 12 3 Gas category 3P G31 37 50 mbar Venturi restrictor diameter mm 5...

Page 26: ...commended 5 non return valve mandatory 6 circulation pump optional 9 drain valve 10 manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drain 14 draw off poi...

Page 27: ...y energy loss 1 Optional fit a temperature gauge 12 so you can check the temperature of the tap water 2 Fit the T P valve 3 3 Fit a stop valve 11 in the hot water outlet pipe for servicing 3 6 3 Circu...

Page 28: ...required at draw off points a circulation pump can be installed This improves comfort and reduces water wastage 1 Fit a circulation pump 6 of the correct capacity for the length and resistance of the...

Page 29: ...competent person in compliance with general and locally applicable regulations 1 3 Regulations Depending on the approved installation types there are several alternatives for connecting the air suppl...

Page 30: ...Installation 28 Instruction manual DR FC 3 is Installation types IMD 0790 R0 C43 C13 C53 B23 C33...

Page 31: ...ou use less than the stated maximum pipe length the maximum number of bends still may not be exceeded The following example illustrates how to use the table Installation type Description B23 Air for c...

Page 32: ...type approved for the water heater Use of an incorrect roof or wall mounted flue terminal can cause the installation to malfunction Concentric wall flue terminal specifications C13 IMD 0794 R0 Subjec...

Page 33: ...C 80 95 120 532702158 1 Manufacturer Muelink Grol Model M2000 DDV HR C Pipe material Construction Concentric Flue gas discharge Thick walled aluminium with lipped sealing ring Air supply Thin walled g...

Page 34: ...e 4 6 metres per bend must be added This brings the total pipe length to 4 6 x 8 10 36 8 10 46 8 m This is less than the maximum length of 55 metres stated in the table The installation therefore fulf...

Page 35: ...olating transformer please contact the supplier The figure shows a view of the terminal block and the table explains the relevant connections Connector block In preparation you must first remove the t...

Page 36: ...r heater 3 10 4 Isolating transformer An isolating transformer should be used if there is a case of floating neutral 1 Refer to the fitting instructions provided with the isolating transformer Contact...

Page 37: ...the covers onto the water heater 3 11 Checking supply pressure CO2 value and switching pressure Note Before starting the water heater and or checking the supply pressure and or the CO2 value and or t...

Page 38: ...Gas data Note Consult the mains gas supply company if the supply pressure is not correct You cannot yet start using the water heater You must now take the water heater out of service 10 3 Isolating th...

Page 39: ...FULL LOAD Read the value from the CO2 meter and wait until this measured value has remained stable for some time This may take several minutes 13 Then compare the measured CO2 value against the value...

Page 40: ...e table then you may not start the water heater Switch off the water heater Shut off the gas supply to the water heater Replace the covers on the water heater 19 Contact the water heater s supplier Pa...

Page 41: ...ollows 1 Isolate 10 3 Isolating the water heater from the mains the water heater from the power supply 2 Carefully remove the covers from the water heater 3 The electrical section is now visible 4 Rem...

Page 42: ...show 11 Check whether the measured value matches the value from the table 3 4 3 Gas data Note If the PRESSURE SWITCH message does not appear there is a fault This must be resolved first by a qualifie...

Page 43: ...hrough 60 1 Isolate the water heater from the power supply 10 3 Isolating the water heater from the mains 2 Shut off the gas supply 3 Undo the screws of the covers 4 Carefully remove the covers from t...

Page 44: ...icker over the existing sticker on the gas control valve This makes it clear that the gas control valve no longer functions on the gas for which it was originally adjusted 18 Fit the gas control valve...

Page 45: ...rom the water heater 5 Detach the 3 part gas coupling 1 adjacent to the gas control valve 6 Detach the hoses marked H and L at their couplings 2 and 3 on the gas control valve The hoses are attached w...

Page 46: ...ix it in place using the hose clamp 5 24 Refit the connector 4 to the gas control valve 25 Insert the hose with code H into the coupling 3 on the offset adjuster and insert the hose with code L into t...

Page 47: ...e 10 manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drain 14 draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aeratio...

Page 48: ...ng a pressure reducing valve 1 The expansion valve in the protected cold supply set up is defective or incorrectly fitted 5 2 Filling vented installations To fill the water heater proceed as follows 1...

Page 49: ...ve 10 manual gas valve mandatory 11 service stop valve 12 temperature gauge optional 13 condensation drain 14 draw off points 15 expansion valve mandatory 16 expansion vessel mandatory 17 3 way aerati...

Page 50: ...alve 4 in the cold water inlet A 10 Open the drain valve 9 6 2 Draining vented installations Some service activities require the water heater to be drained The procedure is as follows 1 Activate the M...

Page 51: ...both with and without icons 7 3 Explanation of icons The table explains the meanings of the icons Icons and their meaning 7 4 ON OFF switch on controller The ON OFF switch of the controller turns the...

Page 52: ...n menu The main menu comprises OFF ON WEEK PROGRAM EXTRA PERIOD and SETTINGS You have to scroll down further to see the options EXTRA PERIOD and SETTINGS The selected option is confirmed using Pressin...

Page 53: ...rarily overruled to fulfil a single period of demand When the period has passed the water heater automatically returns to the previous operating mode The figure shows the display with the following in...

Page 54: ...re the water heater can resume operation BLOCKING ERRORS These errors disappear automatically once the cause of the error has been removed after which the water heater resumes operation by itself The...

Page 55: ...gh the operating cycle 2 3 Water heater operating cycle If the operating cycle is not run then there is no heat demand should this happen then Tset will probably need to be set 11 4 Setting the water...

Page 56: ...ed and ignition takes place The icon is activated The message IGNITION appears 6 After ignition the flame is detected and the water heater will be running This means that actual heating has started Th...

Page 57: ...ing the water heater from the mains The water heater may only be isolated from mains power in the correct way The correct procedure is as follows 1 Activate the MENU with 2 Position the cursor in fron...

Page 58: ...Shutting down 56 Instruction manual DR FC 10 gis...

Page 59: ...after 30 seconds the water heater will automatically return to the mode it was previously in 11 2 Notation convention for menu related instructions The MENU of the controller is divided into sub menus...

Page 60: ...is 65 C If you wish you can change every setting in the standard week program of the water heater When the week program is running if the water temperature becomes too low then the water heater will...

Page 61: ...to the minute digits which will blink Note Because the switch off time can never be earlier than the switch on time the switch off time setting is automatically adjusted with the switch on time 4 Use...

Page 62: ...eek program setting the switch off time times 4 After changing all desired switch on and switch off times you can start running the week program Scroll with to START OPERATION Confirm with 11 8 Adding...

Page 63: ...heater are programmed as in the figure To delete a period proceed as follows 1 WEEK PROGRAM PROGRAM OVERVIEW Confirm with 2 Scroll with to PROGRAM OVERVIEW Confirm with The display shows the menu for...

Page 64: ...l up the menu for entering an extra period via 2 EXTRA PERIOD Confirm with The display show the settings for the extra period Setting the switch on time 1 Use and to set the day In the example this is...

Page 65: ...tions Adjustable settings Menu language Current day of week and time Displayable water heater specifications this category is only relevant to the installation engineer and or service and maintenance...

Page 66: ...specifications Note This category is solely intended for the installation engineer and or service and maintenance engineer The corrected data is shown in the table of general and electrical data 3 4...

Page 67: ...n is called the hysteresis The standard setting for this margin is 5 C The operating cycle starts when the water temperature drops to 5 C below the SETPOINT and ends when the water reaches 5 C above t...

Page 68: ...val 14 2 Determining service interval which defines the frequency of maintenance by the service and maintenance engineer based on the number of burning hours The service interval is based on the numbe...

Page 69: ...To switch legionella prevention on or off select ANTI LEGIONELLA Select NO to switch legionella prevention off Select YES to switch legionella prevention on The following screen appears Select START t...

Page 70: ...Service program 68 Instruction manual DR FC 12 is...

Page 71: ...ion See the figures The first shows a possible error the second shows the appropriate checking action There are various types of errors all falling into one of two groups LOCK OUT ERRORS When the caus...

Page 72: ...ation engineer or local gas company The display is off The water heater is off Start the water heater 9 Starting the water heater No supply voltage present 1 Check whether the isolator is ON 2 Check t...

Page 73: ...sufficient or no hot water The water heater is off Start the water heater 9 Starting the water heater No supply voltage present 1 Check whether the isolator is ON 2 Check that there is power to the is...

Page 74: ...ou must contact your installation engineer S03 blocking error Open circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Sensor is not correctly connected Connect the sensor lead to JP...

Page 75: ...r installation engineer S13 blocking error Short circuit in sensor 2 of temperature sensor T1 at the top of the tank 1 Short circuit in sensor circuit Replace the cable and or sensor To replace the ne...

Page 76: ...ation engineer to have an isolating transformer installed F02 lock out error Fan fails to run at correct speed Defective motor and or rotor 1 Check the motor and rotor 2 Replace the fan if the motor o...

Page 77: ...rectly fitted Refit them if necessary 3 Check for cracks in the hoses on the pressure switch and in the air supply hose between fan and burner If necessary replace the hoses 4 Check whether the chimne...

Page 78: ...This must lie between 2 and 10 Ohm at room temperature 4 Check that the hot surface igniter lights up during ignition 5 If necessary replace the hot surface igniter If the error persists contact your...

Page 79: ...ed or is persistent contact your installation engineer To replace the necessary parts you must contact your installation engineer F08 lock out error Error message from safety relay Flame detection bef...

Page 80: ...error EEPROM contents do not match the software version Processor software error C03 blocking error Reset error Too many resets in too short a period Wait for the error to disappear maximum 1 hour If...

Page 81: ...necessary Replace the sensor if the error persists To replace the necessary parts you must contact your installation engineer E04 lock out error Defect in the dummy sensor 2 The two temperature senso...

Page 82: ...gineer Anode protection not working The cables between the potentiostat and anodes are loose or have been connected incorrectly The earth connection of the anodes is loose The water heater is not fill...

Page 83: ...The standard setting is 500 burning hours Example In the first three months the water heater has burnt 300 hours During maintenance it is evident that one service per year will be sufficient Therefore...

Page 84: ...Service interval 82 Instruction manual DR FC 14 is...

Page 85: ...l and the full serial number of the water heater These details can be found on the rating plate Only by ordering with this information can you be sure to receive the correct spare parts 15 2 Preparati...

Page 86: ...tected cold supply setup The water should spurt out 16 Check the drainage pipes from the discharge points of all valves and remove any scale deposits that may be present 17 Drain the water heater see...

Page 87: ...it is essential to clean the condensation water discharge and condensation trap regularly 15 4 Gas side maintenance 15 4 1 Introduction The following steps must be carried out on the gas side 1 Clean...

Page 88: ...the following steps 1 Fill the water heater 5 Filling 2 Start the water heater 9 Starting the water heater 3 Check the CO2 value 3 11 2 CO2 adjustment 4 Check the switching pressure of the pressure s...

Page 89: ...Instruction manual DR FC 87 s 16 Warranty Contact your supplier for the warranty conditons of this water heater...

Page 90: ...Warranty 88 Instruction manual DR FC 16 s...

Page 91: ...struction manual DR FC 89 is 17 Appendices 17 1 Introduction This appendix contains Menu structure 17 2 Menu structure Electrical diagram 17 3 Electrical diagram Week program card 17 4 Week program ca...

Page 92: ...REGULATION INTERVAL FULL LOAD PARTIAL LOAD EXTRA PERIOD SERVICE INTERVAL SETTINGS LANGUAGE SERVICE OPERATION START OPERATION SELECT APPLIANCE PROGRAM OVERVIEW PUMP RELAY HISTORY OF ERRORS CHANGE SETP...

Page 93: ...Instruction manual DR FC 91 is...

Page 94: ...X 6 6 X X 6 6 X X 6 JP3 JP11 X 6 6 X F3 X 3 X 2 F1 1 X J2 Q P O S 6 6 12 11 16 15 14 13 19 18 17 20 24 21 22 23 J33 A R J38 J37 X X J34 J35 J39 J36 4 4 M X X 4 X 2 1 3 2 1 1 2 3 1 2 3 4 2 1 1 5 6 2 3...

Page 95: ...er 0 I switch M Display N Fan O Temperature sensor T2 bottom of tank P Dummy Q Temperature sensor T1 top of tank R Selection resistor S Pressure switch T Power anodes U Power anode signal V Potentiost...

Page 96: ...Appendices 94 Instruction manual DR FC 17 is...

Page 97: ...N OFF OFF 5 ON C ON OFF OFF 6 ON C ON OFF OFF 7 ON C ON OFF OFF 8 ON C ON OFF OFF 9 ON C ON OFF OFF 10 ON C ON OFF OFF 11 ON C ON OFF OFF Period DAY TIME Tset Pump 1 ON MO 14 30 70 C ON OFF OFF MO 16...

Page 98: ...Instruction manual DR FC 96...

Page 99: ...and 49 installation diagram 24 installation engineer 10 J join air supply 27 circulation pipe 25 26 cold water side 25 26 electrical 32 flue gas discharge 27 gas 26 hot water side 25 L language settin...

Page 100: ...9 1 3 UK Index Instruction manual DR FC W water composition 18 setting the temperature 57 water heater displaying history 66 displaying specifications 64 displaying the selection 66 protection 15 type...

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