DORCHESTER DR-FC 25 Installation, Commissioning And Maintenance Instructions Download Page 1

Page: 1 / 98

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.

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

FAMILY) I

LPG (3

FAMILY) I

. PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN

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

THIS WATER HEATER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES

PUBLICATION NO. 500001153

ISSUE ‘A’
FEBRUARY 2006

DORCHESTER

DR-FC 25 to DR-FC 60

HOT WATER

STORAGE HEATERS

Installation, Commissioning

and Maintenance Instructions

Summary of Contents for DR-FC 25

Page 1: ...OR SERVICING EQUIPMENT THIS WATER HEATER IS FOR USE ON GROUP H NATURAL GAS 2ND FAMILY I2H OR LPG 3RD FAMILY I3 PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFI...

Page 2: ...2...

Page 3: ...ion 14 2 5 1 Unvented installation 14 2 5 2 Vented installation 14 2 5 3 T P valve 14 2 6 Options 15 2 6 1 LPG 15 2 6 2 Unvented Supply 15 2 6 3 Top to Bottom Circulation 15 3 Installation 17 3 1 Intr...

Page 4: ...Filling vented installations 39 4 3 Draining the water heater 41 4 3 1 Draining unvented installations 41 4 3 2 Draining vented installations 41 5 The control panel 43 5 1 Introduction 43 5 2 Operati...

Page 5: ...69 9 2 Setting the hysteresis 69 9 3 Displaying the error history 69 9 4 Displaying the water heater history 70 9 5 Display the selected water heater 70 9 6 Setting the pump on off 70 9 7 Setting the...

Page 6: ...6 Instruction Manual DR FC gis A Appendices 95 A 1 Introduction 95 A 2 Electrical diagram DR FC 96...

Page 7: ...llow the printed instructions may lead to personal injury and damage to the water heater 1 2 What to do if you smell gas Warning Whenever there is a smell of gas No naked flames No smoking Avoid causi...

Page 8: ...t not exceeding 70 kW BS 5440 Installation and maintenance of flues and ventilation for gas appliances of rated input not exceeding 70 kW net 1st 2nd and 3rd family gases Part 1 Flues Part 2 Ventilati...

Page 9: ...or the service and maintenance engineer to check the water heater on both the water and gas side three months after installation Based on this check the best maintenance frequency can be determined n...

Page 10: ...gis Describes the main menu of the display This is the actual menu for the user however the installer and service and maintenance engineers will also need to use this menu 9 Service program is Descri...

Page 11: ...of the water heater Legend a top cover b hot water outlet c electrical connection block d control panel e pressure switch f control panel g temperature sensor T1 h combustion chamber i anode j heater...

Page 12: ...and thereby increases the performance of the unit The condensate yielded by this process is discharged via the siphon w The PU insulation layer x prevents heat loss The inside of the heater is enamell...

Page 13: ...ssure switch The pressure switch ensures the discharge of flue gases and the supply of incoming air during the pre purge and normal running of the water heater The standard position of the pressure sw...

Page 14: ...n against an excessively high water supply pressure These components are fitted to the cold water pipe See paragraph 3 6 1 Cold water side 2 5 2 Vented installation With a vented installation excess p...

Page 15: ...to be fired 2 6 2 Unvented Supply The heaters can be supplied with a purpose designed and sized unvented kit comprising pressure reducing valve non return valve expansion vessel expansion relief valve...

Page 16: ...Functioning of the water heater 16 Instruction Manual DR FC 2 gis...

Page 17: ...er connections Unvented Water connections Vented Gas connection Air supply and flue gas discharge Electrical connection Checking the supply pressure and burner pressure Conversion to a different gas c...

Page 18: ...nces For access to the water heater it is recommended that the following clearances are observed see Figure 3 2 AA around the water heater s control column and cleaning openings 100 cm BB around the w...

Page 19: ...om the heater and or connections can cause damage to the immediate environment or floors below the level of the boiler room If this is the case then the water heater should be installed above a wastew...

Page 20: ...394 Table 3 3 Dimensions Dime nsion Description DR FC 25 DR FC 30 DR FC 45 DR FC 60 A Total height mm 1370 1900 1900 1900 D Diameter of the water heater mm 705 705 705 705 G Diameter of air supply flu...

Page 21: ...Rp 1 Table 3 4 General and electrical data DESCRIPTION Unit DR FC 25 DR FC 30 DR FC 45 DR FC 60 Capacity litres 227 386 386 386 Empty weight kg 175 220 220 220 Maximum working pressure bar 8 8 8 8 Ma...

Page 22: ...mbar 8 5 8 5 8 5 11 5 Gas consumption 1 m3 h 3 1 3 3 5 0 6 0 Data for LP gas 3 General Orifice diameter mm 2 50 2 60 3 40 3 80 1 flat sealing plate 2 burner pressure regulator 1 or 2 1 1 1 1 G30 30 m...

Page 23: ...tory h stop valve mandatory i temperature gauge optional j condensation drainage mandatory k hot water draw off points l expansion valve mandatory m expansion vessel mandatory n 3 way venting valve op...

Page 24: ...3 6 3 Hot water side See b in Figure 3 3 n Remark Insulating long hot water pipes prevents unnecessary energy loss 1 Optional fit a temperature gauge i to be able to check the temperature of the tap w...

Page 25: ...ot water outlet pipe for use when servicing 4 If a circulation pipe is to be fitted then refer to paragraph 3 7 4 3 7 4 Circulation pipe See c in Figure 3 3 If an immediate flow of hot water is requir...

Page 26: ...DR FC water heaters are approved for installation types B23 C13 C33 C43 C53 and C63 The most common installation types are C13 Concentric wall flue terminal and C33 Concentric roof flue terminal This...

Page 27: ...ust slope towards the water heater with a minimum of 5 mm per metre running length Table 3 6 Chimney configurations for concentric wall and roof termination Dimension 1 1 See Figure 3 4 Wall flue term...

Page 28: ...MDV SE 1 Pipe material flue gas discharge Thick walled aluminium with lip ring seal Pipe material air intake Thin walled galvanised sheet steel Pipe diameter Concentric DR FC 25 80 125 mm DR FC 30 45...

Page 29: ...mp a program controlled pump a Heater ON and an Alarm OFF to the water heater For these options see 3 10 4 Isolating Transformer 3 10 5 Continuous pump IMD 0398 Figure 3 5 Roof flue terminal Table 3 8...

Page 30: ...neutral of the water heater There should also be no potential difference present between neutral N and earth A If this is the case then an isolating transformer must be applied in the supply circuit S...

Page 31: ...must have cores of at least 3 x 1 0 mm2 1 Connect phase L neutral N and earth A of the power cable to terminals 22 through 24 of the connector block as indicated in Table 3 9 2 Fit the power cable in...

Page 32: ...a facility for connecting an external ON OFF switch In the OFF position the programmed operating mode is active In the ON position the programmed operating mode is overruled and the ON mode is active...

Page 33: ...eed as follows 1 Disconnect the water heater from the power supply See paragraph 7 3 2 Isolate the water heater from the power supply 2 Undo the screws of the covers 3 Carefully remove the black cover...

Page 34: ...installer or supplier If the water heater is fitted with a burner pressure regulator then the pressure can be adjusted by following steps 13 through 17 13 Remove the cap 8 from the burner pressure reg...

Page 35: ...using a special conversion kit cNote After conversion check the supply pressure and the burner pressure 1 Disconnect the water heater from the mains See paragraph 7 3 2 Isolate the water heater from t...

Page 36: ...he metal of the gas air distribution plate 5 10 Select and fit the correct orifice from the conversion kit based on Tabel 3 5 The injector diameter is stamped into each injector 6 11 Check whether the...

Page 37: ...be replaced Unscrew the connector 0 from the gas control If necessary remove the flat sealing plate or burner pressure regulator 7 If necessary fit the flat sealing plate or burner pressure regulator...

Page 38: ...er 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 wa...

Page 39: ...supply pressure There should be no water coming out of the expansion valve l nor the T P valve b If this does happen the cause might be The water supply pressure is greater than the specified 3 5 bar...

Page 40: ...datory h stop valve mandatory i temperature gauge optional j condensation drainage mandatory k hot water draw off points l expansion valve mandatory m expansion vessel mandatory n 3 way venting valve...

Page 41: ...protected cold supply setup b 10 Open the drain valve f 11 Vent the water heater or installation so that it drains completely empty 4 3 2 Draining vented installations Some service activities require...

Page 42: ...Filling and draining 42 Instruction Manual DR FC 4 gis...

Page 43: ...line display with 20 characters per line 6 push buttons for operating the water heater below the display 6 graphical symbols above the display a connector for a service PC an ON OFF switch The push b...

Page 44: ...itches to OFF mode See paragraph 6 2 Operating modes n Remark To electrically disconnect the water heater you must use the main switch between the water heater and the mains power supply 5 5 Navigatio...

Page 45: ...selected option is confirmed using E With the R button you go back one page in a menu and all options selected in the current menu are lost n Remark The R button is also used to reset the water heate...

Page 46: ...The control panel 46 Instruction Manual DR FC 5 gis...

Page 47: ...dle or depending on the heating cycle a text such as HEAT DEMAND See 7 4 The water heater s heating cycle EXTRA In this mode one extra period is programmed and activated In this mode the OFF or PROG p...

Page 48: ...ater heater enters this condition the display will show the following information line one error code comprising a letter and two digits followed by the error description lines two through four altern...

Page 49: ...In that case contact your service and maintenance engineer n Remark The message SERVICE REQUIRED is based on the number of burning hours and the preset service interval Should the service interval hav...

Page 50: ...Status of the water heater 50 Instruction Manual DR FC 6 gis...

Page 51: ...to the water heater using the isolator between the water heater and the power supply 4 Turn the control panel ON by setting ON OFF switch to position I The display will now show INTERNAL CHECK for abo...

Page 52: ...ing in the water heater Activate the frost protection as follows 1 Press button B to select the main menu 2 Using H and L position the cursor beside OFF Confirm with E The frost protection cuts in if...

Page 53: ...completely empty 7 4 The water heater s heating cycle The water heater s heating cycle is activated as soon as the measured water temperature Tnet falls below the threshold value Tset This threshold v...

Page 54: ...s opened and ignition takes place The G 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 st...

Page 55: ...gis 8 Following the post purge the fan stops and the pressure switch opens The D and S icons are dimmed The message POST PURGE disappears At the first subsequent heat demand the heating cycle will re...

Page 56: ...Starting up and shutting down 56 Instruction Manual DR FC 7 gis...

Page 57: ...OFF ON WEEK PROGRAM EXTRA PERIOD SETTINGS Figure 8 1 Main menu OFF Select this option if you wish to shut the water heater down for a brief period but do not wish to drain it In this mode the frost pr...

Page 58: ...e value Confirm with E After confirming the water heater enters ON mode n Remark If the temperature setting is higher than the current water temperature it is possible that the water heater does not i...

Page 59: ...heater s standard week program 8 5 4 Adding times to a week program 8 5 5 Deleting times from a week program 8 5 2 Starting up and shutting down the week program The week program can be started up fr...

Page 60: ...xample this is 08 Confirm with E The cursor moves to the minute digits which will blink See Figure 8 10 n Remark Because the switch off time can never be earlier than the switch on time the switch off...

Page 61: ...o scroll to another day and change more switch on and switch off times Simply repeat steps 3 through 10 12 After changing all desired switch on and switch off times you can start running the week prog...

Page 62: ...ew period added scroll down with L to START OPERATION and confirm with E 8 5 5 Deleting times from a week program All switch on off times are shown sequentially in the display Assume that the switch o...

Page 63: ...e R to cancel deletion The switching period has been deleted You will return now to the week program menu The cursor is beside the first programmed period See Figure 8 27 7 Scroll with L to START OPER...

Page 64: ...gits which will blink See Figure 8 30 3 Use H and L to set the switch on hour to the desired value In the example this is 08 Confirm with E The cursor moves to the minute digits which will blink See F...

Page 65: ...ain settings and display certain water heater specifications See Table 8 1 8 7 2 Setting menu language Bring up the menu for selecting the language via 1 B SETTINGS Confirm with E The display shows th...

Page 66: ...h H and L to the current hour for example 15 Confirm with E 5 The cursor moves to the minute digits which will blink Scroll with H and L to the next minute in time for example 45 Confirm the minute se...

Page 67: ...AL The relevant display specification appears see Figure 8 49 Table 8 2 Water heater specifications Water heater Ignition speed of fan Running speed of fan Regulation interval DR FC 25 4500 rpm 4980 r...

Page 68: ...Main menu 68 Instruction Manual DR FC 8 gis...

Page 69: ...e water heater might not immediately start the heating cycle see chapter 7 4 The water heater s heating cycle To prevent excessively frequent switching on and off a there is a heating margin We refer...

Page 70: ...turned ON or OFF via S PUMP RELAY The standard setting for the pump relay is OFF Figure 9 7 shows the related display If the mode WEEK PROGRAM or EXTRA PERIOD is active then the setting for mode WEEK...

Page 71: ...range is from 0 through 100 Figure 9 9 shows the related display 9 9 Setting the backlight time Adjust the backlight time the time that the display backlight stays lit after the last button is pressed...

Page 72: ...Service program 72 Instruction Manual DR FC 9 is...

Page 73: ...nating every 2 seconds See Figure 10 1 and Figure 10 2 The displayed errors are divided into two groups There are various types of errors LOCK OUT ERRORS When the cause is no longer present these erro...

Page 74: ...ubleshooting table for general errors Table 10 1 General errors Sheet 1 of 3 Symptom Cause Solution Remark Gas smell Gas leak Warning Immediately close the main gas valve Warning Do not operate any sw...

Page 75: ...asured must be 230 VAC 15 10 See appendix A 2 Electrical diagram DR FC If the error cannot be rectified contact your installer Defective fuse s Replace fuse s To replace the fuses you must contact you...

Page 76: ...nt 1 Check whether the mains switch is ON 2 Check that there is power to the mains switch 3 Check whether the ON OFF switch of the control panel is ON position I 4 Check whether there is power to the...

Page 77: ...C Damaged wiring or defective sensor Replace sensor T 1 To replace the necessary parts you must contact your installer S03 blocking error Open circuit from sensor 2 of temperature sensor T 1 at the to...

Page 78: ...the necessary parts you must contact your installer S13 blocking error Short circuit from sensor 2 of temperature sensor T 1 at the top of the heater Short circuit in the sensor circuit Replace senso...

Page 79: ...tent contact your installer Floating neutral Install an isolating transformer See 3 10 4 Isolating Transformer Contact your installer to have an isolating transformer installed F02 lock out error Fan...

Page 80: ...nd the air supply hose between fan and burner are correctly fitted Refit these if necessary 3 Check the hoses on the pressure switch and the air supply hose between fan and burner for cracks If necess...

Page 81: ...alve s open and shut correctly 3 If necessary replace the gas control Defect in the hot surface igniter circuit 1 Check that the hot surface igniter is correctly connected JP2 2 Check the wiring of th...

Page 82: ...probe is broken cracked 1 Check whether the ceramic part of the flame probe is still intact in the vicinity of the air distribution plate of the burner 2 If this is not the case the flame probe must b...

Page 83: ...Displaying water heater specifications 2 Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly fitted Refit these if necessary 3 Check for cracks in...

Page 84: ...ce may only be performed by a qualified service and maintenance engineer F11 lock out error Flame detection with closed gas valve Defective gas valves See F07 Table 10 2 Displayed errors Sheet 8 of 10...

Page 85: ...nstaller 3 If the frequency is correct but the error persists replace the control panel To replace the necessary parts you must contact your installer Internal error message from the water heater cont...

Page 86: ...E03 blocking error Error in temperature sensor T 1 at the top of the heater The temperature differential between the two temperature sensors in the heater is 10 C over a period of 60 seconds or longe...

Page 87: ...is Instruction Manual DR FC 87 Warning Maintenance may only be performed by a qualified service and maintenance engineer...

Page 88: ...Troubleshooting 88 Instruction Manual DR FC 10 gis...

Page 89: ...0 1000 or 1500 burning hours 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...

Page 90: ...Maintenance frequency 90 Instruction Manual DR FC 11 gs...

Page 91: ...ter Only by ordering with this information can you be sure to receive the correct spare parts These details can be found on the rating plate 12 2 Preparation for maintenance To test whether all compon...

Page 92: ...se where necessary See paragraph 3 11 Checking the supply pressure and burner pressure 13 Check that all components of the flue gas system are properly attached 14 Check the pressure differential acro...

Page 93: ...s the service life of the water heater and also improves the heating process Take the rate of scale formation into account when deciding on maintenance frequency 1 Remove the cover plate 1 on the oute...

Page 94: ...t the burner 6 Fit the flue gas discharge n Remark Check the pressure differential again after cleaning If the pressure differential is too low following cleaning please contact the supplier of the wa...

Page 95: ...Instruction Manual DR FC 95 A Appendices A 1 Introduction This appendix contains The Electrical diagram DR FC A Week program card is...

Page 96: ...nnector for display to controller JP2 Connector for flame probe and hot surface igniter JP3 Connector for temperature sensor T2 JP4 Connector for dummy JP5 Connector for temperature sensor T1 JP6 Conn...

Page 97: ...ON OFF 13 ON C ON OFF OFF OFF 3 ON C ON OFF 14 ON C ON OFF OFF OFF 4 ON C ON OFF 15 ON C ON OFF OFF OFF 5 ON C ON OFF 16 ON C ON OFF OFF OFF 6 ON C ON OFF 17 ON C ON OFF OFF OFF 7 ON C ON OFF 18 ON C...

Page 98: ...Appendices 98 Instruction Manual DR FC A is...

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