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DORCHESTER DR-RS 105, Installation, Commissioning And Servicing Instructions

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DORCHESTER DR-RS 105 Installation, Commissioning And Servicing Instructions Download Page 4

4

Instruction manual DR-RS

gis

3.8

Gas connection -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 27

3.9

Air supply and flue gas discharge  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 27
3.9.1

Introduction   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 27

3.9.2

Fitting flue gas discharge and air supply for DR-RS 25, 40, 65 -  - 27

3.9.3

Fitting flue gas discharge and air supply for DR-RS 85 and 105  - 30

3.10

Electrical connections -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 33
3.10.1

Introduction   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 33

3.10.2

Preparation-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 33

3.10.3

Mains   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 34

3.11

Checking the supply pressure and burner pressure   -  -  -  -  -  -  -  -  -  -  -  - 35

3.12

Conversion to a different gas category -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 39
3.12.1

Introduction   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 39

3.12.2

Conversion -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 39

3.12.3

Replacing orifices

  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 40

3.12.4

Replacing burner pressure regulator or flat plate
(DR-RS 25-40-65-85)-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 42

4

Filling and draining -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -   43

4.1

Introduction -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 43

4.2

Filling the water heater   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 44
4.2.1

Filling unvented installations   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 44

4.2.2

Filling vented installations-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 45

4.3

Draining the water heater  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 45
4.3.1

Draining unvented installations  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 45

4.3.2

Draining vented installations   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 45

5

Controls-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -   47

5.1

Introduction -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 47

5.2

Control panel  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 47

5.3

Explanation of the symbols  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 48

5.4

ON/OFF switch  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 48

5.5

Control thermostat   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 48

5.6

Burner control reset button   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 48

6

Status of the water heater   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -   49

6.1

Introduction -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 49

6.2

Operating modes  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 49

6.3

Error conditions -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 49

7

Starting up and shutting down -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -   51

7.1

Introduction -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 51

7.2

Starting up  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 51

7.3

Shutting down-  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 51
7.3.1

Shut the water heater down for a brief period (’OFF mode’)  -  -  - 51

7.3.2

Isolate the water heater from the power supply  -  -  -  -  -  -  -  -  - 51

7.3.3

Shut the water heater down for a longer period  -  -  -  -  -  -  -  -  - 51

7.4

The water heater’s heating cycle   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 52

8

Troubleshooting   -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -   53

8.1

Introduction -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 53

8.2

Troubleshooting table for general errors -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 54

8.3

Troubleshooting table ’insufficient hot water’ -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 55

8.4

Troubleshooting table ’no hot water’ -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  -  - 56

Summary of Contents for DR-RS 105

Page 1: ...S I2H LPG I3 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 2ND FAMILY I2H OR...

Page 2: ...2...

Page 3: ...llation 15 2 5 3 Temparature and Pressure valve T P valve 15 2 6 Indicators and Alarms 15 2 6 1 Volt Free Contacts 15 2 7 Options 15 2 7 1 LPG 15 2 7 2 Unvented Supply 15 2 7 3 Top to Bottom Circulati...

Page 4: ...44 4 2 2 Filling vented installations 45 4 3 Draining the water heater 45 4 3 1 Draining unvented installations 45 4 3 2 Draining vented installations 45 5 Controls 47 5 1 Introduction 47 5 2 Control...

Page 5: ...maintenance 60 9 3 1 Introduction 60 9 3 2 Checking the anodes 60 9 3 3 Descaling and cleaning the heater 60 9 4 Gas side maintenance 61 9 4 1 Introduction 61 9 4 2 Cleaning the burners 61 9 4 3 Clea...

Page 6: ...6 Instruction manual DR RS gis...

Page 7: ...onal 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 causing sparks Do not use any electrical equipment...

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: ...tallation Based on this check the best maintenance frequency can be determined n Remark Regular maintenance extends the service life of the water heater Both the end user and the service and maintenan...

Page 10: ...rol panel and how to use it 6 Status of the water heater gis This chapter describes the status mode or condition that the water heater may have and possible actions to take 7 Starting up and shutting...

Page 11: ...11 2 Functioning of the water heater 2 1 Introduction Topics covered in this chapter Functional description of the water heater The water heater s heating cycle Protection for the water heater Safety...

Page 12: ...8 hot water tank 9 insulation layer 10 air restrictor 11 cleaning opening 12 cold water inlet 13 drain valve 14 combustion chamber with air distribution plate 15 bar burners burner tray 16 hot water o...

Page 13: ...istribution plate The insulation layer 9 prevents heat loss The inside of the hot water tank is enamelled to protect against corrosion The anodes 5 provide additional protection 2 3 The water heater s...

Page 14: ...ble 2 1 Temperature protection Protection Description Frost thermostat If the frost thermostat sensor 25 detects a temperature of 20 C or lower the water heater s heating cycle will start See paragrap...

Page 15: ...s the water pressure in the water heater and the water temperature at the top of it If the pressure in the water heater becomes excessive 7 bar or the water temperature is too high 97 C the valve will...

Page 16: ...ompliance with the HSE guidance and the DHss Code of Practice for The Control of Legionellae in Health Care Premises a pump circulation kit can be supplied comprising 230 volt single phase pump non re...

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

Page 18: ...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 water heater its...

Page 19: ...age from the it 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 wast...

Page 20: ...pecifica tions The water heater is supplied without accessories Check the dimensions and other specifications for the accessories to be used based on Figure 3 2 and Table 3 3 Figure 3 2 Plan and eleva...

Page 21: ...40 540 540 S Height of T P valve connection mm 1600 1600 1600 1600 1600 1 Cold water supply connection external thread R11 2 R11 2 R11 2 R11 2 R11 2 2 Hot water outlet connection internal thread Rp11...

Page 22: ...minal output kW 25 9 41 5 66 2 89 0 100 3 Supply pressure mbar 20 20 20 20 20 Burner pressure mbar 12 5 12 9 12 9 12 5 14 0 Gas consumption 1 m3 h 3 1 5 0 7 9 10 8 12 2 Specifications for LP gas Gener...

Page 23: ...input gross kW 29 9 47 0 75 7 108 7 122 5 Nominal output kW 25 0 38 9 62 6 89 0 100 3 Supply pressure mbar 37 37 37 37 37 Burner pressure 2 mbar 22 0 Gas consumption 1 kg h 2 2 3 4 5 5 7 9 8 9 Table...

Page 24: ...lve mandatory i stop valve mandatory j temperature gauge recommended k top to bottom recirculation pump optional l top box m hot water draw off points n condensation drainage o expension valve mandato...

Page 25: ...unnecessary energy loss 1 Optional Fit a temperature gauge j to be able to check the temperature of the tap water 2 Fit the T P valve c 3 Fit a stop valve i in the hot water outlet pipe for use when...

Page 26: ...recirculation pump k 2 Fit non return valve e 3 Fit stop valves i 3 7 3 Hot water side See b in Figure 3 3 n Remark Insulating long hot water pipes prevents unnecessary energy loss 1 Fit the safety va...

Page 27: ...er also to paragraph 1 3 Regulations and documents 3 9 1 Introduction The connections for the air supply and the flue gas discharge of the DR RS 25 40 and 65 differ from those of the DR RS 85 and 105...

Page 28: ...562702039 DR RS 40 562702040 DR RS 65 562702041 Construction Concentric Tube material Construction Concentric Flue gas discharge Thick walled aluminium with lipped sealing ring Air supply Thin walled...

Page 29: ...rt No DR RS 25 562702043 DR RS 40 562702044 DR RS 65 562702045 Construction Concentric Tube material Construction Concentric Flue gas discharge Thick walled aluminium with lipped sealing ring Air supp...

Page 30: ...an cause the installation to malfunction The following requirements must also be fulfilled The maximum chimney length allowed A B C is 7 metres The maximum number of 45 or 90 bends allowed is 2 If you...

Page 31: ...wall flue terminal Item Description Wall flue terminal and transition piece 1 Part No 562702042 Construction Concentric Tube material Construction Parallel Flue gas discharge Thick walled aluminium wi...

Page 32: ...c roof flue terminal Item Description Roof flue terminal and transition piece 1 Part No 562702046 Construction Concentric Tube material Construction Parallel Flue gas discharge Thick walled aluminium...

Page 33: ...ations and documents 3 10 1 Introduction Topics covered in this paragraph 3 10 2 Preparation 3 10 3 Mains 3 10 2 Preparation Figure 3 10 shows a front view of the electrical connection block Table 3 1...

Page 34: ...he mains by means of a permanent electrical connection A double pole isolator with contacts gaps of at least 3 mm must be fitted local to the water heater The power cable must have cores of at least 3...

Page 35: ...e and burner pressure If necessary adjust these to be certain of optimum performance of the water heater cNote The easiest way to check the gas pressures is by using two pressure gauges This procedure...

Page 36: ...gas pipes should be vented and free of leakage 4 Open the gas supply 5 Connect a pressure gauge to test nipple e 6 Switch on the power to the water heater using the isolator on the water heater 7 Set...

Page 37: ...djusting screw clockwise burner pressure increases 13 DR RS 105 Adjust the burner pressure by turning burner pressure control adjusting screw c Pg using the supplied Allen key depending on the correct...

Page 38: ...Installation 38 Instruction manual DR RS 3 is...

Page 39: ...he diameter of the pilot flame orifice is different If this is the case then the pilot flame orifice must be replaced See paragraph 3 11 3 Replace orifice 4 Referring to Table 3 5 compare the present...

Page 40: ...w the connector s e of the gas control f 4 Detach the gas coupling g before the gas control 5 Remove the ten screws holding the burner tray h in place 6 Withdraw the burner tray from the water heater...

Page 41: ...ove the main orifices e b Fit the main orifices from the conversion kit You can check the required orifice diameter based on Table 3 5 Gas data The orifice diameter is shown on the orifice by means of...

Page 42: ...lace them 1 Complete steps 7 through 9 of paragraph 3 12 3 Replacing orifices 2 Detach the burner pressure regulator a or flat plate d See Figure 3 11 Gas control valve 3 Fit the burner pressure regul...

Page 43: ...Instruction manual DR RS 43 4 Filling and draining 4 1 Introduction Topics covered in this chapter Filling the water heater Draining the water heater gis...

Page 44: ...ve mandatory ca safety valve d stop valve recommended e non return valve mandatory ea non return valve f circulation pump optional g drain valve h gas valve mandatory i stop valve mandatory j temperat...

Page 45: ...valve i on the cold water side a so that cold water flows into the water heater 5 Completely fill the water heater when cold water flows at normal pressure from the nearest hot water draw off point th...

Page 46: ...Filling and draining 46 Instruction manual DR RS 4 gis 4 Close the stop valve i in the hot water pipe 5 Close the stop valve between the water tank and the cold water inlet 6 Open the drain valve g...

Page 47: ...panel 5 3 Explanation of the symbols 5 4 ON OFF switch 5 5 Control thermostat 5 6 Burner control reset button 5 2 Control panel Figure 5 1 shows the control panel The panel consists of an ON OFF swit...

Page 48: ...nuous over a scale of 1 to 4 Table 5 2 shows the temperatures corresponding to each position 5 6 Burner control reset button An error can cause the burner control to lock out When this happens the red...

Page 49: ...ion If the water heater should go into an error state you will be unable to continuosly draw hot water These error conditions are divided into three groups Lock out error in the burner control When th...

Page 50: ...gis If as end user you find the water heater in an error condition you may attempt to re start the water heater by pressing the reset button once However should the error return or become persistent...

Page 51: ...od OFF mode Isolate the water heater from the power supply Shut the water heater down for a longer period 7 3 1 Shut the water heater down for a brief period OFF mode To shut the water heater down for...

Page 52: ...the example set out below n Remark The water heater runs through an identical cycle when frost protection is activated 1 The control thermostat sensor measures the water temperature The water tempera...

Page 53: ...cause the reset button must be pressed to re start the water heater The water heater cycles continuously When this happens the water heater continues to attempt to start up but an error is causing the...

Page 54: ...o naked flames Warning Ventilate the boiler room n Remark Immediately contact your installer or local gas company Water leakage Leakage from one of the water connections threaded Tighten the threaded...

Page 55: ...orifice See 9 4 3 Cleaning the orifices Contaminated air supply Improve the air supply Table 8 1 General errors Sheet 2 of 2 Symptom Cause Solution Remark Table 8 2 Insufficient hot water Symptom Cau...

Page 56: ...ycle blocking error The air pressure switch does not close 1 Blockage in the flue gas discharge or air supply Trace the blockage Remove the blockage 2 Defective air pressure switch Check the wiring of...

Page 57: ...ror cannot be resolved or is persistent contact your installer b Failed attempt to start No gas 1 Check that the gas valve is open 2 Check that gas control opens clicking of the gas control 3 Check th...

Page 58: ...is Instruction manual DR RS 58 Warning Maintenance may only be performed by a qualified service and maintenance engineer...

Page 59: ...he ON OFF switch on the control panel to position 0 2 Set the control thermostat note the original setting to the highest position and put the ON OFF switch back to position I 3 If there is no heat de...

Page 60: ...baffles Replace them if necessary See paragraph 9 4 4 Checking the flue baffles 12 Fit a new sealing ring around the edge of the hot water tank and replace the cover 13 Replace the top box 14 Feed th...

Page 61: ...suitable cleaner 7 Close the cleaning opening To avoid damage to the tank the bolts that fasten the lid should be tightened with a torque no greater than 50 Nm Use suitable tools for this To properly...

Page 62: ...h 9 3 2 Checking the anodes 2 Remove the flue baffles from the water heater 3 Check the flue baffles for rust and remove any which is present 4 Check the flue baffles for wear and replace any worn flu...

Page 63: ...Instruction manual DR RS 63 A Electrical diagram DR RS is...

Page 64: ...st thermostat G Control thermostat H ON OFF switch K Safety thermostat L High limit thermostat M Burner control N Connector clip strip P Earthing strip R Relay Max 250V 10A OPTIONAL COMPONENTS S Clock...

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