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DORCHESTER DR-FC 25 User Manual

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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
ND
FAMILY) I2H OR
LPG (3
RD
FAMILY) I3+. 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

Table of Contents

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DORCHESTER DR-FC 25 Specifications

General IconGeneral
BrandDORCHESTER
ModelDR-FC 25
CategoryWater Heater
LanguageEnglish

Summary

Introduction

About the water heater

Manual describes installation, service, and use of DR-FC water heater, its features, and compliance.

What to do if you smell gas

Instructions to follow if a gas smell is detected, emphasizing safety precautions.

Regulations and documents

Lists relevant regulations, standards, and documents for appliance installation and safety.

Target groups

Identifies the three main target groups for the manual and their corresponding symbols.

Maintenance

Recommends annual service for water and gas sides, and checks after installation.

Forms of notation

Explains the different notations used in the manual, including Remark, Note, and Warning.

Overview of this document

Provides a summary of the document's chapters and their target groups.

Functioning of the water heater

Introduction

Lists topics covered in the chapter: functional description, heating cycle, protection, and safety.

Functional description of the water heater

Explains the components of the water heater through a cut-away view and legend.

The water heater's heating cycle

Details the cold water entry, heating process, air supply, flue gas, condensation, and insulation.

Protection for the water heater

Explains how the control panel monitors water temperature and ensures safe combustion.

Water temperature protection

Explains frost protection, maximum temperature safeguard, and extra safety lockout.

Gas control

Describes the gas control system, including safety valves and softlite ignition.

Fan

Explains the fan's role in air supply, pre/post-purge, and speed monitoring.

Pressure switch

Details the pressure switch function for flue gas discharge and air supply during operation.

Flame probe

Explains the flame probe's role in detecting flame via ionization for safety.

Safety of the installation

Covers safety aspects for unvented, vented, and T&P valve installations.

Unvented installation

Details safety components for unvented systems to prevent excessive pressure.

Vented installation

Explains safety requirements for vented systems, including open tank and vent pipe.

T&P valve

Describes the mandatory T&P valve for unvented installations and its function.

Options

Discusses optional variations like LPG, unvented supply kits, and circulation pumps.

Installation

Introduction

Lists installation activities: packaging, environmental conditions, specs, connections, gas, flue, electrical, pressure, conversion.

Packaging

Advises careful removal of packaging and unpacking near the intended location.

Environmental conditions

Discusses room-sealed installation types and installation in closed or open rooms.

Humidity and ambient temperature

Specifies maximum humidity (93% RH at +25°C) and functional ambient temperature range (0-60°C).

Maximum floor loading

Details weight specifications for different models and the need to consider floor loading.

Working clearances

Recommends specific clearances (AA, BB) for access to controls, openings, and anode replacement.

Technical specifications

Refers to dimensions and accessory specifications based on figures and tables.

Installation diagram

Refers to diagrams for unvented and vented installations and their connections.

Water connections, Unvented

Details cold water, recirculating pump, hot water, circulation pipe, and condensation drainage connections.

Water connections, Vented

Details cold water, recirculating pump, hot water, circulation pipe, and condensation drainage connections.

Gas connection

Provides instructions for connecting the gas supply, including safety and pipe sizing.

Air supply and flue gas discharge

Discusses approved installation types for air and flue systems, including terminal specifications.

Concentric wall flue terminal

Specifies the required wall flue terminal model and its material and diameter specifications.

Concentric roof flue terminal

Specifies the required roof flue terminal model and its material and diameter specifications.

Electrical connection

Topics covered: preparation, mains voltage, and optional connections.

Preparation for Electrical Connection

Details essential steps for connecting phase, neutral, and earth, and checking for potential differences.

Mains voltage

Explains the requirement for a permanent electrical connection and a double pole isolator.

Isolating Transformer

Describes when an isolating transformer should be used and how to connect it.

Continuous pump

Explains how to connect a continuous pump to the water heater.

Program-controlled pump

Details how to connect a program-controlled pump, dependent on control panel settings.

Extra ON mode switch ("Heater ON")

Describes the function of the external ON/OFF switch for overriding operating modes.

Connecting extra error signal ("Alarm OUT")

Explains connecting an external signal for error indication, e.g., turning on a lamp.

Checking the supply pressure and burner pressure

Provides a procedure for checking gas supply and burner pressures using pressure gauges.

Conversion to a different gas category

Outlines the procedure for adapting the water heater for different gas categories using a conversion kit.

Filling and draining

Introduction

Lists topics covered: filling the water heater and draining the water heater.

Filling the water heater

Details the process of filling the water heater for both unvented and vented installations.

Filling unvented installations

Step-by-step guide to filling an unvented water heater installation, including bleeding air.

Filling vented installations

Step-by-step guide to filling a vented water heater installation, including bleeding air.

Draining the water heater

Provides procedures for draining the water heater for both unvented and vented installations.

The control panel

Introduction

Describes the menu-driven control panel, its display, buttons, and connectors.

Operating

Explains how to operate the water heater using the control panel's display and buttons.

Explanation of the icons

Provides a table explaining the meaning of the icons displayed on the control panel.

ON/OFF switch of control panel

Details the function of the ON/OFF switch for the control panel and its effect on the water heater.

Navigation buttons

Explains the use of navigation buttons (UP, DOWN, ENTER, RESET) for menu operation.

PC connection

Describes the PC connection for technicians to read status and history for troubleshooting.

Status of the water heater

Introduction

Lists topics covered: operating modes, error conditions, and service condition.

Operating modes

Describes the four basic operating modes: OFF, ON, EXTRA, and PROG, with display examples.

Error conditions

Explains how errors are displayed, types of errors (lock out, blocking), and basic troubleshooting steps.

Service condition

Describes the 'SERVICE REQUIRED' message and its relation to burning hours and service intervals.

Starting up and shutting down

Introduction

Lists topics covered: starting up and shutting down the water heater.

Starting up

Provides a step-by-step guide for starting up the water heater, including filling and power connection.

Shutting down

Covers procedures for shutting down: brief period (OFF mode), isolating from power, and longer periods.

Shut the water heater down for a longer period

Instructions for long-term shutdown, including draining the water heater.

The water heater's heating cycle

Explains the sequence of states (HEAT DEMAND, PRE-PURGE, IGNITION, RUNNING, POST-PURGE) during heating.

Main menu

Introduction

Introduces the main menu accessed via the control panel and lists its primary options.

Notational convention for menu-related instructions

Explains the notation used for navigating menus and sub-menus within the manual.

Switching into "ON mode"

Describes how to switch the water heater into the 'ON mode' from any operational mode.

Setting the water temperature

Details how to set the water temperature via the SETPOINT MENU and during ON mode.

Week programme

Explains how to set water temperature for specific days and times using the week program.

Adding times to a week program

Guides users on how to insert new switch-on and switch-off times into a week program.

Deleting times from a week program

Instructs on how to remove programmed switch-on/off times from the week program.

Extra period

Explains how to use an extra period to activate the heater for a specific duration.

Programming an extra period

Provides steps for programming an extra period, including setting times and temperatures.

Settings

Allows adjustment of certain settings and display of water heater specifications.

Setting menu language

Guides on how to select the desired language for the control panel's menu interface.

Setting day and time

Details the procedure for setting the current day of the week and time on the control panel.

Displaying water heater specifications

Explains how to view water heater specifications like fan speed and regulation interval.

Service program

Introduction

Outlines the functions of the service program for installers and maintenance engineers.

Setting the hysteresis

Explains how to set the hysteresis (heating margin) to prevent frequent switching on/off.

Displaying the error history

Guides on how to view 'Blocking errors' and 'Lock out errors' from the control panel.

Displaying the water heater history

Explains how to display burning hours, ignitions, and error counts of the water heater.

Display the selected water heater

Shows how to view the currently selected water heater model, preset at the factory.

Setting the pump on/off

Details how to control the circulation pump's ON/OFF state via the service menu.

Setting the service interval

Explains how to set the service interval based on burning hours for maintenance reminders.

Setting the display contrast

Guides on adjusting the display contrast percentage from 0% to 100%.

Setting the backlight time

Details how to set the duration the display backlight remains lit after button presses.

Setting the display scroll speed

Explains how to adjust the display scroll speed for menu navigation.

Troubleshooting

Introduction

Distinguishes between general errors and displayed errors, and how they are reported.

Troubleshooting table for general errors

Provides solutions for general errors like gas smell, no hot water, and water leakage.

Troubleshooting table for displayed errors

Lists displayed error codes, possible causes, solutions, and remarks for error resolution.

Maintenance frequency

Introduction

Recommends annual service for water and gas sides, and notes maintenance frequency depends on usage.

Determining service interval

Explains how the service interval is set based on burning hours and triggers 'SERVICE REQUIRED' message.

Maintenance

Introduction

States that maintenance is performed by approved engineers on water and gas sides.

Preparation for maintenance

Details steps to test components and prepare the water heater before service.

Water-side maintenance

Covers checks and cleaning for anodes, heater descaling, and condensate discharge.

Gas-side maintenance

Covers cleaning of the burner, orifice, and heat exchanger.

Cleaning heat exchanger

Provides instructions for cleaning the combustion chamber and heat exchanger using vacuum and water.

Finalising maintenance

Includes steps like filling, restarting the heater, and removing the 'SERVICE REQUIRED' message.

Appendices

Introduction

States that the appendix contains the Electrical diagram DR-FC and a Week program card.

Electrical diagram DR-FC

Presents the detailed electrical wiring diagram for the DR-FC water heater.

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