DORCHESTER DR-FC 25, DR-FC30, DR-FC95, DR-FC45, DR-FC120 Installation, Comissioning And Maintenance Instructions

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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.

THIS WATER HEATER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.

0309429

Errata

The amendments below apply to determining and setting the correct service interval for these appliances. These instructions supercede the previous instructions on how to determine and set the service interval..

Setting the service interval

The service interval is a feature of the controller to help the service and maintenance engineer set the maintenance frequency ("Determining service

interval").

The service interval is determined by the number of months that the appliance has been running. This can be set to 6, 9 and 12 months. The default service interval is 12 months. A message appears when the set number of months is reached (see

section "Service condition" in manual). Set the

service interval as follows:

• :

SERVICE INTERVAL

6 9 MONTHS

→ 12

Determining service interval

The 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 service interval can be set to 6, 9 or 12 months. The default setting is 12 months

When the set number of months has passed, the message

SERVICE REQUIRED will appear on

the display. When this message appears, the service and maintenance engineer must be contacted.

!!! WARNING !!!

MAX.BURNING HOURS:

SERVICE REQUIRED

To reset the message

The displayed message can be reset in either of two ways.

1. Temporary reset: To postpone the message, press

RESET once.

The message will reappear on the display 7 days later.

2. Full reset: To fully reset the message, press and hold both

RESET and ENTER at the same time for

5 sec.

On completion of the full reset of the message, the message below will appear on the display. This message will NOT be shown after a temporary reset of the message.

RESET

SERVICE INTERVAL

SUCCESSFUL

Instruction manual DR-FC 3

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Read this manual carefully

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 heater.

Nothing from this publication may be copied, reproduced and/or published by means of printing, photocopying or by whatsoever means, without the prior written approval of the supplier.

The supplier reserves the right to modify specifications stated in this manual.

Trademarks

Any brand names mentioned in this manual are registered trademarks of their respective owners.

Liability

The supplier accepts no liability for claims from third 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 General Conditions. These are available on request, free of charge.

Although considerable care has been taken to ensure a correct and suitably comprehensive description of all relevant components, the manual may nonetheless contain errors and inaccuracies.

Should you detect any errors or inaccuracies in the manual, we would be grateful if you would inform us. This helps us to further improve our documentation.

More information

If you have any comments or queries concerning specific aspects related to the water heater, then please do not hesitate to contact the supplier.

In the event of problems with your gas, electricity or water supply connections, please contact the supplier/installation engineer of your installation.

4 Instruction manual DR-FC

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Instruction manual DR-FC 5

Table of contents

1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.1 About the water heater - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.2 What to do if you smell gas- - - - - - - - - - - - - - - - - - - - - - - - - 9

1.3 Regulations - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 9

1.4 Target groups - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 10

1.5 Maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 11

1.6 Notation conventions- - - - - - - - - - - - - - - - - - - - - - - - - - - 11

1.7 Overview of this document - - - - - - - - - - - - - - - - - - - - - - - - 12

2 Working principle of the water heater - - - - - - - - - - - - - 13

2.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 13

2.2 General working principle of the water heater - - - - - - - - - - - - - - - 13

2.3 Water heater operating cycle - - - - - - - - - - - - - - - - - - - - - - - 15

2.4 Protection for the water heater - - - - - - - - - - - - - - - - - - - - - - 15

2.5 Safety of the installation - - - - - - - - - - - - - - - - - - - - - - - - - 16

3 Installation - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.2 Packaging - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.3 Ambient conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - 17

3.4 Technical specifications - - - - - - - - - - - - - - - - - - - - - - - - - 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 connection - - - - - - - - - - - - - - - - - - - - - - - - - - - 32

3.11 Checking supply pressure, CO

value and switching pressure- - - - - - - 35

4 Conversion to a different gas category - - - - - - - - - - - - 41

4.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 41

4.2 Conversion of DR-FC 25 through 60 - - - - - - - - - - - - - - - - - - - 41

4.3 Conversion of DR-FC 80 through 120 - - - - - - - - - - - - - - - - - - 43

5 Filling - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 45

5.1 Filling unvented installations - - - - - - - - - - - - - - - - - - - - - - - 46

5.2 Filling vented installations - - - - - - - - - - - - - - - - - - - - - - - - 46

6 Draining - - - - - - - - - - - - - - - - - - - - - - - - - - - - 47

6.1 Draining unvented installations - - - - - - - - - - - - - - - - - - - - - - 48

6.2 Draining vented installations - - - - - - - - - - - - - - - - - - - - - - - 48

7 The control panel- - - - - - - - - - - - - - - - - - - - - - - - 49

7.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.2 Control - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.3 Explanation of icons - - - - - - - - - - - - - - - - - - - - - - - - - - - 49

7.4 ON/OFF switch on controller - - - - - - - - - - - - - - - - - - - - - - - 49

7.5 Navigation buttons - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50

7.6 PC connection - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 50

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Table of contents

6 Instruction manual DR-FC

8 Status of the water heater - - - - - - - - - - - - - - - - - - - 51

8.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

8.2 Operating modes - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 51

8.3 Error conditions - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

8.4 Service condition - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

8.5 Anode warning - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 52

9 Starting the water heater - - - - - - - - - - - - - - - - - - - - 53

9.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 53

9.2 Starting the water heater - - - - - - - - - - - - - - - - - - - - - - - - - 53

9.3 Water heater operating cycle - - - - - - - - - - - - - - - - - - - - - - - 53

10 Shutting down - - - - - - - - - - - - - - - - - - - - - - - - - 55

10.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 55

10.2 Decommissioning the water heater for a short period- - - - - - - - - - - - 55

10.3 Isolating the water heater from the mains - - - - - - - - - - - - - - - - - 55

10.4 Decommissioning the water heater for a long period - - - - - - - - - - - - 55

11 Main menu - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

11.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 57

11.2 Notation convention for menu-related instructions - - - - - - - - - - - - - 57

11.3 Switching to "ON mode" - - - - - - - - - - - - - - - - - - - - - - - - - - 57

11.4 Setting 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 Deleting times from a week program- - - - - - - - - - - - - - - - - - - - 61

11.10 Extra period- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 62

11.11 Settings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 63

12 Service program - - - - - - - - - - - - - - - - - - - - - - - - 65

12.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

12.2 Setting the hysteresis - - - - - - - - - - - - - - - - - - - - - - - - - - - 65

12.3 Displaying the error history - - - - - - - - - - - - - - - - - - - - - - - - 65

12.4 Displaying the water heater history - - - - - - - - - - - - - - - - - - - - 66

12.5 Display the selected water heater - - - - - - - - - - - - - - - - - - - - - 66

12.6 Switching the pump on or off - - - - - - - - - - - - - - - - - - - - - - - 66

12.7 Setting the service interval - - - - - - - - - - - - - - - - - - - - - - - - 66

12.8 Service mode - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 66

12.9 Setting legionella prevention- - - - - - - - - - - - - - - - - - - - - - - - 67

13 Errors - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

13.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 69

13.2 Troubleshooting table for general errors - - - - - - - - - - - - - - - - - - 70

13.3 Troubleshooting table for displayed errors - - - - - - - - - - - - - - - - - 72

13.4 Warnings on the display- - - - - - - - - - - - - - - - - - - - - - - - - - 80

14 Service interval - - - - - - - - - - - - - - - - - - - - - - - - - 81

14.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 81

14.2 Determining service interval - - - - - - - - - - - - - - - - - - - - - - - - 81

Instruction manual DR-FC 7

15 Performing maintenance - - - - - - - - - - - - - - - - - - - - 83

15.1 Introduction - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 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 structure- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 90

17.3 Electrical diagram - - - - - - - - - - - - - - - - - - - - - - - - - - - - 92

17.4 Week program card - - - - - - - - - - - - - - - - - - - - - - - - - - - 95

Table of contents

8 Instruction manual DR-FC

Instruction manual DR-FC 9

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1 Introduction

1.1 About the water heater

This manual describes how to install, service and use the DR-FC water heater. The DR-FC water heater is a condensing water heater with a fan in the air intake. The DR-FC can be installed as either an open or room-sealed water heater. A concentric chimney connector is fitted standard to the water heater. Alternatively, the water heater can be connected using a parallel system.

The possible installation types are B23, C13, C33, C43, C53 and C63.

The information in this manual applies to types: DR-FC 25, DR-FC 30, DR-FC 45, DR-FC 60, DR-FC 80, DR-FC 95 and DR-FC 120.

The water heater has been manufactured and equipped in accordance with the European standard for gas-fired storage water heaters for the production of domestic hot water (EN 89). The water heaters are therefore compliant with the European Directive for Gas water heaters, and and are entitled to bear the 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 heater.

1.2 What to do if you smell gas

Warning

If you smell gas:

No naked flames! No smoking!

Avoid causing sparks! Do not use any electrical equipment or switch, i.e. no telephones, plugs or bells!

Open windows and doors!

Shut off the mains gas supply valve!

Warn occupants and leave the building!

After leaving the building, alert the gas distribution company or your installation engineer.

1.3 Regulations

Gas Safety (installations and Use) Regulations 1998 (as amended). It is law

that all gas appliances are installed by competent persons, in accordance with the above regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest and that of safety, to ensure that this law is complied with.

The installation of the water heater MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, IEE Regulations and the Water Supply (water fittings) Regulations.

0063

Introduction

10 Instruction manual DR-FC

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The installation should also be in accordance with any relevant requirements of the HSE, local gas region and local authority and the relevant recommendations of the following documents:

British and European Standards

• BS 6891:

Installation of low pressure gas pipework of up to 35 mm (R1¼) in domestic premises (2nd family gas) - Specification. Note: for lager installations see IGE/UP/2 below.

• BS 6798:

Specification for installation and maintenance of gas-fired boilers of rated input not exceeding 70 kW net.

• BS 6644:

Specification for installation of gas-fired hot water boilers of rated inputs between 70 kW (net) and 1.8 MW (net) (2nd and 3rd family gases).

• BS 6700:

Design, installation, testing and maintenance of services supplying water for domestic use within buildings and their cartilages - Specifications

• BS EN 806-2:

Specification for installations inside buildings conveying water for 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 ventilation for gas appliances of rated input not exceeding 70 kW net (1st, 2nd and 3rd family gases).

Part 1: Specification for installation of gas appliances to chimneys and for maintenance of chimneys.

Part 2: Specification for installation and maintenance of ventilation for gas appliances.

Institute of Gas Engineers and Managers (IGEM) Publications

• IGE/UP/1:

Soundness testing and purging of industrial and commercial gas installations.

• IGE/UP/1A:

Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations.

• IGE/UP/2:

Gas installation pipework, boosters and compressors on industrial and commercial premises.

• IGE/UP/10:

Installation of flued gas appliances in industrial and commercial premises.

CIBSE Publications

• Guide G: Public Health Engineering.

1.4 Target groups

The three target groups for this manual are:

• (end) users;

• installation engineers;

• service and maintenance engineers.

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Symbols on each page indicate the target groups for whom the information is intended. See the table.

Target group symbols

Caution

This water heater is not intended for use by persons with reduced physical, sensory or mental capacities, or who lack the necessary experience or knowledge, unless the person responsible for their safety is supervising them or has explained to them how the water heater should be used.

Caution

This water heater is not intended to be used by children. Always supervise children, and ensure that they do not play with the water heater.

1.5 Maintenance

A service should be carried out at least once a year, both on the water side and on the gas side. Among other things, the service interval depends on the water quality, the average burning time per day 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 side within three months following installation. Based on this check, the best service interval can be determined.

Note

Regular maintenance extends the service life of the water heater.

Both the end user and the service and maintenance engineer are responsible for regular maintenance. They will need to establish clear agreements on this.

Note

If the water heater is not regularly serviced, the warranty will become void.

1.6 Notation conventions

The following notation is used in this manual:

Note

Important information.

Caution

Ignoring this information can lead to the water heater being damaged.

Warning

Failure to carefully read this information may lead to danger of personal

injury, and serious damage to the water heater.

Symbol Target Group

(End) user

Installation engineer

Service and maintenance engineer

Introduction

12 Instruction manual DR-FC

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1.7 Overview of this document

The table provides an overview of the contents of this document.

Contents of this document

Chapter Target groups Description

Working principle of the water heater

This chapter describes the working principle of the water heater.

Installation This chapter describes the installation activities to be carried out

before final commissioning.

Conversion to a different gas category

This chapter describes how to convert the water heater to a different gas category and/or family of gases.

Filling This chapter describes how to fill the water heater.

Draining This chapter describes how to drain the water heater.

The control panel This chapter describes the general control of the water heater using

the display.

Status of the water heater

This chapter describes the status (mode or condition) that the water heater may have, and possible actions to take.

Starting the water heater

This chapter describes how to start the water heater. The general operating cycle of the water heater is also described.

Shutting down This chapter describes how to decommission the 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 maintenance engineers will also need to use this menu.

Service program This chapter describes the service menu. It is mainly intended for

the installation engineer and service and maintenance engineers. End users may also refer to this chapter for additional information about the water heater.

Errors This chapter is mainly intended for the installation engineer and the

service and maintenance engineer. It describes water heater errors. These errors are reported on the display. A troubleshooting table of possible causes and solutions is provided. End users may also refer to this chapter for additional information about the water heater.

Service interval This chapter describes how to determine the optimum service

interval (frequency of regular maintenance). Both the end user and the service and maintenance engineer are responsible for regular maintenance. They need to reach clear agreement on this.

Note

If the water heater is not regularly serviced, the warranty will

become void.

Performing maintenance

This chapter sets out the maintenance tasks to be carried out.

Warranty This chapter states the warranty terms and conditions.

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2 Working principle of

the water heater

2.1 Introduction

This chapter covers the following topics:

• General working principle of the water heater;

• Water heater operating cycle;

• Protection for the water heater;

• Safety of the installation.

2.2 General working

principle of the water heater

The water heater is fitted with a modulating premix burner system with 1:1 gas-to-air ratio regulation. The air required for combustion is delivered by the fan (18). The gas is supplied via the gas control valve (16) and the venturi (30) on the intake side of the fan. The 1:1 gas-to-air ratio always guarantees the most efficient gas/air mixture.

In this water heater, the cold water enters the bottom of the tank through the cold water inlet (14). The tap water, heated by the combustion chamber (8) and heat exchanger (11), leaves the 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 immediately added.

The special design of the heat exchanger (11) ensures that the flue gases are first led downwards via the combustion chamber, then upwards via the heat exchanger, and downwards again alongside the water in the tank. The flue gases gradually become cooler in the process. Because the cooled flue gases flow alongside the cold water lower down in the tank, they start to condense. This condensation causes latent heat energy to be transferred to the cooler water, thereby increasing the performance of the unit. The condensate yielded by this process is discharged via the condens trap (23).

The insulation layer (24) prevents heat loss. The inside of the tank is enamelled to protect against corrosion. The anodes (9) provide extra protection against corrosion.

The water heater has an inspection and cleaning opening (12) for maintenance.

14 Instruction manual DR-FC

Cut-away view of the water heater

Legend DR-FC 25, 30, 45, 60 DR-FC 80, 95, 120

Unused numbers are not applicable

1. cover

2. hot water outlet

3. electrical connector block

4. controller

5. pressure switch

6. control panel

7. temperature sensor T

8. combustion chamber

9. anode

10. tank

11. heat exchanger

12. inspection and cleaning opening

13. temperature sensor T

14. cold water inlet

15. drain valve

16. gas control valve

17. burner

18. fan

19. air supply hose

20. hot surface igniter

21. flame probe

22. chimney pipe

23. condens trap

24. insulation layer

28. potentiostat

29. base

30. venturi

58. flue gas test point

IMD-0758 R0

IMD-0757 R0

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2.3 Water heater operating cycle

The temperature sensor T1 (7) measures the water temperature at the top of the water heater T

top

). This temperature is sent to the controller. As soon as T1 is

lower than the set water temperature (T

set

), the controller registers a "heat demand". The fan (18) starts running and the gas control valve (16) is opened. The fan runs at full speed and the gas is mixed with the air in the venturi (30). This mixture is ignited by the hot surface igniter (20) and the water becomes heated. As soon as the water temperature approaches T

set

the fan rpm drops

to the partial load speed (this is also referred to as modulating). Once T

rises

above T

set

, the heat demand ends and the controller stops the operating cycle. When responding to both the start and end of the heat demand, the controller assumes a certain margin. We refer to this margin as the hysteresis (12.2 "Setting the hysteresis").

2.4 Protection for the water heater

2.4.1 Introduction

The controller monitors the water temperature and ensures safe combustion. This takes place using:

•the Protection for the water heater;

•the Gas control valve;

•the Fan

•the Pressure switch;

•the Flame probe.

2.4.2 Water temperature protection

Using temperature sensors T1 (7) and T2 (13), the controller 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 gas control valve so that gas can be supplied to the burner. As a safety measure, the gas control valve has a double shut-off valve. Both valves shut off the gas supply.

2.4.4 Fan

The fan (18) provides an optimum air supply when there is a heat demand. As a safety feature, the fan ensures that any gases present in the combustion chamber are removed, both before and after combustion. We refer to this as pre- and post-purge.

The fan speed is continuously monitored by the controller (4). The controller takes control if the fan rpm varies too much from the value set.

Protection Description

Against frost (T

< 5°C of T2 < 5°C)

The frost protection cuts in. The water is heated to 20°C.

Against overheating of water (T

> 88°C of T2 > 88°C)

The high-limit safeguard serves to prevent overheating and/or excessive formation of scale in the water heater. If the high-limit safeguard is activated, the heating is stopped. This causes the water in the tank to cool down. Once the water has cooled sufficiently (T

< 81°C), the controller resets the water

heater.

For extra safety (T

> 93°C of T2 > 93°C)

A lockout error of the water heater controller takes place. The controller must be manually reset before the water heater can resume operation (8.3 "Error

conditions"). The reset may only be performed if T

<81°C.

Working principle of the water heater

16 Instruction manual DR-FC

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2.4.5 Pressure switch

The pressure switch only guarantees the supply of air during pre-purging of the water heater. If the pressure difference during pre-purging is sufficient, the pressure switch closes. The table (3.4.2 "General and electrical specifications") shows the trip point for each water heater.

Note

The trip point of the pressure switch is not adjustable.

2.4.6 Flame probe

To ensure that no gas can flow when there is no combustion, the water heater is fitted with a flame probe (21). The controller uses this probe to detect the presence of a flame, by means of ionisation detection. The controller closes the gas control valve the instant it detects that there is a gas flow but no flame.

2.5 Safety of the installation

Excessive pressure in the tank can damage the enamelled layer (in the water heater) or the tank itself. An inlet combination and pressure-reducing valve prevents this. The inlet combination acts as a stop valve, non-return valve and overflow valve. If the water mains pressure is too high (3.4.2 "General and

electrical specifications"), a pressure-reducing valve must be used. Both

components must be fitted in the cold water inlet (3.7 "Vented water

connections").

The use of an expansion vessel, expansion valve and/or pressure reducing valve depends on the type of installation: unvented or vented.

2.5.1 Unvented installation

With an unvented installation, an expansion valve and expansion vessel prevent the buildup of excessive pressure in the tank. This prevents damage being 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 from the tank into the cold water supply system. The pressure-reducing valve protects the water heater against excess mains water pressure (3.4.2 "General and electrical

specifications"). These components are installed in the cold water

inlet (3.7 "Vented water connections").

2.5.2 Vented installation

With a vented installation, excess pressure is taken up by the open cold water head tank. The level of the cold water head tank determines the maximum working pressure (3.4.2 "General and electrical specifications") in the tank. The water heater must also be fitted with a vent pipe from the hot water pipe, which opens into the cold water head tank.

Ideally, the vent pipe should discharge into a separate discharge channel/drain or otherwise to the open cold water head tank. The water heater should also be fitted with a stop valve (3.6.2 "Hot water side") on the hot water side.

2.5.3 T&P valve

A T&P valve is only mandatory in unvented installations. However, the supplier also recommends using a T&P valve in vented installations.

A T&P (Temperature and Pressure Relief) valve monitors the pressure in the tank and the water temperature at the top of the tank. If the pressure in the tank becomes too high (3.4.2 "General and electrical specifications"), the valve will open. The hot water can now flow out of the tank. Because the water heater is under water supply pressure, cold water will automatically flow into the tank. The valve remains open until the unsafe situation has been rectified. The water heater is fitted standard with a connection for a T&P valve (3.6.2 "Hot water

side").

Instruction manual DR-FC 17

3 Installation

Warning

The installation should be carried out by a competent person in compliance with the general and locally applicable regulations imposed by the gas, water and power supply companies and the fire service.

The water heater may only be installed in a boiler room that complies with the requirements stated in national and local ventilation regulations (1.3 "Regulations").

3.1 Introduction

This chapter describes the installation activities to be carried out before final commissioning (9 "Starting the water heater"), namely:

• Packaging;

• Ambient conditions;

• Technical specifications;

• Unvented water connections;

• Vented water connections;

• Gas connection;

• Air supply and chimney flue discharge;

• Electrical connection;

• Checking supply pressure, CO

value and switching pressure;

For possible conversion to a different gas category, see conversion (4 "Conversion to a different gas category").

3.2 Packaging

To avoid damaging the 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 that the water heater is not damaged after unpacking.

3.3 Ambient conditions

The water heater is suitable for either open or room-sealed combustion. If installed as a room-sealed water heater, it is independent of the installation site for the necessary external air supply. In this event, there are no additional ventilation requirements.

If the water heater is to be installed as an open system, it must meet the locally-applicable directives and ventilation regulations for open water heaters.

The possible installation types are B23, C13, C33, C43, C53 and C63.

Caution

The water heater may not be used in rooms where chemical substances are stored or used due to the risk of explosion, and corrosion of the water heater. Some propellants, bleaching agents and degreasing agents etc. disperse vapours that are explosive and/or cause accelerated corrosion. If the water heater is used in a room in which such substances are present, the warranty will be void.

Installation

18 Instruction manual DR-FC

3.3.1 Air humidity and ambient temperature

The boiler room must be frost-free, or be protected against frost. The table shows the ambient conditions that must be adhered to for correct functioning of the electronics present in the water heater to be guaranteed.

Air humidity and ambient temperature specifications

3.3.2 Water heater maximum floor load

Allow for the water heater's weight and the maximum floor load; refer to the table (3.4.2 "General and electrical specifications").

3.3.3 Water composition

The water heater is intended for heating drinking water. The drinking water must comply with 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 the table, then the

tank protection cannot be guaranteed (16 "Warranty").

3.3.4 Working clearances

For access to the water heater, it is recommended that the following clearances are observed (see figure):

• AA: around the water heater's control column and cleaning openings: 100 cm.

• BB: all sides of the water heater: 50 cm.

• Top of the water heater: 100 cm

Air humidity and ambient temperature

Air humidity max. 93% RH at +25°C

Ambient temperature Functional: 0 <

T < 60°C

Water composition

Hardness (alkaline earth ions)

> 1.00 mmol/l:

• German hardness > 5.6 °dH

• French hardness > 10.0 °fH

• English hardness > 7.0 °eH

Conductivity > 125 µS/cm

Acidity (pH value) 7.0 < pH value < 9.5

Instruction manual DR-FC 19

Working clearances

Note

When installing the water heater, be aware that any leakage from the tank and/or connections can cause damage to the immediate environment or floors below the level of the boiler room. If this is the case, the water heater should be installed above a waste water drain or in 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.

3.4 Technical specifications

The water heater is supplied without accessories. Check the dimensions (3.4 "Technical specifications"), gas data (3.4.3 "Gas data") and other specifications (3.4.2 "General and electrical specifications") of any accessories you plan to use.

DR-FC 25 through 60 DR-FC 80 through 120

IMD-0765 R0

20 Instruction manual DR-FC

3.4.1 Dimensions of the water heater

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 R

45º

18º

45º

6.5º

IMD-0775 R0

45º

18º

45º

44º

Instruction manual DR-FC 21

Dimensions (all dimensions in mm, unless otherwise stated)

Dimension

Description Unit DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 DR-FC 80 DR-FC 95 DR-FC 120

A Total height mm 1485 2005 2005 2005 2060 2060 2060

C Position on base mm 490 490 490 490 530 530 530

D Water heater diameter mm 705 705 705 705 850 850 850

E Depth mm 925 925 925 925 1000 1000 1000

F Width mm 850 850 850 850 900 900 900

G Diameter of flue gas discharge mm 100/150 100/150 100/150 100/150 130/200 130/200 130/200

H Height of flue gas outlet/air supply mm 1460 2000 2000 2000 1995 1995 1995

Hx x position flue gas outlet mm 265 265 265 265 310 310 310

Hy x position flue gas outlet mm 375 375 375 375 440 440 440

K Height of gas connection mm 1365 1895 1895 1895 1855 1855 1855

M Height of cold water 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 opening mm 265 270 270 270 290 290 290

R Height of drain valve connection mm 180 170 170 170 225 225 225

S Height of T&P valve connection mm 995 1505 1505 1505 1425 1425 1425

W Height of condensation drain mm 220 240 240 240 240 240 240

1 Cold water inlet connection (male) - R 1

R 11/

2 Hot water outlet (male) - R 11/

R 11/

3 Gas inlet connection (female) - R 3/4"R

/4"R

/4"

4 Drain valve connection (female) -

/4"

5 T&P valve connection (female) - 1" - 11.5 NPT 1" - 11.5 NPT 1" - 11.5 NPT 1" - 11.5 NPT 1" - 11.5 NPT 1" - 11.5 NPT 1" - 11.5 NPT

6 Cleaning/inspection opening mm 95 x 70 95 x 70 95 x 70 95 x 70 95 x 70 95 x 70 95 x 70

7 Condensation drain connection (female) - Rp 1 Rp 1 Rp 1 Rp 1 Rp 1 Rp 1 Rp 1

22 Instruction manual DR-FC

3.4.2 General and electrical specifications

DESCRIPTION Unit DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 DR-FC 80 DR-FC 95 DR-FC 120

Contents litres 227 386 386 386 504 504 504

Empty weight kg 202 239 239 239 480 480 480

Maximum floor load kg 429 625 625 625 984 984 984

Maximum operating pressure (vented) kPa (bar) 800 (8) 800 (8) 800 (8) 800 (8) 800 (8) 800 (8) 800 (8)

Maximum operating pressure (unvented) kPa (bar) 550 (5.5) 550 (5.5) 550 (5.5) 550 (5.5) 550 (5.5) 550 (5.5) 550 (5.5)

Regulation interval, control thermostat

C 40…80 40…80 40…80 40…80 40…80 40…80 40…80

Default value, control thermostat

C65656565656565

Regulation interval, hysteresis up

C0…50…50…50…50…50…50…5

Default value, hysteresis up

C5555555

Regulation interval, hysteresis down

C 0…10 0…10 0…10 0…10 0…10 0…10 0…10

Default value, hysteresis down

C5555555

Number of (power) anodes -1222222

Measured pressure differential across pressure switch Pa ≥ 145 ≥ 145 ≥ 145 ≥ 145 ≥ 240 ≥ 240 ≥ 240

Pressure differential to open the pressure switch Pa < 115 < 115 < 115 < 115 < 210 < 210 < 210

Heating time ∆T = 45ºC minutes 23 38 25 20 19 16 13

DESCRIPTION Unit DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 DR-FC 80 DR-FC 95 DR-FC 120

Electrical power consumption W 45 45 75 115 95 145 240

Supply voltage (-15% +10% VAC) volts 230 230 230 230 230 230 230

Mains frequency (± 1Hz) Hz 50 50 50 50 50 50 50

IP class - IP 20 IP 20 IP 20 IP 20 IP 20 IP 20 IP 20

DESCRIPTION Unit: Value

Maximum mains pressure of cold water supply (vented) kPa (bar) 800 (8)

Maximum mains pressure of cold water supply (unvented) kPa (bar) 550 (5.5)

Maximum mains pressure of the protected cold supply setup kPa (bar) 500 (5)

Overflow pressure T&P kPa (bar) 700 (7)

Overflow temperature T&P °C 97

Instruction manual DR-FC 23

3.4.3 Gas data

2H3P

description Unit: DR-FC 25 DR-FC 30 DR-FC 45 DR-FC 60 DR-FC 80 DR-FC 95 DR-FC 120

Gas category 2H: G20-20 mbar

Venturi restrictor diameter mm 7.60 7.60 7.60 7.60 8.60 8.60 8.60

Nominal input (gross) kW 31.6 32.6 51.2 62.1 85.0 103.4 126.3

Nominal capacity kW 30.5 32.0 49.3 59.3 82.6 98.7 119.4

Supply pressure mbar 20 20 20 20 20 20 20

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* m

/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 5.45 5.45 5.45 5.45 6.60 6.60 6.60

Nominal input (gross) kW 31.0 32.0 50.1 60.8 83.2 101.2 123.6

Nominal capacity kW 30.5 32.0 49.3 59.3 82.6 98.7 119.4

Supply pressure mbar 37 / 50 37 / 50 37 / 50 37 / 50 37 / 50 37 / 50 37 / 50

Vol% 10.0 + 1.0 10.0 + 1.0 10.0 + 1.0 10.0 + 1.0 9.6 + 1.0 9.6 + 1.0 9.6 + 1.0

Gas consumption* kg/h 2.3 2.3 3.7 4.4 6.1 7.4 9.0

(*) Based on 1013.25 mbar and 15°C.

Installation

24 Instruction manual DR-FC

3.5 Installation diagram

The figure shows the Installation diagram. This diagram is referred to in the sections describing the actual connection procedure.

Installation diagram

Legend Vented and unvented

Unused numbers are not applicable

1. pressure relief valve (mandatory if the mains water pressure is too high)

3. T&P valve (mandatory)

4. stop valve (recommended)

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 points

15. expansion valve (mandatory)

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. cold water head tank

19. float switch

A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow protection

IMD-0780 R

4645

14 1414

UNVENTED

VENTED

Instruction manual DR-FC 25

3.6 Unvented water connections

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.6.1 Cold water side

See (A) in the installation diagram (3.5 "Installation diagram").

1. Fit an approved stop valve (4) on the cold water side as required by the applicable regulations (1.3 "Regulations").

2. The maximum working pressure of the water heater is 8 bar. Because the pressure in the water pipe at times can exceed 8 bar, you must fit an approved pressure-reducing valve (1).

3. Fit a non-return valve (5) and an expansion vessel (16).

4. Fit an expansion valve (15) and connect the overflow side to an open waste water pipe.

3.6.2 Hot water side

See (B) in the installation diagram (3.5 "Installation diagram").

Note

Insulating long hot water pipes prevents unnecessary 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 Circulation pipe

See (C) in the installation diagram (3.5 "Installation diagram").

If an immediate flow of hot water is 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 circulation system.

2. Fit a non-return valve (5) after the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for servicing (4).

4. Connect the circulation pipe according to the installation diagram (3.5 "Installation diagram").

3.6.4 Condensation drain

1. Fit a sloping waste water pipe to the condens trap (13) for condensation drainage and connect this via an open connection to the waste water discharge.

Caution

If the condensation drain is not fitted to the waste water discharge using an

open connection, this can cause faults.

Installation

26 Instruction manual DR-FC

3.7 Vented water connections

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.7.1 Cold water side

See (A) in the installation diagram (3.5 "Installation diagram").

1. Fit an approved stop valve (4) on the cold water side between the cold water head tank (18) and the water heater, as required by applicable regulations.

3.7.2 Hot water side

See (B) in the installation diagram (3.5 "Installation diagram").

Note

Insulating long hot water pipes prevents unnecessary energy loss.

1. Fit the T&P valve (3).

2. Optional: fit a temperature gauge (12) so you can check the temperature of the tap water.

3. Fit a stop valve (4) in the hot water outlet pipe for servicing.

4. If a circulation pipe is required, continue by installing the circulation pipe (3.6.3 "Circulation pipe").

3.7.3 Circulation pipe

See (C) in the installation diagram (3.5 "Installation diagram").

If an immediate flow of hot water is 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 circulation system.

2. Fit a non-return valve (5) after the circulation pump to guarantee the direction of circulation.

3. Fit two stop valves for servicing (4).

4. Connect the circulation pipe according to the installation diagram (3.5 "Installation diagram").

3.7.4 Condensation drain

1. Fit a sloping waste water pipe to the condens trap (13) for condensation drainage and connect this via an open connection to the waste water discharge.

Caution

If the condensation drain is not fitted to the waste water discharge using an

open connection, this can cause faults.

3.8 Gas connection

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

Caution

Make sure that the diameter and length of the gas supply pipe are large

enough to supply sufficient capacity to the water heater.

See (D) in the installation diagram (3.5 "Installation diagram").

1. Fit a manual gas valve (10) in the gas supply pipe.

2. Blow the gas pipe clean before use.

Instruction manual DR-FC 27

3. Close the manual gas valve.

4. Fit the gas supply pipe to the gas control valve.

Warning

After fitting, check for leaks.

3.9 Air supply and chimney flue discharge

3.9.1 Introduction

This section covers the following topics:

• Requirements for flue gas discharge materials

• Concentric connections

• Parallel connections

3.9.2 Requirements for flue gas discharge materials

Warning

The installation should be carried out by a 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 supply and chimney flue.

The water heaters are approved for installations of type B23, C13, C33, C43, C53 and C63.

This manual discusses installation types C13 and C33 in detail. If the water heater has to function in accordance with B23, C43, C53 or C63, you can obtain more information by contacting the supplier.

The figure and table give information about these types of installation. For an explanation of the possibilities, please contact the manufacturer.

Installation

28 Instruction manual DR-FC

Installation types

IMD-0790 R

C43

C13 C53

B23 C33

Instruction manual DR-FC 29

Explanation of types of installation

Note

Make sure that the chimney flue discharges into an area approved for this

type of installation.

3.9.3 Concentric connections

The table shows the requirements for concentric systems.

Warning

Install flue gas discharge pipe runs with a run-off of 5 mm per metre towards

the water heater.

Flue gas discharge requirements for concentric systems (C13, C33)

Caution

Both conditions stated in the table must be fulfilled.

Even if you use less than the stated maximum number of bends, the maximum pipe length still may not be exceeded.

Even if you 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 combustion is drawn from the boiler room.

C13 Concentric and/or parallel wall flue terminal.

C33 Concentric and / or parallel roof flue terminal

C43 Water heaters on common air supply and flue gas discharge (concentric

and/or parallel) in multi-storey building.

C53 Air supply and flue gas discharge terminal types mixed.

C63 Water heaters supplied without flue gas discharge materials and/or terminal.

These water heaters must be installed in compliance with local regulations.

Water heater Diameter Maximum

length

Maximum number of 90° bends

DR-FC 25, 30, 45, 60 100/150 mm 40 m 7

DR-FC 80, 95, 120 130/200 mm 15 m 4

Installation

30 Instruction manual DR-FC

Practical example of concentric flue gas discharge

Example

The figure shows a DR-FC 30 installation. The water heater must be fitted with 25 m of concentric pipe (C13/C33) and four 90 degree bends. The configuration must be checked for compliance with the requirements stated in the table.

Water heater with concentric flue gas discharge material

According to the table, the maximum length allowed is 40 metres, and there may be up to seven 90 degree bends. Both requirements are fulfilled.

Specifications

Caution

For type C13 and C33 installations,the supplier prescribes the use of a roof or wall flue terminal, exclusively of a 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

Subject Description

Wall flue terminal set:

• 1x Wall flue terminal (incl. wall flange & clamping ring)

• 1x Pipe 500 mm

• 1x Bend 90°

Art. No. DR-FC 25, 30, 45, 60 562702040

DR-FC 80, 95, 120 562702041

Manufacturer Muelink & Grol

Model M2000 MDV SEC

Pipe material Construction Concentric

Flue gas discharge

Thick-walled aluminium with lipped sealing ring.

Air supply Thin-walled galvanised sheet steel.

Pipe diameters Flue gas

discharge

DR-FC 25, 30, 45, 60 Ø 100 mm

DR-FC 80, 95, 120 Ø 130 mm

Air supply DR-FC 25, 30, 45, 60 Ø 150 mm

DR-FC 80, 95, 120 Ø 200 mm

(1)

No other wall flue terminal is permitted. Use this article number to order the wall flue terminal set from the

supplier, manufacturer or wholesaler.

Instruction manual DR-FC 31

Concentric roof flue terminal specifications C33

3.9.4 Parallel connections

The table states the maximum pipe lengths for parallel systems. The maximum pipe length depends on the chosen diameter.

Warning

Install flue gas discharge pipe runs with a run-off of 5 mm per metre towards

the water heater.

Chimney flue requirements for parallel systems

You must use the longest pipe when calculating the pipe length. For example, if the chimney pipe is 10 metres and the air supply pipe is 8 metres, use 10 metres as the length for the calculation. Next, add the L

equivalent

for every 90° and 45° bend to this 10 metres, in both the air supply and flue gas outlet. The following practical example illustrates how to use the table.

Subject Description

Roof flue terminal set:

• 1x Roof flue terminal (incl. clamping ring)

• 1x Pipe 1000 mm

• 1x Roofplate

Art. No. DR-FC 25, 30, 45, 60 532702155

DR-FC 80, 95, 120 532702158

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 galvanised sheet steel.

Pipe diameters Flue gas

discharge

DR-FC 25, 30, 45, 60 Ø 100 mm

DR-FC 80, 95, 120 Ø 130 mm

Air supply DR-FC 25, 30, 45, 60 Ø 150 mm

DR-FC 80, 95, 120 Ø 200 mm

(1)

No other roof flue terminal may be used. Use this item number to order the roof flue terminal set from the

supplier, manufacturer or wholesalor.

Water heater Diameter1Maximum

total length

equivalent

90° bend

equivalent

45° bend

DR-FC 25, 30, 45, 60100 mm 55 m 4.6 m 1.2 m

DR-FC 80, 95, 120 130 mm 65 m 2.4 m 1.4 m

DR-FC 25, 30, 45, 60130 mm 100 m 2.4 m 1.4 m

DR-FC 80, 95, 120 150 mm 100 m 2.6 m 1.6 m

(1) Parallel systems with diameters of 100 or 130 mm. If the maximum total

length for a diameter of 100 mm is insufficient, 130 mm diameter should be used. If the maximum total length for a diameter of 130 mm is insufficient,

150 mm diameter should be used. Any diameter enlargement must be carried out on both air supply and flue gas discharge.

Installation

32 Instruction manual DR-FC

Practical example of parallel flue gas discharge

Example

The figure shows a DR-FC 30 installation. This has to be fitted with a 10 m parallel pipe of 100 mm diameter, and eight 90 degree bends. The configuration must be checked for compliance with the requirements stated in the table.

Water heater with parallel flue gas discharge material

The longest pipe must be used to check the maximum length. In this case, the chimney pipe is the longest. This is 10 metres. This 10 metres is the sum of pipe sections 1, 2, 3, 4 and 5. The length of the transition piece can be ignored. The total number of bends used in the chimney flue and air supply is 8. The bend in the transition piece can be ignored. According to the table, 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 fulfils the requirements.

3.10 Electrical connection

Warning

The installation should be carried out by a competent person, in compliance

with general and locally applicable regulations (1.3 "Regulations").

3.10.1 Introduction

This section covers the following topics:

• Preparation;

• Connecting the mains power;

Optionally, it is possible to connect an isolating transformer, a continuous pump, a program-controlled pump, an extra ON mode switch and an extra alarm signal to the water heater. For these options, see:

• Isolating transformer;

• Connecting a program-controlled pump;

• Connecting an extra ON mode switch

Note

The optional components are not included in the electrical power consumption rating stated in the table (3.4.2 "General and electrical

specifications").

IMD-0792 R0

Instruction manual DR-FC 33

3.10.2 Preparation

Caution

The water heater is phase-sensitive. It is absolutely essential to connect the mains live (L) to the live of the water heater, and the mains neutral (N) to the neutral of the water heater.

Caution

There must be no potential difference between neutral (N) and earth ( ). If this is the case, then an isolating transformer (3.10.4 "Isolating transformer") must be used in the supply circuit.

For more information or to order this isolating 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 two covers, and the cover of the electrical section.

1. Undo the screws of the covers.

2. Carefully remove the covers from the water heater.

The electrical section is now visible.

3. Loosen the 2 screws (A) and remove the cover (B) from the electrical

section. The connector block (C) is now visible.

Note

Consult the table for the connections and consult the electrical diagram for

the electrical component connections.

Legend

A. screws B. cover C. terminal block

IMD-0795 R

Installation

34 Instruction manual DR-FC

Terminal block

3.10.3 Connecting the mains power

The water heater is supplied without a power cable and isolator.

Note

In order to receive electrical power, the water heater has to be connected to the mains power by means of a permanent electrical connection. A double-pole isolator with a contact gap of at least 3 mm must be fitted between this permanent connection and the water heater. The power cable must have cores of at least 3 x 1.0 mm 2 .

Warning

Leave the water heater electrically isolated until you are ready to

commission it.

1. Connect neutral (N), live (L) and earth ( ) of the power cable to

terminals 1 thru 3 of the terminal block as shown in the table (3.10.2 "Preparation").

2. Fit the power cable in the strain relief.

3. Connect the power cable to the isolator.

4. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water 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 the supplier for details of the correct isolating transformer.)

2. Connect neutral (N), live (L) and earth ( ) of the power cable to

terminals 4 thru 9 of the terminal block as shown in the table (3.10.2 "Preparation").

3. Fit the cables in the strain relief.

4. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

5. Connect the power cable to the isolator.

3.10.5 Connecting a program-controlled pump

1. Connect neutral (N), live (L) and earth ( ) to terminals 13, 14 and 15 as

shown in the table (3.10.2 "Preparation").

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

Mains

voltage

Isolating transformer

Alarm Out

Program-

controlled

pump

Exter-

nal

ON/OFF

BUS-

link

primary secondary

NL NL

X1X

X3X4X5X

12345678910111213141516 through 2021222324

Instruction manual DR-FC 35

3.10.6 Connecting an extra ON mode switch

External ON/OFF is an option 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 "ON mode" is active.

1. Connect leads (X

and X4) to terminals 21 and 22 according to the

table (3.10.2 "Preparation").

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

3.10.7 Connecting extra error signal

The water heater has a terminal that is switched when an error is detected. This can be used to signal errors, for example with a lamp. A 230 V circuit can be directly powered. Other voltages require a relay prescribed by the manufacturer.

1. Connect the live leads (X

and X2) to points 10 and 11 according to the table (3.10.2 "Preparation"). If required, connect earth ( ) to terminal 12.

2. Fit the cable in the strain relief.

3. If you have no more connections to make:

- Fit the cover on the terminal block.

- Fit the covers onto the water heater.

3.11 Checking supply pressure, CO

value

and switching pressure

Note

Before starting the water heater and/or checking the supply pressure and/or the CO2 value and/or the switching pressure, you should first fill (5 "Filling") the water heater .

Caution

During commissioning or after conversion, you must always check the

supply pressure, the CO2 value and the switching pressure.

Note

In order to check the supply pressure, the CO

value and the switching

pressure, you must have a CO2 meter and a pressure gauge available.

3.11.1 Procedure for checking the supply pressure

To check the supply pressure, proceed as follows:

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. The gas control valve has a test point that can be used for measuring the

supply pressure.

This test point has a sealing screw. Loosen the sealing screw by a few turns. Do not completely loosen it; it can be difficult to re-tighten.

5. Open the gas supply and vent the gas supply line with the supply pressure

test point.

6. Connect a pressure gauge to the supply pressure test point as soon as gas

starts to flow from this test point.

Installation

36 Instruction manual DR-FC

7. Switch on the power to the water heater using the isolator on the water heater.

8. Switch the controller ON by setting the 0/I switch to position I.

The display will now show

INTERNAL CHECK

for about 10 seconds, and

will then go to the main menu.

9. Activate "ON mode" by going through the following steps:

- Press once on the blue arrow ( ) to position the cursor beside

then press . The display shown here will appear.

- Confirm the selection

START OPERATION

with .

The water heater is now in "ON mode" and will ignite.

10. Once the display shows the text

RUNNING

you must wait about 1 minute before reading the dynamic pressures (the fan needs this time to run up to full rotational speed).

11. Use the pressure gauge to read the supply pressure from the test point and check it against the value from the gas table (3.4.3 "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 the water heater from the mains").

12. Shut off the gas supply.

13. Disconnect the pressure gauge and retighten the sealing screw in the test

point.

14. If there is nothing else you need to check or adjust, you can put the covers

back on the water heater.

3.11.2 CO2-adjustment

To check the CO2 value during full load and partial load and to adjust it if necessary, proceed as follows:

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. Place the CO

meter measurement probe in the test point (58) of the flue

gas outlet pipe.

5. Open the gas supply and vent the gas supply line.

6. Use the main switch to apply mains voltage to the water heater.

INTERNAL CHECK

MENU »OFF ^ ON È WEEK PROGRAM

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

Instruction manual DR-FC 37

7. Start (9 "Starting the water heater") the water heater.

8. Go to menu :

SERVICE OPERATION

9. Generate a heat demand by tapping off hot water from the water heater until it is cold or by raising the value for

Tset

in the

SERVICE

menu. Use for

this.

Full-load measurement

10. From the service menu, select:

SERVICE OPERATION

FULL LOAD

- Confirm with .

11. You are now in the

FULL LOAD

service menu.

12. The water heater is now running at

FULL LOAD

. Read the value from the

meter and wait until this measured value has remained stable for some

time. This may take several minutes.

13. Then compare the measured CO

value against the value from the

table (3.4.3 "Gas data").

DR-FC 25 through 60

14. If necessary, adjust the CO

value using the adjustment screw (2) until the value is within the range listed in the table of CO2 values. Use the supplied Allen key (3) for this. The key can be found in the plastic bag that is attached to the water heater.

adjustment

SERVICE Ê Ê FULL LOAD 47 ÉC Tset 70ÉC RUNNING

Legend

1. test point

2. adjustment screw

3. Allen key for adjustment screw

IMD-0764 R0

Installation

38 Instruction manual DR-FC

Note

Turning to the left (anticlockwise) means more gas (higher CO2 level) and

turning to the right (clockwise) means less gas (lower CO2 level).

15. If you have increased

Tset

, set it back to the original value using .

16. Continue with the low-load CO

measurement.

DR-FC 80 through 120

17. If the measured value is within the range given in the table of CO

values:

- If you have increased

Tset

, set it back to the original value using .

- Continue with the low-load CO

measurement.

18. If the measured value is not within the range of CO

values from the 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.

Partial load measurement

20. Now continue with the partial load measurement:

-Press .

-Select

PARTIAL LOAD

-Press .

21. The water heater is now running at

PARTIAL LOAD

. Read the value from

the CO

meter and wait until this measured value has remained stable for

some time. This may take several minutes.

22. Then compare the measured CO

value against the value from the

table (3.4.3 "Gas data").

23. If necessary, adjust the CO

value using the adjustment screw until the value

is within the range listed in the table of CO

values.

adjustment

Legend

1. test point

2. adjusting screw

IMD-0762 R0

Instruction manual DR-FC 39

Note

Turning to the left (anticlockwise) means less gas (lower CO2 level) and

turning to the right (clockwise) means more gas (higher CO2 level).

24. Remove the CO

measurement probe from the test point of the flue gas

outlet pipe.

25. Put the cap back on the flue gas outlet test point.

26. Shut off the gas supply.

27. Replace the covers.

3.11.3 Switching pressure measurement

To measure the switching pressure, proceed as follows:

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. Remove the black caps from the pressure switch test point

5. Connect the + of the pressure gauge to the H of the pressure switch test point.

6. Connect the - of the pressure gauge to the L of the pressure switch test point

7. Zero the pressure gauge.

8. Start (9 "Starting the water heater") the water heater.

9. The water heater will now run through the operating cycle (2.3 "Water heater

operating cycle").

Legend

1. test point

2. adjusting screw

IMD-0763 R0

Installation

40 Instruction manual DR-FC

10. Read the pressure from the meter at the moment when the water heater switches from

PRE PURGE

PRESSURE SWITCH

. At this point, the

water heater's display will 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 qualified service engineer.

12. Shut off the gas supply.

13. Disconnect the pressure gauge.

14. Put the two black caps back on the pressure switch.

15. Replace the covers.

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRESSURE SWITCH

Instruction manual DR-FC 41

4 Conversion to a

different gas category

4.1 Introduction

Caution

The conversion may only by carried out by a competent person.

If the water heater must operate on a family of gases (LP gas or natural gas) or other gas category than that for which the water heater has been set at the factory, the water heater will have to be adapted using a special conversion kit.

Caution

After conversion you must check and adjust the supply pressure, the CO

value and the switching pressure.

4.2 Conversion of DR-FC 25 through 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 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 (3 and 4) on the gas control valve. The hoses are attached with pneumatic couplings.

Detach coupling

7. Grip the nearest part of the pneumatic coupling.

8. Push this back.

9. Grip the hose firmly and pull it out of the coupling.

10. Release the coupling.

11. Unscrew the connector (2) from the gas control valve.

12. Remove the gas control valve from the venturi flange (6, four Phillips screws).

IMD-

080

4 R

1. 4.3.2.

Conversion to a different gas category

42 Instruction manual DR-FC

Conversion of gas control valve in DR-FC 25 through 60

13. Remove the restrictor (5, incl. gasket).

14. Select the correct restrictor (including gasket) from the conversion set using the gas table (3.4.3 "Gas data"). The restrictor diameter is shown on the restrictor.

Caution

If no restrictor diameter is stated in the gas table, then only the gasket from

the conversion set needs to be fitted.

15. Fit the restrictor (including the gasket) into the flange of the venturi.

Note

The lugs of the gasket must align exactly to the holes in the flange.

16. From the conversion set, take the "small" sticker that indicates the new (modified) gas category.

17. Affix the sticker 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 onto the flange of the venturi (6, four cross-head screws).

19. Refit the connector (2) to the gas control valve.

20. Insert the hose with code "H" into the coupling (3) on the offset adjuster and insert the hose with code "L" into the coupling (4) next to the test point on the gas control valve.

21. Re-fit the three-part gas coupling (1).

22. Check the supply pressure (3.11.1 "Procedure for checking the supply

pressure"), the CO

value (3.11.2 "CO2-adjustment") and the switching

pressure (3.11.3 "Switching pressure measurement").

Legend

1. 3-part connector

2. gas inlet connector

3. offset adjustment coupling

4. gas inlet coupling

5. restrictor (incl. gasket)

6. venturi flange

7. test point

8. gas control valve sticker

IMD-0796 R0

Instruction manual DR-FC 43

23. Replace the covers.

24. From the conversion set, take the "large" sticker that indicates the new (modified) gas category. Affix this below the identification plate of the water heater. This makes it clear that the water heater no longer functions on the gas for which it was originally supplied.

4.3 Conversion of DR-FC 80 through 120

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 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 with pneumatic couplings.

Detach coupling

7. Grip the nearest part of the pneumatic coupling.

8. Push this back.

9. Grip the hose firmly and pull it out of the coupling.

10. Release the coupling.

11. Unscrew the connector (4) of the gas inlet.

12. Undo the hose clip (5) between the air supply pipe and the venturi and slide the pipe out of the venturi.

13. Remove the six bolts that fix the venturi onto the fan.

14. Remove the entire venturi/gas control valve unit.

15. Remove the gas control valve from the venturi flange (7, four Phillips screws).

IMD-

080

4 R

1. 4.3.2.

Conversion to a different gas category

44 Instruction manual DR-FC

Conversion of gas control valve in DR-FC 80 through 120

16. Remove the restrictor (8) and gaskets (9 and 10).

17. Select the correct restrictor from the conversion set using the gas table (3.4.3 "Gas data").

18. Fit the restrictor (including two new gaskets from the conversion set) in the flange of the venturi.

19. From the conversion set, take the "small" sticker that indicates the new (modified) gas category.

20. Affix the sticker 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.

21. Fit the gas control valve onto the flange of the venturi (7, four cross-head screws).

22. Fit the venturi unit onto the fan using the six bolts.

23. Slide the air supply pipe over the venturi and fix 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 the coupling (2) next to the test point on the gas control valve.

26. Re-fit the three-part gas coupling (1).

27. Check the supply pressure (3.11.1 "Procedure for checking the supply

pressure"), the CO

value (3.11.2 "CO2-adjustment") and the switching

pressure (3.11.3 "Switching pressure measurement").

28. Replace the covers.

29. From the conversion set, take the "large" sticker that indicates the new (modified) gas category.

30. Affix this below the identification plate of the water heater. This makes it clear that the water heater no longer functions on the gas for which it was originally supplied.

Legend

1. 3-part connector

2. gas inlet coupling

3. offset adjustment coupling

4. gas inlet connector

5. hose clamp

6. venturi

7. venturi flange

8. restrictor

9. restrictor gasket

10. flange/gas control valve gasket

11. gas control valve sticker

IMD-0797 R0

Instruction manual DR-FC 45

gis

5 Filling

Installation diagram

Legend Vented and unvented

Unused numbers are not applicable

1. pressure relief valve (mandatory if the mains water pressure is too high)

3. T&P valve (mandatory)

4. stop valve (recommended)

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 points

15. expansion valve (mandatory)

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. cold water head tank

19. float switch

A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow protection

IMD-0780 R

464

14 1414

UNVENTED

VENTED

Filling

46 Instruction manual DR-FC

gis

5.1 Filling unvented installations

To fill the water heater, proceed as follows:

1. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6).

2. Close the drain valve (9).

3. Open the nearest hot water draw-off point (14).

4. Open the stop valve (4) on the cold water side (A) so that cold water flows into the water heater.

5. Completely fill the water heater. When a full water jet flows from the nearest draw-off point, the water heater is full.

6. Bleed the entire installation of air, for example by opening all draw-off points.

7. The water heater is now under water supply pressure. There should now be no water coming out of the inlet combination expansion valve or (if used) out of the T&P valve (3). If there is, the cause might be:

- The water supply pressure is greater than the specified

value (3.4.2 "General and electrical specifications"). Rectify this by fitting 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. Open the stop valve (11) in the hot water pipe and, if present, the stop valves (4) for the circulation pump (6).

2. Close the drain valve (9).

3. Open the nearest hot water draw-off point (14).

4. Open the stop valve (4) on the cold water side (A) so that cold water flows into the water heater.

5. Completely fill the water heater. When a full water jet flows from the nearest draw-off point, the water heater is full.

6. Bleed the entire installation of air, for example by opening all draw-off points.

- The water supply pressure is greater than the specified

value (3.4.2 "General and electrical specifications"). Rectify this by fitting a pressure reducing valve (1).

- The expansion valve in the protected cold supply set-up is defective or

incorrectly fitted.

Instruction manual DR-FC 47

gis

6 Draining

Installation diagram

Legend Vented and unvented

Unused numbers are not applicable

1. pressure relief valve (mandatory if the mains water pressure is too high)

3. T&P valve (mandatory)

4. stop valve (recommended)

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 points

15. expansion valve (mandatory)

16. expansion vessel (mandatory)

17. 3-way aeration valve (recommended)

18. cold water head tank

19. float switch

A. cold water supply B. hot water supply C. circulation pipe D. gas supply E. overflow pipe H. overflow protection

IMD-0780 R0

4645

14 1414

UNVENTED

VENTED

Draining

48 Instruction manual DR-FC

gis

6.1 Draining unvented installations

Some service activities require the water heater to be drained. The procedure is as follows:

1. Activate the

with .

2. Position the cursor in front of

OFF

3. Confirm

OFF

with .

4. Wait until the fan has stopped. The icon is then dimmed.

Caution

Failure to wait until the fan stops can cause damage to the water heater.

5. Switch the water heater OFF (position 0) using the ON/OFF switch on the control panel.

6. Isolate the water heater from the power supply by setting the isolator between the water heater and the mains power supply to position 0.

7. Shut off the gas supply (10).

8. Close the stop valve (11) in the hot water pipe.

9. Close the supply valve (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

with .

2. Position the cursor in front of

OFF

3. Confirm

OFF

with .

4. Wait until the fan has stopped. The icon is then dimmed.

Caution Failure to wait until the fan stops can cause damage to the water

heater.

5. Switch the water heater OFF (position 0) using the ON/OFF switch on the control panel.

6. Isolate the water heater from the power supply by setting the isolator between the water heater and the mains power supply to position 0.

7. Shut off the gas supply (10).

8. Close the stop valve (11) in the hot water pipe.

9. Close the stop valve (4) between the cold water head tank and the cold water inlet (A).

10. Open the drain valve (9).

11. Bleed the water heater (or installation) so that it drains completely.

MENU »OFF ^ ON È WEEK PROGRAM

Instruction manual DR-FC 49

gis

7 The control panel

7.1 Introduction

This chapter covers the following topics:

• Control;

• Explanation of icons;

• ON/OFF switch on controller;

• Navigation buttons;

• PC connection.

7.2 Control

The control panel is completely menu-driven, and comprises:

• a 4-line display with 20 characters per line;

• 6 buttons for controlling the water heater (below the display);

• 6 graphical symbols (above the display);

• a connector for a service PC;

• an ON/OFF switch.

The buttons are divided into three groups:

• Navigation buttons:

- Buttons for UP , and DOWN ;

-Enter: ;

- Reset button:

• The main menu (11 "Main menu"): ;

• the service program (12 "Service program"): . This chapter is specifically intended for the service and maintenance engineer and installation engineer.

In this manual, the display of the controller is shown as in the figure, 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 water heater ON and OFF. Note that in the OFF position the water heater remains electrically live, in order for the continuous pump to stay running.

After switching on, the text

INTERNAL CHECK

appears on the display for about 10 seconds. The main menu (11 "Main menu") then appears. If no selection is made in the main menu, the water heater automatically switches to the OFF mode (8.2 "Operating modes").

Note

To electrically isolate the water heater, you must use the isolator between the water heater and the mains power supply.

»START OPERATION ^ CHANGE SETPOINT È Tset=70ÉC

Name Explanation

Heat demand Heat demand detected

Purge Pre- and post-purge using

fan

Pressure switch Pressure switch is closed

Glow (Pre)glow

Gas control valve

Gas control valve open/ignition

Flame detection Water heater operational

INTERNAL CHECK

The control panel

50 Instruction manual DR-FC

gis

7.5 Navigation buttons

The use of these buttons is explained with the help of the figure showing the main menu (11 "Main menu").

The navigation buttons are:

• Buttons for UP , and DOWN ;

• Enter: ;

• Reset button: .

The arrows

and È indicate that you can scroll up

and/or down. Use the buttons and to scroll.

The cursor

points to the option to be activated. In the display as shown in the figure, you can scroll through the main 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 .

Pressing the button takes you back one page in a menu and discards all options selected in the current menu.

Note

The button is also used to reset the water

heater following an error.

7.6 PC connection

The PC connection is exclusively intended to enable technicians from the supplier to read the status and history of the water heater. These details can be important for troubleshooting and/or resolving complaints.

MENU OFF ^»ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

Instruction manual DR-FC 51

gis

8 Status of the water

heater

8.1 Introduction

This chapter covers the following topics:

• Operating modes;

• Error conditions;

• Service condition;

• Anode warning.

8.2 Operating modes

When running, the water heater has four basic operating modes, namely:

•

OFF

•

EXTRA

•

PROG

8.2.1

OFF

In this mode, the frost protection is activated. The figure shows the display with the following information:

• line one: the text

OFF

;

• line two: the time, the day and T

. (2.3 "Water

heater operating cycle")

• lines three and four: the text

FROST PROTECTION ACTIVATED

8.2.2

In this mode, the water heater continually responds to the hot water demand. The figure shows the display with the following information:

• line one: the text ON;

• line two: the time, the day and T

. (2.3 "Water

heater operating cycle")

• line three: the programmed water temperature T

set

;

• line four: is empty when the water heater is idle, or depending on the operating cycle (2.3 "Water

heater operating cycle"), displays a text such as

HEAT DEMAND

8.2.3

EXTRA

In this mode, one extra period is programmed and activated. In this mode, the

OFF

PROG

mode is temporarily 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 information:

• line one: the text

EXTRA

;

• line two: the time, the day and T

; (2.3 "Water

heater operating cycle")

• line three: the switch-on time and the related water

temperature setting;

• line four: the text

PERIOD ACTIVATED

8.2.4

PROG

In this mode a preset week program is active, and the water heater responds continually to demand within the time periods set in the week program. There are two distinct situations possible in this mode:

1. The current time falls within a set time period

of the week program.

The figure shows the display with the following information:

- line one: the text

PROG

;

- line two: the time, the day and T

; (2.3 "Water heater operating cycle")

- line three: the next scheduled switch-off time and the water temperature T

set

of the active

period

- line four: is empty, or depending on the operating cycle (2.3 "Water heater operating

cycle") , displays a text such as

HEAT DEMAND

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

ON 13:45 Thursday 67ÉC

Tset 75ÉC

EXTRA 12:30 Thursday 76ÉC TH 12:45 Tset 75ÉC PERIOD ACTIVATED

PROG 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC

PROG 12:00 Monday 76ÉC MO 11:15 PERIOD ACTIVATED

Status of the water heater

52 Instruction manual DR-FC

gis

2. The current time falls outside a set time period

of the week program.

The figure shows the display with the following information:

- line one: the text

PROG

;

- line two: the time, the day and T

; (2.3 "Water heater operating cycle")

- line three: the next scheduled switch-on time;

- line four: displays the text

PERIOD ACTIVATED

In all modes, the temperature may at any moment drop below the desired temperature. The water heater then enters an operating cycle. This operating cycle is identical (2.3 "Water heater operating cycle") for all basic operating modes.

Note

Setting and if necessary programming of the basic operating modes are described in the main menu (11 "Main menu") chapter.

8.3 Error conditions

The figure shows an example of an error condition. If the water 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 to four: alternately, a brief explanation of

the error, and a brief action to resolve the error.

Caution

The displayed action to resolve the error may only

be performed by a service and maintenance engineer.

There are various types of errors:

• LOCK OUT ERRORS

When the cause has been removed, these errors require a reset with the button before 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 display does not show what type of error has been detected. A comprehensive overview of the errors is provided elsewhere in the manual (13 "Errors").

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 button once.

However, if the error returns or occurs several times in a short time, you must contact your service and maintenance engineer.

8.4 Service condition

The figure shows the message

SERVICE REQUIRED

. If this message appears, the water heater needs a service and maintenance inspection. In this case, contact your service and maintenance engineer.

Note

The message

SERVICE REQUIRED

is based on the number of expired burning hours and the preset service interval. If the service interval has been incorrectly selected, contact the service and maintenance engineer for instructions on how to rectify this. Information on the frequency of maintenance is provided elsewhere in the manual (14 "Service interval").

8.5 Anode warning

This message appears when the anode protection is no longer active. If the message appears, you must contact your service and maintenance engineer.

Note

The water heater continues to function when this

message appears.

S04: SENSOR ERROR

CHECK

SENSOR OR DUMMY

!!! WARNING !!!

MAX. BURNING HOURS:

SERVICE REQUIRED

!!! WARNING !!!

POWER ANODE MALFUNCTION

Instruction manual DR-FC 53

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9 Starting the water

heater

9.1 Introduction

This chapter covers the following topics:

• Starting the water heater.

• Water heater operating cycle.

9.2 Starting the water heater

Start the water heater as follows:

1. Fill the water heater (5 "Filling").

2. Open (3.5 "Installation diagram") the manual gas valve.

3. Switch on the power to the water heater using the isolator between the water heater and the power supply.

4. Switch the controller ON by setting the ON/OFF switch to position I.

The display will now show

INTERNAL CHECK

for about 10 seconds, and will then go to the main menu.

5. Press once on the blue arrow ( ) to position the cursor beside

, then press . The

display shown in the figure will appear.

6. Confirm the selection

START OPERATION

with

The water heater is now in "ON mode". If there is a heat demand, the water heater will run through 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

temperature").

9.3 Water heater operating cycle

The water heater's operating cycle is activated when the measured water temperature (T1) falls below the threshold value (T

set

). This threshold value depends on the currently selected water heater operating mode. For example, if the water heater is in "OFF mode" (frost protection), then this value is 5

C. If the water heater is in "ON mode", then this threshold value is selectable, for example, 65oC.

The operating cycle runs successively through the following states:

1. HEAT DEMAND

2. PRE-PURGE;

3. PRESSURE SWITCH;

4. PRE-GLOW;

5. IGNITION

6. RUNNING;

7. POST-PURGE.

The entire cycle is explained in the following example, which assumes the water heater is in operating mode

Note

The same operating cycle applies to the other

operating modes.

INTERNAL CHECK

MENU »OFF ^ ON È WEEK PROGRAM

»START OPERATION ^ CHANGE SETPOINT È Tset=65ÉC

Starting the water heater

54 Instruction manual DR-FC

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When the water heater starts, it will run through the following steps:

1. The water temperature drops below the set temperature of (for example)

°C. The controller detects a heat demand and starts the operating cycle.

- The icon is activated.

- The message

HEAT DEMAND

appears.

2. Once demand is registered, the fan is started to exhaust any gases that may be present. This phase is called pre-purge and lasts about 15 seconds.

- The icon is activated.

- The message

PRE PURGE

appears.

3. During the pre-purge, the pressure switch closes.

- The icon is activated.

- The message

PRESSURE SWITCH

appears.

4. This is then followed by the (pre-)glow of the hot surface igniter.

- The icons and are dimmed

- The icon is activated.

5. After a number of seconds pre-glow, the gas control valve is opened 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:

- The icon is dimmed.

- The icon is activated.

- The message

RUNNING

appears.

7. When the water is up to temperature, the heat demand drops off and the post-purge starts. This lasts about 25 seconds.

- The icons , and are dimmed.

- The icon is activated.

- The message

POST PURGE

appears.

8. Following the post-purge, the fan stops and the pressure switch opens:

- The icons and are dimmed.

- The message

POST PURGE

vanishes.

With any subsequent heat demand, the operating cycle will resume from step 1.

ON Ê 13:45 Thursday 63ÉC

Tset 65ÉC

HEAT DEMAND

ON Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRE PURGE

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

PRESSURE SWITCH

ON Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

GLOW PLUG

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

IGNITION

ON Ê Ê Ê 13:45 Thursday 63ÉC

Tset 65ÉC

RUNNING

ON Ê Ê 13:45 Thursday 65ÉC

Tset 65ÉC

POST PURGE

ON 14:05 Thursday 65ÉC

Instruction manual DR-FC 55

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10 Shutting down

10.1 Introduction

This chapter describes:

• Decommissioning the water heater for a short

period.

• Isolating the water heater from the mains;

• Decommissioning the water heater for a long

period.

10.2 Decommissioning the water heater for

a short period

To decommission the water heater for a short period, you must activate the frost protection.

The frost protection will prevent water from freezing in the water heater.

Activate the frost protection as follows:

1. Press button to select the main menu.

2. Using and , place the cursor beside

OFF

Confirm with .

The frost protection cuts in when the water temperature drops below 5°C. The text

FROST

will then appear on line one of the display. The water heater will heat the water to 20°C (T

set

) before

dropping back to mode

OFF

Note

These values of 5°C and 20°C cannot be adjusted.

Caution

The anode protection remains active when the

OFF mode is selected.

Note

If the water heater is not used for longer than two months and the water is not drained, air bubbles may form in the water heater. This can lead to air in the water pipes.

10.3 Isolating 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

with .

2. Position the cursor in front of

OFF

3. Confirm

OFF

with .

Caution Failure to wait until the fan stops can cause

damage to the water heater.

4. Wait until the fan has stopped. The icon is then

dimmed.

5. Switch the water heater OFF (position 0) using

the ON/OFF switch on the control panel.

6. Isolate the water heater from the power supply by

setting the isolator between the water heater and the mains power supply to position 0.

Note

Setting the main switch between the water heater and the electricity mains to 0 will switch off the power supply to the potentiostat; there is then no longer any anode protection.

10.4 Decommissioning the water heater for

a long period

Drain the water heater if you are decommissioning it for a long period. Proceed as follows:

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. Close the stop valve in the hot water pipe.

4. Close the supply valve of the protected cold supply

set-up.

5. Open the drain valve

6. Bleed the water heater (or installation) so that it

drains completely.

OFF 13:45 Thursday 6ÉC FROST PROTECTION ACTIVATED

MENU »OFF ^ ON È WEEK PROGRAM

Shutting down

56 Instruction manual DR-FC

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Instruction manual DR-FC 57

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11 Main menu

11.1 Introduction

The

is reached by pressing the button on the

controller.

The main menu comprises:

•

OFF

Select this option if you wish to shut the water heater down (10 "Shutting down") for a brief period, but do not wish to drain it. In this mode, the frost protection is active. This prevents water from freezing in the water heater.

•

In this mode, the water heater continually responds to the hot water demand (11.3 "Switching to "ON mode"").

•

WEEK PROGRAM

Select this option to allow the water heater to respond to demand only during pre-programmed periods (11.5 "Week program"). Outside those periods, only frost protection is active.

•

EXTRA PERIOD

Select this option to overrule

OFF

mode or

PROG

mode (i.e. Week program) so that a single temporary period (11.10 "Extra period") of heat demand will be fulfilled.

•

SETTINGS

Select this option to set (11.11 "Settings") the language and the time. You can also use this option to display the regulation interval (temperature), and the ignition and working speeds of the fan.

Note

If you fail to make any selection with the main menu open, then 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

( ) of the controller is divided into

sub-menus. For example,

SETTINGS

is one of the

functions reached from the main menu. The menu

SETTINGS

is itself divided into sub-menus. For

example,

LANGUAGE

is a sub-menu of

SETTINGS

So, for example, to select menu

LANGUAGE

, this

manual employs the following convention:

• :

SETTINGS

LANGUAGE

Confirm with .

This means:

1. : Activate the main menu with .

SETTINGS

: Using button and/or go to

SETTINGS

and confirm with .

LANGUAGE

: Using button and/or go to

LANGUAGE

4. Confirm with . After pressing ,

you will have activated sub-menu

LANGUAGE

11.3 Switching to "ON mode"

You can switch the water heater to ON mode from any operational mode, as follows:

1. :

START OPERATION

Confirm with .

Note

Also refer to the chapter on starting the water

heater (9 "Starting the water heater").

11.4 Setting the water temperature

11.4.1 Setting the water temperature via

the SET POINT MENU

The water temperature can be set to any value between 40°C and 80°C.

Set the water temperature via:

1. :

CHANGE SETPOINT

Confirm with .

2. Use:

• to increase the value;

• to decrease the value.

»OFF ^ ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

START OPERATION ^»CHANGE SETPOINT È Tset=65ÉC

Main menu

58 Instruction manual DR-FC

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• Confirm with .After confirming, the water heater enters "ONmode".

Note

If the preset temperature is higher than the current water temperature, then the water heater might not immediately start the operating cycle. To prevent excessively frequent switching on and off, there is a heating margin. The standard setting for this margin is 4°C. The water heater starts heating when the water temperature is 4°C colder than the SETPOINT. We refer to this margin as the hysteresis. The service and maintenance engineer can adjust this setting (12.2 "Setting the hysteresis").

11.4.2 Setting water temperature during

ON mode

The water temperature can also be directly adjusted when the water heater is in "ONmode". Simply use:

• to increase the value;

• to decrease the value.

• Confirm with .

11.5 Week program

Using the week program, you can set the water temperature for the days and times you wish.

If the water heater is running under a week program, then this is indicated on the display by the text

PROG

on the first line (see the figure). The second line shows the time of day, the day of the week and the temperature. The third line shows the next switching time of the week program and the programmed temperature. The fourth line shows the text

PROGRAM ACTIVATED

The water heater's default week program switches the water heater on every day at 00:00 hours and off at 23:59 hours. The default water temperature setting 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 run through the operating cycle (2.3 "Water heater

operating cycle"), then return to the week program.

The following topics are covered here:

• Starting and stopping the week program

• Changing the water heater's standard week

program

• Adding times to a week program

• Deleting times from a week program

11.6 Starting and stopping the week

program

The week program can be started up from any other operating mode, as follows:

1. :

WEEK PROGRAM

START OPERATION

Confirm with .

A week program can be shut down simply by activating a different operating mode, for example the "ON mode".

11.7 Changing the water heater's standard

week program

Note

First fill-in the desired week program on the

supplied week program card.

A week program is made up of a number of programmable periods in which you can have the water heater switch on and off. A period consists of:

• switch-on time: day of the week, hours and minutes:

• switch-off time: hours and minutes;

• the water temperature setting;

• on/off setting for a program-controlled pump.

Note

The switch-off time must always be followed by a switch-off time on the same day of the week. A maximum of three periods per day may be programmed. You can program a maximum of 21 periods.

Call up the menu for the week program as follows:

•:

WEEK PROGRAM

PROGRAM OVERVIEW

Confirm with .

SETPOINT

» 65ÉC

ON 13:45 Thursday 65ÉC

Tset»65ÉC

PROG 07:55 Monday 64ÉC MO 08:00 Tset 75ÉC PROGRAM ACTIVATED

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

Instruction manual DR-FC 59

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The display shows the menu for the week program, see the figure below. With the default setting, the program switches on and off every day at 00:00 and 23:59 hours respectively, the water temperature is 65°C and the pump is switched on (

Example

As an example, we will set the switch-on time for Sunday to 08:15 hours, and the matching switch-off time to 12:45 hours. The water temperature will be set to 75 °C and the pump will run continuously. The following settings are entered one by one via the menu: the switch-on time, the switch-off time, the desired water temperature, and the mode of the program-controlled pump.

11.7.1 Week program: setting the switch-on time

1. Bring the cursor to SU

Confirm with .

The day indicated by

blinks.

2. Use and to set the desired day. In the example

this is

(Sunday).

Confirm with .

The cursor moves to the hour digits, which will blink.

3. Use and to set the hours. In the example, this

08.

Confirm with .

The cursor moves 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 and to set the minutes. In the example,

this is 15.

Confirm with .

The cursor moves to the switch-off hour digits, which will blink.

11.7.2 Week program: setting the

switch-off time

1. Use and to set the hours. In the example, this

Confirm with .

The cursor moves to the minute digits, which will blink.

2. Use and to set the minutes. In the example,

this is

Confirm with .

The cursor moves to the desired water temperature.

DAY TIME Tset ON »SU 00:00 65ÉC P OFF SU 23:59 ON MO 00:00 65ÉC P

OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59 ON WE 00:00 65ÉC P OFF WE 23:59 ON TH 00:00 65ÉC P OFF TH 23:59 ON FR 00:00 65ÉC P OFF FR 23:59 ON SA 00:00 65ÉC P OFF SA 23:59

INSERT DELETE

START OPERATION

ON »SU 00:00 OFF SU 23:59 Tset 65ÉC PUMP ON SAVE

ON SU»00:00 OFF SU 00:59 Tset 65ÉC PUMP ON SAVE

ON SU 08»00 OFF SU 08:00 Tset 65ÉC PUMP ON SAVE

ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON SAVE

ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON SAVE

ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON SAVE

Main menu

60 Instruction manual DR-FC

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11.7.3 Week program: setting the water temperature

1. Use and to set the water temperature. In the

example this is 75°C.

Confirm with .

The cursor moves to

PUMP ON

11.7.4 Week program: setting the program-controlled pump

1. If required, a pump can be controlled during the

period. Use and to set

PUMP ON

. The pump ensures a regular circulation of hot water in the hot water pipes. You can skip this step if you there is no pump in your hot water circuit.

Confirm with .

The cursor moves to

SAVE

2. Confirm with .

The display shown in the figure will appear.

3. If you wish, you can use to scroll to another day, and change more switch-on (11.7.1 "Week

program: setting the switch-on time") and

switch-off (11.7.2 "Week 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 times to a week program

Call up the menu to

INSERT

switch-on and switch-off

times into a week program as follows:

1. :

WEEK PROGRAM

PROGRAM OVERVIEW

Confirm with .

The display shows the menu for the week program. The cursor points to the active period.

2. Scroll to

INSERT

Confirm with .

The sub-menu for adding a period will appear.

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON SAVE

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON »SAVE

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

OFF MO 23:59 ON TU 00:00 65ÉC P OFF TU 23:59

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

....................

OFF SA 23:59

INSERT DELETE START OPERATION

ON »SU 08:15 OFFSU12:45 Tset 75ÉC PUMP ON SAVE

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Example

As an example, we will program an extra period in which the switch-on time is set to 18:00 hours, and the corresponding switch-off time to 22:00 hours. The water temperature will be set to 75 °C and the pump will run continuously.

3. Proceed as follows:

a. Set the switch-on time (11.7.1 "Week program:

setting the switch-on time").

b. Set the switch-off time (11.7.2 "Week program:

setting the switch-off time").

c. Set the water temperature (11.7.3 "Week

program: setting the water temperature").

d. Set the program-controlled

pump (11.7.4 "Week program: setting the

program-controlled pump").

4. To activate the week program with the new period added, scroll down with to

START OPERATION

and confirm with .

11.9 Deleting times from a week program

All switch-on/off times are shown sequentially in the display. Assume that the switch-on/off times for the water 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 the week program.

3. Scroll with to

DELETE

Confirm with .

To warn you that you are now working in the delete sub-menu, the cursor is replaced with an exclamation mark (!) and the period settings will blink.

4. Scroll with to the day to be deleted. For example,

(Sunday) in the second period. See

the figure.

Confirm with .

DAY TIME Tset ON »SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59

INSERT DELETE START OPERATION

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P

OFF SU 22:00

....................

OFF SA 23:59 INSERT

DELETE

START OPERATION

OFF ^»ON È WEEK PROGRAM

WEEK PROGRAM

START OPERATION ^»PROGRAM OVERVIEW È

DAY TIME Tset ON !SU 08:15 75ÉC P OFF SU 12:45 ON SU 18:00 75ÉC P

OFF SU 22:00

....................

OFF SA 23:59

INSERT DELETE

START OPERATION

DAY TIME Tset ON !SU 18:00 75ÉC P OFF SU 22:00 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59

INSERT DELETE START OPERATION

Main menu

62 Instruction manual DR-FC

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5. The lines showing switch-on/off times are replaced by the text

DELETE BLOCK?

. See the figure.

Confirm with . (or use to cancel)

The switching period has been deleted. You will return now to the week program menu. The cursor points to the first programmed period.

6. Scroll with to

START OPERATION

Confirm with .

The week program is active.

11.10 Extra period

Use an extra period when you either want to have the water heater switch on and off for a certain period, either without modifying the active week program, or without taking the water heater out of OFF mode (frost protection active).

If the water heater is running under an "extra period", then this is indicated in the display with the text

EXTRA

During the extra period (11.10.1 "Programming an

extra period"), if the water temperature becomes too

low, the water heater will run through the operating cycle (2.3 "Water heater operating cycle"), then return to the extra period.

The same settings can be made for an extra period as for a week program (11.7 "Changing the water

heater's standard week program").

11.10.1 Programming an extra period

1. Call 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

Confirm with .

The cursor moves to the hour digits, which will blink.

2. Use and to set the switch-on hour to the desired value. In the example, this is

08.

Confirm with .

The cursor moves 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.

3. Use and to set the minutes. In the example,

this is

Confirm with .

The cursor moves to the hour digits of the switch-off period.

Setting the switch-off time

1. Use and to set the hours. In the example, this

012

Confirm with .

The cursor moves to the minute digits, which will blink.

DAY TIME Tset ON ! DELETE OFF BLOCK? ON MO 00:00 65ÉC P

DAY TIME Tset ON »SU 08:15 75ÉC P OFF SU 12:45 ON MO 00:00 65ÉC P

OFF MO 23:59

....................

OFF SA 23:59

INSERT DELETE

START OPERATION

EXTRA 10:00 Monday 76ÉC MO 11:15 Tset 75ÉC PERIOD ACTIVATED

ON ^ WEEK PROGRAM È»EXTRA PERIOD

ON SU»00:00 OFF SU 00:59 Tset 65ÉC PUMP ON START

ON SU 08»00 OFF SU 08:00 Tset 65ÉC PUMP ON START

ON SU 08:15 OFF SU»08:15 Tset 65ÉC PUMP ON START

ON SU 08:15 OFF SU 12»15 Tset 65ÉC PUMP ON START

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2. Use and to set the minutes. In the example, this is 45.

Confirm with .

The cursor moves to the water temperature. See the figure

Setting the water temperature

1. Use and to set the water temperature. In the example this is 75°C.

Confirm with .

The cursor moves to

PUMP ON

Setting the program-controlled pump

1. If required, a pump can be controlled during the period. Use and to set

PUMP ON

. The pump ensures a regular circulation of hot water in the hot water pipes. You can skip this step if you there is no pump in your hot water circuit.

Confirm with .

The cursor moves to

START

2. Confirm with .

The extra period has been programmed.

Note

Once the extra period has completed running, the

controller returns to the mode ON, OFF or

WEEK PROGRAM

. The following week, the extra

period will NOT be automatically switched back on.

11.11 Settings

Using the option

SETTINGS

you can adjust certain settings, and display certain water heater specifications:

• 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 engineer

- Regulation interval (water temperature).

- Ignition speed of fan.

- Working speed of fan.

11.11.1 Setting menu language

To set menu language:

1. Call up the menu for selecting the language as follows:

2. :

SETTINGS

Confirm with .

The display shows the menu for settings.

3. The cursor is positioned beside

LANGUAGE

Confirm with .

The display shows the language selection menu.

4. Scroll with to the desired language.

Confirm with .

The language is set.

11.11.2 Setting day and time

To enter the time and day:

1. Call up the menu for entering the day and time as follows:

2. :

SETTINGS

Confirm with .

The display shows the menu for settings.

ON SU 08:15 OFF SU 12:45 Tset»65ÉC PUMP ON START

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP»ON START

ON SU 08:15 OFF SU 12:45 Tset 75ÉC PUMP ON »START

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

SETTINGS »LANGUAGE ^ DAY/TIME È SPECIFICATIONS

LANGUAGE

ENGLISH ^ NEDERLANDS È»DEUTSCH

FRANCAIS

ITALIANO

CZECH ESPANOL

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

Main menu

64 Instruction manual DR-FC

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3. Scroll with and to

DAY/TIME

Confirm with .

The display shows the sub-menu for adjusting the day.

4. The cursor is positioned beside

Sunday

Scroll with and to the desired day.

Confirm with .

The day has been set. The display shows the sub-menu for adjusting the time.

5. The cursor moves to the hour digits, which will blink.

Scroll with and to the current hour, for example 15.

Confirm with .

6. The cursor moves to the minute digits, which will blink.

Scroll with and to the next minute, for example

45.

Confirm the minute setting with

The time has been set.

Note

The water heater takes no account of daylight

saving.

11.11.3 Displaying water heater 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 (3.4.2 "General and electrical

specifications").

Call up the menu to display the water heater specifications as follows:

1. :

SETTINGS

Confirm with .

2. Scroll with to

SPECIFICATIONS

Confirm with .

The display shows the sub-menu for displaying water heater specifications.

3. Scroll with to the section to be displayed, for

example

REGULATION INTERVAL

The corresponding display appears.

SETTINGS

LANGUAGE ^»DAY/TIME È SPECIFICATIONS

DAY

»Sunday ^ Monday È Tuesday

Wednesday Thursday Friday Saturday

TIME »00:00

TIME 15»00

TIME 15»45

WEEK PROGRAM ^ EXTRA PERIOD È»SETTINGS

SETTINGS

LANGUAGE ^ DAY/TIME È»SPECIFICATIONS

SPECIFICATIONS »REGULATION INTERVAL ^ IGNITION SPEED È WORKING SPEED

REGULATION INTERVAL

80ÉC

Instruction manual DR-FC 65

12 Service program

12.1 Introduction

The service program is used by the installation engineer or service and maintenance engineer for:

• Displaying the water heater history;

• Displaying the error history;

• Displaying the water heater history;

• Display the selected water heater;

• Switching the pump on or off;

• Setting the service interval;

• Service mode;

• Setting legionella prevention.

These sub-menus are briefly described in the following paragraphs. If you are not generally familiar with the use of the displays and menus, first read the relevant chapter (7 "The control panel").

Note

The notation convention for the service menu is identical to that of the main menu (11.2 "Notation

convention for menu-related instructions"). The

difference is, you use to bring up the service program, instead of which brings up the main menu.

12.2 Setting the hysteresis

If the preset temperature (SET POINT) is higher than the current water temperature, the water heater might not immediately start the operating cycle (2.3 "Water

heater operating cycle"). To prevent excessively

frequent switching on and off, there is a heating margin. This margin 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 the SETPOINT.

Set the hysteresis as follows:

•:

HYSTERESE UP

The figure shows an example

Set the hysteresis as follows

•:

HYSTERESE DOWN

12.3 Displaying the error history

Display the error history as follows:

•:

HISTORY OF ERRORS

The controller will display an overview of "Blocking errors" and "Lock out errors". In both cases, note that the controller reserves 15 lines for the last 15 error messages. If there are fewer than 15 error messages, an ellipsis (...) is displayed. The display first shows the "Blocking errors". When is pressed, the "Lock out errors" are then displayed.

The figure shows an example of "Blocking errors". In this case, the text

HISTORY OF ERRORS

is followed

(B)

The figure shows an example of "Lock out errors". In this case, the text

HISTORY OF ERRORS

is followed

(L)

Note

For an overview of all errors and the possible causes, please refer to the relevant chapter (13 "Errors").

SERVICE MENU »HYSTERESE ^ HISTORY OF ERRORS È APPLIANCE HISTORY

SELECT APPLIANCE PUMP RELAY SERVICE INTERVAL SERVICE OPERATION ANTI LEGIONELLA

HYSTERESE UP »3ÉC

HISTORY OF ERRORS(B)

S04 SENSOR ERROR F06 IONIZATION

È CO2 50 HZ ERROR

HISTORY OF ERRORS(L)

F02 FAN F07 FLAME ERROR

È ...

Service program

66 Instruction manual DR-FC

12.4 Displaying the water heater history

The water heater history sub-menu is used to display the burning hours, the number of ignitions, the number of flame errors and the number of ignition errors.

Call up the menu for displaying the water heater history as follows:

•:

APPLIANCE HISTORY

The figure shows an example.

12.5 Display the selected water heater

Call up the menu for displaying the water heater selection as follows:

•:

SELECT APPLIANCE

The water heater number can be found on the rating plate.

The water heater selection has been correctly preset in the factory.

12.6 Switching the pump on or off

If a program-controlled pump is installed (3.10.5 "Connecting a program-controlled

pump") , it can be switched ON or OFF as follows:

•:

PUMP RELAY

The standard setting for the pump relay is OFF.

If the mode

WEEK PROGRAM

EXTRA PERIOD

active, then the setting for mode

WEEK PROGRAM

EXTRA PERIOD

has priority over the ON/OFF

selection for the pump relay in the service menu.

Example

One of the week program periods is currently active. During this period, the pump relay setting is OFF. If the pump relay is set ON in the service menu, the pump will nonetheless remain OFF. The pump will only switch ON once the week program period has ended.

12.7 Setting the service interval

See Errata. interval (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 number of burning hours. This can be set to 500, 1000 and 1500 hours. The standard setting for number of hours is 500. Once the preset number of hours is reached, an appropriate message (8.4 "Service condition") will appear. Set the service interval as follows:

•:

SERVICE INTERVAL

12.8 Service mode

The Installation engineer uses the

SERVICE

OPERATION

menu to adjust the water heater CO2

setting during

FULL LOAD

and

PARTIAL LOAD

operation.

Use :

SERVICE OPERATION

to display the

SERVICE OPERATION

menu.

and can be used to switch between

PARTIAL

LOAD

and

FULL LOAD

If there is a heat demand, the water heater will first run through a startup cycle, then continue to operate in

FULL LOAD

PARTIAL LOAD

mode.

If there is no heat demand, the installation engineer must create one. This can be done by draining the water heater until it is cold or by temporarily raising the set point using . After adjustment, the set point must be set back to the original value using .

if you exit the

SERVICE OPERATION

menu or if no buttons are pressed for a period of 15 minutes, the water heater will revert to the original operating mode.

APPLIANCE HISTORY BURNINGHOURS 000410 ^IGNITIONS 001000 ÈFLAME ERRORS 000021

IGNIT ERROR 000013

SELECT APPLIANCE »5934 ^ 8576 È 3379

6527

....

PUMP RELAY »ON

OFF

SERVICE INTERVAL » 500 ^ 1000 BURNING HOURS È 1500

SERVICE OPERATION »FULL LOAD PARTIAL LOAD

Instruction manual DR-FC 67

Temporarily raising the setpoint during

FULL

LOAD

PARTIAL LOAD

1. :>:

SERVICE OPERATION

2. Select

FULL LOAD

PARTIAL LOAD

The example below describes the situation for

FULL LOAD

, which is identical to that for

PARTIAL LOAD

3. Confirm with .

4. To create a heat demand, you can temporarily raise the set point using to e.g. 70

5. Confirm with .

6. After adjusting for the CO

value (3.11.2 "CO

-adjustment"), you must use

to restore the set point to its original value.

7. Press twice to return to the

menu via the

SERVICE OPERATION

menu.

12.9 Setting legionella prevention

To prevent infection with legionella bacteria, the water heater heats the water to 65 °C once per week, for 1 hour. This period is adjustable. By default, this period is set to Monday from 02:00 to 03:00 hours.

12.9.1 Switching legionella prevention on and off

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

to activate the period currently

displayed.

The following display appears. This display indicates that legionella prevention is switched on.

12.9.2 Changing legionella prevention start time

If you wish to change the start time, select:

ANTI LEGIONELLA

YES

Change

The following display appears.

• Now set the day and time the same way as

described for setting an extra period in the week menu (11.10.1 "Programming an extra period"). In this case however, the pump will be automatically started.

• Select

START

to start.

SERVICE OPERATION »FULL LOAD PARTIAL LOAD

SERVICE Ê Ê Ê FULL LOAD 47ÉC Tset 65ÉC RUNNING

SERVICE Ê Ê Ê FULL LOAD 47ÉC Tset 70ÉC RUNNING

»OFF ^ ON È WEEK PROGRAM

EXTRA PERIOD SETTINGS

ANTI LEGIONELLA »YES NO

ON MO 02:00 LEG OFF MO 03:00 Tset 65ÉC »START Change

LEG Ê Ê Ê 02:45 Monday 60ÉC MO 03:00 Tset 65ÉC RUNNING

ON »MO 02:00 LEG OFF MO 03:00 Tset 65ÉC START

Service program

68 Instruction manual DR-FC

Instruction manual DR-FC 69

gis

13 Errors

13.1 Introduction

A distinction is made between:

• General errors

General errors are not reported on the display. General errors are:

- Gas smell

- Display does not light up

- Insufficient or no hot water.

- Water leakage

- Explosive ignition.

The manual includes (13.2 "Introduction") a table with general errors.

• Displayed errors

Errors are reported on the display as follows:

- Line one: an error code and a brief description. The code consists of a letter and two digits.

- Lines two, three and four: a long description, alternating with a recommended action. 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 cause has been removed, these errors require a reset with the button, before 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 manual includes (13.3 "Troubleshooting table for displayed errors") a table of error messages that can appear on the display.

• Warnings on the display

The warnings (13.4 "Warnings on the display") apply to the water heater.

S02: SENSOR ERROR

TOP TANK SENSOR 1

NOT CONNECTED

S02: SENSOR ERROR

CHECK TOP TANK

SENSOR

Instruction manual DR-FC 70

13.2 Troubleshooting table for general errors

Warning

Maintenance may only be performed by a qualified service and maintenance engineer.

General errors

Indication Cause Measure Remark

Gas smell Gas leak

Warning

Close the main gas valve at once.

Warning

Do not operate any switches.

Warning

No naked flames.

Warning

Ventilate the boiler room.

Warning

Immediately contact your installation 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 that there is power to the isolator.

3. Check whether the ON/OFF switch of the controller is ON (position I).

4. Check whether there is power to the electrical connector block.

5. The measured voltage must be 230 V

AC (-15%, +10%)

See the electrical diagram (17 "Appendices"). If the error persists, consult your installation engineer.

Defective fuse(s) Replace fuse(s) To replace the fuses, you must contact your installation engineer.

Instruction manual DR-FC 71

Water leakage Leakage from a water

connection (threaded)

Tighten the threaded connection If the leak persists, consult your installation engineer

Condensate leakage Check that the condensation water discharge is working properly.

Rectify if necessary

Leakage from another nearby water water heater or pipe segment

Trace the leak

Leakage from the water heater tank

Consult the supplier and/or manufacturer

Explosive ignition Incorrect supply

pressure and/or CO

Set (3.11 "Checking supply pressure, CO2 value and switching

pressure") the correct supply pressure and/or CO

If ignition is not improved, consult your installation engineer.

Contaminated burner Clean the burner (15.4.2 "Clean burner")

Insufficient 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 isolator.

3. Check whether the ON/OFF switch of the controller is ON (position I).

4. Check whether there is power to the electrical connector block.

5. The measured voltage must be 230 V

AC (-15%, +10%)

See the electrical diagram (17 "Appendices"). If the error persists, consult your installation engineer.

Hot water supply is used up

Reduce hot water consumption and give the water heater time to heat up.

If there continues to be insufficient or no hot water, consult your installation engineer.

The controller is in the OFF position.

Switch the controller to the ON position (11.3 "Switching to "ON

mode"").

Temperature (T

set

) is

set too low.

Set temperature (T

set

) to a higher setting (11.4 "Setting the water

temperature").

Indication Cause Measure Remark

Instruction manual DR-FC 72

13.3 Troubleshooting table for displayed errors

Displayed errors

Code + description Cause Measure Remark

S01 (blocking error)

Open circuit from temperature sensor T

at the bottom of the tank.

Sensor is not (correctly) connected

Connect the sensor lead to JP3 See the electrical diagram (17 "Appendices").

Damaged cable and/or defective sensor

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

S02 (blocking error)

Open circuit from sensor 1 of temperature sensor T1 at the top of tank

(1)

Sensor is not (correctly) connected

Connect the sensor lead to JP5 See the electrical diagram (17 "Appendices").

Damaged cable and/or defective sensor

Damaged cable and/or defective sensor To replace the necessary parts, you 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 JP5 See the electrical diagram (17 "Appendices").

Damaged cable and/or defective sensor

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

S04 (blocking error)

Open circuit from dummy 1

Dummy is not (correctly) connected

Connect the dummy sensor (dummy sensor 1 and 2) leads to JP4. See the electrical diagram (17 "Appendices").

Defective dummy Replace the dummy sensor To replace the necessary parts, you must contact your installation

engineer

S05 (blocking error)

Open circuit from dummy 2

Dummy is not (correctly) connected

Connect the dummy sensor (dummy sensor 1 and 2) leads to JP4. See the electrical diagram (17 "Appendices").

Defective dummy Replace the dummy sensor To replace the necessary parts, you must contact your installation

engineer

Instruction manual DR-FC 73

S11 (blocking error)

Short circuit in temperature sensor T

at the bottom of the tank.

Short circuit in sensor circuit

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

S12 (blocking error)

Short circuit in sensor 1 of temperature sensor T

at top of tank

(1)

Short circuit in sensor circuit

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

S13 (blocking error)

Short circuit in sensor 2 of temperature sensor T

at the top of the tank

(1)

Short circuit in sensor circuit

Replace the cable and/or sensor. To replace the necessary parts, you must contact your installation

engineer

S14 (blocking error)

Short circuit from dummy 1

Short circuit in sensor circuit

Replace the dummy sensor

(2)

To replace the necessary parts, you must contact your installation engineer

S15 (blocking error)

Short circuit from dummy 2

Short circuit in sensor circuit

Replace the dummy sensor

(2)

To replace the necessary parts, you must contact your installation engineer

Code + description Cause Measure Remark

Instruction manual DR-FC 74

F01 (blocking error)

Defect in power supply circuit

Live and neutral connected wrong way around.

Be sure to connect the live and neutral correctly (3.10 "Electrical

connection"); the water heater is phase-sensitive

See the electrical diagram (17 "Appendices").

Condensation on the flame probe

1. Disconnect the lead at the flame probe

2. Ignite the water heater three times, with an interrupted ionisation circuit

3. Reconnect the ionisation lead to the flame probe

4. Ignite the water heater again

5. The repeated ignition attempts will have caused the condensation to evaporate

If errors persist, contact your installation engineer

Floating neutral Install an isolating transformer (3.10.4 "Isolating transformer") Contact your installation 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 or rotor is defective.

3. Reset controller

See the electrical diagram (17 "Appendices").

To have the wiring replaced and a new fan fitted, you must contact your installation engineer

Damaged wiring 1. Check the wiring between the fan and the controller.

2. If any wires are damaged, the wiring harness must be replaced.

3. Reset controller

Contaminated or blocked fan

1. Check if the fan is dirty and repair it if necessary.

2. Check that the rotor can rotate freely

3. Reset controller

If the error cannot be resolved or is persistent, contact your installation engineer

Because of a drop in the supply voltage, the fan will not run at the correct speed.

1. Check the supply voltage, this must be 230 V

AC (-15%, +10%)

2. Reset controller

Code + description Cause Measure Remark

Instruction manual DR-FC 75

F03 (lock out error)

The pressure switch fails to work correctly

Damaged wiring/Open circuit

1. Check the wiring between the pressure switch and the controller

2. If necessary, replace the wiring

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation

engineer Pressure switch not closing

1. Check the fan speed (12.5 "Display the selected water heater")

2. Check that the hoses on the pressure switch and the air supply hose between fan and burner are correctly 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 chimney flue is compliant (3.9 "Air supply

and chimney flue discharge").

5. Check for blockage in the chimney flue. Remove any blockage that may be present

6. Check for blockage in the condensation water discharge. Remove any blockage that may be present.

7. Measure the pressure differential across the pressure switch. See the table (12.5 "Display the selected water heater"). If there is insufficient pressure differential, clean the heat exchanger. If the pressure differential is acceptable, check that the pressure switch is closing, using a multimeter.

Code + description Cause Measure Remark

Instruction manual DR-FC 76

F04 (lock out error)

Three unsuccessful ignition attempts.

No gas 1. Open the main gas supply valve and/or the manual gas supply

valve before the gas control valve

2. Check supply pressure to the gas control valve

3. If necessary, restore the gas supply

To restore the gas supply, contact your installation engineer

Air in the gas pipes Bleed the air out of the gas pipe (3.11 "Checking supply pressure,

value and switching pressure")

See Checking supply pressure, CO

value and switching pressure

for how to bleed air from the gas line, and how to measure the supply pressure and burner pressure. To replace the necessary parts, you must contact your installation engineer

Defect in the hot surface igniter circuit

1. Check that the hot surface igniter is correctly connected (JP2).

2. Check the wiring of the hot surface igniter.

3. Measure the resistance across the hot surface igniter. 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 installation engineer. To replace the necessary parts, you must contact your installation engineer

Defect in the ionisation circuit

1. Check that the flame probe is correctly connected (JP2)

2. Check the wiring of the flame probe

3. Measure the ionisation current. This must be a minimum of

1.5 microA.

4. If necessary, replace the wiring.

Supply voltage too low Check the supply voltage, this must be 230 V

AC (-15%, +10%)

F05 (lock out error)

Too many flame errors have been signalled.

Incorrect roof or wall flue terminal. Recirculating flue gases.

1. Check that the correct roof or wall flue terminal has been installed (3.9 "Air supply and chimney flue discharge").

2. If necessary, install the correct roof or wall flue terminal.

3. Check that the roof or wall flue terminal discharges into a permitted area.

If the error cannot be resolved or is persistent, contact your installation engineer

Code + description Cause Measure Remark

Instruction manual DR-FC 77

F06 (blocking error)

Short circuit between flame probe and earth

Damaged cable in contact with metal surface or bent flame probe.

Check the wiring and the flame probe. Replace the wiring and/or flame probe if necessary.

If the error persists, contact your installation engineer. To replace the necessary parts, you must contact your installation engineer

Ceramic part of the flame 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 not the flame probe must be replaced.

F07 (lock out error)

A flame has been detected after the gas control valve was closed.

Defective gas control valves

1. Check whether there is still burner pressure present, after the gas control valves have closed.

2. Check whether a flame is still present, after the gas control valves have closed.

3. If this is the case, the gas control valve must be replaced.

If the error cannot be resolved 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 before the gas control valve opened.

1. Reset controller.

2. If the error appears again, replace the controller.

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

F09 (lock out error)

Water temperature protection.

Temperature at the top of the tank exceeds 93

1. Check that the circulation pump (if present) is working

2. Check the position of temperature sensor T

3. Reset controller

If the error cannot be resolved or is persistent, contact your installation engineer

F11 (blocking error)

Flame detection with closed gas control valve.

Defective gas control valves

See F07.

F19 (blocking error)

Power supply voltage is too low.

There is not enough supply voltage.

1. Check that there is power to the controller

2. The measured voltage must be 230 V

AC (-15%, +10%)

See the electrical diagram (17 "Appendices"). If the error persists, consult your installation engineer

Code + description Cause Measure Remark

Instruction manual DR-FC 78

C02 (lock out error)

Error message from the controller.

Incorrect reference voltage from the AD converter.

1. Reset controller.

2. Check that the frequency of the power supply is compliant (3.4.2 "General and electrical specifications"). If not, contact your installation engineer

3. If the frequency is correct but the error persists, replace the controller.

To replace the necessary parts, you must contact your installation engineer

Internal error message from the controller.

• EEPROM read error

• 50 Hz error

• Internal communication error

Internal error message from the controller.

• Gas valve relay error

• Safety relay error

• Ignition relay error

• RAM error

• EEPROM 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 the error does not disappear, replace the water heater controller.

To replace the necessary parts, you must contact your installation engineer

C04 (blocking error)

Appliance selection error

Incorrect water heater selection/Incorrect selection resistor

1. Check whether the correct water heater is selected (12.5 "Display the selected water heater").

2. If the correct water heater is selected, fit the correct selection resistor.

3. If incorrect water heater selected, select the correct one.

If the error cannot be resolved or is persistent, contact your installation engineer To replace the necessary parts, you must contact your installation engineer

Code + description Cause Measure Remark

Instruction manual DR-FC 79

E01 (blocking error)

The temperature protection at the top of the tank has been activated.

The temperature of the water at the top of the tank is > 85

None. This is a temporary message that may appear from time to time, but will disappear automatically.

E03 (lock-out error)

Error in temperature sensor T

at the top of

the tank.

The two temperature sensors in the tank detect a difference of >

10oC over a period of

at least 60 seconds.

1. Check sensor position and wiring.

2. Reset the controller if 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 sensors detect a difference of > 10oC over a period of at least 60 seconds.

1. Check the wiring of the dummy 1 and dummy 2.

2. Reset the controller if necessary. Replace the dummy sensor if the error persists.

To replace the necessary parts, you must contact your installation engineer

(1) Temperature sensor T

is a 2-in-1 sensor; T1 contains 2 NTCs for maximum thermostat and safety thermostat protection.

(2) The dummy flue gas sensor consists of dummy flue gas sensor 1 and dummy flue gas sensor 2.

Code + description Cause Measure Remark

Instruction manual DR-FC 80

13.4 Warnings on the display

Warnings on the display

Indication Cause Measure Remark

Maximum burning hours: Service required.

The actual burning hours have exceeded the preset burning hours.

Water heater runs, but displays a warning For maintenance to your water heater, please contact your

installation engineer.

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 filled with water.

Water heater runs, but displays a warning.

Note

The water heater is functioning, but there is no anode protection

for the tank.

1. Connect the wiring correctly and the warning will disappear.

2. If the wiring is correct but the warning remains, check that the earth connection is good and whether the tank is filled with water.

Instruction manual DR-FC 81

14 Service interval

14.1 Introduction

Note

Regular maintenance extends the service life of the water heater.

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 side three months after installation. Based on this check, the best service interval can be determined.

14.2 Determining service interval

See Errata. and maintenance engineer can determine the frequency of maintenance, based on the number of burning hours.

The service interval can be set to: 500, 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 will be sufficient. Therefore, after one year, some 1200 burning hours will have elapsed. The first value below 1200 hours that can be selected is 1000 burning hours.

In this case, the service and maintenance engineer sets the interval to 1000.

In the first three months, the water heater has burned for 300 hours. During maintenance, it is evident (perhaps due to the water quality) that service will be required at least once every 6 months.

Therefore, after six months, some 600 burning hours will have elapsed. The first value below 600 hours that can be selected is 500 burning hours.

In this case, the service and maintenance engineer sets the interval to 500.

Once the set number of burning hours has elapsed, the message

SERVICE REQUIRED

will appear on the display. When this message

appears, the service and maintenance engineer must be contacted.

!!! WARNING !!!

MAX. BURNINGHOURS:

SERVICE REQUIRED

Service interval

82 Instruction manual DR-FC

Instruction manual DR-FC 83

15 Performing

maintenance

15.1 Introduction

Caution

Maintenance may only by carried out by an approved service and

maintenance engineer.

At each service, the water heater undergoes maintenance on both the water side and the gas side. The maintenance must be carried out in the following order.

1. Preparation for maintenance

2. Water-side maintenance

3. Gas-side maintenance

4. Finalizing maintenance

Note

Before ordering spare parts, it is important to write down the installation type, water heater model, 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 Preparation for maintenance

To test whether all components are still working properly, complete the following steps:

1. Activate the

with .

2. Use: and to place the cursor beside

OFF

3. Confirm

OFF

with .

4. Wait until the fan has stopped. The icon is then dimmed.

Caution Failure to wait until the fan stops can cause damage to the water

heater.

5. Switch the water heater OFF (position 0) using the ON/OFF switch on the control panel.

6. Switch the controller ON by setting the ON/OFF switch to position I.

MENU »OFF ^ ON È WEEK PROGRAM

INTERNAL CHECK

Performing maintenance

84 Instruction manual DR-FC

The display will now show

INTERNAL CHECK

for about 10 seconds, and

will then go to the main menu.

7. Activate "ON mode" by going through the following steps:

- Press once on the blue arrow ( ) to position the cursor beside ON, then press .

- Confirm the selection

START OPERATION

with .

8. If there is no heat demand, then raise T

set

. Note the original setting. Draw

some hot water off to create heat demand.

9. Check whether the operating cycle runs correctly (2.3 "Water heater

operating cycle").

10. If you have adjusted T

set

, return it to the original value (11.4 "Setting the

water temperature").

11. Remove the cover on the top of the water heater.

12. Check the supply and burner pressures (3.11 "Checking supply pressure,

value and switching pressure") and adjust these where necessary.

13. Check that all components of the chimney flue system are properly attached.

14. Check the pressure differential across the pressure switch (3.11.3 "Switching pressure measurement") and, if this is too low, the heat exchanger should be cleaned (15.4.3 "Clean heat exchanger").

15. Test the operation of the overflow valve of the protected 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 draining (6 "Draining")).

15.3 Water-side maintenance

15.3.1 Introduction

The following steps must be carried out on the water side:

1. Descaling and cleaning the tank.

2. Clean condensation water discharge.

15.3.2 Descaling and cleaning the tank

Scale and lime build-up prevent effective conduction of the heat to the water. Periodic cleaning and descaling prevents build-up of these deposits. This increases the service life of the water heater, and also improves the heating process.

Take the rate of scale formation into account when deciding on the service interval. Scale formation depends on the local water composition, the water consumption and the water temperature setting. A water temperature setting of maximum 60°C is recommended for the prevention of excessive scale build-up.

To guarantee a good, watertight seal around the cleaning opening, replace the gasket, washers, bolts and, if necessary, the lid with new parts before reassembly (see the figure). A special set is obtainable from the supplier/manufacturer.

To simplify descaling and cleaning of the tank, the water heater is equipped with two cleaning openings.

MENU »OFF ^ ON È WEEK PROGRAM

Instruction manual DR-FC 85

1. Remove the cover plate (1) on the outer jacket (see the figure).

2. Undo the bolts.

3. Remove the cover and the gasket.

4. Inspect the tank and remove the loose scale deposits and contamination.

5. If the scale cannot be removed by hand, descale the water heater with a descaling agent. Contact the supplier/manufacturer for advice on what descaling agent to use.

6. Close the cleaning opening. To avoid damage to the tank, tighten the bolts that fasten the lid with a torque no greater than 50 Nm. Use suitable tools for this.

15.3.3 Clean condensation water discharge

To prevent blockages, 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 burner.

2. Clean heat exchanger.

3. Finalizing maintenance.

15.4.2 Clean burner

1. Detach the burner.

2. Remove all contamination present on the burner.

3. Fit the burner.

15.4.3 Clean heat exchanger

1. Detach the burner.

2. Clean the combustion chamber of the heat exchanger using a vacuum cleaner and a soft brush.

3. Detach the chimney flue.

4. Clean the end of the heat exchanger using tap water.

5. Fit the burner.

6. Fit the chimney flue.

Note

Check the pressure differential again after cleaning. If the pressure differential is too low following cleaning, please contact the supplier of the water heater.

IMD-0080 R1

Performing maintenance

86 Instruction manual DR-FC

15.5 Finalizing maintenance

To finalize the maintenance, carry out the following steps:

1. Fill the water heater (5 "Filling").

2. Start the water heater (9 "Starting the water heater")

3. Check the CO

value (3.11.2 "CO2-adjustment").

4. Check the switching pressure of the pressure switch. (3.11.3 "Switching

pressure measurement")

5. Erase the message

SERVICE REQUIRED

. Do this by pressing once on

then once on .

Instruction manual DR-FC 87

16 Warranty

Contact your supplier for the warranty-conditons of this water heater.

Warranty

88 Instruction manual DR-FC

Instruction manual DR-FC 89

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 card")

Appendices

90 Instruction manual DR-FC

17.2 Menu structure

IGNITION SPEED

WORKING SPEED

DAY/TIME

SPECIFICATIONS

ANTI LEGIONELLA

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 SETPOINT

APPLIANCE

HISTORY

WEEK-

PROGRAMMA

HYSTERESE DOWN

HYSTERESE UP

START OPERATION

CONTROL

SERVICE

PROGRAM

MAIN MENU

HYSTERESE

OFF

Instruction manual DR-FC 91

Appendices

92 Instruction manual DR-FC

17.3 Electrical diagram

Electrical diagram

1 = brown, 2 = blue, 3 = yellow/green, 4 = black, 5 = white, 6 = grey / beige, 7 = green

1 23456 10789

443

JP8

J29

XX X

JP12

JP6

JP2

J19

J21

X XXXX

J20

JP5

JP4

JP3

JP11

X3X

2F11

X J2

16151413

191817 20 2421 22 23

J33

J38

J37

J34

J35

J39

J36

4 4

XX4X

624

513

7 44

3 21

XXX

230VAC 50Hz

Primair

NL LN

Secundair

511

3 5

3312

J40

0309 361 R0

Instruction manual DR-FC 93

TERMINAL BLOCK CONNECTIONS:

Earth

N Neutral

L Live input of controller

Live input of isolating transformer (primary side)

L2 Live output of isolating transformer (secondary side)

Live input of program-controlled pump

COMPONENTS:

A Controller

B flame probe

C hot surface igniter

D Gas control valve

E Burner earth connection

F Extra ON mode switch

G Program-controlled pump

H Extra error signal connection

J Isolating transformer

K Double-pole isolator

L Controller 0/I switch

MDisplay

NFan

O Temperature sensor (T

- bottom of tank)

PDummy

Q Temperature sensor (T

- top of tank)

R Selection resistor

S Pressure switch

T Power anodes

U Power anode signal

V Potentiostat

CONTROLLER CONNECTIONS:

J2 Power connection for controller

J19 Extra error signal connection

J20 Gas inlet connection

J21 Program-controlled pump connection

J40 Fan connection

J36 Controller display connection

JP2 Flame probe and hot surface igniter connection

JP3 Temperature sensor T

connection

JP4 Dummy connection

JP5 Temperature sensor T

connection

JP6 Selection resistor and pressure switch connection

JP8 Extra ON mode switch connection

F1 Fuse (T 3.15 A - 250 V)

F3 Fuse (T 3.15 A - 250 V)

Appendices

94 Instruction manual DR-FC

Instruction manual DR-FC 95

17.4 Week program card

You can cut the week program card out and keep it near the water heater.

Example

Period DAY TIME Tset Pump

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

....°C

ON/ OFF

OFF

10.

....°C

ON/ OFF

OFF

11.

....°C

ON/ OFF

OFF

Period DAY TIME Tset Pump

ON MO

14:30

70 °C

ON/ OFF

OFF MO

16:15

Period DAY TIME Ts et Pump

12.

....°C

ON/ OFF

OFF

13.

....°C

ON/ OFF

OFF

14.

....°C

ON/ OFF

OFF

15.

....°C

ON/ OFF

OFF

16.

....°C

ON/ OFF

OFF

17.

....°C

ON/ OFF

OFF

18.

....°C

ON/ OFF

OFF

19.

....°C

ON/ OFF

OFF

20.

....°C

ON/ OFF

OFF

21.

....°C

ON/ OFF

OFF

Instruction manual DR-FC 96

Instruction manual DR-FC 97

Index

actuation 57 ambient conditions 17 ambient temperature 18

connecting the air supply 27 connecting the chimney flue 27 connecting the circulation pipe 25, 26 connecting the cold water side 25, 26 connecting the hot water side 25 conversion to a different gas category 41

descaling 84 displaying error history 65 document contents 12 draining 47

electrical connection 32 error 52 extra period

setting 62

fan 15 filling 45 flame probe 16

gas category, conversion to different 41 gas connection 26 general specifications 3

humidity 18 hysteresis setting 65

icons

(Pre)glow 49 explanation 49 flame detection 49 gas control valve 49

heat demand 49 installation diagram 24 installation engineer 10

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

language setting 63 liability 3

maintenance

condensation water discharge 85 descaling 84 gas-side 85 heat exchanger 85 performing 83 preparation 83 scale 84

mode

ERROR 52 SERVICE REQUIRED 52

navigation buttons 50 notation conventions 11

ON mode 57 ON/OFF switch 49 operating cycle 15

packaging 17 protection 15 pump 66

scale 84 scrolling 50 service 11, 81 service engineer 10 service required 52 setting date 63 setting the service interval 66 shutting down

electrically isolating 55 long period 55

short period 55 specifications 19 symbol

installation engineer 10

service engineer 10

user 10

target groups 10 terminal block 33 ThermoControl

ON/OFF switch 49 trademarks 3

user 10

gis

0309 429 1.3 UK

Index

Instruction manual DR-FC

water

composition 18 setting the temperature 57

water heater

displaying history 66 displaying specifications 64 displaying the selection 66 protection 15 types 9, 17

DORCHESTER DR-FC 25, DR-FC30, DR-FC95, DR-FC45, DR-FC120 Installation, Comissioning And Maintenance Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual