Hamworthy DR90L-CE, DR35L-CE Installation, Commissioning And Servicing Instructions

Appendix 4

IMPORTANT NOTE

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

Installation, Commissioning

and Servicing Instructions

supplement

Dorchester

DR35L-CE to DR90L-CE

Hot Water Storage Heaters

Homepage

Register

Fully Automatic

Customer Services

TECHNICAL ENQUIRIES 01202 662527 / 662528

To supplement the detailed technical brochures, technical advice on the application and use of products in
the Hamworthy Heating range is available from our technical team in Poole and our accredited agents.

SITE ASSEMBLY 01202 662555

Specialist teams are available for on site assembly of the full range of Hamworthy boilers (excluding
Lulworth). Boiler sections for site assembly must be positioned within the boiler house prior to the arrival
of the assembly team and provide sufficient space for safe working. Handling sections into boiler houses
other than at ground level may be subject to additional charges.

The normal assembly price does not include for the fitting of boiler casings or the burner, however this can
be carried out at the time of build at additional cost.

Providing the facilities are available on site, a hydraulic test will be carried out within the terms of BS779.
Upon completion a certificate of assembly and test will be issued.

COMMISSIONING 01202 662555

Commissioning of equipment by Hamworthy Heating’s own engineers, accredited agents or specialist sub­contractors will ensure that the equipment is operating safely and efficiently. Hamworthy commissioning
reports provide a detailed record of the original status of the plant, which is essential for future routine
maintenance and trouble free operation.

Standard warranty terms provide for the free of charge replacement of defective parts, but does not
include labour. When the equipment is commissioned and routinely maintained by Hamworthy Heating
under a Service Maintenance Agreement then the warranty terms will cover both parts and labour.

MAINTENANCE AGREEMENTS 01202 662555

Regular routine servicing by Hamworthy Heating’s engineers ensures trouble free operation and optimum
efficiency. The frequency of visits required is variable, dependent upon the equipment type and usage.
Annual service agreements are available on all Hamworthy products to meet individual requirements.

Planned maintenance of equipment by routine servicing reduces operational costs considerably below that
associated with repair or breakdown approach.

BREAKDOWN SERVICE, REPAIR, REPLACEMENT 01202 662555

Even when the commissioning and routine servicing has been carried out to the highest standard there
are always occasions when the unexpected breakdowns occur. Hamworthy provide a rapid response
breakdown, repair or replacement service through head office at Poole and accredited agents located
throughout the UK.

SPARE PARTS 01202 662525

A comprehensive spare parts service is operated from our factory in Poole, providing replacement parts
for both current and discontinued products. In some instances spares may be available from accredited
agents.

Delivery of parts and components is normally from stock within 7 days. However, a 24 hour delivery
service is available for breakdowns and emergencies for the additional cost of the courier. Please contact
our spares team, providing details of product type, serial number, model or any other identifying marks or
codes to determine part requirements wherever possible.

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C

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APPENDIX 4

DORCHESTER

DR35L-CE TO DR90L-CE

HOT WATER

STORAGE HEATERS

INSTALLATION, COMMISSIONING

AND MAINTENANCE MANUAL FOR

FULLY AUTOMATIC CONTROLS

NOTE! THESE INSTRUCTIONS MUST BE READ AND

UNDERSTOOD BEFORE INSTALLING OR

COMMISSIONING THIS HOT WATER HEATER

PUBLICATION NO. 5000010029
ISSUE ‘C’
June 1995

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C

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This Page Left Intentionally Blank

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C

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APPENDIX 4 TO DRL INSTALLERS GUIDE

DRL SERIES OF HOT WATER STORAGE
HEATERS FITTED WITH FULLY AUTOMATIC
CONTROLS FIRING NATURAL GAS.

To be used in conjunction with the main
installer's guide - publication number

500001001.

DESCRIPTION

The Hamworthy DRL series of hot water storage
heaters can also be supplied with fully automatic
controls. The fully automatic control provides a
safe light-up and shutdown programme for the
burner, flame detection being based on the well
known rectification principle.

When the controlling thermostat calls for heat a
high energy spark is produced at the spark
electrode and the compact gas control valve
(see Fig 1) is energised to establish a gas flame
on the burner bars.

Failure to establish and detect flame during a
start-up attempt results in lockout after the expiry
of the nominal 5 seconds ignition safety time.
Flame failure during a `run' results in an
immediate attempt to safely re-light the burner.
Failure to establish and detect flame during a
re-light attempt results in lockout after the expiry
of the 5 seconds safety ignition time. A false
flame signal at the start point and during the 13
seconds waiting time prior to the introduction of
the spark causes the control box to lockout.

These water heaters are very similar to the basic
range of permanent pilot models and for general
information concerning technical data, water
flows, installation recommendations, etc,
attention is drawn to the installation and
commissioning instructions in the main manual

500001001.

The basic differences between the permanent
pilot, natural gas models and the fully automatic
versions are as follows:-

1) The Honeywell V4410 softlite gas control
valve is replaced by a Dungs MB DLE 407 B01

compact gas control valve on the DR70L and
DR90L (see Fig 1), and a VR4601 compact
valve on the DR35L and DR50L - These valves
incorporate slow opening to produce a low
flame start.

2) The thermocouple is replaced by a flame
rectification probe.

3) The Piezo unit and electrode are replaced
by a spark generator and a spark electrode
(see Fig 1).

4) A Satronic TF1 812 2B controller is
incorporated into the ignition system (see Fig

1).

5) The gas inlet connection dimension from
the centre line of the heater is altered, see
Figure 1.

CONTROL SYSTEM

Control Thermostat

The control thermostat (B1N) on the DRL
automatic heaters is similar to that used on
the permanent pilot versions. However, the
thermostat is connected in series with the main
supply to the Satronic controller (see Fig 2).
On activation the thermostat interrupts the
supply to the controller, the flame is
extinguished and the heater shuts down.

For further details refer to the main manual.

Limit Thermostat

A manual reset limit thermostat (B1f) is pre­wired in series with the supply to the Satronic
controller (see Fig 2). In the event of the limit
thermostat being activated, power to the
controller is interrupted and the heater shuts
down. The limit thermostat must then be reset
by removing the plastic cap on the unit and
pressing the green button exposed (see Fig

3). The heater will then automatically restart.

NOTE! In the event of the overheat limit
thermostat being activated, the complete
heater installation should be inspected to trace
and isolate the cause of the problem

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C

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before any further firing takes place.

Controller

The Satronic controller supervises the ignition
and safety shutdown of the heater in the
event of flame failure. Supply to the controller
is via the thermostats previously described
(see Fig 2).

COMMISSIONING

Checks

Before attempting to commission any heater,
ensure that any personnel involved are aware
of what action is to be taken. Begin by
making the checks listed in the main installers
guide with the amendment to e) as follows:-

e) Gas supply is connected but turned off,
gas cock closed, unions are tightened (with
any seals in position), test points are tight,
burners are correctly positioned, injectors are
tight, spark electrode and flame probe are
correctly positioned with 3-4 mm gaps, above
burner bars and are undamaged particularly
ceramic portion (do not over-tighten electrode
retaining nuts). Electrode and probe leads
are fully screwed into electrode connectors
which are firmly connected to the appropriate
electrode.

Procedure for Lighting

Turn control thermostat to the minimum
setting (35°C) and ensure electrical supply
is off.

Open heater gas cock.

Check that any electrical circuits are closed
and switch on the power supply to the
appliance. Adjust the control thermostat to
the recommended required setting (to a value
not exceeding 60°C). Within 13 seconds the
spark will operate, the gas valve will open
and the burners will light on low flame and
automatically increase to full flame. If the
burner does not light, spark will continue for
5 seconds, after which time the control box

will `lockout' in a safe condition with the lockout
button illuminated. If this occurs, switch off
power supply, wait 3 minutes, check that gas is
available at heater (revent to outside of building
if necessary), reinstate power supply and press
the lockout button to reset and repeat the
sequence.

After the heater has operated for approximately
5 minutes, switch off the power, slacken the gas
pressure test point screw on the gas manifold
and fit manometer. Switch the heater on and
measure the operating gas pressure. Check
readings against pressure required in Table 1
in the main manual. Adjust the appliance
regulator as necessary by:-

a) DR35L-DR50L (Honeywell valve VR4601
A). Remove the aluminium plug (see Fig 4)
and, using a screw driver turn the adjusting
screw to alter the pressure, clockwise to
increase, anti-clockwise to decrease. Replace
plug.

b) DR70L-DR90L (DUNGS MB-DLE 407 B01)
Rotate pivoted cover from over adjustment
screw on front of Dungs valve and, using a
screwdriver turn the adjusting screw to alter the
pressure, clockwise to increase, anti-clockwise
to decrease. Replace cover.

Remove manometer, remembering to re tighten
pressure test point. Relight the burner and
check that no waste gas spillage occurs from
any draught diverter. Check operation of control
thermostat by adjusting the temperature setting,
thus lighting and extinguishing the flame.

SERVICING

Removal of Gas Train

Unscrew and disconnect the two halves of the

3

/4 gas pipework union at the inlet to the compact
gas control valve and remove and retain the
union rubber sealing ring.

Remove the three core power supply lead to
the compact gas control valve as follows.

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C

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Unscrew the retaining screw securing the din
plug/s in place and carefully pull the plug/s
away from the valve or separate the plug and
socket in line connector near the control box.

Disconnect the flame probe and electrode
leads by pulling off the ceramic cap from the
flame probe and the rubber cap from the
spark electrode.

The gas train assembly is secured to the
heater by two nuts on the front feet and screw
in the bottom of the heater casing at the
centre of the gas manifold. Removal of these
enables the assembly to be withdrawn.

The electrode and flame probe should be
checked for cracked ceramics and wear.
Replace as necessary and adjust to correct
gaps. For servicing of the burners and the
internals of the heater, refer to the main
installers guide, with the exception of the pilot
burner which is not fitted to the automatic
version.

Reassemble components in reverse order,
taking care to replace the rubber sealing ring
in the union.

FAULT FINDING

1. Heater will not start, controller not
locked out:-

Check continuity across control thermostat
with control at operating temperature
position.

Check for high temperature limit thermostat
lockout.

2. Heater starts but controller goes to
lockout without ignition:-

Check gas valve operation (by pressure at
manifold test point during a start up attempt).

Check ignition electrode connector (wire is
firmly screwed into ceramic connector) and
ignition transformer if no spark is produced.

3. Heater starts, ignition occurs, controller
immediately goes to lockout:-

DR35-90L

Check flame probe connector (wire is firmly
screwed into ceramic connector).

Check flame probe position ie touching the
burner bar or not in the flame will cause a
lockout (see Fig 5 for correct probe position).

DR70-90L

Reduce flame ignition time by adjusting the
main valve initial opening. Remove the
protective cap from the top of the valve (see
Fig 4), reverse it and use to turn the spindle
exposed. This adjusts the rapid initial
opening of the valve and thus the initial gas
pressure. The valve is initially set at the
minimum opening position, turn counter­clockwise to increase the opening. Restart
the heater and replace protective cap.

Replace control box. NOTE! To remove
control box from its base, using a screwdriver
remove the retaining screw in the front of the
box and gently pull from the base. Locate
and press home the new one and retighten
screw.

ADDITIONAL RECOMMENDED SPARES

Description Part Number

Control Valve 3/4 Dungs 533903013
Compact Gas Control Valve
23 mm in/out Honeywell
VR4601A (special) 531907008
Limit Thermostat 533901191
Controller 533901006
Ignition transformer 533901062
Electrode (ignition) 533805008
Probe (Flame Sensing) 533805007
Ceramic Cap (Probe) 533901060
Rubber Cap (Electrode) 533901255

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Hamworthy Heating
Accredited Agents

Central & South West England Scotland
Driver Engineering Limited McDowall Modular Services

778 Wimborne Road, Moordown 97a Hawthorn Street
Bournemouth BH9 2DX Glasgow G22 6JD
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]

North West England Northern Ireland
Gillies Modular Services McCaig Collim Limited

210-218 New Chester Road 92-94 Dargan Crescent
Birkenhead Duncrue Industrial Estate
Merseyside L41 9BG Belfast BT3 9JP
Tel: [phone] Tel: [phone]
Fax: [phone] Fax: [phone]

North East England Southern Ireland
Allison Heating Products HEVAC Limited

17 Beach Road 70-72 Lower Dorset Street
South Shields Dublin 1, Ireland
Tyne & Wear NE33 2QH Tel: [phone]
Tel: [phone] Fax: [phone]

Fax: [phone]

For all other areas, or for further advice, please contact Hamworthy Heating
head office service department in Poole, telephone [phone].

Direct Dial Telephone Numbers

Hamworthy Heating

Connect direct for better service

HAMWORTHY HEATING LIMITED

Fleets Corner, Poole, Dorset, BH17 0HH. England.
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expert technical and commercial advice on heating, flue and water systems.

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For problems of a technical nature and further product support, our Technical Applications Engineers offer specifiers and
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ground level. Our contracts team will progress despatch and liaise individual delivery arrangements.

SPARE PARTS ....................................................... 01202 662525

A comprehensive spare parts service is operated from our factory in Poole, providing replacement parts for both current and
discontinued products. Please contact our spares team, providing details of product type, serial number, model and part
requirements wherever possible.

SERVICE DEPARTMENT ...................................... 01202 662555

At Hamworthy Heating we employ our own skilled service engineers who are trained to work on all of our products. Our
National coverage of all UK mainland sites is supported by a network of Authorised Service Agents who can provide the same
high level of service and product expertise.

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HAMWORTHY HEATING LIMITED

Shady Lane, Great Barr, Birmingham, B44 9ER
Main Switchboard tel: [phone].

Customer Services fax: [phone].

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Our factory in Birmingham offers a comprehensive range of flue products from stock, or alternatively provides a full design
and installation service incorporating sizing, site survey and drawings for approval prior to manufacture.

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Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.