Hamworthy DORCHESTER DR90L-CE User guide

Appendix 4
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
Installation, Commissioning
and Servicing Instructions
supplement
orchester
R35L-CE to R90L-CE
Hot Water Storage Heaters
HomepageRegister
Fully Automatic

Customer Services
TECHNICAL ENQUIRIES 01202 662527 / 662528
To supplemen he de ailed echnical brochures, echnical advice on he applica ion and use of produc s in
he Hamwor hy Hea ing range is available from our echnical eam in Poole and our accredi ed agen s.
SITE ASSEMBLY 01202 662555
Specialis eams are available for on si e assembly of he full range of Hamwor hy boilers (excluding
Lulwor h). Boiler sec ions for si e assembly mus be posi ioned wi hin he boiler house prior o he arrival
of he assembly eam and provide sufficien space for safe working. Handling sec ions in o boiler houses
o her han a ground level may be subjec o addi ional charges.
The normal assembly price does no include for he fi ing of boiler casings or he burner, however his can
be carried ou a he ime of build a addi ional cos .
Providing he facili ies are available on si e, a hydraulic es will be carried ou wi hin he erms of BS779.
Upon comple ion a cer ifica e of assembly and es will be issued.
COMMISSIONING 01202 662555
Commissioning of equipmen by Hamwor hy Hea ing’s own engineers, accredi ed agen s or specialis sub-
con rac ors will ensure ha he equipmen is opera ing safely and efficien ly. Hamwor hy commissioning
repor s provide a de ailed record of he original s a us of he plan , which is essen ial for fu ure rou ine
main enance and rouble free opera ion.
S andard warran y erms provide for he free of charge replacemen of defec ive par s, bu does no
include labour. When he equipmen is commissioned and rou inely main ained by Hamwor hy Hea ing
under a Service Main enance Agreemen hen he warran y erms will cover bo h par s and labour.
MAINTENANCE AGREEMENTS 01202 662555
Regular rou ine servicing by Hamwor hy Hea ing’s engineers ensures rouble free opera ion and op imum
efficiency. The frequency of visi s required is variable, dependen upon he equipmen ype and usage.
Annual service agreemen s are available on all Hamwor hy produc s o mee individual requiremen s.
Planned main enance of equipmen by rou ine servicing reduces opera ional cos s considerably below ha
associa ed wi h repair or breakdown approach.
BREAK OWN SERVICE, REPAIR, REPLACEMENT 01202 662555
Even when he commissioning and rou ine servicing has been carried ou o he highes s andard here
are always occasions when he unexpec ed breakdowns occur. Hamwor hy provide a rapid response
breakdown, repair or replacemen service hrough head office a Poole and accredi ed agen s loca ed
hroughou he UK.
SPARE PARTS 01202 662525
A comprehensive spare par s service is opera ed from our fac ory in Poole, providing replacemen par s
for bo h curren and discon inued produc s. In some ins ances spares may be available from accredi ed
agen s.
Delivery of par s and componen s is normally from s ock wi hin 7 days. However, a 24 hour delivery
service is available for breakdowns and emergencies for he addi ional cos of he courier. Please con ac
our spares eam, providing de ails of produc ype, serial number, model or any o her iden ifying marks or
codes o de ermine par requiremen s wherever possible.

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
i
APPEN IX 4
ORCHESTER
R35L-CE TO R90L-CE
HOT WATER
STORAGE HEATERS
INSTALLATION, COMMISSIONING
AN MAINTENANCE MANUAL FOR
FULLY AUTOMATIC CONTROLS
NOTE! THESE INSTRUCTIONS MUST BE REA AN
UN ERSTOO BEFORE INSTALLING OR
COMMISSIONING THIS HOT WATER HEATER
PUBLICATION NO. 5000010029
ISSUE ‘C’
June 1995

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
ii
This Page Lef In en ionally Blank

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
1
APPEN IX 4 TO RL INSTALLERS GUI E
RL SERIES OF HOT WATER STORAGE
HEATERS FITTE WITH FULLY AUTOMATIC
CONTROLS FIRING NATURAL GAS.
To be used in conjunc ion wi h he main
ins aller's guide - publica ion number
500001001.
ESCRIPTION
The Hamwor hy DRL series of ho wa er s orage
hea ers can also be supplied wi h fully au oma ic
con rols. The fully au oma ic con rol provides a
safe ligh -up and shu down programme for he
burner, flame de ec ion being based on he well
known rec ifica ion principle.
When he con rolling hermos a calls for hea a
high energy spark is produced a he spark
elec rode and he compac gas con rol valve
(see Fig 1) is energised o es ablish a gas flame
on he burner bars.
Failure o es ablish and de ec flame during a
s ar -up a emp resul s in lockou af er he expiry
of he nominal 5 seconds igni ion safe y ime.
Flame failure during a `run' resul s in an
immedia e a emp o safely re-ligh he burner.
Failure o es ablish and de ec flame during a
re-ligh a emp resul s in lockou af er he expiry
of he 5 seconds safe y igni ion ime. A false
flame signal a he s ar poin and during he 13
seconds wai ing ime prior o he in roduc ion of
he spark causes he con rol box o lockou .
These wa er hea ers are very similar o he basic
range of permanen pilo models and for general
informa ion concerning echnical da a, wa er
flows, ins alla ion recommenda ions, e c,
a en ion is drawn o he ins alla ion and
commissioning ins ruc ions in he main manual
500001001.
The basic differences be ween he permanen
pilo , na ural gas models and he fully au oma ic
versions are as follows:-
1) The Honeywell V4410 sof li e gas con rol
valve is replaced by a Dungs MB DLE 407 B01
compac gas con rol valve on he DR70L and
DR90L (see Fig 1), and a VR4601 compac
valve on he DR35L and DR50L - These valves
incorpora e slow opening o produce a low
flame s ar .
2) The hermocouple is replaced by a flame
rec ifica ion probe.
3) The Piezo uni and elec rode are replaced
by a spark genera or and a spark elec rode
(see Fig 1).
4) A Sa ronic TF1 812 2B con roller is
incorpora ed in o he igni ion sys em (see Fig
1).
5) The gas inle connec ion dimension from
he cen re line of he hea er is al ered, see
Figure 1.
CONTROL SYSTEM
Control Thermostat
The con rol hermos a (B1N) on he DRL
au oma ic hea ers is similar o ha used on
he permanen pilo versions. However, he
hermos a is connec ed in series wi h he main
supply o he Sa ronic con roller (see Fig 2).
On ac iva ion he hermos a in errup s he
supply o he con roller, he flame is
ex inguished and he hea er shu s down.
For fur her de ails refer o he main manual.
Limit Thermostat
A manual rese limi hermos a (B1f) is pre-
wired in series wi h he supply o he Sa ronic
con roller (see Fig 2). In he even of he limi
hermos a being ac iva ed, power o he
con roller is in errup ed and he hea er shu s
down. The limi hermos a mus hen be rese
by removing he plas ic cap on he uni and
pressing he green bu on exposed (see Fig
3). The hea er will hen au oma ically res ar .
NOTE! In he even of he overhea limi
hermos a being ac iva ed, he comple e
hea er ins alla ion should be inspec ed o race
and isola e he cause of he problem

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
2
before any fur her firing akes place.
Controller
The Sa ronic con roller supervises he igni ion
and safe y shu down of he hea er in he
even of flame failure. Supply o he con roller
is via he hermos a s previously described
(see Fig 2).
COMMISSIONING
Checks
Before a emp ing o commission any hea er,
ensure ha any personnel involved are aware
of wha ac ion is o be aken. Begin by
making he checks lis ed in he main ins allers
guide wi h he amendmen o e) as follows:-
e) Gas supply is connec ed bu urned off,
gas cock closed, unions are igh ened (wi h
any seals in posi ion), es poin s are igh ,
burners are correc ly posi ioned, injec ors are
igh , spark elec rode and flame probe are
correc ly posi ioned wi h 3-4 mm gaps, above
burner bars and are undamaged par icularly
ceramic por ion (do no over- igh en elec rode
re aining nu s). Elec rode and probe leads
are fully screwed in o elec rode connec ors
which are firmly connec ed o he appropria e
elec rode.
Procedure for Lighting
Turn con rol hermos a o he minimum
se ing (35°C) and ensure elec rical supply
is off.
Open hea er gas cock.
Check ha any elec rical circui s are closed
and swi ch on he power supply o he
appliance. Adjus he con rol hermos a o
he recommended required se ing ( o a value
no exceeding 60°C). Wi hin 13 seconds he
spark will opera e, he gas valve will open
and he burners will ligh on low flame and
au oma ically increase o full flame. If he
burner does no ligh , spark will con inue for
5 seconds, af er which ime he con rol box
will `lockou ' in a safe condi ion wi h he lockou
bu on illumina ed. If his occurs, swi ch off
power supply, wai 3 minu es, check ha gas is
available a hea er (reven o ou side of building
if necessary), reins a e power supply and press
he lockou bu on o rese and repea he
sequence.
Af er he hea er has opera ed for approxima ely
5 minu es, swi ch off he power, slacken he gas
pressure es poin screw on he gas manifold
and fi manome er. Swi ch he hea er on and
measure he opera ing gas pressure. Check
readings agains pressure required in Table 1
in he main manual. Adjus he appliance
regula or as necessary by:-
a) DR35L-DR50L (Honeywell valve VR4601
A). Remove he aluminium plug (see Fig 4)
and, using a screw driver urn he adjus ing
screw o al er he pressure, clockwise o
increase, an i-clockwise o decrease. Replace
plug.
b) DR70L-DR90L (DUNGS MB-DLE 407 B01)
Ro a e pivo ed cover from over adjus men
screw on fron of Dungs valve and, using a
screwdriver urn he adjus ing screw o al er he
pressure, clockwise o increase, an i-clockwise
o decrease. Replace cover.
Remove manome er, remembering o re igh en
pressure es poin . Religh he burner and
check ha no was e gas spillage occurs from
any draugh diver er. Check opera ion of con rol
hermos a by adjus ing he empera ure se ing,
hus ligh ing and ex inguishing he flame.
SERVICING
Removal of Gas Train
Unscrew and disconnec he wo halves of he
3/4 gas pipework union a he inle o he compac
gas con rol valve and remove and re ain he
union rubber sealing ring.
Remove he hree core power supply lead o
he compac gas con rol valve as follows.

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
3
Unscrew he re aining screw securing he din
plug/s in place and carefully pull he plug/s
away from he valve or separa e he plug and
socke in line connec or near he con rol box.
Disconnec he flame probe and elec rode
leads by pulling off he ceramic cap from he
flame probe and he rubber cap from he
spark elec rode.
The gas rain assembly is secured o he
hea er by wo nu s on he fron fee and screw
in he bo om of he hea er casing a he
cen re of he gas manifold. Removal of hese
enables he assembly o be wi hdrawn.
The elec rode and flame probe should be
checked for cracked ceramics and wear.
Replace as necessary and adjus o correc
gaps. For servicing of he burners and he
in ernals of he hea er, refer o he main
ins allers guide, wi h he excep ion of he pilo
burner which is no fi ed o he au oma ic
version.
Reassemble componen s in reverse order,
aking care o replace he rubber sealing ring
in he union.
FAULT FIN ING
1. Heater will not start, controller not
locked out:-
Check con inui y across con rol hermos a
wi h con rol a opera ing empera ure
posi ion.
Check for high empera ure limi hermos a
lockou .
2. Heater starts but controller goes to
lockout without ignition:-
Check gas valve opera ion (by pressure a
manifold es poin during a s ar up a emp ).
Check igni ion elec rode connec or (wire is
firmly screwed in o ceramic connec or) and
igni ion ransformer if no spark is produced.
3. Hea er s ar s, igni ion occurs, con roller
immedia ely goes o lockou :-
R35-90L
Check flame probe connec or (wire is firmly
screwed in o ceramic connec or).
Check flame probe posi ion ie ouching he
burner bar or no in he flame will cause a
lockou (see Fig 5 for correc probe posi ion).
R70-90L
Reduce flame igni ion ime by adjus ing he
main valve ini ial opening. Remove he
pro ec ive cap from he op of he valve (see
Fig 4), reverse i and use o urn he spindle
exposed. This adjus s he rapid ini ial
opening of he valve and hus he ini ial gas
pressure. The valve is ini ially se a he
minimum opening posi ion, urn coun er-
clockwise o increase he opening. Res ar
he hea er and replace pro ec ive cap.
Replace con rol box. NOTE! To remove
con rol box from i s base, using a screwdriver
remove he re aining screw in he fron of he
box and gen ly pull from he base. Loca e
and press home he new one and re igh en
screw.
A ITIONAL RECOMMEN E SPARES
escription Part Number
Con rol Valve 3/4 Dungs 533903013
Compac Gas Con rol Valve
23 mm in/ou Honeywell
VR4601A (special) 531907008
Limi Thermos a 533901191
Con roller 533901006
Igni ion ransformer 533901062
Elec rode (igni ion) 533805008
Probe (Flame Sensing) 533805007
Ceramic Cap (Probe) 533901060
Rubber Cap (Elec rode) 533901255

HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
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HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
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HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
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HAMWORTHY HEATING LTD. APPENDIX 4 500001029/C
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Hamworthy Heating
Accredited Agents
Central & South West England Scotland
river Engineering Limited Mc owall Modular Services
778 Wimborne Road, Moordown 97a Haw horn S ree
Bournemou h BH9 2DX Glasgow G22 6JD
Tel: 01202 525140 Tel: 0141 336 8795
Fax: 01202 536442 Fax: 0141 336 8954
North West England Northern Ireland
Gillies Modular Services McCaig Collim Limited
210-218 New Ches er Road 92-94 Dargan Crescen
Birkenhead Duncrue Indus rial Es a e
Merseyside L41 9BG Belfas BT3 9JP
Tel: 0151 666 1030 Tel: 01232 777788
Fax: 0151 647 8101 Fax: 01232 776865
North East England Southern Ireland
Allison Heating Products HEVAC Limited
17 Beach Road 70-72 Lower Dorse S ree
Sou h Shields Dublin 1, Ireland
Tyne & Wear NE33 2QH Tel: 003531 830 1211
Tel: 0191 455 7898 Fax: 003531 830 1990
Fax: 0191 455 7899
For all other areas, or for further advice, please contact Hamworthy Heating
head office service department in Poole, telephone 01202 662500.

irect ial Telephone Numbers
Hamworthy Heating
Connec direc for be er service
HAMWORTHY HEATING LIMITE
Flee s Corner, Poole, Dorse , BH17 0HH. England.
Main Swi chboard el: 01202 662500.
Cus omer Services fax: 01202 665111.
POOLE OFFICE
Boilers • controllers • water heaters • pressurisation sets • cold water boosters
GENERAL ENQUIRIES ........................................... 01202 662552
For general enquiries on produc s and services available from Hamwor hy Hea ing, our Cus omer Liaison s aff are on hand o
answer your ques ions.
QUOTATIONS .......................................................... 01202 662552
Hamwor hy Hea ing provide an efficien pricing and quo a ion service. Our Cus omer Liaison s aff will also be pleased o
arrange for one of our Sales Engineers or Au horised Sales Agen s, o visi you o discuss your needs in person, and offer
exper echnical and commercial advice on hea ing, flue and wa er sys ems.
TECHNICAL ENQUIRIES...................................... 01202 662527/662528
For problems of a echnical na ure and fur her produc suppor , our Technical Applica ions Engineers offer specifiers and
con rac ors advice on all aspec s of equipmen applica ion, configura ion and capabili y.
OR ER ENQUIRIES .............................................. 01202 662518
For an efficien response o order acknowledgemen and adminis ra ive queries, con ac our order
processing eam.
ELIVERY ENQUIRIES......................................... 01202 662515/662504
Deliveries from Hamwor hy Hea ing arrive direc from he fac ory on a vehicle equipped wi h a ail-lif for ease of off-loading o
ground level. Our con rac s eam will progress despa ch and liaise individual delivery arrangemen s.
SPARE PARTS ....................................................... 01202 662525
A comprehensive spare par s service is opera ed from our fac ory in Poole, providing replacemen par s for bo h curren and
discon inued produc s. Please con ac our spares eam, providing de ails of produc ype, serial number, model and par
requiremen s wherever possible.
SERVICE EPARTMENT ...................................... 01202 662555
A Hamwor hy Hea ing we employ our own skilled service engineers who are rained o work on all of our produc s. Our
Na ional coverage of all UK mainland si es is suppor ed by a ne work of Au horised Service Agen s who can provide he same
high level of service and produc exper ise.
EXPORT .................................................................. +44 (0)1202 662514
Hamwor hy Hea ing has an expanding global ne work of dis ribu ors and par ner companies providing local con ac , produc
and af er sales service. This ne work curren ly includes I aly, Benelux, Germany, Bal ic S a es, Finland, Russia, Poland, Aus-
ralia, Sou h Africa, Hong Kong and China.
BIRMINGHAM OFFICE
HAMWORTHY HEATING LIMITE
Shady Lane, Grea Barr, Birmingham, B44 9ER
Main Swi chboard el: 0121 360 7000.
Cus omer Services fax: 0121 325 0890.
Flue components • design service • bespoke manufacture • installation
FLUE PRO UCTS (ALL ENQUIRIES) ................... 0121 360 7000
Our fac ory in Birmingham offers a comprehensive range of flue produc s from s ock, or al erna ively provides a full design
and ins alla ion service incorpora ing sizing, si e survey and drawings for approval prior o manufac ure.
Associa e Companies, Offices and Agen s hroughou he World.
Hamwor hy reserves he righ o make changes and improvemen s which may necessi a e al era ion o he specifica ion wi hou prior no ice.
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