Roberts-Gordon DAT100 - Manuals

Page 3 - TABLE OF CONTENTS; Performance Data - Graph of Air Flows v

© 2007 Roberts-Gordon, LLC All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping or information storage and retrieval systems - without the wri...

Page 5 - TABLE OF FIGURES; Type B

TABLE OF FIGURES Figure 1: Condense Drain ......................................................... 3Figure 2: Installation Clearances and Clearances to Combustibles ............................................................. 4 Figure 3: Suspension Methods ............................................

Page 8 - * Halogenated Hydrocarbons; National Standards and Applicable Codes; CAUTION; Do not use heater in an area containing corrosive

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 2 SECTION 1: HEATER SAFETY Your Safety is Important to Us!This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and followi...

Page 9 - Figure 3

SECTION 3: C RITICAL C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSIDERATIONS3.1 Basic Information The CTUD heater that forms the heating section of the DualAir ® unit has an automatic ignition burner and may be operated as fully modulating or ON/OFF operation.The standard unit has the air flow from lef...

Page 10 - WARNING; Figure 1; Free blowing DualAir

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 4 Figure 2: Installation Clearances and Clearances to Combustibles WARNING Fire H a z ard S ome objects will catch fire or explode when placed close to heater. K eep all flammable objects, liquids and vapours the ...

Page 11 - Alternate; Side View

SECTION 4: S PECIFICATIONS 5 SECTION 4: SPECIFICATIONS4.1 DAT 225 Air Intake Flue Heater Section Fan Compartment Electrical Connections (behind door) Filter Compartment Condense Drain Air Outlet Spigot (35 mm flange) Air Intake 130 mm dia Coil Protection, Frost Thermostat & Pressure Switch Alter...

Page 12 - General Technical Data Table; Reduce the maximum length stated by 1 m for each 90° bend installed.; Model

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 6 4.2 General Technical Data Table Electrical load at 230v 50Hz measured by calculating from total run current of appliance. * Do not exceed the maximum length of flue stated or heater may not operate properly. Re...

Page 13 - Technical Data Table - Heater Section; Appliance Category II

SECTION 4: S PECIFICATIONS 7 4.3 Technical Data Table - Heater Section Appliance Category II 2H/L 3B/P Gas rates corrected to standard conditions 1013.25 mbar 15°C. * See Page 44, Figure 19 for detailed Combination Fan/Limit Thermostat settings. Model Heat Input kW Gross Calorific Value Btu/h x 1000...

Page 14 - Performance Data - Graph of Air Flows v Static Pressure; Air Flow m

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 8 4.4 DualAir ® Performance Data - Graph of Air Flows v Static Pressure 4.4.1 DAT75 and 90 (2.2 kW or 4 kW motor) 4.4.2 DAT10 0 and 115 (4 kW motor) 350 300 250200150 100 50 0 2.4 2.6 2.8 3.0 3.2 3.4 2.2 400 Air F...

Page 15 - Shelf Mounting and Suspension

SECTION 5: H EATER I NSTALLATION 9 SECTION 5: HEATER INSTALLATION5.1 General DualAir ® units are designed for installation above 2.5 m. When connected to duct delivery systems any suitable location will be acceptable. For floor mounting, the DualAir ® unit may stand directly on its base. 5.2 Handlin...

Page 17 - Refit the air intake spigot to the flexible hose re-; Inner Spigot

SECTION 6: F LUE I NSTALLATION 11 5. Refit the air intake spigot to the flexible hose re- using the hose clamp and to the upper panel using the original screws. 6. Align the flues’ inner and outer spigots and attach through the holes in the upper panel re-using the original screws. 7. Refit the lowe...

Page 19 - Open Flued Installation; See Page 12, Figure 7; Heaters Installed Within the Heated Space; per kilowatt of total rated heat input and; Building Ventilation; and local and national; Isolated Equipment Rooms; See Page 13, Figure 9; Units Installed in Isolated Equipment Rooms; lue

SECTION 7: A IR S UPPLY 13 SECTION 7: AIR SUPPLY7.1 Room Sealed Installation When installed as a room sealed heater, the air for combustion is drawn in from outside the building. It is important to ensure that there is adequate ventilation to provide air for the distribution fan/s. 7.2 Open Flued In...

Page 21 - SECTION 9: GAS PIPING; ption

SECTION 9: G AS P IPING 15 SECTION 9: GAS PIPING It is important that the gas supply pipe and the electrical connections do not support any of the heater’s weight.A gas meter is connected to the service pipe by the gas supply company. An existing meter should be checked, preferably by the company, t...

Page 22 - Models; See Page 20, Section; k H

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 16 SECTION 10: WIRING AND ELECTRICAL INFORMATION10.1 Electrical Supply All heater models need a constant 400 V 50 Hz 3 ø supply connected to terminals L 1 ,L 2 , L 3 , N & Earth. Polarity "L 1 & N"...

Page 23 - DAT Main Circuit Board Terminal Identification

SECTION 10: W IRING AND E LECTRICAL I NFORMATION 17 10.3 DAT Main Circuit Board Terminal Identification Terminal Number Use Relay/Function Operation 1 Input or Output External Fan Control Input for Remote Fan Opera- tion Output for Fan Operation Monitor Optional - Main Fan Runs from External Control...

Page 24 - DAT Wiring Diagram; SITE; For external fan wiring,

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 18 10.4 DAT Wiring Diagram S 4563 C Honeywell L N E COMBUSTION F AN PRESSURE SWITCH BLUE Secondary Limit Thermostat N/C PINK GREY PURPLE RESET PUSH LOCKOUT RUN GREEN/YELLOW BLACK WHITE YELLOW GREEN/YELLOW BROWN BL...

Page 25 - DAT Wiring Diagram; Site wiring connections shown

SECTION 10: W IRING AND E LECTRICAL I NFORMATION 19 10.5 DAT Wiring Diagram 7 R1 230 V motor fan main R1/1 Condensor control circuitlimit devices 9 Aux contact A2 overload & Fuse 5A 2 4 6 96 95 contactor 14 13 2 4 1 3 6 5 A1 Relay 1 Remote fan controls 230 V This appliance must be Earthed 10 N 4...

Page 26 - DAT Site Connections at Main Circuit Board

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 20 10.6 DAT Site Connections at Main Circuit Board 9 10 1 L1 N L3 L2 3 2 4 5 7 8 11 12 13 14 15 16 17 18 19 20 21 22 27 25 26 28 23 24 cooling condenser Lockout Warning 230 V Remote Lockout Reset Heat ON MUST be T...

Page 27 - Cooling Coils/Condensers; through Page; Mechanical Checks

SECTION 11: C OMMISSIONING 21 SECTION 11: COMMISSIONINGGas Fired Heater Installation, service, commissioning and annual inspection of the heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment. Read this manual carefully before installation, comm...

Page 28 - CLOSE; *Purge time begins at pressure switch change over.

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 22 Figure 12: Automatic Burner Control Box Sequence Figure 13: Modureg Gas Valve Burner sequence for Honeywell S4563 or S4565C Flame Signal Start Gas Valve Ignition Spark Supply 230 V CLOSE DOWN RUN START ts** Sig...

Page 29 - on; Check Gas Rate

SECTION 11: C OMMISSIONING 23 11.4.2 Commissioning the Gas Valves All DualAir ® units are fitted with fully modulating burner operation. The Honeywell automatic gas valves are fitted with the Honeywell Modureg modulating regulator. See Page 22, Figure 13 . The Modureg device provides the adjustments...

Page 31 - Heater Operation; See; Pull out for normal operation.; Red limit reset button; Press to reset

SECTION 12: U SER I NSTRUCTIONS 25 SECTION 12: USER INSTRUCTIONS12.1 User Instructions The DualAir ® units are fully automatic and operate from the external controls fitted on site. The only user controls at the heater are the:Burner lockout reset button: ................................... See Page...

Page 32 - on Page; Simple Fault Finding

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 26 12.3.3 Burner Lockout Reset Button The red warning light will illuminate when the control has gone to lockout. This may be caused by flame failure. Press the reset button,( See Page 5, Section 4.1 ), or the rem...

Page 34 - Motor

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 28 SECTION 13: SERVICING13.1 Servicing Instructions After commissioning, the DualAir ® unit will require maintenance to be carried out annually. If the DualAir ® unit is used in a dirty or dusty area, more frequen...

Page 35 - Gas Control Valve Maintenance; See Page

SECTION 13: S ERVICING 29 13.5 Gas Control Valve Maintenance No regular maintenance is required on these devices. To change gas control valves, See Page 36, Step 16.1 and Page 40, Section 16.5 . Do not repair or disassemble on site.Replace faulty gas valves with genuine ROBERTS GORDON ® replacement ...

Page 36 - Burner Conversion; See Page 36, Section

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 30 SECTION 14: CONVERSION BETWEEN GASES14.1 General Conversion between gasses will require a change of burner injectors and the gas valve re-commissioning to the new conditions. 14.2 Burner Conversion Conversion o...

Page 37 - Start; Conduct Commissioning procedure as shown

SECTION 15: T ROUBLESHOOTING 31 SECTION 15: TROUBLESHOOTING15.1 General WARNING Explosion Hazard Installation must be done by a registered installer/ contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier. Failure to follow these instructions can res...

Page 38 - Troubleshooting For Automatic Ignition Burner Systems

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 32 15.2 Troubleshooting For Automatic Ignition Burner Systems If problems persist, contact ROBERTS GORDON ® at Tel: +44(0) 190 249 8733 or www.rg-inc.com Heater Operating TROUBLESHOOT ENDS. No Trace fault in super...

Page 39 - Troubleshooting for Flame Supervision System; START

SECTION 15: T ROUBLESHOOTING 33 15.3 Troubleshooting for Flame Supervision System Repair or replace as necessary. If problems persist, contact ROBERTS GORDON ® at Tel: +44(0) 190 249 8733 or www.rg-inc.com Control box faulty. Replace with correct type. Use section 15.1 to trace the fault. Heater Ope...

Page 41 - Troubleshooting for Fan Contactor; Conduct Commissioning procedure as

SECTION 15: T ROUBLESHOOTING 35 15.6 Troubleshooting for Fan Contactor Replace combination thermostat. Wiring faulty or faulty combination thermostat. Investigate. If problems persist, contact ROBERTS GORDON ® at Tel: +44(0) 190 249 8733 or www.rg-inc.com Relay R3 faulty. Replace. Does fan run at co...

Page 42 - SECTION 16: REMOVAL AND REPLACEMENT PARTS; See warnings and notes; Burner Components; See Page 5, Section 4; Figure 17: Standard Regulator Removal; . Once fitted follow commissioning; Remove Standard

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 36 SECTION 16: REMOVAL AND REPLACEMENT PARTS See warnings and notes on Page 28, Section 13 before removing or replacing parts. Burner Components All serviceable burner parts are accessed by the door on the side of...

Page 43 - Burner Compartment; M ODEL

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 37 16.2 Burner Compartment 16.2.1 Burner Injectors Remove flexible air duct from spigot Remove access plate Remove screws and pull off burner cover Viewing port for flame probe Viewing port for ignition electrode Flame probe Burner compartment cover Rubbe...

Page 45 - Carry out a commission after working on or changing a flue fan.; M O DEL

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 39 16.4 Flue Fan IT IS IMPORTANT THAT ONLY THE CORRECT FLUE FAN SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS. Carry out a commission after working on or changing a flue fan. See Page 25, Section 12 . Vent Box Outlet Gasket Flue Fan Ven...

Page 46 - Heater Pressure Switch; grey; P re ssure S w itch; Colour Code

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 40 16.5 Heater Pressure Switch Pull off 3 way connector. Spring open plastic clips of mounting cradle. Replace with correct type of pressure switch for model. The pressure switches are colour coded for each pressu...

Page 47 - Cooling Coil Safety Devices

SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 41 16.6 Cooling Coil Safety Devices 16.6.1 Cooling Coil Frost Thermostat The sensing element for this device is inserted into the pocket of the cooling coil situated through the access hole in the coil cover. The frost thermostat has two settings marked a...

Page 48 - Fan Motor Removal; Disconnect the electrical connections at the; the same to ensure

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 42 16.7 Ignition ControlIT IS IMPORTANT THAT ONLY THE CORRECT IGNITION CONTROL SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS. 16.7.1 S4563C This control is mounted at the electrical mounting pla...

Page 50 - Figure 19: Combination Fan/Limit Thermostat

D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 44 Figure 19: Combination Fan/Limit Thermostat Dial Set Point 3 Limit Temp. Set Point 1 Fan Off Set Point 2 Fan On Fan Terminals Manual Fan Switch (White) BREAK-OFF LINKMUST BE REMOVED Limit Terminals Limit Stat M...

Page 52 - Attach this information to the wall near the ROBERTS GORDON

www.rg-inc.com Printed in U.S.A P/N 91040089 Fax: +44 (0)121 506 7701 Service Telephone: +44 (0)121 506 7709 Service Fax: +44 (0)121 506 7702 E-mail: [email protected] E-mail: [email protected] Roberts-Gordon, LLC 1250 William Street P.O. Box 44 Buffalo, NY 14240-0044 USA Roberts-Gordon Europe Limi...