Page 3 - TABLE OF CONTENTS; Converting from Top to Side Terminations
© 2005 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 written permission of R...
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; AUTI
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 CONSIDERATIONS 3.1 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 l...
Page 10 - WARNING; Fire Hazard; 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 Hazard Some objects will catch fire or explode when placed close to heater.Keep all flammable objects, liquids and vapours the requir...
Page 11 - SECTION 4: SPECIFICATIONS; Alternate; Side View
SECTION 4: S PECIFICATIONS 5 SECTION 4: SPECIFICATIONS 4.1 DAT (all models) 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 & Pressur...
Page 12 - 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 (all models) 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...
Page 13 - Appliance Category II
SECTION 4: S PECIFICATIONS 7 4.3 Technical Data Table - Heater Section (all models) Appliance Category II 2H/L 3B/P Gas rates corrected to standard conditions 1013.25 mbar 15°C. * See Page 43, Figure 19 for detailed Combination Fan/Limit Thermostat settings. Model Heat Input kW Gross Calorific Value...
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 DAT100 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 Fl...
Page 15 - SECTION 5: HEATER INSTALLATION; rush Hazard
SECTION 5: H EATER I NSTALLATION 9 SECTION 5: HEATER INSTALLATION 5.1 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 Handli...
Page 17 - Refit the air intake spigot to the flexible hose re-
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 18 - Flue
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 12 Figure 7: Vertical and Horizontal Flue Termination - Type B 22 Appliance Figure 8: Vertical and Horizontal Flue Termination - Type C 12 C 32 & C 62 Appliances Flue Masterflash Roof Terminal Metal Sleeve (25...
Page 19 - See Page 12, Figure 7
SECTION 7: A IR S UPPLY 13 SECTION 7: AIR SUPPLY 7.1 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 20 - on Page
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 14 SECTION 8: OPTIONAL HEATER CONFIGURATIONS 8.1 Distribution Duct DualAir ® units are designed to be connected to distribution and air inlet ducting. It is recommended that flexible duct connectors and/or attenua...
Page 21 - SECTION 9: GAS PIPING
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, ...
Page 22 - See Page 20, Section; Electrical Shock Hazard
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 INFORMATION 10.1 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 - 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 Models 75-115 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/Y...
Page 25 - Site wiring connections shown
SECTION 10: W IRING AND E LECTRICAL I NFORMATION 19 10.5 DAT Wiring Diagram Models 75-115 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 ...
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 - through Page
SECTION 11: C OMMISSIONING 21 SECTION 11: COMMISSIONING Gas 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, com...
Page 28 - *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 230v CLOSE DOWN RUN START ts Signal...
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 - SECTION 12: USER INSTRUCTIONS; See; Pull out for normal operation.; Red limit reset button; Press to reset
SECTION 12: U SER I NSTRUCTIONS 25 SECTION 12: USER INSTRUCTIONS 12.1 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 26, Section 12.3....
Page 33 - SECTION 13: SERVICING; See Page 36, Section; Figure 16: Belt Tension; ut Hazard
SECTION 13: S ERVICING 27 SECTION 13: SERVICING 13.1 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 frequent maintenance may be necessary. Installation, Service and Annua...
Page 34 - See Page; Do not repair or disassemble on site.; . Ensure that the fan is
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 28 13.5 Gas Control Valve Maintenance (all models) No regular maintenance is required on these devices. To change gas control valves, See Page 35, Step 16.1 and Page 39, Section 16.5 . Do not repair or disassemble...
Page 35 - SECTION 14: CONVERSION BETWEEN GASES; See Page 35, Section
SECTION 14: C ONVERSION B ETWEEN G ASES 29 SECTION 14: CONVERSION BETWEEN GASES 14.1 General Conversion bet ween gasses will require a change of burner injectors and the gas valve re-commissioning to the new conditions. 14.2 Burner Conversion Conversion of the burner assembly from one gas to the oth...
Page 36 - SECTION 15: TROUBLESHOOTING; Start; Conduct Commissioning procedure as shown
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 30 SECTION 15: TROUBLESHOOTING 15.1 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 y...
Page 37 - Troubleshooting For Automatic Ignition Burner Systems
SECTION 15: T ROUBLESHOOTING 31 15.2 Troubleshooting For Automatic Ignition Burner Systems If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0) 1902 498733 or www.rg-inc.com Heater Operating TROUBLESHOOT ENDS. No Trace fault in supervision system. See Section 16.3. No Yes Is red lockout lig...
Page 38 - Troubleshooting for Flame Supervision System; START
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 32 15.3 Troubleshooting for Flame Supervision System Repair or replace as necessary. If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0) 1902 498733 www.combat.co.uk or www.rg-inc.com Control box faulty....
Page 39 - Troubleshooting for Solenoid Valves
SECTION 15: T ROUBLESHOOTING 33 15.4 Troubleshooting for Solenoid Valves 15.5 Troubleshooting for Main Fan Valve faulty. Replace with one of correct type. Fault elsewhere Fault elsewhere If problems persist, contact ROBERTS GORDON ® at Tel: +44 (0) 1902 498733 or www.rg-inc.com Valve Operating TROUB...
Page 40 - Troubleshooting for Fan Contactor; Conduct Commissioning procedure as
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 34 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) 1902 498733 or w...
Page 41 - 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
SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 35 SECTION 16: REMOVAL AND REPLACEMENT PARTS See warnings and notes on Page 27, Section 13 before removing or replacing parts. Burner Components All serviceable burner parts are accessed by the door on the side of the heater. See Page 5, Section 4 . 16.1 ...
Page 42 - Burner Compartment; Ensure gas tight fitting of injectors.; MODEL
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 36 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 ...
Page 44 - Carry out a commission after working on or changing a flue fan.
D UAL A IR ® H EATING AND COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M ANUAL 38 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, Sectio...
Page 45 - Heater Pressure Switch; arbon Monoxide Hazard; grey; Pressure Switch; Colour Code
SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 39 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 pressure setting. Carry out a commission after w...
Page 47 - Ignition Control; Disconnect the electrical connections at the; the same to ensure
SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 41 16.7 Ignition Control IT IS IMPORTANT THAT ONLY THE CORRECT IGNITION CONTROL SPECIFIED FOR EACH MODEL TYPE IS USED WHEN REPLACING THESE ITEMS. 16.7.1 S4563C Models 75 to 115 This control is mounted at the electrical mounting plate. Pull out the 3 cable...
Page 49 - Figure 19: Combination Fan/Limit Thermostat
SECTION 16: R EMOVAL AND R EPLACEMENT P ARTS 43 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 Manual Reset Button(Red) Push in Lock Wire ...
