Roberts Gorden DualAir DAT100, DualAir DAT75, DualAir DAT115, DualAir DAT90 Operation And Service Manual

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Page 1

WARNING

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. DO NOT try to light any appliance.

3. DO NOT use electrical switches.

4. DO NOT use any telephone in your building.

5. Leave the building.

6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions.

7. If you cannot reach your gas supplier, call the Fire Department.

Fire Hazard

Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance.

Some objects will catch fire or explode when placed close to heater.

Failure to follow these instructions can result in death, injury or property damage.

Roberts-Gordon Europe Limited

Oxford Street Bilston, West Midlands WV14 7EG UK Telephone: +44(0) 1902 494425 Fax: +44(0) 1902 403200 Service Telephone: +44(0) 1902 498733 Service Fax: +44(0) 1902 401464 E-mail: uksales@rg-inc.com E-mail: export@rg-inc.com

www.rg-inc.com

WARNING

Installation must be done by a registered installer/ contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier.

Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the installation, operation and service manual thoroughly before installing or servicing this equipment.

Installer

Please take the time to read and understand

these instructions prior to any installation.

Installer must give a copy of this manual to the owner.

Owner

Keep this manual in a safe place in order to provide

your serviceman with necessary information.

Quality in Any Language™

DualAir

Installation, Commissioning,

Operation & Service Manual

DAT75

DAT90 DAT100 DAT115

P/N X527 Rev B 10/05

Heating and Cooling Units

Page 2

Page 3

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 Roberts-Gordon.

Printed in U.K.

TABLE OF CONTENTS

SECTION 1: Heater Safety......................................................2

SECTION 2: Installer Responsibility .....................................2

2.1 Clearances to Combustibles ........................................2

2.2 Corrosive Chemicals....................................................2

2.3 National Standards and Applicable Codes .................. 2

SECTION 3: Critical Considerations......................................3

3.1 Basic Information.........................................................3

3.2 Location and Suspension ............................................3

3.3 Minimum Required Installation Clearances .................3

3.4 Clearances to Combustibles ........................................3

3.5 Ventilation .................................................................... 3

3.6 Gas Supply ..................................................................3

3.7 Electrical Supply .......................................................... 3

3.8 Flue..............................................................................3

3.9 Coil Condense Drain.................................................... 3

SECTION 4: Specifications .................................................... 5

4.1 DAT (all models) ..........................................................5

4.2 General Technical Data Table (all models) .................. 6

4.3 Technical Data Table - Heater Section (all models) .....7

4.4 DualAir

Performance Data -

Graph of Air Flows v Static Pressure ........................... 8

SECTION 5: Heater Installation.............................................. 9

5.1 General........................................................................ 9

5.2 Handling ......................................................................9

5.3 Shelf Mounting and Suspension.................................. 9

SECTION 6: Flue Installation ...............................................10

6.1 Flue Installation.......................................................... 10

6.2 Type C

, C32 & C62 Appliance..................................... 10

6.3 Type B22 Appliance..................................................... 10

6.4 Converting from Top to Side Terminations

for Flue and Air Intake. .............................................. 10

SECTION 7: Air Supply......................................................... 13

7.1 Room Sealed Installation ........................................... 13

7.2 Open Flued Installation .............................................. 13

7.3 Building Ventilation ..................................................... 13

7.4 Isolated Equipment Rooms ........................................13

SECTION 8: Optional Heater Configurations...................... 14

8.1 Distribution Duct ........................................................14

SECTION 9: Gas Piping........................................................15

9.1 Connections............................................................... 15

SECTION 10: Wiring and Electrical Information.................16

10.1 Electrical Supply ...................................................... 16

10.2 Remote Control........................................................ 16

10.3 DAT Main Circuit Board Terminal Identification ........ 17

10.4 DAT Wiring Diagram Models 75-115 ........................ 18

10.5 DAT Wiring Diagram Models 75-115 ........................ 19

10.6 DAT Site Connections at Main Circuit Board............ 20

SECTION 11: Commissioning .............................................. 21

11.1 Pre Commission Checks...........................................21

11.2 Gas Supply............................................................... 21

11.3 Mechanical Checks................................................... 21

11.4 Begin Commissioning...............................................21

11.5 Combustion Testing (all models)............................... 23

11.6 Turning Off the DualAir

Unit.....................................24

11.7 External Controls ......................................................24

11.8 Complete the Commissioning...................................24

11.9 Instruction to the User ..............................................24

SECTION 12: User Instructions............................................25

12.1 User Instructions......................................................25

12.2 Heater Operation......................................................25

12.3 Common User Controls (all models) ........................25

12.4 Cooling Section Operation .......................................26

12.5 Heating Section Lighting Instructions.......................26

12.6 Simple Fault Finding (all models) .............................26

SECTION 13: Servicing.........................................................27

13.1 Servicing Instructions...............................................27

13.2 Burner Maintenance.................................................27

13.3 Fan/Motor Assembly Maintenance...........................27

13.4 Heat Exchanger Maintenance..................................27

13.5 Gas Control Valve Maintenance (all models) ...........28

13.6 Flue Fan ...................................................................28

SECTION 14: Conversion Between Gases ..........................29

14.1 General ....................................................................29

14.2 Burner Conversion ...................................................29

14.3 Gas Valves ...............................................................29

SECTION 15: Troubleshooting .............................................30

15.1 General ....................................................................30

15.2 Troubleshooting For Automatic Ignition

Burner Systems .......................................................31

15.3 Troubleshooting for Flame Supervision System .......32

15.4 Troubleshooting for Solenoid Valves ........................33

15.5 Troubleshooting for Main Fan...................................33

15.6 Troubleshooting for Fan Contactor ...........................34

SECTION 16: Removal and Replacement Parts..................35

16.1 Gas Valve .................................................................35

16.2 Burner Compartment ...............................................36

16.3 Ignition Electrode and Flame Probe.........................37

16.4 Flue Fan ...................................................................38

16.5 Heater Pressure Switch............................................39

16.6 Cooling Coil Safety Devices.....................................40

16.7 Ignition Control .........................................................41

16.8 Fan Motor Removal ..................................................41

16.9 Combination Fan/Limit Thermostat..........................42

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TABLE OF FIGURES

Figure 1: Condense Drain ......................................................... 3

Figure 2: Installation Clearances and Clearances to

Combustibles............................................................. 4

Figure 3: Suspension Methods ................................................. 9

Figure 4: Flue and Roof Detail................................................ 10

Figure 5: Control Section & Upper Panel ................................ 11

Figure 6: Alternate .................................................................. 11

Figure 7: Vertical and Horizontal Flue Termination -

Ty pe B

Appliance................................................... 12

Figure 8: Vertical and Horizontal Flue Termination -

Ty pe C12 C32 & C62 Appliances.................................. 12

Figure 9: DualAir

Units Installed in Isolated

Equipment Rooms................................................... 13

Figure 10: Ducting................................................................... 14

Figure 11: Gas Connection with Stainless Steel

Flex Connector ....................................................... 15

Figure 12: Automatic Burner Control Box Sequence............... 22

Figure 13: Modureg Gas Valve................................................22

Figure 14: Heater Operating Sequence ..................................25

Figure 15: Fan/Limit Thermostat ............................................. 25

Figure 16: Belt Tension ...........................................................27

Figure 17: Standard Regulator Removal................................. 35

Figure 18: Cooling Coil Safety Devices. ..................................40

Figure 19: Combination Fan/Limit Thermostat........................ 43

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Product Approval

ROBERTS GORDON® appliances have been tested and CE certified as complying with the essential requirements of the Gas Appliance Directive, The Low Voltage Directive, The Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas and L.P. gas when installed, commissioned and maintained in accordance with these instructions.

These instructions refer to appliances designed to operate in the European Union. Appliances designed for other countries (Non European Union) are available on request. This appliance must be installed in accordance with the local and national codes in force and used

only in a sufficiently ventilated space, as specified in these instructions. Before installation, check that the local gas distribution systems, nature of gas and pressure, and

adjustment of the appliance are compatible.

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DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 following the warnings in these sections.

Installation, Service and Annual Inspection of the DualAir

unit must be done by a registered installer/ contractor qualified in the installation and service of gas-fired heating equipment.

Read this manual carefully before installation, operation, or service of this equipment.

This DualAir

unit is designed for heating and cooling non-residential indoor spaces. Do not install in residential spaces. These instructions, the layout drawing, local codes and ordinances, and applicable standards that apply to gas piping, electrical wiring, venting, refrigerant installation, etc., must be thoroughly understood before proceeding with the installation.

SECTION 2: INSTALLER RESPONSIBILITY

• To supply and install a suitable condenser unit along with associated refrigerant circuits in accordance with the requirements of all relevant local and national codes.

• To install the DualAir

unit, as well as the gas and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon recommends the installer contact a local building inspector, Fire Officer or insurance company for guidance.

• To use the information given in the manual together with the local and national codes to perform the installation.

• To install the DualAir

unit in accordance with the

Clearances to Combustibles of this DualAir

unit.

• To furnish all needed materials not furnished as standard equipment.

• To plan location of supports, flues and air intakes.

• To provide access for servicing.

• To provide the owner with a copy of this installation, commissioning, operation and service manual.

• To never use the DualAir

unit as support for ladder or other access equipment and never hang or suspend anything from heater.

• To ensure that there is sufficient ventilation in the area to comply with the requirements of all relevant local and national codes.

2.1 Clearances to Combustibles

In all situations, clearances to combustibles must be maintained. Caution must be used when running the DualAir

unit near combustible materials such as wood, paper, rubber, etc. A wall tag is on the back cover of this manual as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles. Affix the tag on a wall near the DualAir

unit.

2.2 Corrosive Chemicals

Roberts-Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the sub-contractor, or the owner identifies the presence of combustible materials, corrosive chemicals or halogenated hydrocarbons* anywhere in the premises.

* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the lifespan of the DualAir

unit

components will be greatly reduced. Warranty will be invalid if the heater is exposed to halogenated hydrocarbons.

2.3 National Standards and Applicable Codes

All Appliances must be installed in accordance with the latest revision of applicable standards and local and national codes. This refers also to the electric, gas, refrigerant and venting installation. Note: Additional standards for installations in Public Garages, Aircraft Hangars, etc. may be applicable.

CAUTION

Do not use heater in an area containing corrosive chemicals.

Corrosive chemicals will damage the burner and heat exchanger parts.

Failure to follow these instructions can result in property damage.

Page 9

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 left to right when viewed from the controls side.

A special order version with the opposite air flow is available where the combustion air intake and flue will be at the front of the unit.

3.2 Location and Suspension

All models:

• Must be installed indoors.

• Must be installed in a level position.

• May be mounted on the floor or on a shelf of non-combustible material. (See Page 5, Section 4 and Page 9, Figure 3 for support points)

• May be suspended from above (See Page 9, Figure 3),on the floor, or from wall brackets of sufficient strength to support the DualAir

unit as listed in the Dimension Data Table on Page 6, Section 4.2. Drop rods must be a minimum of 12 mm diameter mild steel. Six suspension points are located on top of the DualAir

unit.

• Must be installed in a manner which allows the hinged door to be fully opened to provide access to all serviceable components.

3.3 Minimum Required Installation Clearances

Clearances around the DualAir

unit and flue must be as indicated on Page 4, Figure 2, Page 10, Figure 4 through Page 12, Figure 8 to ensure access for servicing, and correct operation.

3.4 Clearances to Combustibles

Clearances must be as indicated on Page 4, Figure

2. If no clearances to combustibles are indicated

then installation clearances apply.

3.5 Ventilation

It is important to ensure that there is adequate air circulation around the DualAir

unit to supply air for combustion, ventilation and distribution in accordance with local and national codes.

3.6 Gas Supply

It is important that the gas supply pipe is sized correctly to provide the inlet pressure as stated on the heater data plate. The gas supply pipe and electrical connections must not support any of the heater's weight.

3.7 Electrical Supply

A permanent 400v 3ø 50Hz electrical supply is required at the main electrical terminals. The heater also requires suitable energy controls in accordance with Section 10.

3.8 Flue

Choose a location to allow for the proper alignment of the flue. Each DualAir

unit must be fitted with an individual and correctly sized sealed flue system (See Page 10, Section 6).

No other appliance may be connected to the flue. For room sealed installation the air intake must be

the same size sealed system and the flue/air intake must terminate at an approved concentric wall or roof terminal.

3.9 Coil Condense Drain

The cooling coil must be fitted with a suitable condense drain. The condense pipe work should be in plastic or copper piping in accordance with the latest revision of applicable standards and local and national codes.

Figure 1: Condense Drain

Failure to install the condense drain correctly may cause water carry over into the fan compartment, which may then escape and cause property damage.

100 mm min.

Install to Suitable Drain

Drain to Open Funnel

Trap must be filled with water to be effective and prevent air being drawn backwards into the drip tray.

Page 10

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 required distance away from the heater.

Failure to follow these instructions can result in death, injury or property damage.

Clearances to Combustibles

Alternative

Wall

Terminal

Roof Terminal

Air

Intake

Flue

15 cm

2.5 - 3.5 m*

3 m

60 cm

Installation Clearances

Customers

Suitable

Condenser

Unit

Insulated

Refrigerant pipes

to cooling coil

by Customer

Condense

Drain

Install to

suitable drain,

See Page 3,

Figure 1.

Air Flow

50 cm

50 cm**

30 cm

15 cm

If installed at low levels where individuals can come in contact with hot heat exchanger components, adequate guarding must be provided.

All distances are minimum clearance requirements for service access, air flow and safety.

Free blowing DualAir

units must always be installed at least 1.8 m above the floor. Ducted installations may be floor mounted. The flue pipe must have clearance from combustibles by 5 cm.

**80 cm is necessary to service heater.

* Free blowing DualAir

units may be mounted at a higher level if destratification fans and/or turn down nozzles are installed.

Page 11

SECTION 4: SPECIFICATIONS

4.1 DAT (all models)

225

Air Intake

Flue

Heater Section Fan Compartment

Electrical

Connections

(behind door)

Filter CompartmentCondense Drain

Air Outlet Spigot (35 mm flange)

Air Intake 130 mm dia

Coil Protection,

Frost Thermostat

& Pressure Switch

Alternate Flue & Air Intake Position

Cooling Coil

Air Inlet Spigot

(35 mm flange)

3010

896 225

1239

Internal

Spigot Height

1417

Flue 130 mm dia

Lockout

Reset

Green

Burner

Red

Lockout

Warning

Amber

Dirty Filter

Warning

734

Gas

Connection

112 7

20 mm Conduit Entry for Electrical Connections

1494

671

2070 532

1239

Internal

Spigot

Height

1250 Internal Spigot Width

Alternate Flue & Air Intake Position

315

89051 399

1340

1590

Extension Cover for Refrigerant Pipe-work

538

1032

Standard Flue & Air Intake Position

Side View

Front View

Rear View

Front View (Left Version)

Rear View (Left Version)

Page 12

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 properly.

Reduce the maximum length stated by 1 m for each 90° bend installed.

**If minimum air flow requirements are not met then temperature limit devices will shut down the heater.

Model

Designed Air Flow # with Clean Filters

/sec

Min Air Flow at Coil

/sec

Max Air Flow at Coil

/sec

Fan Unit

Fan Pulley mm PCD

Motor Pulley mm PCD

Vee Belts

Total Electrical Load kW

Motor Size kW

Full Load Current A

Run Current at Designed Air Flow # A

Start Current A

Inlet Connection in

Outlet Connection in

Condensate Connection ISO 7-R

Refrigerant

°C Dry Bulb

°C Wet Bulb

°C Dry Bulb

°C Wet Bulb

All Models

Initial Pressure Loss

mbar

Max. Recommended Pressure Loss

mbar

Weight kg

NR dB(A)

SPL dB(A)

NR dB(A)

SPL dB(A)

NR dB(A)

SPL dB(A)

68 68 73 75

5.4

23.0 24.0

7.0 / 7.5

57.74 71.54

2.88

1.66

3.71

2A x 112 / 2A x 118

115

3.7

2.60

5.34

75 90

2 x A 63

2A x 180 / 2A x 200

2A x 100 / 2A x 95

Fan Data

457-486 Double Inlet Belt Drive

2A x 180

2 x A 64

100

Max Cooling Load Split into Two Equal

Circuits

Design Temp. ON

Design Temp. OFF

R407C

612 621

1 5/8 copper

638 647

0.4

1.5

Qty. 6 - Farr 30/30 grade 100 x 635 x 406

Filters - All Models

7/8 copper

1 3/8 copper

18.07

14.66

Electrical Data - All models need 400v 50Hz 3N supply. Single phase supply output for control circuit 230v 50Hz fused at 5 Amp. All alarm and status signals 230v 50Hz. Modulation input 0-10vDC.

Cooling Coil - DX

4.0

7.5

2.2

4.45

4.0 / 4.5

3.3

Physical Data

Noise from Cabinet at 1 m 67.5

13.72

12.3

19.4

Noise from Air Inlet at 1 m

77 75

Noise from Air Outlet at 1 m

81 7776

Page 13

SECTION 4: SPECIFICATIONS

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

Btu/h x 1000

Heat Input kW

Net Calorific Value

Btu/h x 1000

Approximate kW

Max Heat Output

Btu/h x 1000

Min Heat Input - Low Fire kW

Gross Calorific Value

Btu/h x 1000

Min Heat Input - Low Fire kW

Net Calorific Value

Btu/h x 1000

Set Point 1 Fan OFF Temp.

°C

Set Point 2 Fan ON Temp.

°C

Set Point 3 Limit Temp. °C

Secondary Limit Thermostat

°C

Max Burner Pressure mba

Min Burner Pressure - Low Fire mbar

Max Burner Pressure mba

Min Burner Pressure - Low Fire mbar

Max Burner Pressure mba

Max Gas Flow Rate

kg/h

liquid l/h

Min Burner Pressure - Low Fire mbar

Min Gas Flow Rate

kg/h

liquid l/h

Max Burner Pressure mba

Max Gas Flow Rate

kg/h

liquid l/h

Min Burner Pressure - Low Fire mbar

Min Gas Flow Rate

kg/h

liquid l/h

68.6 234

77.7 265

Min Heat Output - Low Fire

54.6 186

63.7 217

9.24

1.86

4.53

7.91

2.16

5.29

11.209.87

2.32

5.66

2.63

6.42

9.2

3.75

9.17

13.2 14.1 16.0

3.09 3.32

7.55 8.09

9.0 9.5 9.0

18.3 19.4 18.3

11.3

6.5

2.65

18.7

8.96 10.43 11.20 12.67

4.55 5.31 5.69 6.45

2.46 2.86 3.07 3.48

12.5 13.4 12.4 12.7

12.8 14.9 16.0 18.1

6.5 7.58 8.13 9.21

3.51 4.09 4.39 4.97

25.6 27.3 25.3 25.9

7.74

273.4

6.64

234.6

9.40

332.0293.2

8.30

4.9 5.04.54.6

335.1 391 419 474

9.49 11.06 11.86 13.43

279.3 316.4

10.0 9.3 9.2 10.2

6.30 7.4 7.9 9.0

3.23 2.9 3.0 3.1

319 371 398 451

9.0 10.5 11.3 12.8

6.6 6.0 6.2 6.3

121

457

134

115

119

90 100

289

84.7

320

93.8

379

111

413

111

256

74.9

284

83.3

334

365

107

406

239

265

77.7

311

341

100

379

293

324

227

66.5

266

LPG Gas Propane (G31) Data - Inlet Pressure 37 mbar (Alternative where permitted 50 mbar) Minimum 25 mbar Maximum 57.5 mbar

LPG Butane (G30) Data - Inlet Pressure 29 mbar Min 20 mbar Max 35 mbar

205

60.2

50 45 85

222.5 259.6

*Combination Fan/Limit Thermostat Settings

Min Gas Flow Rate

Max Gas Flow Rate

Natural Gas (G20) Data - Inlet Pressure 20 mbar Min 17 mbar Max 25 mbar

Natural Gas (G25) Data - Inlet Pressure 25 mbar Min 20 mbar Max 30 mbar

70 75

Page 14

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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

250

200

150

100

2.4 2.6 2.8 3.0 3.2

3.4

2.2

400

Air Flow m3/sec

95 mm motor pulley x 180 mm fan pulley 100 mm motor pulley x 200 mm fan pulley

Static Pressure Pa

350

300

250

200

150

100

3.0 3.2 3.4 3.6 3.8

4.0

2.8

400

Air Flow m3/sec 118 mm Pulley 112 mm Pulley

Static Pressure Pa

Page 15

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 Handling

All DualAir

units have steel channel sections at the base to be used to support the equipment. Three steel sections are also provided across the top of the unit for support. The DualAir

unit may be

suspended from these top sections. The DualAir

unit is heavy and proper handling

equipment must be used by trained engineers.

5.3 Shelf Mounting and Suspension

For typical suspension See Page 9, Figure 3.

Figure 3: Suspension Methods

WARNING

Crush Hazard

Use 12 mm steel drop rod minimum.

Failure of the supports can result in death, injury or property damage.

12 mm

Steel

Drop Rod

Nut

Washers

Nut

Locknut

Rolled Steel

Channel

Floor

Base

Page 16

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

SECTION 6: FLUE INSTALLATION

6.1 Flue Installation

The flue must terminate outside of the building. Flues and air intakes must be fully sealed and correctly sized for the model. Flues should be assembled as detailed on Page 10, Figure 4 through Page 12, Figure 8. The joints between the flue terminal and the roof or wall must be sealed. If the flue passes through a wall or ceiling of combustible material it must be enclosed by a sleeve of noncombustible material and be separated from the sleeve by at least a 25 mm air gap.

Flues and air intakes must be adequately supported so that the DualAir

unit does not

bear the weight of the pipes.

For flue termination See Page 10, Figure 4 through Page 12, Figure 8.

6.2 Type C

, C32 & C62 Appliance

Room Sealed. The heaters are designed to be installed as room

sealed appliances. The flue and air intake are run as separate pipes to the concentric wall or roof terminal. See Page 12, Figure 8.

6.3 Type B

Appliance

The flue must terminate outside the building and be fitted with a low resistance terminal.

See Page 10, Figure 4 through Page 12, Figure 7.

6.3.1 Air Intake Terminal Cover

For Type B

appliance installations, an Air Intake Terminal Cover is an available option. The cover is scored flat sheet metal that must be bent into shape. See Page 12, Figure 7. Remove and retain the screws for the Air Inlet spigot. Use these screws to attach the cover in position over the spigot.

Figure 4: Flue and Roof Detail

6.4 Converting from Top to Side Terminations for Flue and Air Intake.

1. Remove the control section lower door and upper panel. See Page 11, Figure 5 through Figure 6 for details.

6.4.1 Flue Conversion

1. Remove the inner and outer flue spigots from the top. Retain the spigot and internal seal.

2. Disassemble the flue back to spigot "A". See Page 11, Figure 6. Ensure all seals are still in place.

3. Fit 90° bend directly into spigot "A" pointing forwards.

4. Cut a 90 mm length from the 360 mm flue that was removed.

5. Attach this piece to the 90° bend, then attach the inner spigot that was removed.

6.4.2 Air Intake Conversion

1. Remove the flexible hose from the air intake spigot.

2. Remove the spigot from the top.

3. Move the blanking plate from the upper panel (previously removed) to the top to cover the original flue and air intake holes.

4. Refit the upper panel feeding the air intake flexible hose through the upper hole and aligning the flue with the lower hole.

WARNING

Fire Hazard

Some objects will catch fire or explode when placed close to the heater section.

Keep all flammable objects, liquids and vapours the required distance away from the heater section.

Failure to follow these instructions can result in death, injury or property damage.

Roof

Flue

Terminal

Metal Sleeve

Masterflash

soaker flashing

or Rain Collar.

Flue

25mm Air Gap to

Combustible Material

Page 17

SECTION 6: FLUE INSTALLATION

5. Refit the air intake spigot to the flexible hose reusing 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 reusing the original screws.

7. Refit the lower door.

Figure 5: Control Section & Upper Panel

Figure 6: Alternate

Upper Panel

Lower Door

Blanking Plate

Hose Clamp

360 mm Lenght of 130 mm dia Flue

Flexible Hose

Inner and Outer Flue Spigots

Air Intake Spigot

Control Section

Spigot "A"

90° Bend

90mm Flue

Inner Spigot

Hose Clamp

Flexible Hose

Upper Panel

Outer Spigots

Page 18

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

Figure 7: Vertical and Horizontal Flue Termination - Type B

Appliance

Figure 8: Vertical and Horizontal Flue Termination - Type C

12 C32

& C62 Appliances

Flue

Masterflash

Roof Terminal

Metal Sleeve

(25 mm air gap to

combustible material)

Air Intake

Terminal Cover

Fold leg

down

Fold foot

out

Flue

Roof Terminal

Air Intake

Manifold

Masterflash

Page 19

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 Installation

Ensure adequate air supply at all times for both combustion and heating requirements in accordance with local and national codes. The air supply to the heater must be fitted with a low resistance terminal to prevent the ingress of debris. See Page 12, Figure 7.

7.2.1 Heaters Installed Within the Heated Space

Where the volume of the heated space is greater than 4.7 m

per kilowatt of total rated heat input and the air change rate is at least 0.5/h, additional high and low level ventilation will not be required.

For a building having an air change rate less than

0.5/h, ventilation will be necessary in accordance with local and national codes. Ventilation direct to outside must be provided as follows:

• Heaters above 70 kW heat input = 350 cm

2.5 cm

per kW of rated heat input above 70 kW

7.3 Building Ventilation

Where ventilation is required air must be taken from an outside point where it is not likely to be contaminated or obstructed.

Where natural ventilation is used, suitable ventilation with outside air at low level must be provided in accordance with Section 7.2.1 and local and national codes.

Where mechanical ventilation is used, extract rate must be 5% - 10% less than the inlet rate. The mechanical ventilation must be interlocked with the burner on the heater.

7.4 Isolated Equipment Rooms

Ventilation must prevent the isolated equipment room temperature from exceeding 32°C as well as prevent any negative air pressure within the room. See Page 13, Figure 9. Any isolated equipment room containing air heaters will require permanent air vents direct to outside air in compliance with local codes.

Where natural ventilation is used, suitable permanent openings at low and high level, communicating directly with the outside air, must be provided.

Where mechanical ventilation is used, extract rate must be 5% - 10% less than the inlet rate. The mechanical ventilation must be interlocked with the burner on the heater.

Figure 9: DualAir

Units Installed in Isolated Equipment Rooms.

Wall

Outside

Wall

High level ventilation

Low level

ventilation

Max Temperature 32° C Room air pressure must not be negative.

Duct distribution system or discharge to heated space.

Return air duct from heated space or fresh air from outside

Flue

Air Intake

Manifold

Page 20

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 attenuators are used to reduce duct born noises. It is recommended that the inlet ducting is arranged

with both fresh air and recirculating air dampers to take advantage of the "free cooling" stage provided.

Distribution ducting must be insulated to prevent heat gain during cooling mode.

The air flow must be in the direction as stated for the version being installed with the heater at the discharge end.

The duct must be designed as described on Page 14, Section 8.1 and Figure 10 to ensure that there is a homogenous air flow across the whole heat exchanger. Failure to provide a properly distributed air flow will reduce the life of the heat exchanger.

Contact Roberts-Gordon Europe Ltd. Design Department for recommendations regarding duct resistance and design. Tel: +44 (0) 1902 494425

Figure 10: Ducting

Dimension

X

*Minimum-

Twice

Dimension

X

Airflow Indicator

Flexible Flange

Ducting

NOTE: Duct size will be full size of inlet and outlet. All joints between the heater and duct work should be made as air tight as possible. *Inlet Duct Minimum Dimension same as Outlet Duct Minimum Dimension

Page 21

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, to ensure that the meter is adequate for the rate of gas supply required. Installation pipes must be fitted in accordance with local and national codes. Pipe work from the meter to the heater(s) must be of adequate size.

9.1 Connections

Connect the heater to the gas supply ensuring that the final connections are as follows:

• The gas supply pipe is adequately sized to carry the total volume of gas for the complete installation.

• An isolating valve and union connection should be used and fitted into the supply adjacent to the heater.

• For suspended heaters use an approved metal flexible connection between the isolating valve and the heater. To reduce pressure loss, use

one pipe size larger than the heater gas connection.

IMPORTANT - the complete installation must be purged and tested for gas soundness in accordance with local and national codes.

Figure 11: Gas Connection with Stainless Steel Flex Connector

WARNING

Fire Hazard

Connect gas supply according to Figure 11.

Gas can leak if not installed properly.

Failure to follow these instructions can result in death, injury or property damage.

Gas Isolating Valve

Cap

Union

Connection

Option B:

Medium or Heavy Guage Tubing Gas Connection

Option A:

Stainless Steel Flex Gas Connector

Drip Leg

Hold gas nipple securely

with pipe wrench when attaching the flex gas connector.

Do not twist flexible

gas connector.

Ensure all joints are

gas tight.

Do not bend flexible gas connector sharply.

Page 22

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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,L2

, L3, N & Earth.

Polarity "L

& N" must be correct. The voltage between neutral and earth should be 0 and never exceed 15 volts.

All heaters and controls must be correctly earthed. All external wiring must comply with the relevant

local codes. Wire specification H05VV-F. External controls must have a constant 230 V 50 Hz

1 Ø supply.

An isolator with a contact separation of at least 3 mm on all poles must be installed adjacent to, but not attached to the DualAir

unit to disconnect all

supplies to the heater and any remote control.

The final connection to the heater should be made by flexible cable or conduit to the main terminal block in the control section using 1 mm

cable on all

models.

All cables entering through the top of the heater should be routed via the metal shield to prevent inadvertent contact with the flue.

Models .................Fuse Size

DAT 75 & 90...............5 A

DAT 100 & 115 ...........10 A

10.2 Remote Control

Roberts Gordon market a dedicated DualAir

control that will operate all the available features of the unit. The DualAir

unit requires a 230 V remote control to provide a time control and Multistage heating/ cooling temperature control. See Page 20, Section

10.6.

To operate the modulating gas burner a further input of 0-10 V DC is required with 0V giving minimum fire and a 10V giving full fire, wired in screened cable (Belden 8451 or equivalent).

10.2.1 Remote Frost Thermostat

When required, connect to terminals 2 and 3 in the main terminal block.

Locate within the heated space adjacent to the most vulnerable equipment that requires protection.

See Page 17, Section 10.3 through Page 18, Section

10.4.

10.2.2 Remote Fan Controls

The fan will operate automatically. A switch or control wired between terminals 2 & 1 in

the terminal block will allow external control of the fan(s).

The fan may be operated continuously from an external control, with the burner/cooling cycling on and off.

WARNING

Electrical Shock Hazard

Disconnect electrical power before servicing.

Failure to follow these instructions can result in death or electrical shock.

Page 23

SECTION 10: WIRING AND ELECTRICAL INFORMATION

10.3 DAT Main Circuit Board Terminal Identification

Termina l

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

2 Output 230 V to external control

230 V 50 Hz supply of external

thermostat or control

3 Input Burner On

Burner Fires.

R1 energizes with gas valve

Burner Operates.

Fan Operates via R1

4 Output 230 V Burner ON Signal

Optional Remote Indication of

Burner ON.

5 Output

Neutral for Signals & External Control

7 Output 230 V Burner Lockout Signal

Optional Remote Indication of

Burner Lockout

8 Input

Burner Lockout Reset from N

(5)

Optional Remote Burner Lock-

out Reset (must be from N)

9 & 10

Volt Free Safety Circuits for

External Condensers

Site Wiring to Condensers Normally Closed Controls

Break on Fault Position

DualAir

units contains Coil

Frost Thermostat, Coil Pres-

sure Switch & Auxiliary Contact

on Contactor

11 Input

230 V 1st Stage of Cooling

(Free Cooling)

R2 On

Burner OFF

Fan ON from R2

Dampers Output to T16

12 Input

230 V 2nd Stage of Cooling

Cooling Coil Stage 1

R2 OFF

R3 ON

Burner OFF

Fan ON from R3

Dampers Output to T15

Output to Condenser 1 at T17

& 18

13 Input

230 V 3rd Stage of Cooling

Cooling Coil Stage 2

R3 ON R4 ON

All input 12 Operations

Output to Condenser 2 at T19

& 20

14, 15 & 16 Output

230 V Output for Optional

Damper

From R2

14 = Neutral

15 = Recirculated Air

16 = Fresh Air

17 & 18

Volt Free Control Circuit

Condenser 1

R3 ON Normally Open Contact

for Condenser 1

19 & 20

Volt Free Control Circuit

Condenser 2

R3 ON R4 ON

Normally Open Contact

for Condenser 2

21 & 22 Output

230 V Output to

Remote Dirty Filter Warning

21 = L

22 = N

23 & 24

Volt Free Output to

Remote Dirty Filter Warning

Alternative Dirty Filter Indication for BMS or DualAir

Con-

trol

Normally Open Contact

for Dirty Filter Indication

25 & 26 Input

0 - 10 V DC Input for

Modulating Burner

T3 Must Be Live to Operate

Burner

0 V = Minimum Fire

10 V = Maximum Fire

Page 24

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

10.4 DAT Wiring Diagram Models 75-115

S 4563 C Honeywell

COMBUSTION FAN

PRESSURE SWITCH

BLUE

Secondary Limit

Thermostat N/C

PINK

GREY

PURPLE

RESET

PUSH

LOCKOUT

RUN

GREEN/YELLOW

BLACK

WHITE

YELLOW

GREEN/YELLOW

BROWN

BLUE

BROWN

BLUE

MAINS FILTER

BLACK

SENSE

IGNITION

BLACK

BROWN

BLUE

LIMIT

FAN

BROWN

SITE WIRING

N L 1 2 3 7 8

RED

Grey

Pink

Red

Black

White

Brown

Blue

NC\P(2)

Pressure Switch

Detail

NO\P(3)

C \P(1)

BLACK

YELLOW

WHITE

Yellow

Continued on Next Page

NOTE:

For external fan wiring, See Page 20, Section 10.6.

If any of the original wire supplied with the heater must be replaced, it must be replaced with wiring material having a temperature rating of at least 105° C and 600 volts.

Page 25

SECTION 10: WIRING AND ELECTRICAL INFORMATION

10.5 DAT Wiring Diagram Models 75-115

R1 230 V

motor

fan

main

R1/1

Condensor control circuit

limit devices

Aux contact

overload &

Fuse 5A

contactor

14 13

Relay

Remote fan controls 230 V

This appliance

must be Earthed

400 V 50 Hz 3 N Suppy

Heating Stage 230 V

230 V output to controls

Heat ON 230 V

Heat ON (Green)

Lockout (Red)

Dirty filter warning (Amber)

Coil

3 1 3

Burner

Coil Safety

Filter pressure Sw

Green

Pressure Switch

Filter

Limit

Heat On

Neutral

Common

Red

Reset

Lock Out

R2/1

R2 230 V

R3/1

R3/3

Damper supply 230 V

Remote Lockout reset 230 V

1st stage cool (free cool)

Dirty filter warning 230 V

Recirc' air

Fresh air

cooling condenser

Honeywell Modureg Valve 0-28 V DC

Burner Modulation control

0 - 10 V DC signal

System ground

282726

Control inputs 230 V

Press

Coil

Frost

Stat

Warning lamps (230 V)

Heater Supply

Orange

Brown-white

Red-white

White

Black

Brown

Blue

Violet

Yellow

Pink

Grey

R5 230 V

R5/1

Grey

Blue

Pink

Lock Out

Red

Violet

R2/2

R3/2

Lockout 230 V

R3 230 V

R4 230 V

R4/1

2nd stage cool 3rd stage cool

1st stage

2nd stage

cooling condenser

Site wiring connections shown

Volt free dirty filter signal

Grey

Black

White

Brown

Blue

Yellow

Red

Page 26

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

10.6 DAT Site Connections at Main Circuit Board

cooling condenser

Lockout Warning 230 V

Remote Lockout Reset

Heat ON

MUST be

This appliance

3 N Suppy

400 V 50 Hz

Earthed

Indication 230 V

1st stage cooling condenser

Damper Supply

Recirc' air

Fresh air

2nd stage

Dirty Filter Warning 230 V

System Ground

Optional Frost Thermostat 230 V

Time Switch Control 230 V

Optional External Fan Control 230 V

Screen

Volt Free Dirty Filter Warning

Volt Free Condenser Control Circuit Safety Devices

Heating Stage for ON/OFF and Burner Modulation

MultiStage Temperature Control (or similar)

Cooling Stage 1 (free cooling when fresh air is connected and dampers fitted)

Cooling Stage 2 (1st stage cooling coil)

Cooling Stage 3 (2nd stage cooling coil)

Burner Modulating Signal

0 - 10 DC 0 V = Minimum Fire

Screened Cable Belden 8451 (or equivalent) Earthed at one end

Volt Free Condenser Control Circuits

Page 27

SECTION 11: COMMISSIONING

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, commissioning, operation, or service of this equipment. All components are accessed via the hinged door. Opening the door exposes live electrical connections and hot components.

Cooling Coils/Condensers

Installation, service, commissioning and annual inspection of the cooling equipment must be done by a contractor qualified in the installation and service of refrigeration equipment. Read condenser manufacturers manual carefully before installation, commissioning, operation, or service of this equipment.

11.1 Pre Commission Checks All pre commission checks must be carried out

before lighting the heater.

Ensure that the heater and all controls are suitable for the gas, pressure and electrical supply to which they are to be connected.

11.1.1 Louvers

Where fitted, the air delivery louvers need to be set during commissioning to give the required air distribution.

11.1.2 Electrical Checks

1. Check that all site wiring is connected in accordance with the appropriate wiring diagrams on Page 17, Section 10.3 through Page 20, Section 10.6.

2. Check the correct fuse size is fitted; See Page 16, Section 10.1.

11.2 Gas Supply

All aspects of the gas installation including the gas meter must be inspected, tested for soundness and purged in accordance with local and national codes.

11.3 Mechanical Checks

1. Check that the fan is free to run and that the fan rotates in the correct direction. To reverse rotation transpose two of the incoming phase connections.

2. Check that the flue and air intake are installed in accordance with these instructions and local regulations.

3. Check that the settings of the Combination Fan/ Limit thermostat are correct - See Page 7, Sec- tion 4.3 and Page 8, Figure 4.4.

NOTE: The second limit thermostat is preset and sealed at the factory and is not adjustable.

11.4 Begin Commissioning

11.4.1 Before Operating the Heater

To ensure that all the controls are in safe working order, operate the heater for the first time with the isolating gas valve turned off.

1. Turn off the isolating gas valve

2. Using the installed external control, turn on the burner. The automatic sequence will now begin as described on Page 22, Figure 12.

There will be no ignition of the burner and lockout will occur, proving the controls are operating correctly.

WARNING

Electrical Shock Hazard

Use extreme caution while commissioning.

Failure to follow these instructions can result in death or electrical shock.

WARNING

Cut Hazard

Turn off gas and electrical supply before maintenance.

Fan can start automatically at any time.

Failure to follow these instructions can result in severe injury or product damage.

Page 28

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 DOWNRUNSTART

Signals Output By Control

Required Incoming Signals

Flue Fan

Pressure Switch

30 Sec. Purge*

*Purge time begins at pressure switch change over. ts=Safety time S4563C 3 seconds (alternate 5 seconds) S4565C 5 seconds

If at any stage the flame fails, the control will go to "lockout". The red light will illuminate and the control must be manually reset before further start attempt.

Inlet Pressure

Gas Outlet

Outlet Pressure

Plug for

Main Gas Valve

Gas Inlet

Plug for

Main Gas Valve

Max Pressure Adjustment

Min Pressure Adjustment

6.3mm AMP

Terminals for

Modulation

Modureg Modulating Regulator

Honeywell Gas Valve

Moving Shaft

Page 29

SECTION 11: COMMISSIONING

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 for maximum and minimum firing and is set using the two adjustments. See Page 22, Figure 13.

The external control will operate the burner between these two limits depending on heat demand.

The minimum set point must not be set lower than the minimum burner pressure stated on Page 6, Section 4.2.

11.4.3 Commissioning the Gas Valve

There are two stages to commissioning the modulation equipment.

The minimum pressure setting must be adjusted first, any adjustment of the minimum pressure setting will affect the maximum pressure setting.

For ON/OFF non-modulating operation set the minimum firing rate to be the maximum burner pressure as on Page 6, Section 4.2

11.4.3.1 Set Minimum Pressure

1. Disconnect the leads from the coil of the Modureg regulator.

2. Connect a suitable manometer to the burner pressure test point of the main gas valve.

3. Turn on any external controls and allow the burner to fire for at least five minutes.

4. Remove cap and using a suitable 9mm spanner adjust the burner minimum set pressure to the value shown on Page 6, Section 4.2.

11.4.3.2 Set Maximum Pressure (Not Required for ON/OFF burners)

1. Press in the moving shaft of the Modureg valve and hold in this position while adjusting the burner maximum pressure to the value shown on Page 6, Section 4.2. For adjustments See Page 22, Figure 13. NOTE: If the correct burner pressure cannot be reached, then check the inlet pressure to the valve, with the burner firing. See Page 6, Sec- tion 4.2 for inlet pressure requirements.

Do not continue to adjust the regulator if the pressure is not changing.

If the inlet pressure is too low to allow a correct burner pressure setting, then the gas inlet pressure must be corrected before completing the commission.

2. Release the moving shaft and observe that the burner pressure returns to the minimum setting.

3. Turn off the external controls and reconnect the electrical leads to the Modureg regulator.

4. Turn on the external controls and allow the burner to fire once again observing the burner pressure.

5. Using the temperature set point device of the installed control system, set for maximum burner firing and observe that the burner pressure slowly rises to the maximum as set.

6. Reset the temperature set point by small steps until the burner pressure slowly drops to the minimum pressure set. Repeat Step 5 and observe that the maximum set point is again achieved.

Check Gas Rate

1. After burner pressure adjustment, allow the heater to operate for at least 15 minutes and then re-check settings.

2. Remove the manometer and refit all covers to the valve and tighten the screw of the outlet pressure tap.

3. Check gas flow rate at gas meter.

11.5 Combustion Testing (all models)

The only adjustment to alter combustion performance is burner pressure. Combustion quality must be tested to prove correct heater operation. Incorrect results will indicate faults with the installation or appliance.

Combustion testing must be carried out at full fire with all covers in place. The flue gas is sampled in the flue, within 1 meter of the heater. The values of CO

should be between 6.5% to 8.0% for natural gas and 7.0% to 9.1% for LPG dependant upon model.

The CO will be up to 80 ppm (0.008%) dry, air free dependant upon model. Temperature rise of the flue gases above ambient should be approximately 160° C to 180° C. Seal test hole in flue after testing.

Following the above operate the heater for 30 minutes at the minimum firing rate. Following this time the temperature of the products of combustion in the flue should be measured. If the flue products temperature is below 80° C then the minimum firing rate should be increased. Continuous operation of the burner with flue gas temperature of below 80° C will cause condensation to form in the heat exchanger and flue system. This will cause nuisance water collection and a shortened heat exchanger life.

Page 30

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

Pressure Switch

The pressure switch is factory pre-set for each model and is not adjustable.

11.6 Turning Off the DualAir

Unit

Set the external controls to the off position and the main burner will stop.

The fans will run until they are stopped automatically by the fan thermostat.

Do not use Electrical Isolator for control of heater. Electrical Isolator will switch off the fan. Heat exchanger could be damaged. Warranty will not cover damage to the heat exchanger if operated improperly.

11.7 External Controls

External Controls may include time switch, room thermostat and frost thermostat. Operate each control to ensure that they function correctly. Set the time switch (if fitted) and room thermostat to the users’ requirements. Operate the external controls and ensure that the installed cooling stages operate correctly as described on Page 17, Section 10.3.

11.8 Complete the Commissioning

Ensure that all covers are fitted correctly and all test points are properly sealed.

11.9 Instruction to the User

Explain the controls of the DualAir

unit to the user including how to turn it on and off, using the controls fitted on site.

Give this manual to the user. Ensure that the user is shown and understands the

importance of maintaining clearances to combustibles and the user instructions on Page 25, Section 12 through Page 26, Section 12.6 and all warnings defined in this manual.

Page 31

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 12.3.3

Limit thermostat

reset...........................See Page 25, Section 12.3.1

Second limit thermostat

reset button ..............See Page 25, Section 12.3.2

12.2 Heater Operation

When the heater has been switched on by the remote controls installed, the main burner will automatically turn on. The burner control box will control the ignition of the flame. All heaters require a constant gas and electricity supply which must not be interrupted during the normal operation of this heater.

12.2.1 Warning Lights

The DualAir

unit has three warning lights; GREEN = Heater ON, burner attempting to fire RED = Burner LOCKOUT, see Section 12.3.3. AMBER = Dirty Filter, replace filter, air flow is dropping to an unacceptably low value.

Figure 14: Heater Operating Sequence

12.3 Common User Controls (all models)

12.3.1 Combination Fan/Limit Thermostat

The Combination Fan/Limit Thermostat is located inside the access door at the top of the heater. See Page 37, Section 16.3.

This control ensures the heater does not blow cold air in the normal heating cycle and protects the heat exchanger against overheating.

Figure 15: Fan/Limit Thermostat

12.3.2 Secondary Limit Thermostat

WARNING

Electrical Shock Hazard

Disconnect electrical power before servicing.

Failure to follow these instructions can result in death or electrical shock.

RUN ON

CLOSE DOWN

THERMOSTAT

CALL FOR

HEAT

BURNER

RUN

FAN

White fan button

Pull out for normal operation.

Press in for constant fan.

Red limit reset button

(Press to reset)

The combination fan/limit thermostat is preset during commissioning.

See Page 7, Section 4.3 and Page 8, Figure 4.4. NOTE: To reset, the heat exchanger must be cool.

If the air flow is reduced due to power failure the limit thermostat will cause the burner to lockout.

Description Part Number

Combination Fan/Limit Thermostat K017A

Press to reset

These are hand reset devices to give further protection against fan failure.

NOTE: To reset, the heat exchanger must be cool.

Description Part Number

CTUA 40 & 50; CTUB 50 & 60 90412101 All Other Models 90412100

WARNING

Explosion Hazard

If control locks out, do not make more than 3 attempts to restart the heater.

Dangerous gas mixtures can build up.

The fault must be traced and repaired by a registered installer or service engineer.

Failure to follow these instructions can result in death, injury or property damage.

Page 32

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 remote reset if installed on site.

12.4 Cooling Section Operation

The temperature control will bring on the fan to operate the DualAir

unit in cooling mode dependant on the current temperature and set point. Once the temperature rises above the set point there are three stages of cooling available dependant on site installation.

Cooling Stage 1 (optional free cooling). The fan runs and change over dampers (if fitted) allow fresh air to be drawn from outside.

If the temperature continues to rise then Cooling Stage 2 operates. The fan runs, the dampers (if fitted) return to recirculating air and the first condenser operates to provide cooling at half load. Should the temperature continue to rise, Cooling Stage 3 operates. The fan runs, the dampers (if fitted) remain in recirculating air and the second condenser operates to provide cooling at full load.

12.4.1 Filters

Air cleaning filters are fitted to the DualAir

unit to protect the cooling coil and provide improved environmental conditions.

The filters will require to be replaced at least three time per year and in dirty environments cleaning of the filters may be required at more frequent intervals.

When the filters are dirty the warning light will show see Page 25, Section 12.2.1. The filters must be cleaned or replaced immediately.

Do not operate the DualAir

unit without filters as the cooling coil may become blocked and impossible to clean.

12.5 Heating Section Lighting Instructions

12.5.1 To Turn On Heater

1. Ensure that the electrical and gas supplies to the heater are on. Check that the on site controls are “ON”.

NOTE: The thermostat setting must be above the ambient temperature for the heater to operate.

2. The green light will be on and the automatic firing sequence will begin as described on Page 22, Figure 12. The heater will now operate automatically under the control of the on site controls. Following long shut down periods, the control may go to lockout. See Page 26, Sec- tion 12.3.3.

12.5.2 To Turn the Heater Off

Set the installed remote controls to “OFF”. The burner will turn off immediately.

The fan will continue to run for a few minutes. To restart turn the control used above to “ON”.

12.6 Simple Fault Finding (all models)

Possible reasons for the heater not operating are:

1. Gas supply not turned ON.

2. Electricity supply not turned ON.

3. The time and/or temperature controls are not “ON”.

4. One or both of the Limit Thermostats may have operated. This may be caused by an interruption of the electrical supply or failure of the distribution fan.

If the Limit Thermostats persistently operate, there is a fault which must be investigated by a contractor qualified in the installation and service of gas-fired heating equipment.

12.6.1 Simple Fault Finding (burner faults)

If the burner fails to ignite for any reason, it will go to lockout. This will be indicated by the red light on the heater or at the remote indicator (if fitted).

1. Press in and release the lockout reset button. If a remote reset is not fitted a reset button is on the side panel of the heater. See Page 5, Sec- tion 4.1.

WARNING

FOR YOUR SAFETY

If you smell gas:

1. Open windows.

2. DO NOT try to light any appliance.

3. DO NOT use electrical switches.

4. DO NOT use any telephone in your building.

5. Leave the building.

6. Immediately call your local gas supplier after leaving the building. Follow the gas suppliers instructions.

7. If you cannot reach your gas supplier, call the Fire Department.

Fire Hazard

Do not store or use petrol or other flammable vapours and liquids in the vicinity of this or any other appliance.

Some objects will catch fire or explode when placed close to heater.

Failure to follow these instructions can result in death, injury or property damage.

Page 33

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 Annual Inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment.

NOTE 1: After any maintenance or repair work always test fire the heater in accordance with the commissioning instructions on Page 21, Section 11 through Page 24, Section 11.9 to ensure all safety systems are in working order before leaving the heater to operate. Minor faults may be traced by using the troubleshooting charts on Page 30, Section 15 through Page 33, Section 15.5.

NOTE 2: Check all gas pipes and pipe joints to ensure there are no cracks or gas leaks.

NOTE 3: Inspect all suspended components and hardware. Insure that they are in good condition, properly tightened, and corrosion free.

13.1.1 Cooling Equipment

The cooling coil does not require maintenance except that during filter replacement it is recommended to clean the surface of the coil with a soft brush and vacuum cleaner. Carry out any maintenance recommended by the condenser manufacturer.

13.1.2 Filters

The air filters should be inspected regularly to ensure that no excessive build up of deposit is being experienced. If heavy deposit is being formed, then the filters may be cleaned using a vacuum cleaner. Filters should be replaced at least every four months to ensure that adequate air flow.

The cooling equipment will automatically turn off should the air flow drop to a preset low value even though the fan will still run. The maximum resistance across a dirty filter should be no more than 150 Pa (1.5 mbar) and the dirty filter warning light will be on. A resistance higher than this indicates that the filters must be replaced.

13.2 Burner Maintenance

1. Open the hinged door and remove the burner compartment cover. See Page 36, Section

16.2.

2. Clean any deposits from the main burner which may have formed in the injectors or venturi of the burner. See Page 36, Section 16.2.

3. Remove the ignition electrode and flame probe. Check condition of ignition electrode and flame probe. Clean off any deposits which may have been formed, check condition of ceramic insulators. Replace as necessary.

13.3 Fan/Motor Assembly Maintenance

The main fan bearings are permanently sealed and do not need lubrication. Before cleaning, turn off gas and electrical supply. Remove the fan compartment covers and use a small brush or duster to clean the fan blades from each side. Replace fan(s) when done.

Figure 16: Belt Tension

Check the condition and tension of the drive belts. The condition is best inspected with the belts removed. Check for chaffing or lateral cracks. Replace belts as a matched pair as necessary. Do not over-tighten belts, as this may cause bearing damage.

13.4 Heat Exchanger Maintenance

The heat exchanger will remain clean unless a problem has developed with combustion. Inspect the heat exchanger. Look for signs of overheating at the front tubes which may indicate burner over firing or persistently low air flows.

WARNING

Cut Hazard

Turn off gas and electrical supply before maintenance.

Fan can start automatically at any time.

Failure to follow these instructions can result in severe injury or product damage.

Motor

Pulley

Fan

Pulley

8 mm to 10 mm

Page 34

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 on site. Replace faulty gas valves with genuine

ROBERTS GORDON

replacement parts.

13.6 Flue Fan

The flue fan should not require maintenance. However, If the air pressure switch is causing burner lockout then remove the flue fan from the vent box. See Page 38, Section 16.4. Ensure that the fan is free to run and that the fan wheel is clean.

Page 35

SECTION 14: CONVERSION BETWEEN GASES

14.1 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 of the burner assembly from one gas to the other is the same for all types of heaters.

1. Remove the burner compartment cover as shown on Page 36, Section 16.2.

2. Remove the connection between the gas valve outlet and the manifold. See Page 35, Section

16.1 for gas valve removal.

3. Remove the manifold from the burner assembly by removing the screws at the top and bottom. See Page 36, Section 16.2.1.

4. Remove the main burner injectors.

5. Replace with the injectors for the new gas ensuring a gas tight seal.

6. Refit all components in reverse order.

14.3 Gas Valves

All gas valves used on the DualAir

units have pressure regulators that may be set to operate on Natural gas or LPG.

Conversion is carried out by re-setting the burner pressure to the value in the data table during commissioning. See Page 7, Section 4.3.

Ensure that the gas inlet pressure to the heater is correct for the new gas, and that the gas supply has been purged of the old gas.

Page 36

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 your gas supplier.

Failure to follow these instructions can result in death, injury or property damage.

If problems persist, contact

ROBERTS GORDON

Tel: +44 (0)1902 498733

or www.rg-inc.com

Heater Operating

TROUBLESHOOT ENDS.

Adjust or replace

as necessary.

Is combination fan/limit

thermostat set correctly?

See sections 5.3 &11.3.

Use 15.2 to test burner.

Replace combination

fan/limit thermostat.

See sections 5.3 & 11.3 to

check combination

fan/limit thermostat settings.

Does the fan run?

Has burner Locked Out?

Yes

With external controls on,

does the burner continue

through the heating cycle?

Ye s

Press the white button on

the combination fan/limit

thermostat. Does the

fan run now?

Yes

Does the fan run?

Use 15.5 to test fan.

Ye s

Yes

Use 15.2 to test burner.

Is Red lockout

warning light on?

Yes

Turn on supplies.

Are gas & electrical

supplies on?

Ye s

Start

Ye s

For your safety and optimum heater performance use only ROBERTS GORDON® replacement parts.

Conduct Commissioning procedure as shown on Page 21, Section 11

Page 37

SECTION 15: TROUBLESHOOTING

15.2 Troubleshooting For Automatic Ignition Burner Systems

If problems persist, contact

ROBERTS GORDON

Tel: +44 (0) 1902 498733

or www.rg-inc.com

Heater Operating

TROUBLESHOOT ENDS.

Trace fault in supervision

system. See Section 16.3.

Ye s

Is red lockout light on?

Is the flame current at

least 1 µAmp DC when

the flame lights?

Ignition control faulty

replace.

See Section 15.6.

Is HT lead okay and

connected?

Is spark electrode okay?

Ye s

Replace valve.

Is the gas valve operating?

To test valve,

see Section 15.4.

Does the flame light?

Ye s

Wait 30 - 40 seconds.

Is ignition spark operating?

Ye s

Flue fan faulty replace

Burner control faulty or plug in connections faulty. Repair

or replace as necessary

Check for too much flue/air inlet

duct. Check for blockage in

combustion air circuit.

Check for faulty air pressure

switch. See section 16.5.

Does air pressure switch

change over?

Yes

Have limit thermostats

operated or light faulty?

Reset or replace as

necessary.

Is 230v supply at fan

connections?

Does flue fan run?

Are external controls on?

Yes

Ye s

Is the green light on?

Yes

Is red lockout light on?

Yes

Press in lockout reset button

on rear of heater or remote

reset button if fitted.

Turn on supplies.

Are gas & electrical

supplies on?

Yes

Start

Ye s

WARNING

Electrical Shock Hazard

Do not touch ignition components.

Voltage from ignition components is high.

Failure to follow these instructions can result in death or electrical shock.

There are two burner controls used. Honeywell S4563C and S4565C. They both have similar operating sequences. To measure flame current, connect a 0 - 50 μA DC meter in series with the flame probe. If the meter reads negative values, then reverse the test leads.

For your safety and optimum heater performance use only ROBERTS GORDON

replacement parts.

Conduct Commissioning procedure as shown

on Page 21, Section 11

Page 38

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

15.3 Troubleshooting for Flame Supervision System

Repair or replace as

necessary.

If problems persist, contact

ROBERTS GORDON

Tel: +44 (0) 1902 498733

www.combat.co.uk or www.rg-inc.com

Control box faulty.

Replace with correct type.

Use section 15.1 to

trace the fault.

Heater Operating

TROUBLESHOOT ENDS.

Repair or replace as

necessary.

Is inlet burner gas pressure

correct? Is live and neutral

polarity correct? Is

flame probe circuit correct?

Is there a current flowing in

the flame probe circuit with no

flame present?

Yes

Does lockout occur when

there is a flame present?

Yes

Is the connecting lead damaged? Is the flame probe damaged or touching earthed

components?

Is the green light on and

at least 1 µA DC fame

current?

Connect a DC ammeter in

series with the flame probe.

Yes

START

NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC.

Page 39

SECTION 15: TROUBLESHOOTING

15.4 Troubleshooting for Solenoid Valves

15.5 Troubleshooting for Main Fan

Valve faulty.

Replace with one of

correct type.

Fault elsewhere

If problems persist, contact

ROBERTS GORDON

Tel: +44 (0) 1902 498733

or www.rg-inc.com

Valve Operating

TROUBLESHOOT ENDS.

Ye s

Valve faulty.

Replace with one of

correct type.

Does gas pressure at

outlet of valve return to zero or

lower when valve turns off?

Yes

Does gas pressure at outlet

of the valve rise when

valve turns on?

Ye s

Is gas pressure at inlet of the

valve correct for gas type?

Note pressure found.

Yes

START

Is 230v at the valve

terminals at the

appropriate time.

Yes

If problems persist, contact

ROBERTS GORDON

Tel: +44 (0) 1902 498733

or www.rg-inc.com

Fan Operating

TROUBLESHOOT ENDS.

Fan motor or contactor faulty.

Replace with correct type.

Use Section 15.6 to

trace fault.

Combination fan/limit

thermostat faulty.

Replace with correct type.

Is there 230v between

terminals 1 and N of the

main terminal block?

Does fan run when the white

button of combination fan/limit

thermostat is pushed in?

Use Section 5.3 & 11.3 to

check combination fan/limit

thermostat settings. Reset or

replace as necessary.

Fault elsewhere.

Check wiring.

Is Power supply 400 V

between any two phases or

230 V between any Phase and

N at the main terminal block?

Yes

Ye s

START

Yes

Does fan turn on and

off while burner is firing

continously?

Yes

Does fan run

automatically?

Yes

For your safety and optimum heater performance use only ROBERTS GORDON® replacement parts.

Conduct Commissioning procedure as shown on Page 21, Section 11

Page 40

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

15.6 Troubleshooting for Fan Contactor

Replace

combination thermostat.

Wiring faulty or faulty

combination thermostat.

Investigate.

If problems persist, contact

ROBERTS GORDON

Tel: +44 (0) 1902 498733

or www.rg-inc.com

Relay R3 faulty.

Replace.

Does fan run at cooling

stage 2 (T12 live)?

Does fan run at cooling

stage 1 (T11 live)?

Ye s

Replace or tighten belts.

Transpose two incoming

phase connections.

Is fan/motor rotation

correct?

Overload Faulty

Replace.

Are fan belts

loose or broken?

Ye s

Has fuse 1 on the

printed circuit board

blown?

Ye s

Press in overload reset

button and retest.

Fan Operating

TROUBLESHOOT ENDS.

Does fan run when white

button of combination

thermostat is pushed in?

Fault elsewhere

Is power supply 400v at

three phase and N at the

main terminal?

Yes

START

No No

Yes

Does main fan run

automatically

in heating mode?

Is there 230v at contactor

coil terminal A1 and A2?

Does fan motor run with

little or no air flow?

Yes

Is there 230v between

terminals 96 and A1 on

the contactor?

Contactor faulty.

Replace.

Replace fuse and

investigate.

Ye s

Overload operated. Check for

three phases at mains

terminals, loose electrical

terminals and motor overload.

Check filters and

ducting for blockage.

Does fan run

as burner fires?

Ye s

Relay R1 faulty.

Replace.

Ye s

Does main fan run

automatically

in cooling mode?

Relay R2 faulty.

Replace.

Ye s

For your safety and optimum heater performance use only ROBERTS GORDON® replacement parts.

Conduct Commissionin

g p

rocedure as on Page 21, Section 11

Page 41

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 Gas Valve

The VR4605 gas valve is fitted with the V7335A modureg regulator (P/N L512) supplied as a separate component.

When replacing the gas valve the modureg will need to be fitted on site. To fit the modureg, remove the standard regulator by removing the two screws retaining the rubber sealing washer. See Page 35,

Figure 17

Figure 17: Standard Regulator Removal

Fit the modureg ensuring that the rubber seal is in place and the two screws are tight. See Page 35, Section 16.1.1. Once fitted follow commissioning procedure in Section 11.

16.1.1 Gas Valve Replacement - (all models)

16.1.2 Gas Valve Replacement continued- (all models)

Replace in reverse order. Verify that the gas flow direction of the valve is correct. Re-use the "O" ring seal in the outlet flange where fitted. Check that all the joints are leak free. Reset gas valve. See Page 23, Section 11.4.2.

IT IS IMPORTANT THAT ONLY THE CORRECT GAS VALVES SPECIFIED FOR EACH MODEL

TYPE ARE USED WHEN REPLACING THESE CONTROLS.

Remove Standard

Regulator

Sealing Washer

Step 1 Unscrew gas pipe from the

valve inlet.

Step 2

Unscrew valve from the

burner manifold

unscrew the screws for

the inlet and outlet flanges.

Ignition Control

Rubber

Seal

Modureg Modulating

Regulator

Description Part Number

Gas Valve VR4605 90033404 Ignition Control 90434020

Page 42

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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

Rubber Seal

Ignition electrode

The burner compartment is a sealed compartment. Following any work, re-seal the compartment with the gas pipe rubber seal fully in place and all screws fitted and tight.

Remove manifold

screws and pull

out manifold

Manifold

Burners

Injectors

Burner

screws

Burner venturi

Unscrew

Injectors

Manifold

Marking

Ensure gas tight fitting of injectors. Ensure correct alignment with burners. Ensure all pipe joints are gas tight.

75 90 100 115

12 14 15 17

mm dia 2.71 2.71 2.71 2.71

in dia 0.1067 0.1067 0.1067 0.1067

36 36 36 36

91930036 91930036 91930036 91930036

mm dia 1.51 1.51 1.51 1.51

in dia 0.0594 0.0594 0.0594 0.0594

53 53 53 53

91930053 91930053 91930053 91930053

Marking RG P/N

Injector Size

Injector Quantity

LPG Gas Propane (G31) and LPG Gas Butane (G30)

MODEL

Injector Size

Marking RG P/N

Natural Gas (G20) and (G25)

Page 43

SECTION 16: REMOVAL AND REPLACEMENT PARTS

16.3 Ignition Electrode and Flame Probe.

Flame

Probe

Ignition

Electrode

Remove

Screw

Ignition

Electrode

Burners

Flame Probe

Burners

Burner Compartment

Front Views

Remove all

burner compartment

screws to remove

the burner

compartment and

access the

Front View.

Fan/Limit Thermostat

Secondary

Limit

Thermostat

(3 mm)

.120"

spark

gap

Description Part Number

Spark Electrode 90427411 Automatic Ignition Flame Probe 90439300 Burners (all models) 92000000

To replace the Ignition Electrode or Flame probe, remove the electrical lead and screw. Pull out from mounting. Refit in reverse ensuring that the gap to burner is as shown in the Front View of the Burner Compartment.

Page 44

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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

Vent Box

screws

Flue

Adapter

Flue Adapter

to Flue Fan

screws

Rear Panel

Hole

Disconnect

electrical connections

at plug in tabs.

Mounting Plate

to Vent Box

screws

Mounting

Plate

Gasket

Air Plate

Mounting Plate

to Flue Fan

screws

Vent Box

Gasket

Remove screws securing outlet flange to the flue adapter.

Remove screws securing flue fan mounting plate to vent box Remove screws securing mounting plate to fan. Refit in reverse. Use new gaskets. Ensure sealed joints. Ensure mounting plate orifice is clear and not obstructed.

MODEL 75 90 100 115

Flue Fan

AO Smith

JFIG07INS

AO Smith

JFIG07INS

AO Smith

JFIG07INS

Torin DSF

146-052

077274

RG P/N

90710001 90710001 90710001 90710450 Air mm dia 97.0 103.6 110.5 152.4 Plate in dia 3.82 4.08 4.35 6 RG P/N 11011134 11011133 11011132 11011131

Page 45

SECTION 16: REMOVAL AND REPLACEMENT PARTS

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 working on or changing a pressure switch. See Page 21, Section 11.

Carbon Monoxide Hazard

Use correct pressure switch specified for each model.

Use of incorrect pressure switch could cause unsafe condition.

Failure to follow these instructions can result in death or serious injury.

WARNING

75 90 100 115

90439811 90439807 90439811 90439807

grey brown grey brown

Pressure Switch

RG P/N

Colour Code

Page 46

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

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 as set point with an arrow head and "diff". The control should be set at 5° C with a 1° C differential.

To replace, remove screw and pull off knob. Remove cover. Disconnect wires. Pull the sensing element out of the pocket in the coil. Replace in reverse order.

16.6.2 Pressure Switches

The coil and dirty filter pressure switches are preset and different. They are differential pressure switches measuring the pressure loss across the coil or filter.

Coil Pressure Switch

(Normally open contact) used to prove adequate air flow for safe operation of cooling coil.

Filter Pressure Switch

(Normally open contact) used to give indication of filter becoming blocked.

To replace, remove coil compartment cover. Disconnect wires noting their position. Remove the flexible tubing noting the position of the tube connection. Replace in reverse order and check operation.

Figure 18: Cooling Coil Safety Devices.

Coil Frost Thermostat

set at 5°C with 1°C diff.

Filter

White

Red

Coil Pressure Switch

set at 0.57 mbar (.23 in wc)

Filter Pressure Switch

set at 1.17 mbar (.47 in wc)

Negative

Pressure

Positive

Pressure

Set

Point

N.O

Connections

Description Part Number

Coil Pressure Switch 90439801 Filter Pressure Switch 90439804 Coil Frost Thermostat K018

Page 47

SECTION 16: REMOVAL AND REPLACEMENT PARTS

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 connectors.

Pull out ignition cable, ignition earth and flame probe cable noting their positions. Remove the screws. Refit in reverse. Ensure correct location of ignition and flame probe cables.

16.8 Fan Motor Removal

1. Disconnect the electrical connections at the contactor and pull the cable back to the fan motor.

2. Slacken the belt tensioning nuts and remove the drive belts.

3. Unscrew the motor mounting bolt. (motor is heavy, may need two people)

4. Remove the motor pulley by using a hexagonal key to remove the taper lock screws. Use one of these screws to fit into the centre jacking screw and tighten into this position to separate the taper lock bush and the pulley.

5. Replace in reverse order. Use a straight edge to ensure both pulleys line up. Ensure the pulley fixing screws are tight and belt tension is correct (use new belts if required). Ensure motor rotation is correct.

Locknut

(ensure tight)

Belt Tension Adjustment

Taper Lock

Screws

Jacking Screw

Position

Motor Fixing

Bolts

Pivot Bolts

(ensure tight)

(adjust both ends

the same to ensure

motor is parallel

to fan case)

Page 48

DUALAIR® HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL

16.8.1 Fan Removal and Replacement

1. Remove motor leaving the pulley in place. See Page 41, Section 16.8.

2. Remove screws securing the fan outlet flange to the fan panel. (captive nuts)

3. Remove nuts and bolts securing the fan feet to the mounting brackets.

4. Slide the fan out. (fan is heavy, may need two people)

5. Remove the fan mounting brackets from the fan. Retain components to fit to new fan.

6. Remove the Fan pulley by using a hexagonal key to remove the taper lock screws. Use one of these screws to fit into the centre jacking screw and tighten into this position to separate the taper lock bush and the pulley.

7. Refit the components above to the new fan and refit in reverse order.

8. Check belt alignment and tension.

9. Check fan rotation is correct.

16.9 Combination Fan/Limit Thermostat

16.9.1 Removal and Replacement

1. Remove wires.

2. Remove the mounting screws.

3. Fit a new thermostat ensuring that the correct temperature setting and type are selected. See Page 7, Section 4.3 through Page 8, Figure 4.4.

4. Reconnect wires and test operation.

Mounting Rail

Fan Foot

Screws

Fan Mounting

Brackets

(re-use on new fan)

Fan Outlet Flange

Securing Screws

Fan Plate

Bracket Screws

(re-use on new fan)

Description Part Number

Torin Fan DDC 270-270 A047 Torin Fan DDC 241-241 A049

Page 49

SECTION 16: REMOVAL AND REPLACEMENT PARTS

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 LINK MUST BE REMOVED

Limit Terminals

Limit Stat

Manual

Reset Button (Red)

Push in Lock

Wire to Controlled Equipment

Push Screwdriver in and hold to release

Pull out for normal operation.

Push in for continuous fan.

WARNING

Fire Hazard

Break-off link must be removed from replacement thermostat.

Heat exchanger damage may result.

Failure to follow these instructions can result in death, injury, property damage or product damage.

Page 50

Page 51

Page 52

www.rg-inc.com Printed in the U.S.A.

Attach this information to the wall near the ROBERTS GORDON® heater

Installation Code and Annual Inspections: All installations of ROBERTS GORDON® products must be performed by a contractor qualified in the installation and service of gas-fired heating equipment

and conform to all requirements of all applicable governmental authorities pertaining to the installation and operation of the equipment.

For optimum performance and safety, Roberts-Gordon recommends that a qualified contractor annually inspect your ROBERTS GORDON® products and perform service where necessary, using only ROBERTS GORDON

replacement parts.

including photocopying, recording, taping or information storage and retrieval systems - without the written permission of Roberts-Gordon.

Read the installation, Commissioning, Operation and Service Manual thoroughly before installation, operation or service.

OPERATING INSTRUCTIONS

1. STOP! Read all safety instructions on this information sheet.

2. Open the manual gas valve in the heater supply line.

3. Turn on electric power to the heater.

4. Set the thermostat to desired setting (above ambient temperature). The automatic starting sequence begins. NOTE: Following long shutdown periods, the burner control may go to to 'LOCKOUT' during the start sequence. Push the reset button to recommence firing. Contact service department if 'LOCKOUT' continues (see manual for details).

1. Turn the thermostat/time switch to 'OFF'. The burner will turn 'OFF' immediately, but fans will continue to cool heat exchanger until the fan thermostat switches off.

1. Set the thermostat to off or the lowest setting.

2. Turn off electric power to the heater.

3. Turn off the manual gas valve in the heater supply line.

4. Call your registered installer/contractor qualified in the installation and service of gas-fired heating equipment.

IF THE HEATER WILL NOT OPERATE, TO ENSURE YOUR SAFETY,

FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER

Fire Hazard

Some objects can catch fire or explode when placed close to heater.

Keep all flammable objects, liquids and vapors the required clearances to combustibles away from heater.

Failure to follow these instructions can result in death, injury or property damage.

TO TURN OFF THE HEATER

Service Telephone: +44(0) 1902 498733 Service Fax: +44(0) 1902 401464 E-mail: uksales@rg-inc.com E-mail: export@rg-inc.com

WARNING

Roberts-Gordon, LLC

1250 William Street P.O. Box 44 Buffalo, NY 14240-0044 USA

Roberts-Gordon Europe Limited

Oxford Street Bilston, West Midlands WV14 7EG UK Telephone: +44(0) 1902 494425 Fax: +44(0) 1902 403200

Clearances to Combustibles

**80 cm is necessary to service heater.

50 cm

50 cm**

30 cm

15 cm

Alternative

Wall

Terminal

Roof Terminal

Air

Intake

Flue

15 cm

2.5 - 3.5 m*

3 m

60 cm

Installation Clearances

Customers

Suitable

Condenser

Unit

Insulated

Refrigerant pipes

to cooling coil

by Customer

Condense Drain

Install to

suitable drain

Air Flow

Telephone: 716.852.4400 Fax: 716.852.0854 Toll Free: 800.828.7450

Roberts Gorden DualAir DAT100, DualAir DAT75, DualAir DAT115, DualAir DAT90 Operation And Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual