Roberts Gorden Dualair DA260G Series, Installation, Comissioning, Service & User Instructions

Page 1: ...servicing this equipment Installation must be done by a contractor qualified in the installation and service of gas oil fired heating equipment whichever is applicable Installer Please take time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the user owner Owner User Keep this manual in a safe place close to the heater to provide yo...

Page 2: ...Details of condense drain for cooling coil ...

Page 3: ...appliances designed to operate in the following countries Ireland IE Spain ES Italy IT United Kingdom GB Appliances designed for other countries are available on request This Appliance must be installed in accordance with the rules in force and used only in a sufficiently ventilated space as specified in these instructions Before installation check that the local distribution conditions nature of ...

Page 4: ...rts List 12 Commissioning Data Sheet THE AIR HEATER SECTIONS OF THE ON OFF BURNER APPLIANCES ARE FOR USE WITH NATURAL GAS OR L P G ONLY AS STATED ON THE HEATER DATA PLATE Conversion between gasses must be carried out in accordance with section 10 of these instructions THESE INSTRUCTIONS ARE TO BE LEFT WITH THE USER OR NEAR THE HEATER Note Every effort is made to ensure that the information contain...

Page 5: ...sioned in accordance with local regulations and the requirements of Section 3 of these Instructions A permanent electrical supply of 400 volts 50 Hz three phase and Neutral is required for the operation of the heater and fan and all models must be earthed Note the burner operates on 230v 50 Hz taken internally from the above supply 1 1 4 Fan Section The fan section houses the double inlet belt dri...

Page 6: ...oil from airborne particles Filters must be fitted and maintained to ensure proper operation of the equipment 1 1 7 Controls See Section 3 9 1 2 Heater Operation 1 2 1 Automatic Ignition Burner Roberts Gordon CUHD A range warm air heaters are fitted with an automatic ignition control which ignites the gas and monitors for the safe operation of the burner each time the external controls call for th...

Page 7: ...r Flow Main Heater Section Flue Air Outlet Spigot Burner Controls Main Fan Unit Condense Drain Cooling Coil Filter Panels Air Inlet Spigot Connections for refigerant pipework Filter Panels access Electrical Terminal box for all connections ...

Page 8: ...Page 6 Fig 2 1 DualAir 300 Module Dimensions Section 2 Technical Data FRONT VIEW REAR VIEW SIDE VIEW ...

Page 9: ...Page 7 Fig 2 2 DualAir 380 Module Dimensions FRONT VIEW REAR VIEW SIDE VIEW ...

Page 10: ...h 4 0kW Motor 0 20 40 60 80 100 120 140 160 180 200 2 5 2 6 2 7 2 8 2 9 3 0 3 1 3 2 3 3 Air Flow m 3 sec Static Pressure Pa Air flow with 118 mm motor pulley Graph of Air Flow v Static Pressure for Model DualAir 380 DX Coil with 4 0kw Motor 0 50 100 150 200 250 300 350 2 6 2 8 3 3 2 3 4 3 6 3 8 4 4 2 Air Flow m sec Static Pressure Pa Air Flow 125 mm Pulley ...

Page 11: ...le y 180m m 0 50 100 150 200 250 300 350 2 2 2 2 4 2 6 2 8 3 3 2 3 4 3 6 3 8 4 Air Flow m 3 s M inim um a ir flo w 2 6 m 3 s Static Pressure Pa A ir Flow v Ex ternal s tatic pres s ure G ra ph of Air Flow v S ta tic P re ssure for Dua lAir 300 w ith Chille d W a te r Coil 4kW m otor w ith 118m m pcd pulle y Fa n pulle y 180m m pcd 0 40 80 120 160 200 2 2 2 2 4 2 6 2 8 3 3 2 Air Flow m 3 s M inim u...

Page 12: ...D o t y l p p u s l a c i r t c e l E l a r t u e n e s a h p e e r h t z H 0 5 v 0 0 4 l a r t u e n e s a h p e e r h t z H 0 5 v 0 0 4 d a o l l a c i r t c e l e l a t o T W k 1 6 W k 1 6 r e t a e h m o r f d e i l p p u s s t i u c r i c l o r t n o C A 5 d e s u f z H 0 5 v 0 3 2 A 5 d e s u f z H 0 5 v 0 3 2 X D l i o C g n i l o o C d a o l g n i l o o c m u m i x a M s n o i t c e n n o ...

Page 13: ...5 0 L S A G G P L e z i S r o t c e j n I m m 4 5 0 x 7 m m 4 5 0 x 7 k r a m d n a 0 5 2 0 5 2 E N A P O R P r a b m e r u s s e r P t e l n I 7 3 7 3 G W s n I e r u s s e r P t e l n I 8 4 1 8 4 1 r h M e t a R e n a p o r P 4 1 4 7 2 5 r h g k e t a R e n a p o r P 6 8 7 1 0 0 1 r h r t L d i u q i L e t a R e n a p o r P 4 5 1 6 9 1 E N A T U B r a b m e r u s s e r P t e l n I 9 2 9 2 G W s ...

Page 14: ...for the current external demand when in the cooling mode 2 3 Limit Thermostats There are two limit thermostats on these heaters to protect them from overheating should the air flow fail for any reason One is within the Honeywell combination thermostat and the second is situated on the side of the heater towards the rear of the CUHD heater section 2 3 1 Honeywell Combination Fan Limit Thermostat Th...

Page 15: ...r models these are fitted so that the sensing element is on the lower rear of the heat exchanger in the same way as for the standard CUHD unit heater The operating head of the thermostat is located on the side panel of the CUHD heater section To reset this thermostat a Remove the screw on cover of the thermostat b Push in the button in the centre of the thermostat Note the heat exchanger must be c...

Page 16: ... 972 Control Box The fully automatic gas burner fitted to all CUHD A models is controlled by a Satronic TFI 812 2B Mod 10 plug in control box This control ensures the safe start and stop sequence and also monitors the safe presence of a flame Fig 2 3 Satronic DKG 972 Control Box Sequence 2 5 2 Sequence of Events With the external controls on and calling for heat the control box will self check and...

Page 17: ...sfied the control box turns off all outputs simultaneously and returns to rest position for the beginning of the next sequence 2 5 3 Fault Conditions If at any stage the flame fails the control will go to lockout The red light will glow and the control will need to be manually reset before any further start attempt can be made Minimum flame probe current 1 µA DC Typical flame probe current 3 5 µA ...

Page 18: ... the built in equipment a differential pressure switch is fitted to monitor the overall pressure loss across the cooling coil and filters The control is designed to turn off the control circuit of the external condenser units to prevent any damage to the cooling coil due to blocked filters or other reduced air flow This should be set on site to reflect the installed conditions and to monitor the d...

Page 19: ...ng Regulations The I E E Regulations The Health and Safety at Work etc Acts Any Requirements of the Local Authority Fire Officer and Insurance Company The installation will be similar to the one shown in Figure 3 1 WARNING AIR HEATERS SHOULD NOT BE INSTALLED IN CORROSIVE ATMOSPHERES i e NEAR PLATING OR DEGREASING PLANTS OR IN AREAS WHERE THERE IS A FIRE RISK CONSULT LOCAL REGULATIONS FOR FURTHER I...

Page 20: ... distribution air must be ducted to and from the unit and adequate provision must be made for the combustion air as described in Sections 3 5 3 6 When sited above floor level then a suitable access platform should be provided to provide safe working conditions for the routine maintenance of the burner fan and filters Access for burner maintenance is required at the heater front under the outlet sp...

Page 21: ...x spigot width dimension Minimum length of outlet duct 2 x spigot width dimension d e r i u q e R s e c n a r a e l C e g n a R r i A l a u D s e d i S t a e c n a r a e l C B s r e t l i f e v o m e r o t r e t a e h f o h t d i W e s a B o t t h g i e H C A N r e n r u b e v o m e r o t e c n a r a e l C D m 1 1 l a i r e t a m e l b i t s u b m o c m o r f e c n a r a e l C E m 3 r e t a e h e ...

Page 22: ...oss through the connector Natural Gas The gas meter and service must be checked by the local gas supply undertaking to ensure that it is adequate to deal with the total connected load of the completed installation L P G For L P G applications each heater must be provided with gas with the inlet pressure closely controlled to 37 mbar 25 45 for Propane G31 or 29 mbar 20 35 for Butane G30 This is bes...

Page 23: ...ind rivets or sheradised PK screws To do this offer the female end of each bend in turn to the branch arm and secure to the two components together ensuring that the dimension F shown on Fig 3 2 is correct Also ensure that when the assembly is standing on a flat surface the central flue section is exactly vertical The assembled unit is then fitted to the heater Ensure that the combination flue is ...

Page 24: ...stible material and be separated from the sleeve by at least a 25 mm air gap The temperature of any combustible material near the flue or heater must not exceed 65 C when the heater is in operation The flue must be at least 50mm from any other combustible material The joints between the flue and the roof or wall must be made good to prevent water ingress The joint between the flue and the female s...

Page 25: ...y and there is mechanical extraction the design extract rate must be 5 to 10 less than the design inlet rate so that the room will be at a higher pressure than outside air 3 7 Distribution Ductwork Dual Air range heaters are supplied with inlet and outlet duct spigots for mounting the heater into a customer designed duct system All distribution ducting should be adequately insulated for the effici...

Page 26: ...ature control etc are not provided with the DualAir unit but may be provided as optional equipment The unit is designed to be controlled by a multi stage thermostat temperature control to provide at least two stages of cooling and one stage of heating A typical control to select would be similar to the Eberle KLRE 52561 which may be used as supplied or with a remote sensor extra As standard DualAi...

Page 27: ...ing operation is not impaired See the Controls Table in Section 5 for more information 3 9 2 Siting of temperature Controls or Room Thermostats The temperature controls or room thermostats should be mounted on a wall or column at a height of approximately 1 5 metres from the floor of the building being heated cooled It is important for both comfort and fuel economy that the control or thermostat i...

Page 28: ...w Earth Continuity Test The appliance earthing must be tested using a suitable method according to local regulations The resistance of the earth circuit from the heater to the earth connection must be 0 1 ohm or less Polarity Test Connect one lead of a suitable voltmeter to earth and connect the other lead to the each of the phase supply terminals in turn at the heater Turn on power to heater A re...

Page 29: ...y Run To ensure that all the controls are in safe working order it is advisable to operate the fully automatic controls for the first time with no main gas To do this unplug the electrical plug from the main gas valves there are two plugs for Nova automatic valves Now using the installed external control turn on the burner The automatic sequence will now begin as described in Section 2 The electri...

Page 30: ... VR 420AB 1002 Main gas valve The main gas control valve used on all versions of the models CUHA A CUHB A CUHC A and CUHD A 340 and 380 is the Honeywell VR 420AB 1002 combination gas valve These controls contain two main safety shut off valves and burner pressure regulator Outlet flange with outlet pressure test point Inlet flange with inlet pressure test point Electrical Connection Pressure regul...

Page 31: ...e flue within 1 metre of the heater and tested for contents of CO2 carbon dioxide CO carbon monoxide and temperature rise The values of CO2 should be between 5 5 and 6 5 CO should be no more than 0 0015 15 PPM and the temperature rise of the flue gasses above ambient should be approximately 160 C to 180 C when running at full rate Combustion testing must be carried out with all covers etc fully fi...

Page 32: ...l the protection it requires It is strongly reccomended that this control is connected and set to give the cooling coil protection from freezing which would cause severe damage 4 11 Handing Over Ensure that all covers are fitted correctly and all test points are properly sealed before leaving the appliance When the commission is complete explain to the user the controls of the heater including how...

Page 33: ...Page 31 Fig 5 1 Wiring for DualAir Units On Off Burner 230v Controls Section 5 Wiring Diagrams ...

Page 34: ...Page 32 Fig 5 2 Wiring for DualAir Units On Off Burner 24v Controls ...

Page 35: ...Page 33 Fig 5 3 Wiring for DualAir Units Hi Low Burner 230v Controls ...

Page 36: ...Page 34 Fig 5 4 Wiring for DualAir Units Hi Low Burner 24v Controls ...

Page 37: ...Page 35 Fig 5 6 Wiring for DualAir Units BMS Burner Modulation 230v Controls ...

Page 38: ...Page 36 Fig 5 7 Wiring for DualAir Units BMS Burner Modulation 24v Controls ...

Page 39: ...Page 37 Fig 5 7 Wiring for DualAir Units Full Burner Modulation 230v Controls ...

Page 40: ...Page 38 Fig 5 8 Wiring for DualAir Units Full Burner Modulation 24v Controls ...

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Page 51: ... l o o c e e r F n O 2 R f f O r e n r u B 2 R m o r f s n u r n a F o t e v i r d y e h t n e h t d e t t i f s r e p m a d f I n o i t i s o p r i a h s e r f T U P N I 3 1 r o C A v 0 3 2 C A v 4 2 g n i l o o c e g a t s d n 2 n O 3 R f f O r e n r u B 3 R m o r f s n u r n a F o t e v i r d y e h t n e h t d e t t i f s r e p m a d f I n o i t i s o p r i a d e t a l u c r i c e r s r e s n e...

Page 52: ...ction 4 should be carried out to ensure that peak efficiency and safety is maintained The air filters fitted to the DualAir unit should be inspected regularly New filters will be required at three month intervals dependant upon conditions Minor faults may be traced by use of the Fault Finding Charts Section 8 6 1 Burner Maintenance 1 Remove the Burner Assembly as in 7 1 2 Check condition of igniti...

Page 53: ... first removing the burner tray 6 4 Gas Control Valves There is no regular maintenance required on these devices To change gas control valves see Section 7 4 It is not recommended for gas control valves to be repaired or disassembled on site Any faulty gas valve should be changed for the correct replacement 6 5 Air Filters The air filters should be inspected regularly to ensure that no excessive b...

Page 54: ... to the main burner inlet manifold using the angled flange outlet of the valve or a navy union The pilot gas supply will be in 4mm OD steel pipe and be connected to the pilot gas valve using a suitable compression fitting Undo the pilot supply compression fitting Unplug the flame probe lead from its socket and the HT lead from the spark generator Disconnect the main burner gas supply pipe at the g...

Page 55: ...injectors are being removed they are now accessible each one is screwed into its port of the manifold with a soft metal sealing washer and may be removed using a 13mm spanner 7 2 5 On replacing injectors ensure that they seat onto the soft metal washer to effect a tight seal and that the correct one is fitted for gas being burned See marking stamped onto the injector and tables in Section 2 It is ...

Page 56: ... Pilot Burner 7 3 Ignition Burner Assembly CAUTION Do not kink or tightly bend the pilot gas pipe The pilot burner for use on natural gas is fitted with an injector marked 34 The pilot burner for use on L P G is fitted with an injector marked 19 ...

Page 57: ...the flame probe ignition electrode and gas pipe from the rear of the ignition burner 7 3 3 To replace directly reverse the above Note It is important that the correct injector is used and that when assembling the gas pipe to the pilot burner that the injector is fitted onto the special compression nut so that as the gas pipe is withdrawn the injector is drawn out of the burner Failure to fit the i...

Page 58: ...ween the gas valve and the burner This allows the gas valves to be removed from the heater To disassemble gas train To separate the start and main gas valves remove the screws securing the main gas valve flanges being careful to retain the screws and O ring seal Using suitable tools unscrew the pilot line from the main gas line at the BSP m f elbow by turn This will allow the pilot or the main gas...

Page 59: ...e fan plate Remove the fan motor assembly from the compartment WARNING The motor is mounted at the top of the fan and so the assembly will be top heavy It may be easier to handle if the motor is removed from the fan first Take care not to damage the thermal insulation in the fan compartment any damage must be properly repaired or the insulation replaced to prevent insulation fibres from distributi...

Page 60: ...r Unscrew the fixing screws to remove the contactor from the panel To refit reverse the above operations Check rotation of fan following work on the contactor 7 7 Combination Fan Limit Thermostat 7 7 1 To gain access to this thermostat remove the cover retaining screw and pull of the cover 7 7 2 Disconnect the electrical connections by pushing in with a small screwdriver and pulling out the wires ...

Page 61: ... not to kink or crack it Proceed to replace by reversing the above procedure ensuring that the sensing bulb at the end of the capillary tube is positioned against the base of the heat exchanger Secure the capillary tube re using the metal bracket from the original one 7 9 Filters The filters are replaced by removing the filter access panel at the inlet end of the DUALAIR unit and sliding out the o...

Page 62: ... section 4 3 to Replace combination check fan stat thermostat settings YES YES NO NO Does burner stop after Has burner Check for correct Check operation Running for several Locked out operation of fan setting of minutes with the combination stat controls still on YES YES Repair or replace as necessary NO Use 8 2 to test burner YES Heater operating WARNING Fault finding should only be carried out b...

Page 63: ... Check flame current is at Check Inlet pressure of gas comes ON least 1 µ amps DC when is correct for gas type pilot lights YES YES Remove pilot burner as in 7 3 inspect flame probe and lead Replace if faulty NO Control box faulty Replace with correct type NO NO Main burner fires Check for 230v at output Control box faulty from control box Replace with correct type YES YES Use 8 4 to check valves ...

Page 64: ...or if not possible afterwrds as the lockout reason is stored in a non volatile lockout mode memory The information system communicates with the outside world using a LED the used Flash Code is similar to the Morse Code The messages are optically transmitted by an appopriately flashing LED Using an additional terminal optional the messages can be recorded and displayed in easy readable form 8 2 1 1...

Page 65: ...provided Turn on all controls and ensure that there is a supply to the burner Green light ON YES Is there a current flowing in Repair or replace the flame probe circuit Inspect and test the flame probe as necessary with no flame present and wiring for damaged insulation and short circuits to earth NO YES Does lockout occur when Check adequate gas pressure Control box faulty there is a flame presen...

Page 66: ...and appropriate time controls including limit thermostats YES NO Test gas pressure at inlet of valve Fault elsewhere Test gas pressure at outlet of valve NO Pressure should rise on outlet Solenoid valve faulty when valve energises Replace as necessary YES Valve Working 8 4 Fault Finding for Solenoid Valves ...

Page 67: ...of fan contactor and check setting See Note 1 NO NO Fan now runs Check for 400v three phase Contactor or overload at input and output of faulty contactor Replace as necessary YES YES Check and test wiring to motor M otor faulty Replace complete fan unit YES M otor stops after Thermal overload in motor running for some time faulty Replace complete fan unit NO M OTOR RUNNING The fan on the Dual Air ...

Page 68: ...g the timed on period for the heating cooling plant and warm air is discharged from the front of the heater When the remote controls turn off the heater the burner turns off immediately leaving the fan s to run on to cool the heat exchanger When cooled sufficiently the fan thermostat will turn off the fan s For operation of the on site controls for heating and cooling please consult the instructio...

Page 69: ...mit thermostat is preset during commissioning see 4 3 Note the heat exchanger must have cooled for reset to be possible 9 2 2 Secondary Limit Thermostat There is also a secondary limit thermostat situated on the heater side panel at the rear of the heater section see fig 2 1 This is a hand reset device designed to fail safe and give further protection to the heaters against fan failure To reset th...

Page 70: ...operation of the heater and indicates that there is a fault condition which must be corrected WARNING Do not operate the Lockout reset button more than three times Turn off the heater and consult a competent heating engineer to correct the fault 9 3 3 To Turn the Heater Off short periods Operate the installed remote controls to the OFF position The burner will turn off immediately but the distribu...

Page 71: ...the cover after use If the Limit thermostats persistently operate then there is a fault which must be investigated by a competent engineer Any other problem will require the assistance of a Service Engineer Some possible reasons for the cooling not operating 1 Controls not calling for cooling 2 Fan failed 3 Filters dirty 4 Local isolator for condenser units turned off 9 4 1 Simple Fault Finding Au...

Page 72: ... to be replaced 4 times per year For service contact your Heating Supplier The DualAir cabinet may be cleaned using a damp cloth with a little domestic detergent Do not use excessive water or abrasive materials WARNING Do not operate the lockout reset button more than three times Turn off the heater and consult a competent heating engineer to correct the fault EMERGENCY INSTRUCTIONS If a gas leak ...

Page 73: ...s valves vary according to the models size and method of control i e manual or automatic ignition but in all cases the valve DOES NOT contain a gas pressure regulator The correct operation of the heater depends on the close control of the gas inlet pressure to the appliance 10 2 Burner Conversion To convert the burner assembly from one gas to the other is the same for all types of heater i Remove ...

Page 74: ...ith its spring iii Replace the adjusting screw and original cover with the blanking nut attachment This device screws fully into the body of the regulator until it stops and puts the regulator out of action The step opening feature of the main valve will still operate To Convert Nova Valve from L P G to Natural Gas Reverse the instructions above Fig 10 2 Conversion of Nova Family Valve Blanking sc...

Page 75: ... Unscrew the regulator adjusting screw counter clockwise to a halfway position before lighting te appliance and further adjusting this screw to give the appropriate burner pressure shown in the table on Page 11 Table 2 6 3 Replace the dust cover Fig 10 3 Conversion of Honeywell gas Valve for L P G Honeywell VR 420AB 1002 Main gas valve The main gas control valve used on all versions of the models ...

Page 76: ...lenoid valve L 085 Main burner injectors natural gas B 094 Main burner injectors L P G gas B 095 Sealing washers for main burner injectors B 210 Pilot burner injector for natural gas B 184 Pilot burner for all gas types B 186 Pilot burner injector for L P G gas B 088 Honeywell combination fan limit thermostat K 017A Second limit thermostat K 120A Full Modulation Control Board L 504 BMS Modulation ...

Page 77: ...PERATURE C GROSS STACK TEMPERATURE C NET STACK TEMPERATURE C CARBON DIOXIDE IN FLUE CO2 CARBON MONOXIDE IN FLUE CO P P M ESTIMATED EFFICIENCY State net or gross COMMENTS CUSTOMER SITE ADDRESS HEATER LOCATOIN MODEL SERIAL NUMBER GAS TYPE NATURAL L P G ENGINEER SIGNATURE DATE Section 12 Commissioning Data Sheet ...

Page 78: ...401464 SPARES Tel 01902 499051 Fax 01902 492411 MAIN SWITCHBOARD Tel 01902 494425 Fax 01902 403200 Roberts Gordon Oxford Street Bilston West Midlands WV14 7EG Tel 01902 494425 Fax 01902 403200 e mail enquiry combat co uk www combat co uk www rg inc com ...