Roberts Gorden DualAir DAT100, Operation And Service Manual

Page 1: ...3200 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 pro...

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Page 3: ...ON 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 Commis...

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Page 5: ...al and Horizontal Flue Termination Type 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 Figu...

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Page 7: ...ntained 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 installa...

Page 8: ... and service manual To never use the DualAir unit as support for lad der 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 r...

Page 9: ...ces 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 he...

Page 10: ...rs 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 ...

Page 11: ...oil Air Inlet Spigot 35 mm flange 3010 896 225 1239 Internal Spigot Height 1417 Flue 130 mm dia Lockout Reset Green Burner On Red Lockout Warning Amber Dirty Filter Warning 734 Gas Connection 1127 20 mm Conduit Entry for Electrical Connections 1494 671 2070 532 1239 Internal Spigot Height 1250 Internal Spigot Width Alternate Flue Air Intake Position 315 890 51 399 1340 1590 Extension Cover for Ref...

Page 12: ...O 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 1 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...

Page 13: ...ow 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 20 9 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...

Page 14: ...and 90 2 2 kW or 4 kW motor 4 4 2 DAT100 and 115 4 kW motor 350 300 250 200 150 100 50 0 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 50 0 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: ...ed 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...

Page 16: ...e 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 in...

Page 17: ... attach through the holes in the upper panel re using 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 Spigo...

Page 18: ...zontal Flue Termination Type B22 Appliance Figure 8 Vertical and Horizontal Flue Termination Type C12 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: ... 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 heat...

Page 20: ...t 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...

Page 21: ...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...

Page 22: ...tent 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 ...

Page 23: ... 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...

Page 24: ...YELLOW BROWN BLUE BROWN BLUE MAINS FILTER BLACK SENSE IGNITION BLACK BROWN BLUE LIMIT FAN BROWN BROWN SITE WIRING N L 1 2 3 7 8 RED 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 ...

Page 25: ...4 R2 1 R2 230 V 7 2 7 2 R3 1 4 10 1 2 1 3 9 R3 3 1 11 3 Damper supply 230 V Remote Lockout reset 230 V 8 N N 1st stage cool free cool 11 12 13 14 Dirty filter warning 230 V Recirc air Fresh air cooling condenser 17 16 15 18 19 22 21 20 Honeywell Modureg Valve 0 28 V DC Burner Modulation control 0 10 V DC signal System ground 28 27 26 25 Control inputs 230 V Press Sw Coil Frost Stat Warning lamps 2...

Page 26: ...age Dirty Filter Warning 230 V System Ground Optional Frost Thermostat 230 V Time Switch Control 230 V Optional External Fan Control 230 V N L N 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 C...

Page 27: ...t 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 rota tion transpose two of the incoming phase con nections 2 Ch...

Page 28: ...Switch P C NO NC 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 G...

Page 29: ... 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 contr...

Page 30: ...itch 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 poi...

Page 31: ...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 ON RUN ON CLOSE DOWN THERMOSTAT CALL FOR HEA...

Page 32: ...ust be above the ambient temperature for the heater to operate 2 The green light will be on and the automatic fir ing 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 remot...

Page 33: ...ically 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...

Page 34: ...ee 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 ...

Page 35: ...ion 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 ope...

Page 36: ...n fan limit thermostat set correctly See sections 5 3 11 3 No 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 No Has burner Locked Out Yes No With external controls on does the burner continue through the heating cycle No Yes Press the white button on the combination fan limit thermostat Does...

Page 37: ...ressure switch See section 16 5 Does air pressure switch change over No Yes Have limit thermostats operated or light faulty Reset or replace as necessary Is 230v supply at fan connections Does flue fan run No Are external controls on Yes Yes Is the green light on No Yes Is red lockout light on No Yes Press in lockout reset button on rear of heater or remote reset button if fitted Turn on supplies ...

Page 38: ... No 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 No Does lockout occur when there is a flame present Yes Is the connecting lead damaged Is the flame probe damaged or touching earthed components No Is the green light on and at lea...

Page 39: ...S GORDON at Tel 44 0 1902 498733 or www rg inc com Fan Operating TROUBLESHOOT ENDS No 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 Secti...

Page 40: ... TROUBLESHOOT ENDS No 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 No Yes START No No Yes Does main fan run automatically in heating mode No Is there 230v at contactor coil terminal A1 and A2 Does fan motor run with little or no air flow Yes Yes No Is there 230v between terminals 96 and A1 on th...

Page 41: ...bber 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...

Page 42: ...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 9...

Page 43: ...ove 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...

Page 44: ... 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 9...

Page 45: ...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 gre...

Page 46: ...hey 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 t...

Page 47: ...ble 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 ...

Page 48: ...ws 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...

Page 49: ...T 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 pr...

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Page 52: ...equence 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 ...