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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.
Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of this or any other appli-
ance.
Failure to follow these instructions
can result in death, injury or property
damage.
WARNING
Improper installation, adjustment, alteration,
service or maintenance can result in death, injury
or property damage. Read the Installation,
operation and service manuals thoroughly before
installing or 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).
© Copyright 2002 Roberts-Gordon
Heating & Cooling Unit
DA260G AND VARIANTS
DA300G AND VARIANTS
DA300L AND VARIANTS
DA325G AND VARIANTS
DA380G AND VARIANTS
DA380L AND VARIANTS
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 your serviceman with information should it
become necessary.
Roberts-Gordon Europe Ltd.
Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: +44 (0)1902 494425
Fax: +44 (0)1902 403200
email: uksales@rg-inc.com
www.combat.co.uk
www.rg-inc.com
V1
Installer
X525D 02/03
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Summary of Contents for Roberts Gorden Dualair DA260G Series
- Page 1 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.
- Page 2 Details of condense drain for cooling coil...
- Page 3 The gas heater section of these appliances have been tested and certified as complying with the essential requirements of the Gas Appliance Directive, The Low Voltage Directive and The Electromagnetic Compatibility Directive for use on natural gas and L..P.G. gas when installed, commissioned and maintained in accordance with these instructions .
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Page 4: Table Of Contents
Contents The parts of this manual are numbered by section, clause and sub-clause. Hence 1:2:3 refers to Section 1, clause 2, sub clause 3. Figure numbers also follow this notation, hence Fig. 2:3 is Section 2, Fig. 3. SECTION 1. General Specification 2. - Page 5 Section 1. General Specification - DualAir® Unit Basic Information 1.1.2 Description The DualAir® combined heating and cooling unit is formed by four sections combined into a single unit and delivered as a complete assembly ready for installation on site. The DualAir® unit is designed to be installed with the air flow from right to left as shown in Fig 1.1.
- Page 6 1.1.5.2 Chilled Water Coil A single chilled water coil can be fitted as an option. This type of coil is designed to operate at 6°C 'Water On' temperature. There is no other equipment supplied with the coil and all chilled water pipe- work and controls must be supplied by the installer to suit the equipment being installed with the Chiller units.
- Page 7 Air Flow Flue Connections for Main Heater Section refigerant pipework Cooling Coil Air Inlet Spigot Filter Panels Air Outlet Spigot Electrical Terminal Burner Controls box for all connections Main Fan Unit Filter Panels Condense Drain access...
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Page 8: Technical Data
Section 2. Technical Data SIDE VIEW FRONT VIEW REAR VIEW Fig. 2.1 DualAir® 300 Module - Dimensions Page 6... - Page 9 SIDE VIEW FRONT VIEW REAR VIEW Fig. 2.2 DualAir® 380 Module - Dimensions Page 7...
- Page 10 Graph of Air Flow v Static Pressure for Model DualAir 300 Range with 4.0kW Motor Air Flow m /sec Air flow with 118 mm motor pulley Fig. 2.3 Design Graph - DualAir® 300 - DX COIL Graph of Air Flow v Static Pressure for Model DualAir®...
- Page 11 G ra p h o f A i r F lo w v S ta tic P re ssu re fo r D u a l A i r® 300 w ith C h ill e d W a te r C o il 4kW m o to r w ith 118m m p cd p u lle y.
- Page 12 Table 2.5 General Technical Data ® r ® r o i t h t i e t l h t i e t l . n i s / ³ s / ³ s / ³ s / ³ t i n t l e i r d t l e...
- Page 13 Table 2.6 Gas Heater Section - Technical Data (On/off Burner) ¾ " " 1 / ³ / ³ t l l e / ³ / r t / ³ / r t . T . l l e Data shown is for On/Off burner. For Modulating and High/Low burners, please refer to data for CUH/A300 and CUH/A380 units in the relevant Manual Supplement supplied.
- Page 14 Gas Controls - Automatic Ignition (On/Off Burner*) The heaters may be fitted with one of two types of gas control valves dependent upon the model, each giving the same control elements as follows (see Section 4) 2.1.1 Main Gas Burner The multifunctional main gas valve contains a gas regulator and two automatic shut off valves.
- Page 15 2.3.2 Second Limit Thermostat This is a manual reset device - see Figs. 1 .1 & 2.1. Note: On the DualAir® 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.
- Page 16 Fan Relay (R1 on wiring Diagram) This two pole relay is provided to ensure that the fan will always run when the burner is firing, as the temperature rise through the heat exchanger is much lower than for the standard heater, due to the increased air flow.
- Page 17 Electric Ignition OFF Five seconds later the electric ignition turns off, leaving the start gas flame to be proved as stable. Main Gas Valve Energises Following a short delay the main gas valves energise and the main flame cross lights from the start gas.
- Page 18 Motor Starter and Thermal Overload On belt driven fan models the motor is controlled by a direct on line contactor starter fitted with thermal overload protection. If the thermal overload should operate the main fan will not run. To reset, press in the reset button on the overload unit (see Fig.
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Page 19: Heater Installation
Section 3. Heater Installation Required Standards It is important that all gas appliances are installed by competent persons, in accordance with the relevant requirements of the local laws and regulations. Failure to install gas appliances correctly could lead to prosecution. THE RELEVANT REGULATIONS ARE: Gas Safety (Installations and Use) Regulations 1994;... - Page 20 3.2.2 Installation For installation the unit may be supported by the 6 lifting eyes provided, from positions vertically above each point. Alternatively the 12mm D screwed rod which is supplied connecting the eye bolts to the base frame may be replaced with extended 12mm rod or similar to provide a continuous support system.
- Page 21 Fig 3.1 Typical Installation Clearance Data e t l l a i ' F ' Note: DualAir® inlet and outlet ducts: Minimum length of inlet duct: 2 x spigot width dimension. Minimum length of outlet duct: 2 x spigot width dimension. It is important that the gas supply pipe and the electrical connections do not support any of the heaters weight.
- Page 22 Gas Supply General The installation must comply with local laws and regulations, and the complete installation including the meter where fitted, must be purged and tested for soundness. The gas supply must be via metal pipes and terminate at the heater with a service gas cock and union as in Fig.
- Page 23 3.4.1 Model DualAir® 380 Only The model DualAir® 380 heaters are provided with two outlet spigots on top of the heater and a flue assembly as shown in Fig 3.2 to combine these two flue outlets into a single vertical flue for the appliance.
- Page 24 3.4.2. All models The flue must be terminated at least one metre higher than the section of the roof it intersects (see Fig 3.1). Furthermore if the point of intersection with the roof is within 2.5m of a nearby structure the terminal must be at least 1m above that structure.
- Page 25 For buildings with a design air change rate 0.5/h or greater and where the volume of the heated space is greater than 4.7 m per kilowatt of total rated heat input, as appropriate, additional high and low level ventilation will not be required. Where natural ventilation is used for compartment/plant rooms, suitable permanent openings at low and high level, communicating directly with the outside air, must be provided.
- Page 26 Electrical Supply A constant 400 volt 50 Hz three phase and Neutral supply is required for DualAir® models connected to terminals L1,L2,L3, N & Earth. The full load current of the motor is 8.7Amps. It is important that the polarity is correct as incorrect polarity will prevent the burner control box from operating correctly.
- Page 27 3.9.1.2 Fan Controls The fan is designed to operate automatically providing there is a constant supply to the main terminals. However, a switch wired between terminals L & 1 in the terminal block at the side of the heater will provide for constant running of the fan/s.
- Page 28 Section 4. Commissioning the Heater - All Types Before starting to commission a heater read this section through and fully understand its contents. Only competent engineers should carry out the work. Commissioning of the cooling equipment must be carried out in accordance with the cooling equipment manufacturers instructions and relevant codes of practice.
- Page 29 Gas Supply The whole of the gas installation including the meter should be inspected, tested for soundness and purged in accordance with local regulations. It will be necessary to ensure that the air is fully purged from the heater inlet pipe up to the main gas valve inlet test nipple before the start gas burner will ignite.
- Page 30 Regulator (under cover) Inlet Pressure Pilot gas outlet of valve Burner pressure Fig. 4.1 S.I.T. Nova 0.822.177 Automatic Ignition Gas Valve (On/Off Burner) 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.
- Page 31 Burner Commissioning Tests With the main burner operating for at least 15 minutes carry out a spillage test on the draught diverter in accordance with BS 5440 Part 1 ensuring that all doors and windows in the area are closed and that any extract fans are turned ON.
- Page 32 4.10 Air Handling Controls 4.10.1 Pressure Switches The pressure switches for the air filters and cooling coil should be set on site so that the cooling equipment is protected against reduced air flow. The pressure loss across the coil and filters as new and clean should be measured and a sensible margin estimated to allow for increasing pressure loss as the filters become dirty.
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Page 33: Wiring Diagram
Section 5. Wiring Diagrams Fig. 5.1 Wiring for DualAir® Units - On/Off Burner - 230v Controls Page 31... - Page 34 Fig. 5.2 Wiring for DualAir® Units - On/Off Burner - 24v Controls Page 32...
- Page 35 Fig. 5.3 Wiring for DualAir® Units - Hi/Low Burner - 230v Controls Page 33...
- Page 36 Fig. 5.4 Wiring for DualAir® Units - Hi/Low Burner - 24v Controls Page 34...
- Page 37 Fig. 5.6 Wiring for DualAir® Units BMS Burner Modulation - 230v Controls Page 35...
- Page 38 Fig. 5.7 Wiring for DualAir® Units BMS Burner Modulation - 24v Controls Page 36...
- Page 39 Fig. 5.7 Wiring for DualAir® Units Full Burner Modulation - 230v Controls Page 37...
- Page 40 Fig. 5.8 Wiring for DualAir® Units Full Burner Modulation - 24v Controls Page 38...
- Page 51 Description of Control Sequence Important Note: Terminals 3, 4, 12, 13 and 14 maybe 23ov AC or 24v AC dependent upon the controls specification - see Wiring Diagram on heater & & & & & f / l t l i &...
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Page 52: Servicing Instructions
Section 6. Servicing Instructions After commissioning, the heater will require maintenance to be carried out at least once per year to ensure that peak performance and safety are maintained. If the heater is used in a dirty or dusty area, then more frequent maintenance may be necessary. - Page 53 Fan/Motor Assembly The main fan requires very little maintenance as the bearings are sealed for life and need no lubrication. If the fan blades need cleaning, use a small brush or duster to clean the fan blades from each side of the fan.
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Page 54: Removal And Replacement Of Parts
Section 7. Removal & Replacement of Parts See warnings and notes at the start of Section 6 before removing or replacing parts. Burner Tray The burner tray may be removed from the heater only from the front. For the DualAir® unit the gas valves need to be disconnected from the burner manifold at the union or flange provided before the burner tray may be pulled forward. - Page 55 Main Burner Bars/Injectors 7.2.1 Remove the burner tray as in 7.1. 7.2.2 To remove the burner bars first remove the screws securing the retaining bar at the front end of the burner and pull off the retaining bar (see Fig.7.1). Remove the screws securing the burner rear baffle and pull it upwards to remove.
- Page 56 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. Fig 7.1 Burner Tray Assembly Fig 7.2 Pilot Burner Page 44...
- Page 57 7.3.1 Removal of pilot burner To remove the pilot burner on the DualAir® unit requires the burner tray to be removed as described in 7.1. However if access is available from below the DualAir® unit then the pilot may be accessed by removing the bottom panel of the controls section.
- Page 58 7.4.2 Removal of Gas Valves There are two mounting systems used for the automatic ignition gas valves. Honeywell gas valve (for On/Off Burner) These are connected to the main gas manifold using a navy union and flanges at the valve. Electrical connection is by a plug on the end of a flying lead.
- Page 59 7.6.1 Main Fan Motor Disconnect electrical connections at contactor/overloads which are in the controls compartment (see Fig. 2.4). WARNING: THE MOTOR IS HEAVY Remove the fan compartment access panel to gain access to the motor. Unscrew the bolts securing the motor to the mounting bracket. The motor will now lift out. To refit: reverse the above procedure, adjusting the tension of the belts as in 6.1 and ensuring that the pulleys are properly aligned, i.e.
- Page 60 Disconnect the overload fixing and connecting screws at the bottom of the contactor. Ensure that any replacement overload is of the correct rating and that it is reset as in 2.8 ‘A’ - The contactor is fixed by two diagonally opposite screws. To remove: First remove the overloads as above, then remove the line connections to the top of the contactor (noting the colour code) and the two coil connections at the top rear of the contactor.
- Page 61 Second Limit Thermostat 7.8.1 Remove the mounting nut securing the thermostat to the heater side. 7.8.2 Open the control compartment cover to gain access to the body of the thermostat and its electrical connections. Remove the access panel in the inlet duct to gain access to the capillary tube and sensing element. Disconnect the push-on electrical connections from the thermostat.
- Page 62 Section 8. Fault Finding (Heater Section) General for Automatic Ignition WARNING Fault finding should only be carried out by experienced engineers who fully understand the operation of the burners. There is a risk, including that of explosion, when burners are faulty and not repaired correctly. I s "Loc kout "...
- Page 63 Fault Finding for Automatic Ignition Burner Systems WARNING Ignition output from the STA RT spark generator is 160 kv to earth. A ll c ontrols ON Extreme care must be taken To measure flame current, connect I s Gre e n light ON ? Che c k for e le c tric a l supply ope ra tion of e xte rna l c ontrols a 0 - 50 µA DC meter in series with...
- Page 64 8.2.1 Satronic DKG 972 Control Information System The information system is microprocessor based and reports on all aspects of burner control box operation and flame supervision. It informs continuously about the actual programming sequence the unit is just performing. Besides monitoring of the programming sequence it also allows to identify errors during start up of operation without any additional testing devices.
- Page 65 Flame Supervision System M a xim um fla m e c urre nt M inim um flam e c urre nt with no fla m e with pilot only 0 to 0.5 µA D.C. 1.0 µA D.C. Typic a l fla m e c urre nt 3.0 to 5.0 µA with m a in B urne r ON Conne c t a D.C.
- Page 66 Fault Finding for Solenoid Valves Sta rt Te st for 230v a c ross va lve F a ult e lse whe re supply te rm ina ls a t the Che c k a ll c onne c tions a nd a ppropria te tim e c ontrols inc luding lim it the rm osta ts...
- Page 67 Fault Finding for Main Fan The fan on the Dual-Air unit is operated from M ain fan will not op erate several control points When the burner is on See controls table in section 6. Dependant upon which control is currently calling for fan run then the appropriate relay Check for 400v three Fault elsewhere...
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Page 68: User Instructions
Section 9. User Instructions The DualAir® range of heaters are fully automatic and operate from the remote controls fitted on site. The only user controls situated on the heater are: The burner lockout reset button See 9.2.3. The fan run button See 9.2.1 The limit thermostat reset See 9.2.1... - Page 69 User Controls Common to All Versions 9.2.1 Combination Fan/Limit Thermostat This is located on the top side of the heater, see Fig.2.1. This control ensures the heater does not blow cold air in the normal heating cycle and protects the heat exchanger against overheating.
- Page 70 WARNING If the control should go to ‘lockout’ again, do not make more than three attempts at restarting the heater. The fault must be traced and repaired by a competent person. Lighting Instructions 9.3.1 Ensure that the electrical and gas supplies to the heater are on. Check that the time switch or other on site controls are in an “ON”...
- Page 71 Simple Fault Finding - General Some possible reasons for the heater not operating are:- Gas supply not turned ON. Electricity supply not turned ON. The installed time and/or temperature controls are not “ON”. One or both of the limit thermostats may have operated. This may be caused by inadvertent removal of the electrical supply or failure of the distribution fan.
- Page 72 Service Requirements This heater will require servicing at least once per year except when operating in a dirty or dusty area, when more frequent service may be necessary. The service should be carried out by a competent engineer in accordance with the requirements of this manual. The air filters fitted to the Dual-Air unit will require regular inspection and possibly cleaning.
- Page 73 Section 10. Conversion Between Gasses (On/off Burner) 10.1 General All versions of the heaters use the same main burner bars and pilot burners. Natural Gas All natural gas versions use the same main burner injectors marked 840, and pilot injectors marked The gas valves vary according to the models size but in all cases the valve contains a gas pressure regulator to allow for setting of the burner pressure.
- Page 74 10.3 Gas Valves - Automatic Ignition The valve used for this range of heaters is the S.I.T. Nova gas valve. 10.3.1 Nova Range Valves Nova range main valves may be converted to operate with or without a burner gas pressure regulator. To convert Nova valve from Natural Gas to L.P.G.
- Page 75 10.3.2 Conversion of Honeywell Valve to L.P.G. Remove the dust cover of the pressure regulator. Screw the regulator adjusting screw clockwise down fully. Replace the dust cover tightly and apply paint or similar across the mating face of cover and valve.
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Page 76: Parts List
Section 11. Parts List DESCRIPTION PART NUMBER Modulating 380 Gas Valve: Honeywell L 502 Moduulating 300 Gas Valve: Honeywell L 501 On/Off 380 Gas Valve: Honeywell L 059B On/Off 300 Gas Valve: S.I.T. Nova L 421 Exclusion screw for Nova valves (All Types) for L.P.G. L 425 Automatic Ignition pilot solenoid valve L 085... -
Page 77: Commissioning Data Sheet
Section 12. Commissioning Data Sheet CUSTOMER SITE ADDRESS HEATER LOCATOIN MODEL SERIAL NUMBER GAS TYPE NATURAL/L.P.G. INLET GAS PRESSURE mbar BURNER GAS PRESSURE mbar GAS RATE MEASURED AT METER /hr (ft /hr) AMBIANT TEMPERATURE °C GROSS STACK TEMPERATURE °C NET STACK TEMPERATURE °C CARBON DIOXIDE IN FLUE CO CARBON MONOXIDE IN FLUE CO.. - Page 78 C O N T A C T S SERVICE Tel: 01902 498733 Fax: 01902 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...