Roberts Gorden DualAir DAT100 Operation And Service Manual
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© Copyright 2005 Roberts-Gordon
Heating and Cooling Units
Installation, Commissioning,
Operation & Service Manual
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.
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
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
DualAir
Installer
Owner
P/N X527 Rev B 10/05
®
DAT75
DAT90
DAT100
DAT115
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Table of Contents
Troubleshooting
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Summary of Contents for Roberts Gorden DualAir DAT100
- Page 1 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 ® DAT75 DAT90 DAT100 DAT115 Installer Owner P/N X527 Rev B 10/05...
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Page 3: Table Of Contents
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... - Page 5 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...
- Page 7 Product Approval...
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Page 8: Section 1: Heater Safety
® EATING AND COOLING NITS 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 ®... -
Page 9: Section 3: Critical Considerations
Figure 1: Condense Drain ® unit. ® unit and flue must Failure to install the condense drain correctly may cause water carry over into the fan compartment, which may then escape and cause property damage. unit to supply air for RITICAL ONSIDERATIONS ®... -
Page 10: Figure 2: Installation Clearances And Clearances To Combustibles
® EATING AND COOLING NITS Figure 2: Installation Clearances and Clearances to Combustibles * Free blowing DualAir ® a higher level if destratification fans and/or turn down nozzles are installed. ® Free blowing DualAir units must always be installed at least 1.8 m above the floor. Ducted installations may be floor mounted. -
Page 11: Section 4: Specifications
SECTION 4: S PECIFICATIONS SECTION 4: SPECIFICATIONS 4.1 DAT (all models) -
Page 12: General Technical Data Table (All Models)
® EATING AND COOLING NITS 4.2 General Technical Data Table (all models) Fan Data Designed Air Flow # with Clean Filters Min Air Flow at Coil Max Air Flow at Coil Fan Unit Fan Pulley Motor Pulley Vee Belts Electrical Data - All models need 400v 50Hz 3N supply. Single phase supply output for control circuit 230v 50Hz fused at 5 Amp. -
Page 13: Technical Data Table - Heater Section (All Models)
Max Gas Flow Rate Min Burner Pressure - Low Fire Min Gas Flow Rate Gas rates corrected to standard conditions 1013.25 mbar 15°C. *See Page 43, Figure 19 for detailed Combination Fan/Limit Thermostat settings. Model Btu/h x 1000 Btu/h x 1000 Btu/h x 1000 66.5... -
Page 14: Dualair Performance Data - Graph Of Air Flows V Static Pressure
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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) -
Page 15: Section 5: Heater Installation
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 directly on its base. 5.2 Handling ® All DualAir units have steel channel sections at the base to be used to support the equipment. -
Page 16: Section 6: Flue Installation
® EATING AND COOLING NITS 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. -
Page 17: Figure 5: Control Section & Upper Panel
5. Refit the air intake spigot to the flexible hose re- using the hose clamp and to the upper panel using the original screws. 6. Align the flues’ inner and outer spigots and attach through the holes in the upper panel re- using the original screws. -
Page 18: Figure 7: Vertical And Horizontal Flue Termination - Type B Appliance
® EATING AND COOLING NITS Figure 7: Vertical and Horizontal Flue Termination - Type B Figure 8: Vertical and Horizontal Flue Termination - Type C NSTALLATION PERATION AND ERVICE ANUAL Appliance & C Appliances... -
Page 19: Section 7: Air Supply
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. -
Page 20: Section 8: Optional Heater Configurations
® EATING AND COOLING NITS 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"... -
Page 21: Section 9: Gas Piping
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. -
Page 22: Section 10: Wiring And Electrical Information
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 cable on all external control, with the burner/cooling cycling on and off. -
Page 23: Dat Main Circuit Board Terminal Identification
T3 Must Be Live to Operate Burner IRING AND LECTRICAL NFORMATION Operation Optional - Main Fan Runs from External Control 230 V 50 Hz supply of external thermostat or control Burner Operates. Fan Operates via R1 Optional Remote Indication of Burner ON. -
Page 24: Dat Wiring Diagram Models 75-115
EATING AND COOLING NITS 10.4 DAT Wiring Diagram Models 75-115 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°... -
Page 25: Dat Wiring Diagram Models 75-115
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.5 DAT Wiring Diagram Models 75-115... -
Page 26: Dat Site Connections At Main Circuit Board
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 10.6 DAT Site Connections at Main Circuit Board... -
Page 27: Section 11: Commissioning
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. -
Page 28: Figure 12: Automatic Burner Control Box Sequence
® EATING AND COOLING NITS Figure 12: Automatic Burner Control Box Sequence 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. Figure 13: Modureg Gas Valve NSTALLATION PERATION AND... -
Page 29: Combustion Testing (All Models)
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. -
Page 30: Turning Off The Dualair Unit
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. -
Page 31: Section 12: User Instructions
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. -
Page 32: Cooling Section Operation
The burner will turn off immediately. NSTALLATION PERATION AND ERVICE 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. -
Page 33: Section 13: Servicing
® unit will require 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. -
Page 34: Gas Control Valve Maintenance (All Models)
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
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. -
Page 36: Section 15: Troubleshooting
® EATING AND COOLING NITS SECTION 15: TROUBLESHOOTING 15.1 General For your safety and optimum heater performance use only ROBERTS GORDON Conduct Commissioning procedure as shown on Page 21, Section 11 NSTALLATION PERATION AND ERVICE ANUAL ® replacement parts. -
Page 37: Troubleshooting For Automatic Ignition Burner Systems
15.2 Troubleshooting For Automatic Ignition Burner Systems 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. -
Page 38: Troubleshooting For Flame Supervision System
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 15.3 Troubleshooting for Flame Supervision System NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC. -
Page 39: Troubleshooting For Solenoid Valves
15.4 Troubleshooting for Solenoid Valves 15.5 Troubleshooting for Main Fan For your safety and optimum heater performance use only ROBERTS GORDON Conduct Commissioning procedure as shown on Page 21, Section 11 ROUBLESHOOTING ® replacement parts. -
Page 40: Troubleshooting For Fan Contactor
® EATING AND COOLING NITS 15.6 Troubleshooting for Fan Contactor For your safety and optimum heater performance use only ROBERTS GORDON Conduct Commissioning procedure as on Page 21, Section 11 NSTALLATION PERATION AND ERVICE ANUAL ® replacement parts. -
Page 41: Section 16: Removal And Replacement Parts
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... -
Page 42: Burner Compartment
® EATING AND COOLING NITS 16.2 Burner Compartment 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. 16.2.1 Burner Injectors Ensure gas tight fitting of injectors. Ensure correct alignment with burners. -
Page 43: Ignition Electrode And Flame Probe
16.3 Ignition Electrode and Flame Probe. 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. Description Part Number Spark Electrode... -
Page 44: 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. NSTALLATION PERATION AND... -
Page 45: Heater Pressure Switch
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 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. -
Page 46: Cooling Coil Safety Devices
® EATING AND COOLING NITS 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". -
Page 47: Ignition Control
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. -
Page 48: Combination Fan/Limit Thermostat
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. -
Page 49: Figure 19: Combination Fan/Limit Thermostat
Figure 19: Combination Fan/Limit Thermostat Set Point 3 Limit Temp. Set Point 2 Fan On Set Point 1 Fan Off Fan Terminals Manual Fan Switch (White) Pull out for normal operation. Push in for continuous fan. Dial Push in Lock... - Page 52 Roberts-Gordon Europe Limited Roberts-Gordon, LLC...