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© Copyright 2007 Roberts-Gordon, LLC
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
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands WS10 7SH UK
Telephone: +44 (0)121 506 7700
Fax: +44 (0)121 506 7701
Service Telephone: +44 (0)190 249 8733
Service Fax: +44(0)190 240 1464
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 C 10/07
®
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Troubleshooting
Related Manuals for Roberts Gorden DUAL AIR DAT100
Summary of Contents for Roberts Gorden DUAL AIR DAT100
- Page 1 ® Heating and Cooling Units Installation, Commissioning, Operation & Service Manual DAT75 DAT90 DAT100 DAT115 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1: Heater Safety............2 SECTION 12: User Instructions..........25 SECTION 2: Installer Responsibility ........2 12.1 User Instructions ............25 2.1 Clearances to Combustibles ........2 12.2 Heater Operation............25 2.2 Corrosive Chemicals............ 2 12.3 Common User Controls..........25 2.3 National Standards and Applicable Codes ....2 12.4 Cooling Section Operation ........26 SECTION 3: Critical Considerations ........ - Page 5 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 ..............
- Page 7 Product Approval...
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Page 8: Section 1: Heater Safety
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL SECTION 1: HEATER SAFETY Your Safety is Important to Us! 2.1 Clearances to Combustibles This symbol is used throughout the In all situations, clearances to combustibles must be manual to notify you of possible fire, maintained. -
Page 9: Section 3: Critical Considerations
SECTION 3: C RITICAL ONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Basic Information 3.7 Electrical Supply The CTUD heater that forms the heating section of A permanent 400v 3ø 50Hz electrical supply is required at the main electrical terminals. The heater ®... -
Page 10: Figure 2: Installation Clearances And Clearances To Combustibles
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL Figure 2: Installation Clearances and Clearances to Combustibles **80 cm is necessary to ® * Free blowing DualAir units may be mounted at service heater. a higher level if destratification fans and/or turn down nozzles are installed. -
Page 11: Section 4: Specifications
SECTION 4: S PECIFICATIONS SECTION 4: SPECIFICATIONS 4.1 DAT... -
Page 12: General Technical Data Table
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 4.2 General Technical Data Table Model Fan Data 2.88 Designed Air Flow # with Clean Filters /sec 1.66 2.60 Min Air Flow at Coil /sec 3.71 5.34 Max Air Flow at Coil /sec Fan Unit 457-486 Double Inlet Belt Drive... -
Page 13: Technical Data Table - Heater Section
SECTION 4: S PECIFICATIONS 4.3 Technical Data Table - Heater Section Appliance Category II 2H/L 3B/P Model Heat Input Gross Calorific Value Btu/h x 1000 Heat Input Net Calorific Value Btu/h x 1000 Approximate Max Heat Output Btu/h x 1000 66.5 77.7 83.3... -
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: H EATER NSTALLATION SECTION 5: HEATER INSTALLATION 5.3 Shelf Mounting and Suspension 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. -
Page 16: Section 6: Flue Installation
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: FLUE INSTALLATION 6.1 Flue Installation Figure 4: Flue and Roof Detail The flue must terminate outside of the building. Flues and air intakes must be fully sealed and correctly sized for the model. -
Page 17: Figure 5: Control Section & Upper Panel
SECTION 6: F NSTALLATION 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 NSTALLATION PERATION AND ERVICE ANUAL Figure 7: Vertical and Horizontal Flue Termination - Type B Appliance Figure 8: Vertical and Horizontal Flue Termination - Type C & C Appliances... -
Page 19: Section 7: Air Supply
SECTION 7: A UPPLY SECTION 7: AIR SUPPLY 7.1 Room Sealed Installation 7.3 Building Ventilation When installed as a room sealed heater, the air for Where ventilation is required, air must be taken from combustion is drawn in from outside the building. It an outside point where it is not likely to be is important to ensure that there is adequate contaminated or obstructed. -
Page 20: Section 8: Optional Heater Configurations
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL SECTION 8: OPTIONAL HEATER CONFIGURATIONS 8.1 Distribution Duct The duct must be designed as described on Page ® DualAir units are designed to be connected to 14, Section 8.1 and Figure 10 to ensure that there is distribution and air inlet ducting. -
Page 21: Section 9: Gas Piping
SECTION 9: G IPING SECTION 9: GAS PIPING 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. -
Page 22: Section 10: Wiring And Electrical Information
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: WIRING AND ELECTRICAL INFORMATION 10.1 Electrical Supply cooling temperature control. See Page 20, Section 10.6. All heater models need a constant 400 V 50 Hz 3 ø To operate the modulating gas burner, a further supply connected to terminals L , N &... -
Page 23: Dat Main Circuit Board Terminal Identification
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.3 DAT Main Circuit Board Terminal Identification Terminal Relay/Function Operation Number Input for Remote Fan Opera- Optional - Main Fan Runs from 1 Input or Output External Fan Control tion Output for Fan Operation External Control Monitor 230 V 50 Hz supply of external... -
Page 24: Dat Wiring Diagram
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 10.4 DAT Wiring Diagram 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
SECTION 10: W IRING AND LECTRICAL NFORMATION 10.5 DAT Wiring Diagram... -
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
SECTION 11: C OMMISSIONING SECTION 11: COMMISSIONING Gas Fired Heater 11.1.2 Electrical Checks Installation, service, commissioning and annual 1. Check that all site wiring is connected in inspection of the heater must be done by a accordance with the appropriate wiring dia- contractor qualified in the installation and service of grams on Page 17 , Section 10.3 through Page gas-fired heating equipment. -
Page 28: Figure 12: Automatic Burner Control Box Sequence
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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... -
Page 29: Combustion Testing
SECTION 11: C OMMISSIONING 11.4.2 Commissioning the Gas Valves sure must be corrected before completing the commission. ® All DualAir units are fitted with fully modulating burner operation. The Honeywell automatic gas 2. Release the moving shaft and observe that the valves are fitted with the Honeywell Modureg burner pressure returns to the minimum setting. -
Page 30: Turning Off The Dualair Unit
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL water collection and a shortened heat exchanger life. 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. -
Page 31: Section 12: User Instructions
SECTION 12: U NSTRUCTIONS SECTION 12: USER INSTRUCTIONS 12.1 User Instructions 12.3 Common User Controls 12.3.1 Combination Fan/Limit Thermostat ® The DualAir units are fully automatic and operate from the external controls fitted on site. The Combination Fan/Limit Thermostat is located inside the access door at the top of the heater. -
Page 32: Cooling Section Operation
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL ® 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. - Page 33 SECTION 12: U NSTRUCTIONS...
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Page 34: Section 13: Servicing
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: SERVICING 13.1 Servicing Instructions to ensure that adequate air flow. The cooling equipment will automatically turn off ® After commissioning, the DualAir unit will require should the air flow drop to a preset low value even maintenance to be carried out annually. -
Page 35: Gas Control Valve Maintenance
SECTION 13: S ERVICING 13.5 Gas Control Valve Maintenance No regular maintenance is required on these devices. To change gas control valves, See Page 36, Step 16.1 and Page 40, Section 16.5. Do not repair or disassemble on site. Replace faulty gas valves with genuine ®... -
Page 36: Section 14: Conversion Between Gases
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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. -
Page 37: Section 15: Troubleshooting
SECTION 15: T ROUBLESHOOTING SECTION 15: TROUBLESHOOTING 15.1 General ® 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: Troubleshooting For Automatic Ignition Burner Systems
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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. -
Page 39: Troubleshooting For Flame Supervision System
SECTION 15: T ROUBLESHOOTING 15.3 Troubleshooting for Flame Supervision System NOTE: Minimum flame probe current 1 μA DC. Typical flame probe current 3-5 μA DC. -
Page 40: Troubleshooting For Solenoid Valves
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 15.4 Troubleshooting for Solenoid Valves 15.5 Troubleshooting for Main Fan ® For your safety and optimum heater performance use only ROBERTS GORDON replacement parts. Conduct Commissioning procedure as shown on Page 21, Section 11... -
Page 41: Troubleshooting For Fan Contactor
SECTION 15: T ROUBLESHOOTING 15.6 Troubleshooting for Fan Contactor ® For your safety and optimum heater performance use only ROBERTS GORDON replacement parts. Conduct Commissioning procedure as on Page 21, Section 11... -
Page 42: Section 16: Removal And Replacement Parts
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: REMOVAL AND REPLACEMENT PARTS Figure 17: Standard Regulator Removal See warnings and notes on Page 28, Section 13 before removing or replacing parts. Burner Components All serviceable burner parts are accessed by the door on the side of the heater. -
Page 43: Burner Compartment
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 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. -
Page 44: Ignition Electrode And Flame Probe
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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. -
Page 45: Flue Fan
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 16.4 Flue Fan 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. -
Page 46: Heater Pressure Switch
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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 47: Cooling Coil Safety Devices
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 16.6 Cooling Coil Safety Devices 16.6.1 Cooling Coil Frost Thermostat Coil Pressure Switch (Normally open contact) used to prove adequate air The sensing element for this device is inserted into flow for safe operation of cooling coil. the pocket of the cooling coil situated through the access hole in the coil cover. -
Page 48: Ignition Control
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL 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 This control is mounted at the electrical mounting plate. -
Page 49: Combination Fan/Limit Thermostat
SECTION 16: R EMOVAL AND EPLACEMENT ARTS 16.8.1 Fan Removal and Replacement Description Part Number Torin Fan DDC 270-270 A047 Torin Fan DDC 241-241 A049 1. Remove motor leaving the pulley in place. 3. Fit a new thermostat ensuring that the correct See Page 42, Section 16.8. -
Page 50: Figure 19: Combination Fan/Limit Thermostat
® EATING AND COOLING NITS NSTALLATION PERATION AND ERVICE ANUAL Figure 19: Combination Fan/Limit Thermostat Dial Set Point 3 Limit Temp. Set Point 2 Fan On Push Screwdriver in and hold to release Set Point 1 Fan Off Push in Lock Wire to Controlled Equipment Fan Terminals Limit Stat... - Page 52 Roberts-Gordon, LLC Roberts-Gordon Europe Limited...