Roberts Gorden DAT100 manual

W ARNING FOR Y OUR SAFETY If you smell g as: 1 . Open windo ws. 2. DO NO T try to light an y appliance. 3. DO NO T use electrical s witches. 4. DO NO T use any t elephone in your b uilding. 5. Leav e the build ing. 6. Immediatel y call your local gas supplier af ter leaving the b uilding. F ollow the gas supplier  s instructions. 7 . If you cann[...]

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© 2007 R ober ts-Gor don, LLC All rights reserved. No part of this work cover ed by the cop yr ights herein ma y be repr oduced or copied in any f or m or by any means - graphic, electronic, or mechanical, including photocop ying, recor ding, taping or information storage and retriev al syst ems - without the writt en per mission of Rober ts-Gordo[...]

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TABLE OF FIGURES Fi gur e 1: C ondens e Drain ................. ............ ................ ............ 3 F igur e 2: In stalla tion Cle arance s and Cl earanc es to Comb ustibl es .......... ................. ...................... ............ 4 Fi gure 3: Susp ension Methods ............... ...................... ............ 9 Fi gur e 4: Fl[...]

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1 Pr oduct Appro val ROBERTS GORDON ® appliances have been tested and CE certified as complying with the essential requirements of the Gas Appliance Directive, the Low V oltage Directive, the Electromagnetic Compatibility Directive and the Machinery Directive for use on natural gas and LPG when installed, commissioned and maintained in accordance [...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 2 SECTION 1: HEATER SAFETY Y our Saf ety is Impor tant t o Us! This s ymbol is used thr oughout the manual t o notify y ou of pos sibl e f ir e, electrical or burn hazar ds. Ple ase pa y special at t ention when reading and f ollow ing the warnings i n thes[...]

SECTION 3: C RITI C AL C ONSIDER ATIONS 3 SECTION 3: CRITICAL CONSI DERATIONS 3.1 Basic Inf ormation The CTUD heat er that f orm s the heati ng section of the Dual Air ® unit ha s an automa tic ignit ion b ur ner and ma y be operat ed as fully modulating or ON/ OFF operat ion. The standar d unit has the air flo w fr om lef t to right when vie wed [...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 4 F i gure 2: Installation Cl earanc es and Clear ances to Combust ibles W ARNING Fire H a z ard S ome objects will catch fire or explode when placed close to heater . K eep all flammable objects, liquids and vapours the required distance away from the heat[...]

SECTION 4: S PECIFICATIONS 5 SECTION 4: SPECIF ICATIONS 4.1 D A T 225 Air Intak e Flue Heater Section F an Compar tment Electrical Connections (behind door) Filt er Compar tment Condense Drain Air Outlet Spigot (35 mm flange) Air Intak e 130 mm dia Coil P rot ection, F rost Thermostat & P ressur e Switch Alternate Flue & Air Intak e P ositi[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 6 4.2 Gener al T echnical Data T able Electrical load at 230v 50Hz meas ured by calc ulating fr om tot al run curr ent of a ppliance . * Do not e x ceed the maximum l ength of f lue stat ed or heat er may not oper ate properly . R educe the max imum length [...]

SECTION 4: S PECIFICATIONS 7 4.3 T echni cal Data T able - Heater Sect ion Appliance C ategor y II 2H/L 3B/ P Gas rat es correct ed to st andar d conditions 1 0 1 3.25 mbar 1 5°C. * See P age 44, F igur e 19 f or detailed Combinat ion F an/L imit Thermostat set tings . Model Heat Input kW Gross Cal orific V alue Btu/h x 1000 Heat Input kW Net Calo[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 8 4.4 DualA ir ® P erf ormance Data - Graph of A ir Flo w s v Static P ressur e 4.4.1 D A T75 and 9 0 (2.2 kW or 4 kW mot or) 4.4.2 D A T1 0 0 and 1 1 5 (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 m 3 /sec 95 mm motor[...]

SECTION 5: H EATER I NSTALLATION 9 SECTION 5: HEATER INSTALLATION 5.1 Gener al D ualAi r ® units ar e designed f or i nstalla tion abo v e 2.5 m. W hen connect ed to duct del iv er y sy stems an y suitab le locati on wi ll be a cceptable . F or floor mounting , the DualA ir ® unit ma y stand dir ectly on i ts base . 5.2 Handling All Dual Air ® u[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 10 SECTION 6: FLUE INSTALLATION 6.1 Flue Instal lation The f lue m ust t er minate outside of the b uilding . Flues and air int akes must be fully sealed and corr ectly sized f or the model. Flues should be assemb led as detailed on P age 1 0, F igure 4 thr[...]

SECTION 6: F LUE I NSTALLATION 11 5. Ref it the ai r int ake spigot t o the fl e x ib le hose re- using the hose clamp and to th e upper panel using the original scr ews . 6. Align the fl ues ’ inner and out er spigots and at tach thr ough the holes in the upper panel re- using the original scr ews . 7 . Ref it t he lo wer door . F i gure 5: Cont[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 12 F igure 7: V er tical and Hor izontal Flue T ermination - T ype B 22 Appliance F igure 8: V er tical and Hor izontal Flue T ermination - T ype C 12 C 32 & C 62 Appl iances F lue Masterflash Roof T er minal Metal Sleev e ( 25 mm air gap to combustib l[...]

SECTION 7: A IR S UPPLY 13 SECTION 7: AIR SUPPLY 7 .1 Room Sealed Insta llation W hen inst alled as a r oom sealed hea ter , the a ir f or comb ustion i s dra wn in fr om outside th e b uilding . It is impor tant t o ensure that ther e is adequat e v entilation to pr ovide air f or the distribu tion f an/s. 7 .2 Open Flued Installation Ensur e adeq[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 14 SECTION 8: OPTIONAL HEATER CONFIGUR ATIONS 8.1 Distr ib ution Duct D ualAi r ® units ar e designed t o be connect ed to distrib ution and air inl et ductin g . It is r ecommended that fl e xible duct connect ors and/ or at t enuat ors ar e used to reduc[...]

SECTION 9: G AS P IPING 15 SECTION 9: GAS PIPING It is impor tant that the gas supply pipe and the electrical co nnections do not support any of the heat er’ s weight. A ga s meter i s connect ed to the service pipe by the ga s supply company . An e xisting met er should be chec ked, pre ferab ly by the compan y , to ensure that the met er is ade[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 16 SECTION 1 0: WI RING AND ELECTRICAL INF ORMATION 1 0.1 Electr ical Suppl y All heat er models need a constant 400 V 50 Hz 3 ø supply co nnecte d t o terminals L 1 ,L 2 , L 3 , N & Earth. Po l a r i t y " L 1 & N" must be corr ect. The [...]

SECTION 1 0: W IRING AN D E LECTRICAL I NFORMATION 17 1 0.3 D A T Main Circuit Board T erminal Identi f ication T er minal Number Use R ela y/F uncti on Operat ion 1 Input or Output Extern al F an Control Input for Remot e F an Opera- tion Outp ut for F an Operation Monitor Option al - Main F a n Runs from Exter nal Control 2 Output 230 V to ext er[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 18 1 0.4 D A T Wir ing Diagr am S 4563 C Honeywell L N E COMBUSTION F AN PRESSURE SWITCH BLUE Secondary Limit Thermostat N/C PINK GREY PURPLE RESET PUSH LOCKOUT RUN GREEN/YELLOW BLACK WHITE YELLOW GREEN/YELLOW BROWN BLUE BROWN BLUE MAINS FIL TER BLACK SENSE[...]

SECTION 1 0: W IRING AN D E LECTRICAL I NFORMATION 19 1 0.5 D A T Wir ing Diagr am 7 R1 230 V motor fan main R1/1 Condensor control circuit limit devices 9 Aux contact A2 overload & Fuse 5A 2 4 6 96 95 contactor 14 13 2 4 1 3 6 5 A1 Relay 1 Remote fan controls 230 V This appliance must be Earthed 10 N 400 V 50 Hz 3 N Suppy L1 L2 L3 Heating S ta[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 20 1 0.6 D A T Site Connections at Main Cir cuit Board 9 10 1 L1 N L3 L2 3 2 4 5 7 8 11 12 13 14 15 16 17 18 19 20 21 22 27 25 26 28 23 24 cooling condenser Lockout W arning 230 V Remote Lockout Reset Heat ON MUST be This appliance 3 N Suppy 400 V 50 Hz Ear[...]

SECTION 1 1 : C OMMISSION ING 21 SECTION 1 1: COMMISSIONING Gas Fi red Heat er Inst allation , ser vice, commissioning and ann ual inspecti on of the heat er must be done b y a contr act or qualif ied in the insta l lation and service of ga s-f ired heati ng equipment. R ead this man ual car efully befor e installat ion, commissio ning, operat ion,[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 22 F i gure 1 2: A utomatic Bur ner Contr ol Box Sequence F i gure 13: M odur eg Gas V alv e Burner sequence for Honeyw ell S4563 or S4565C Flame Signal Start Gas V alv e Ignition Spark Supply 230 V CL OSE DO WN RU N ST ART ts** Signals Output By Contr ol F[...]

SECTION 1 1 : C OMMISSION ING 23 1 1 .4.2 Commissioni ng the Gas V alves All Dual Air ® units are f it ted w ith fully modulati ng bu r ner opera tion. The Hone ywell aut omatic gas v alv es are f it ted wit h the Honeyw ell Modureg modulating r egulat or . See P age 22, F igur e 1 3 . The Modureg de vice pr ovi des the adjustments f or maximum an[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 24 w ater collection and a shor tened heat e x changer life. P ress ure S witc h The pre ssure s w itch is f actory pre-set f or each model and i s not adj ustab le. 1 1 .6 T urnin g Of f the Dual Air ® Unit Set the e xt er nal contr ols to the of f positi[...]

SECTION 1 2: U SER I NSTRUCTIONS 25 SECTION 1 2: USER INSTRUCTIONS 1 2.1 User Instructi ons The DualA ir ® units ar e fully aut omatic and operat e fr om the e xternal contr ols fit ted on sit e. The only user contr ols at the heater ar e the: Bur ner loc kout r eset but t on: ...... ..... .... ..... .... .... ....... See P age 26, Section 1 2.3.3[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 26 1 2.3.3 Burner Lock out Reset But ton The r ed warning light w ill illuminat e when the control has gone t o lock out. This ma y be caused by f lame f ailure . P ress the r eset but ton, ( See P age 5, Section 4.1 ), or the r emote r eset if installed on[...]

SECTION 1 2: U SER I NSTRUCTIONS 27 W ARNING FOR Y OUR SAFETY If you smell g as: 1 . Open windows. 2. DO NOT try to light an y appliance. 3. DO NOT use electrical s witches. 4. DO NOT use any t elephone in your b uilding. 5. Leave the build ing. 6. Immediately call y our local gas supplier af ter leaving the b uilding. Follo w the gas supplier  [...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 28 SECTION 1 3: SERVICING 1 3.1 Servicing Instruct ions Af ter commis sioning , the DualA i r ® unit w ill r equir e maint enance t o be carried out annually . If the D ualAi r ® unit is used in a dir ty or dust y area, mor e fr equent maint enance may be[...]

SECTION 1 3: S ERVICING 29 1 3.5 Gas Contr ol V alve Maint enance No r egular mai ntenan ce is r equir ed on these de vices. T o change gas contr ol v alv es , See P age 36, St ep 16.1 and P a ge 40, Section 1 6.5 . Do not repai r or disassemb le on site. R eplace faulty gas v alves wi th genuine ROBER TS GO RDON ® replaceme nt par ts. 1 3.6 Flue [...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 30 SECTION 1 4: CON VER SION BETWEEN GA SES 1 4.1 General C onv ersion bet w een g asses wi ll re quir e a change of bu r ner inject ors and t he gas v alv e re-c ommissioning t o the ne w conditio ns. 1 4.2 Burner Con ver sion C onv ersion of the bu r ner [...]

SECTION 1 5: T ROUBLESHOOTING 31 SECTION 1 5: T ROUBLESHOOTING 1 5.1 General W ARNING Explosion Hazard Installation must be done by a registered installer/ contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier. Failure to follo w these instructions can result in death, injury or property damage. If[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 32 1 5.2 T roub leshooting F or A utomatic I gnition Bur ner Sy stems If prob lems persist, contact ROBERTS GORDON ® at T el: +44(0) 1 90 249 8733 or www .rg-inc.com Heater Operating TROUBLESHOO T ENDS. No T race fault in supervision sy stem. See Section 1[...]

SECTION 1 5: T ROUBLESHOOTING 33 1 5.3 T roub leshooting f or Flame Supervision S yst em Repair or r eplace as necessary . If prob lems persist, contact ROBERTS GORDON ® at T el: +44(0) 1 90 249 8733 or www .rg-inc.com Contr ol box f ault y . Replace with correct type. Use section 1 5.1 to trace the f ault. Heater Operating TROUBLESHOO T ENDS. No [...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 34 1 5.4 T roub leshooting f or Solenoi d V alv es 1 5.5 T roub l eshooting f or Main F an V alve f ault y . Replace with one of correct type. F ault elsewhere F ault elsewhere If prob lems persist, contact ROBERTS GORDON ® at T el: +44(0) 1 90 249 8733 or[...]

SECTION 1 5: T ROUBLESHOOTING 35 1 5.6 T roub leshooting f or Fan Contactor Replace combination thermostat. Wiring faulty or faulty combination thermostat. Investig ate. If prob lems persist, contact ROBERTS GORDON ® at T el: +44(0) 1 90 249 8733 or www .rg-inc.com Rela y R3 faulty . Replace. Does fan run at cooling stage 2 (T1 2 live)? No Does fa[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 36 SECTION 1 6: REMO VAL AND REPLACEMENT P AR TS See w ar nings and not es on P age 2 8, Section 1 3 bef ore r emoving or r eplacing parts. Burner Components All serviceabl e b urner par t s ar e accessed b y the door on t he side of the heat er . See P age[...]

SE CTI ON 1 6: R EMOV AL AND R EPLA CEME NT P AR TS 37 1 6.2 Burner Compartment 1 6.2.1 Burner Inject ors Remove flexible air duct from spigot Remove access plate Remove screws and pull off burner cover Viewing port for flame probe Viewing port for ignition electrode Flame probe Burner compartment cover Rubber Seal Ignition electrode The burner com[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 38 1 6.3 Ignition Electr ode and Flame Probe. Flame Probe Ignition Electrode Remove Screw Ignition Electrode Burners Flame Probe Burners Burner Compartment Front Views Remove all burner compartment screws to remove the burner compartment and access the F[...]

SE CTI ON 1 6: R EMOV AL AND R EPLA CEME NT P AR TS 39 1 6.4 Flue Fan IT IS IMPORT ANT THA T ONL Y THE CORRECT FLUE F AN SPECIFIED FOR EA CH MODEL TYPE IS USED WHEN REPLA CING THESE ITEMS. C arry out a commission af te r working on or changing a f lue f an. See P age 25, Sect ion 1 2 . V ent Box Outlet Gasket Flue Fan V ent Box screws Flue Adapter [...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 40 1 6.5 Heater P ressure S wit ch P ull of f 3 wa y connect or . Spring open plas tic clips of mounting cr adle. R eplace w ith corr ect type of pr essur e sw itch f or model. The pr essur e sw itches ar e colou r coded f or each pr essure se t ting. C arr[...]

SE CTI ON 1 6: R EMOV AL AND R EPLA CEME NT P AR TS 41 1 6.6 Cooling Coil Safety De vices 1 6.6.1 Cooling Coil F r ost Thermost at The sensing element f or thi s de vice is ins er ted int o the poc k et of the cooling coil situated th rough the access hole in the coil cov er . The fr ost thermostat has two set t ings marked as se t point w ith an a[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 42 1 6.7 Ignition Contr ol IT IS IMPORT ANT THA T ONL Y THE CORRECT IGNITION CONTROL SPECIFIED FOR EA CH MODEL TYPE IS USED W HEN REPLA CING THESE ITEMS. 1 6.7 .1 S4563C This contr ol is mounted at the electrical mounti ng plat e. P ull out th e 3 cable con[...]

SE CTI ON 1 6: R EMOV AL AND R EPLA CEME NT P AR TS 43 1 6.8.1 F an R em ov al and R eplacement 1 . Remo ve mot or leaving the pul le y in place. See P age 4 2, Section 1 6.8 . 2. Remo ve scr e ws securing the fan outl et flange to the f an panel. (captiv e nuts) 3. Remo ve nu ts and bolt s securing the f an f eet t o the mounting brac kets . 4. Sl[...]

D UAL A IR ® H EATING AND COOL ING U NITS I NSTALLAT ION O PER ATION AND S ER VI CE M ANUAL 44 F i gure 1 9: Combination F an/Limit Thermostat Dial Set P o int 3 Li mit T emp. Set P oint 1 F a n Off Set P oint 2 F a n On Fa n T e r m i n a l s Manual F an Switch (Whit e) BREAK-OFF LINK MUST BE REMO VE D Limit T er mi nals Limit Stat Manual Res e t[...]

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