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Roberts Gorden DAT90 manual

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Table of contents for the manual

  • Page 1

    W ARNING 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. 7. If you cannot reach your gas su[...]

  • Page 2

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  • Page 3

    © 2005 All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including photocopying, recording, taping or information storage and retrieval systems - without the written permission of Roberts-Gordon. P r inted in U .K. T ABLE OF CONTE[...]

  • Page 4

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  • Page 5

    TABLE OF FIGURES Fi gure 1: C ondense Drain ........... .............. .............. .............. .... 3 Figur e 2: Installation Clearances and Clearances to Com bustib les ....... ........... .............. .............. ........... .... 4 Fi gure 3: Suspension Methods ....................... .............. ............ 9 Fi gure 4: Flue and R[...]

  • Page 6

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  • Page 7

    1 P roduct Ap pro v al 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 L.P . gas when installed, commissioned and maintained in acc[...]

  • Page 8

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 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 possib le f ir e, electrical or b ur n hazar ds. Please pa y special at tention when r eading and f ollo wing the w ar nings in these [...]

  • Page 9

    SECTION 3: C RITI CA L C ONSIDERATIONS 3 SECTION 3: CRITICAL CONSI DERATIONS 3.1 Basic Inf or mation The CTUD heat er that f or ms the heating section of the DualA ir ® unit has an aut omatic ignition b urner and ma y be operat ed as fully modulating or ON/OFF operation . The standar d unit has the air flow fr om lef t to r ight when vie wed fr om[...]

  • Page 10

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 4 F igur e 2: Installation Clear ances and Clear ances t o Comb ustibles W ARNING Fire Hazard Some objects will catch fire or explode when placed close to heater . Keep all flammable objects, liquids and vapours the required distance awa y from the heater . Fa[...]

  • Page 11

    SECTION 4: S PECIF ICATIONS 5 SECTION 4: SPECIFICATIONS 4.1 D A T (all models) 225 Air Intak e Flue Heater Section F an Compartment Electrical Connections (behind door) Filt er Compartment Condense Drain Air Outlet Spigot (35 mm flange) Air Intak e 1 30 mm dia Coil P rotection, F rost Ther mostat & P r essure S witch Alternate Flue & Air In[...]

  • Page 12

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 6 4.2 Gener al T echnical Data T able (all models) Electr ical load at 230v 50Hz measur ed by calculating fr om t ota l run current of app liance. * Do not e x ceed the maximum length of f lue stat ed or heat er ma y not operate pr operly . R educe the maximum[...]

  • Page 13

    SECTION 4: S PECIF ICATIONS 7 4.3 T echnical Data T able - He ater Section (a ll models) Appliance C at egor y II 2H/L 3B/P Gas rat es corr ect ed t o standar d conditions 1 0 1 3.25 mbar 1 5°C. * See P age 43, F igure 1 9 f or detailed Combination F an/Limit Ther mostat set tings. Model Heat Input kW Gross Cal orific V alu e Btu/h x 1000 Heat Inp[...]

  • Page 14

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 8 4.4 DualA ir ® P erformance Data - Gr aph of A ir Flo ws v Static P res sure 4.4.1 D A T75 and 90 (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 pull[...]

  • Page 15

    SECTION 5: H EATER I NSTALLATION 9 SECTION 5: HEATER INSTALLATION 5.1 Gener al DualA ir ® units are designed f or inst allation abo v e 2.5 m. When conne cted t o duct delivery sy stems an y suitab le location w ill be accept ab le. F or f loor mounting , the D ualA ir ® unit may stand directly on its base . 5.2 Handling All DualA ir ® units hav[...]

  • Page 16

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 10 SECTION 6: FLUE INSTALLATION 6.1 Flue Installati on The flue m ust t erminate outside of th e building . Flues and air intak es m ust be fully sealed and correctly siz ed f or the model. Flues should be assembled as detailed on P age 1 0, F igur e 4 through[...]

  • Page 17

    SECTION 6: F LUE I NSTALLATION 11 5. Ref it the air intak e spigot t o the fle xible hose r e- using the hose clamp and t o the upper panel using the or iginal scr e ws. 6. Align the flues ’ inner and out er spigots and at tach through the holes in the upper panel r e- using the or iginal scr e ws. 7 . R ef it the low er door . F igur e 5: Contr [...]

  • Page 18

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 12 F igur e 7: V er tical and Horiz ontal Flue T ermination - T ype B 22 Appliance F igur e 8: V er tical and Horiz ontal Flue T ermination - T ype C 12 C 32 & C 62 Appliances Flue Masterflash Roof T er minal Metal Sleev e (25 mm air gap to combustib le ma[...]

  • Page 19

    SECTION 7: A IR S UPPLY 13 SECTION 7: AIR SUPPLY 7 .1 Room Sealed Installation When installed as a r oom sealed he ater the a ir f or combustion is dra wn in fr om outside the b uilding . It is impor tant to ensur e that ther e is adequat e v entilation t o pr ov ide air f or the distr ib ution f an/s. 7 .2 Open Flued Installation Ensure adeq uate [...]

  • Page 20

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 14 SECTION 8: OPTIONAL HEATER CONF IGUR ATIONS 8.1 Distr ibutio n Duct DualA ir ® units are designed t o be connect ed to distrib ution and air inlet ducting. It is r ecommended that f le xib le duct connect ors and/ or at tenuat or s ar e used t o r educe du[...]

  • Page 21

    SECTION 9: G AS P IPING 15 SECTION 9: GAS PIPING It is impor tant that the g as supply pipe and the electrical connections do not supp or t any of the heat er’ s weigh t. A gas met er is connected t o the service pipe by the Gas Supply Compan y . An exist ing meter should be check ed, pr eferab l y by the Compan y , to ensur e that the met er is [...]

  • Page 22

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 16 SECTION 1 0: WIR ING AND ELECTRICAL INF ORMATION 1 0.1 Electrical Supply All heater models need a const ant 400 V 50 Hz 3 ø supply connected t o t erminals L 1 ,L 2 , L 3 , N & Ear t h. Po l a r i t y " L 1 & N" must be corr ect. The v ol[...]

  • Page 23

    SECTION 1 0: W IR ING AND E LECT RICAL I NFOR MATION 17 1 0.3 D A T Main Circuit Boar d T erminal Identif ication Te r m i n a l Number Use R ela y/F unction Oper ation 1 Input or Outp ut Exte rnal F an Con tr ol Input for Remot e F a n Opera- tion Output f or F an Oper ation Monit or Optional - Ma in F an Runs from External Contro l 2 Output 230 V[...]

  • Page 24

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 18 1 0.4 D A T Wir ing Diagr am Models 75-1 1 5 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 TE[...]

  • Page 25

    SECTION 1 0: W IR ING AND E LECT RICAL I NFOR MATION 19 1 0.5 D A T Wir ing Diagr am Models 75-1 1 5 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 [...]

  • Page 26

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 20 1 0.6 D A T Site Connections at Main Cir cuit Boar d 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 Earth[...]

  • Page 27

    SECTION 1 1: C OMMISSIONING 21 SECTION 1 1 : COMMISSIONING Gas F ire d Heater Installation, service, commissioning and ann ual inspection of the heat er m ust be done b y a contract or qualif ied in the inst allation and ser vice of gas-f ired heating equipment. R ead this manual carefully bef ore installation, commissi oning, operation, or service[...]

  • Page 28

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 22 F igur e 1 2: A ut omatic Burner Control Bo x Sequence F igur e 1 3: Modureg Gas V alve Burner sequence for Honeywell S4563 or S4565C Flame Signal Start Gas V alve Ignition Spark Supply 230v CLOSE DOWN RUN ST ART ts Signals Output By Control Required Incomi[...]

  • Page 29

    SECTION 1 1: C OMMISSIONING 23 1 1 .4.2 Commissioning the Gas V alv es All DualA ir ® units ar e f it ted with fully modulating burner operation. The Hon eyw ell aut omatic g as v alv es are f itt ed w ith the Hone ywell Modur eg modulating re gulat or . See P age 22, F igure 1 3 . The Modur eg de vice provides the a djustments f or maximum and mi[...]

  • Page 30

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 24 P ressur e S w itch The pr essur e s witch is f actor y pre -set f or each model and is not adjustab le . 1 1 .6 T urning Of f the DualAir ® Unit Set the e xt ernal controls t o the of f position and the main burner will stop . The f ans w ill run until th[...]

  • Page 31

    SECTION 1 2: U SER I NSTRUCTIONS 25 SECTION 1 2: USER INSTRUCTIONS 1 2.1 User Instr uctions The Du alAir ® units a re fully automatic an d operat e from the e xternal controls f itt ed on sit e. The only user controls at th e heater a re the: Burner lockout reset b utt on ................ See P age 26, Section 1 2.3.3 Limit thermostat reset ......[...]

  • Page 32

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 26 1 2.3.3 Bur ner Lock out R eset But t on The red warning light will illuminat e when the contr ol has gone t o loc k out. This ma y be caused by f lame f ailur e. P ress the r eset but ton,( See P age 5, Section 4.1 ), or the r emot e reset if installed on [...]

  • Page 33

    SECTION 1 3: S ERVICING 27 SECTION 1 3: SERVICING 1 3.1 Servicing Instructions Af t er commissioning , the D ualA ir ® unit w ill requir e mainten ance t o be carr ied out annually . If the DualA ir ® unit is used in a dir t y or dust y area, mor e frequ ent maint enance ma y be necessar y . Installation, Service and Annual Inspection of heat er [...]

  • Page 34

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 28 1 3.5 Gas Contr ol V alve Maintenance (al l models) No regu lar maint enance is r equir ed on these de vices . T o change g as contr ol v al v es, See P age 35, Step 1 6.1 and P age 39, Section 1 6.5 . Do not r epair or disassem ble on sit e. R eplace fault[...]

  • Page 35

    SECTION 1 4: C ON V ERSION B ETW EEN G ASES 29 SECTION 1 4: CON VERSION BETW E EN GASES 1 4.1 Gener al Con ver sion bet ween g asses wi ll requir e a change of burner injector s and the gas v al v e r e-commissioning to th e new con ditions. 1 4.2 Bur ner Con version Con v er sion of the b u r ner assembly fr om one g as t o the other is the same f[...]

  • Page 36

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 30 SECTION 1 5: T R OUBLESHOOTING 1 5.1 Gener al 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 f ollow thes[...]

  • Page 37

    SECTION 1 5: T ROUBLESHOOTING 31 1 5.2 T r oubleshooting F or Aut omatic Ignition Burner S y stems If problems persist, contact ROBERTS GORDON ® at T el: +44 (0) 1902 498733 or www .rg-inc.com Heater Operating TROUBLESHOO T ENDS. No T race fault in supervision system. See Section 16.3. No Ye s Is red lock out light on? No Is the flame current at l[...]

  • Page 38

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 32 1 5.3 T r oubleshooting f or Flame Supervision Sy st em Repair or replace as necessary . If problems persist, contact ROBERTS GORDON ® at T el: +44 (0) 1902 498733 www .combat.co.uk or www .rg-inc.com Control box faulty . Replace with correct type. Use sec[...]

  • Page 39

    SECTION 1 5: T ROUBLESHOOTING 33 1 5.4 T r oubleshooting f or Solenoid V alves 1 5.5 T r oubleshooting f or Main Fan V alve faulty . Replace with one of correct type. Fault elsewhere Fault elsewhere If problems persist, contact ROBERTS GORDON ® at T el: +44 (0) 1902 498733 or www .rg-inc.com V alve Operating TROUBLESHOO T ENDS. No Ye s V alve faul[...]

  • Page 40

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 34 1 5.6 T r oubleshooting f or Fan Contactor Replace combination thermostat. Wiring faulty or faulty combination thermostat. Investigate . If problems persist, contact ROBERTS GORDON ® at T el: +44 (0) 1902 498733 or www .rg-inc.com Relay R3 f aulty . Replac[...]

  • Page 41

    SECTION 1 6: R EMO VAL AND R EPLACEMENT P ARTS 35 SECTION 1 6: R EMO V AL AND REPLACEMENT P AR TS See warnings and not es on P age 27 , Section 1 3 bef or e r emoving or r eplacing par ts. Burner Componen ts All ser viceable b ur ner par ts are accessed by the door on the side of the heat er . See P age 5, Section 4 . 1 6.1 Gas V alve The VR4605 g [...]

  • Page 42

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 36 1 6.2 Bur ner Compartment 1 6.2.1 Bur ner Inject or s 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 Rubb[...]

  • Page 43

    SECTION 1 6: R EMO VAL AND R EPLACEMENT P ARTS 37 1 6.3 Ignition Electr ode and Flame P robe. 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 Front View. Fan/Limit Thermost at Secondary[...]

  • Page 44

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 38 1 6.4 Flue F an IT IS IMPOR T ANT THA T ONL Y THE CORRECT FLUE F AN SPECIFIED FOR EA CH MODEL TYPE IS USED WHEN REPLA CING THESE ITEMS. C arr y out a commission af ter working on or changing a fl ue f an. See P age 25, Sectio n 1 2 . V ent Box Outlet Gasket[...]

  • Page 45

    SECTION 1 6: R EMO VAL AND R EPLACEMENT P ARTS 39 1 6.5 Heater P ressure S witch P ull of f 3 wa y connector . Spring open plastic clips of mounting cradle . R eplace w ith corr ect t ype of pressur e sw itch f or mod el. The pr essure s witches are colo ur coded f or each pr essur e set ting. C arr y out a commission af ter working on or changing [...]

  • Page 46

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 40 1 6.6 Cooling Coil Saf ety De vices 1 6.6.1 Cooling Coil F rost Thermostat The sensing element f or this de vice is inserted int o the poc ke t of the cooling coil situat ed thr ough the access hole in the coil cov er . The fr ost thermostat has t wo set ti[...]

  • Page 47

    SECTION 1 6: R EMO VAL AND R EPLACEMENT P ARTS 41 1 6.7 Ignition Contr o l IT IS IMPOR T ANT THA T ONL Y THE CORRECT IGNITION CONTROL SPECIFIED FOR EA CH MODEL TYPE IS USED WHEN REPLA CING THESE ITEMS. 1 6.7 .1 S4563C Models 75 to 1 1 5 This contr ol is mount ed at the electr ical mounting plate . P ull out the 3 cable conn ector s. P ull o ut igni[...]

  • Page 48

    D UAL A IR ® H EATING AN D COOLING U NITS I NSTALLATION O PERATION AND S ERVICE M AN UAL 42 1 6.8.1 F an R emo va l and Replace ment 1 . R emov e mot or lea ving the pulle y in place . See P age 41, Section 1 6.8 . 2. Remo v e scr ews secu ri ng the f an outlet f lange to the f an panel. (captiv e n uts) 3. Remo v e nuts a nd bolts securi ng the f[...]

  • Page 49

    SECTION 1 6: R EMO VAL AND R EPLACEMENT P ARTS 43 F igur e 1 9: Combination F an/Limit Ther mostat Dial Set P oin t 3 Limit T emp. Set P oint 1 F a n Of f Set P oint 2 F a n On Fa n T e r m i n a l s Manual F a n Sw itch (Wh it e) BREAK-OFF LINK MUST BE REMO VED Limit T erminals Limit Stat Manual Res e t B u tton (Re d) P ush in Loc k Wir e to C on[...]

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  • Page 52

    www .rg-inc.com P rinted in the U.S .A. At tach this inf ormation t o the wall near the R OBER TS GORDON ® heater Installation Code and Ann ual Inspections: All inst allations of ROBERTS GORDON ® pr oducts must be performed by a contr actor qualified in the installation and service of gas-fir ed heating equipment and conform to all requir ements [...]