Roberts Gorden DualAir DAT100 Operation manual

WARNING
FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to li ht any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your buildin .
5. Leave the buildin .
6. Immediately call your local as
supplier after leavin the buildin .
Follow the as suppliers
instructions.
7. If you cannot reach your as
supplier, call the Fire Department.
Fire Hazard
Do not store or use petrol or other
flammable vapours and liquids in the
vicinity of this or any other appliance.
Some objects will catch fire or explode
when placed close to heater.
Failure to follow these instructions can
result in death, injury or property
dama e.
Roberts-Gordon Europe Limited
Oxford Street
Bilston, West Midlands WV14 7EG UK
Telephone: [phone]
Fax: [phone]
Service Telephone: [phone]
Service Fax: [phone]
E-mail: [email protected]
E-mail: [email protected]
www.rg-inc.com
WARNING
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or property
damage. Read the installation, operation and service
manual thoroughly before installing or servicing
this equipment.
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.
© Copyright 2005 Roberts-Gordon
Quality in Any Language™
DualAir®
Installation, Commissioning,
Operation & Service Manual
DAT75
DAT90
DAT100
DAT115
P/N X527 Rev B 10/05
Heating and Cooling Units

© 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.
Printed in U.K.
TABLE OF CONTENTS
SECTION 1: Heater Safety...................................................... 2
SECTION 2: Installer Responsibility ..................................... 2
2.1 Clearances to Combustibles ........................................ 2
2.2 Corrosive Chemicals.................................................... 2
2.3 National Standards and Applicable Codes .................. 2
SECTION 3: Critical Considerations...................................... 3
3.1 Basic Information......................................................... 3
3.2 Location and Suspension ............................................ 3
3.3 Minimum Required Installation Clearances ................. 3
3.4 Clearances to Combustibles ........................................ 3
3.5 Ventilation .................................................................... 3
3.6 Gas Supply ..................................................................3
3.7 Electrical Supply ..........................................................3
3.8 Flue.............................................................................. 3
3.9 Coil Condense Drain....................................................3
SECTION 4: Specifications .................................................... 5
4.1 DAT (all models) .......................................................... 5
4.2 General Technical Data Table (all models) ..................6
4.3 Technical Data Table - Heater Section (all models) ..... 7
4.4 DualAir®Performance Data -
Graph of Air Flows v Static Pressure ........................... 8
SECTION 5: Heater Installation.............................................. 9
5.1 General ........................................................................ 9
5.2 Handling ...................................................................... 9
5.3 Shelf Mounting and Suspension..................................9
SECTION 6: Flue Installation ............................................... 10
6.1 Flue Installation.......................................................... 10
6.2 Type C12, C32 & C62 Appliance..................................... 10
6.3 Type B22 Appliance..................................................... 10
6.4 Converting from Top to Side Terminations
for Flue and Air Intake. .............................................. 10
SECTION 7: Air Supply......................................................... 13
7.1 Room Sealed Installation ........................................... 13
7.2 Open Flued Installation .............................................. 13
7.3 Building Ventilation ..................................................... 13
7.4 Isolated Equipment Rooms ........................................ 13
SECTION 8: Optional Heater Configurations...................... 14
8.1 Distribution Duct ........................................................ 14
SECTION 9: Gas Piping ........................................................ 15
9.1 Connections............................................................... 15
SECTION 10: Wiring and Electrical Information................. 16
10.1 Electrical Supply ...................................................... 16
10.2 Remote Control ........................................................ 16
10.3 DAT Main Circuit Board Terminal Identification ........ 17
10.4 DAT Wiring Diagram Models 75-115 ........................ 18
10.5 DAT Wiring Diagram Models 75-115 ........................ 19
10.6 DAT Site Connections at Main Circuit Board............ 20
SECTION 11: Commissioning .............................................. 21
11.1 Pre Commission Checks...........................................21
11.2 Gas Supply ............................................................... 21
11.3 Mechanical Checks................................................... 21
11.4 Begin Commissioning ............................................... 21
11.5 Combustion Testing (all models)............................... 23
11.6 Turning Off the DualAir®Unit..................................... 24
11.7 External Controls ...................................................... 24
11.8 Complete the Commissioning................................... 24
11.9 Instruction to the User .............................................. 24
SECTION 12: User Instructions............................................25
12.1 User Instructions ......................................................25
12.2 Heater Operation......................................................25
12.3 Common User Controls (all models) ........................25
12.4 Cooling Section Operation .......................................26
12.5 Heating Section Lighting Instructions.......................26
12.6 Simple Fault Finding (all models) .............................26
SECTION 13: Servicing .........................................................27
13.1 Servicing Instructions...............................................27
13.2 Burner Maintenance.................................................27
13.3 Fan/Motor Assembly Maintenance...........................27
13.4 Heat Exchanger Maintenance..................................27
13.5 Gas Control Valve Maintenance (all models) ...........28
13.6 Flue Fan ...................................................................28
SECTION 14: Conversion Between Gases ..........................29
14.1 General ....................................................................29
14.2 Burner Conversion ...................................................29
14.3 Gas Valves ...............................................................29
SECTION 15: Troubleshooting .............................................30
15.1 General ....................................................................30
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
16.3 Ignition Electrode and Flame Probe. ........................37
16.4 Flue Fan ...................................................................38
16.5 Heater Pressure Switch............................................39
16.6 Cooling Coil Safety Devices .....................................40
16.7 Ignition Control .........................................................41
16.8 Fan Motor Removal ..................................................41
16.9 Combination Fan/Limit Thermostat ..........................42

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 .................................................................. 11
Figure 7: Vertical and Horizontal Flue Termination -
Ty p e B 22 Appliance................................................... 12
Figure 8: Vertical and Horizontal Flue Termination -
Ty p e C 12 C32 & C62 Appliances.................................. 12
Figure 9: DualAir®Units Installed in Isolated
Equipment Rooms. .................................................. 13
Figure 10: Ducting................................................................... 14
Figure 11: Gas Connection with Stainless Steel
Flex Connector ....................................................... 15
Figure 12: Automatic Burner Control Box Sequence............... 22
Figure 13: Modureg Gas Valve................................................ 22
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

1
Product Approval
ROBERTS GORDON
®
appliances have been tested and CE certified as complying with the essential
requirements of the Gas Appliance Directive, The Low Voltage Directive, The Electromagnetic
Compatibility Directive and the Machinery Directive for use on natural gas and L.P. gas when installed,
commissioned and maintained in accordance with these instructions.
These instructions refer to appliances designed to operate in the European Union.
Appliances designed for other countries (Non European Union) are available on request.
This appliance must be installed in accordance with the local and national codes in force and used
only in a sufficiently ventilated space, as specified in these instructions.
Before installation, check that the local gas distribution systems, nature of gas and pressure, and
adjustment of the appliance are compatible.

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
2
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®unit must be done by a registered installer/
contractor qualified in the installation and service of
gas-fired heating equipment.
Read this manual carefully before installation,
operation, or service of this equipment.
This DualAir®unit is designed for heating and
cooling non-residential indoor spaces. Do not install
in residential spaces. These instructions, the layout
drawing, local codes and ordinances, and applicable
standards that apply to gas piping, electrical wiring,
venting, refrigerant installation, etc., must be
thoroughly understood before proceeding with the
installation.
SECTION 2: INSTALLER RESPONSIBILITY
• To supply and install a suitable condenser unit
along with associated refrigerant circuits in
accordance with the requirements of
all relevant local and national codes.
• To install the DualAir®unit, as well as the gas
and electrical supplies, in accordance with appli-
cable specifications and codes. Roberts-Gordon
recommends the installer contact a local
building inspector, Fire Officer or insurance
company for guidance.
• To use the information given in the manual
together with the local and national codes to
perform the installation.
• To install the DualAir®unit in accordance with the
Clearances to Combustibles of this DualAir®unit.
• To furnish all needed materials not furnished
as standard equipment.
• To plan location of supports, flues and air
intakes.
• To provide access for servicing.
• To provide the owner with a copy of this
installation, commissioning, operation and
service manual.
• To never use the DualAir®unit as support for lad-
der or other access equipment and never hang
or
suspend anything from heater.
• To ensure that there is sufficient ventilation in the
area to comply with the requirements of
all relevant local and national codes.
2.1 Clearances to Combustibles
In all situations, clearances to combustibles must be
maintained. Caution must be used when running the
DualAir®unit near combustible materials such as
wood, paper, rubber, etc. A wall tag is on the back
cover of this manual as a permanent reminder of the
safety instructions and the importance of the
required clearances to combustibles. Affix the tag on
a wall near the DualAir®unit.
2.2 Corrosive Chemicals
Roberts-Gordon cannot be responsible for ensuring
that all appropriate safety measures are undertaken
prior to installation; this is entirely the responsibility
of the installer. It is essential that the contractor, the
sub-contractor, or the owner identifies the presence
of combustible materials, corrosive chemicals or
halogenated hydrocarbons* anywhere in the
premises.
* Halogenated Hydrocarbons are a family of chemical
compounds characterized by the presence of halogen
elements (fluorine, chlorine, bromine, etc.). These com-
pounds are frequently used in refrigerants, cleaning
agents, solvents, etc. If these compounds enter the air
supply of the burner, the lifespan of the DualAir®unit
components will be greatly reduced. Warranty will be
invalid if the heater is exposed to halogenated hydrocar-
bons.
2.3 National Standards and Applicable Codes
All Appliances must be installed in accordance with
the latest revision of applicable standards and local
and national codes. This refers also to the electric,
gas, refrigerant and venting installation. Note:
Additional standards for installations in Public
Garages, Aircraft Hangars, etc. may be applicable.
CA TION
Do not use heater in an area containing corrosive
chemicals.
Corrosive chemicals will damage the burner and
heat exchanger parts.
Failure to follow these instructions can result in
property damage.

SECTION 3: CRITICAL CONSIDERATIONS
3
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Basic Information
The CTUD heater that forms the heating section of
the DualAir®unit has an automatic ignition burner
and may be operated as fully modulating or ON/OFF
operation.
The standard unit has the air flow from left to right
when viewed from the controls side.
A special order version with the opposite air flow is
available where the combustion air intake and flue
will be at the front of the unit.
3.2 Location and Suspension
All models:
• Must be installed indoors.
• Must be installed in a level position.
• May be mounted on the floor or on a shelf of
non-combustible material. (See Page 5, Section
4and Page 9, Figure 3 for support points)
• May be suspended from above (See Page 9,
Figure 3),on the floor, or from wall brackets of
sufficient strength to support the DualAir®unit as
listed in the Dimension Data Table on Page 6,
Section 4.2. Drop rods must be a minimum of 12
mm diameter mild steel. Six suspension points
are located on top of the DualAir®unit.
• Must be installed in a manner which allows the
hinged door to be fully opened to provide access
to all serviceable components.
3.3 Minimum Required Installation Clearances
Clearances around the DualAir®unit and flue must
be as indicated on Page 4, Figure 2, Page 10,
Figure 4 through Page 12, Figure 8 to ensure
access for servicing, and correct operation.
3.4 Clearances to Combustibles
Clearances must be as indicated on Page 4, Figure
2. If no clearances to combustibles are indicated
then installation clearances apply.
3.5 Ventilation
It is important to ensure that there is adequate air
circulation around the DualAir®unit to supply air for
combustion, ventilation and distribution in
accordance with local and national codes.
3.6 Gas Supply
It is important that the gas supply pipe is sized
correctly to provide the inlet pressure as stated on
the heater data plate. The gas supply pipe and
electrical connections must not support any of the
heater's weight.
3.7 Electrical Supply
A permanent 400v 3ø 50Hz electrical supply is
required at the main electrical terminals. The heater
also requires suitable energy controls in accordance
with Section 10.
3.8 Flue
Choose a location to allow for the proper alignment
of the flue. Each DualAir®unit must be fitted with an
individual and correctly sized sealed flue system
(See Page 10, Section 6).
No other appliance may be connected to the flue.
For room sealed installation the air intake must be
the same size sealed system and the flue/air intake
must terminate at an approved concentric wall or
roof terminal.
3.9 Coil Condense Drain
The cooling coil must be fitted with a suitable
condense drain. The condense pipe work should be
in plastic or copper piping in accordance with the
latest revision of applicable standards and local and
national codes.
Figure 1: Condense Drain
Failure to install the condense drain correctly may
cause water carry over into the fan compartment,
which may then escape and cause property
damage.
100 mm min.
Install to Suitable Drain
Drain to Open Funnel
Trap must be filled with
water to be effective and
prevent air being drawn
bac wards into the drip tray.

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
4
Figure 2: Installation Clearances and Clearances to Combustibles
WARNING
Fire Hazard
Some objects will catch fire or explode when placed
close to heater.
Keep all flammable objects, liquids and vapours the
required distance away from the heater.
Failure to follow these instructions can result in death,
injury or property dama e.
Clearances to Combustibles
Alternative
Wall
Terminal
Roof Terminal
Air
Inta e Flue
15 cm
2.5 - 3.5 m*
3 m
60 cm
Installation Clearances
Customers
Suitable
Condenser
Unit
Insulated
Refrigerant pipes
to cooling coil
by Customer
Condense
Drain
Install to
suitable drain,
See Page 3,
Figure 1.
Air Flow 50 cm 50 cm**
30 cm
15 cm
If installed at low levels where individuals can come in contact with hot heat exchanger components,
adequate guarding must be provided.
All distances are minimum clearance requirements for service access, air flow and safety.
Free blowing DualAir®units must always be installed at least 1.8 m above the floor.
Ducted installations may be floor mounted.
The flue pipe must have clearance from combustibles by 5 cm.
**80 cm is necessary to
service heater.
* Free blowing DualAir®units may be mounted at
a higher level if destratification fans and/or turn
down nozzles are installed.

SECTION 4: SPECIFICATIONS
5
SECTION 4: SPECIFICATIONS
4.1 DAT (all models)
225
Air Intake
Flue
Heater Section Fan Compartment
Electrical
Connections
(behind door)
Filter CompartmentCondense Drain
Air utlet
Spigot
(35 mm flange)
Air Intake 130 mm dia
Coil Protection,
Frost Thermostat
& Pressure Switch
Alternate
Flue &
Air Intake
Position
Cooling Coil
Air Inlet Spigot
(35 mm flange)
3010
896 225
1239
Internal
Spigot
Height
1417
Flue 130 mm dia
Lockout
Reset Green
Burner
n
Red
Lockout
Warning
Amber
Dirty Filter
Warning
734
Gas
Connection
1127
20 mm Conduit Entry
for Electrical Connections
1494
671
2070 532
1239
Internal
Spigot
Height
1250 Internal Spigot Width
Alternate
Flue &
Air Intake
Position
315
89051 399
1340
1590
Extension
Cover for
Refrigerant
Pipe-work
538
1032 Standard Flue &
Air Intake Position
Side View
Front View
Rear View
Front View (Left Version)
Rear View (Left Version)

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
6
4.2 General Technical Data Table (all models)
Electrical load at 230v 50Hz measured by calculating from total run current of appliance.
* Do not exceed the maximum length of flue stated or heater may not operate properly.
Reduce the maximum length stated by 1 m for each 90° bend installed.
**If minimum air flow requirements are not met then temperature limit devices will shut down the heater.
Model
Designed Air Flow # with Clean Filters m3/sec
Min Air Flow at Coil m3/sec
Max Air Flow at Coil m3/sec
Fan Unit
Fan Pulley mm PCD
Motor Pulley mm PCD
Vee Belts
Total Electrical Load kW
Motor Size kW
Full Load Current A
Run Current at Designed Air Flow # A
Start Current A
Inlet Connection in
Outlet Connection in
Condensate Connection ISO 7-R
Refrigerant °C Dry Bulb
°C Wet Bulb
°C Dry Bulb
°C Wet Bulb
All Models
Initial Pressure Loss mbar
Max. Recommended Pressure Loss mbar
Weight kg
NR dB(A)
SPL dB(A)
NR dB(A)
SPL dB(A)
NR dB(A)
SPL dB(A)
68
68
73
75
5.4
1
23.0 24.0
7.0 / 7.5
57.74 71.54
2.88
1.66
3.71
2A x 112 / 2A x 118
115
3.7
2.60
5.34
75 90
2 x A 63
2A x 180 / 2A x 200
2A x 100 / 2A x 95
Fan Data
457-486 Double Inlet Belt Drive
2A x 180
2 x A 64
100
kW
Max Cooling Load Split into Two Equal
Circuits
Design Temp. ON
Design Temp. OFF
27 R407C
612 621
1 5/8 copper
638 647
65
0.4
1.5
Qty. 6 - Farr 30/30 grade 100 x 635 x 406
Filters - All Models
7/8 copper
1 3/8 copper
18.07
14.66
Electrical Data - All models need 400v 50Hz 3N supply. Single phase supply output for control circuit
230v 50Hz fused at 5 Amp. All alarm and status signals 230v 50Hz. Modulation input 0-10vDC.
Cooling Coil - DX
4.0
7.5
2.2
4.45
4.0 / 4.5
3.3
Physical Data
Noise from Cabinet at 1 m 67.5
72
13.72 13 12.3
19.4 25
Noise from Air Inlet at 1 m 77 75
Noise from Air Outlet at 1 m 81 7776

SECTION 4: SPECIFICATIONS
7
4.3 Technical Data Table - Heater Section (all models)
Appliance Category II 2H/L 3B/P
Gas rates corrected to standard conditions 1013.25 mbar 15°C.
*See Page 43, Figure 19 for detailed Combination Fan/Limit Thermostat settings.
Model
Heat Input kW
Gross Calorific Value Btu/h x 1000
Heat Input kW
Net Calorific Value Btu/h x 1000
Approximate kW
Max Heat Output Btu/h x 1000
Min Heat Input - Low Fire kW
Gross Calorific Value Btu/h x 1000
Min Heat Input - Low Fire kW
Net Calorific Value Btu/h x 1000
kW
Btu/h x 1000
Set Point 1 Fan OFF Temp. °C
Set Point 2 Fan ON Temp. °C
Set Point 3 Limit Temp. °C
Secondary Limit Thermostat °C
Max Burner Pressure mba
r
m3
/
h
ft3
/
h
Min Burner Pressure - Low Fire mbar
m3
/
h
ft3
/
h
Max Burner Pressure mba
r
m3
/
h
ft3/h
Min Burner Pressure - Low Fire mbar
m3/h
ft3/h
Max Burner Pressure mba
r
m3
/
h
Max Gas Flow Rate kg/h
liquid l/h
Min Burner Pressure - Low Fire mbar
m3
/
h
Min Gas Flow Rate kg/h
liquid l/h
Max Burner Pressure mba
r
m3
/
h
Max Gas Flow Rate kg/h
liquid l/h
Min Burner Pressure - Low Fire mbar
m3
/
h
Min Gas Flow Rate kg/h
liquid l/h
68.6
234 77.7 265
Min Heat Output - Low Fire 54.6
186 63.7 217
9.24
1.86
4.53
7.91
2.16
5.29 11.209.87
2.32
5.66 2.63 6.42
9.2
3.75
9.17
13.2 14.1 16.0
3.09 3.32
7.55 8.09
9.0 9.5 9.0
18.3 19.4 18.3
11.3
6.5
2.65 18.7
8.96 10.43 11.20 12.67
4.55 5.31 5.69 6.45
2.46 2.86 3.07 3.48
12.5 13.4 12.4 12.7
12.8 14.9 16.0 18.1
6.5 7.58 8.13 9.21
3.51 4.09 4.39 4.97
25.6 27.3 25.3 25.9
7.74
273.4
6.64
234.6 9.40 332.0293.2
8.30
4.9 5.04.54.6
335.1 391 419 474
9.49 11.06 11.86 13.43
279.3 316.4
10.0 9.3 9.2 10.2
6.30 7.4 7.9 9.0
3.23 2.9 3.0 3.1
319 371 398 451
9.0 10.5 11.3 12.8
45
6.6 6.0 6.2 6.3
121
457
134
115
119
90 100
289
84.7
320
93.8
379
111
413
111
256
74.9
284
83.3
334
98
365
107
406
75
239
70
265
77.7
311
91
341
100
379
293
86
324
95
227
66.5
266
78
LPG Gas Propane (G31) Data - Inlet Pressure 37 mbar (Alternative where permitted 50 mbar) Minimum
25 mbar Maximum 57.5 mbar
LPG Butane (G30) Data - Inlet Pressure 29 mbar Min 20 mbar Max 35 mbar
205
60.2
30
50 45
85
222.5 259.6
*Combination Fan/Limit Thermostat Settings
Min Gas Flow Rate
Min Gas Flow Rate
Max Gas Flow Rate
Max Gas Flow Rate
Natural Gas (G20) Data - Inlet Pressure 20 mbar Min 17 mbar Max 25 mbar
Natural Gas (G25) Data - Inlet Pressure 25 mbar Min 20 mbar Max 30 mbar
70 75
75

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
8
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)
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 m3/sec 95 mm motor pulley x 180 mm fan pulley
100 mm motor pulley x 200 mm fan pulley
Static Pressure Pa
350
300
250
200
150
100
50
0
3.0 3.2 3.4 3.6 3.8 4.0
2.8
400
Air Flow m3/sec
118 mm Pulley 112 mm Pulley
Static Pressure Pa

SECTION 5: HEATER INSTALLATION
9
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®unit may stand
directly on its base.
5.2 Handling
All DualAir®units have steel channel sections at the
base to be used to support the equipment. Three
steel sections are also provided across the top of the
unit for support. The DualAir®unit may be
suspended from these top sections.
The DualAir®unit is heavy and proper handling
equipment must be used by trained engineers.
5.3 Shelf Mounting and Suspension
For typical suspension See Page 9, Figure 3.
Figure 3: Suspension Methods
WARNING
Crush Hazard
Use 12 mm steel drop rod
minimum.
Failure of the supports can
result in death, injury
or property dama e.
12 mm
Steel
Drop Rod
Nut
Washers
Nut
Locknut
Rolled Steel
Channel
Floor
Base

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
10
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. The joints between the flue
terminal and the roof or wall must be sealed. If the
flue passes through a wall or ceiling of combustible
material it must be enclosed by a sleeve of non-
combustible material and be separated from the
sleeve by at least a 25 mm air gap.
Flues and air intakes must be adequately
supported so that the DualAir®unit does not
bear the weight of the pipes.
For flue termination See Page 10, Figure 4 through
Page 12, Figure 8.
6.2 Type C12, C32 & C62 Appliance
Room Sealed.
The heaters are designed to be installed as room
sealed appliances. The flue and air intake are run as
separate pipes to the concentric wall or roof
terminal. See Page 12, Figure 8.
6.3 Type B22 Appliance
The flue must terminate outside the building and be
fitted with a low resistance terminal.
See Page 10, Figure 4 through Page 12, Figure 7.
6.3.1 Air Intake Terminal Cover
For Type B22 appliance installations, an Air Intake
Terminal Cover is an available option. The cover is
scored flat sheet metal that must be bent into shape.
See Page 12, Figure 7. Remove and retain the
screws for the Air Inlet spigot. Use these screws to
attach the cover in position over the spigot.
Figure 4: Flue and Roof Detail
6.4 Converting from Top to Side Terminations for
Flue and Air Intake.
1. Remove the control section lower door and
upper panel. See Page 11, Figure 5 through
Figure 6 for details.
6.4.1 Flue Conversion
1. Remove the inner and outer flue spigots from
the top. Retain the spigot and internal seal.
2. Disassemble the flue back to spigot "A". See
Page 11, Figure 6. Ensure all seals are still in
place.
3. Fit 90° bend directly into spigot "A" pointing
forwards.
4. Cut a 90 mm length from the 360 mm flue that
was removed.
5. Attach this piece to the 90° bend, then attach
the inner spigot that was removed.
6.4.2 Air Intake Conversion
1. Remove the flexible hose from the air intake
spigot.
2. Remove the spigot from the top.
3. Move the blanking plate from the upper panel
(previously removed) to the top to cover the
original flue and air intake holes.
4. Refit the upper panel feeding the air intake flex-
ible hose through the upper hole and aligning
the flue with the lower hole.
WARNING
Fire Hazard
Some objects will catch fire or explode when placed
close to the heater section.
Keep all flammable objects, liquids and vapours the
required distance away from the heater section.
Failure to follow these instructions can result in death,
injury or property dama e. Roof
Flue
Terminal
Metal Sleeve
Masterflash
soaker flashing
or Rain Collar.
Flue
25mm Air Gap to
Combustible Material

SECTION 6: FLUE INSTALLATION
11
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.
7. Refit the lower door.
Figure 5: Control Section & Upper Panel
Figure 6: Alternate
Upper Panel
Lower Door
Blan ing Plate
Hose Clamp
360 mm Lenght
of 130 mm dia Flue
Flexible Hose
Inner and Outer
Flue Spigots
Air Inta e Spigot
Control Section
Spigot "A"
90° Bend
90mm Flue
Inner Spigot
Hose Clamp
Flexible Hose
Upper Panel
Outer Spigots

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
12
Figure 7: Vertical and Horizontal Flue Termination - Type B22 Appliance
Figure 8: Vertical and Horizontal Flue Termination - Type C12 C32 & C62 Appliances
Flue
Masterflash
Roof Terminal
Metal Sleeve
(25 mm air gap to
combustible material)
Air Intake
Terminal Cover
Fold leg
down
Fold foot
out
Flue
Roof Terminal
Air Intake
Manifold
Masterflash

SECTION 7: AIR SUPPLY
13
SECTION 7: AIR SUPPLY
7.1 Room Sealed Installation
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. The air
supply to the heater must be fitted with a low
resistance terminal to prevent the ingress of debris.
See Page 12, Figure 7.
7.2.1 Heaters Installed Within the Heated Space
Where the volume of the heated space is greater
than 4.7 m3per kilowatt of total rated heat input and
the air change rate is at least 0.5/h, additional high
and low level ventilation will not be required.
For a building having an air change rate less than
0.5/h, ventilation will be necessary in accordance
with local and national codes. Ventilation direct to
outside must be provided as follows:
• Heaters above 70 kW heat input = 350 cm2+
2.5 cm2per kW of rated heat input above 70 kW
7.3 Building Ventilation
Where ventilation is required air must be taken from
an outside point where it is not likely to be
contaminated or obstructed.
Where natural ventilation is used, suitable ventilation
with outside air at low level must be provided in
accordance with Section 7.2.1 and local and national
codes.
Where mechanical ventilation is used, extract rate
must be 5% - 10% less than the inlet rate. The
mechanical ventilation must be interlocked with the
burner on the heater.
7.4 Isolated Equipment Rooms
Ventilation must prevent the isolated equipment
room temperature from exceeding 32°C as well as
prevent any negative air pressure within the room.
See Page 13, Figure 9. Any isolated equipment
room containing air heaters will require permanent
air vents direct to outside air in compliance with local
codes.
Where natural ventilation is used, suitable
permanent openings at low and high level,
communicating directly with the outside air, must be
provided.
Where mechanical ventilation is used, extract rate
must be 5% - 10% less than the inlet rate. The
mechanical ventilation must be interlocked with the
burner on the heater.
Figure 9: DualAir®Units Installed in Isolated Equipment Rooms.
Wall Outside
Wall
High level
ventilation
Low level
ventilation
Max Temperature 32° C
Room air pressure must not be negative.
Duct distribution
system or
discharge to
heated space.
Return air duct
from heated
space or fresh
air from outside
Flue
Air Intake
Manifold

DUALAIR®HEATING AND COOLING UNITS INSTALLATION OPERATION AND SERVICE MANUAL
14
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" stage provided.
Distribution ducting must be insulated to prevent
heat gain during cooling mode.
The air flow must be in the direction as stated for the
version being installed with the heater at the
discharge end.
The duct must be designed as described on Page
14, Section 8.1 and Figure 10 to ensure that there is
a homogenous air flow across the whole heat
exchanger. Failure to provide a properly distributed
air flow will reduce the life of the heat exchanger.
Contact Roberts-Gordon Europe Ltd. Design
Department for recommendations regarding
duct resistance and design. Tel: [phone]
494425
Figure 10: Ducting
Dimension
X
*Minimum
Twice
Dimension
X
Airflow Indicator
Flexible Flange
Ducting
NOTE: Duct size will be full size of inlet and outlet.
All joints between the heater and duct work should be
made as air tight as possible.
*Inlet Duct Minimum Dimension same as Outlet Duct
Minimum Dimension