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Roberts Gorden HE20UT Heating System User Manual

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1. Roberts Gordon LLC ww rgrine com PIN 91031404 Rev C Wiring Labe 3 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 2 INSTALLER RESPONSIBILITY To install the heater as well as the gas and electrical supplies in accordance with applicable specifications and codes Roberts Gordon LLC recommends the installer contact a local Building Inspector or Fire Marshal for guidance To use the information given in a layout drawing and in the manual together with the cited codes and regulations to perform the installation To install the heater in accordance with the clearances to combustibles To furnish all needed materials not furnished as standard equipment To plan location of supports To provide access to burners for servicing on all sides for burner removal To provide the owner with a copy of this Installation Operation and Service Manual To never use heater as support for ladder or other access equipment and never hang or suspend anything from heater To ensure there is adequate air circulation around the heater and to supply air for combustion ventilation and distribution in accordance with local codes To safely and adequately install heater using materi als with a minimal working load of 33 kg To ensure the heater is placed in an approved application 2 1 Low Level User Instructio
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3. 49 SECTION 3 Clearances To Combustibles 5 11 5 Fresh Air Supply 49 3 1 Required Clearances to Combustibles 5 11 6 Outside Combustion Air Supply 50 3 2 Clearances Data Linear and Double Linear 6 11 7 Common Ductl 51 3 3 Clearances Data U Tube 8 SECTION 12 Gas Piping 52 SECTION 4 Major Component Descriptions 10 SECTION 13 Wiring 54 SECTION 5 General Suspension Details 11 13 1 Typical External Wiring Diagram SECTION 6 Linear amp Double Linear Heater Linear or U Tube 54 Installation 13 13 2 Typical External Wiring Diagram 6 1 Linear Standard Parts List 13 Double Linear Option 1 55 6 2 Double Linear Standard Parts List 16 13 3 Typical External Wiring Diagram 6 3 Burner Tube Installation 19 Double Linear Option 2 55 6 4 Coupling and Tube Assembly 19 13 4 Typical External Wiring Diagram 6 5 Tube Clamp Package Installation 2
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5. 33 SECTION 16 Troubleshooting 62 SECTION 8 Multiburner Configuration amp 16 1 Troubleshooting Flow Chart Linear Double Installation 35 Linear and U Tube 63 8 1 Initial 35 16 2 Troubleshooting Flow Chart Multiburner 65 SECTION 9 Burner amp Fan Installation 37 16 3 Manifold Gas Pressure Setting 67 9 1 Burner Installation 37 SECTION 17 Replacement Paris 68 9 2 Standard Fan Assembly 37 17 1 Replacement Packages 70 9 3 IP55 Fan 26 38 SECTION 18 Specifications 71 9 4 Linear amp U tube Fan Installation 38 18 1 Material Specifications 71 9 5 Double Linear Fan Installation 39 18 2 Heater Specifications 71 9 6 Multiburner 83 90 BWLG Fan Assembly 18 3 Venting Specifications 71 Horizontal and Vertical Outlets 40 18 4 Suspension Specifications 71 9 7 Condensate Drain Assembly
6. 40 18 5 Controls Specifications 71 SECTION 10 Optional Heater Accessories 41 18 6 Linear Healer e t 72 10 1 Reflector Side Extension Installation 42 18 7 Double Linear Heater 72 10 2 U Tube Cover Installation 43 18 8 U tube 22 72 10 3 Decorative Grille Installation 44 18 9 Burner Specifications 73 10 4 Protective Grille Installation 45 2010 Roberts Gordon Europe Limited 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 Europe Limited Printed in U K TABLE OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Bottom and Back Panel La
7. Figure 20 Double Linear General Assembly Overview abeyoed duel eqny deo pug m IEM p SInO 2 A ddns 4V 459 pulg Jo deg jue Q 17 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Figure 21 Double Linear Layout Overview LEGEND E 1 Burner Repeated Reflector R tute Ur HE30DL Y Opposite ide Tube Reflector Hanger Coupling Assembly Fan Assembly Repeated Tee Assembly Opposite HE4ODL HESODL HE60DL Repeated HE70DL m dq d 7 ide a reflector width not shown 365 mm e distance typical between hangers 3050 mm b end cap to burner fan 50 mm burner height 241 mm c end cap to hanger 50 mm burner length 445 mm d distance first hanger 2290 mm Model HESODL HE40DL HE50DL HE60DL HE70DL Reflector 700 mm 250 mm 250 mm 530 mm 530 mm Overlap approx 18 of 73 SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION Step 6 3 Burner Tube Installation Note Tubing requires a downward Offset mounting slope of 18 mm per 6000 mm hole must be away from burner m to the top B Bow Shackle Hanger Burner Tube Weld seam x must be to the bottom of the tube Description Part Number Burner Tube 03051100 Bow Shackle E0007576 Tube Reflector Hang
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9. on na oa oa oa o o o O oo 10 O oo 10 o LO e o mo N N LO nr q q LO WwW L L ul Li LI LI LI II II II II II I I I A 200 200 200 250 250 275 300 300 B 200 200 200 200 200 200 200 200 y C 1500 1660 1660 1860 1960 2030 2110 2160 D 1370 1520 1520 1630 1750 1820 1880 2000 6 of 73 SECTION 3 CLEARANCES TO COMBUSTIBLES NOTE 1 All dimensions are from the surfaces of all tubes couplings tees elbows and crosses 2 Clearances B C and D can be reduced by 5096 after 7500 mm of tubing downstream from the burner 3 All measurements are in millimeters FIGURE 7 LINEAR 8 DOUBLE LINEAR 2 FOOT DECO GRILLE PROTECTIVE GRILLE l l oa ba Ga ba GA b m m o O oo lo O oo 10 o o LO o P C A N M On q L0 Li Lil LI Lil LI Lil LI Li LI LI LI y x A 150 150 150 150 150 150 200 200 C 2 B 890 970 970 1020 1170 1220 1280 1330 B lt _D gt Y C 1570 1650 1650 1780 1930 1970 2010 2080 D 890 970 970 1020 1170 1220 1280 1330 FIGURE 8 UNDERSHIELD d R oa oa Ga Ga o o o 0 t O oo O oo 10 O o LO o u o A N On r r LO Li Li LI LL Li Lil Li Li Li Li LI I A 150 150 150 150 150 150 B 990 1020 1270 1270
10. Based on Gross Caloric Value 73 of 73 Attach this information to a wall near the ROBERTS GORDONS heater ROBERTS GORDON Infrared Heating Read the Installation Operation and Service Manual thoroughly before installation operation or service Know your model number and installed configuration Model number and installed configuration are found on the burner and in the Installation Operation and Service Manual Write the largest clearance dimensions with permanent ink according to your model number and configuration in the open spaces below OPERATING INSTRUCTIONS 1 STOP Read all safety instructions on this information sheet 2 Open the manual gas valve in the heater supply line 3 Turn on electric power to the heater 4 Set the thermostat to desired setting TO TURN OFF THE HEATER 1 Set the thermostat to off or the lowest setting Fire Hazard IF THE HEATER WILL NOT OPERATE TO ENSURE YOUR SAFETY FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from heater Setthe thermostat to off or the lowest setting Some objects will catch fire or explode when placed close to Turn off electric power to the heater heater Turn off the manual gas valve in the heater supply line Call your registered installer contractor qualified in the Failure to follow these instructions can result in death injury install
11. 18 9 Burner Specifications Figure 35 BLACKHEAT HE Linear and U tube Specifications Reflector 100 mm Swirler f ie t Burner Tube Tube Length lt 499 mmf Plan View Tube Length 100 mm Burner Tube i Internal Swirler Fan Tube b U Tube Swirler must always be located in Fan Tube 18 9 1 Standard Burner Specifications Models HE15 HE20 HE25 HE30 HE35 HE40 HE45 HE50 Burner Airplate ID Number 515 505 513 502 500 501 500 506 Jet Numbers Natural G20 amp 25 31 28 5 32 17 12 8 3 1 Jet Numbers Propane Butane 47 43 39 33 31 3 2mm 29 28 Gas Consumption Natural G20 m h 1 43 1 91 2 38 2 86 3 36 3 81 4 29 4 77 Natural G25 ms h 1 66 2 22 2 77 3 32 3 88 4 43 4 99 5 54 Propane mxh 0 56 0 75 0 94 1 13 132 151 169 1 88 kgh 1 07 1 43 1 79 2 15 2 50 2 86 322 8 58 Butane ms h 0 43 0 57 0 72 0 86 1 00 1 15 1 29 1 43 Governor Pressure Butane mbar 20 4 20 4 19 7 19 7 19 7 19 7 20 20 9 in vvg 8 1 8 2 7 9 7 9 7 9 7 9 8 0 8 4 mbar 28 4 27 1 26 9 26 6 26 9 26 9 27 4 26 9 Propane in vvg 11 4 10 9 10 8 10 7 10 8 10 8 11 0 10 8 Governor Pressure Natural G20 mbar 10 0 9 5 9 5 9 5 9 2 9 5 8 7 8 7 i i Butane Propane Natural G20 in wg 4 0 3 8 3 8 3 8 3 7 3 8 3 5 3 5 Natural G25 mbar 15 4 14 9 15 2 14 9 14 2 14 9 13 7 13 2 Natural G25 in wg 6 2 6 0 6 1 6 0 5 7 6 0 5 5 5 3
12. Reflector Side Extension 42 of 73 SECTION 10 OPTIONAL HEATER ACCESSORIES 10 2 U Tube Cover Installation The package contains two reflector joint pieces P N 02750901 one 8 reflector and 18 x 8 sheet metal screws Install the u tube cover using the following procedure Step 10 2 1 Cut the 8 reflector in half to be used on both sides to cover the u tube Step 10 2 2 Flatten 4 reflector edge where joint piece matches Puta Step 10 2 3 mark on the 4 reflector directly over the tube center Center the accessory joint piece on the mark and scribe its contour on the reflector Scribe the location of the mounting holes Cut away the reflector to clear the tube leaving about 25 mm of material inside the scribed contour to attach the accessory joint Drill or punch six 3 mm diameter holes in reflector in the positions shown below Reflector Scribe Joint Contour Cut away contour with tin snips Punch Drill six 3 mm holes maximum Step 10 2 4 Use six 8 sheet metal screws to attach the joint piece Reflector Reflector Joint with six 8 Do not remove sheet metal screws cut out Repeat Steps 10 2 1 through 10 2 4 to attach the reflector ioint piece on the other reflector Step 10 2 5 The overlap of both reflector joint pieces is attached with six 8 sheet metal screvvs Secure overlap with six 8 sheet metal screws m 4 Reflector Sections 43 of 7
13. EN Reflector R Tube Tube Reflector Hanger Coupling Assembly HE20UT HE25UT 2 HE30UT T HE35UT 9 HE40UT HE45UT PE HESQUT 9 FF a overall width not shown 850 mm e distance typical between hangers 3050 mm b end cap to burner fan 50 mm f distance between last full tube c end cap to hanger 50 mm hanger and half tube hanger 1900 mm d distance first hanger 2290 mm g burner height 241 mm h burner length 445 mm Model HE15UT HE20UT HE25UT HE30UT HE35UT HE40UT HE45UT HE50UT Reflector Overlap 1780mm 250 mm 250 mm 580 mm 580 mm 580 mm 690 mm 690 mm approx 28 of 73 Step 7 2 U tube Hanger Placement 7 Suspension Chain VVashers Bolt Torque 13 5 Nm 129 in Ib Tube and Reflector Hanger Optional Hanging Configuration Reflector Hanger 2290 mm x 250 mm Description Part Number Bow Shackle E0007576 Tube Reflector Hanger 03090100 Spreader Bar 07260010 Step 73 Burner Tube and Fan Tube Installation Burner Tube Description Part Number Burner Tube 03051100 Fan Tube S5127VV SECTION 7 U TUBE HEATER NSTALLATION NOTE Spreader bar must be used on single suspension point installations Do not hang heater from spreader bar Bovv Shackle Suspension Tube and Reflector Hanger See Assembly Drawing Offset mounting hole must be
14. m 0 5 o o 5 pad a Q Burner Neon EB Tp Tp 10 sec 10 sec 40 sec max Interruption of main Burner Lockout 11 sec typical flame sensing signal received after 3 ignition trial failures NOTE If the heater operates for more than 24 hours continuously the ignition module will automatically recycle the burner to ensure that all safety functions are still in working condition 14 1 Heater Lockout Indication Optional 14 1 1 Heater Lockout Indicator by Connector In case of flame loss during operation of the heater the A 230 V signal is provided which enables the ROBERTS burner control unit goes to lockout mode after three GORDONe controller BMS system etc to indicate the ignition trials At this stage a signal or closed relay will heater that has failed An additional wire has to be enable the ROBERTS GORDONe controller BMS installed from the heater lockout indicator connector to system etc to indicate precisely which heater has failed the monitoring computer See Page 56 Section 13 5 This can be done by two options 57 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Description Part Number Connector male Lockout Indicator 91324000 Connector female Lockout Indicator 91324001 Wire Blue 12 91300011 Wire Brown 12 91300012 14 1 2 Heater Lockout Indicator by Volt Free Con
15. 0043980 R Gasket 3 8 OD x 3 16 ID 92700002 HE25 90439804 HE40 90439805 Amber Neon Lamp 91320604 S Valve Gasket 03200100 E Gas Valve 90033101 T Window Gasket 92700003 F Governor Screw N A U Fresh Air Adaptor Gasket 92700005 G Outlet Pressure Tap N A V Gasket 1 2 x 17 3 8 92700006 Cable Gland U169 W Gasket 1 2 x 8 5 92700007 Star Washer 96212100 N S Wire 90427704 J 7 2007 N A N S Burner Tube Gasket 92700004 K Burner Cup Assembly 03020100 N S Wire Harness Main Power 03320404 L Mica Window Assembly 03360004 N S Wire Harness Pressure Switch 03320405 M Electrode Assembly 90427403 N S Purple Wire 07250007 N Fresh Air Adapter 90501002 N S Electrode Gasket 02558501 See Page 70 Section 171 69 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 17 1 Replacement Packages 171 1 Screw and Gasket Replacement Package P N 03360005 Description K Quantity Part Number Screw M4x8mm 2 93304506 Screw 10 24 x 5 8 4 93313100 Screw 8 x 3 8 4 94118107 Screw M8 x 20 mm 2 93304507 Burner Tube Gasket 1 92700004 Fresh Air Intake Gasket 1 92700005 Rubber Gasket 10 92700002 Gas Valve Gasket 1 03200100 17 1 2 Viewer Window Replacement Package P N 03360004 Description Quantity Part Number Viewer Ring 1 01390203 Mica Window Square 1 02553200 Window Gasket 2 92700003 Screw M6 x 16 mm 2 93304505 Rubber Gasket 2 92700008 17 1 3 Door Ga
16. 1650 1650 1860 1960 2040 2110 2160 560 560 560 560 560 560 560 560 1 x Y o O w gt Model FIGURE 15 U TUBE PROTECTIVE GRILLE 5 e LO LO e LO A T N N e eo q LO i o Lu Lu LI Lu 25275 A 150 150 150 150 150 150 200 200 B 890 970 970 1020 1170 1220 1270 1380 1580 1730 1730 1910 1980 2050 2110 2210 D 760 940 940 1000 1090 1150 1200 1300 FIGURE 16 U TUBE VENTING o AN N c r LO Radiant tubes 9 L ul E 1000 1000 1000 1000 1000 1000 1000 1000 F 500 500 500 500 500 500 500 500 9 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 4 MAJOR COMPONENT DESCRIPTIONS Burner shown with Tube Reflector Gasket Aluminium or Must be installed with the Stainless Steel flame observation window Alternate overlap as facing down shown on overview Minimum overlap is 160 mm Burner Tube Tube Fan Tube with Internal Swirler Supplied in 3000 mm lengths Heat treated aluminised tube Supplied in 3000 mm lengths Fan Burner tube is always the first supplied in 3000 mm lengths tube is always the last tube on the tube after the burner heater where the fan is attached The swirler i
17. N Weld seam must be to the _bottom of the tube 29 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Step 73 1 Tube Clamp Package Installation Description Part Number Tube Clamp Package 01318901 Tube Clamp 01396801 Bolt 97113940 Flat Washer 95211600 Nut 92113900 Nut Torque 13 56 Nm 120 in Ib N Lock Washer Tube Clamp Step 7 4 U tube Support Bracket Assembly Installation U bolt Tight to s Bracket A X Fan Tube 117 Burner Tube U tube Standard Loose U bolt 100 mm u bolt secured to bracket 100 mm u bolt secured to burner tube vvith M6 lockvvashers vvith M6 lockvvashers and M6 nuts and M6 nuts on top and TIGHT bottom to allow for tube expansion and contraction 30 of 73 U tube Opposite 45 Tight U bolt 100 mm u bolt 100 mm u bolt secured to burner tube secured to bracket with M6 lockwashers with M6 lockwashers and M6 nuts and M6 nuts on top and TIGHT bottom to allow for tube expansion and contraction U bolt Nut Torque 90 in Ib 10 2 Nm Lock Washer Torque 90 in Ib 10 2 Nm SECTION 7 U TUBE HEATER INSTALLATION Step 7 5 Coupling and Tube Assembly Close coupling Start slide bar coupling lock with tab onto coupling a Slide Bar Ceu N Wide End lt Coupling 76 mm to SA 101 mm VW S eS ua Slide Bar an S Coupling Orient cou
18. ROBERTS GORDON representatives Please contact us for any further information you may require including the Installation Operation and Service Manual This product is not for residential use 2009 Roberts Gordon LLC 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 written permission of Roberts Gordon LLC www rg inc com Printed in U S A P N 91037912 Rev H
19. T g m ogee in Manometer 416 d L5 U L4 U LS Governor orifice pressure while burner is running See Page 73 Section 18 9 1 ES SECTION 16 TROUBLESHOOTING Gas supply pressure while burner is running See Page 71 Section 18 2 3 67 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 17 REPLACEMENT PARTS ADANGER A WARNING Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine ROBERTS GORDON replacement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage 68 of 73 SECTION 17 REPLACEMENT PARTS Item Description Part Number Item Description Part Number A Automatic Control Unit 90438702 P Gasket 1 2 OD x 1 4 ID 92700008 B Flex Line Adapter 91220700 Q Gasket 1 2 OD x 3 16 ID 92700001 Pressure Switch for jer 90439801 MINORE
20. dirt and dust Clean and reinstall as required Tubes Make sure there are no cracks Make sure tubes are connected and suspended securely See Page 11 Section 5 Make sure there is no sagging bending or distortion Gas Line Check for gas leaks See Page 52 Section 12 Burner Observation Window Make sure it is clean and free of cracks or holes Clean and replace as required Blower Scroll Wheel and Motor Compressed air or a vacuum cleaner may be used to clean dust and dirt Burner Cup and Orifice Clear of obstructions even spider webs will cause problems Carefully remove any dust and debris from the burner Electrode Replace if there are cracked ceramics excessive carbon residue or erosion of the electrode The electrode gap should be 3 mm Thermostat There should be no exposed wire or damage to the thermostat Suspension Points See Page 54 Section 13 Make sure the heater is hanging securely Look for signs of wear on the chain or ceiling See Page 11 Section 5 Sports Hall Guard Decorative and Protective Grilles optional The grille must be securely attached If the grille is loose or off contact a contractor qualified in the installation and service of gas fired heating equipment for repair Check that side reflector extensions are installed correctly and secured in place if necessary Decorative grille only See Page 44 Section 10 3 3 and Page 45 Section 10 4 Make
21. from the compartment To ensure IP55 protection replace the gasket on the gas valve inlet flange P N 03200100 The solenoid s can be removed from the body by unscrewing central screw Replace in reverse sequence 15 3 4 Automatic Flame Control Unit Remove black ignition lead Withdraw the 10 point edge connector Unscrew two screws from the cover Replace if faulty Refit in reverse sequence 15 3 5 Pressure Switch Disconnect the two silicone tubes Remove electrical plug Remove one screw which secures the pressure switch to the burner Remove pressure switch Replace pressure switch if faulty and refit in reverse sequence ensuring that the rubber tubes are reconnected to the switch correctly 15 3 6 Neons Remove the two push on connectors and unscrew the nut Replace in reverse sequence 15 4 Maintenance Checklist Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts Gordon LLC and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon LLC recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform
22. manual to the attention of the user or purchaser instruct them in the safe operation of the heater s SECTION 15 SERVICING INSTRUCTIONS ADANGER Electrical Shock Hazard Explosion Hazard Disconnect electric before service More than one disconnect switch may be required to disconnect electric from heater Heater must be connected to a properly grounded electrica source Turn off gas supply to Allow heater to cool heater before service SECTION 15 SERVICING INSTRUCTIONS A WARNING Burn Hazard Cut Pinch Hazard Wear protective gear before service during installation operation and service Tubing may still be hot after operation Edges are sharp Failure to follow these instructions can result in death electric shock injury or property damage IMPORTANT Never use the heater as a support for ladders or other access equipment Always test for gas soundness with a suitable detection fluid after completing any servicing or exchange of gas carrying component On completion of any service fault finding tasks which require the breaking and remaking of electrical connections the checks A Earth Continuity B Polarity and C Resistance to Earth must then be repeated 15 1 Annual Procedure Carry out the following procedure annually The preferred time would be immediately before the winter heating period If very dirty conditions arise it may be necessary to carry out this procedure more often If the
23. service where necessary using only replacement parts sold and supplied by Roberts Gordon LLC The Vicinity of the Heater Do not store or use flammable objects liquids or vapours near the heater Immediately remove these items if they are present See Page 5 Section 3 Vehicles and Other Objects Maintain the clearances to combustibles Do not hang anything from or place anything on the heater Make sure nothing is lodged underneath the reflector in between the tubes or in the decorative or protective grilles included with select models Immediately remove objects in violation of the clearances to combustibles See Page 5 Section 3 Reflector Support reflector with reflector hanger and support strap Reflector must not touch tube Make sure there is no dirt sagging cracking or distortion Do not operate if there is sagging cracking or distortion Make sure reflectors are correctly overlapped Clean outside surface with a damp cloth 60 of 73 SECTION 15 SERVICING INSTRUCTIONS Vent Pipe Venting must be intact Using a flashlight look for obstructions cracks on the pipe gaps in the sealed areas or corrosion The area must be free of dirt and dust Remove any carbon deposits or scale using a wire brush See Page 49 Section 11 Outside Air Inlet Inlet must be intact Look for obstructions cracks on the pipe gaps in the sealed areas or corrosion The area must be free of
24. supports Section 6 are schematic only and provide a general and u clips depend on the individual installation Use guideline of where hangers reflector supports and either pop rivets or sheet metal screws instead of u clips u clips are to be installed when installing end caps and joint pieces in areas where To ensure proper expansion and contraction movement of impact and high wind may be a factor The following rules the reflectors a combination of u clips and reflector must be observed 1 The first reflector after the burner must be affixed in Tight the middle of the reflector with a reflector support and Sheet Metal tight screws Screw Reflector Reflector Support Strap Overlap must J be a minimum I Option B J of 160 mm Slip Overlap Reflector 2 The overlap at the first and second reflector is a slip 4 i Loose screws overlap Thereafter every third reflector joint is a WS loosened 2 mm slip overlap A slip overlap is achieved by either AX to allow slippage a both reflectors lay inside a hanger no reflector support needed eS b using a reflector support with f SS loose screws at the reflector Option A overlap Slip Overlap 3 The remaining reflector overlaps require a non slip overlap connection To affix the reflectors together in a non slip overlap either a use reflector support and tight screws b if both reflectors lay inside a hanger 77 or sheet metal screvvs may be used Option A N
25. unit takes in air through an air duct or filter assembly more frequent service may be necessary 15 1 1 Burner and Fan Removal Isolate the heater from the gas and electrical supplies Remove the fan plug from the burner Unscrew the securing screws on the burner flange The burner can now be removed Take care not to disturb the gasket on the flanged burner tube Unscrew the securing screw on the fan flange spigot The fan can now be removed 15 1 2 Burner and Fan Removal Maintenance Remove the fan and burner independently to floor level and clean both items internally using a soft brush and compressed air if available Take care not to damage the internal parts of the burner Check fan impeller for cleanliness and free rotation The electrodes are an integral part of the burner To check spark gap remove the securing screws on the electrode and withdraw it ensuring the gasket is not damaged Spark gap on electrode should be approximately 3 mm 15 1 3 Tube and Reflector Maintenance With burner and fan removed clean the outer surfaces of the tubes using a brush and wipe the inner surface of the reflector with a soft damp cloth use a household detergent if necessary Never use abrasive cleaners on the reflectors Reassemble the burner and fan in reverse order Carry out the Testing Procedure See Page 58 Section 14 2 15 2 Sealing Gaskets During annual service all gaskets as indicated on Page 68 Section 17 must be insp
26. 1 Multiburner essem 55 6 6 Reflector Installation 22 13 5 Internal Wiring Diagram 56 6 7 Double Linear Tee Installation SECTION 14 Operation 57 For Double Linear Heaters Only 24 14 1 Heater Lockout Indication Optional 57 SECTION 7 U tube Heater Installation 25 14 2 Testing 58 7 1 U tube Standard Parts List 25 14 3 Commissioning Multiburner 58 7 2 U tube Hanger Placement 29 14 4 System Checks 58 7 3 Burner Tube and Fan Tube Installation 29 14 5 User 5 58 7 4 U tube Support Bracket Assembly SECTION 15 Servicing Instructions 59 Installation ederet te hasan due 30 15 1 Annual 59 7 5 Coupling and Tube Assembiy 31 15 2 Sealing Gaskets 59 7 6 Tube Installation 32 15 3 Component Removal 59 7 7 U tube Installation 32 15 4 Maintenance Checklist 60 7 8 Reflector Installation
27. 1370 1400 840 965 1120 1120 1220 1270 D 990 1020 1270 1270 1370 1400 When installed in the first 3 m FIGURE 9 LINEAR amp DOUBLE LINEAR VENTING l l _ Ga Ga ba Ga b m m o to O oo lo O oo Lo o o LO o 5 QN N e e nr q LO Radiant tubes Li Li Li Li Li LI LI Li Li Li I E 1000 1000 1000 1000 1000 1000 1000 1000 F 500 500 500 500 500 500 500 500 7 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 3 3 Clearances Data U Tube NOTE 1 All dimensions are from the surfaces of all tubes couplings tees elbows and crosses 2 Clearances B C and D can be reduced by 50 after 7500 mm of tubing downstream from the burner 3 All measurements are in millimeters 4 Add 60 mm clearance to uncovered u tube FIGURE 10 U TUBE HORIZONTAL MOUNT 2 2 2 2 2 2 2 2 1 8084 6808 S 8 y o Lu Li Li LI LI LI zaa D A 150 150 150 150 150 150 200 200 B 890 970 970 1020 1170 1220 1270 1380 1580 1730 1730 1910 1980 2050 2110 2210 D 760 940 940 1000 1090 1150 1200 1300 FIGURE 11 U TUBE ONE SIDE REFLECTOR 2 2 2 2 5 2 2 2 o in tO o Lo o Lo o A a N e eo r LO A LI LI LI LI LI L
28. 3 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 10 3 Decorative Grille Installation Step 10 3 1 Grille Installation Tube and Reflector Hanger Reflector bw 610 mm x 1220 mm Aluminium Grille Description Part Number Aluminium Grille 91407000 Description Part Number Deco Grille Shield 01365900 NOTE If the decorative grille system is to be installed in an area with considerable air movement it is recommended that one 8 x 3 8 sheet metal screw be installed per reflector extension to prevent it from blowing over al Insert screw here See note A Reflector Side Extension Distance A Extension Minimum Maximum Part No Width 40mm 150mm 01370408 200mm Description Part Number 150 mm 260 mm 01370412 300 mm Reflector Side Extension 01370412 260 mm 370 mm 01370416 400 mm 44 of 73 SECTION 10 OPTIONAL HEATER ACCESSORIES 10 4 Protective Grille Installation Step 10 4 1 Silicone Cap Installation o o 2 m Part Number 91915951 6P Bend up 90 Description Silicone Cap D Pull outvvard Step 10 4 3 Grille Installation o g o m Final Grille Section 45 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 10 5 Sports Hall Guard Installation Step 10 5 1 Grille Installation Strap Stainless Steel Tube a
29. 4 1 eui ssoJoe Jeduun e eoe g ON ON uo uun Ue eui s oq Jejsouueu dn win lnpouu uonlu i vejd y 63 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Troubleshooting Flow Chart Linear Double Linear and U Tube S9JIM 10e1109 e2e deu ON MO spe Josues epoJj2e e ay uo uohelnsul eui si S A lnpoul eoejdeu p l e Aew uous 02 plou yos eoejdeu eanssejd J0uJ8A0B y isnipy Suonoeuuoo usilqe1s ti asianay ON S A pe1oouuoo SOA Ajsadoid ajnpow y ye unm y s u ul SI Er 4 D S1 A 1 N lenn N pue AHT eui ey l n qonuo gewone eoejday S A 8 1294109 e2e deu 6 Hun oN l04u09 oneuoine y Sun uuo2 s lim y 91V oN ponad uoniuBi eui ON fBuunp lqelleAe inss ld jenno 586 l vi si un uoniu amp i S A A 0 9Jeui S s euluu191 A EA uo BelloA nse lN S A yenuew siu JO uonoes 6 5 UUM 92U pJ022 Ul inss ld hino seb eui si ef ON S A 1eu nq y episul ile pue y l 1edoud ay 10 s ur7 eBung
30. 6 U tube Horizontal 48 U tube Angle Mounted 48 LING AN vives heed aie tee eters cc 48 Individual Flue Connection Detail 50 Flue Connection Dimensions 50 Air Supply with Flue Configurations 51 Gas Connection with Stainless Steel Flex enra nanan ERa TLEER 53 Sequence of Operation Chart 57 Burner Cup Position 60 BLACKHEAT HE Linear and U tube Specifications 73 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 LPG 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 appl
31. 8 Tube 100 mm x 3048 mm 2 2 4 4 5127W Fan Tube 100 mm x 3048 mm with 3048 mm Swirler 2 2 2 2 5134W Fan Tube 100 mm x 3048 mm with 2134 mm Swirler 2 E0009170 Tee 100 mm x 100 mm x 100 mm 1 1 1 1 1 01329600 Standard Coupling Assembly 6 8 8 10 10 01329700 Coupling Lock 6 8 8 10 10 02750303 1 Reflector Aluminium 2439 mm 6 8 8 12 12 02750388 Reflector Stainless Steel 2439 mm Optional 6 8 8 12 12 02750800 Reflector End Cap Aluminium 4 4 4 4 4 027508SH Reflector End Cap Stainless Optional 4 4 4 4 4 03090100 Tube and Reflector Hanger 6 8 8 10 10 01318901 Tube Clamp Package including Nut Washer amp Bolt 2 2 2 2 2 91908004 Wire Form 4 6 6 10 10 03050000 Reflector Support Strap 4 6 6 10 10 E0007576 Bow Shackle 6 8 8 10 10 91107720 U Clip Package 20 Pieces 2 2 2 2 2 E0007582 Height Adjuster 6 8 8 10 10 94320812 Screw 8 x 3 4 Goes with 03050000 8 12 12 20 20 PVC coating must be removed prior to installation If an IP55 protected fan is required this fan replaces 07260001 07260002 or 07260003 Some models may receive S hooks P N 91907302 or spring hooks P N 91903300 rather than bow shackles 16 of 73 SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION uel pejoajoid Gd 24 esn 10 c Aiddng JOM AEME ugy 91890 3 1 ON diy US 1d obeyed duue O eqni eqn ugy lqussv 4847 10109
32. AL l l Pp 2 P gt rm N N LO Part No Description us 96411500 Lockwasher 6mm 6 6 6 6 6 6 6 6 94320812 Screw 8 x 3 4 Goes with 03050000 4 8 8 8 8 8 12 12 S7199K Damper Flange Assembly For use on Multiburner Systems 1 Per Heater PVC coating must be removed prior to installation If an IP55 protected fan is required this fan replaces 07260001 07260002 or 07260003 Some models may receive S hooks P N 91907302 or spring hooks P N 91903300 rather than bow shackles 26 of 73 SECTION 7 U TUBE HEATER INSTALLATION J9 U92 0 1 ww 097 pejoejoud pGd 24 esn 10 Sqn 084 39 WO Aeme Ue 918201 sdeo pug 57 sd lo n j Builidnoo eqn 1euung z jexyoeug oddng o qm n z IEM pisino woog P duue eqni 5 V o 8 lt jeuung lt g A ddns B Ji us l 5 A do 7 pig Iquu ssv sedweq JO 062 ju9A lt 1 E ye H jeuonao n J JJIANS JeuJeju Jo edid ni i o eqn ued lt m noddns we aS N ejBuis 104 N A qwu ssy uej g 5 o F 27 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Figure 23 BLACKHEAT HE U tube Layout Overview LEGEND pu B HE15UT 9
33. Bracket n Hex Nut p 7 pe p p 1010 mm 47 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 10 7 Wall Mounting Install wall mounting brackets at the height shown in the Model Quantity of Wall Model Quantity of Wall i Mounting Brackets Mounting Brackets layout drawing provided by the estimator Space wall HETSUT 5 HETSST 3 mounting brackets and hangers as indicated by f HE20UT 3 HED0ST 4 dimensions d e and f in the relevant Layout Overview HE25UT 3 HE25ST 4 drawing for your heater For Linear heaters see Page 15 HE30UT 3 HE30ST 5 Figure 19 for Double Linear heaters see Page 18 Figure 3 ET 5 HE40UT 3 HE40ST 5 21 and for u tube heaters 388 Page 28 Figure 23 HEUT TEST s 10 71 Hardware Installation HE50UT 4 HE50ST 6 The wall mounting brackets must be attached to a suitable wall through all mounting holes Screw sizes less than M8 5 16 may not be used In order for the wall mounting brackets to adequately carry the weight of the heater it must be installed with best building practice Figure 26 U tube Horizontal Figure 27 U tube Angle Mounted Figure 28 Linear Burner must be below fan 48 of 73 SECTION 11 VENTING AND FRESH AIR SUPPLY SECTION 11 VENTING AND FRESH AIR SUPPLY flue must be self supporting Suitable terminals must be fi
34. FOR YOUR SAFETY If you smell gas Open windows DO NOTtry to light any appliance DO NOT use electrical switches DO NOT use any telephone in your building Extinguish any open flame Leave the building Immediately call your local gas supplier after leaving the building Follow the gas supplier s instructions f you cannot reach your gas supplier call the Fire Department A WARNING ROBERTS GORDON Blachheat HE Vacuum Assisted Linear Double Linear U Tube and Multi Burner Gas Fired Heating Systems Installation Operation amp Service Manual Fire Hazard cu HETSUT 155 HE30DL ances to combustibles avvay from H E20 UT H E20ST H E40DL n HE25UT 255 HE50DL 77777 HE30UT HE30ST HESODL Failure to follovv these instructions can HE35UT HE35ST HE70DL 27 77 iniury or property HE40UT HE40ST HE45UT HE45ST HE50UT HE50ST IP55 Protected Burner Box A WARNING 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 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 Owner Keep this manual in a safe place in order to provide Installation must be done by a registered installer your serviceman
35. I LI LI Y z r r r A 150 150 150 150 150 150 200 200 o B 230 230 230 230 230 230 230 230 l C 1580 1760 1760 1930 2090 2130 2160 2240 D 1200 1380 1380 1500 1660 1710 1760 1860 FIGURE 12 U TUBE TWO SIDE REFLECTORS 2 2 2 2 2 2 2 2 o in tO o Lo o Lo o A o T N N c lt t LO A LI LI LI LI LI LI LI LI n N A 150 150 150 150 150 150 200 200 p B 590 640 640 690 820 860 890 1020 C 1660 1810 1810 1960 2110 2160 2210 2320 D 590 640 640 690 820 860 890 1020 FIGURE 13 U TUBE FULL 45 MOUNT gt gt gt gt gt gt gt gt LO o LO QN N e e 00 LI LI LI LI LI LI LI LI A 200 200 200 200 200 200 200 200 B 200 200 200 200 200 200 200 200 C 1500 1650 1650 1860 1960 2040 2110 2160 D 1070 1170 1170 1320 1550 1620 1680 1780 8 of 73 SECTION 3 CLEARANCES TO COMBUSTIBLES NOTE 1 All dimensions are from the surfaces of all tubes couplings tees elbows and crosses 2 Clearances B C and D can be reduced by 5096 after 7500 mm of tubing downstream from the burner 3 All measurements are in millimeters 4 Add 60 mm clearance to uncovered u tube FIGURE 14 U TUBE OPPOSITE 45 TILT 2 2 5 2 2 2 LO o LO o LO o LO o N N e e t r LO Lu LI Li LI LI LI LI LI r r r r r r r 200 200 200 250 250 275 300 300 1370 1530 1530 1630 1780 1830 1880 1930 1500
36. ION 13 WIRING A DANGER Electrical Shock Hazard Disconnect electric before service Heater must be properly grounded Failure to follow these instructions can result in death or electrical shock Connect to the electrical supply using the power wire coming out of the wire gland via a locally mounted IP55 protected double pole fused switch having a minimum disconnection of 3 mm on each pole This switch should be fused to 3 amps There are no control connections in the standard burner Control is affected by interruption of the main power inlet See Page 54 Section 13 1 through Page 55 Section 13 4 for the external wiring details for the single burner double linear and multiburner heater systems If the IP55 protected fan MB 56 2BM is used with a single burner linear or U tube it must be wired as shown on Page 55 Section 13 2 The fan must be protected with a 3 A fuse If the heater lockout indication is required a BLACKHEAT HE lockout indicator package P N 03360008 must be installed in every burner Drill a 20 5 mm hole to fit the wire gland See Page 56 Section 13 5 for wire connections Remove the taps from the power wire Description Part Number BLACKHEAT HE Lockout Indicator Package 03360008 Cable Gland U169 Power Wire 91300010 Blue Wire 91300011 Brown Wire 91300012 All wiring must comply with current wiring regulations and any local regulations which may apply Always switc
37. L Model Magnetek JF1G 18 3 2 IP54 Protected Fans HE15 20 25 30 35 Model Torin DSA 508 128 P N 90710051 HE40 45 50 Model Torin DSF 146 052 P N 90710053 HESODL 40DL Model Torin DSA 524 202 P N 90710052 HE5ODL 7ODL Model Torin DSF 146 052 P N 90710053 Multiburner Model Airflow 83 BTLW IP55 22002 Model Airflow 90 BTLVV IP55 Consult the manufacturer for availability of alternate fans 18 3 3 Flue The flue must be 100 mm or greater in diameter and must conform to National Codes The flue must be self supporting Inlet must be 100 mm diameter Multiburner Flue will be 150 mm diameter Flue material must conform to National Codes The flue must be self supporting 18 4 Suspension Specifications Hang heater vvith materials vvith a minimum vvorking load of 33 kg 18 5 Controls Specifications Time svvitches thermostats etc can be vvired into the electrical supply External controls supplied as an optional extra 71 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 92 w 92 oN 92 LO LO LO LO N N se LO 18 6 Linear Heater m m Input Gross kW 15 20 25 30 35 40 45 50 51 Input Net kW 13 5 18 22 5 27 31 5 36 40 5 45 46 Tube Lengt
38. O JeBueH Jojoayey pue eqn N eqn seuing F oDeyxyoeg duel qn S Jl US 13 19 deo JU A o Q 14 of 73 SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION Figure 19 Linear Layout Overview LEGEND HE15ST f si Reflector D tube Tube Reflector Hanger Coupling Assembiy HE20ST HE25ST f a e i Assembly Damper Assembly HE30ST HE35ST Pa HE40ST RE HE45ST 4 HE50ST reflector width not shown 365mm e distance typical between hangers 3050 mm end cap to burner fan 50 mm f burner height 241 mm end cap to hanger 50 mm g burner length 445 mm distance first hanger 2290 mm O o 00 H H H lH Model HE15ST HE20ST HE25ST HE30ST HE35ST HE40ST HE45ST HE50ST Reflector Overlap 700 mm 250 mm 250 mm 530 mm 530 mm 530 mm 330 mm 330 mm approx 15 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 6 2 Double Linear Standard Parts List m 8 E E Part No Description bu n ui tu 2l 033XXXXX Burner Assembly Input and Fuel Varies 2 2 2 2 2 07260002 1 Fan Package XP 2 1 1 07260003 1 Fan Package XP 3 1 1 1 1 1 07260052 Fan Package 2 IP55 optional 1 1 07260053 Package 3 IP55 optional 1 1 1 03051100 Burner Tube 100 mm x 3048 mm 2 2 2 2 2 9140940
39. OO blue Automatic Control Unit brown T i 1 i Electrode NMU E sense Gas Valve Optional Volt Free Connecter Dotted line wires are an option Optional 46 yellow e Volt Free Connection Power Wire Exhaust Fan 9 Relay ol yellow oz Volt Free r blue lox NAY 2 Connector 1 0006000 00000 o O o AUTOMATIC CONTROL UNIT 56 of 73 SECTION 14 OPERATION SECTION 14 IGER ADANGER A WARNING Electrical Shock Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Disconnect electric Turn off gas supply to Allow heater to cool Wear protective gear before service heater before service before service during installation operation and service More than one Tubing may still be hot disconnect switch may after operation Edges are sharp be required to disconnect electric from heater Heater must be connected to a H grounded electrica source Failure to follow these instructions can result in death electric shock injury or property damage Figure 33 Sequence of Operation Chart KEY TO TO T1 T2 T3 SYMBOLS Thermostat Fan BE Pressure Switch 69 Neon JP Ignition Gas LX Valve 8 Flame Sensing Lockout Alarm Signal optional d
40. STALLATION OPERATION AND SERVICE MANUAL Step 6 7 Double Linear Tee Installation For Double Linear Heaters Only iwaw i qay r D z Fan Tube Weld Spot Coupling Coupling Description Part Number Tee E0009170 Fan Tube S51XXW Coupling 01329600 Slide Bar Coupling Lock 01329700 Tube Reflector Hanger 03090100 24 of 73 SECTION 7 U TUBE HEATER INSTALLATION A WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury 7 1 U tube Standard Parts List SECTION 7 U TUBE HEATER INSTALLATION The figures in this section provide a general overview of component placement in a u tube system The location of some components such as supports and couplings is crucial for proper installation Assemble the heater components as shown on Page 27 Figure 22 For optional reflector configurations for u tube heaters see Page 8 Figure 10 through Page 9 Figure 16 Install appropriate suspension hardvvare beam clamps chain or rod at predetermined locations Adjustments of chain length will provide uniform pitch If any step is unclear please contact Roberts Gordon LLC at 44 0 121 506 7700 S 5 B B B PartNo Description u 1919 B B kl 033XXXXX B
41. age Installation Washer s Torque 13 56 Nm 120 in lb Description Part Number Tube Clamp Package 01318901 Tube Clamp 01396801 Bolt 97113940 Flat VVasher 95211600 Nut 92113900 21 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Step 6 6 Reflector Installation A WARNING Fire Hazard Support reflector with reflector hanger and support strap Reflector must not touch tube Failure to follow these instructions can result in death injury or property damage Reflector Description Part Number Tube Reflector Hanger 03090100 Burner Tube 03051100 Reflector 02750303 22 of 73 SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION Step 6 6 1 Reflector U clip and Reflector Support Installation The pictorial drawings of the heater construction in supports are used The positioning of reflector supports Section 6 are schematic only and provide a general and u clips depend on the individual installation Use guideline of where hangers reflector supports and either pop rivets or sheet metal screws instead of u clips u clips are to be installed when installing end caps and joint pieces in areas where To ensure proper expansion and contraction movement of impact and high wind may be a factor The following rules the reflectors a combination of u clips and reflector must be observed 1 The first reflector after the burner must be affixed
42. ation and service of gas fired heating equipment or property damage Maintain clearance to the side and clearance below the heater from vehicles and combustible materials Roberts Gordon LLC Roberts Gordon Europe Limited Service Telephone 44 0 121 506 7709 1250 William Street Unit A Kings Hill Business Park Service Fax 44 0 121 506 7702 P O Box 44 Darlaston Road Wednesbury E mail uksales rg inc com Buffalo NY 14240 0044 USA VVest Midlands WS10 7SH UK E mail export rg inc com Telephone 44 0 121 506 7700 Telephone 716 852 4400 Fax 44 0 121 506 7701 Fax 716 852 0854 Toll Free 800 828 7450 Installation Code and Annual Inspections All installation and service of ROBERTS GORDON equipment must be performed by a contractor qualified in the installation and service of equipment sold and supplied by Roberts Gordon and conform to all requirements set forth in the ROBERTS GORDON manuals and all applicable governmental authorities pertaining to the installation service and operation of the equipment To help facilitate optimum performance and safety Roberts Gordon recommends that a qualified contractor conduct at a minimum annual inspections of your ROBERTS GORDON equipment and perform service where necessary using only replacement parts sold and supplied by Roberts Gordon Further Information Applications engineering and detailed guidance on systems design installation and equipment performance is available through
43. bel Placement 2 Control Side Label Placement 3 Linear amp Double Linear Horizontal Mounts 6 Linear amp Double Linear One Side Reflector 6 Linear amp Double Linear Two Side Reflectors 6 Linear amp Double Linear 45 Mount 6 Linear amp Double Linear 2 Foot Deco Grille Protective Grille 7 Undershield 7 Linear amp Double Linear Venting 7 U Tube Horizontal Mount 8 U Tube One Side Reflector 8 U Tube Two Side Reflectors 8 U Tube Full 45 Mount 8 U Tube Opposite 45 Tilt 9 U Tube Protective Grille 9 U Tube Venting 9 Critical Hanger Placement 12 Linear General Assembly Overview 14 Linear Layout Overview 15 Double Linear General Assembly Overview nnn 17 Double Linear Layout Overview 18 BLACKHEAT HE U tube Assembly eur m 27 BLACKHEAT HE U tube Layout OVer VIGW core rero dure tarot rs oed Dvd uu 28 Multiburner Damper Flange Installation 35 Typical Manifold Layout Linear and U Tube Configuration 3
44. e 25 Typical Manifold Layout Linear and U Tube Configuration HE25UT HE25UT Typical Fan Arrangement 100 mm Manifold 150 mm Hanger 150 mm Manifold RS Max mM Eh b I Paena tea 4H Locate fan away from wet 100 Tee 100 Damper Typical Cross Cross 100 x 150 x 100 x 150 100 x 150 x 100 x 150 ID ID Sleeve 100 mm Hanger NOTE Be sure to Reducer silicone seal all 100 x 150 manifold joints environment HE25ST HE25ST HE25ST 36 of 73 SECTION 9 BURNER amp FAN INSTALLATION SECTION 9 BURNER amp FAN INSTALLATION Step 9 1 Burner Installation NOTE Tube Clamp Package not shown for clarity For details see Page 21 Step 6 5 Lock Washer Bolt Torque 13 5 Nm au S EM 120 in Ib 2 k RR b 2 Description Part Number Bolt 072600XX Lock VVasher 9641600 Gasket 02568200 Burner 033XXXXX Step 9 2 Standard Fan Assembly Fan Assembly Note Apply Silicone Recommended Vent Adapter Screw Torque 2 Nm 18 in Ib Install vent adapter vvith clamp in the up position Description Part Number Fan Assembiy 072600XX Vent Adapter C1323B Screw C0061B 37 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 9 3 IP55 Fan Assembly Fan Assembly Wire Gland tighten securely Note Apply Silicone Recomme
45. ected for cuts misalignment or dryness All round rubber gaskets sealing the screw holes must be replaced in three year intervals or earlier as needed All other gaskets must be replaced every five years or earlier as needed Old gaskets must be removed completely before installing the new gasket When replacing gaskets on screws ensure that the screws are not over tightened Deformation of the gasket is an indication of suffcient torque The control and combustion chamber doors have internal seals replacements must be attached to the same location 15 3 Component Removal First isolate the heater from the gas and electricity supply Entry to the burner assembly is gained by removing the six door screws and removing the control chamber door Entry to the combustion chamber is gained by removing the combustion chamber door 59 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 15 3 1 Electrode Figure 34 Burner Cup Position Burner Cup center horizontally Electrode Assembly 15 3 2 Burner Head Injector Jet When the cover is removed completely the burner assembly is exposed Unscrew the burner cup Remove brass injector jet orifice Replace in reverse sequence 15 3 3 Solenoid Valve Governor Remove burner head Unscrew two screws securing the solenoid governor body Withdraw the electrical connector and remove the flexible gas line connector The solenoid governor and fittings can now be withdrawn
46. ed in environmental temperatures below 0 C SECTION 3 CLEARANCES TO COMBUSTIBLES SECTION 3 CLEARANCES TO COMBUSTIBLES Consult local Building Inspector Fire Insurance Carrier or other authorities for approval of proposed AWA H M N G installation when there is a possibility of exposure to combustible airborne materials or vapours Hang heater in accordance to the minimum suspension requirements on Page 11 Section 5 Fire Hazard Keep all flammable objects liquids and vapors the minimum required clearances to combustibles away from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 3 1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the heater to prevent fire hazards Caution should be used when running the system near combustibles Combustibles are materials that may catch on fire and include common items such as wood paper rubber fabric etc Maintain clearances to combustibles at all times for safety Clearances for all heater models are located on Page 6 Figure 3 through Page 9 Figure 16 in this manual Check the clearances on each burner for the model heater being installed to make sure the product is suitable for your application and the clearances are maintained Read and follow the safety guidelines below Keep petrol or ot
47. er 03090100 Step 6 4 Coupling and Tube Assembly Close coupling Start slide bar coupling lock with tab onto coupling 7 Slide Bar Wide End lt Coupling 76 mm tos lt s D Tighten coupling to join tubes V S Si Orient coupling so that l Coupling the impact block is in the 2 00 or 10 00 o clock R positions b Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 Tue 91409408 19 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Step 6 4 1 Coupling and Tube Assembly Continued Tighten slide bar as shown below Drive slide bar until tight End of slide bar should be within tolerance listed below Correct Slide Bar AC Incorrect Slide Bar dimensions si position l Repeat Step 6 4 A D until all tubes are assembled See Page 20 Section 6 4 2 shown below Step 6 4 2 Coupling and Tube Assembly Continued Number of Tubes HE15ST 6000 2 HE20ST 9000 HE25ST 9000 HE30ST 12 000 HE35ST 12 000 HE40ST 12 000 HE45ST 15 000 HE50ST 15 000 HE55ST 18 000 Model Overall Tube Length mm c l aj S Co co 2290 mm 250 mm 3050 mm Typ 250 mm Total Overall heat exchanger Tube Length 20 of 73 SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION Step 6 5 Tube Clamp Pack
48. flame is established check the gas pressure reading and adjust if necessary See data label Check the gas pressure at the outlet of the gas valve See Page 73 Section 18 9 1 for pressure set tings or refer to the data plate Switch off the electrical supply shutting down the heater remove pressure gauge refit pressure test point screw ensuring a tight gas seal Replace gov ernor cover cap Repeat this procedure for each burner in the sys tem Close the control chamber and secure with six screws 8 Balancing Hot Suction Reconnect all the burners on the system and allow them to reach full operating temperature approxi mately 20 minutes Return to each burner and recheck the hot suctions at the tee on the inlet to the pressure switch Re adjust the damper so that the hot suction of 1 7 mbar is achieved and lock the damper in position 14 4 System Checks Switch on again at the local switch to help ensure smooth ignition Carry out the following system checks When running turn off the gas supply at the appliance The heater will immediately shut down followed by one attempt at restoration followed by lockout Linear and Double Linear only When running disconnect the fan plug from the burner The unit should shut down within three seconds proving operation of the pressure switch 14 5 User Instructions After satisfactory testing ensure that the client is fully aware of the operation of the system Bring this
49. g Flow Chart Multiburner Suoinoeuuoo e 1e pesn eq pinous juejeos uoollis UBIH H doldulu palesu eg Aew S10 DBUUOD 1 1 ploj lue W SaM 199 10 2 006 09 ON MO Speo Josues epoJj29 e eui uo uoheinsul aui S A N ainpow ABU Aew uonlubi 09 plougjos vejd y aunssaid JouJ8A0B ay 1sn py woul MMM ye ouljuo 10 1022 90S 12100 prt xe4 40 0022 90S 121 0 prt 191 je uopioo si qoti joe1uoo sisi d suu qo1d J SaNa L1OOHS318nOHL S A eued onuo Spu yeoy 40 122 ey ueuM H y y uo ON uan si uinq v oq ON SuomnonJjsul JeS19A91 10 AOQE ueAIB einpeooud uono s uoneono ds yenuew 511 Jo 54011995 xoeuo 1euJnq 0 S unnoeA Buum pue BunueA qnsuo5 Jadoid 10 uiejs s 1sn py J ON S A S A En Lf 1991109 J010UJ U9ueJq e ul si uinq amp MO 00 S A quind ay uonejor eui six ON peop Aue aay ey ON fumes unnogA au S S A d y n l s s eui S J 59 s A Suonoeuuoo usilqe1s u AHETOd S A L Anu
50. gas valve See Page 73 Section 18 9 1 for pressure settings or refer to the data plate Switch off the electrical supply shutting down the heater remove pressure gauge tighten pressure test point screw ensuring a tight gas seal Replace governor cover cap Replace control chamber door 14 3 Commissioning Multiburner 1 Establish that a satisfactory purged gas supply and an electrical supply is available to the heater 2 ENSURE that all the dampers are in the fully open position 3 With the gas supply off at each of the burners and the electrical supply isolated open the control chamber secured by six screws 4 Ensure that all time clocks and thermostats are set to call for heat 58 of 73 5 Switch on the electrical supply at the main isolator This will start the exhaust fan 6 Balancing Cold Suction Check each burner vacuum by connecting an inclined pressure gauge to the tee on the pressure switch inlet side in the burner Adjust the damper so that the suction is 1 9 mbar Repeat for each burner 7 Start at the end burner furthest from the exhaust fan with the inclined pressure gauge connected as described above Turn on the gas and electrical sup ply reset the pressure switch by removing suction from the inlet side of the pressure switch waiting several seconds and reconnecting The start up sequence described on Page 57 Section 14 should take place If not refer to detailed fault finding sequence When
51. h mm 6096 9144 9144 12192 12192 12192 15240 15240 Overall Heater Length mm 6887 9935 9935 12983 12963 13028 16076 16076 VVeight kg 41 55 55 68 68 68 81 81 Heated Area m 20 160 30 210 40 265 50 315 55 370 65 420 70 475 80 525 Minimum Installation Height mm 3500 3500 3500 3500 4600 5000 5000 5000 un Installation Height 3599 3600 3900 4200 4800 5500 6700 7600 i ca ca ca g 2 18 7 Double Linear Heater Input Gross kW 30 40 50 60 70 Input Net kW 27 5 36 45 54 63 Tube Length mm 12802 18898 18898 24994 24994 Overall Heater Length mm 13914 20010 20010 26106 26106 Weight kg 82 110 110 136 136 Heated Area m 50 315 65 420 80 525 100 630 110 740 Minimum Installation Height mm 3500 3500 3500 3500 4600 Recommended Installation Height mm 3500 3600 3900 4200 4800 2 2 2 2 2 LO LO LO LC N N LO 18 8 U tube Heater Input Gross kW 15 20 25 30 35 40 45 50 Input Net kW 13 5 18 22 5 27 31 5 36 40 5 45 Tube Length mm 3531 5055 5055 6579 6579 6579 8103 8103 Overall Heater Length mm 4048 5572 5572 7096 7096 7096 8620 8620 Weight kg 39 54 54 65 65 66 96 96 Heated Area m 20 160 30 210 40 265 50 315 55 370 65 420 70 475 80 525 Minimum Installation Height mm 3500 3500 4000 4700 5000 5000 5000 5000 Recommended Installation Height mm 3500 3600 4000 4700 5000 5500 6700 7600 72 of 73 SECTION 18 SPECIFICATIONS
52. h a maximum pressure drop of 13 mm wc When gas piping is not included in the layout drawing the local gas supplier will usually help in planning the gas piping IMPORTANT the complete installation must be tested for gas soundness and be purged in accordance with local and national codes Check the pipe and tubing ends for leaks before placing heating equipment into service When checking for gas leaks use a soap and water solution never use an open flame SECTION 12 GAS PIPING Figure 32 Gas Connection with Stainless Steel Flex Connector CORRECT POSITIONS CAUTION Product Damage Hazard Shut Off Valve included with gas hose must be parallel to burner gas inlet The 80 mm Hold gas nipple securely with pipe wrench displacement shown is for the cold condition when attaching gas hose This displacement may reduce when the system is fired Failure to follow these instructions can result in product damage Vertical as shown left 80 mm max displacement Side View PA Horizontal Flexible Gas Hose 910 mm length Heater Movement End View s INCORRECT POSITIONS VVRONG INSTALLATION mm Alternate positions okay Heater Movement Heater Movement T Heater Movement Heater Movement lt lt em 53 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL SECT
53. h off the supply to the burner before removing the burner side panel 13 1 Typical External Wiring Diagram Linear or U Tube Controller or Thermostat Earth Green Yello 4 Wire Cable 1 Burner 2 Burner 1 54 of 73 W Green Yello 4 Wire Cable 4 Wire Cable Burner 3 SECTION 13 WIRING 13 2 Typical External Wiring Diagram Double Linear Option 1 Controller or Thermostat 50Hz Earth Burner 1 13 3 Typical External Wiring Diagram Double Linear Option 2 Controller or L Thermostat N Earth Burner 1 Burner 2 13 4 Typical External Wiring Diagram Multiburner e Controller 1 N t arth H 1 1 Burner 2 Burner 3 83 90 BTLW Fan Burner 4 Burner 5 Burner 6 55 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 13 5 Internal Wiring Diagram Dotted line wires are an option Lockout Indicator Connector Pressure Switch FAN f TN Filter POWER EXHAUST 230 V 50 HZ Fan Neon black green yellow d 0900000 00000 _ Burner Earth Stud Neon OQ
54. heater in area containing corrosive chemicals Refer to appropriate Material Safety Data Sheets MSDS Failure to follow these instructions can result in product damage Roberts Gordon LLC 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 heater compo nents will be greatly reduced An outside air supply must be provided to the burners whenever the presence of these compounds is suspected Warranty will be invalid if the heater is exposed to halogenated hydrocarbons 2 3 National Standards and Applicable Codes All appliances must be installed in accordance with the latest revision of the applicable standards and national codes This refers also to the electric gas and venting installation Note Additional standards for installations in Public Garages Aircraft Hangars etc may be applicable The heater must not be operat
55. her combustible materials including flammable objects liquids dust or vapours away from this heater or any other appliance The stated clearances to combustibles represents a surface temperature of 32 C 90 F above room tem perature Building materials with a low heat tolerance such as plastics vinyl siding canvas tri ply etc may be subject to degradation at lower temperatures It is the installer s responsibility to assure that adja cent materials are protected from degradation Maintain clearances from heat sensitive equipment and workstations Maintain clearances from vehicles parked below the heater Maintain clearances from swinging and overhead doors overhead cranes vehicle lifts partitions storage racks hoists building construction etc In locations used for the storage of combustible mate rials signs must be posted to specify the maximum permissible stacking height to maintain required clearances from the heater to the combustibles Signs must be posted adjacent to the heater thermostat In the absence of a thermostat signs must be posted in a conspicuous location 5 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 3 2 Clearances Data Linear and Double Linear NOTE 1 All dimensions are from the surfaces of all tubes couplings tees elbows and crosses 2 Clearances B C and D can be reduced by 50 after 7500 mm of tubing downstream from the burner 3 All measurements are in millimete
56. iance are compatible 1of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 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 heater 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 heater is designed for heating nonresidential 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 etc must be thoroughly understood before proceeding with the installation Protective gear is to be worn during installation operation and service Thin sheet metal parts such as the reflector portion of the heater and the various venting components have sharp edges To prevent injury the use of work gloves is recommended The use of gloves will also prevent the transfer of body oils from the hands to the surface of the reflector Before installation check that the local distribution conditions nature of gas and pressure and adjustment of the appliance are compatible The heater mus
57. in Tight the middle of the reflector with a reflector support and Sheet Metal tight screws Screw Reflector Reflector Support Reflecto Strap r SW Overlap must be a minimum Option B J of 160 mm Slip Overlap Reflector 2 The overlap at the first and second reflector is a slip Loose screws overlap Thereafter every third reflector joint is a WN loosened 2 mm slip overlap A slip overlap is achieved by either WN b to allow slippage a both reflectors lay inside a hanger no reflector support needed b using a reflector support vvith gt SS loose screws at the reflector Option A overlap Slip Overlap 3 The remaining reflector overlaps require a non slip overlap connection To affix the reflectors together in a non slip overlap either a use reflector support and tight screws b if both reflectors lay inside a hanger Dea or sheet metal screws may be used Option A Non Slip Overlap This section of three reflectors joined b Tight together must be affixed to the tube with gt Screws at least one reflector support with tight Option B SN S screws Non Slip Overlap abo Description Part Number Reflector Support Package 03050010 Wire Form 91908004 Reflector Support Strap 03050000 Screw 8 x 3 4 94320812 U clip Package 91107720 Reflector End Cap 027508XX U clip 2 clips per non slip overlap inside a hanger 23 of 73 BLACKHEAT HE IN
58. ling Assembly 1 2 2 3 3 3 4 4 01329700 Coupling Lock 1 2 2 3 3 3 4 4 02750303 Reflector Aluminium 2439 mm 3 4 4 6 6 6 7 7 027503SS Reflector Stainless Steel 2439 mm Optional 3 4 4 6 6 6 7 7 02750800 Reflector End Cap Aluminium 2 2 2 2 2 2 2 2 027508SH 1 Reflector End Cap Stainless Optional 2 2 2 2 2 2 2 2 03090100 Tube and Reflector Hanger 3 4 4 5 5 5 6 6 01318901 Tube Clamp Package including Nut Washer amp Bolt 1 1 1 1 1 1 1 1 91908004 Wire Form 2 3 3 5 6 6 94320812 Screw 8 x 3 4 Goes with 03050000 4 6 6 10 10 10 12 12 03050000 Reflector Support Strap 2 3 3 5 5 5 6 6 E0007576 Bow Shackle 3 4 4 5 5 5 6 6 91107720 U Clip Package 20 Pieces 1 1 1 1 1 1 1 1 S7199K 1 Damper Flange Assembly For use on Multiburner Systems 1 Per Heater PVC coating must be removed prior to installation Some models may receive S hooks P N 91907302 If an IP55 protected fan is required this fan replaces OT spring hooks P N 91903300 rather than bow 07260001 07260002 or 07260003 shackles 13 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL euunqniniw 104 uel vSdl eui esn Jo K quiessy 1eduue l6uis 104 x 7 JUSLUUOJIAUS 19 WO eme 9je20 1 3 ON A lquiessy ue 6 ONL uej Jopayey Figure 18 Linear General Assembly Overview yoddns 10129 J94 HEAA p s n
59. more information please consult your ROBERTS GORDON independent distributor In order to have trouble free performance of your heater and maintain the IP55 protection follow all instructions in this manual especially the replacement of sealing gaskets 1 3 Safety Labels and Their Placement Product safety signs or labels should be replaced by the product user when they are no longer legible Please contact Roberts Gordon LLC or your ROBERTS GORDONe independent distributor to obtain replacement signs or labels See Page 2 Figure 1 through Page 3 Figure 2 orifice Size Electrical Rating Country of Destination Year of Production Printed inthe U S A PIN 91031300NA Rev A Back Panel by ROBERTSGORDON Logo Label Figure 2 Control Side Label Placement Control Side Panel Control Side Panel Inside Description Part Number Logo Label 91033200 Wiring Diagram Label 91031404 SECTION 1 HEATER SAFETY Blackheat by ROBERTS GORDON Logo Label PRESSURE INTERNAL WIRING DIAGRAM IP55 qur un NTROLU purl n T ill sas varve it
60. nd Reflector Hanger Reflector Description Part Number Mesh Guard 2438 mm E0009855 Mesh Guard 1524 mm C2329B Strap Stainless Steel S5218VV Step 10 5 2 Fastener Installation Strap Stainless Steel Tube and Reflector Hanger Tube Description Part Number Nut Spire C1088B Screw 8 x 3 8 C1089B Mesh Guard L Screw 8 x 3 8 Nut Spire Step 10 5 3 Mesh Guard Connection 46 of 73 10 6 Undershield Installation 10 6 1 Hanger Installation Reflector Description Part Number Undershield Reflector Package 1010 mm S7399K Assembly Hanging Bracket Stud M6 x 90 C0318B C0693B Nut M6 C0090B 10 6 2 Undershield Installation Description Part Number Undershield Reflector Package 1010 mm Undershield Reflector 1010 mm S7399K C0521B Nut M6 C0090B Shield Support Bracket 02751700 10 6 3 Adjust Undershield Height ge N p N N p N p p ww SECTION 10 OPTIONAL HEATER ACCESSORIES p Undershield Reflector p ay _ Shield Support
61. nded I Vent Adapter Washer Nut e Torque 2 Nm Install vent adapter NN 18 in Ib with clamp in the up position Description Part Number Fan Assembly 072600XX Vent Adapter C1323B Nut M6 0061 Washer M6 C0039B 9 4 Linear amp U tube Fan Installation Tighten securely until tube cannot be removed Fan Assembly 38 of 73 SECTION 9 BURNER amp FAN INSTALLATION Step 9 5 Double Linear Fan Installation Tighten securely until tube cannot be removed LU Fan Assembly Step 9 5 1 Double Linear Fan Installation Continued Suspension Chain lt ER Bow 2 Shackle Height Adjuster TY Fan Assembl a y l 39 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Step 9 6 Multiburner 83 90 BWLG Fan Assembly Horizontal and Vertical Outlets Horizontal Exhaust Louver 83 90 BWLG Fan ID ID Sleeve i 4 a R Exhaust Sleeve Horizontal Exhaust Bend EN s z m Vertical Exhaust Tee 91 D Condensation runs to low level Condensate SR Aluminum Fr ube lt 1 BSP threaded hole Description Part Number Use 1 hs 34 17 3 4 CPVC pipe Vertical Exhaust Tee C1324B not supplied Horizontal Exhaust Bend C1325B Horizontal Exhaust Sleeve C1326B Non Return Valve Horizontal Exhaust Louver S5055F Condensate Cap 4 02718851 Condensate Cap 6 02718852 Non Retu
62. nector A volt free contact relay is closed which enables the ROBERTS GORDONS controller BMS system etc to indicate the heater that has failed An additional wire has to be installed from the heater volt free connector to the monitoring computer See Page 56 Section 13 5 Description Part Number Connector male Volt Free 91324000 Connector female Volt Free 91324001 VVire Blue 7 91300004 Wire Brown 7 91300005 Wire Yellow 12 91300003 Screw 8 x 3 8 Hex Wshr PHH Type 23 94961406 Base relay 2 C1050B Relay G2R1 SN IMO 220 V 10 A C1049B 14 2 Testing Establish that a satisfactory purged gas supply and an electrical supply is available to the heater Ensure that all time clocks and thermostats are set to call for heat With the gas supply cut off and the electrical supply isolated by switching off at the local switch open the control chamber secured by the screws Loosen the sealing screw from the pressure test point and remove the cover cap from the governor Turn on the gas supply and connect appliance electrical plug Ensure that the timer or thermostat if fitted are set to call for full gas rate Switch on at the local switch The sequence as described should take place If not refer to detailed fault finding sequence When flame is established check the gas pressure reading and adjust if necessary Refer to burner data label Check the gas pressure at the outlet of the
63. ns In all situations clearances to combustibles must be maintained Signs should be posted in storage areas to specify the maximum stacking height of items placed below heater to maintain required clearances to combustibles Minimum clearances must be maintained from vehicles parked below the heater Caution should be used when running the system near combustible materials such as wood paper rubber etc Consideration should be given to partitions storage racks hoists building construction etc A laminated wall tag is available for the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles Please contact Roberts Gordon or your ROBERTS GORDON independent distributor to obtain the wall tag Affix the tag by peeling off the backing of the adhesive strips on the rear surface and position the tag on a wall near the heater e g thermostat A copy of the wall tag P N 91037912 is illustrated on the back cover This copy of the wall tag can be affixed on the wall near the heater Know your model number and installed configuration Model number and installed configuration are found on the burner and in the Installation Operation and Service Manual Write the largest clearance dimensions with permanent ink according to your model number and configuration in the open spaces on the tag 4 of 73 2 2 Corrosive Chemicals A CAUTION Product Damage Hazard Do not use
64. nuo usilqeys k ON S A ON L f L E peioeuuoo amp pesio o p usilqe1s aim uo Aes SOA anpoul oN fenn N pU AI1 v ay y Jo Ajinunuoo eui S ON si uinq eui oq u ye eui SI amp amp S A fonuo oneujojne eoe dou S A Ls MO Hun 104002 Auedwoo sef 106 400 S8JIM JOaIOQ e0e dey ON oneulojne y Jojo ye Aiddns seb yo9uo Bunoeuuoo S HM y 1V 4009 dois eui SEB y uD 2 ON ON ponad uoniufi uun uoniu6i Buunp L uontu6i Buunp uonoes ON ufBuunp lqelieAe S A A OFZ 948Uuls sleuiuu lt 1 05 ees einsseid eunsseJd hno seb 1 u S uo ANSELIN seb jejur 1u loluns 194 S V SOA NN f Ienueu siy JO ile jo p ind ON uomnoes suoneoueds seul eBing ON Pul Seen S N ON Qui si uinq ile oq SUEBp 022E Ul u nss d 1epnno sef y si S A aunq y pisu ile pue y l 1edoud y 10 S A 66 of 73 16 3 Manifold Gas Pressure Setting o 5 Q g S S 10 dd c 8 8 o
65. on Slip Overlap N This section of three reflectors joined together must be affixed to the tube with at least one reflector support with tight Option B screws Non Slip Overlap Description Part Number Reflector Support Package 03050010 2 clips per Wire Form 91908004 non slip overlap Reflector Support Strap 03050000 inside a hanger Screw 8 x 3 4 94320812 U clip Package 91107720 Reflector End Cap 027508XX 34 of 73 SECTION 8 MULTIBURNER CONFIGURATION amp INSTALLATION SECTION 8 MULTIBURNER CONFIGURATION amp INSTALLATION A WARNING A WARNING Severe Injury Hazard Cut Pinch Hazard Secure burner to burner tube with bolts and Wear protective gear during installation lockwashers operation and service Hang heater with materials with a minimum Edges are sharp working load of 75 Ibs 33 kg Failure to follow these instructions can result Failure to follow these instructions can result EISE in death injury or property damage 8 1 Initial Assembly See Page 13 Section 6 for linear heater assembly instructions See Page 25 Section 7 for u tube heater assembly instructions Check layout drawings for location of manifold pipe installation Figure 24 Multiburner Damper Flange Installation Damper Flange m Assembiy 7 Note E T Install in the fully open position 35 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Figur
66. pling so that Q the impact block is in the w a Tube 2 00 or 10 00 o clock positions Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 Tube 91409408 Step 7 5 1 Coupling and Tube Assembly Continued Tighten slide bar as shown below Drive slide bar until tight End of slide bar should be i within tolerance listed below Correct Slide Bar Incorrect Slide Bar dimensions gt position gt Repeat Step 75 A D until all tubes are assembled 31 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Step 7 6 Tube Installation Step 7 7 U tube Installation U tube Support Bracket Assembly U tube Description Part Number Coupling 01329600 Slide Bar Coupling Lock 01329700 U tube 01335901 32 of 73 SECTION 7 U TUBE HEATER INSTALLATION Step 7 8 Reflector Installation A WARNING Fire Hazard Support reflector with reflector hanger and support strap Reflector must not touch tube Failure to follow these instructions can result in death injury or property damage Reflector Description Part Number Reflector 02750303 33 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Step 7 8 1 Reflector U clip and Reflector Support Installation The pictorial drawings of the heater construction in supports are used The positioning of reflector
67. rn Valve 90201200 Must be connected to a drain system in accordance with local codes Step 9 7 Condensate Drain Assembly Condensate Cap 1 BSP threaded hole Use 1 x 34 reducer not supplied 3 4 CPVC Pipe 3 4 Female Non Return Valve gt 3 4 CPVC Must be connected Pipe to a drain system Description Part Number in accordance with Condensate Cap 4 02718851 local codes Condensate Cap 6 02718852 Non Return Valve 90201200 40 of 73 SECTION 10 OPTIONAL HEATER ACCESSORIES SECTION 10 OPTIONAL HEATER ACCESSORIES A WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury 41 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL 10 1 Reflector Side Extension Installation Step 10 1 1 Bracket Installation a Tube and Reflector Hanger Reflector Support Reflector Side Extension Bracket lt 2 per reflector Use additional supports in high air movement applications Description Part Number Reflector Side Extension Package S7377K Reflector Side Extension 01368000 Retainer Clips 02751200 Reflector Side Extension 01329910 Step 10 1 2 Side Reflector Installation Cut relief notches for supports and hangers Retainer Clip 2 per side
68. rs FIGURE 3 LINEAR amp DOUBLE LINEAR HORIZONTAL MOUNTS e wa E i o Q no oa oa na o o o lo O oo 10 O oo lo O o LO e A Oo N st N LO nr q q LO W Li L LI ul LU Lu Li LI LI LI p r LI I I I I I I I A 150 150 150 150 150 150 200 200 hoe Bom B 890 970 970 1020 1170 1220 1280 1330 Y C 1570 1650 1650 1780 1930 1970 2010 2080 D 890 970 970 1020 1170 1220 1280 1330 FIGURE 4 LINEAR amp DOUBLE LINEAR ONE SIDE REFLECTOR ba ba Ga Ga 0 m m o L O oo lo O oo Lo O o LO e Q r N LO c nr q q LO W LL L L ul LU LU LI LI LI II II II II II I I I A 150 150 150 150 150 150 200 200 7 B 230 230 230 230 230 230 230 230 Y C 1580 1760 1760 1930 2090 2130 2160 2240 D 1200 1380 1380 1500 1660 1710 1760 1860 FIGURE 5 LINEAR amp DOUBLE LINEAR TWO SIDE REFLECTORS s 98 a ga ova to m L O oo Lo O oo lo O o LO e A D N Tr N LO c c lt q q LO W Li LI LI LI LI II II II II II I I I A 150 150 150 150 150 150 200 200 B 590 640 640 690 820 860 890 1020 C 1660 1810 1810 1960 2110 2160 2210 2320 D 590 640 640 690 820 860 890 1020 FIGURE 6 LINEAR amp DOUBLE LINEAR 45 MOUNT
69. s are sharp Supply Duct Fresh Air Adapter Failure to follow these instructions can result in injury 11 1 Type C42 C32 amp Ce 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 special concentric wall or roof terminal The wire mesh inside the fresh air adapter on the heater must be removed prior to installation See Page 51 Figure 31 11 2 Type Boo Appliance The flue must be fitted with a low resistance terminal See Page 51 Figure 31 11 3 Flue Installation The fan outlet may discharge vertically or horizontally Connection should be made using 100 mm minimum diameter Aluminium or Stainless Steel flue material to National Standard and must be adapted to insert into the 100 mm flue adapter Both fresh air supply and flue duct shall not exceed 10 000 mm HE15 and HE20 flue must be insulated if longer than 5 000 mm HE25 flue must be insulated if longer than 8 000 mm For each 90 bend subtract 1 000 mm from the maximum flue length The 49 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Figure 29 Individual Flue Connection Detail Fan Tube EA Fan Assembly Screw x Torque 2 Nm k 18inlb 5 Flue Adapter S Flue Pipe Figure 30 Flue Connection Dimensions End of Tube Fan Tube B Famo T A 8 nanne A 8 6 11 6 Outside Combus
70. s welded inside of the Tube and Reflector Hanger tube end with Clamp Package Position this hanger no more than 100 mm away from the burner assembly 7 Coupling Assembly gt with Lock Reflector End Cap Punch out center section to Tube and Reflector Hanger accommodate tube Suspend system from these hangers Fan Assembly Includes Flange Reflector Support Strap Wire Fan assembly is attached to the last Form amp 8 x 3 4 Screw section of heat exchanger tubing fan tube Damper Flange Assembly For use on Multiburner Systems Flex Gas Line Fan Flange Assembly and Screws Tee Assembly HH Height S hook M 1 Adjuster S upport Bracket D Bow Spring Shackle Hook 2 10 of 73 SECTION 5 GENERAL SUSPENSION DETAILS A WARNING Severe Injury Hazard Secure burner to burner tube with bolts and lockwashers Hang heater with materials with a minimum working load of 75 Ibs 33 kg Failure to follow these instructions can result in death injury or property damage A WARNING Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp Failure to follow these instructions can result in injury To ensure your safety and comply with the terms of the warranty all units must be installed in accordance with these instructions The gas or the electrical supply lines must not be used to support the heater Do not locate the gas or electrical suppl
71. sket Replacement Package P N 03360002 Description Quantity Part Number Screw 10 24 x 5 8 2 93313100 Silicone Gasket 4 92700006 Silicone Gasket 6 92700007 Rubber Gasket 13 92700001 17 1 4 Gas Valve Replacement Package P N 03360003 Description Quantity Part Number Gas Valve SIT 840 1 90033101 Screw M4 x 8 mm 2 93304506 Gas Valve Gasket 1 03200100 70 of 73 SECTION 18 SPECIFICATIONS 18 1 Material Specifications 18 1 1 Combustion and Tubes 100 mm dia 16 gauge heat treated aluminised mild steel 18 1 2 Reflectors NS3 H14 aluminium or 1 4016 2R stainless steel option 18 2 Heater Specifications 18 2 1 Sequence Controller Fully automatic single try direct spark 100 shut off ignition flame rectification module 18 2 2 Electrical Rating 230 V 50 Hz 1 1 Connection minimum IP55 function box 18 2 3 Gas Supply Connection Rc1 2 1 2 BSP int Natural G20 Minimum Inlet 15 mbar 6 in wg Maximum Inlet 50 mbar 20 in wg Natural G25 Minimum Inlet 175 mbar 7 in wg Maximum Inlet 50 mbar 20 in wg LP Gas Propane or Butane Minimum Inlet 32 5 mbar 13 in wg Maximum Inlet 50 mbar 20 in wg SECTION 18 SPECIFICATIONS 18 3 Venting Specifications 18 3 1 Fans HE15 20 25 30 35 Model Torin DSF 133 42 HE40 45 50 Model AO Smith JF1G HESODL 40DL Model Torin DSA 524 202 HE5ODL 60DL 70D
72. sure shield is installed correctly and secured in place if necessary Decorative grille only See Page 44 Section 10 3 2 Wall Tag If a wall tag is present make sure it is legible and accurate Please contact Roberts Gordon LLC or your ROBERTS GORDON independent distributor if you need a wall tag See Page 4 Section 2 1 61 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 16 TROUBLESHOOTING A DANGER Electrical Shock Hazard Disconnect electric before service Heater must be properly grounded Failure to follow these instructions can result in death or electrical shock A WARNING Fire Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Keep all flammable Turn off gas supply to Allow heater to cool Wear protective gear objects liquids and heater before service before service during installation vapors the minimum operation and service required clearances to Tubing may still be hot combustibles away after operation Edges are sharp from heater Some objects will catch fire or explode when placed close to heater Failure to follow these instructions can result in death injury or property damage 62 of 73 TROUBLESHOOTING SECTION 16 16 1 Troubleshooting Flow Chart Linear Double Linear and U Tube
73. t be applied and operated under the general concepts of reasonable use For additional copies of the Installation Operation and Service Manual please contact Roberts Gordon LLC Figure 1 Bottom and Back Panel Label Placement Fan Burner Fan Burner Label Appli Fan Burner 8 Blackheat Rating Plate Label Blachheat Bottom Panel Part Number 91033200 91031300 91033300 Description Logo Label Rating Plate Label Fan Burner Label 2 of 73 Model No Serial No lance Typel Gas Pressure at Manifold qarlar ei onte Valo c 1 1 Manpower Requirements To prevent personal injury and damage to the heater two persons will be required for installation 1 2 IP55 Protection The burner is certified to protection class of IP55 This means that the internal components of the burner are protected against extreme dusty atmosphere and water jets from all sides Outside air supply and flue are mandatory for this heater The standard exhaust fans mentioned in this manual do NOT have IP55 protection and must be outside the wet environment If the fan is to be installed in the wet environment a special IP54 protected fan must be used Consult Roberts Gordon LLC for alternative exhaust fans Optional stainless steel burner box provides long life in the most corrosive applications Always ensure that the environment to be heated is not of an explosive or flammable nature For
74. tion Air Supply 11 6 1 Air Supply Requirements Clean air must be ducted into the burner box through the When fresh air duct is used follow one of these rules 100 mm diameter spigot on the back of the burner box The flue must penetrate the roof while fresh air can See Page 49 Section 11 3 for recommendations on duct penetrate any wall See Page 51 Figure 31 length Air duct should be as straight as possible Consult The flue and fresh air supply must penetrate the roof the manufacturer if more than 1 x 90 bend is necessary at a minimum of 1 000 mm apart The fresh air duct must be self supporting See Page 51 Figure 31 The flue must penetrate 1 000 mm higher than the fresh air inlet on the same wall See Page 51 Figure 31 50 of 73 SECTION 11 VENTING AND FRESH AIR SUPPLY Figure 31 Air Supply with Flue Configurations ni Min 1000mm C s 32 w Min 1000mm gt Flue 11 7 Common Duct VVhen using a common air inlet duct alvvays ensure that the area of the common air inlet duct represents the area of all air ducts 51 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL SECTION 12 GAS PIPING AWARNING Fire Hazard Tighten gas line fittings to connect gas supply according to Figure 32 Flex gas line can crack when twisted Gas line moves during normal operation Use only 1000 mm long connector of 1 2 or 3 4 nominal ID Failure to follo
75. ts and couplings is crucial for proper installation Assemble the heater components as shown on Page 14 Figure 18 For optional reflector configurations for linear heaters see Page 6 Figure 3 through Page 7 Figure 9 Install Cut Pinch Hazard appropriate suspension hardware beam clamps chain or rod at predetermined locations Adjustments of chain Wear protective gear during installation length will provide uniform pitch operation and service If any step is unclear please contact Roberts Gordon Edges are sharp LLC at 44 0 121 506 7700 Failure to follow these instructions can result in injury 6 1 Linear Standard Parts List lim m oo ooo lil S B 812 6 PartNo Description 99 Bf r d 033XXXXX Burner Assembly Input and Fuel Varies 1 1 1 1 1 1 1 1 07260001 Fan Package XP 1 1 1 1 1 1 07260002 Fan Package XP 2 optional 07260003 Fan Package XP 3 1 1 1 07260051 Fan Package 1 IP55 optional 1 1 1 1 1 07260052 Fan Package 2 IP55 optional 07260053 Fan Package 3 IP55 optional 1 1 1 03051100 Burner Tube 100 mm x 3048 mm 1 1 1 1 1 1 1 1 91409408 Tube 100 mm x 3048 mm 1 1 2 2 2 3 3 95127 Fan Tube 100 mm x 3048 mm with 3048 mm Swirler 1 1 1 1 1 1 1 S5134W Fan Tube 100 mm x 3048 mm with 2134 mm Swirler 1 01329600 Standard Coup
76. tted for horizontal and vertical flue AWAR N N G In order to locate fans that are not IP54 protected away from the wet environment a 100 mm diameter extension tube between the heat exchanger end and fan must be installed This length must be subtracted from the maximum flue length Fans Horizontal Vertical 83BWLG 190 mm x 75 mm hole 150 mm dia 90 BWLG 190 mm x 75 mm hole 150 mm dia Carbon Monoxide Hazard Multiburner systems are not approved for unvented use and must be vented outdoors 11 4 Ventilation Requirements Detailed recommendations for air supply are given in the relevant National Standards There must be an adequate Heaters must be installed according to the supply of air for both combustion and general ventilation installation manual Air vents should have negligible resistance Do not locate air vents where they can be easily blocked or flooded or adiacent to any flues or extraction systems carrying flammable vapour AWARNING 11 5 Fresh Air Supply The burner is equipped with a fresh air adapter which has a silicone gasket incorporated This adapter accepts tubes with 100 mm outside diameter Unitary heaters installed unvented must be interlocked with sufficient building exhaust Failure to follow these instructions can result in death or injury if Cut Pinch Hazard 100 mm OD Wear protective gear during installation M Fresh Air operation and service Edge
77. urner Assembly Input and Fuel Varies 1 1 1 1 1 1 1 1 07260001 Fan Package XP1 1 1 1 1 1 07260002 Fan Package XP2 optional 07260003 Fan Package XP3 1 1 1 07260051 Package 1 IP55 optional 1 1 1 1 1 07260052 Package 2 IP55 optional 07260053 Package 3 IP55 optional 1 1 1 03051100 Burner Tube 100 mm x 3048 mm 1 1 1 1 1 1 1 1 91409408 Tube 100 mm x 3048 mm 2 2 2 2 2 91409423 Tube 100 mm x 1524 mm 2 2 2 2 5127W Fan Tube 100 mm x 3048 mm with 3048 mm Swirler 1 1 1 1 1 1 1 5134W Fan Tube 100 mm x 3048 mm with 2134 mm Swirler 1 01335901 U tube 1 1 1 1 1 1 1 1 01329600 Standard Coupling Assembly 2 4 4 4 4 4 6 6 01329700 Coupling Lock 2 4 4 4 4 4 6 6 02750303 Reflector Aluminium 2439 mm 4 4 4 6 6 6 8 8 02750355 Reflector Stainless Steel 2439 mm Optional 4 4 4 6 6 6 8 8 02750800 Reflector End Cap Aluminium 4 4 4 4 4 4 4 4 027508SH Reflector End Cap Stainless Optional 4 4 4 4 4 4 4 4 03090100 Tube and Reflector Hanger 4 6 6 6 6 6 8 8 01318901 Tube Clamp Package including Nut Washer amp Bolt 1 1 1 1 1 1 1 1 91908004 Wire Form 2 4 4 4 4 4 6 6 03050000 Reflector Support Strap 2 4 4 4 4 4 6 6 03020501 U tube Support Bracket 1 1 1 1 1 1 1 1 E0007576 Bow Shackle 4 6 6 6 6 6 8 8 91107720 U clip Package 20 Pieces 2 2 2 2 2 2 2 2 91912501 U bolt M6 2 2 2 2 2 2 2 2 00908 Nut M6 6 6 6 6 6 6 6 6 25 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANU
78. w these instructions can result in death injury or property damage AWARNING Explosion Hazard Leak test all components of gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with heater connected Failure to follow these instructions can result in death injury or property damage It is important that the gas supply pipe and electrical connections do not support any of the heater s weight Installation pipes should be fitted in accordance with National Standards Pipe work from the meter to the heater s must be of adequate size Pipes of smaller size than the heater inlet gas connection should not be used Install the gas hose as shown on Page 53 Figure 32 The gas hose accommodates expansion of the heating system and allows for easy installation and service of the burner Before connecting the burners to the supply system verify that all high pressure testing of the gas piping has been completed 52 of 73 There is an expansion of the tube with each firing cycle This will cause the burner to move with respect to the gas hose This can cause a gas leak resulting in an unsafe condition if the gas connection is not made in strict accordance with Figure 32 Meter and service must be large enough to handle all the burners being installed plus any other connected load The gas hose which feeds the system must be large enough to supply the required gas wit
79. with necessary information contractor qualified in the installation and service of gas fired heating equipment or your gas supplier 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 0 121 506 7709 Service Fax 44 0 121 506 7702 E mail uksales rg inc com E mail export rg inc com Www rg inc com 2010 Roberts Gordon LLC 170102UK Rev E 09 10 TABLE OF CONTENTS SECTION 1 Heater Safety 2 10 5 Sports Hall Guard Installation 46 1 1 Manpower Requirements 2 10 6 Undershield Installation 47 1 2 IP55 Protectloni u l u tms 2 10 7 Wall 555 48 1 3 Safety Labels and Their Placement 2 SECTION 11 Venting and Fresh Air Suppiy 49 SECTION 2 Installer Responsibility 4 11 1 Type C12 C32 amp C62 Appliance 49 2 1 Low Level User Instructions 4 11 2 Type B22 Appliance 49 2 2 Corrosive Chemicals 4 11 3 Flue Installation 2 5 49 2 3 National Standards and Applicable Codes 4 11 4 Ventilation Requirements
80. y lines directly over the path of the flue products from the heater The heater must be installed in a location that it is readily accessible for servicing The heaters must be installed with clearances to combustibles as indicated on the rating plate and in this manual The minimum and maximum gas inlet pressures must be maintained as indicated on the rating plate Typical installation configurations are shown on Page 12 Figure 17 NOTE Some models may receive S hooks P N 91907302 or spring hooks P N 91903300 rather than bow shackles SECTION 5 GENERAL SUSPENSION DETAILS 11 of 73 BLACKHEAT HE INSTALLATION OPERATION AND SERVICE MANUAL Figure 17 Critical Hanger Placement Typical Suspension Details Screw Hook Concrete min 10 mm 5 Beam VVasher lamp Anchor Locknut I Beam d 9 Bow Shackle gt is Front Vievv 45 Angle 100 mm Max Description Part Number Burner Tube 03051100 S hook Spring Hook 91907302 91903300 Bow Shackle E0007576 Tube Reflector Hanger 12 of 73 03090100 SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION SECTION 6 LINEAR amp DOUBLE LINEAR HEATER INSTALLATION A WARNING The figures in this section provide a general overview of component placement in a Linear and Double Linear system The location of some components such as suppor

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