Roberts Gorden BH15 User Manual

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FOR YOUR SAFETY

If you smell gas:

1.Open windows.

2.DO NOT try to light any appliance.

3.DO NOT use electrical switches.

4.DO NOT use any telephone in your building.

5.Leave the building.

6.Immediately call your local gas supplier after leaving the building. Follow the gas supplier’s instructions.

7.If you cannot reach your gas supplier, call the Fire Department.

DO NOT store or use petrol or other flammable vapors and liquids in the vicinity of this or any other appliance.

Blackheat®

Vacuum Assisted

Linear & U-Tube

Gas Fired Radiant

Heating

Systems

Installation, Operation &

Service Manual

BH15

BH20

BH25

BH30

BH35

BH40

BH45

BH50

WARNING

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.

Installation must be done by a contractor qualified in the installation and service of gas-fired heating equipment.

Installer

Please take the time to read and understand these instructions prior to any installation.

Installer must give a copy of this manual to the owner.

Owner

Keep this manual in a safe place to provide your serviceman with information should it become necessary.

Hurll Nu-Way Pty Ltd

14 Aristoc Road

GLEN WAVERLEY VIC 3150

Telephone: +61 3 9561 2100

Fax: +61 3 9560 8992

www.rg-inc.com

170101AUNZ

Rev. 2

4/03

TABLE OF CONTENTS		Note: Pages 2,16,17,18,23,32,35,46,54,55 have been deleted as not relevant.
SECTION 1: Heater Safety......................................................			1	SECTION 12: Venting ............................................................		42
SECTION 2: Installer Responsibility		.....................................	1	12.1	Flue Installation........................................................	42
2.1	Low Level User Instructions.........................................		1	12.2	Flueless Installation (U.K. Only)...............................	42
2.2	Halogenated Hydrocarbons .........................................		1	12.3	Ventilation Requirements .........................................	42
2.3	National Standards and Applicable Codes ..................		1	12.4	Outside Combustion Air Supply ...............................	43
SECTION 3: Critical Considerations		.....................................	3	12.5 Common Duct ..........................................................		43
3.1	Minimum Required Clearances to Combustibles.........		3	SECTION 13: Gas Piping ......................................................		44
3.2	Clearance Data - Linear................	4		SECTION 14: Wiring..............................................................		45
3.3	Clearance Data -U Tube.................	6		14.1	BLACKHEAT® Typical External Wiring Diagram
SECTION 4: Specifications ....................................................			8	(Linear or U Tube) ............................................................		45
4.1	Material Specifications.................................................		8
4.2	Heater Specifications...................................................		8
4.3	Venting Specifications..................................................		8
4.4	Suspension Specifications...........................................		8
4.5	Controls Specifications ................................................		8
4.6	Linear Heater...............................................................		9
				14.5	BLACKHEAT® Internal Wiring Diagram .................	47
4.8	U-Tube Heater .............................................................		9	SECTION 15: Operation ........................................................		48
4.9	Burner Specifications.................................................		10	15.1	Heater Lockout Indication (Optional)........................	48
SECTION 5: Major Component Descriptions .....................			11	15.2	Testing......................................................................	48
SECTION 6: General Suspension Details ..........................			12	15.3	Commisioning ..........................................................	48
6.1	Suspension Details ....................................................		12	15.4	System Checks ........................................................	49
SECTION 7: Linear Heater Installation........................... ...			13	15.5	User Instructions ......................................................	49
7.1	Linear Standard Parts List .........................................		13	SECTION 16: Servicing Instructions ...................................		50
				16.1	Annual Procedure ....................................................	50
7.3	Burner Tube Installation ............................................		19	16.2	Component Removal ...............................................	50
7.4	Coupling and Tube Assembly....................................		19	SECTION 17: Troubleshooting .............................................		52
7.5	Tube Clamp Package Installation ..............................		21	17.1 Troubleshooting Flow Chart (Linear and
7.6	Reflector Installation ..................................................		21	U-Tube) ............................................................................		52
				17.3	Manifold Gas Pressure Setting ................................	56
SECTION 8: U-Tube Heater Installation ..............................			24	SECTION 18: Replacement Parts.........................................		57
8.1	U-Tube Standard Parts List........................................		24
8.2	Critical Hanger Placement.........................................		27
8.3	Burner Tube and Fan Tube Installation ....................		27
8.4	U-Tube Support Bracket Assembly Installation .........		28
8.5	Coupling and Tube Assembly....................................		29
8.6	Tube Installation ........................................................		30
8.7	U-Tube Installation ....................................................		30
8.8	Reflector Installation ..................................................		31
SECTION 10: Burner & Fan Installation ..............................			33
10.1 Burner Installation....................................................			33
10.2 Fan Assembly..........................................................			33
10.3 Linear & U-Tube Fan Installation..............................			34
SECTION 11: Optional Heater Accessories........................			36
11.1 Reflector Side Extension Installation .......................			36
11.2 Decorative Grille Installation ....................................			37
11.3 Protective Grille Installation .....................................			38
11.4 Sports Hall Guard Installation..................................			39
11.5 Universal Shield Installation.....................................			40
11.6 Undershield Installation ...........................................			41

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.

TABLE OF FIGURES

Figure 1: Deleted
Figure 2: Linear Horizontal Mounts ...............	4
Figure 3: Linear, One Side Reflector..............	4
Figure 4: Linear, Two Side Reflectors ............	4
Figure 5: Linear, 45° Mount............................	4
Figure 6: Linear, 1 Foot and 2 Foot Deco
Grille ..........................................................................		5
Figure 7: Linear, Protective Grille...................	5
Figure 8: Linear, Venting ................................	5
Figure 9: U-Tube, Horizontal Mount ..........................................		6
Figure 10: U-Tube, One Side Reflector .....................................		6
Figure 11: U-Tube, Two Side Reflectors ...................................		6
Figure 12: U-Tube, Full 45° Mount ............................................		6
Figure 13: U-Tube, Opposite 45° Tilt.........................................		7
Figure 14: U-Tube, Protective Grille ..........................................		7
Figure 15: U-Tube, Venting .......................................................		7
Figure 16: BLACKHEAT® Linear and U-Tube	........................	10
Figure 17: BLACKHEAT® Linear General Assembly
Overview................................................................		14
Figure 18: BLACKHEAT® Linear Layout Overviews ..............		15
Figure 19: Deleted
Figure 20: Deleted
Figure 21: Reflector Overlap Detail.........................................		22
Figure 22: BLACKHEAT® BH15UT Assembly Overview .......		25
Figure 23: BLACKHEAT® U-Tube Layout Overviews.............		26
Figure 24: Deleted
Figure 25: Typical Manifold Layout (Linear and U-Tube
Configuration) ........................................................		32
Figure 26: Individual Flue Connection Detail ..........................		42
Figure 27: Fresh Air Intake Spigot ..........................................		43
Figure 28: Air Supply with Flue Configurations.......................		43
Figure 29: Gas Connection with Stainless Steel Flex
Connector ..............................................................		44
Figure 30: Sequence of Operation Chart................................		48
Figure 31: Burner Cup Position...............................................		50

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.

WARNING

Installation, Service and Annual Inspection of heater must be done by a contractor qualified in the installation and service of gas-fired heating equipment.

Read this manual carefully before installation, operation, or service of this equipment.

Failure to follow these instructions can result in death, injury or property damage.

A wall tag is supplied with the BLACKHEAT® heater as a permanent reminder of the safety instructions and the importance of the minimum required clearances to combustibles. A copy of the wall tag is illustrated on Page 2, Figure 1. Peel off the backing of the adhesive strips on the rear surface of the tag and position the tag on a wall near the BLACKHEAT® heater (e.g. thermostat or ROBERTS GORDON® BZC Microprocessor Controller).

2.2 Halogenated Hydrocarbons

CAUTION

Do not use heater in an area containing corrosive chemicals.

Avoid the use of corrosive chemicals to ensure a longer life of the burner, tubing and other parts.

Failure to follow these instructions can result in property damage.

This heater is designed for heating non-residential indoor

spaces. Do not install in residential spaces. These instructions, layouts , AS5601/AG 601,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.

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 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.

2.1 Low Level User Instructions

In all situations, clearances to combustibles must be maintained. Failure to observe clearances to combustibles can result in death, severe injury or property damage. 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.

Roberts-Gordon cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the subcontractor, or the owner identifies the presence of combustible materials or halogenated hydrocarbons* anywhere in the premises.

* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (flourine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the lifespan of the heater components 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 AS5601/AG 601 and other relevant

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.

SECTION 3: CRITICAL CONSIDERATIONS

WARNING





Fire Hazard		Burn Hazard
Some objects will catch fire	Keep all persons,
or explode when placed	especially children, away
close to heater.	from heater.
Keep all flammable objects,	Do not touch any part of
liquids and vapors the	the heater.
minimum required	Heater is very hot.
clearances to combustibles	Heater is very hot.
away from heater.	Failure to follow these
Failure to follow these	instructions can result in
Failure to follow these	severe injury.
instructions can result in	severe injury.
death or injury.

3.1 Minimum Required Clearances to Combustibles

Clearances are the required distances that combustible objects must be kept away from the heater to prevent serious fire hazards. Combustibles are materials, which may catch on fire and include common items such as wood, paper, rubber, fabric, etc. Maintain clearances to combustibles at all times for your safety.

Clearances for all heater models are located on Page 4, Figure 2 through Page 7, Figure 15 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 other combustible materials including flammable objects, liquids, dust or vapours away from this heater or any other appliance.

•Maintain clearances from heat sensitive material, equipment and workstations.

•Maintain clearances from vehicles parked below the heater.

•Maintain clearances from swinging doors, overhead cranes, vehicle lifts, partitions, storage racks, hoists, etc.

•In locations used for the storage of combustible materials, 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.

•Consult local Building Inspector, Fire Insurance Carrier or other authorities for approval of proposed 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 9, Section 4.6 through Page 9, Section 4.8.

•If the radiant tubes must pass through the building structure, be sure that adequate sleeving and fire stop is installed to prevent scorching and/or fire hazard.

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

3.2 Clearance Data -

NOTE: 1. All dimensions are from the Tube surface.

2.Clearances B, C and D can be reduced by 50% after 7 m of tubing downstream from the burner.

3.All measurements are in Millimeters.

FIGURE 2: LINEAR , HORIZONTAL MOUNTS

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

A	150	150	150	150	150	150	200	200
B	890	970	970	1020	1170	1220	1280	1330

C	1570	1650	1650	1780	1930	1970	2010	2080
D	890	970	970	1020	1170	1220	1280	1330

FIGURE 3: LINEAR , ONE SIDE REFLECTOR

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50
A	150	150	150	150	150	150	200	200
B	230	230	230	230	230	230	230	230
C	1580	1760	1760	1930	2090	2130	2160	2240
D	1200	1380	1380	1500	1660	1710	1760	1860

FIGURE 4: LINEAR, TWO SIDE REFLECTORS

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

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 5: LINEAR, 45° MOUNT

		Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

		A	200	200	200	250	250	275	300	300
B	D	B	200	200	200	200	200	200	200	200

		C	1500	1660	1660	1860	1960	2030	2110	2160


		D	1370	1520	1520	1630	1750	1820	1880	2000

SECTION 3: CRITICAL CONSIDERATIONS

NOTE: 1. All dimensions are from the Tube surface.

2.Clearances B, C and D can be reduced by 50% after 7 m of tubing downstream from the burner.

3.All measurements are in Millimeters.

FIGURE 6: LINEAR , 1 FOOT AND 2 FOOT DECO GRILLE

B D

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

A	150	150	150	150	150	150	200	200
B	890	970	970	1020	1170	1220	1280	1330
B	890	970	970	1020	1170	1220	1280	1330

C	1570	1650	1650	1780	1930	1970	2010	2080
D	890	970	970	1020	1170	1220	1280	1330

FIGURE 7: LINEAR , PROTECTIVE GRILLE

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

A	150	150	150	150	150	150	200	200
B	890	970	970	1020	1170	1220	1280	1330

C	1570	1650	1650	1780	1930	1970	2010	2080
D	890	970	970	1020	1170	1220	1280	1330

FIGURE 8: LINEAR , VENTING

Unvented

Radiant tubes

Fan

Vented

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

E	1000	1000	1000	1000	1000	1000	1000	1000
F	500	500	500	500	500	500	500	500

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

3.3 Clearance Data -U Tube

NOTE: 1. All dimensions are from the Tube surface.

2.Clearances B, C and D can be reduced by 50% after 7 m of tubing downstream from the burner.

3.All measurements are in Millimeters.

FIGURE 9: U-TUBE, HORIZONTAL MOUNT

Model

			A
B	C	D	B

BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

150	150	150	150	150	150	200	200
890	970	970	1020	1170	1220	1270	1380

1580	1730	1730	1910	1980	2050	2110	2210

760	940	940	1000	1090	1150	1200	1300

FIGURE 10: U-TUBE, ONE SIDE REFLECTOR

B	C	D

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50

A	150	150	150	150	150	150	200	200
B	230	230	230	230	230	230	230	230

C	1580	1760	1760	1930	2090	2130	2160	2240
D	1200	1380	1380	1500	1660	1710	1760	1860

FIGURE 11: U-TUBE, TWO SIDE REFLECTORS

	A
B	C	D
B		D

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50
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 12: U-TUBE, FULL 45° MOUNT

Model	BH15	BH20	BH25	BH30	BH35	BH40	BH45	BH50
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

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