Roberts Gorden BH40ST, BH50UT, BH60DL, BH70DL, BH30UT 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.Extinguish any open flame.

6.Leave the building.

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

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

WARNING

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.

Blackheat®

Vacuum Assisted

Linear, Double Linear,

U-Tube, and Multi-Burner

Gas Fired Heating Systems

Installation, Operation &

Service Manual

BH15UT BH15ST BH30DL BH20UT BH20ST BH40DL BH25UT/EF BH25ST/EF BH50DL/EF BH30UT/EF BH30ST/EF BH60DL/EF BH35UT/EF BH35ST/EF BH70DL/EF BH40UT/EF BH40ST/EF BH45UT/EF BH45ST/EF BH50UT/EF BH50ST/EF

BH55ST

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 registered installer/ contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier.

Installer

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

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

Owner

Keep this manual in a safe place in order to provide your serviceman with necessary information.

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

© 2012 Roberts-Gordon LLC

170101UK Rev. P-1 08/12

TABLE OF CONTENTS

SECTION 1: Heater Safety ............................................

2

SECTION 11: Venting ..................................................

50

1.1 Manpower Requirements ....................................

2

11.1 General Venting Requirements .......................

50

1.2 Safety Labels and Their Placement ....................

2

11.2 Ventilation Requirements.................................

50

SECTION 2: Installer Responsibility............................

4

11.3 Outside Combustion Air Supply.......................

51

2.1

Low Level User Instructions................................

4

11.4 Common Duct .................................................

52

2.2

Corrosive Chemicals...........................................

4

SECTION 12: Gas Piping ............................................

53

2.3

National Standards and Applicable Codes .........

4

SECTION 13: Wiring....................................................

55

SECTION 3: Clearances to Combustibles...................

5

13.1

Typical External Wiring Diagram

 

3.1

Required Clearances to Combustibles ...............

5

 

(Linear or U-Tube)...........................................

55

3.2

Clearance Data - Linear and Double Linear .......

6

13.2

Typical External Wiring Diagram

 

3.3

Clearance Data -U Tube .....................................

8

 

(Double Linear Option 1) ................................

55

SECTION 4: Major Component Descriptions............

10

13.3

Typical External Wiring Diagram

 

SECTION 5: General Suspension Details .................

11

 

(Double Linear Option 2) ................................

56

SECTION 6: Linear & Double Linear Heater

 

13.4

Typical External Wiring Diagram

 

 

Installation..............................................

13

 

(Multiburner) ...................................................

56

6.1

Linear Standard Parts List ................................

13

13.5

Internal Wiring Diagram .................................

57

6.2

Double Linear Standard Parts List....................

16

SECTION 14: Operation ..............................................

58

6.3

Burner Tube Installation ...................................

19

14.1

Heater Lockout Indication (Optional) ..............

58

6.4

Coupling and Tube Assembly...........................

19

14.2

Testing ............................................................

59

6.5

Tube Clamp Package Installation.....................

21

14.3

Commissioning (Multiburner)..........................

59

6.6

Reflector Installation .........................................

22

14.4

System Checks...............................................

59

6.7

Double Linear Tee Installation

 

14.5

User Instructions.............................................

59

 

(for double linear heaters only) .........................

24

14.6

ECA Approved Systems (Multiburner only).....

60

SECTION 7: U-Tube Heater Installation.....................

25

SECTION 15: Servicing Instructions .........................

61

7.1 U-Tube Standard Parts List ...............................

25

15.1

Annual Procedure ...........................................

61

7.2

U-Tube Hanger Placement...............................

29

15.2

Component Removal ......................................

61

7.3

Burner Tube and Fan Tube Installation ...........

29

15.3

Maintenance Checklist....................................

62

7.4

U-Tube Support Bracket Assembly

 

SECTION 16: Troubleshooting...................................

64

 

Installation ........................................................

30

16.1

Troubleshooting Flow Chart

 

7.5

Coupling and Tube Assembly...........................

31

 

(Linear, Double Linear and U-Tube)................

65

7.6

Tube Installation ...............................................

32

16.2

Troubleshooting Flow Chart (Multiburner) ......

67

7.7

U-Tube Installation ...........................................

32

16.3

Manifold Gas Pressure Setting .......................

69

7.8

Reflector Installation .........................................

33

SECTION 17: Replacement Parts...............................

70

SECTION 8: Multiburner Configuration &

 

SECTION 18: Specifications.......................................

72

 

Installation .............................................

35

18.1

Material Specifications....................................

72

8.1

Initial Assembly.................................................

35

18.2

Heater Specifications......................................

72

SECTION 9: Burner & Fan Installation ......................

37

18.3

Venting Specifications.....................................

72

9.1

Burner Installation.............................................

37

18.4

Suspension Specifications..............................

72

9.2

Fan Assembly...................................................

37

18.5

Controls Specifications ...................................

72

9.3

Linear & U-Tube Fan Installation ......................

38

18.6

Linear Heater..................................................

73

9.4

Double Linear Fan Installation..........................

38

18.7

Double Linear Heater......................................

73

9.5

Multiburner 83/90 BWLG Fan Assembly

 

18.8

U-Tube Heater ................................................

73

 

(Horizontal and Vertical Outlets) ......................

39

18.9

Burner Specifications......................................

74

9.6

Condensate Drain Assembly ............................

40

 

 

 

SECTION 10: Optional Heater Accessories ..............

41

 

 

 

10.1 Reflector Side Extension Installation...............

42

 

 

 

10.2 U-Tube Cover Installation................................

43

 

 

 

10.3 Decorative Grille Installation ...........................

44

 

 

 

10.4 Protective Grille Installation.............................

45

 

 

 

10.5 Sports Hall Guard Installation .........................

46

 

 

 

10.6 Undershield Installation...................................

47

 

 

 

10.7 Wall Mounting .................................................

48

 

 

 

© 2010 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 the written permission of Roberts-Gordon LLC.

Printed in U.K.

TABLE OF FIGURES

 

Figure 1: Side and Back Panel Label Placement............

2

Figure 2: Top Panel Label Placement.............................

3

Figure 3: Linear & Double Linear, Horizontal Mounts .....

6

Figure 4: Linear & Double Linear, One Side Reflector....

6

Figure 5: Linear & Double Linear, Two Side Reflectors ..

6

Figure 6: Linear & Double Linear, 45° Mount..................

6

Figure 7: Linear & Double Linear, 2 Foot Deco Grille .....

7

Figure 8: Linear & Double Linear, Protective Grille.........

7

Figure 9: Undershield .....................................................

7

Figure 10: Linear & Double Linear, Venting....................

7

Figure 11: U-Tube, Horizontal Mount..............................

8

Figure 12: U-Tube, One Side Reflector...........................

8

Figure 13: U-Tube, Two Side Reflectors.........................

8

Figure 14: U-Tube, Full 45° Mount..................................

8

Figure 15: U-Tube, Opposite 45° Tilt ..............................

9

Figure 16: U-Tube, Protective Grille................................

9

Figure 17: U-Tube, Venting.............................................

9

Figure 18: Critical Hanger Placement ...........................

12

Figure 19: Linear General Assembly Overview.............

14

Figure 20: Linear Layout Overview ...............................

15

Figure 21: Double Linear General Assembly

 

Overview ......................................................

17

Figure 22: Double Linear Layout Overview...................

18

Figure 23: U-Tube Assembly Overview ........................

27

Figure 24: U-Tube Layout Overview .............................

28

Figure 25: Multiburner Damper Flange Installation.......

35

Figure 26: Typical Manifold Layout (Linear and

 

U-Tube Configuration)..................................

36

Figure 27: U-Tube (Horizontal) .....................................

48

Figure 28: U-Tube (Angle Mounted) .............................

49

Figure 29: Linear...........................................................

49

Figure 30: Individual Flue Connection Detail ................

51

Figure 31: Flue Connection Dimensions.......................

51

Figure 32: Fresh Air Intake Spigot ................................

52

Figure 33: Air Supply with Flue Configurations.............

52

Figure 34: Gas Connection with Stainless Steel Flex

 

Connector.....................................................

54

Figure 35: Sequence of Operation Chart ......................

58

Figure 36: Burner Cup Position.....................................

61

Figure 37: Linear and U-Tube Specifications................

74

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 appliance are compatible.

1 of 75

BLACKHEAT® 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.

For additional copies of the Installation, Operation andService Manual, please contact Roberts-Gordon LLC.

1.1 Manpower Requirements

To prevent personal injury and damage to the heater, two persons will be required for installation.

1.2 Safety Labels and Their Placement

Product safety signs or labels should be replaced by the product user when they are no longer legible. Contact Roberts-Gordon for obtaining replacement signs or labels. See Page 2, Figure 1 through Page 3, Figure 2.

Figure 1: Side and Back Panel Label Placement

Logo Label

Fan/Burner Label

Side Panel

Rating Plate Label

Back Panel

Description

Part Number

Logo Label

91033200

Fan/Burner Label

91033300

Rating Plate Label

91031300

2 of 74

SECTION 1: HEATER SAFETY

Figure 2: Top Panel Label Placement

 

Top Panel

Gas Connection Label

 

Top Panel - Inside Door

 

Description

Part Number

 

Gas Connection Label

91018126

 

Internal Wiring Label

91031401

Internal Wiring Label

 

 

3 of 75

BLACKHEAT® 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 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 a 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 materials with a minimal working load of 33 kg.

To ensure the heater is placed in an approved application.

2.1 Low Level User Instructions

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 or ROBERTS GORDON® Controller).

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.

2.2 Corrosive Chemicals

CAUTION

Product Damage Hazard

Do not use 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 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, 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 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 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.

4 of 74

SECTION 3: CLEARANCES TO COMBUSTIBLES

SECTION 3: CLEARANCES TO COMBUSTIBLES

WARNING

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, which 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 17 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.

The stated clearances to combustibles represents a surface temperature of 32°C (90° F) above room temperature. 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 adjacent 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 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 73, Section 18.6 through Section 18.8.

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.

5 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

3.2 Clearance 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 millimeters.

FIGURE 3: LINEAR & DOUBLE LINEAR, HORIZONTAL MOUNTS

 

 

 

 

 

 

 

 

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

BH30ST/EF BH60DL/EF

 

 

 

 

 

 

 

 

A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

A

150

150

150

150

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

 

 

D

 

C

 

 

 

 

 

 

B

890

970

970

1020

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

1570

1650

1650

1780

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D

890

970

970

1020

 

 

 

 

 

 

 

 

 

 

 

 

 

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

150

150

200

200

1170

1220

1280

1330

1930

1970

2010

2080

1170

1220

1280

1330

 

 

 

 

FIGURE 4: LINEAR & DOUBLE LINEAR, ONE SIDE REFLECTOR

A

 

 

C

B

D

 

 

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

BH30ST/EF BH60DL/EF

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

 

 

 

 

 

 

 

 

 

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 5: LINEAR & DOUBLE LINEAR, TWO SIDE REFLECTORS

A

 

 

C

B

D

 

 

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

BH30ST/EF BH60DL/EF

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

 

 

 

 

 

 

 

 

 

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 & DOUBLE LINEAR, 45° MOUNT

A

C

B D

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

BH30ST/EF BH60DL/EF

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

 

 

 

 

 

 

 

 

 

A

200

200

200

250

250

275

300

300

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

 

 

 

 

 

 

 

 

 

* BH55ST only available in multiburner.

6 of 74

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 50% after 7500 mm of tubing downstream from the burner.

3.All measurements are in millimeters.

FIGURE 7: LINEAR & DOUBLE LINEAR, 2

A

Model

BH15ST

BH30DL

BH20ST

FOOT DECO GRILLE

BH40DL

BH25ST/EF

BH50DL/EF

BH30ST/EF

BH60DL/EF

BH35ST/EF

BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF

& BH55ST*

C

 

B

D

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 & DOUBLE LINEAR, PROTECTIVE GRILLE

A

 

 

C

B

D

 

 

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

BH30ST/EF BH60DL/EF

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

 

 

 

 

 

 

 

 

 

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 9: UNDERSHIELD **

A

 

 

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

 

 

 

 

 

 

 

 

 

A

150

150

150

C

B

D

B

990

1020

1270

 

 

 

 

 

C

840

965

1120

 

 

 

D

990

1020

1270

** When installed in the first 6 m - Not for use on EF models.

BH30ST/EF BH60DL/EF

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

150

150

150

-

-

1270

1370

1400

-

-

1120

1220

1270

-

-

1270

1370

1400

-

-

 

 

 

 

 

FIGURE 10: LINEAR & DOUBLE LINEAR, VENTING

 

E

Radiant tubes

Fan

F

Model

BH15ST BH30DL

BH20ST BH40DL

BH25ST/EF BH50DL/EF

BH30ST/EF BH60DL/EF

BH35ST/EF BH70DL/EF

BH40ST/EF

BH45ST/EF

BH50ST/EF & BH55ST*

 

 

 

 

 

 

 

 

 

E

1000

1000

1000

1000

1000

1000

1000

1000

F

500

500

500

500

500

500

500

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

* BH55ST only available in multiburner.

7 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

3.3 Clearance 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 11: U-TUBE, HORIZONTAL MOUNT

A

B D

C

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

A

150

150

150

150

150

150

200

200

B

890

970

970

1020

1170

1220

1270

1380

 

 

 

 

 

 

 

 

 

C

1580

1730

1730

1910

1980

2050

2110

2210

 

 

 

 

 

 

 

 

 

D

760

940

940

1000

1090

1150

1200

1300

 

 

 

 

 

 

 

 

 

FIGURE 12: U-TUBE, ONE SIDE REFLECTOR

A

B D

C

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

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 13: U-TUBE, TWO SIDE REFLECTORS

A

B D

C

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

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 14: U-TUBE, FULL 45° MOUNT

A

BD

C

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

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 74

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 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 15: U-TUBE, OPPOSITE 45° TILT

A

B D

C

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

A

200

200

200

250

250

275

300

300

B

1370

1530

1530

1630

1780

1830

1880

1930

 

 

 

 

 

 

 

 

 

C

1500

1650

1650

1860

1960

2040

2110

2160

 

 

 

 

 

 

 

 

 

D

560

560

560

560

560

560

560

560

 

 

 

 

 

 

 

 

 

FIGURE 16: U-TUBE, PROTECTIVE GRILLE

A

B D

C

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

A

150

150

150

150

150

150

200

200

B

890

970

970

1020

1170

1220

1270

1380

 

 

 

 

 

 

 

 

 

C

1580

1730

1730

1910

1980

2050

2110

2210

 

 

 

 

 

 

 

 

 

D

760

940

940

1000

1090

1150

1200

1300

 

 

 

 

 

 

 

 

 

FIGURE 17: U-TUBE, VENTING

 

E

Radiant tubes

Fan

F

Model

BH15UT

BH20UT

BH25UT/EF

BH30UT/EF

BH35UT/EF

BH40UT/EF

BH45UT/EF

BH50UT/EF

 

 

 

 

 

 

 

 

 

E

1000

1000

1000

1000

1000

1000

1000

1000

F

500

500

500

500

500

500

500

500

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

9 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

SECTION 4: MAJOR COMPONENT DESCRIPTIONS

Burner (shown with Tube Gasket)

Must be installed with the flame observation window facing down.

Reflector (Aluminium or Stainless Steel)

Alternate overlap as shown on overview. Minimum overlap is 160 mm.

Burner Tube

Tube

Supplied in 3,000 mm lengths.

Heat treated aluminised tube

Burner tube is always the first

supplied in 3,000 mm lengths.

tube after the burner.

 

Tube and Reflector Hanger with Clamp Package

Position this hanger no more than 100 mm away from the burner assembly.

Tube and Reflector Hanger

Suspend system from these hangers.

Reflector Support Strap, Wire

Form & #8 x 3/4 (3.9 x 19mm)

Screw

Flex Gas Line

Tee

Assembly

U-Tube

U-Tube

Support

Bracket

Fan Tube with Internal Swirler

Supplied in 3,000 mm lengths. Fan tube is always the last tube on the heater where the fan is attached.

The swirler is welded to the inside of the tube end.

Coupling Assembly with Lock

Reflector End Cap

Punch out center section to accommodate tube.

Fan Assembly (Includes Flange)

Fan Assembly is attached to the last section of heat exchanger tubing (Fan Tube).

Damper Flange Assembly

For use on Multiburner Systems.

Fan Flange Assembly

and Screws

S-hook

Height

Adjuster

Spring

Bow

Hook

Shackle

10 of 74

SECTION 5: GENERAL SUSPENSION DETAILS

SECTION 5: GENERAL SUSPENSION DETAILS

WARNING

Severe Injury Hazard

Secure burner to burner tube with bolts and lockwashers.

Hang heater with materials with a minimum working load of 75 lbs (33 kg).

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

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 electric supply 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 heater must be installed in accordance with clearances to combustibles as indicated 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 18.

Note: Some modles will receive S-hooks (P/N 91907302) or spring hooks (P/N 91903300), rather than bow shackles.

11 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

Figure 18: Critical Hanger Placement

Side View

Bow Shackle

Hanger

 

Hanger

 

100 mm

Front View

45° Angle

 

 

 

 

Max.

 

 

Description

Part Number

 

 

Burner Tube

03051100

 

 

Bow Shackle

E0007576

 

 

Tube/Reflector Hanger

03090100

 

 

12 of 74

SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION

SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION

WARNING

Cut/Pinch Hazard

Wear protective gear during installation, operation and service.

Edges are sharp.

Failure to follow these instructions can result in injury.

The figures in this section provide a general overview of component placement in a BLACKHEAT® Linear and Double Linear system. The location of some components such as supports and couplings is crucial for proper installation. Assemble the heater components as shown on Page 14, Figure 19.

For optional reflector configurations for linear heaters see Page 6, Figure 3 through Page 7, Figure 10. Install appropriate suspension hardware, 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 at +44 (0)121 506 7700.

6.1 Linear Standard Parts List

Part No.

Description

BH15ST

BH20ST

BH25ST BH25ST/EF

BH30ST BH30ST/EF

BH35ST BH35ST/EF

BH40ST BH40ST/EF

BH45ST BH45ST/EF

BH50ST BH50ST/EF

BH55ST

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

072XXXXX

Burner Assembly (Input and Fuel Varies)

1

1

1

1

1

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

07260001

Fan Package XP 1

1

1

1

1

-

-

-

-

-

 

 

 

 

 

 

 

 

 

 

 

07260002

Fan Package XP2

-

-

-

-

1

1

1

-

-

 

 

 

 

 

 

 

 

 

 

 

07260003

Fan Package XP 3

-

-

-

-

-

-

-

1

-

 

 

 

 

 

 

 

 

 

 

 

03051100

Burner Tube, 100 mm x 3048 mm

1

1

1

1

1

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

91409408

Tube, 100 mm x 3048 mm

-

1

1

2

2

2

3

3

4

 

 

 

 

 

 

 

 

 

 

 

S5127W

Fan Tube, 100 mm x 3048 mm, with 3048 mm Swirler

-

1

1

1

1

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

S5134W

Fan Tube, 100 mm x 3048 mm, with 2134 mm Swirler

1

-

-

-

-

-

-

-

-

 

 

 

 

 

 

 

 

 

 

 

01329600

Standard Coupling Assembly

1

2

2

3

3

3

4

4

5

 

 

 

 

 

 

 

 

 

 

 

01329700

Coupling Lock

1

2

2

3

3

3

4

4

5

 

 

 

 

 

 

 

 

 

 

 

02750303

Reflector, Aluminium, 2439 mm

3

4

4

6

6

6

7

7

8

 

 

 

 

 

 

 

 

 

 

 

027503SS

Reflector, Stainless Steel, 2439 mm (Optional)*

3

4

4

6

6

6

7

7

8

 

 

 

 

 

 

 

 

 

 

 

02750800

Reflector End Cap, Aluminium

2

2

2

2

2

2

2

2

2

 

 

 

 

 

 

 

 

 

 

 

027508SH

Reflector End Cap, Stainless (Optional)*

2

2

2

2

2

2

2

2

2

 

 

 

 

 

 

 

 

 

 

 

03090100

Tube and Reflector Hanger

3

4

4

5

5

5

6

6

7

 

 

 

 

 

 

 

 

 

 

 

01318901

Tube Clamp Package (including Nut, Washer & Bolt)

1

1

1

1

1

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

91908004

Wire Form

2

3

3

5

5

5

6

6

7

 

 

 

 

 

 

 

 

 

 

 

94320812

Screw #8 x 3/4 (3.9mm x 19mm), (goes with 03050000)

4

6

6

10

10

10

12

12

14

 

 

 

 

 

 

 

 

 

 

 

03050000

Reflector Support Strap

2

3

3

5

5

5

6

6

7

 

 

 

 

 

 

 

 

 

 

 

E0007576

Bow Shackle**

3

4

4

5

5

5

6

6

7

 

 

 

 

 

 

 

 

 

 

 

91107720

U-Clip Package (20 Pieces)

1

1

1

1

1

1

1

1

1

 

 

 

 

 

 

 

 

 

 

 

S7199K

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) or spring hooks (P/N 919003300), rather than bow shackles.

13 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

Figure 19: Linear General Assembly Overview

 

 

 

 

 

U-Clips

 

Fan Assembly (For Single Heater)

Assembly Multiburner)

 

 

 

 

 

Weld Spot

 

Damper (Required for

 

 

 

 

 

Tube

Internal Swirler

 

 

 

 

 

 

 

Fan

 

 

 

 

Reflector

 

 

 

 

 

 

 

Reflector End Cap

 

Burner

Reflector Hanger

Coupling

Reflector Support

 

 

 

Burner

Clamp Package

Tube and

 

 

 

 

 

 

Tube

 

 

 

 

 

 

 

14 of 74

 

 

 

 

 

 

 

 

SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION

Figure 20: Linear Layout Overview

 

 

 

bc

b

 

 

 

 

LEGEND

 

 

g

d

e

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Burner

BH15ST

 

f

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Reflector

 

 

 

bc

 

 

 

b

 

Tube

 

 

 

 

 

 

 

Tube/Reflector

 

 

g

d

e

e

 

 

 

 

 

 

 

 

 

 

 

 

Hanger

 

 

 

 

 

 

 

 

 

Coupling

BH20ST

 

f

 

 

 

 

 

 

Assembly

 

 

 

 

 

 

 

 

BH25ST/EF

 

 

 

 

 

 

Fan

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Assembly

 

 

 

b

 

 

 

 

b

Damper

 

 

 

 

 

 

 

Assembly

 

 

 

c

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

g

d

e

e

 

e

 

 

BH30ST/EF

 

 

 

 

 

 

 

 

BH35ST/EF

f

 

 

 

 

 

 

 

BH40ST/EF

 

 

 

 

 

 

 

 

 

 

 

bc

 

 

 

 

 

b

 

 

g

d

e

e

 

e

e

 

BH45ST/EF

f

 

 

 

 

 

 

 

BH50ST/EF

 

 

 

 

 

 

 

 

 

 

bc

 

 

 

 

 

b

 

 

g

d

e

e

 

e

e

e

BH55ST

 

f

 

 

 

 

 

 

 

a

=

reflector width (not shown) - 365 mm

e

=

distance typical between hangers - 3050 mm

b

=

end cap to burner/fan - 50 mm

f

=

burner height - 366 mm

 

c

=

end cap to hanger - 50 mm

g

=

burner length - 291 mm

 

d

=

distance first hanger - 2290 mm

 

 

 

 

 

Model BH15ST BH20ST BH25ST/EF BH30ST/EF BH35ST/EF BH40ST/EF BH45ST/EF BH50ST/EF BH55ST

Reflector

Overlap 700 mm 250 mm 250 mm 530 mm 530 mm 530 mm 330 mm 330 mm 200 mm

(approx.)

15 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

6.2 Double Linear Standard Parts List

Part No.

Description

BH30DL

BH40DL

BH50DL BH50DL/EF

BH60DL BH60DL/EF

BH70DL BH70DL/EF

 

 

 

 

 

 

 

 

 

 

 

 

072XXXXX

Burner Assembly (Input and Fuel Varies)

2

2

2

2

2

 

 

 

 

 

 

 

07260002

Fan Package XP2

1

1

-

-

-

 

 

 

 

 

 

 

07260003

Fan Package XP 3

-

-

1

1

1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

03051100

Burner Tube, 100 mm x 3048 mm

2

2

2

2

2

 

 

 

 

 

 

 

91409408

Tube, 100 mm x 3048 mm

-

2

2

4

4

 

 

 

 

 

 

 

S5127W

Fan Tube, 100 mm x 3048 mm, with 3048 mm Swirler

-

2

2

2

2

 

 

 

 

 

 

 

S5134W

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

4

6

6

8

8

 

 

 

 

 

 

 

01329700

Coupling Lock

4

6

6

8

8

 

 

 

 

 

 

 

 

 

 

 

 

 

 

02750303

Reflector, Aluminium, 2439 mm

6

8

8

12

12

 

 

 

 

 

 

 

027503SS

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 & 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 (3.9mm x 19mm), (goes with 03050000)

8

12

12

20

20

 

 

 

 

 

 

 

* PVC coating must be removed prior to installation.

**Some models may receive S-hooks (P/N 91907302) or spring hooks (P/N 91903300), rather than bow shackles

16 of 74

SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION

Figure 21: Double Linear General Assembly Overview

 

 

 

 

Fan Assembly

 

 

Tube

 

 

 

 

 

 

 

Fan

 

 

Reflector

 

 

 

Swirler Weld Spot

1200 mm approx.

Reflector End Cap

 

 

 

 

Hanger

Internal

 

Burner

Tube Clamp Package

Burner Tube

Reflector Support

Tube and Reflector

 

 

U-Clips

Coupling

Tube Clamp Package

17 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

Figure 22: Double Linear Layout Overview

BH30DL f

BH40DL BH50DL/EF f

 

 

 

LEGEND

 

bc

b

 

g

d

e

Burner

 

 

Repeated

Reflector

 

 

Opposite

 

 

 

Side

Tube

 

 

 

Tube/Reflector

 

 

 

Hanger

 

 

Coupling

 

 

Assembly

 

 

Fan

bc

b

Assembly

 

g

d

e

e

 

Tee Assembly

 

 

 

 

Repeated

 

 

 

 

 

 

 

 

 

Opposite

 

 

 

 

 

Side

 

bc

b

g

d

e

e

e

BH60DL/EF

f

Repeated

BH70DL/EF

Opposite

 

 

Side

a

=

reflector width (not shown) - 365 mm

e

=

distance typical between hangers - 3050 mm

b

=

end cap to burner/fan - 50 mm

f

=

burner height - 366 mm

 

 

c

=

end cap to hanger - 50 mm

g

=

burner length - 291 mm

 

 

d

=

distance first hanger - 2290 mm

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Model

 

 

BH30DL

 

BH40DL

BH50DL/EF

BH60DL/EF

BH70DL/EF

 

 

 

 

 

 

 

Reflector Overlap (approx.)

700 mm

 

250 mm

250 mm

530 mm

530 mm

 

 

 

 

 

 

 

 

 

 

18 of 74

Roberts Gorden BH40ST, BH50UT, BH60DL, BH70DL, BH30UT User Manual

SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION

Step 6.3 Burner Tube Installation

Note:

 

Tubing requires a downward

Offset mounting

slope of 13 mm per 6000 mm

hole must be

away from burner.

to the top.

Bow Shackle

Hanger

 

Burner Tube

Weld

 

 

must

 

bottom

 

2290 mm ± 250 mm

Description

Part Number

Burner Tube

03051100

Bow Shackle

E0007576

Tube/Reflector Hanger

03090100

Step 6.4 Coupling and Tube Assembly

A Close coupling

B Start slide bar/coupling lock

with tab.

onto coupling.

 

Tab

 

Slide Bar

 

Wide End

Open

Coupling

 

76 mm to

 

101 mm

 

Closed

C Insert tubes into coupling.

D Tighten coupling to join tubes.

 

 

Slide Bar

Orient coupling so that

 

Coupling

 

 

the impact block is in the

 

Tube

2:00 or 10:00 o’clock

 

positions

 

 

Tube

 

 

Tube

Description

Part Number

 

Coupling

01329600

 

Slide Bar/Coupling Lock

01329700

 

Tube

91409408

19 of 75

BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL

Step 6.4.1 Coupling and Tube Assembly (Continued)

Tighten slide bar as shown below.

Correct

dimensions

Drive slide bar until tight. End of slide bar should be within tolerance listed below.

± 50 mm

Incorrect

position

• 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)

Model

Overall Tube Length (mm)

Number

of Tubes

 

 

BH15ST

6,000

2

BH20ST

9,000

3

BH25ST/EF

9,000

3

BH30ST/EF

12,000

4

BH35ST/EF

12,000

4

BH40ST/EF

12,000

4

BH45ST/EF

15,000

5

BH50ST/EF

15,000

5

BH55ST

18,000

6

 

Weld spot

 

 

at end of

 

Total Overall

heat exchanger

 

 

 

Tube Length

 

 

20 of 74

 

 

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