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.
Blackheat
Vacuum Assisted
Linear, Double Linear,
8. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
U-Tube, and Multi-Burner
Gas Fired Heating Systems
Installation, Operation &
Service Manual
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clear-
ances to combustibles away from
heater.
BH15UT
BH20UT
BH15ST
BH20ST
BH30DL
BH40DL
BH25UT/EF BH25ST/EF BH50DL/EF
BH30UT/EF BH30ST/EF BH60DL/EF
BH35UT/EF BH35ST/EF BH70DL/EF
BH40UT/EF BH40ST/EF
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.
BH45UT/EF BH45ST/EF
BH50UT/EF BH50ST/EF
BH55ST
Installer
WARNING
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
your serviceman with necessary information.
Installation must be done by a registered installer/
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: [email protected]
E-mail: [email protected]
© 2012 Roberts-Gordon LLC
170101UK Rev. P-1 08/12
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TABLE OF CONTENTS
SECTION 1: Heater Safety............................................2 SECTION 11: Venting ..................................................50
2.2 Corrosive Chemicals...........................................4 SECTION 12: Gas Piping ............................................53
2.3 National Standards and Applicable Codes .........4 SECTION 13: Wiring....................................................55
SECTION 6: Linear & Double Linear Heater
13.1 Typical External Wiring Diagram
13.2 Typical External Wiring Diagram
13.3 Typical External Wiring Diagram
13.4 Typical External Wiring Diagram
6.2 Double Linear Standard Parts List....................16 SECTION 14: Operation..............................................58
6.7 Double Linear Tee Installation
SECTION 7: U-Tube Heater Installation.....................25 SECTION 15: Servicing Instructions.........................61
7.4 U-Tube Support Bracket Assembly
16.1 Troubleshooting Flow Chart
7.8 Reflector Installation.........................................33 SECTION 17: Replacement Parts...............................70
SECTION 8: Multiburner Configuration &
9.5 Multiburner 83/90 BWLG Fan Assembly
Roberts-Gordon LLC
© 2010
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.
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TABLE OF FIGURES
Figure 21: Double Linear General Assembly
Figure 26: Typical Manifold Layout (Linear and
Figure 34: Gas Connection with Stainless Steel Flex
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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.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 1: HEATER SAFETY
Your Safety is Important to Us!
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.
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.
Before installation, check that the local distribution
conditions, nature of gas and pressure, and adjustment of
the appliance are compatible.
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.
For additional copies of the Installation, Operation
andService Manual, please contact Roberts-Gordon LLC.
Read this manual carefully before installation, operation
or service of this equipment.
1.1 Manpower Requirements
To prevent personal injury and damage to the heater, two
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.
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
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
Figure 1: Side and Back Panel Label Placement
Logo Label
Fan/Burner Label
Side Panel
Rating Plate Label
Back Panel
Description
Logo Label
Fan/Burner Label
Rating Plate Label
Part Number
91033200
91033300
91031300
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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.
2.2 Corrosive Chemicals
CAUTION
• To use the information given in a layout drawing and
in the manual together with the cited codes and
regulations to perform the installation.
Product Damage Hazard
• To install the heater in accordance with the clear-
Do not use heater in area containing
corrosive chemicals.
ances to combustibles.
• To furnish all needed materials not furnished as
standard equipment.
Refer to appropriate Material Safety Data
Sheets (MSDS).
• To plan location of supports.
• To provide access to burners for servicing on all
sides, for burner removal.
Failure to follow these instructions can result
in product damage.
• To provide the owner with a copy of this installation,
operation and service manual.
Roberts-Gordon cannot be responsible for ensuring that
all appropriate safety measures are undertaken prior to
installation; this is entirely the responsibility of the
installer. It is essential that the contractor, the sub-
contractor, or the owner identifies the presence of
combustible materials, corrosive chemicals or
• To never use heater as support for a ladder or other
access equipment and never hang or suspend any-
thing 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.
halogenated hydrocarbons* anywhere in the premises.
• To safely and adequately install heater using materi-
als with a minimal working load of 33 kg.
* 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.
• 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.
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.
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.
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SECTION 3: CLEARANCES TO COMBUSTIBLES
• 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.
SECTION 3: CLEARANCES TO COMBUSTIBLES
WARNING
• Hang heater in accordance to the minimum
• 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.
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,
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 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, stor-
age 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 combusti-
bles. Signs must be posted adjacent to the heater
thermostat. In the absence of a thermostat, signs
must be posted in a conspicuous location.
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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
A
C
A
B
C
D
150
890
150
970
150
970
150
150
150
200
200
B
D
1020
1780
1020
1170
1930
1170
1220
1970
1220
1280
2010
1280
1330
2080
1330
1570
890
1650
970
1650
970
FIGURE 4: LINEAR & DOUBLE LINEAR, ONE SIDE REFLECTOR
A
A
B
150
230
150
230
150
230
150
230
150
230
150
230
200
230
200
230
B
D
C
C
D
1580
1200
1760
1380
1760
1380
1930
1500
2090
1660
2130
1710
2160
1760
2240
1860
FIGURE 5: LINEAR & DOUBLE LINEAR, TWO SIDE REFLECTORS
A
A
B
C
D
150
590
150
640
150
640
150
690
150
820
150
860
200
890
200
B
D
C
1020
2320
1020
1660
590
1810
640
1810
640
1960
690
2110
820
2160
860
2210
890
FIGURE 6: LINEAR & DOUBLE LINEAR, 45° MOUNT
A
A
B
C
D
200
200
200
200
200
200
250
200
250
200
275
200
300
200
300
200
C
B
D
1500
1370
1660
1520
1660
1520
1860
1630
1960
1750
2030
1820
2110
1880
2160
2000
* BH55ST only available in multiburner.
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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 FOOT DECO GRILLE
A
A
B
C
D
150
890
150
970
150
970
150
150
150
200
200
C
1020
1780
1020
1170
1930
1170
1220
1970
1220
1280
2010
1280
1330
2080
1330
B
D
1570
890
1650
970
1650
970
FIGURE 8: LINEAR & DOUBLE LINEAR, PROTECTIVE GRILLE
A
A
B
150
890
150
970
150
970
150
150
150
200
200
B
D
C
1020
1170
1220
1280
1330
C
D
1570
890
1650
970
1650
970
1780
1020
1930
1170
1970
1220
2010
1280
2080
1330
FIGURE 9: UNDERSHIELD **
A
A
150
990
150
150
150
150
150
-
-
-
-
B
D
C
B
C
D
1020
1270
1270
1370
1400
840
965
1120
1120
1270
1220
1370
1270
1400
-
-
-
-
990
1020
1270
** When installed in the first 6 m - Not for use on EF models.
FIGURE 10: LINEAR & DOUBLE LINEAR, VENTING
E
Fan
Radiant tubes
F
E
F
1000
500
1000
500
1000
500
1000
500
1000
500
1000
500
1000
500
1000
500
* BH55ST only available in multiburner.
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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
C
D
A
B
150
890
150
970
150
970
150
150
150
200
200
B
1020
1170
1220
1270
1380
C
D
1580
760
1730
940
1730
940
1910
1000
1980
1090
2050
1150
2110
1200
2210
1300
FIGURE 12: U-TUBE, ONE SIDE REFLECTOR
A
D
B
A
B
C
D
150
230
150
230
150
230
150
230
150
230
150
230
200
230
200
230
C
1580
1200
1760
1380
1760
1380
1930
1500
2090
1660
2130
1710
2160
1760
2240
1860
FIGURE 13: U-TUBE, TWO SIDE REFLECTORS
A
D
B
A
B
150
590
150
640
150
640
150
690
150
820
150
860
200
890
200
C
1020
C
D
1660
590
1810
640
1810
640
1960
690
2110
820
2160
860
2210
890
2320
1020
FIGURE 14: U-TUBE, FULL 45° MOUNT
A
B
D
A
B
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
200
C
C
D
1500
1070
1650
1170
1650
1170
1860
1320
1960
1550
2040
1620
2110
1680
2160
1780
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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
D
B
A
B
C
D
200
1370
1500
560
200
1530
1650
560
200
1530
1650
560
250
1630
1860
560
250
1780
1960
560
275
1830
2040
560
300
1880
2110
560
300
1930
2160
560
C
FIGURE 16: U-TUBE, PROTECTIVE GRILLE
A
A
B
150
890
150
970
150
970
150
150
150
200
200
D
B
C
1020
1170
1220
1270
1380
C
D
1580
760
1730
940
1730
940
1910
1000
1980
1090
2050
1150
2110
1200
2210
1300
FIGURE 17: U-TUBE, VENTING
E
Fan
Radiant tubes
F
E
F
1000
500
1000
500
1000
500
1000
500
1000
500
1000
500
1000
500
1000
500
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 4: MAJOR COMPONENT DESCRIPTIONS
Burner (shown with Tube
Reflector
Gasket)
(Aluminium or
Stainless Steel)
Must be installed with the
flame observation window
facing down.
Alternate overlap as
shown on overview.
Minimum overlap is
160 mm.
Burner Tube
Fan Tube with Internal Swirler
Tube
Supplied in 3,000 mm lengths.
Burner tube is always the first
tube after the burner.
Supplied in 3,000 mm lengths. Fan
tube is always the last tube on the
heater where the fan is attached.
Heat treated aluminised tube
supplied in 3,000 mm lengths.
The swirler is welded to the inside
of the tube end.
Tube and Reflector Hanger
with Clamp Package
Coupling Assembly
with Lock
Position this hanger no more
than 100 mm away from the
burner assembly.
Reflector End Cap
Punch out center section to
accommodate tube.
Tube and Reflector Hanger
Suspend system from these
hangers.
Fan Assembly (Includes Flange)
Fan Assembly is attached to the last
section of heat exchanger tubing
(Fan Tube).
Reflector Support Strap, Wire
Form & #8 x 3/4 (3.9 x 19mm)
Screw
Damper Flange Assembly
For use on Multiburner Systems.
Flex Gas Line
Fan Flange Assembly
and Screws
Tee
Assembly
Height
S-hook
Adjuster
U-Tube
Spring
Hook
Bow
Shackle
U-Tube
Support
Bracket
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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
18.
Note: Some modles will receive S-hooks (P/N 91907302)
or spring hooks (P/N 91903300), rather than bow
shackles.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Figure 18: Critical Hanger Placement
Typical Suspension Details
Screw Hook
min. 10 mm
Washer
Locknut
Concrete
Beam
Beam
Clamp
Anchor
I-Beam
I-Beam
Washer
10 mm
Rod
600 mm
minimum*
Wood
Beam
300 mm
minimum*
Bow
Shackle
Turnbuckle
(not included)
* Allows for thermal expansion of system.
Bow Shackle
Hanger
Side View
Hanger
Front View
45° Angle
100 mm
Max.
Description
Part Number
Burner Tube
Bow Shackle
Tube/Reflector Hanger
03051100
E0007576
03090100
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SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION
SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION
The figures in this section provide a general overview of
®
component placement in a BLACKHEAT Linear and
WARNING
Double Linear system. The location of some components
such as supports and couplings is crucial for proper
installation. Assemble the heater components as shown
appropriate suspension hardware, beam clamps, chain or
rod at predetermined locations. Adjustments of chain
length will provide uniform pitch.
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
If any step is unclear, please contact Roberts-Gordon at
+44 (0)121 506 7700.
Edges are sharp.
Failure to follow these instructions can result
in injury.
6.1 Linear Standard Parts List
Part No.
Description
072XXXXX Burner Assembly (Input and Fuel Varies)
07260001 Fan Package XP 1
1
1
-
1
1
-
1
1
-
1
1
-
1
-
1
-
1
-
1
-
1
-
07260002 Fan Package XP2
1
-
1
-
1
-
-
-
07260003 Fan Package XP 3
-
-
-
-
1
1
3
1
-
-
03051100 Burner Tube, 100 mm x 3048 mm
91409408 Tube, 100 mm x 3048 mm
1
-
1
1
1
-
1
1
1
-
1
2
1
-
1
2
1
-
1
2
1
-
1
3
1
-
1
4
1
-
S5127W Fan Tube, 100 mm x 3048 mm, with 3048 mm Swirler
S5134W Fan Tube, 100 mm x 3048 mm, with 2134 mm Swirler
01329600 Standard Coupling Assembly
01329700 Coupling Lock
-
1
1
1
3
3
2
2
3
1
2
4
2
3
1
2
2
4
4
2
2
4
1
3
6
3
4
1
2
2
4
4
2
2
4
1
3
6
3
4
1
3
3
6
6
2
2
5
1
5
10
5
5
1
3
3
6
6
2
2
5
1
5
10
5
5
1
3
3
6
6
2
2
5
1
5
10
5
5
1
4
4
7
7
2
2
6
1
6
12
6
6
1
4
4
7
7
2
2
6
1
6
12
6
6
1
5
5
8
8
2
2
7
1
7
14
7
7
1
02750303 Reflector, Aluminium, 2439 mm
027503SS Reflector, Stainless Steel, 2439 mm (Optional)*
02750800 Reflector End Cap, Aluminium
027508SH Reflector End Cap, Stainless (Optional)*
03090100 Tube and Reflector Hanger
01318901 Tube Clamp Package (including Nut, Washer & Bolt)
91908004 Wire Form
94320812 Screw #8 x 3/4 (3.9mm x 19mm), (goes with 03050000)
03050000 Reflector Support Strap
E0007576 Bow Shackle**
91107720 U-Clip Package (20 Pieces)
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
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SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION
Figure 20: Linear Layout Overview
b
b
c
LEGEND
g
d
e
Burner
BH15ST
f
Reflector
Tube
b
b
c
Tube/Reflector
Hanger
g
d
e
e
Coupling
Assembly
BH20ST
BH25ST/EF
f
Fan
Assembly
Damper
Assembly
b
b
c
g
g
g
d
d
d
e
e
e
e
e
e
e
BH30ST/EF
BH35ST/EF
BH40ST/EF
f
f
f
b
b
c
e
e
BH45ST/EF
BH50ST/EF
b
b
c
e
e
e
BH55ST
a = reflector width (not shown) - 365 mm
b = end cap to burner/fan - 50 mm
c = end cap to hanger - 50 mm
e = distance typical between hangers - 3050 mm
f = burner height - 366 mm
g = burner length - 291 mm
d = distance first hanger - 2290 mm
BH15ST BH20ST BH25ST/EF BH30ST/EF BH35ST/EF BH40ST/EF BH45ST/EF BH50ST/EF BH55ST
Model
Reflector
Overlap 700 mm 250 mm
250 mm
530 mm
530 mm
530 mm
330 mm
330 mm
200 mm
(approx.)
15 of 75
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
6.2 Double Linear Standard Parts List
Part No.
Description
072XXXXX Burner Assembly (Input and Fuel Varies)
07260002 Fan Package XP2
2
1
-
2
1
-
2
-
2
-
2
-
07260003 Fan Package XP 3
1
1
1
03051100 Burner Tube, 100 mm x 3048 mm
91409408 Tube, 100 mm x 3048 mm
2
-
2
2
2
-
2
2
2
-
2
4
2
-
2
4
2
-
S5127W Fan Tube, 100 mm x 3048 mm, with 3048 mm Swirler
S5134W Fan Tube, 100 mm x 3048 mm, with 2134 mm Swirler
E0009170 Tee, 100 mm x 100 mm x 100 mm
01329600 Standard Coupling Assembly
-
2
1
4
4
1
6
6
1
6
6
1
8
8
1
8
8
01329700 Coupling Lock
02750303 Reflector, Aluminium, 2439 mm
6
6
4
4
8
8
4
4
8
8
4
4
12
12
4
12
12
4
027503SS Reflector, Stainless Steel, 2439 mm (Optional)*
02750800 Reflector End Cap, Aluminium
027508SH Reflector End Cap, Stainless (Optional)*
4
4
03090100 Tube and Reflector Hanger
01318901 Tube Clamp Package (including Nut, Washer & Bolt)
91908004 Wire Form
6
2
4
4
8
2
6
6
8
2
6
6
10
2
10
2
10
10
10
10
03050000 Reflector Support Strap
E0007576 Bow Shackle**
6
2
6
8
8
2
8
2
10
2
10
2
91107720 U-Clip Package (20 Pieces)
E0007582 Height Adjuster
8
8
10
20
10
20
94320812 Screw #8 x 3/4 (3.9mm x 19mm), (goes with 03050000)
12
12
* 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
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Figure 22: Double Linear Layout Overview
LEGEND
b
b
c
g
d
e
Burner
Reflector
Tube
Repeated
Opposite
Side
BH30DL
f
Tube/Reflector
Hanger
Coupling
Assembly
Fan
Assembly
b
b
c
g
d
e
e
Tee Assembly
Repeated
Opposite
Side
BH40DL
BH50DL/EF
f
b
b
c
g
d
e
e
e
BH60DL/EF
BH70DL/EF
Repeated
Opposite
Side
f
a = reflector width (not shown) - 365 mm
b = end cap to burner/fan - 50 mm
c = end cap to hanger - 50 mm
e = distance typical between hangers - 3050 mm
f = burner height - 366 mm
g = burner length - 291 mm
d = distance first hanger - 2290 mm
BH30DL
BH40DL
BH50DL/EF
BH60DL/EF
BH70DL/EF
Model
Reflector Overlap (approx.)
700 mm
250 mm
250 mm
530 mm
530 mm
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SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION
Step 6.3 Burner Tube Installation
Note:
Tubing requires a downward
slope of 13 mm per 6000 mm
away from burner.
Offset mounting
hole must be
to the top.
Bow Shackle
Hanger
Burner Tube
Weld seam
must be to the
bottom of the tube.
2290 mm ± 250 mm
Description
Part Number
Burner Tube
Bow Shackle
Tube/Reflector Hanger
03051100
E0007576
03090100
Step 6.4 Coupling and Tube Assembly
Start slide bar/coupling lock
Close coupling
A
B
onto coupling.
with tab.
Tab
Slide Bar
Wide End
Coupling
Open
76 mm to
101 mm
Closed
Tighten coupling to join tubes.
Insert tubes into coupling.
D
C
Slide Bar
Coupling
Orient coupling so that
the impact block is in the
2:00 or 10:00 o’clock
positions
Tube
Tube
Description
Coupling
Part Number
01329600
Tube
Slide Bar/Coupling Lock
Tube
01329700
91409408
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BLACKHEAT® 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.
± 50 mm
Correct Slide Bar
dimensions
Incorrect Slide Bar
position
Step 6.4.2 Coupling and Tube Assembly (Continued)
Number
of Tubes
Model
Overall Tube Length (mm)
BH15ST
BH20ST
6,000
9,000
9,000
12,000
12,000
12,000
15,000
15,000
18,000
2
3
3
4
4
4
5
5
6
BH25ST/EF
BH30ST/EF
BH35ST/EF
BH40ST/EF
BH45ST/EF
BH50ST/EF
BH55ST
2290 mm
± 250 mm
3050 mm Typ
± 250 mm
Weld spot
at end of
heat exchanger
Total Overall
Tube Length
20 of 74
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Step 6.6 Reflector Installation
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.
Hanger
Burner Tube
Reflector
Description
Tube/Reflector Hanger
Burner Tube
Part Number
03090100
03051100
Reflector
02750303
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SECTION 6: LINEAR & DOUBLE LINEAR HEATER INSTALLATION
Step 6.6.1 Reflector, U-Clip and Reflector Support Installation
The pictorial drawings of the heater construction in
guideline of where hangers, reflector supports and
U-clips are to be installed.
supports are used. The positioning of reflector supports
and U-clips depend on the individual installation. Use
either pop rivets or sheet metal screws instead of U-clips
when installing end caps and joint pieces in areas where
impact and high wind may be a factor.The following rules
must be observed:
To ensure proper expansion and contraction movement of
the reflectors, a combination of U-clips and reflector
1. The first reflector after the burner must be affixed in
the middle of the reflector with a reflector support and
tight screws.
Tight
Sheet Metal
Screw
Wire Form
Reflector
End Cap
First
Reflector
Reflector Support
Strap
U-Clips
Overlap must
be a minimum
of 160 mm
Option B
Slip Overlap
Reflector
Reflector
Support
160 mm
2. The overlap at the first and second reflector is a slip
overlap. Thereafter, every third reflector joint is a
slip overlap. A slip overlap is achieved by either:
a.) both reflectors lay inside a hanger.
(no reflector support needed).
Loose screws
loosened 2 mm
to allow slippage.
b.) using a reflector support with
loose screws at the reflector
Option A
Slip Overlap
overlap.
3. The remaining reflector overlaps require a
non-slip overlap connection. To affix the
reflectors together in a non-slip overlap
either:
Option A
Non-Slip Overlap
a.) use reflector support and tight screws.
b.) if both reflectors lay inside a hanger,
u-clips or sheet metal screws may be
used.
Reflector
This section of three reflectors joined
together must be affixed to the tube with
at least one reflector support with tight
screws.
Tight
Screws
Option B
Non-Slip Overlap
Description
Reflector Support Package
Wire Form
Reflector Support Strap
Screw #8 x 3/4
U-Clip Package
Part Number
03050010
91908004
03050000
94320812
91107720
027508XX
U-Clip
(2 clips per
non-slip overlap
inside a hanger)
Reflector End Cap
23 of 75
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Step 6.7 Double Linear Tee Installation (for double linear heaters only)
Fan Tube
Weld Spot
Coupling
Tee
Coupling
Weld Spot
Description
Tee
Fan Tube
Part Number
E0009170
S51XXW
Fan Tube
Coupling
Slide Bar/Coupling Lock
Tube/Reflector Hanger
01329600
01329700
03090100
24 of 74
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SECTION 7: U-TUBE HEATER INSTALLATION
SECTION 7: U-TUBE HEATER INSTALLATION
The figures in this section provide a general overview of
component placement in a BLACKHEAT U-tube system.
The location of some components such as supports and
couplings is crucial for proper installation. Assemble the
®
WARNING
For optional reflector configurations for U-tube heaters,
appropriate suspension hardware, beam clamps, chain or
rod at predetermined locations. Adjustments of chain
length will provide uniform pitch.
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
If any step is unclear, please contact Roberts-Gordon at
+44 (0)121 506 7700.
Edges are sharp.
Failure to follow these instructions can result
in injury.
7.1 U-Tube Standard Parts List
Part No.
Description
072XXXXX Burner Assembly (Input and Fuel Varies)
07260001 Fan Package XP1
1
1
-
1
1
-
1
1
-
1
1
-
1
-
1
-
1
-
1
-
07260002 Fan Package XP2
1
-
1
-
1
-
-
07260003 Fan Package XP3
-
-
-
-
1
03051100 Burner Tube, 100 mm x 3048 mm
91409408 Tube, 100 mm x 3048 mm
91409423 Tube, 100 mm x 1524 mm
S5127W Fan Tube, 100 mm x 3048 mm, with 3048 mm Swirler
S5134W Fan Tube, 100 mm x 3048 mm, with 2134 mm Swirler
01335901 U-Bend
1
-
1
-
1
-
1
2
-
1
2
-
1
2
-
1
2
2
1
-
1
2
-
2
1
-
2
1
-
2
-
1
-
1
-
1
-
1
1
1
2
2
4
4
4
4
4
1
2
2
1
4
2
2
6
6
-
1
4
4
4
4
4
4
6
1
4
4
1
6
2
2
6
6
1
4
4
4
4
4
4
6
1
4
4
1
6
2
2
6
6
1
4
4
6
6
4
4
6
1
4
4
1
6
2
2
6
6
1
4
4
6
6
4
4
6
1
4
4
1
6
2
2
6
6
1
4
4
6
6
4
4
6
1
4
4
1
6
2
2
6
6
1
6
6
8
8
4
4
8
1
6
6
1
8
2
2
6
6
1
01329600 Standard Coupling Assembly
01329700 Coupling Lock
6
6
02750303 Reflector, Aluminium, 2439 mm
027503SS Reflector, Stainless Steel, 2439 mm (Optional)*
02750800 Reflector End Cap, Aluminium
027508SH Reflector End Cap, Stainless (Optional)*
03090100 Tube and Reflector Hanger
01318901 Tube Clamp Package (including Nut, Washer & Bolt)
91908004 Wire Form
8
8
4
4
8
1
6
03050000 Reflector Support Strap
03020501 U-Bend Support Bracket
E0007576 Bow Shackle**
6
1
8
91107720 U-Clip Package (20 Pieces)
91912501 U-Bolt M6
2
2
C0090B Nut M6
6
6
96411500 Lockwasher 6mm
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Part No.
Description
94320812 Screw #8 x 3/4 (3.9mm x 19mm), (goes with 03050000)
S7199K Damper Flange Assembly (For use on Multiburner Systems)
4
8
8
8
8
8
12
12
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 91903300), rather than bow shackles
26 of 74
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Figure 24: U-Tube Layout Overview
b
c
h
d
LEGEND
g
BH15UT
Burner
Reflector
Tube
b
c
h
d
f
Tube/Reflector
Hanger
Coupling
Assembly
BH20UT
BH25UT/EF
g
U-Tube
b
c
h
d
e
BH30UT/EF
BH35UT/EF
BH40UT/EF
g
b
c
h
d
e
f
BH45UT/EF
BH50UT/EF
g
a = overall width (not shown) - 850 mm
b = end cap to burner/fan - 50 mm
c = end cap to hanger - 50 mm
e = distance typical between hangers - 3050 mm
f = distance between last full tube
hanger and half tube hanger - 1900 mm
g = burner height - 366 mm
d = distance first hanger - 2290 mm
h = burner length - 291 mm
Model
BH15UT BH20UT BH25UT/EF BH30UT/EF BH35UT/EF BH40UT/EF BH45UT/EF BH50UT/EF
1780 mm 250 mm 250 mm 580 mm 580 mm 580 mm 690 mm 690 mm
Reflector
Overlap
(approx.)
28 of 74
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SECTION 7: U-TUBE HEATER INSTALLATION
Step 7.2 U-Tube Hanger Placement
Spreader
Bar
Bow
Shackle
NOTE: Spreader bar must be used on
single suspension point installations.
Do not hang heater from spreader bar.
Threaded
Bar
Suspension
Bow
Shackle
Chain
Washers
Suspension
Bolt
Chain
(Torque:
13.5 Nm
129 in lb)
Tube and Reflector
Hanger
Optional
Hanging
Configuration
Tube and Reflector
Hanger
First Tube and
Reflector Hanger
2290 mm ± 250 mm
See Assembly
Drawing
Description
Bow Shackle
Tube/Reflector Hanger
Spreader Bar
Part Number
E0007576
03090100
07260010
Step 7.3 Burner Tube and Fan Tube Installation
Offset mounting
hole must be
to the top.
Weld
Spot
Fan Tube
Weld seam
must be to the
bottom of the tube.
Burner Tube
Description
Burner Tube
Fan Tube
Part Number
03051100
S5127W
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Step 7.3.1 Tube Clamp Package Installation
Weld
Spot
Bolt
Nut
(Torque: 13.56 Nm
120 in lb)
Lock Washer
Tube Clamp
Description
Tube Clamp Package
Tube Clamp
Bolt
Flat Washer
Nut
Part Number
01318901
01396801
97113940
95211600
92113900
Step 7.4 U-Tube Support Bracket Assembly Installation
U-bolt
Tight to
Bracket
Fan Tube
U-bolt
Tight to
Burner
Tube
Tube
U-tube, Standard
U-tube, Opposite 45°
U-bolt
Nut (Torque:
90 in lb
10.2 Nm)
Tight
U-bolt
Loose
Tight
U-bolt
Loose
U-bolt
Lock Washer
Lock Washer
U-bolt
100 mm u-bolt,
secured to burner tube
with M6 lockwashers
and M6 nuts.
100 mm u-bolt,
secured to bracket
with M6 lockwashers
and M6 nuts on top and
bottom to allow for tube
expansion and contraction.
100 mm u-bolt,
100 mm u-bolt,
secured to burner tube secured to bracket
with M6 lockwashers with M6 lockwashers
and M6 nuts.
TIGHT.
and M6 nuts on top and
bottom to allow for tube
expansion and contraction.
Nut
TIGHT.
(Torque: 90 in lb
10.2 Nm)
30 of 74
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SECTION 7: U-TUBE HEATER INSTALLATION
Step 7.5 Coupling and Tube Assembly
Start slide bar/coupling lock
Close coupling
A
B
onto coupling.
with tab.
Tab
Slide Bar
Wide End
Coupling
Open
76 mm to
101 mm
Closed
Tighten coupling to join tubes.
Insert tubes into coupling.
D
C
Slide Bar
Coupling
Orient coupling so that
the impact block is in the
2:00 or 10:00 o’clock
positions
Tube
Tube
Description
Coupling
Part Number
01329600
Tube
Slide Bar/Coupling Lock
Tube
01329700
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
within tolerance listed below.
± 50 mm
Correct Slide Bar
dimensions
Incorrect Slide Bar
position
31 of 75
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Step 7.6 Tube Installation
Weld Spot
Coupling
Tube
Step 7.7 U-Tube Installation
Weld Spot
U-tube Support
Bracket Assembly
Coupling
U-tube
Description
Coupling
Slide Bar/Coupling Lock
U-Tube
Part Number
01329600
01329700
01335901
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SECTION 7: U-TUBE HEATER INSTALLATION
Step 7.8 Reflector Installation
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.
Weld Spot
Reflector
Description
Part Number
Reflector
02750303
33 of 75
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Step 7.8.1 Reflector, U-Clip and Reflector Support Installation
The pictorial drawings of the heater construction in
guideline of where hangers, reflector supports and
U-clips are to be installed.
supports are used. The positioning of reflector supports
and U-clips depend on the individual installation. Use
either pop rivets or sheet metal screws instead of U-clips
when installing end caps and joint pieces in areas where
impact and high wind may be a factor. The following rules
must be observed:
To ensure proper expansion and contraction movement of
the reflectors, a combination of U-clips and reflector
1. The first reflector after the burner must be affixed in
the middle of the reflector with a reflector support and
tight screws.
Tight
Sheet Metal
Screw
Wire Form
Reflector
End Cap
First
Reflector
Reflector Support
Strap
U-Clips
Overlap must
be a minimum
of 160 mm
Option B
Slip Overlap
Reflector
Reflector
Support
160 mm
2. The overlap at the first and second reflector is a slip
overlap. Thereafter, every third reflector joint is a
slip overlap. A slip overlap is achieved by either:
a.) both reflectors lay inside a hanger.
(no reflector support needed).
Loose screws
loosened 2 mm
to allow slippage.
b.) using a reflector support with
loose screws at the reflector
Option A
Slip Overlap
overlap.
3. The remaining reflector overlaps require a
non-slip overlap connection. To affix the
reflectors together in a non-slip overlap
either:
Option A
Non-Slip Overlap
a.) use reflector support and tight screws.
b.) if both reflectors lay inside a hanger,
u-clips or sheet metal screws may be
used.
Reflector
This section of three reflectors joined
together must be affixed to the tube with
at least one reflector support with tight
screws.
Tight
Screws
Option B
Non-Slip Overlap
Description
Reflector Support Package
Wire Form
Reflector Support Strap
Screw #8 x 3/4 (3.9 x 19mm)
U-Clip Package
Part Number
03050010
91908004
03050000
94320812
91107720
027508XX
U-Clip
(2 clips per
non-slip overlap
inside a hanger)
Reflector End Cap
34 of 74
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SECTION 8: MULTIBURNER CONFIGURATION & INSTALLATION
SECTION 8: MULTIBURNER CONFIGURATION & INSTALLATION
WARNING
WARNING
Severe Injury Hazard
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
Secure burner to burner tube with bolts and
lockwashers.
Edges are sharp.
Hang heater with materials with a minimum
working load of 75 lbs (33 kg).
Failure to follow these instructions can result
in injury.
Failure to follow these instructions can result
in death, injury or property damage.
8.1 Initial Assembly
See Page 13, Section 6 for linear heater assembly
instructions.
instructions.
Check layout drawings for location of manifold pipe
installation.
Figure 25: Multiburner Damper Flange Installation
Damper Flange
Assembly
Fan Tube
Note:
Install in the
fully open position
Weld Spot
35 of 75
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Figure 26: Typical Manifold Layout (Linear and U-Tube Configuration)
BH25UT
BH25UT
BH25UT
Typical Fan
Arrangement
100 mm Manifold
150 mm Hanger
150 mm Manifold
Damper (Typical)
Max
1000
mm
Max
3000 mm
Tee
(100 x 100 x 100)
Cross
Cross
ID/ID Sleeve
(100 x 150 x 100 x 150)
(100 x 150 x 100 x 150)
100 mm Hanger
Reducer
(100 x 150)
NOTE: Be sure to
silicone seal all
manifold joints
BH25ST
BH25ST
BH25ST
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SECTION 9: BURNER & FAN INSTALLATION
SECTION 9: BURNER & FAN INSTALLATION
Step 9.1 Burner Installation
NOTE: Tube clamp package not shown for clarity.
Gasket
Lock
Washer
Bolt
(Torque: 13.5 Nm
120 in lb)
Burner
Description
Bolt
Lock Washer
Gasket
Part Number
94273914
96411600
02568200
0720XXXX
Burner
Step 9.2 Fan Assembly
Fan Assembly
Note: Apply Silicone
(Recommended)
Vent Adapter
Screw
(Torque: 2 Nm
18 in lb)
Install vent adapter
with clamp in the
up position.
Description
Fan Assembly
Vent Adapter
Screw
Part Number
072600XX
9071060X
E00075XX
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
9.3 Linear & U-Tube Fan Installation
Tighten securely until tube
cannot be removed.
Fan Assembly
Fan Tube
Weld Spot
Step 9.4 Double Linear Fan Installation
Tee
Tighten securely until tube
cannot be removed.
Fan Assembly
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SECTION 9: BURNER & FAN INSTALLATION
Step 9.4.1 Double Linear Fan Installation (Continued)
Suspension Chain
Bow
Shackle
Height Adjuster
Fan Assembly
Tee
Weld Spot
Step 9.5 Multiburner 83/90 BWLG Fan Assembly (Horizontal and Vertical Outlets)
Horizontal
Exhaust Louver
83/90 BWLG Fan
ID/ID Sleeve
Inlet Cone
Horizontal
Exhaust Sleeve
Horizontal
Exhaust Bend
Vertical Exhaust Tee
Tee
Condensation
runs to low level
Spiral Aluminum
Tube
Condensate Cap
1" BSP threaded hole.
Use 1" x ¾" reducer.
(not supplied)
3/4" CPVC pipe
Description
Part Number
C1324B
C1325B
C1326B
S5055F
02718851
02718852
90201200
Vertical Exhaust Tee
Horizontal Exhaust Bend
Horizontal Exhaust Sleeve
Horizontal Exhaust Louver
Condensate Cap 4"
Condensate Cap 6"
Non-Return Valve
Non-Return Valve
Must be connected
to a drain system
in accordance with
local codes.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Step 9.6 Condensate Drain Assembly
Wall
Tee
Fan
Condensate Cap
1" BSP threaded hole.
Use 1" x ¾" reducer.
(not supplied)
3/4" CPVC Pipe
3/4" Female
Non-Return
Valve
Flow
3/4" CPVC
Pipe
Must be connected
to a drain system
in accordance with
local codes.
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SECTION 10: OPTIONAL HEATER ACCESSORIES
SECTION 10: OPTIONAL HEATER ACCESSORIES
WARNING
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
Edges are sharp.
Failure to follow these instructions can result
in injury.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
10.1 Reflector Side Extension Installation
Step 10.1.1 Bracket Installation
Tube
Reflector
Tube and Reflector Hanger
Reflector Support
Reflector Side
Extension Bracket
(2 per reflector)
Use additional supports
in high air movement
applications.
Description
Part Number
S7377K
01368000
02751200
01329910
Reflector Side Extension Package
Reflector Side Extension
Retainer Clips
Reflector Side Extension
Step 10.1.2 Side Reflector Installation
Sheet Metal Screw
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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
Step 10.2.3
Flatten 4’ reflector edge where joint piece matches. Put a
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 1”
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.
4' Reflector
Section
Cut away contour
with tin snips.
Reflector
Joint
Scribe
Contour
Flatten
Edge
Punch/Drill six
3 mm holes
250 mm
maximum
Step 10.2.4
Use six #8 sheet metal screws to attach the joint piece.
Attach Reflector
Joint with six #8
sheet metal screws.
Reflector
End Cap
(Do not remove
cut out)
Step 10.2.5
The overlap of both reflector joint pieces is attached with six #8 sheet metal screws.
Secure overlap
with six #8
sheet metal screws.
4' Reflector Sections
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
10.3 Decorative Grille Installation
Step 10.3.1 Grille Installation
Description
Part Number
Aluminium Grille 610 mm X1220 mm
91407000
Step 10.3.2 Frame Shield Installation
Step 10.3.3 Reflector Side Extension Installation for Decorative Grilles
Distance "A"
Extension
Part No.
Minimum
Maximum
150 mm
260 mm
370 mm
Width
40
150
260
01370408
01370412
01370416
200 mm
300 mm
400 mm
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SECTION 10: OPTIONAL HEATER ACCESSORIES
10.4 Protective Grille Installation
Step 10.4.1 Silicone Cap Installation
Silicone Cap
Grille
Finger
Description
Part Number
08050001
08050002
Grille Section
Grille End Cap
Silicone Cap
91915951-6P
Step 10.4.2 Grille End Cap Installation
Grille
Grille End Cap
A
C
B
Bend up 90°.
D
Pull outward.
Step 10.4.3 Grille Installation
Reflector
1010 mm
Final Grille
Section
Grille
Grille
End Cap
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
10.5 Sports Hall Guard Installation
Step 10.5.1 Grille Installation
Strap - Stainless Steel
Tube and
Reflector Hanger
Reflector
Tube
Reflector Support
Description
Part Number
E0009855
C2329B
Mesh Guard 2438 mm
Mesh Guard 1524 mm
Strap Stainless Steel
Mesh Guard
S5218W
Step 10.5.2 Fastener Installation
Description
Nut Spire
Screw #8 x 3/8
Part Number
C1088B
C1089B
Step 10.5.3 Mesh Guard Connection
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SECTION 10: OPTIONAL HEATER ACCESSORIES
10.6 Undershield Installation
10.6.1 Hanger Installation
Reflector
Assembly Hanging Bracket
Stud
Hex Nut
Tube
Description
Part Number
S7399K
C0318B
Undershield Reflector Package 101 cm
Assembly Hanging Bracket
Stud M6 x 90
C0693B
Nut M6
C0090B
10.6.2 Undershield Installation
Undershield Reflector
Description
Part Number
S7399K
C0521B
C0090B
02751700
Undershield Reflector Package 1010 mm
Undershield Reflector 1010 mm
Nut M6
Shield Support Bracket
Hex Nut
Shield Support Bracket
10.6.3 Adjust Undershield Height
1010 mm
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
mounting brackets to adequately carry the weight of the
heater, it must be installed with best building practice.
10.7 Wall Mounting
Install wall mounting brackets at the height shown in the
layout drawing provided by the estimator. Space wall
mounting brackets and hangers as indicated by
dimensions d, e and f (u-tube) in the relevant layout
24.
Quantity of Wall
Mounting Brackets
Quantity of Wall
Mounting Brackets
Model
Model
BH15UT
BH20UT
2
3
3
3
3
3
4
4
BH15ST
BH20ST
3
4
4
5
5
5
6
6
BH25UT/EF
BH30UT/EF
BH35UT/EF
BH40UT/EF
BH45UT/EF
BH50UT/EF
BH25ST/EF
BH30ST/EF
BH35ST/EF
BH40ST/EF
BH45ST/EF
BH50ST/EF
10.7.1 Hardware Installation
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
Figure 27: U-Tube (Horizontal)
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
insulated if longer than 8,000 mm. Contact the
manufacturer if more than 2 x 45° offset bends are
necessary. The flue must be self supporting.
SECTION 11: VENTING
WARNING
Fans
Horizontal
Vertical
83 BWLG
190 x 75 (hole)
150 mm dia.
90 BWLG
190 x 75 (hole)
150 mm dia.
11.1.4 Flueless Installation
If the heater is being installed in an area where
combustion products can be dissipated within the
building, ensure that the fan outlet is horizontal and away
from the burner. Where installation is close to a wall
Carbon Monoxide Hazard
Multiburner systems are not approved for
unvented use and must be vented outdoors.
(perimeter system) or other obstruction close to the fan
outlet or wall angle mounted, install the heater so that the
fan tube is the furthest away from the wall or obstruction,
i.e. the fan will always blow into the building or away from
the obstruction.
Unitary heaters installed unvented must be
interlocked with sufficient building exhaust.
Heaters must be installed according to the
installation manual.
Failure to follow these instructions can result
in death or injury.
11.2 Ventilation Requirements
Detailed recommendations for air supply are given in the
relevant National Standards. There must be an adequate
supply of air for both combustion and general ventilation.
Air vents should have negligible resistance. Do not locate
air vents where they can be easily blocked or flooded, or
adjacent to any flues or extraction systems carrying
flammable vapour.
WARNING
11.2.1 Flue Installation
Where the heater(s) is flued, the space containing it must
have a permanent outside air vent with a minimum
effective area of 4.5 cm2per kW of heat input. If
mechanical ventilation is employed, the minimum proven
airflow rate shall be 2.35 m3/h per kW of heat input.
Cut/Pinch Hazard
Wear protective gear during installation,
operation and service.
Edges are sharp.
If the flue is to be horizontally vented through a wall, a
wind-proof terminal must be fitted to outdoor vent pipe to
prevent a back draught.
Failure to follow these instructions can result
in injury.
11.2.2 Flueless Installation (EN 13410)
11.1 General Venting Requirements
11.1.1 Type C12 , C32 & C62 Appliance
Room Sealed
The installation room must have a volume of at least
3
10m /kW of installed nominal heat input. A minimum of
3
10m /h of exhaust air per kW of operating heat input must
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 ventilated out of the installation room by either thermal
or mechanical evacuation. Appropriate exhaust and fresh
air openings must be provided and exhaust fans
interlocked with the operation of the heating equipment.
Further no exhaust system is necessary if the building air
change rate is greater than 1.5 per hour or the density of
3
operating heat input is not greater than 5 W/m .
11.1.2 Type B22 Appliance
11.1.3 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. BH15 and BH20 flue must
be insulated if longer than 5,000 mm. BH25 flue must be
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SECTION 11: VENTING
Figure 30: Individual Flue Connection Detail
Fan Assembly
Fan Tube
Nut
Lockwasher
Screw
(Torque: 2 Nm
18 in lb)
Flue Adapter
Flue Pipe
Figure 31: Flue Connection Dimensions
C
End of Tube
A
B
Fan Tube
Fan
Heater Model Fan Model
A
B
C
Part Number
C2374B
90710000
BH 15-30
BH 35-50
Torin DSF-133-42
AO Smith JF1G
79 mm
89 mm
95 mm
102 mm
45 mm
51 mm
11.3 Outside Combustion Air Supply
11.3.1 Air Supply Requirements
Where necessary, clean air may be ducted into the burner When fresh air duct is used, follow one of these rules:
box through an added spigot on the back of the burner
box replacing the existing dust arrest baffle plate.
• The flue must penetrate the roof while fresh air can
length. Air duct should be as straight as possible. Do not
use bends in excess of 45°. Consult the manufacturer if
more than 2 x 45° offset bends are necessary. The fresh
• The flue and fresh air supply must penetrate the
• The flue must penetrate 1 m higher than the fresh air
air duct must be self supporting.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Figure 32: Fresh Air Intake Spigot
Burner
Sheetmetal
Screw
Dust Arrest
Baffle Plate
Description
Dust Arrest Baffle
Fresh Air Intake Spigot
Part Number
07230000
07260000
100 mm Diameter
Fresh Air Intake Spigot
Figure 33: Air Supply with Flue Configurations
C52
C12
C32
C12 C32 C62
B22
11.4 Common Duct
When using a common air inlet duct, always ensure that
the area of the common air inlet duct represents the area
of all air ducts.
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SECTION 12: GAS PIPING
hose. This can cause a gas leak resulting in an unsafe
condition if the gas connection is not made in strict
SECTION 12: GAS PIPING
WARNING
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 with 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.
Fire Hazard
IMPORTANT - the complete installation must be tested
for gas soundness and be purged in accordance with
local and national codes.
Tighten gas line fittings to connect gas supply
according to Figure 34.
• 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.
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 follow these instructions can result
in death, injury or property damage.
WARNING
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.
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.
There is an expansion of the tube with each firing cycle.
This will cause the burner to move with respect to the gas
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Figure 34: Gas Connection with Stainless Steel Flex Connector
CORRECT POSITIONS
Stainless Steel Flexible Connector
Shut-Off Valve
0°
supplied by Roberts-Gordon 1000 mm Long
Minimum Bend Radius 140 mm
45°
45°
Gas Supply Pipe
Flex Line
Connector
545 mm
minimum
Burner
Correct position with flex connector not supplied by Roberts-Gordon.
CAUTION
Shut-Off Valve
(included with gas
hose) must be parallel
to burner gas inlet. The
80 mm displacement
shown is for the cold
condition. This
displacement may
reduce when the
system is fired.
Product Damage Hazard
Hold gas nipple securely with pipe wrench
when attaching gas hose.
80 mm
max. displacement
Failure to follow these instructions can result
in product damage.
300 mm
Side View
Heater Movement
Flexible Gas Hose
1000 mm length
INCORRECT POSITIONS (WRONG INSTALLATION)
Heater Movement
Heater Movement
Heater Movement
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SECTION 13: WIRING
SECTION 13: WIRING
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 a 3 pin plug via a
locally mounted double pole fused switch having a
minimum disconnection of 3 mm on each pole. This
switch should be fused to 3 amps. The burner is fused at
2 amps. There are no control connections in the standard
burner. Control is affected by interruption of the main
burner, double linear and multiburner heater systems.
All wiring must comply with current wiring regulations and
any local regulations which may apply. Always switch off
the supply to the burner and disconnect by removing the
plug before removing the burner side panel.
13.1 Typical External Wiring Diagram (Linear or U-Tube)
L
N
L
Controller or
Thermostat
N
Earth
230 V
1 Ø
50 Hz
Earth
Burner 1
Burner 2
Burner 3
Fan 1
Fan 2
Fan 3
13.2 Typical External Wiring Diagram (Double Linear Option 1)
Controller or
Thermostat
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 14: OPERATION
WARNING
DANGER
Electrical Shock Hazard
Explosion Hazard
Burn Hazard
Cut/Pinch Hazard
Turn off gas supply to Allow heater to cool
heater before service. before service.
Wear protective gear
during installation,
operation and service.
Disconnect electric
before service.
Tubing may still be hot
after operation.
More than one
Edges are sharp.
disconnect switch may
be required to
disconnect electric from
heater.
Heater must be
connected to a properly
grounded electrical
source.
Failure to follow these instructions can result in death, electric shock, injury or property damage.
Figure 35: Sequence of Operation Chart
T0 T1 T2
T3
T4
T5
T6
T7
T8
KEY TO
SYMBOLS
Thermostat
Fan
P
Pressure
Switch
P
Fan Neon
Neon
Ignition
Gas
Valve
Flame
Sensing
Burner Neon
Lockout Alarm
Signal (optional)
Tp
Tp
Ts
10 sec
10 sec
10 sec
40 sec max.
Interruption of main
flame sensing
Burner Lockout
signal received after
3 ignition trial
failures
11 sec typical
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.
system, etc. to indicate precisely which heater has failed.
This can be done by two options.
14.1 Heater Lockout Indication (Optional)
In case of flame loss during operation of the heater, the
burner control unit goes to lockout mode after three
ignition trials. At this stage a signal or closed relay will
®
enable the ROBERTS GORDON controller, BMS
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SECTION 14: OPERATION
14.1.1 Heater Lockout Indicator by Connector
3. With the gas supply off at each of the burners and
the electrical supply isolated, open the control
chamber secured by two self tapping screws.
A 230 V signal is provided which enables the ROBERTS
®
GORDON controller, BMS system, etc. to indicate the
heater that has failed. An additional wire has to be
installed from the heater lockout indicator connector to
4. Ensure that all time clocks and thermostats are set
to call for heat.
Description
Part Number
91324000
91324001
91300011
5. Switch on the electrical supply at the main isolator.
Connector male - Lockout Indicator
Connector female - Lockout Indicator
Wire Blue 12"
This will start the exhaust fan.
Wire Brown 12"
91300012
6. Balancing Cold Vacuum
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 vacuum is 1.9 mbar. Repeat for each burner.
14.1.2 Heater Lockout Indicator by Volt Free
Connector
A volt free contact relay is closed which enables the
®
ROBERTS GORDON controller, BMS system, etc. to
7. Starting at the end burner (furthest from the exhaust
fan), with the inclined pressure gauge connected as
described above. Turn on the gas supply and con-
nect appliance electrical plug, reset the pressure
switch by removing vacuum from the inlet side of the
pressure switch waiting several seconds and recon-
detailed fault finding sequence. When flame is
established, check the gas pressure reading and
adjust if necessary. See data label.
indicate the heater that has failed. An additional wire has
to be installed from the heater volt free connector to the
Description
Part Number
91324000
91324001
91300004
91300005
91300003
94961406
C1050B
Connector male - Volt Free
Connector female - Volt Free
Wire Blue 7"
Wire Brown 7"
Wire Yellow 12"
Screw #8 x 3/8 Hex Wshr PHH Type 23
Base relay P2RF05E
Relay G2R1-SN IMO 220 V 10 A
Check the gas pressure at the outlet of the gas
valve. See Page 74, Section 18.9.1 or See Page 75,
Section 18.9.2 for pressure settings or refer to the
data plate.
C1049B
14.2 Testing
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.
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 at the appliance isolating cock
and the electrical supply isolated by switching off at the
local switch and removing the appliance inlet plug, open
the control chamber secured by the two screws. Loosen
the sealing screw from the pressure test point and
remove the cover cap from the governor.
Close the control chamber and secure with two
sheet metal screws.
8. Balancing Hot Vacuum
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
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 vacuum at the tee on the inlet to the
pressure switch. Readjust the damper so that the
hot vacuum of 1.5 mbar (2.0 mbar for BH40EF) is
achieved and lock the damper in position.
established, check the gas pressure reading and adjust if
necessary. Refer to burner data label.
Check the gas pressure at the outlet of the gas valve. See
Page 74, Section 18.9.1 or See Page 75, Section 18.9.2
for pressure settings or refer to the data plate.
14.4 System Checks
Switch on again at the local switch to 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 three
ignition attempts followed by lockout.
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. Close burner side cover.
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.
14.3 Commissioning (Multiburner)
1. Establish that a satisfactory purged gas supply and
an electrical supply is available to the heater.
14.5 User Instructions
After satisfactory testing, ensure that the client is fully
aware of the operation of the system. Bring this manual to
2. ENSURE that all the dampers are in the fully open
position.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
the attention of the user or purchaser; instruct them in the
safe operation of the heater(s). Advise the user that if the
system is unflued, any reduction in the natural ventilation
of the building may require a flue to be fitted, or additional
ventilation grilles will be required.
14.6 ECA Approved Systems (Multiburner only)
On ECA approved systems, it must be verified that the
requirement of 91% net combustion efficiency is met.
Measurements of temperature and CO concentration in
2
the exhaust gasses have to be done. The net combustion
efficiency calculates as follows;
100 - [ (t - t ) (A/CO - B) ] = net combustion efficiency
E
R
2m
t
t
- Exhaust Temperature °C
E
R
- Room Temperature °C
A
- G20 = 0.37, G31 = 0.42
B
- G20 = 0.009, G31 = 0.008
CO
- Measured CO Concentration %
2m
2
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SECTION 15: SERVICING INSTRUCTIONS
SECTION 15: SERVICING INSTRUCTIONS
WARNING
DANGER
Electrical Shock Hazard
Explosion Hazard
Burn Hazard
Cut/Pinch Hazard
Turn off gas supply to Allow heater to cool
heater before service. before service.
Wear protective gear
during installation,
operation and service.
Disconnect electric
before service.
Tubing may still be hot
after operation.
More than one
Edges are sharp.
disconnect switch may
be required to
disconnect electric from
heater.
Heater must be
connected to a properly
grounded electrical
source.
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
15.2 Component Removal
First, isolate the heater from the gas and electrical
supplies. Entry to the burner assembly is gained by
removing the door screws and opening the hinged side
cover. Entry to the combustion chamber is gained by
removing the combustion chamber cover.
connections, the checks:- A:Earth Continuity, B:Polarity
and C:Resistance to Earth must then be repeated.
15.1 Annual Procedure
15.2.1 Electrode
Figure 36: Burner Cup Position
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 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.
15.2.2 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.
15.2.3 Solenoid Valve/Governor
Remove burner head. Remove screws securing the
solenoid/governor body bracket. Withdraw the four wires
between the solenoids. The solenoid/governor and
fittings can now be withdrawn from the compartment. The
solenoid(s) can be removed from the body by unscrewing
central screw. Replace in reverse sequence. Note: Earth
is green/yellow.
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
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
15.2.4 Automatic Flame Control Unit
Remove black ignition lead. Withdraw the connectors.
Remove two screws from the cover. Replace if faulty.
Refit in reverse sequence.
15.3 Maintenance Checklist
Installation Code and Annual Inspections:
®
All installation and service of ROBERTS GORDON
equipment must be performed by a contractor
15.2.5 Pressure Switch
qualified in the installation and service of equipment
sold and supplied by Roberts-Gordon and conform
to all requirements set forth in the ROBERTS
Disconnect the two silicone tubes. Remove wires from
the three blades. Remove two screws which secure 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.
®
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
Note: Wires fitted as follows:
NO - Yellow
NC - White
Common - Black
®
inspections of your ROBERTS GORDON
equipment and perform service where necessary,
using only replacement parts sold and supplied by
Roberts-Gordon.
15.2.6 Neons
Remove the two push on connectors and remove the
neons by pushing downwards. Replace in reverse
sequence.
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.
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.
Reflector
Support reflector with 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.
Clean outside surface with a damp cloth.
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.
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 dirt and dust. Clean and reinstall as required.
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SECTION 15: SERVICING INSTRUCTIONS
Tubes
Make sure there are no cracks.
Make sure tubes are connected and suspended securely.
Make sure there is no sagging, bending or distortion.
Gas Line
Burner Observation
Window
Make sure it is clean and free of cracks or holes.
Clean and replace as required.
Blower Scroll, Wheel and Compressed air or a vacuum cleaner may be used to clean dust and dirt.
Motor
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
Make sure the heater is hanging securely.
Look for signs of wear on the chain or ceiling.
Sports Hall Guard,
The grille must be securely attached. If the grille is loose or off, contact a
Decorative and Protective contractor qualified in the installation and service of gas-fired heating equip-
Grilles (optional)
ment for repair.
Check that side reflector extensions are installed correctly and secured in
place if necessary (decorative grille only).
Make sure shield is installed correctly and secured in place if necessary.
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
®
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 16: TROUBLESHOOTING
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.
WARNING
Fire Hazard
Explosion Hazard
Burn Hazard
Cut/Pinch Hazard
Keep all flammable
objects, liquids and
vapors the minimum
required clearances to
combustibles away
from heater.
Turn off gas supply to Allow heater to cool
heater before service. before service.
Wear protective gear
during installation,
operation and service.
Tubing may still be hot
after operation.
Edges are sharp.
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.
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Troubleshooting Flow Chart (Linear, Double Linear and U-Tube)
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
Troubleshooting Flow Chart (Multiburner)
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SECTION 16: TROUBLESHOOTING
16.3 Manifold Gas Pressure Setting
Governor Adjustment Screw
(behind cover)
Manometer
6
6
5
4
3
2
5
4
3
2
1
0
1
2
1
0
1
2
Gas Supply pressure
Governor (orifice) pressure
while burner is running. See
Page 74, Section 18.9.1 or See
Page 75, Section 18.9.2
while burner is running. See
Page 74, Section 18.9.1 or
See Page 75, Section 18.9.2
3
4
5
6
3
4
5
6
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 17: REPLACEMENT PARTS
WARNING
DANGER
Electrical Shock Hazard
Explosion Hazard
Carbon Monoxide Hazard
Fire 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.
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SECTION 17: REPLACEMENT PARTS
A
E
F
D
C
G
H
Q
N
I
L
O
J
M
K
Item Description
Part Number Item Description
Part Number
A
C
Automatic Control Unit
Flex Line Adapter
90438702
91220700
O
Q
Dust Arrest Baffle Plate
Mains in socket with EMC Filter
07230000
90438902
Pressure Switch for
BH25 - BH55, BH50EF, (0.23" w.c.)
BH15 and BH20 (0.32" w.c.)
BH30EF and BH35EF (0.41" w.c.)
BH45EF (0.47" w.c.)
BH40EF (0.79" w.c.)
BH25EF (0.59" w.c.)
Amber Neon Lamp
Gas Valve
Governor Screw
Outlet Pressure Tap
Flex Manifold
Star Washer
90439801
90439802
90439803
90439804
90439808
90439809
91320602
90033101
N/A
D
N/S Ignition Wire
90427704
E
F
G
H
I
N/S Outside Air Kit
07260000
91911700
07261000
94118106
02568200
07250007
N/S Flue Collar 100 mm
N/S Outside Air Mounting Plate
N/S #8 x 3/8 Washer Head Screw
N/S Burner Tube Gasket
N/S Wire Purple 12.5"
N/A
03090702T
96212100
J
Jet Orifice
K
N/A
N/S Wire Harness BH Gas Valve
07250006
(See Page 74, Section 18.9.1)
Burner Cup Assembly
Mica Window Assembly
Electrode Assembly
L
M
N
03020100
02552303
90427403
02558501
N/S Wire Harness BH Pressure Switch
N/S Wire Harness BH Main Power
N/S Lockout Indicator Connector (male)
N/S Lockout Indicator Connector (female)
07250005
07250004
91324000
91324001
N/S Electrode Gasket
Notes:
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
SECTION 18: SPECIFICATIONS
18.1 Material Specifications
18.1.1 Combustion and Tubes
18.3 Venting Specifications
18.3.1 Fans
100 mm dia. 16 gauge heat treated
BH-15, 20, 25, 30............. Model: Torin DSF 133-42
aluminised mild steel.
BH-25 EF, 30 EF, 35 EF,
BH-35, 40, 45 .................. Model: Torin DSA 524-202
18.1.2 Reflectors
NS3 H14 aluminium or 1.4016 2R stainless
steel (option).
BH-40 EF, 45 EF,
50 EF, BH-50 .................. Model: Magnetek JF1G
18.2 Heater Specifications
18.2.1 Sequence Controller
Fully automatic, three try, direct spark, 100% shut off
BH30DL, 40DL, BH50DL/EF,
60DL/EF, 70DL/EF........... Model: Magnetek JF1G
ignition flame rectification module.
Multiburner .................. Model: Airflow 83 BTLW
.................. Model: Airflow 90 BTLW
18.2.2 Electrical
Rating: 230V, 50 Hz, 1 Ø, 1 A
Consult the manufacturer for availability of alternate fans.
Connection: 3 pin moulded plug
18.3.2 Flue
18.2.3 Gas Supply
When fitted, 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.
Connection: Rc1/2 (1/2" BSP int)
Natural G20:
Minimum - Inlet 15 mbar (6 in wg)
Maximum - Inlet 50 mbar (20 in wg)
Multiburner - Flue must be 150 mm diameter and will be
sized to suit arrangement and will connect to the fan. Flue
material must conform to National Codes. The flue must
be self supporting.
Natural G25:
Minimum - Inlet 17.5 mbar (7 in wg)
Maximum - Inlet 50 mbar (20 in wg)
18.4 Suspension Specifications
Hang heater with materials with a minimum working load
of 33 kg.
LP Gas (Propane or Butane):
Minimum - Inlet 32.5 mbar (13 in wg)
Maximum - Inlet 50 mbar (20 in wg)
18.5 Controls Specifications
Time switches, thermostats, etc. can be wired into the
electrical supply. External controls supplied as an
optional extra.
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SECTION 18: SPECIFICATIONS
18.6 Linear Heater
Input - Gross (kW)
Input - Net (kW)
15
20
25
30
35
40
45
50/51
45/46
15240
15850
81
55
13.5
6096
6661
39
18
22.5
9144
9709
55
27
31.5
12192
12767
68
36
40.5
15240
15815
81
49.5
18288
18579
95
Tube Length (mm)
Overall Heater Length (mm)
Weight (kg)
9144
9709
55
12192
12757
68
12192
12767
68
2
Heated Area (m )
20-160 30-210 40-265 50-315 55-370 65-420 70-475 80-525 90-620
Minimum Installation
Height(mm)
3500
3500
3500
3600
3500
3900
3500
4200
4600
4800
5000
5500
5000
6700
5000
7600
6000
8000
Recommended Installation
Height (mm)
* Only available in Multiburner.
18.7 Double Linear Heater
Input - Gross (kW)
30
40
36
50
45
60
54
70
Input - Net (kW)
27.5
63
Tube Length (mm)
12802
13462
82
18898
19558
110
18898
24994
25654
136
24994
25654
136
Overall Heater Length (mm)
19558
110
Weight (kg)
2
Heated Area (m )
50-315
3500
65-420
3500
80-525
3500
3900
100-630
3500
110-740
4600
Minimum Installation Height (mm)
Recommended Installation Height (mm) 3500
3600
4200
4800
18.8 U-Tube Heater
Input - Gross (kW)
Input - Net (kW)
15
20
25
30
35
40
45
50
45
13.5
3531
3822
41
18
22.5
27
31.5
6579
6870
65
36
40.5
Tube Length (mm)
Overall Heater Length (mm)
Weight (kg)
5055
5346
54
5055
5346
54
6579
6870
65
6579
6870
66
8103
8394
96
8103
8394
96
2
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
3600
4000
4000
4700
4700
5000
5000
5000
5500
5000
6700
5000
7600
Recommended Installation Height (mm) 3500
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BLACKHEAT® INSTALLATION OPERATION AND SERVICE MANUAL
18.9 Burner Specifications
Figure 37: Linear and U-Tube Specifications
Fan
367
mm
317
mm
100 mm
Burner Tube
Tube Length
Weld Spot
Damper
457 mm
Plan View
Tube Length
100 mm
Burner Tube
Fan Tube
U-Tube
Weld Spot
*Swirler must always be located in Fan Tube.
18.9.1 Standard
Burner Specifications
BH15
20
BH20
BH25
BH30
BH35
BH40
9
BH45
10
BH50
11
BH55*
Burner Airplate
ID Number
15
12
6
7
19
Jet Numbers -
Natural G20 & 25
E
#30
#46
3.8 mm #19
2.3 mm #37
4.7 mm #9
#33
#3
#2
B
6.8 mm (G25)
Jet Numbers -
Propane/Butane
3.1 mm 3.3 mm #29
#26
#24
Jet Numbers -
Pressure Couple
1.95 mm 2.25 mm 2.5 mm 2.7 mm 2.9 mm 3.2 mm 3.25 mm 3.4 mm
-
Gas Consumption**
Natural G20 (m /h)
1.43
1.66
1.91
2.22
2.38
2.77
2.86
3.32
3.36
3.88
3.81
4.43
4.29
4.99
4.77
5.54
5.25
6.09
2.07 [3.94]
1.57
18.3
7.3
3
Gas Consumption**
3
Natural G25 (m /h)
Gas Consumption**
0.56
[1.07]
0.75
[1.43]
0.94
[1.79]
1.13
[2.15]
1.32
[2.50]
1.51
[2.86]
1.69
[3.22]
1.88
[3.58]
3
Propane (m /h) [kg/h]
Gas Consumption**
0.43
21.4
8.6
0.57
19.7
7.9
0.72
19.2
7.7
0.86
17.4
7.0
1.00
18.2
7.3
1.15
17.9
7.2
1.29
16.9
6.8
1.43
18.4
7.4
3
Butane (m /h)
Governor Pressure
Butane (mbar)
Governor Pressure
Butane (in wg)
Governor Pressure
Propane (mbar)
26.1
10.5
26.1
10.5
26.1
10.5
27.4
11.0
26.1
10.5
28.6
11.5
28.6
11.5
26.1
10.5
26.1
10.5
Governor Pressure
Propane (in wg)
*Only available in Multiburner. **Based on Gross Caloric Value.
Natural G20:
Natural G25:
8.7 mbar
11.1 mbar
3.5 in wg
4.5 in wg
Natural G25 BH 55*:
9.5 mbar
3.8 in wg
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SECTION 18: SPECIFICATIONS
18.9.2 EF Burner Specifications
Burner Airplate ID Number
BH25/EF
14
BH30/EF
5
BH35/EF
BH40/EF
BH45/EF
BH50/EF
6
5
6
10
B
Jet Numbers - Natural G20
#20
#16
#9
3.36
#5
3.81
#2
4.29
3
Gas Consumption** - Natural G20 (m /h)
2.38
2.86
4.86
**Based on Gross Caloric Value.
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Attach this information to a wall near the ROBERTS GORDON® heater.
®
I n f r a r e d H e a t i n g
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
WARNING
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,
Keep all flammable objects, liquids and vapors the minimum
FOLLOW THESE INSTRUCTIONS TO SHUT DOWN YOUR HEATER
required clearances to combustibles away from heater.
1. Set the thermostat to off or the lowest setting.
2. Turn off electric power to the heater.
3. Turn off the manual gas valve in the heater supply line.
4. Call your registered installer/contractor qualified in the
installation and service of gas-fired heating equipment.
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.
Maintain
clearance
to the side and
clearance below
the heater from vehicles
and combustible materials.
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: [email protected]
Roberts-Gordon LLC
1250 William Street
P.O. Box 44
Buffalo, NY 14240-0044 USA
Telephone: 716.852.4400
Fax: 716.852.0854
E-mail: [email protected]
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 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.
Printed in U.S.A.
P/N 91037912 Rev. H
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