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.
TABLE OF CONTENTS SECTION 1: Heater Safety...................................................... 1 1.1 Manpower Requirements ............................................. 1 1.2 Safety Labels and Their Placement ............................. 1 1.3 California Proposition 65 .............................................. 1 SECTION 2: Installer Responsibility ..................................... 4 2.1 Wall Tag ....................................................................... 4 2.2 Corrosive Chemicals....
TABLE OF FIGURES Figure 1: Top and Bottom Panel Label Placement .................... 2 Figure 2: Side and Back Panel Label Placement ...................... 3 Figure 3: Standard Reflector ..................................................... 6 Figure 4: One Side Reflector..................................................... 6 Figure 5: Two Side Reflectors ................................................... 6 Figure 6: 45° Tilt Reflector ........................................................
SECTION 1: HEATER SAFETY 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 contractor qualified in the installation and service of gas-fired heating equipment.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 1: Top and Bottom Panel Label Placement Description Logo Label Vent Length Label Gas Connection Label 2 of 59 Part Number 91031100 91039500 91018123
SECTION 1: HEATER SAFETY FIGURE 2: Side and Back Panel Label Placement Description Part Number Rating Plate Label 91010401 Lighting Instruction Plate Label 91029602 Wiring Label 91030301 Clearances to Combustibles Label 91013412 Proposition 65 Label 91070015 Thermostat Connection Label (not shown) 91037902 3 of 59
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 2: INSTALLER RESPONSIBILITY The installer is responsible for the following: • To install the heater, as well as the gas and electrical supplies, in accordance with applicable specifications and codes. Roberts-Gordon LLC recommends the installer contact a local Building Inspector or Fire Marshal for guidance.
SECTION 3: CLEARANCES TO COMBUSTIBLES SECTION 3: CLEARANCES TO COMBUSTIBLES 3.1 Required Clearances to Combustibles Clearances are the required distances that combustible objects must be away from the heater to prevent serious fire hazards. Combustibles are materials that may catch on fire and include common items such as wood, paper, rubber, fabric, etc. Maintain clearances to combustibles at all times for safety.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows. 2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the burner and burner tube connect.
SECTION 3: CLEARANCES TO COMBUSTIBLES NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows. 2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the burner and burner tube connect.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows. 2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the burner and burner tube connect.
SECTION 3: CLEARANCES TO COMBUSTIBLES NOTE: 1. All dimensions are from the surfaces of all tubes, couplings and elbows. 2. Clearances B, C and D can be reduced by 50% after 25' (7.5 m) of tubing downstream from where the burner and burner tube connect.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes The type of gas appearing on the nameplate must be the type of gas used. Installation must comply with national and local codes and requirements of the local gas company. United States: Refer to National Fuel Gas Code NFPA 54/ANSI Z223.1 - latest revision. Canada: Refer to Natural Gas and Propane Installation Code CSA B149.1 - latest revision. 4.
SECTION 5: MAJOR COMPONENTS SECTION 5: MAJOR COMPONENTS FIGURE 13: Major Component Descriptions Burner with Tube Gasket Must be installed with the flame observation window facing down. Reflector (Aluminum or Stainless Steel) Alternate overlap as shown on overview and on Page 17, Figure 16. Minimum overlap is 6'' (16 cm). Burner Tube Supplied in 10' (3 m) lengths. Burner tube is always the first tube after the burner. Tube Hot rolled or heat treated aluminized tube supplied in 10' (3 m) lengths.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 5.1 Standard Parts List Table 1: Contents of BH-Series Burner Carton Part No.
SECTION 5: MAJOR COMPONENTS Table 3: BH-Series Component Package Guide Model Tubing Length Core Packages Minimum Standard Aluminized BH-40 10' (3 m) - CP10ALUM BH-60 20' (6 m) CP20HRS CP20ALUM BH-80 20' (6 m) CP20HRS CP20ALUM BH-100 30' (9 m) CP30HRS CP30ALUM BH-115 30' (9 m) CP30HRS CP30ALUM BH-125 40' (12 m) CP40HRS CP40ALUM BH-140 40' (12 m) CP40HRS CP40ALUM BH-150 50' (15 m) CP30HRS + EXP20HRS CP30ALUM + EXP20ALUM BH-175 50' (15 m) CP30HRS + EXP20HRS CP30ALUM +
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 6: HEATER INSTALLATION 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.
SECTION 6: HEATER INSTALLATION FIGURE 14: Critical Hanger Placement Typical Suspension Details Beam Clamp Anchor Screw Hook 3/8" 24" min.* (61 cm) Chain Size 3/16" Minimum Rod 3/8" Concrete Beam Wood Beam Locknut Washers X* S-hooks Turnbuckle Not Included * Allows for thermal expansion of system S-hooks Hanger Side View Hanger Reflector Must Be Within 4" (10 cm) Description S-Hook Tube/Reflector Hanger Part Number 91907302 03090100 Front View Run Length 10' (3 m) - 50' (15.2 m) 51' (15.
16 of 59 Reflector Support Tube and Reflector Hanger Coupling Burner Tube Tube Clamp Package Burner Reflector End Cap Reflector Tube Turbulator (With Select Models) Vent Adapter U-Clips BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 15: Linear Heater Assembly Overview
SECTION 6: HEATER INSTALLATION FIGURE 16: Linear Heater Layout Overview b c LEGEND g Burner Reflector d f 10' (3 m) Tube Length Tube Tube/Reflector Hanger b c g Coupling Assembly d e Vent Adapter f a = 14" (36 cm) reflector width (not shown) 20' (6.1 m) Tube Length b = 2" (5 cm) end cap to burner b c = 2" (5 cm) end cap to hanger d = 7' 6" (2.3 m) distance first hanger e = 10' (3 m) distance between hangers g c d e e f 30' (9.1 m) Tube Length f = 12.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 17: Linear Heater Layout Overview (Continued) b c g d e e e e e e e e e e e e e e e e e f 60' (18.3 m) Tube Length g b c d f 70' (21. 3 m) Tube Length g b c d e f 80' (24.4 m) Tube Length Step 6.1 Burner Tube Installation NOTE: Tubing requires a downward slope of 1/2" (13 mm) per 20' (6 m) away from burner. Offset mounting hole must be to the top.
SECTION 6: HEATER INSTALLATION Step 6.2 Tube Clamp Package Installation Bolt Tube Clamp Flat Washer Nut (Torque 120 in/lb 13.56 Nm) Description Tube Clamp Package Tube Clamp Bolt Flat Washer Nut Part Number 01318901 01396801 97113940 95211600 92113900 Step 6.3 Coupling and Tube Assembly Close coupling A with tab. Start slide bar/coupling lock B onto coupling. Tab Slide Bar/Coupling Lock Wide End Coupling Open 3" (8 cm) to 4" (10 cm) Closed C Insert tubes into coupling.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL Step 6.3.1 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. ± 2" (5 cm) Correct slide bar dimensions Incorrect slide bar position • Repeat Step 6.3 A - D until all tubes are assembled. See Page 20, Step 6.3.2. Step 6.3.
SECTION 6: HEATER INSTALLATION Step 6.4 Turbulator Installation Turbulator must be installed in the last standard section of tube. Turbulator is not required on the BH-125/150/175/200. Twis t Turbulator Section Turbulator Adapter Tab Turbulator section 2.5' (76.2 cm) (stainless) used in BH-40 heaters must be in the section of turbulator nearest to the burner. Description Turbulator Adapter 2.5' (76.2 cm) Turbulator Section 2' (61 cm) Turbulator Section 2.5' (76.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL Step 6.5 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. NOTE: All tube surfaces must be covered by a reflector, except for a U-tube.
SECTION 6: HEATER INSTALLATION Step 6.5.1 Reflector, U-Clip and Reflector Support Installation The pictorial drawings of the heater construction in reflector supports and U-clips depend on the Section 6 are schematic only and provide a general individual installation. Use either pop rivets or sheet guideline of where hangers, reflector supports and metal screws instead of u-clips when installing end U-clips are to be installed.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL Step 6.6 Burner Installation Extra chain min. 12" (30 cm) S-hook Burner Tube Burner Description Bolt Burner Lock Washer Gasket 24 of 59 Gasket Part Number 94273914 071XXXXX 96411600 02568200 Lock Washer Bolt (Torque 120 in/lb 13.
SECTION 7: OPTIONAL HEATER ACCESSORIES SECTION 7: 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. 7.1 U-Tube Configuration Heaters (except BH-40) are approved for optional U-tube configurations.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 18: U-Tube Heater Assembly Overview U-tube Support Bracket Reflector Support Burner Vent Adapter Turbulator (With Select Models) Tube Clamp Package Reflector Tube Burner Tube U-tube, Standard Couplings 1 U-tube, 45° 1 1 26 of 59 U-clips 2 Reflector End Caps U-bolt 1 4"Tight (10 cm) u-bolt, 2 2 Loose U-bolt 4" (10 cm) u-bolt, secured to burner tube secured to bracket with with 1/4" (.6 cm) 1/4" (.
SECTION 7: OPTIONAL HEATER ACCESSORIES FIGURE 19: U-Tube Heater Layout Overview LEGEND g b c e Burner Reflector h Tube 10' (3.0 m) 20' (6.1 m) Tube Length* Tube 5' (1.5 m)** Tube/Reflector Hanger g Coupling Assembly b c d f U-tube Vent Adapter (Not Shown) h 30' (9.1 m) Tube Length** a = 14" (36 cm) Reflector Width (Not Shown) b = 2" (5 cm) End Cap to Burner g c = 2" (5 cm) End Cap to Hanger b c d e d = 7' 6" (2.3 m) Distance First Hanger e = 10' (3.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 20: U-Tube Layout Overview (Continued) b c g d e e h 60' (18.3 m) Tube Length b c g d e e f h 70' (21.3 m) Tube Length** b c g d e e e h 80' (24.4 m) Tube Length 7.2 Elbow Package Configuration Step 7.2.
SECTION 7: OPTIONAL HEATER ACCESSORIES Step 7.2.2 Elbow Installation Tube Coupling Step 7.2.3 Reflector Joint Installation Step 7.2.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL Step 7.2.
SECTION 7: OPTIONAL HEATER ACCESSORIES 7.3 Reflector Side Extension Step 7.3.1 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 Reflector Side Extension Package Reflector Side Extension Retainer Clips Sheet Metal Screws Part Number 02712700 01368000 02751200 94118106 Order Separately Reflector Side Extension Bracket 01329910 Step 7.3.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 7.4 Lower Clearance Shield Installation Step 7.4.1 Shield Support Strap Assembly Reflector 17" (43 cm) 12" (30 cm) Align Pilot Holes Lower Clearance Shield Locknuts Washers Screws Description Lower Clearance Shield Package Shield Support Strap Lower Clearance Shield 8' (2.4 m) Locknut #8 Flat Washer #8 Screw #8 x 3/8'' Part Number 01397501 01397500 02793000 92311400 95310800 93511406 7.5 Two-Foot Decorative Grille Installation Step 7.5.
SECTION 7: OPTIONAL HEATER ACCESSORIES Step 7.5.2 Frame Shield Installation Description Deco Grille Shield Part Number 01365900 Step 7.5.3 Reflector Side Extension Installation for Decorative Grilles Distance "A" Minimum Maximum 2" (4 cm) 6" (15 cm) 6" (15 cm) 10" (26 cm) 10" (26 cm) 14" (37 cm) Extension Part No.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 7.6 Protective Grille Installation Step 7.6.1 Silicone Cap Installation Silicone Cap Grille Finger Description Grille Section Grille End Cap Silicone Cap Part Number 08050001 08050002 91915951-6P Step 7.6.2 Grille End Cap Installation B A Grille Grille End Cap C D Bend up 90°. Pull outward. Step 7.6.
SECTION 8: VENTING SECTION 8: VENTING WARNING Carbon Monoxide Hazard 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. WARNING combustible wall must have an approved thimble to conform with the above listed codes. Vent pipe must be sloped downward away from the heater 1/2'' (1 cm) for every 20' (6 m).
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 8.2 Unvented Operation Sufficient ventilation must be provided in the amount of 4 cfm per 1000 Btu/h firing rate (United States); 3 cfm per 1000 Btu/h firing rate (Canada). Use of optional outside combustion air is not recommended with unvented heaters. If exhaust fans are used to supply ventilation air, an interlock switch must be used to prevent the heater from coming on when the fans are off. This may be done using a pressure switch.
SECTION 8: VENTING 8.8 Vertical Ventilation 4'' (10 cm) Pipe Description Vent Cap 4" (10 cm) Part Number 90502300 8.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 8.10 Common Vertical Venting Requirements: • Maximum of four heaters can be commonly vented through the roof. • Heaters must be of the same BTU output. • Heaters must be controlled by a common thermostat. • Connections to a common stack must be positioned to avoid direct opposition between streams of combustion gases.
SECTION 8: VENTING 8.11 Outside Combustion Air Supply IMPORTANT: If the building has a slight negative pressure or corrosive contaminants, such as halogenated hydrocarbons, are present in the air, an outside combustion air supply to the heater is required. Seal all combustion air pipe joints. 8.11.1 Length Requirements Follow the constraints listed on Page 36, Section 8.6. Use of optional outside combustion air is not recommended with unvented heaters.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 8.11.4 Vertical Outside Air Supply for Double Heater Installation Vent Cap Roof 6" (15 cm) Single Wall Pipe Flex Hose (Recommended) Burner Band Clamp (Recommended) Description Vent Cap 6" (15 cm) Sweeping 'T' Connection Burner Flex Hose (Recommended) 4" (10 cm) Single Wall Pipe Part Number 90502302 Requirements: • Heaters must be controlled by a common thermostat. 8.11.
SECTION 9: GAS PIPING SECTION 9: GAS PIPING WARNING Fire Hazard Tighten gas hose fittings to connect gas supply according to Figure 23. Gas hose can crack when twisted. Gas hose moves during normal operation. Use only 36" (91 cm) long connector of 1/2" or 3/4" nominal ID. Connector supplied with heater for U.S. models (not with Canadian models). Failure to follow these instructions can result in death, injury or property damage.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL FIGURE 23: Gas Connection with Flexible Gas Hose CORRECT POSITIONS CAUTION Product Damage Hazard Shut-Off Valve (included with gas hose) must be parallel to burner gas inlet. The 3" (8 cm) displacement shown is for the cold condition. This displacement may reduce when the system is fired. Hold gas nipple securely with pipe wrench when attaching gas hose. Failure to follow these instructions can result in product damage.
SECTION 10: WIRING SECTION 10: WIRING Heaters can be controlled using several methods. Normally thermostats are used to control the heaters but they can also be controlled by an energy management system. Section 10.1 illustrates the connection for heaters controlled by a line voltage thermostat. For heaters on a low voltage thermostat, See Page 44, Section 10.2.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 10.2 Low Voltage Thermostat Wiring FRONT VIEW SPST Transformer Relay 1 Black 4 COIL BACK VIEW R Low Voltage Thermostat C 3 2 6 W 5 COIL G Y Black 120 V-60 Hz Supply Circuit White Red L1 L2 Gnd. Additional Burners N H N Gnd. H Gnd.
SECTION 10: WIRING 10.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL 10.4 Ladder Diagram 10.5 Electrical Connection to the Burner Connect wires together with suitable approved wire connections. L2 Gnd. L1 Green White Black Green to Gnd.
SECTION 11: OPERATION AND MAINTENANCE SECTION 11: OPERATION AND MAINTENANCE WARNING DANGER Electrical Shock Hazard Disconnect electric before service. Explosion Hazard Turn off gas supply to heater before service. Heater must be connected to a properly grounded electrical source. Burn Hazard Allow heater to cool before service. Cut/Pinch Hazard Wear protective gear during installation, operation and service. Tubing may still be hot Edges are sharp. after operation.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL overall heater condition should be thoroughly inspected. NOTE: Gas flow and burner ignition are among the first things that should be throughly inspected. Please see Page 48, Section 11.5 for suggested items to inspect. 11.
SECTION 11: OPERATION AND MAINTENANCE Blower Scroll, Wheel and Motor Compressed air or a vacuum cleaner may be used to clean dust and dirt. Burner Cup and Orifice Clear of obstructions (even spider webs will cause problems). Electrode Carefully remove any dust and debris from the burner. Replace if there are cracked ceramics, excessive carbon residue, or erosion of the electrode. Thermostat Suspension Points The electrode gap should be 1/8" (3.2 mm).
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 12: 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 Keep all flammable objects, liquids and vapors the minimum required clearances to combustibles away from heater. Explosion Hazard Turn off gas supply to heater before service. Burn Hazard Allow heater to cool before service.
Is there spark at the igniter? YES Turn up thermostat. Does the blower turn on? NO NO Check wiring between the power cord, blower motor and transformer. NO YES YES NO Reconnect transformer wires. Place a jumper wire across the pressure switch. Is there a spark? Replace transformer. Replace ignition module. NO YES Remove the blue and yellow wires from the transformer.
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SECTION 12: TROUBLESHOOTING 12.
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL SECTION 13: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Fire Hazard Carbon Monoxide Hazard Use only genuine ROBERTS GORDON® replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage.
SECTION 13: REPLACEMENT PARTS 55 of 59
BH-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL Description Mica Window Assembly Electrode Gasket Tube Gasket Burner Cup Assembly Gas Valve (Natural) Gas Valve (LP) Electrode DSI Ignition Module Transformer Pressure Switch (200) (115, 140, 175) (150) (60, 80, 100, 125) (40) Motor/Blower Assembly Blower Outlet Gasket 56 of 59 Part Number 02553203 02558501 02568200 03020100 90032500 90032502 90427400 90439500K 90436900K 90439801K 90439802K 90439803K 90439805K 90439808K 90709700-P 90709801
SECTION 14: GENERAL SPECIFICATIONS SECTION 14: GENERAL SPECIFICATIONS 14.1 Material Specifications 14.3 Suspension Specifications 14.1.1 Reflectors Hang heater with materials with a minimum working load of 75 lbs (33 kg). See Page 15, Figure 14. .024 Aluminum (Optional .024 Stainless Steel Type 304) 14.4 Controls Specifications 14.2 Heater Specifications Time switches, thermostats, etc. can be wired into the electrical supply. External controls supplied as an 14.2.1 Ignition optional extra.
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SECTION 15: THE ROBERTS GORDON® GORDONRAY® BH WARRANTY SECTION 15: THE ROBERTS GORDON® GORDONRAY® BH WARRANTY ROBERTS-GORDON LLC WILL PAY FOR: Within 36 months from date of purchase by buyer or 42 months from date of shipment by Roberts-Gordon LLC (whichever occurs first), replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect. Roberts-Gordon LLC will require the part in question to be returned to the factory.