Roberts Gorden AG15ST Installation, Operation & Service Manual

Vacuum assisted linear and double linear gas fired heating systems blackheat ag
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FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier's
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clear-
ances 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.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the installation, operation
and service manual thoroughly before installing or
servicing this equipment.
Installation must be done by a registered installer/
contractor qualified in the installation and service
of gas-fired heating equipment or your gas supplier.
© 2011 Roberts-Gordon Europe Ltd
Blackheat
Vacuum Assisted
Linear and Double Linear
Gas Fired Heating
Installation, Operation &
IP55 Protected Burner Box
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.
Keep this manual in a safe place in order to provide
your serviceman with necessary information.
Roberts-Gordon Europe Limited
Unit A, Kings Hill Business Park
Darlaston Road, Wednesbury
West Midlands, WS10 7SH UK
Telephone: +44(0)121 506 7700
Fax: +44(0)121 506 7701
Service Telephone: +44(0)121 506 7709
Service Fax: +44(0)121 506 7702
E-mail: uksales@rg-inc.com
E-mail: export@rg-inc.com
www.brooder-heater.com
AG
®
Systems
Service Manual
AG15ST
AG30DL
AG20ST
AG40DL
AG25ST
AG50DL
AG30ST
AG60DL
AG35ST
AG70DL
AG40ST
AG45ST
AG50ST
For Agricultural Use
Installer
Owner
170103UK Rev B 04/11

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Summary of Contents for Roberts Gorden AG15ST

  • Page 1 8. If you cannot reach your gas supplier, call the Fire Department. Gas Fired Heating WARNING Systems Installation, Operation & Service Manual Fire Hazard AG15ST AG30DL Keep all flammable objects, liquids and vapors the minimum required clear- AG20ST AG40DL ances to combustibles away from AG25ST AG50DL heater.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1: Heater Safety ..........2 11.2 Typical External Wiring Diagram 1.1 Manpower Requirements ........2 (Double Linear Option 1) .........39 1.2 IP55 Protection ............2 11.3 Typical External Wiring Diagram 1.3 Safety Labels and Their Placement ....2 (Double Linear Option 2) .........39 SECTION 2: Installer Responsibility......4 11.4 Internal Wiring Diagram ........40 2.1 Low Level User Instructions........4...
  • Page 5 TABLE OF FIGURES Figure 1: Bottom and Back Panel Label Placement ..3 Figure 2: Control Side Label Placement......3 Figure 3: Linear & Double Linear, Horizontal Mounts..6 Figure 4: Linear & Double Linear, One Side Reflector ..6 Figure 5: Linear & Double Linear, Two Side Reflectors ...6 Figure 6: Linear &...
  • Page 7 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.
  • Page 8: Section 1: Heater Safety

    Please contact Roberts-Gordon LLC or your equipment. ROBERTS GORDON independent distributor to ® Read this manual carefully before installation, operation obtain replacement signs or labels. See Page 3, or service of this equipment.
  • Page 9: Figure 1: Bottom And Back Panel Label Placement

    SECTION 1: H EATER AFETY Figure 1: Bottom and Back Panel Label Placement Infrared Radiant Tube Heater This applicance must be installed in accordance with the rules in force, and used only in a sufficiently ventilated space. Consult instructions before installation and use of this applicance. Model No.
  • Page 10: Section 2: Installer Responsibility

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL SECTION 2: INSTALLER RESPONSIBILITY 2.2 Corrosive Chemicals • To install the heater, as well as the gas and electrical CAUTION supplies, in accordance with applicable specifications and codes. Roberts-Gordon LLC recommends the installer contact a local Building Inspector or Fire Marshal for guidance.
  • Page 11: Section 3: Clearance To Combustibles

    SECTION 3: C LEARANCE OMBUSTIBLES SECTION 3: CLEARANCE TO COMBUSTIBLES • Consult local Building Inspector, Fire Insurance Carrier or other authorities for approval of proposed WARNING installation when there is a possibility of exposure to combustible airborne materials or vapours. •...
  • Page 12: Clearance Data - Linear And Double Linear

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 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.
  • Page 13: Figure 6: Linear & Double Linear, 2 Foot Deco Grille

    SECTION 3: C LEARANCE OMBUSTIBLES 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.
  • Page 14: Section 4: Major Component Descriptions

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL SECTION 4: MAJOR COMPONENT DESCRIPTIONS Burner (shown with Tube Reflector Gasket) (Aluminium or Must be installed with the Stainless Steel) flame observation window Alternate overlap as facing down. shown on overview. Minimum overlap is 160 mm.
  • Page 15: Section 5: General Suspension Details

    SECTION 5: G ENERAL USPENSION ETAILS 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.
  • Page 16: Figure 9: Critical Hanger Placement

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL Figure 9: Critical Hanger Placement Description Part Number Burner Tube 03051100 S-hook 91907302 Spring Hook 91903300 Bow Shackle E0007576 Tube/Reflector Hanger 03090101...
  • Page 17: Section 6: Linear & Double Linear Heater Installation

    SECTION 6: L & D INEAR OUBLE INEAR EATER NSTALLATION SECTION 6: LINEAR & DOUBLE LINEAR For optional reflector configurations for linear heaters see HEATER INSTALLATION Page 6, Figure 3 through Page 7 , Figure 8. Install appropriate suspension hardware, beam clamps, chain or The figures in this section provide a general overview of rod at predetermined locations.
  • Page 18: Figure 10: Linear General Assembly Overview

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL Figure 10: Linear General Assembly Overview...
  • Page 19: Figure 11: Linear Layout Overview

    = end cap to burner/fan - 50 mm f = burner height - 241 mm c = end cap to hanger - 50 mm g = burner length - 445 mm d = distance first hanger - 2290 mm Model AG15ST AG20ST AG25ST AG30ST AG35ST AG40ST AG45ST...
  • Page 20: Double Linear Standard Parts List

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 6.2 Double Linear Standard Parts List Part No. Description 035XXXXX Burner Assembly (Input and Fuel Varies) 07260053 Fan Package 3 IP55 03051100 Burner Tube, 100 mm x 3048 mm 91409408 Tube, 100 mm x 3048 mm S5127W Fan Tube, 100 mm x 3048 mm, with 3048 mm Swirler S5134W...
  • Page 21: Figure 12: Double Linear General Assembly Overview

    SECTION 6: L & D INEAR OUBLE INEAR EATER NSTALLATION Figure 12: Double Linear General Assembly Overview...
  • Page 22: Figure 13: Double Linear Layout Overview

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL Figure 13: Double Linear Layout Overview LEGEND Burner Reflector Repeated AG30DL Opposite Side Tube Tube/Reflector Hanger Coupling Assembly Assembly Tee Assembly Repeated Opposite Side AG40DL AG50DL Repeated AG60DL Opposite AG70DL Side a = reflector width (not shown) - 365 mm e = distance typical between hangers - 3050 mm b = end cap to burner/fan - 50 mm...
  • Page 23: Burner Tube Installation

    SECTION 6: L & D INEAR OUBLE INEAR EATER NSTALLATION Step 6.3 Burner Tube Installation Description Part Number Burner Tube 03051100 Bow Shackle E0007576 Tube/Reflector Hanger 03090101 Step 6.4 Coupling and Tube Assembly Start slide bar/coupling lock Close coupling onto coupling with tab Slide Bar Wide End...
  • Page 24 • Repeat Step 6.4 A - D until all tubes are assembled. See Page 18, Section 6.4.2 shown below. Step 6.4.2 Coupling and Tube Assembly (Continued) Number Model Overall Tube Length (mm) of Tubes AG15ST 6000 AG20ST 9000 AG25ST 9000...
  • Page 25: Tube Clamp Package Installation

    SECTION 6: L & D INEAR OUBLE INEAR EATER NSTALLATION Step 6.5 Tube Clamp Package Installation Description Part Number Tube Clamp Package 01318901 Tube Clamp 01396801 Bolt 97113940 Flat Washer 95211600 92113900...
  • Page 26: Reflector Installation

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 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. Description Part Number Tube/Reflector Hanger...
  • Page 27 SECTION 6: L & D INEAR OUBLE INEAR EATER NSTALLATION Step 6.6.1 Reflector, U-clip and Reflector Support Installation The pictorial drawings of the heater construction in supports are used. The positioning of reflector supports Section 6 are schematic only and provide a general and u-clips depend on the individual installation.
  • Page 28: Section 7: Burner & Fan Installation

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: BURNER & FAN INSTALLATION Step 7.1 Burner Installation NOTE: Tube Clamp Package not shown for clarity. For details, see Page 19, Step 6.5. Description Part Number Bolt 94273914 Lock Washer 96411600 Gasket 02568200...
  • Page 29: Ip55 Fan Assembly

    SECTION 7: B & F URNER NSTALLATION Step 7.2 IP55 Fan Assembly Fan Assembly Wire Gland (tighten securely) Note: Apply Silicone (Recommended) Vent Adapter Washer (Torque: 2 Nm 18 in lb) Install vent adapter with clamp in the up position. Description Part Number Fan Assembly...
  • Page 30: Double Linear Fan Installation

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL Step 7.4 Double Linear Fan Installation Tighten securely until tube cannot be removed. Fan Assembly Step 7.4.1 Double Linear Fan Installation (Continued)
  • Page 31: Section 8: Optional Heater Accessories

    SECTION 8: O PTIONAL EATER CCESSORIES SECTION 8: 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.
  • Page 32: Reflector Side Extension Installation

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 8.1 Reflector Side Extension Installation Step 8.1.1 Bracket Installation Description Part Number Reflector Side Extension Package S7377K Reflector Side Extension 01368000 Retainer Clips 02751200 Reflector Side Extension 01329910 Step 8.1.2 Side Reflector Installation...
  • Page 33: Decorative Grille Installation

    SECTION 8: O PTIONAL EATER CCESSORIES 8.2 Decorative Grille Installation Step 8.2.1 Grille Installation Description Part Number Aluminium Grille 91407000 Step 8.2.2 Frame Shield Installation Description Part Number Deco Grille Shield 01365900 Step 8.2.3 Reflector Side Extension Installation for Decorative Grilles Distance "A"...
  • Page 34: Protective Grille Installation

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 8.3 Protective Grille Installation Step 8.3.1 Silicone Cap Installation Silicone Cap Grille Finger Description Part Number Grille Section 08050001 Grille End Cap 08050002 Silicone Cap 91915951-6P Step 8.3.2 Grille End Cap Installation Grille Grille End Cap Bend up 90°.
  • Page 35: Sports Hall Guard Installation

    SECTION 8: O PTIONAL EATER CCESSORIES 8.4 Sports Hall Guard Installation Step 8.4.1 Grille Installation Description Part Number Mesh Guard 2438 mm E0009855 Mesh Guard 1524 mm C2329B Strap Stainless Steel S5218W Step 8.4.2 Fastener Installation Description Part Number Nut Spire C1088B Screw #8 x 3/8 C1089B...
  • Page 36: Undershield Installation

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 8.5 Undershield Installation Step 8.5.1 Hanger Installation Reflector Assembly Hanging Bracket Hex Nut Stud Tube Description Part Number Undershield Reflector Package 1010 mm S7399K Assembly Hanging Bracket C0318B Stud M6 x 90 C0693B Nut M6 C0090B...
  • Page 37: Wall Mounting

    Model Quantity of Wall Mounting Brackets dimensions d, e and f in the relevant Layout Overview AG15ST AG20ST drawing for your heater. For Linear heaters see Page 13, AG25ST Figure 11, for Double Linear heaters see Page 16, Figure...
  • Page 38: Section 9: Venting And Fresh Air Supply

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL SECTION 9: VENTING AND FRESH AIR SUPPLY flue must be self supporting. Suitable terminals must be fitted for horizontal and vertical flue. WARNING In order to locate fans that are not IP54 protected away from the wet environment, a 100 mm diameter extension tube between the heat exchanger end and fan must be installed.
  • Page 39: Outside Combustion Air Supply

    SECTION 9: V ENTING AND RESH UPPLY Figure 16: Individual Flue Connection Detail Fan Assembly Fan Tube Lockwasher Screw (Torque: 2 Nm 18 in lb) Flue Adapter Flue Pipe Figure 17: Flue Connection Dimensions Fan Part Number 90710051 76 mm 95 mm 31 mm 90710052...
  • Page 40: Common Duct

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL Figure 18: Air Supply with Flue Configurations 9.7 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.
  • Page 41: Section 10: Gas Piping

    SECTION 10: G IPING SECTION 10: GAS PIPING There is an expansion of the tube with each firing cycle. This will cause the burner to move with respect to the gas hose. This can cause a gas leak resulting in an unsafe WARNING condition if the gas connection is not made in strict accordance with Figure 19.
  • Page 42: Figure 19: Gas Connection With Stainless Steel Flex

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL Figure 19: Gas Connection with Stainless Steel Flex Connector CORRECT POSITIONS CAUTION Product Damage Hazard Shut-Off Valve (included with gas hose) must Hold gas nipple securely with pipe wrench be parallel to burner gas inlet. The 80 mm when attaching gas hose.
  • Page 43: Section 11: Wiring

    SECTION 11: W IRING SECTION 11: WIRING Description Part Number DANGER BLACKHEAT ® AG Lockout Indicator Package 03360008 Cable Gland U169 Power Wire 91300010 Blue Wire 91300011 Brown Wire 91300012 All wiring must comply with current wiring regulations and any local regulations which may apply. Always switch off Electrical Shock Hazard the supply to the burner before removing the burner side panel.
  • Page 44: Typical External Wiring Diagram (Double Linear Option 1)

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 11.2 Typical External Wiring Diagram (Double Linear Option 1) Controller or Thermostat Earth 230 V 1 Ø Earth 50 Hz Fuse Burner 2 Burner 1 11.3 Typical External Wiring Diagram (Double Linear Option 2) Controller or Thermostat Earth...
  • Page 45: Internal Wiring Diagram

    SECTION 11: W IRING 11.4 Internal Wiring Diagram...
  • Page 46: Section 12: Operation

    In case of flame loss during operation of the heater, the the monitoring computer. See Page 39, Section 11.4. 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 Description Part Number system, etc.
  • Page 47: Testing

    Adjust the damper so Connector that the suction is 1.9 mbar. Repeat for each burner. A volt free contact relay is closed which enables the ROBERTS GORDON ® controller, BMS system, etc. to 7. Start at the end burner (furthest from the exhaust indicate the heater that has failed.
  • Page 48: Section 13: Servicing Instructions

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL SECTION 13: SERVICING INSTRUCTIONS WARNING DANGER Electrical Shock Hazard Explosion Hazard Burn Hazard Cut/Pinch Hazard Turn off gas supply to Allow heater to cool Wear protective gear Disconnect electric heater before service. before service.
  • Page 49: Maintenance Checklist

    Unscrew the burner cup. Remove Installation Code and Annual Inspections: brass injector jet (orifice). Replace in reverse sequence. All installation and service of ROBERTS GORDON ® equipment must be performed by a contractor qualified in the installation and service of equipment 13.3.3 Solenoid Valve/Governor...
  • Page 50 (Decorative grille only.) See Page 27 , Section 8.2.2. Wall Tag If a wall tag is present, make sure it is legible and accurate. Please contact Roberts-Gordon LLC or your ROBERTS GORDON® independent distributor if you need a wall tag. See Page 4, Section 2.1.
  • Page 51: Section 14: Troubleshooting

    SECTION 14: T ROUBLESHOOTING SECTION 14: 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 Turn off gas supply to Allow heater to cool...
  • Page 52: Troubleshooting Flow Chart (Linear And Double Linear)

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 14.1 Troubleshooting Flow Chart (Linear and Double Linear)
  • Page 53 SECTION 14: T ROUBLESHOOTING Troubleshooting Flow Chart (Linear and Double Linear)
  • Page 54: Manifold Gas Pressure Setting

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 14.2 Manifold Gas Pressure Setting (12) (14) 5(+) (A1) 1(-) (A2) Manometer Gas supply pressure Governor (orifice) pressure while burner is running. See while burner is running. See Page 52, Section 16.2.3. Page 54, Section 16.8.1.
  • Page 55: Section 15: Replacement Parts

    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.
  • Page 56 ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL L, T Item Description Part Number Item Description Part Number Automatic Control Unit 90438702 P Gasket 1/2" OD x 1/4" ID 92700008 Flex Line Adapter 91220700 Q Gasket 1/2" OD x 3/16" ID 92700001 Pressure Switch for HE50...
  • Page 57: Replacement Packages

    SECTION 15: R EPLACEMENT ARTS 15.1 Replacement Packages 15.1.1 Screw and Gasket Replacement Package (P/N 03360005) Description Quantity Part Number Screw M4 x 8mm 93304506 Screw 10-24 x 5/8 94118110 Screw #8 x 3/8 94118107 Screw M8 x 20 mm 93304507 Burner Tube Gasket 92700004...
  • Page 58: Section 16: Specifications

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL SECTION 16: SPECIFICATIONS 16.3 Venting Specifications 16.3.1 IP54 Protected Fans AG15, 20, 25, 30, 35..Model: Torin DSA 508-128 16.1 Material Specifications (P/N 90710051) 16.1.1 Combustion and Tubes 100 mm dia. 16 gauge heat treated aluminised AG40, 45, 50 ....
  • Page 59: Linear Heater

    26106 26106 Overall Heater Length (mm) Weight (kg) *Please contact Roberts-Gordon or your ROBERTS GORDON ® independent distributor to obtain minimum and recommended installation heights. For poultry and other agricultural applications, it is important to install your heater in accordance with the appropriate clearances to combustibles. Also, it is recommended that the design and layout of all your agricultural buildings and barns are performed by a qualified professional in the design, installation and service of equipment sold and supplied by Roberts-Gordon.
  • Page 60: Burner Specifications

    ® AG I LACKHEAT NSTALLATION PERATION AND ERVICE ANUAL 16.8 Burner Specifications Figure 22: Linear Specifications Reflector End View Side View Swirler* 100 mm 241 mm Burner Tube Tube Length 348 mm 499 mm Damper 16.8.1 Burner AG15 AG20 AG25 AG30 AG35 AG40...
  • Page 62 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.

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