Roberts Gorden DF Installation, Operation & Service Manual

Roberts Gorden DF Installation, Operation & Service Manual

Gas-fired, low intensity two stage unitary heater
Table of Contents

Advertisement

Quick Links

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 contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
© 2022 Roberts-Gordon LLC
Model DF
Gas-Fired, Low Intensity
Two Stage Unitary Heater
Installation, Operation &
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 service technician with necessary information.
Roberts-Gordon LLC
1250 William Street
Buffalo, New York 14240-0044
www.robertsgordon.com
Service Manual
DF-80
DF-100
DF-125
DF-150
DF-175
DF-200
Installer
Owner
P/N 173101NA Rev. P 10/22

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the DF and is the answer not in the manual?

Questions and answers

Jason
February 4, 2025

Can we cut burner tube?

Subscribe to Our Youtube Channel

Summary of Contents for Roberts Gorden DF

  • Page 1 If you smell gas: 1. Open windows. 2. DO NOT try to light any appliance. 3. DO NOT use electrical switches. Model DF 4. DO NOT use any telephone in your building. 5. Extinguish any open flame. 6. Leave the building.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1: Heater Safety ............1 10.4 Ladder Diagram ............54 1.1 Manpower Requirements ..........1 10.5 Electrical Connection to the Burner ......54 SECTION 11: Operation and Maintenance ......55 1.2 Safety Labels and Their Placement......1 1.3 California Proposition 65 ..........
  • Page 5: Section 1: Heater Safety

    SECTION 1: H EATER AFETY SECTION 1: HEATER SAFETY For additional copies of the Installation, Operation and Service Manual, please contact Roberts-Gordon Your Safety is Important to Us! LLC. This symbol is used throughout the manual to notify you of 1.1 Manpower Requirements possible fire, electrical or burn hazards.
  • Page 6 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 1: Top and Bottom Panel Label Placement Description Part Number Logo Label 91032500 Vent Length Label 91039500 Gas Connection Label 91018123 Burner Status Light Label 91032900...
  • Page 7 SECTION 1: H EATER AFETY FIGURE 2: Side and Back Panel Label Placement Level droit Level droit Description Part Number Rating Plate Label 91010401 Lighting Instruction Plate Label 91029602 Wiring Label 91032801 Clearances to Combustibles Label 91010461 Proposition 65 Label 91070016 Thermostat Connection Label 91033000...
  • Page 8: Section 2: Installer Responsibility

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 2: INSTALLER RESPONSIBILITY permanent ink according to your model number and configuration in the open spaces on the tag. The installer is responsible for the following: • To install the heater, as well as the gas and 2.2 Corrosive Chemicals...
  • Page 9 SECTION 3: C LEARANCES TO OMBUSTIBLES SECTION 3: CLEARANCES TO COMBUSTIBLES WARNING 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.
  • Page 10 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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.
  • Page 11 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. FIGURE 6: 45° Tilt Reflector (inches) (centimeters) Model DF-80 DF-100 DF-125 DF-150 DF-175 DF-200...
  • Page 12 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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.
  • Page 13 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. FIGURE 12: Venting (inches) (centimeters) Model Unvented Vent DF-80 Pipes Radiant Tubes DF-100 DF-125 Vented DF-150 DF-175/200...
  • Page 14: National Standards And Applicable Codes

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.1 Gas Codes 4.3 Public Garages Type of gas appearing on the nameplate must be Installation in garages must be in accordance the type of gas used. Installation must comply...
  • Page 15: Section 5: Major Components

    SECTION 5: M AJOR OMPONENTS SECTION 5: MAJOR COMPONENTS FIGURE 13: Major Component Descriptions - Standard Reflector Standard Reflector Burner with Tube Gasket (Aluminum or Stainless Steel) Must be installed with the Alternate overlap as shown on overview flame observation window and on Page 18, Figure 17.
  • Page 16 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 14: Major Component Descriptions - High Efficiency Reflector High Efficiency Reflector Burner with Tube Gasket (Aluminum only) Must be installed with the Alternate overlap as shown on flame observation window overview and on Page 18, Figure 17.
  • Page 17: Standard Parts List

    SECTION 5: M AJOR OMPONENTS 5.1 Standard Parts List Table 1: Contents of DF-Series Burner Carton Part No. Description DF-80 DF-100 DF-125 DF-150 DF-175 DF-200 073XXXXX Burner (Rate and Fuel Varies) 90709700 Blower Assembly with Cord 02568200 Gasket (Burner to Burner Tube)
  • Page 18 91907302 S-Hook 03050012 Reflector Support Package-EF (Strap, Wire Form, Screws) 91107720 U-Clip Package 90502701 Vent Adapter 01318902 Tube Clamp Package-EF Part Number Table 4: DF-Series Component Package Guide Standard Reflector Core High Efficiency Reflector Tubing Length Packages Core Packages Model...
  • Page 19: Section 6: Heater Installation

    SECTION 6: H EATER NSTALLATION SECTION 6: HEATER INSTALLATION Expansion and contraction of the tube dictates that the minimum suspension lengths must be WARNING maintained. See table on Page 16, Figure 15. Severe Injury Hazard Secure burner to burner tube with nuts and lockwashers.
  • Page 20 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 15: Critical Hanger Placement NOTE: Suspension material provided by others. Run Length Typical Expansion Minimum “X” Length Description Part Number 10' (3 m) - 50' (15.2 m) ±1" (3 cm) 12" (30.5 cm)
  • Page 21 SECTION 6: H EATER NSTALLATION FIGURE 16: Linear Heater Assembly Overview...
  • Page 22 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 17: Linear Heater Layout Overview...
  • Page 23 SECTION 6: H EATER NSTALLATION FIGURE 18: Linear Heater Layout Overview (Continued) Step 6.1 Burner Tube Installation NOTE: Tubing requires a downward slope of 1/2" (13 mm) Offset mounting per 20' (6 m) away hole must be from burner. to the top. S-Hook Hanger Burner Tube...
  • Page 24 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 6.2 Tube Clamp Package Installation Bolt Tube Clamp Flat Washer (Torque 120 in/lb 13.56 Nm) Description Part Number Tube Clamp Package 0131890X...
  • Page 25 NSTALLATION Step 6.3 Coupling and Tube Assembly NOTE: Prior to coupling installation review Swirler Installation on Model DF-175 requires swirler tab to be installed under coupling. Swirler installation for this model must be complete prior to coupling installation. Close coupling and slide Insert wide end of slide bar/coupling lock into opposite end into tab.
  • Page 26 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 6.3.1 Coupling and Tube Assembly (Continued) Tighten slide bar as shown below. See Page 22, Step 6.3.2 • Repeat Step 6.3 A - D until all tubes are assembled. Step 6.3.2 Coupling and Tube Assembly (Continued)
  • Page 27 NSTALLATION Step 6.4 Turbulator Installation Install turbulator as specified in the “Turbulator Installation” chart below. Turbulator Installation Model Tube Section DF-80 2nd 10' (3 m) Section DF-100 3rd 10' (3 m) Section DF-125 3rd 10' N/A Section DF-150 4th 10' N/A Section...
  • Page 28 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 6.5 Swirler Installation Swirler installation required for models Swirler Installation Chart specified in chart. Model Tube Section Swirler Qty DF-175 4th 10' (3 m) Section 2 Starters + 1 Adapter Begin installing swirler at end of tube section...
  • Page 29 SECTION 6: H EATER NSTALLATION FIGURE 19: Swirler Installation Model: DF-175, 40’ Straight Tube; Swirler Package - 15' (4.5 m) (p/n 03051510K) Fold swirler tab over tube as shown Coupling Internal Coupling Pin Pivot Point Swirler Adapter Section Swirler Starter...
  • Page 30 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 21: Swirler Installation Model: DF-175, 40’ Uneven U-Tube; Swirler Package - 15' (4.5 m) (p/n 03051510K) 10’ (3 m) Tube Burner Tube Pivot Point Swirler Vent Adapter Starter Swirler Section Swirler Starter Adapter 10’...
  • Page 31 SECTION 6: H EATER NSTALLATION FIGURE 22: Swirler Installation Model: DF-200, 50’ Straight Tube; Swirler Package - 10' (3 m) (p/n 03051509K) Pivot Point Swirler Adapter Burner Tube Section Swirler Starter Section Coupling Swirler Adapter Section Swirler Starter Section Vent Adapter FIGURE 23: Swirler Installation Model: DF-200, 50’...
  • Page 32 DF-S ERIES 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.
  • Page 33 SECTION 6: H EATER NSTALLATION Step 6.6.1 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.
  • Page 34 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 6.7 Burner Installation Install combustion blower by placing blower gasket between blower and top of burner. Secure blower to top of burner using (4) supplied #10-32 locknuts. Install flue collar if connecting an outside air inlet.
  • Page 35: Section 7: Optional Heater Accessories

    Page 8, Figure 9. When using a U-tube configuration, the following additional rules must be adhered to: • A minimum of 10' (3 m) on DF-80 and a minimum of 15' (4.5 m) on DF-100/125/150/175/200 is required between the burner and the U-tube.
  • Page 36 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 24: U-Tube Heater Assembly Overview Description Part Number U-Tube Package 03011XXX 180° U-Tube 013359XX Tube and Reflector Hanger 030901XX Coupling 01312700 Reflector End Cap 027508XX U-Tube Support Bracket 030205XX 4" (10 cm) U-Bolts...
  • Page 37 SECTION 7: O PTIONAL EATER CCESSORIES FIGURE 25: U-Tube Heater Layout Overview...
  • Page 38: Elbow Package Configuration

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 26: U-Tube Layout Overview (Continued) 7.2 Elbow Package Configuration Step 7.2.1 Elbow Installation Minimum Distance Required Between Burner and Elbow Minimum Model Distance DF-80 10' (3 m) DF-100 15' (4.5 m) DF-125 15' (4.5 m)
  • Page 39 SECTION 7: O PTIONAL EATER CCESSORIES Step 7.2.2 Elbow Installation Step 7.2.3 Reflector Joint Installation Step 7.2.4 Reflector Joint Installation...
  • Page 40 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 7.2.5 Reflector Joint Detail FIGURE 27: Reflector Joint Detail...
  • Page 41: Reflector Side Extension

    SECTION 7: O PTIONAL EATER CCESSORIES 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 Part Number Reflector Side Extension Package 0271270X Reflector Side Extension...
  • Page 42: Lower Clearance Shield Installation

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.4 Lower Clearance Shield Installation Step 7.4.1 Shield Support Strap Assembly Reflector 12" (30 cm) 17" (43 cm) Align Pilot Holes Lower Clearance Shield Locknuts Washers Description Part Number Lower Clearance Shield Package...
  • Page 43 SECTION 7: O PTIONAL EATER CCESSORIES Step 7.5.2 Frame Shield Installation Description Part Number Deco Grille Shield 24" (61 cm) 01365900 Step 7.5.3 Reflector Side Extension Installation for Decorative Grilles Distance "A" Extension Minimum Maximum Part No. Width 2" (4 cm) 6"...
  • Page 44: Protective Grille Installation

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.6 Protective Grille Installation Step 7.6.1 Silicone Cap Installation Silicone Cap Description Part Number Grille Section 08050001 Grille Grille End Cap 08050002 Finger Grille Section - EF Reflector 08050003 NOTE: Protective Grille NOT APPROVED for...
  • Page 45: Section 8: Venting

    SECTION 8: V ENTING SECTION 8: VENTING prevent leakage of condensation, install the vent adapter with the seam on top and seal the joint using WARNING a high temperature silicone sealant. Any portion of vent pipe passing through a combustible wall must have an approved thimble to conform with the above listed codes.
  • Page 46: Unvented Operation

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL The vent shall not terminate within 3' (0.9 m) of a 90502100) or equivalent, insulated vent terminal. window or door that can be opened in any building, Follow the manufacturer's instructions for proper any non-mechanical air supply inlet to any building, installation.
  • Page 47: Unvented Operation Tube Termination

    SECTION 8: V ENTING Note: Vertical venting will be classified as a Category 4. Double wall vent (Type-B). Used ONLY as a lll if the length of the horizontal portion of the vent continuous section passing through the outside wall, pipe is greater than 75% of the vertical portion of the roof or outside of the building.
  • Page 48: Horizontal Venting (Category Iii) 4" (10 Cm) Pipe

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.8 Horizontal Venting (Category III) 4" (10 cm) Pipe Description Part Number Vent Terminal (Comb. Wall) 90502100 Vent Terminal 02537801-XX Vertical Venting (Category III) 4'' (10 cm) Pipe Description Part Number Vent Cap 4" (10 cm)
  • Page 49: Common Side Wall Horizontal Venting (Category Iii)44

    SECTION 8: V ENTING 8.9 Common Side Wall Horizontal Venting (Category III) Note: A continuous section of type B-vent may only be used to pass through the outside wall or outside of the building. Horizontal venting (Category III) does not allow the use of type B-vent inside of the space. Description Part Number Vent Terminal 6"...
  • Page 50: Common Vertical Venting (Category Iii)

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.10 Common Vertical Venting (Category III) Note: A continuous section of type B-vent may only be used to pass through the roof or outside of the building. Vertical venting (Category III) does not allow the use of type B-vent inside of the space.
  • Page 51: Outside Combustion Air Supply

    SECTION 8: V ENTING 8.11 Outside Combustion Air Supply 8.11.1 Length Requirements IMPORTANT: If the building has a slight negative Follow the constraints listed on Page 43, Section 8.6. pressure or corrosive contaminants, such as halogenated hydrocarbons, are present in the air, an outside combustion air supply to the heater is required.
  • Page 52 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 8.11.3 Horizontal Outside Air Supply for Single Heater Installation 4" (10 cm) Single Wall Pipe Vent Cap Flex Hose (Recommended) Burner Band Clamp (Recommended) Description Part Number Vent Cap 4" (10 cm) 90502300 8.11.4 Vertical Outside Air Supply for Double Heater Installation...
  • Page 53 SECTION 8: V ENTING 8.11.5 Horizontal Outside Air Supply for Double Heater Installation Description Part Number Vent Cap 6" (15 cm) 90502302 Requirements: • Heaters must be controlled by a common thermostat.
  • Page 54: Section 9: Gas Piping

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 9: GAS PIPING Install the gas hose as shown on Page 51, Figure 29. WARNING The 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.
  • Page 55 SECTION 9: G IPING FIGURE 29: Gas Connection with Flexible Gas Hose See Page 66, Section 14 Description Part Number High gas pressure regulator ½” – 2 PSI 90207600 High gas pressure regulator ¾” – 5 PSI 90207602 Description Part Number 1/2"...
  • Page 56: Section 10: Wiring

    PERATION AND ERVICE ANUAL SECTION 10: WIRING Note # 6: The DF-Series heater is a dual firing heating unit and must be connected to a low voltage, DANGER two-stage thermostat for correct operation. A thermostat connector is provided on the exterior of the burner box.
  • Page 57: Multiple Burners For Connection To One Thermostat52

    SECTION 10: W IRING 10.2 Multiple Burners For Connection To One Thermostat POWER SUPPLY ALL BURNERS MUST BE CONNECTED TO GROUND (NOT SHOWN) 120VAC 60 Hz BURNER 1 BURNER 2 BURNER 1 BURNER 2 R RC W W2 R W W2 R C W W2 R W W2 R C W2 W...
  • Page 58: Internal Wiring

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 10.3 Internal Wiring...
  • Page 59: Ladder Diagram

    SECTION 10: W IRING 10.4 Ladder Diagram 10.5 Electrical Connection to the Burner...
  • Page 60: Section 11: Operation And Maintenance

    11.1 Sequence of Operation the spark igniter. The DF-Series heater is a dual firing heating unit that 4. When the flame is established, the sparking must be connected to a two-stage thermostat (P/N - sequence ceases.
  • Page 61: To Shut Off Heater

    SECTION 11: O PERATION AND AINTENANCE 11.4 To Shut Off Heater For best performance, the gas, electrical, thermostat connections, tubing, venting, suspensions and Set thermostat to lowest setting. overall heater condition should be thoroughly Turn OFF electric power to heater. inspected.
  • Page 62 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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.
  • Page 63: Section 12: Troubleshooting

    SECTION 12: T ROUBLESHOOTING SECTION 12: TROUBLESHOOTING DANGER Electrical Shock Hazard Disconnect electric before service. Heater must be properly earthed. 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 64: Troubleshooting Flow Chart

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 12.1 Troubleshooting Flow Chart...
  • Page 65 SECTION 12: T ROUBLESHOOTING...
  • Page 66: Manifold Gas Pressure Setting

    DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 12.2 Manifold Gas Pressure Setting...
  • Page 67: Section 13: Replacement Parts

    SECTION 13: R EPLACEMENT ARTS SECTION 13: 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. See warnings and important information before removing or replacing parts.
  • Page 68 DF-S ERIES NSTALLATION PERATION AND ERVICE ANUAL...
  • Page 69 SECTION 13: R EPLACEMENT ARTS Description Part Number Mica Window Assembly 02553203 Electrode Gasket 02558501 Tube Gasket 02568200 Burner Cup Assembly 03020100 Gas Valve (Natural) 90034900 Electrode 90427400 DSI Ignition Module 90439500K Transformer 90436900K Pressure Switch (200) 90439801K (175) 90439802K (125, 150) 90439803K (80, 100)
  • Page 70: Section 14: General Specifications

    14.2 Heater Specifications Time switches, thermostats, etc. can be wired into 14.2.1 Ignition the electrical supply. External controls supplied as an optional extra. General Specifications for DF-Series heaters are as follows: End View Side View Reflector 12.5" Turbulator (select models)
  • Page 71: Section 15: The Roberts Gordon Gordonray Df Warranty

    GORDONRAY ® ® war, fire, flood, strike, government or court orders, acts of DF in the vicinity of a combustible or explosive God, terrorism, unavailability of supplies, parts or power. No person is authorized to assume for Roberts-Gordon material. LLC any other warranty, obligation or liability.
  • Page 73 2020...

This manual is also suitable for:

Df-80Df-100Df-125Df-150Df-175Df-200

Table of Contents