Roberts Gorden DF Manuel

WARNING

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.

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

Installation must be done by a contractor qualified

in the installation and service of gas-fired heating

equipment or your gas supplier.

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.

Installer

Please take the time to read and understand

these instructions prior to any installation.

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

Owner

Keep this manual in a safe place in order to provide

your service technician with necessary information.

Roberts-Gordon LLC

1250 William Street

Buffalo, New York 14240-0044

www.robertsgordon.com

Model DF

Gas-Fired, Low Intensity

Two Stage Unitary Heater

Installation, Operation &

Service Manual

DF-80

DF-100

DF-125

DF-150

DF-175

DF-200

Roberts-Gordon LLC

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.

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.................................................... 4

2.3 National Standards and Applicable Codes...................4

SECTION 3: Clearances to Combustibles............................. 5

3.1 Required Clearances to Combustibles......................... 5

SECTION 4: National Standards and Applicable Codes.... 10

4.1 Gas Codes................................................................. 10

4.2 Aircraft Hangars ......................................................... 10

4.3 Public Garages .......................................................... 10

4.4 Electrical .................................................................... 10

4.5 Venting ....................................................................... 10

4.6 High Altitude .............................................................. 10

SECTION 5: Major Components .......................................... 11

5.1 Standard Parts List .................................................... 13

SECTION 6: Heater Installation............................................ 15

SECTION 7: Optional Heater Accessories .......................... 30

7.1 U-Tube Configuration..................................................30

7.2 Elbow Package Configuration.....................................33

7.3 Reflector Side Extension ............................................36

7.4 Lower Clearance Shield Installation ........................... 37

7.5 Two-Foot Decorative Grille Installation ....................... 37

7.6 Protective Grille Installation ........................................ 39

SECTION 8: Venting .............................................................. 40

8.1 Venting ....................................................................... 40

8.2 Unvented Operation................................................... 41

8.3 Horizontal Venting (Category III)................................ 41

8.4 Vertical Venting (Category III) .................................... 41

8.5 Unvented Operation Tube Termination.......................42

8.6 Length Requirements ................................................ 42

8.7 Vent Material Recommendations ............................... 42

8.8 Horizontal Venting (Category III) 4" (10 cm) Pipe ...... 43

8.9 Vertical Venting (Category III) 4'' (10 cm) Pipe........... 43

8.10 Common Side Wall Horizontal Venting (Category III)44

8.11 Common Vertical Venting (Category III) ................... 45

8.12 Outside Combustion Air Supply ............................... 46

SECTION 9: Gas Piping ........................................................ 49

SECTION 10: Wiring .............................................................. 51

10.1 Dual Stage Low Voltage Thermostat Wiring.............51

10.2 Multiple Burners For Connection To One Thermostat52

10.3 Internal Wiring..........................................................53

10.4 Ladder Diagram....................................................... 54

10.5 Electrical Connection to the Burner ......................... 54

SECTION 11: Operation and Maintenance.......................... 55

11.1 Sequence of Operation ............................................ 55

11.2 High/Low Firing Operation........................................ 55

11.3 Sequence of Operation ............................................ 55

11.4 To Shut Off Heater .................................................... 56

11.5 To Start Heater ......................................................... 56

11.6 Pre-Season Maintenance and Annual Inspection..... 56

11.7 Maintenance Checklist ............................................. 56

SECTION 12: Troubleshooting ............................................. 58

12.1 Troubleshooting Flow Chart ..................................... 59

12.2 Manifold Gas Pressure Setting ................................ 61

SECTION 13: Replacement Parts ........................................ 62

SECTION 14: General Specifications .................................. 65

14.1 Material Specifications............................................. 65

14.2 Heater Specifications............................................... 65

14.3 Suspension Specifications....................................... 65

14.4 Controls Specifications ............................................ 65

SECTION 15: The ROBERTS GORDON® GORDONRAY® DF

Warranty ................................................................................ 68

Printed in U.S.A.

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.

Read this manual carefully before installation,

operation or service of this equipment.

This heater is designed for heating nonresidential

indoor spaces. Do not install in residential spaces.

This heater is not certified to meet the requirements

of NFPA30A-2012 Section 7.6.6. (maximum tube

temperature of 750 °F (399 °C)). Do not install this

heater in facilities where compressed natural gas

(CNG) or liquid natural gas (LNG) are present. These

instructions, the layout drawing, local codes and

ordinances, and applicable standards that apply to

gas piping, electrical wiring, venting, etc. must be

thoroughly understood before proceeding with the

installation.

Protective gear is to be worn during installation,

operation and service in accordance to the

Occupational Safety and Hazard Administration

(OSHA). Gear must be in accordance to NFPA 70E,

latest revision when working with electrical

components. Thin sheet metal parts have sharp

edges. To prevent injury, the use of work gloves is

recommended. The use of gloves will also prevent

the transfer of body oils from the hands to the surface

of the reflector.

Before installation, check that local distribution

conditions, nature of gas and pressure, and

adjustment of the appliance are compatible.

This heater must be applied and operated under the

general concepts of reasonable use and installed

using best building practices.

This appliance is not intended for use by persons

(including children) with reduced physical, sensory or

mental capabilities, or lack of experience and

knowledge, unless they have been given supervision

or instruction concerning use of the appliance by a

person responsible for their safety. Children should

be supervised to ensure that they do no play with the

appliance.

For additional copies of the Installation, Operation

and Service Manual, please contact Roberts-Gordon

LLC.

1.1 Manpower Requirements

To prevent personal injury and damage to the heater,

two persons will be required for installation.

1.2 Safety Labels and Their Placement

Product safety signs or labels should be replaced by

the product user when they are no longer legible.

Please contact Roberts-Gordon LLC or your

ROBERTS GORDON® independent distributor to

obtain replacement signs or labels. See Page 2,

Figure 1 through Page 3, Figure 2.

1.3 California Proposition 65

In accordance with California Proposition 65

requirements, a warning label must be placed in a

highly visible location on the outside of the

equipment (i.e., near equipment’s serial plate). See

label placement drawing on Page 3, Figure 2 for label

location. Avoid placing label on areas with extreme

heat, cold, corrosive chemicals or other elements. To

order additional labels, please contact Roberts-

Gordon LLC or your ROBERTS GORDON®

independent distributor.

DF-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

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

SECTION 1: HEATER SAFETY

FIGURE 2: Side and Back Panel Label Placement

96244

1231 10 26 85 216 79201

1846 102259

102259

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

DF-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.

• To use the information given in a layout drawing

and in the manual together with the cited codes

and regulations to perform the installation.

• To install the heater in accordance with the

clearances to combustibles.

• To furnish all needed materials not furnished as

standard equipment.

• To plan location of supports.

• To provide access on all sides for burner servicing

and removal.

• To provide the owner with a copy of this

Installation, Operation and Service Manual.

• To never use heater as a support for a ladder or

other access equipment and never hang or

suspend anything from heater.

• To ensure there is adequate air circulation around

the heater and to supply air for combustion,

ventilation and distribution in accordance with

local codes.

• To safely and adequately install heater using

materials with a minimal working load of 75 lbs

(33 kg).

• To ensure the heater is placed in an approved

application.

2.1 Wall Tag

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 LLC

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. For an immediate solution, you may

affix this copy 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. and Page 6, Figure 3 through Page

8, Figure 11. Write the proper clearance dimensions in

permanent ink according to your model number and

configuration in the open spaces on the tag.

2.2 Corrosive Chemicals

Roberts-Gordon LLC 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 halogenated hydrocarbons* anywhere

in the premises.

* Halogenated Hydrocarbons are a family of

chemical compounds characterized by the

presence of halogen elements (fluorine, chlorine,

bromine, etc.). These compounds are frequently

used in refrigerants, cleaning agents, solvents, etc.

If these compounds enter the air supply of the

burner, the life span of the heater components will

be greatly reduced. An outside air supply must be

provided to the burners whenever the presence of

these compounds is suspected. Warranty will be

invalid if the heater is exposed to halogenated

hydrocarbons.

2.3 National Standards and Applicable Codes

All appliances must be installed in accordance with

the latest revision of the applicable standards and

national codes. This refers also to the electric, gas

and venting installation. Note: Additional standards

for installations in public garages, aircraft hangars,

etc. may be applicable.

CAUTION

Product Damage Hazard

Do not use heater in area containing

corrosive chemicals.

Refer to appropriate Material Safety Data

Sheets (MSDS).

Failure to follow these instructions can result

in product damage.

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.

Clearances for all heater models are located on the

burner of the heater and on Page 6, Figure 3 through

Page 8, Figure 11 in this manual. Check the

clearances on each burner for the model heater

being installed to make sure the product is suitable

for your application and the clearances are

maintained. Read and follow the safety guidelines

below:

• Keep gasoline or other combustible materials

including flammable objects, liquids, dust or

vapors away from this heater or any other

appliance.

• The stated clearances to combustibles represents

a surface temperature of 90 °F (32 °C) above

room temperature. Building materials with a low

heat tolerance (such as plastics, vinyl siding,

canvas, tri-ply, etc) may be subject to degradation

at lower temperatures. It is the installer’s

responsibility to assure that adjacent materials

are protected from degradation.

• Maintain clearances from heat sensitive

equipment and workstations.

• Maintain clearances from vehicles parked below

the heater.

• Maintain clearances from swinging and overhead

doors, overhead cranes, vehicle lifts, partitions,

storage racks, hoists, building construction, etc.

• In locations used for the storage of combustible

materials, signs must be posted to specify the

maximum permissible stacking height to maintain

required clearances from the heater to the

combustibles. Signs must be posted adjacent to

the heater thermostat. In the absence of a

thermostat, signs must be posted in a

conspicuous location.

• Consult local Fire Marshal, Fire Insurance Carrier

or other authorities for approval of proposed

installation when there is a possibility of exposure

to combustible airborne materials or vapors.

• Hang heater in accordance to the minimum

suspension requirements on Page 16, Figure 15.

• 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.

WARNING

Fire Hazard

Keep all flammable objects, liquids and

vapors the minimum required clearances to

combustibles away from heater.

Some objects will catch fire or explode when

placed close to heater.

Failure to follow these instructions can result

in death, injury or property damage.

DF-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.

FIGURE 3: Level Reflector

Model (inches) (centimeters)

ABCDABCD

DF-80 6 38 65 38 16 97 166 97

DF-100 6 40 70 40 16 102 178 102

DF-125 6 46 76 46 16 117 194 117

DF-150 6 50 79 50 16 127 201 127

DF-175 8 52 82 52 21 133 209 133

DF-200 8 52 96 52 21 133 244 133

FIGURE 4: One Side Reflector

(inches) (centimeters)

Model A B C D A B C D

DF-80 6 9 69 54 16 23 176 138

DF-100 6 9 76 59 16 23 194 150

DF-125 6 9 82 65 16 23 209 166

DF-150 6 9 85 69 16 23 216 176

DF-175 8 9 88 73 21 23 224 186

DF-200 8 18 102 73 21 46 260 186

FIGURE 5: Two Side Reflectors

(inches) (centimeters)

Model A B C D A B C D

DF-80 6 25 71 25 16 64 181 64

DF-100 6 27 77 27 16 69 196 69

DF-125 6 32 83 32 16 82 211 82

DF-150 6 35 87 35 16 89 221 89

DF-175 8 40 91 40 21 102 232 102

DF-200 8 40 102 40 21 102 260 102

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