Dir 2009/142/EC: GAD
Dir 2004/108/EC: EMC
Dir 2006/95/EC: LVD
Dir 2006/42/EC: MD (annex II, sub B)
WARNING
Please read this document carefully before commencing installation commissioning and/or
servicing. Leave it with the user or attached to the appliance or gas service meter after installation
Improper installation, adjustment, alteration, service, or maintenance can cause property damage, injury, or
death. All work must be carried out by appropriately qualified persons.
The manufacturer does not take any responsibility in the event of non-observance of the regulations
concerning the connection of the apparatus causing a harmful operation possibly resulting in damage to the
apparatus and/or environment in which the unit is installed.
Reznor Europe N.V. – J&M Sabbestraat 130 – B 8930 Menen
Tel : +32 56/52 95 11 - Fax : +32 56/52 95 33
Subject to modifications
P 1/24-1307RHC4DJL/RJL—EN,
TABLE OF CONTENTS
1.0 INTRODUCTION
1.1 Basic Information
1.2 Warranty
2.0 TECHNICAL DATA
3.0 GENERAL REQUIREMENTS
3.1 General
3.2 Specific heater location
3.3 Minimum airflow duty
3.4 Compartment dimensions
3.5 Maximum airflow conditi ons
3.6 Combustion air supply & flue system (applies
only to DJL models)
3.7 Air Supply (applies only to DJL models)
3.8 Electrical supply
3.9 Gas supply
4.0 INSTALLATION
4.1 Uncrating and preparation
4.2 Fitting the combustion air inlet/flue system
(applies only to DJL)
4.3 Electrical Connection
4.4 Room Thermostat Siting
5.0 COMMISSIONING AND TESTING
5.1 Electrical Check
5.2 Gas Connection
5.3 Lighting the Heater
5.3.1 To Turn the Heater ON
5.3.2 To Turn the Heater OFF for Short Periods
5.3.3 To Turn the Heater OFF for Long Periods
5.4 Heater Pipework
5.5 Adjustments
5.6 Options
5.6.1 2 stage burner control
5.6.2 Modureg V7335A 2000 series modulation
system
5.7 Air heater controls & operation
5.8 Handing Over
6.0 SERVICING INSTRUCTIONS
7.0 REMOVAL AND REPLACEMENT OF PARTS
7.1 Main Burner Removal
7.2 Main Burner Injectors
7.3 Ignition System
7.4 Gas control valve
7.5 Limit Controls
7.6 Combustion Air Control Switch
7.7 Combustion Air Fan
8.0 FAULT FINDING
9.0 PARTS LIST
10.0.GAS CONVERSION
11.0 USERS INSTRUCTIONS
12.0 HEALTH & SAFETY STATEMENT
HAZARD INTENSITY LEVELS
1. DANGER: Failure to comply will result in severe
personal injury or death and/or property damage.
2. WA RNING
personal injury or death and/or property damage.
3. CAUTION
personal injury and/or property damage.
: Failure to comply could resul t in severe
: Failure to comply could result in minor
WARNING:
The electrical isolator should only be used in an
emergency and should not be used for closing
down the main burner, as it switches off the fan
prematurely and may damage the heat exchanger,
invalidating the warranty.
This appliance is not intended for use by persons
(including children) with reduced 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 not play with the appliance
1.0 INTRODUCTION
1.1 BASIC INFORMATION
The instructions in this manual apply to the following gasfired/fan-assisted warm air heaters:
RHC 4000(M) DJL
only (when installed where the height above floor level is
greater than 1,8 meters measured to the underside of the
appliance they may be used as a garage air heater).
Model RHC 4000(M) DJL heaters are approved for:
Type C12 - horizontal vent for balanced-flue heaters;
Type C
Type B
(through the wall)
RHC 4000(M) RJL
handlers built for outdoor
Model RHC 4000 RJL heaters are approved for outdoor or
rooftop application.
Category : see table 2A.
All models & sizes are available for use with either natural,
propane or butane gas with operating temperatures between
-15°C and 40°C.
These instructions are only valid for the country of use as
indicated on the appliance. If these symbols are not shown,
it is necessary to obtain appropriate technical instructions.
Such instructions may be obtained upon request from your
supplier.
Check that the local distribution conditions of electricity
supply, type of gas and pressure of the appliance are
compatible with the data plate.
- vertical vent for balanced-flue heaters;
32
– vertical vent (through the roof) or horizontal vent
22
model suitable for indoor air handlers
model suitable for incorporation in air
installation only.
P 2/24-1307RHC4DJL/RJL—EN,
The installation
must comply with the requirements and
recommendations of all relevant national and local
standardisations.. The installation must also be in
accordance with the relevant el ectrical and IEE regul ations.
When the external control calls for heat, an electronic control
begins the ignition sequence to provide for a safe start.
Under normal conditions the fan motor runs constantly and
after a call for heat it switches the heater on thr ough a room
or duct stat. However, in some applications, about 30
seconds after the call for heat, the fan control relay will
activate the fan motor of the air ha ndler.
The electronic control will supervise the flame during the
entire heating cycle to ensure safe operation.
When the required room temperature is reached, the main
burner will shut down leaving the fan running to cool down
the heat exchanger
In some applications, after approximately 45 seconds, the
fan delay relay will turn off the fan (if wired).
2.0 TECHNICAL DATA
2.1SPECIFICATIONS
Table 1 – Specifications
1.2WARRANTY
Warranty is void if:
a) Model RHC 4000(M) DJL/RJL heaters are installed in
atmospheres containing flammable vapors or
atmospheres containing chlorinated or halogenated
hydrocarbons or atmospheres containing any silicone,
aluminum oxide, etc., that adheres to spark ignition
flame sensing probes.
b) The installation is not in accordance with these
instructions.
c) The maximum airflow through the heat exchanger tubes
is not respected (see section 3.5).
d) The required minimum air delivery is not respected (see
table 3a).
e) The duct dimensions do not comply with the prescribed
dimensions (see table 3b).
f) The inlet tem perature (meas ured at the heat exc hanger
inlet) is lower than the value st at ed o n t he ch a rt (s ee f ig.
5 : dew point occurrence chart).
It is important that all gas appliances are installed in
accordance with the rules in force and by appropriately
qualified persons. Failure to install appliances correctly could
lead to prosecution. It is in your own interest and that of
safety to ensure co mpli an ce wi th the law.
Caution : Air heaters should not be installed in corrosive
atmospheres, i.e. near plating spray or de-greasing
plants or in areas where there is a fire risk.
Care should be exercised when designing ducting systems
especially with regard to the application of restriction and
direction turning fittings, i.e. elbows directly on to the air
heater, doing so can cause a n uneven and turbul ent air flo w
across the heat exchanger resulting in heat exchanger spots
and nuisance shut down of the gas burner due to localized
overheating, thus activating thermal over-heat controls.
The location must als o provide sufficient spa ce to allow the
Do not locate the air heater where it may be e xposed to
water spry, rain, etc.
The location chosen for the air heater must permit the
provision of a satisfactory flue system venting to outdoor
atmosphere and adequately ventilated to provide for
combustion air.
Top 150
Flue connector 150
Access panel 600
Non-access side 150
Bottom 50
RJL installation :
A minimum distance of 1500mm must be maintained on the
control side of the appliance.
When installed at ground level a fence to guard against
damage and to protect the public fro m possi ble injur y shoul d
protect the entire installation.
Ensure that the air heater is installed in a level plain and that
the surface onto which it is installed is vibration free.
MINIMUM AIRFLOW REQUIREMENT
3.3
The minimum airflow duty through the heating section
enclosure (see figure 4) must be observed as indicated in
table 3a.
Special attention must be given to ensure Figure 5 : Dew point occurrence chart (condensation zone)
that the temperature rise of the a ir, passing
through the enclosure (duct channel) around
the heat exchanger tubes, is high enough to
20°C
T
avoid condensation forming within the tubes.
This condensation forming could occur by
super cooling of the products of combustion.
Such condensation can be the source of
severe corrosion and damage to tubes or
part of the tubes.
Figure 5 indicates the probability of
condensation forming within the tubes
reference :
- the temperature rise of the air through the
20░C
0°C
E
R
R
E
U
G
T
N
A
A
R
H
C
X
E
T
A
E
H
E
H
T
T
A
0░C
-20°C
-20░C
40K20K0K
30K
E
P
M
E
T
R
I
A
T
E
L
N
I
enclosure (around the tubes)
- the inlet air temperature passing over the
heat exchanger
TEMPERATURE RISE OVER THE HEAT EXCHANGER
In function of the expected minimum inlet air
temperature, the minimum required temperature rise (to
avoid condensation) must be derived from the chart
below (figure 5).
Example
expected minimum inlet temperature = -5°C
minimum required temper ature rise sho wn on the chart
= +13°K
Table 1 indicates the heat output (kW) of the different
models.
The maximum allowable airflow through the enclosure
(duct channel) around the tubes can be calculated as
follows :
V
max
(m³/h)
T
Δ
minimum
0.3423
1000(kW)outputheat
Example :
△T
= 13K (with min. inlet temp. = -5°C)
min
model 4075 09 at 100% heat output : 75.00kW results into
V
= 16850m³/h
max
Remark
:
For air heaters with the option 2 stage gas valve (50%
minimum heat input) or the option modulating gas valve
(30% minimum heat input) attention must be given to
determine the maximum allowable airflow in function of the
appropriate heat input.
Example :
△T
= 13K (with min. inlet temp. = -5°C)
min
model 4075 09 at 50% modulation (see table 1 ‘output’) :
36W
results into :
V
max
3.6COMBUSTION AIR SUPPLY & FLUE SYSTEM
ATTENTION : this section only applies to DJL
models !
The air heater may be installed as a ba lanced flue (Type C)
heater, requiring both a combustion air inlet duct and a
combustion flue outlet duct (use a s eamless alumi nium pipe )
or as a power vented (Type B) heater
flue pipe exhausting to outdoors and takes combustion air
directly from the space to be heated.
The center distance between th e combustion air inlet soc ket
and the flue outlet socket is 225mm for all models.
Each appliance requires it’s own individual flue system.
When several appliances are installed, o ne common flue and
combustion air system, thus combining several heaters, is
not allowed.
, which requires only a
IMPORTANT:
The flue must be installed in accordance with national
and local regulations. Failure to provide proper fluing
could result in death, serious injury and/or property
damage.
The air heater must be installed with a flue to the outside
of the building. Safe operation of any power vented gas
apparatus requires a properly operating flue system,
correct provision for combustion air, and regular
maintenance and inspection.
Use of flue restriction rings (Only for 4000M units !!)
To ensure the efficiency of the units, eventually a flue
restriction ring needs to be fitted in the outlet collar of the
venter housing. The diameter of the restriction ring will be
determined by the flue pipe length and the type of appliance
(combustion air from environment (appliance B) or
combustion air from outside (appliance C)).
CONDENSATION ZONE
10K
1000(kW)36
0.342313
T
h/³m8090
P 7/24-1307RHC4DJL/RJL—EN,
Table 5 : Diameter flue restrictors for DJL
Combustion out and inlet application4110M.13 4125M,15 4150M.18 4175M.21 4200M.24
2X1m pipe length till 2X3m pipe length99mm95mm93mm95mm102mm
C Appliance
B appliance
2X4m pipe length till 2X6m pipe length107mm107mm99mm107mm114mm
2X7m pipe length till 2X9m pipe lengthopenopenopenopenopen
1X1m pipe length till 1X3m pipe length90mm86mm90mm90mm92mm
1X4m pipe length till 1X6m pipe length93mm90mm93mm95mm97mm
1X7m pipe length till 1X9m pipe length96mm93mm95mm99mm102mm
3.6.1 Flues for power vented instal lations
(Type B appliances)
If the air heater is to be in stalled as a type B a ppliance, air
for combustion will be taken from within the space where
the heater is installed. Ensure that an adequate air supply
for combustion and ventilation is provided within the building
in accordance with the regulations & rules in force.
The combustion air inlet socket at the appliance must be
foreseen with an inlet grill of class IP20 (dia 130 = PN 06
22786 134 (for all types))
Table 5 below shows flue pipe sizes and maximum vent
lengths. The minimum flue length is 0.5 meters.
Model RHC 4000(M) DJL
Heater socket & pipe dia mm130
Center distance B mm225
Maximum straight length mm9
Equivalent length of 90° elbow mm1.5
To avoid leakage use single wall flue pipes of seamless
aluminium. All joints must be seal ed to prevent products of
combustion from leaki ng into th e building. A n approv ed flue
terminal (installed through the roof or the wall) i s requ ired .
If the flue passes through a combustible element of the
building it must be enclosed by a sleeve of non-combustible
material and separated from the sleeve by at least a 25 mm
air break.
The temperature of any combustible material near to the
flue must not exceed 65 °C when the heater is in operation .
The flue must be at least 50 mm away from any
combustible material.
Single wall flue pipe exposed to cold air or run through
unheated areas must be insulated. Where condensation is
unavoidable, provision must be made for the condensation
to flow freely to a point to which it can be released, i.e. a
drain or gully.
The condensation drain from the flue must be constructed
from non-corrodible material not less than 20 mm diameter.
Copper or copper-based alloys must not be used for
condensation drains.
3.6.2 Combustion air inlet pipe & flue pipe for
balanced flue installation (Type C appliances)
Balanced flue air heaters are designed to be fitted with a
combustion air inlet duct that obtains outdoor air and a flue
pipe that exhausts flue products to outdoors.
The heaters must be installed with an appropriate
concentric vertical or horizontal vent terminal. The
heaters are only approved for u se when installed with
the appropriate approved co ncentric vent terminal (see
table 6.)
Both the flue and combustion air pipes must be sealed. Use
seamless aluminum pipe.
The flue pipe may include a re-sealable test port to allow
good average sampling of the fl ue gas mixture for testing,
the port must be at least 450 mm away from the air heater
flue connection socket.
Follow any flue pipe manufacturers installation instructions
for making joints, includin g conn ections t o th e air heat er, fo r
passing through a building element and for support
requirements. If more than one air heater is being installed
in the same place each heat er must have a separate flue
system.
Table 6 Combustion air inlet & flue pipe requirements
Model RHC 4000(M) DJL
Heater socket & pipe dia mm
Max. straight length m
Equivalent length of 45 ° elbow m
Equivalent length of 90 ° elbow m
Concentric vertical/horizontal vent or wall terminal: types :
Mugro or Burfix dia130
Flue pipe130
Inlet pipe130
Flue pipe9
Inlet pipe9
Flue pipe0.75
Inlet pipe0.50
Flue pipe1.5
inlet pipe1.5
P 8/24-1307RHC4DJL/RJL--EN
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