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INSTALLATION/ COMMISSIONING/SERVICING
EU)2016/426(GAR),2009/125/EC(ErP), 2014/35/EU(LVD),and2014/30/EU(EMC)
Regulations and Directives.
The following harmonised standards have been applied:
EN 1020, EN 60335-1, EN 60335-2-102, EN 55014-1, and EN 55014-2
Improper installation, adjustment, alteration, service or maintenance can cause property damage, injury or death.
The manufacturer does not take any responsibility in the event of non-observance of the regulations concerning the connection of the apparatus causing a dan-
gerous operation possibly resulting in damage to the apparatus and/or environment in which the unit is installed.
Manual Part No. D301155 Issue C
®
GAS-FIRED POWER VENTED UNIT HEATER
RHC DJL 4000
Please read this document carefully before commencing installation, commissioning and/or servicing.
Leave it with the end user/site agent to be placed in their premises technical file after installation.
All work must be carried out by appropriately qualified persons.
WARNING
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Summary of Contents for Reznor RHC DJL 4000 Series
- Page 1 ® GAS-FIRED POWER VENTED UNIT HEATER RHC DJL 4000 INSTALLATION/ COMMISSIONING/SERVICING EU)2016/426(GAR),2009/125/EC(ErP), 2014/35/EU(LVD),and2014/30/EU(EMC) Regulations and Directives. The following harmonised standards have been applied: EN 1020, EN 60335-1, EN 60335-2-102, EN 55014-1, and EN 55014-2 Please read this document carefully before commencing installation, commissioning and/or servicing. Leave it with the end user/site agent to be placed in their premises technical file after installation.
- Page 2 EC Declaration of Incorporation (Directive 2006/42/EC (annex ll, Sub B) PROHIBITION TO PUT INTO SERVICE Nortek Global HVAC (UK) Ltd., Fens Pool Avenue, Brierley Hill, West Midlands, DY5 1QA, United Kingdom Herewith declares that: Power-vented gas-fired air heaters, type: - RHC 4000 DJL series Are destined to be incorporated in other machines (air-handlers) or to be combined with other machines (air-handling systems), and are for this reason not entirely in compliance with the machinery directive 2006/42/EC.
- Page 3 IMPORTANT NOTICE TO INSTALLERS Installers should satisfy themselves maintenance instructions thoroughly reduced sensory or mental capabilities that the gas pipework installation is before installing or servicing this or lack of experience and knowledge, carried out in accordance with all equipment. unless they have been given supervision current legislation, Codes of Practice and or instruction concerning use of the...
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Page 4: Table Of Contents
CONTENTS PAGE Introduction Servicing Instructions 1.1 Basic Information 1.2 Warranty 6.1 Service procedure Technical Data Removal & Replacement Of Parts 2.1 Specifications 7.1 Main burner removal 2.2 Definitions 7.1.1 Instructions for burner removal (see Figure 17): 7.1.2 Instructions for re-assembly: General Requirements 7.2 Burner injectors 3.1 General... -
Page 5: Introduction
Contained within the text of the manual, 1.2 Warranty the words ‘ ’ and ‘ ’ are used to Caution Warning The total installation should be installed Warranty is void if: highlight certain points. in accordance with the rules in force, relevant National Standards, local Caution is used when failure to follow or regulations, and Codes of Practice. -
Page 6: Technical Data
Technical Data 2.1 Specifications Models 4024-05 4030-06 4036-08 4050 06 4060-07 4075-09 4100-12 4125M15 4150M18 kW High 29.3 36.6 44.0 62.0 74.6 91.5 120.0 153.5 182.9 kW Low 14.7 18.3 22.0 31.0 37.3 45.8 60.0 76.8 91.5 Heat input Gross kW High 29.3 36.6... -
Page 7: Definitions
2.2 Definitions Jacket-less: Appliance B22 / B52 Appliance A gas-fired air heater supplied as a skeleton An appliance where the air for combustion An appliance where the air for combustion appliance e.g. without case or cover. is taken from within the area where the gas is taken from within the area where the gas burner is operated. - Page 8 RHC models RHC models Unit Packaging Total 4024-05 4024-05 4030-06 4030-06 4036-08 4036-08 4050-06 4050-06 4060-07 4060-07 4075-09 4075-09 4100-12 4100-12 4125M15 1272 1082 4125M15 4150M18 1481 1291 4150M18 Table 2.2. - Mounting flange & dimensions Table 3 – Weights (Kg) Figure 5.
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Page 9: General Requirements
AIR STREAM AIR STREAM Figure 10. Compartment dimensions 4024–4036 Figure 11. Compartment dimensions 4050–4150 Models D minimum D maximum 4024-05 1100 4030-06 1100 4036-08 1000 1100 4050-06 1049 4060-07 1049 4075-09 1049 4100-12 1049 4125M15 1272 1202 1049 4150M18 1481 1411 1049 Table 4 –... -
Page 10: Combustion Air Supply & Flue System
CONDENSATION POINT CONDENSATION POINT EURO-C 4000 R(JL) EURO-C 4000 R(JL) EURO-C 4000 D(JL) EURO-C 4000 D(JL) 20 ° C 20 ° C 0 ° C 0 ° C CONDENSATION ZONE CONDENSATION ZONE -20 ° C -20 ° C TEMPERATURE RISE OVER THE HEAT EXCHANGER TEMPERATURE RISE OVER THE HEAT EXCHANGER Table 6 –... -
Page 11: Flues For Power Vented Installations
Single wall flue pipe exposed to cold contact separation of at least 3.0mm on 3.5.1 Flues for power vented installations air or run through unheated areas must all poles should be installed adjacent to (Type B appliances) be insulated. Where condensation the appliance and within reach of any Air for combustion will be taken from is unavoidable, provision must be... -
Page 12: Installation
A 90° action, positive stopped gas service tap must be fitted adjacent to the appliance, fitted in a manner to facilitate appliance burner removal for service purposes, see Figure 13. Ensure that the gas service includes a filter and has been tested and purged in accordance with prescribed practice prior to commissioning and taking the appliance into service. -
Page 13: Commissioning & Testing
Commissioning & Testing Appropriately qualified persons may only RHC 4000 DJL air heaters are all fitted with installation, connections may have carry out the commissioning and testing. automatic spark ignition systems. When been loosened. Check the soundness adequate airflow for combustion is proven of the appliance pipe work using a This section should be read and fully by an air proving control and a pre-purge... -
Page 14: Modureg V7335A 2000 Series Modulation System
Burner gas pressure • Ascertain from section 2 and the • Observe the burner gas pressure on the appliance data plate the correct operating manometer and compare to the required The gas pressure is set for the required gas pressure for the air heater; pressure (table 10);... -
Page 15: Air Heater Controls And Operation
Fault finding “MODUREG” 5.6 Air heater controls and operation Normal Set point operation setting procedure: Equilibrium 'off' Model Check air heater operation after all warm (Pascal) (Pascal) adjustments have been carried out. Set 1. Minimum or Low Fire unobtainable : the temperature control above ambient 4024 05 •... -
Page 16: Removal & Replacement Of Parts
• Remove any soot deposits from the 3. The heat exchanger should remain clean Note: Venter fan motors are lubricated burner with a wire brush. Clean the unless a problem has developed due for life and do not require greasing. ports with a degreaser or acetone. - Page 17 1. Flame sensor 2. LC1 limit control (without reset) 3. Electrical wiring panel 4. Reset lockout signal lamp 5. Differential pressure switch 6. Burner control relay or ignition controller 7. Flue gas extractor for combustion products 8. Electrical connectors 9. Time delay relay 10.
- Page 18 Figure 21. View of the control compartment RHC 4000(M) DJL Figure 22. 1. Flame sensor 2. LC1 limit control (without reset) 3. Electrical wiring panel 4. Reset lockout signal lamp 5. Differential pressure switch 6. Burner control relay or ignition controller 7.
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Page 19: Burner Injectors
7.7 Combustion air fan (venter) If it is determined that the thermal overheat When replacing the capillary control be control needs replacing, use only Reznor careful not to damage the capillary tube 1. Ensure gas supply to the air heater is authorized replacements that are designed by kinking. -
Page 20: Fault Finding
Fault Finding 8.1 Main Fault Finding Chart - Lockout Indicator Light Is "Off", But Air Heater Will Not Operate WARNING Fault finding may only be carried out by appropriately qualified persons Is the thermostat above room temperature and if Set thermostat above room used is the time temperature &... -
Page 21: Ignition Controller Lockout Indicator Light Repeatedly Comes "On
8.2 Ignition Controller Lockout Indicator Light Repeatedly Comes "On" WARNING: Fault finding may only be carried out by appropriately qualified persons Is polarity of mains correct? Correct polarity Does the inlet gas pressure agree with Correct the gas the data badge supply pressure Wait 15"... -
Page 22: Limit Control Fault Finding Chart (Limit Control Trips)
8.3 Limit Control Fault Finding Chart (Limit Control Trips) WARNING: Fault finding may only be carried out by appropriately qualified persons Note: RHC 4000(M) DJL air heaters are equipped with 2 limits (a recycling limit and a manual reset limit). During normal operation, neither limit should trip even if the main electric supply is interrupted during operation. -
Page 23: Parts List
Parts List Description Type Part number Application Settings 30-60617-120 4024 05 120 Pa off 30-60617-120 4030 06 120 Pa off 30-60617-88 4036 08 88 Pa off 30-60617-165 4050 06 165 Pa off Differential pressure switch S3 30-60617-146 4060-07 146Pa off 30-60617-155 4075 09 155 Pa off... -
Page 24: User Operating Instructions
10. User Operating Instructions How the air heater works: To light the heater: Maintenance: Gas is burned by an atmospheric burner 1. Turn on the gas supply to the air heater. 1. Maintenance and service must only be that fires into a heat exchanger. The gas 2. -
Page 25: Health & Safety Statement
11. Health & Safety Statement 11.1 General 11.4 Miscellaneous Characteristics: Non-corrosive, flammable with no poisonous reference-CH poison The manufacturer hereby provides the Small quantities of adhesives and sealants Class 3 Precautions: Avoid handling. This following information on substances used in the product are dried and cured and product can irritate and defat the skin. -
Page 26: Erp Information Requirements
12. ErP Information Requirements... - Page 27 Tel +44 (0)1384 489250 Fax +44 (0)1384 489707 reznorsales@nortek.com www.reznor.eu Nortek Global HVAC is a registered trademark of the Nortek Global HVAC limited. Because of the continuous product innovation, Nortek Global HVAC reserves the right to change product specification without due notice.
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