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INSTALLATION / COMMISSIONING / SERVICING
EU)2016/426(GAR),2009/125/EC(ErP), 2014/35/EU(LVD),and2014/30/EU(EMC)
EN 17082, 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.
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
dangerous operation possibly resulting in damage to the apparatus and/or environment in which the unit is installed.
MANUAL PART NO. D301319 ISS 0
RHC21 8000
GAS FIRED AIR HEATER MODULE
Regulations and Directives.
The following harmonised standards have been applied:
All work must be carried out by appropriately qualified persons.
WARNING
ErP Lot 21
ErP
Seasonal Efficiency
2021
and NOx compliant
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Related Manuals for Nortek Reznor RHC21 8000
Summary of Contents for Nortek Reznor RHC21 8000
- Page 1 ErP Lot 21 Seasonal Efficiency 2021 and NOx compliant RHC21 8000 GAS FIRED AIR HEATER MODULE 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 17082, 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.
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Page 2: Table Of Contents
Contents Important Notice to Installers ..........4 5.12 To turn the air heater OFF for short periods ....28 Health and Safety ............. 5 5.13 To turn the air heater OFF for long periods ....28 1. Introduction ..............6 6 Servicing and maintenance .......... -
Page 4: Important Notice To Installers
In instances where copper pipework is to Important notice to be used for all or part of a gas pipework installers installation, including short length final connections then we advise that installers Before installation, carefully read these consult with the gas supplier or provider and instructions and follow the processes explained satisfy themselves what additional precautions by the manufacturer. -
Page 5: Health And Safety
Health and safety For your safety, if you smell gas: Due consideration should be taken for • Do not try to light any workplace safety, risk assessments and waste appliance disposal. • Do not touch any electrical switch, do not use any phone Any modification of the product may be in your building hazardous and the manufacturer is not liable... -
Page 6: Introduction
1. Introduction the appliance to the conditions of use for the country of installation. Isolate any electrical supply to Check that the local distribution conditions of the heater and controller before electricity supply, type of gas and pressure of proceeding. the appliance are compatible. -
Page 7: Warranty
Warranty Definitions This equipment comes as standard with a Module: manufacturers two year warranty (2 years parts, The gas-fired heating module. 1 year labour) unless agreed otherwise at the time of order. The warranty is void if:- Constructor: • Model RHC21 8000 heaters are installed in The undertaking, which builds a module into atmospheres containing flammable vapours another casing. -
Page 8: Technical Data
2 Technical Data Model RHC21 8045-09 8060-12 8075-09 8100-12 8125M15 8150M18 8175M21 8200M24 Combustion air & flue type Indoor Combustion air & flue type External Rooftop Heat Input High Fire (Hs) 56.00 74.60 91.50 120.00 153.50 183.00 207.00 240.00 Heat Input Low Fire (Hs) 16.80 22.38 24.54... - Page 9 Model RHC21 8045-09 8060-12 8075-09 8100-12 8125M15 8150M18 8175M21 8200M24 at High Fire (Throttle) G20 8.60 8.60 8.60 8.60 8.60 8.60 8.60 8.60 < 50 ppm at Low Fire (Offset) G20 7.90 7.90 7.90 7.90 7.90 7.90 7.90 7.90 < 50 ppm at High Fire (Throttle) G25 8.60 8.60...
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Page 10: Dimensions
3 Dimensions Figure 1 Side View Figure 1.1 RHC21 8045-09, 8060-12, 8075-15, 8100-12 1. Gas connection 2. Flue outlet 3. Electrical connection 4. Condensate connection Figure 1.2 RHC21 8125M15, 8150M18, 8175M21, 8200-M24 RHC21 8045-09 8060-12 8075-09 8100-12 8125M15 8150M18 8175M21 8200M24 1272 1482 1691... - Page 11 3 Dimensions Figure 2 Top View Figure 2.1 RHC21 8045-09, 8060-12, 8075-15, 8100-12 Figure 2.2 RHC21 8125M15, 8150M18, 8`75M21, 8200M24 RHC21 8045-09 8060-12 8075-09 8100-12 8125M15 8150M18 8175M21 8200M24 1244 1244 1844 1844 1844 1844 1844 1844 Table 5 : Dimensions RHC21 8045-09 8060-12...
- Page 12 3 Dimensions Figure 3 Front View Figure 3.1 RHC21 8045-09, 8060-12, 8075-15, 8100-12 Figure 3.2 RHC21 8125M15, 8150M18, 8175M21, 8200M24 RHC21 8045-09 8060-12 8075-09 8100-12 8125M15 8150M18 8175M21 8200M24 1272 1482 1691 1900 1676 1645 2276 2229 2214 2207 2216 2217 Table 7 : Dimensions Page No 12 of 52 Reznor, RHC21 8000 Installation EN May 2021 D301319 Issue 0...
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Page 13: Installation
4 Installation Heater location Do not locate the air heater where it may be General requirements exposed to water spray, rain, etc. The location It is important that all gas chosen for the air heater must permit the appliances are installed in provision of a satisfactory flue system venting to accordance with the rules in force outdoor atmosphere and adequately ventilated... - Page 14 The chart below indicates the probability of As a function of the expected minimum inlet air condensation forming within the tubes with temperature, the minimum required temperature reference to: rise (to avoid condensation) must be derived CONDENSATION POINT from the chart. •...
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Page 15: Compartment Dimensions
Example 2: Tmin = 13K (with minimum inlet temperature = -5°C) model 8100-12 at low fire : 32.79kW results into : 32.79kW 7369 Note: attention must be given to determine the maximum allowable airflow as a function of the appropriate heat input. 4.6 Compartment dimensions RHC21 8045-09... -
Page 16: Combustion Air Supply And Flue Systems
4.7 Combustion air supply & flue system The flue MUST be installed in accordance with national and local RHC21 8000 heaters may be installed as a regulations. Type C room sealed heater requiring both a combustion air inlet pipe and a flue pipe (Type An improperly sized flue system C13, C33 or C53 only) or as a Type B forced can cause unsafe conditions and/or... -
Page 17: Type B Appliances
Single wall flue pipe exposed to must not exceed 65°C when the heater is in cold air or run through unheated operation. The flue must be at least 150 mm areas must be insulated. Where away from any combustible material. condensation is unavoidable, Single wall flue pipe exposed to cold air or run provision must be made for the... -
Page 18: Gas Supply
Single wall seamless aluminium or stainless is adequate to deal with the rate of gas supply steel flue pipes are required. All joints must be required. Installation pipes should be fitted in sealed to prevent the products of combustion accordance with national standards so that the from leaking into the building. -
Page 19: Electrical Supply
Other gas fired plant using the same gas service All heaters and controls must be earthed. must also be taken into account. A lockable isolator with contact separation of A 90° action, positive stopped gas service tap at least 3.0 mm on all poles should be installed must be fitted adjacent to the appliance, fitted adjacent to the appliance and within reach of in a manner to facilitate appliance burner... -
Page 20: Electrical Isolator
If the reset button requires Thermostat(s) and/or temperature sensor(s) activating for any reason, the should be mounted on a vibration free cause must be determined. After surface. Room thermostat(s) / sensor(s) should determining and correcting the be mounted about 1.5m above floor level. problem, restart the heater and Follow the thermostat manufacturers fitting monitor for a period long enough... -
Page 21: Commissioning And Testing
5 Commissioning and testing further with the commissioning; • Check that a suitable thermostat or control RHC21 8000 heaters must be panel has been fitted; commissioned before putting into • Ensure that an electrical isolator with two service. pole separation with a minimum air break Commissioning and testing must only be carried between poles of 3.0 mm has been fitted out by suitably trained and qualified personnel. -
Page 22: Start Up
• Check ignition controller program key 8. The gas pressure must correspond to the matches the resistance value as shown in data in table 3 on page 9. If the gas pressure Combustion data table for the heater model. is higher than 50mbar, a pressure regulator must be installed. -
Page 23: Gas Conversion
1 - Offset adjustment 2 - Inlet pressure measuring point 3 - CO adjustment point (throttle) 4 - Offset pressure measuring point 1 - Offset adjustment Figure 8 Gas valve adjustment models 2 - Inlet pressure measuring point RHC21 8100-12, 8175M21 (1 off) and 3 - CO adjustment point (throttle) 8200M24 (2 off) - Page 24 Model RHC21 8045-09 8060-12 8075-09 8100-12 8125M15 8150M18 8175M21 8200M24 at High Fire (Throttle) G20 8.60 8.60 8.60 8.60 8.60 8.60 8.60 8.60 CO G20 < 50 ppm Throttle Turns from Closed 7.0 out 7.0 out 7.25 out 21.0 in Top Burner Throttle Turns from Closed 6.0 out...
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Page 25: Commissioning
5.9 Commissioning Once the master burner has been commissioned, the slave burner must be General commissioned. To commission the slave burner, Commissioning requires the use of a CO/CO the master burner must be isolated. To isolate flue gas analyser with an inaccuracy < 0.1% and the Master burner and commission the Slave, two pressure gauges. - Page 26 Commissioning procedure Outlet Read section on air-gas ratio control test point adjustment before proceeding. During commissioning the appliance %CO , CO ppm and flue gas temperature values should be Inlet test point compared to those shown in the Combustion Data Table (Table 11 previously). 1.
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Page 27: Commissioning - Hand Over
5.10 Commissioning - hand over After a short delay the air movement fan will start. Once warm up has completed the burner Upon full and satisfactory completion of is released to the control of the 0-10VDC commissioning, a record of commissioning thermostat and will modulate to the requested information should be left with the person heat demand. -
Page 28: To Turn The Air Heater Off For Short Periods
Lockout indication light status light Lockout reset switch Burner On light Reset switch and status lights Standby Pre-purge Ignition Stabilisation Unit is functioning General lockout Lockout due to LC3 over temperature Program key error Figure 7 LED Status 5.12 To turn the air heater OFF for short periods Adjust the room thermostat to its lowest setting or ‘OFF’. - Page 29 Start position The system is not in lock-out and can proceed with the start up sequence upon a demand for heat Pre-purge time This is a period of 35 seconds during which the combustion fan operates prior to activation of the ignition device. Safety time The safety time is the delay between the gas valve being energised and the flame sensor checking for the presence of a flame.
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Page 30: Servicing And Maintenance
6 Servicing and maintenance RHC21 8125M15, 8150M18, 8175M21 and 8200M24 component layout Description Description RHC21 assembly (2 x 8075 or 2 x 8100 or 1 x 8100 and 1 x Tapitscrew 8175) dependant on unit model) Gas train assembly Washer Limit stat bracket Outlet collar AS D=130 VRA Limit stat clips... - Page 31 Description U shape silicon gasket Silicon gasket Control box 1 bracket Control box 2 bracket Double control box assembly with controller Gas train support bracket Reznor, RHC21 8000 Installation EN May 2021 D301319 Issue 0 Page No 31 of 52...
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Page 32: Rhc 8045-09, 8060-12, 8075-09 And 8100-12 Component Layout
RHC21 8045-09, 8060-12, 8075-09 and 8100-12 component layout Description Description Unit assembly Limit control LC3 Tapitscrew 4.8 x 13 Clips U shape silicon gasket Limit stat bracket Silicon gasket Stainless steel 304 spigot Gas train bracket Stainless steel 304 90° elbow Gas train assembly Control box assembly with controller Collector box cover assembly... -
Page 33: Service Procedure
6 Servicing and maintenance 6.1 Service procedure The following procedures should be carried out Only appropriately qualified at least annually: persons may carry out servicing and fault finding on this gas fired • Check the heat exchanger internally and equipment. externally for evidence of physical damage. -
Page 34: Removal And Replacement Of Parts
7 Removal and replacement of parts RHC21 8000 air heaters must only be fitted with authorised replacement parts. These heaters must use certificated spare parts to comply with legislation. 7.1 Replacement of gas valve 1. Unplug the gas valve and combustion fan power cables. -
Page 35: Venturi Cleaning And Replacement
O ring 6 off Fixing screws RHC21 models 8100-12, 8175M21 (1 off valve) and 8200M24 (2 off valves) gas valve inlet flange assembly RHC21 models 8100-12, 8175M21 (1 off valve) and 8200M24 (2 off valves) remove combustion 7. Refit gas valve in reverse order ensuring the fan to reveal gas valve fixing screws o-ring is fitted between the gas valve and venturi. -
Page 36: Combustion Fan Cleaning And Replacement
7.3 Combustion fan cleaning and 4. Before fitting new venturi, ensure throttle screw is fully closed (turn throttle clockwise replacement for RHC21 models 8045-09, 8060-12, 8075- 1. Follow steps 1 to 4 from gas valve 09, 8125M15 (2 off valves) and 8175M21 replacement and step 3 from venturi (1 off valve) models 10-70 and anticlockwise replacement. -
Page 37: Burner Cleaning And Replacement
7.4 Burner cleaning and replacement 1. Follow steps 1 to 4 from gas valve replacement. 2. Unscrew the burner fixings with a deep 10mm socket. 10mm nuts Burner with face insulation removed 7. The burner mesh can be cleaned by either placing it under clean running water or by immersing it in a container full of clean 3. - Page 38 7. With the burner removed the integrity of the Chamber combustion chamber and tube insulation can front insulation be verified. It is normal for small superficial cracks to be present in the surface of the insulation. Chamber Tube insert side insulation Chamber insulation...
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Page 39: Cleaning And Replacement Of Burner Probes
3. Once removed unscrew the 2 fixings with a No gap 10mm socket to release the probe mounting between bracket. tube insert and chamber insulation Probe mounting bracket fittings x2 15. Refit burner probes. Check condition of probe bracket gasket and replace if necessary. -
Page 40: Replacement Of Lc3 Safety Thermostats
7.7 Replacement of LC3 safety 8. Check spark gap against dimensions below, if necessary, adjust using long nose pilers. Be thermostats careful not to crack the ceramic sleeve. 1. Disconnect LC3 electrical connectors. Spark probe 2. Remove LC3 protective cap and lock nut. Length of probe = Location of 78.5mm long probe... -
Page 41: Replacement Of Ignition Controller
7.10 Replacement of lockout circuit 5. The thermostats can now be removed from the mounting bracket. board 6. Replace one or both thermostats as needed. 1. Disconnect all electrical connections. Ensure sensor is pushed up to the return 2. Pinch circuit board retention clips to release. at the end of the bracket and secured in place with the retaining clips. -
Page 42: Fault Finding
8. Fault finding START Ensure gas & electricity supplies are enabled. Turn external controls to call for heat. CHECK:- Voltage is correct - see technical data table Ignition controller fuse Is there power to Does the LED status Integrity of wiring connections light illuminate? the burner? Lockout reset circuit board... - Page 43 CHECK:- Gas supply turned on and purged PAGE 2 Supply pressure Voltage supply to gas valve plug 230V AC / 50 Hz during ignition Ignition controller Does the burner Throttle positioning - see commissioning data table Does the burner ignite after a purge Correct program key fitted spark? period?
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Page 44: Parts Listing
9. Parts listing Description Part Number Application Ignition controller(Brama TC340P) 1031687 8000 range Spark Probe c/w Lead & Blind Grommet 1031978 Flame Sense Probe c/w Lead & Blind Grommet 1031979 Ignition transformer 1030638 Probe mounting gasket set 1037440 8075-09, 8125M15(9), 8150M18, Burner face insulation / burner gasket 1037196 8175M21(9) -
Page 45: User Operating Instructions
10. User operating instructions 10.1 Checks before lighting the air heater 10.4 Overview of operation The heater MUST NOT be controlled Before lighting the heater, ensure:- by switching the main electrical 1. The electrical supply to the heater is OFF supply to it ON and OFF 2. -
Page 46: Important Note
In case of any damage to the appliance, it must be shut down completely and checked by an appropriately qualified person. In the event of difficulties in resolving any of these matters, please do not hesitate to contact the official distributor. 10.6 Important notes •... -
Page 47: Erp Tables
11 ErP table - G20 Reznor, RHC21 8000 Installation EN May 2021 D301319 Issue 0 Page No 47 of 52... -
Page 48: Erp Table - G25
11 ErP table - G25 Page No 48 of 52 Reznor, RHC21 8000 Installation EN May 2021 D301319 Issue 0... -
Page 49: Erp Table - G25.3
11 ErP table - G25.3 Reznor, RHC21 8000 Installation EN May 2021 D301319 Issue 0 Page No 49 of 52... -
Page 50: Handover Document Commissioning Details
Handover Document Commissioning Details Appliance Serial No: ........... Model Type: ............... Customer Name: ....................Address: ..............................................Site name: ............Commissioning Engineer Name ............Gas Safe Reg No......Company Name ....................Commissioning Date: ........Burner Fuel type ............Inlet Pressure .......mbar Working Pressure .......mbar Burner Pressure: Low Fire ....mbar High Fire ......mbar... - Page 51 Notes Reznor, RHC21 8000 Installation EN May 2021 D301319 Issue 0 Page No 51 of 52...
- Page 52 Tel +44 (0)1384 489700 Fax +44 (0)1384 489707 reznorsales@nortek.com www.reznor.eu Nortek Global HVAC is a registered trademark of Nortek Global HVAC limited. Because of the continuous product innovation, Nortek Global HVAC reserves the right to change product specification without due notice.