Reznor RHC21 4000 Installation, Commissioning, Servicing
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Reznor RHC21 4000 Installation, Commissioning, Servicing

Gas fired air heater module
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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. D301334 ISS 0
RHC21 4000
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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Summary of Contents for Reznor RHC21 4000

  • Page 1 ErP Lot 21 Seasonal Efficiency 2021 and NOx compliant RHC21 4000 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.

  • Page 2: Table Of Contents

    Contents Important Notice to Installers ..........4 5.12 To turn the air heater OFF for short periods ....29 Health and Safety ............. 5 5.13 To turn the air heater OFF for long periods ....29 1. Introduction ..............6 6 Servicing and maintenance ..........
  • Page 3 Power-vented gas-fired air heaters Model Type(s): RHC21 4000 Series Models (4024-05 / 4036-08 / 4050-06 / 4060- 07 / 4075-09 / 4100-12 / 4125M15 / 4150M18) This declaration is issued under the sole responsibility of the manufacturer. The object of...

  • Page 4: Important Notice To Installers

    Page No 4 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 5: Health And Safety

    Use only factory authorised parts and spares when replacement is required. In case of persistent problems, contact your distributor. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 5 of 56...

  • Page 6: Introduction

    Page No 6 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 7: Warranty

    The condition, when the temperature is such that the water vapour in the combustion products condenses out. Dimensions: All dimensions are in mm (25.4mm= 1 inch) Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 7 of 56...

  • Page 8: Technical Data

    H2 = heat output at airflow V2 (V2 = minimum airflow required for high heat output H2) H1 = heat output at airflow V1 (V1 = minimum airflow required through enclosure) Table 1 : Specifications Page No 8 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 9 25 / 30 17 / 18 I2ELL Natural Gas (G20/G25.3) 20 / 25 25 / 30 17 / 20 I2EK Table 3 : Gas supply details Reznor, RHC RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 9 of 56...

  • Page 10: Dimensions

    Figure 1.3 RHC21 4125M15, 4150M18 1. Gas connection 2. Flue outlet Figure 1.2 RHC21 4036-08, 4050-06, 3. Electrical connection 4060-07, 4075-09, 4100-12 4. Condensate connection Page No 10 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 11 3 Dimensions Figure 2 Top View Figure 2.1 RHC21 4024-05 Figure 2.3 RHC21 4125M15, 4150M18 Figure 2.2 RHC21 4036-08, 4050-06, 4060-07, 4075-09, 4100-12 Reznor, RHC RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 11 of 56...
  • Page 12 3 Dimensions Figure 3 Front View Figure 3.1 RHC21 4024-05 Figure 3.3 RHC21 4125M15, 4150M18 Figure 3.2 RHC21 4036-08, 4050-06, 4060-07, 4075-09, 4100-12 Page No 12 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 13 1457 Table 4 : Dimensions RHC21 4024-05 4036-08 4050-06 4060-07 4075-09 4100-12 4125M15 4150M18 Unit kg Package Total kg Table 5 : Approximate weights Reznor, RHC RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 13 of 56...

  • Page 14: Installation

    Such condensation can be the source of severe corrosion and damage to tubes or part of the tubes. Page No 14 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 15 Example 1: Tmin = 13K (with minimum inlet temperature = -5°C) model 4075-09 at 100% heat output : 76.04kW results into Vmax = 17088m³/h 76.04kW 17088 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 15 of 56...

  • Page 16: Compartment Dimensions

    RHC4036-08 RHC4050-06 1049 RHC4060-07 1049 RHC4075-09 1049 RHC4100-12 1049 RHC4125M15 1274 1222 1049 RHC4150M18 1484 1432 1049 Table 8 : Duct channel & controls compartment Page No 16 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 17: Combustion Air Supply And Flue Systems

    The products of combustion from the heater must be flued to the outside of the building. A properly sized flue system is required for safe operation of the heater. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 17 of 56...

  • Page 18: Type B Appliances

    Equivalent length of 45° elbow 0.75 Equivalent length of 90° elbow Minimum flue length Table 9 : Flue Diameter and Flue Pipe Lengths Page No 18 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 19: Gas Supply

    A competent and/or qualified engineer is the air heater(s) is essential to maintain the required to either install a new gas meter to the nominal heat input. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 19 of 56...

  • Page 20: Electrical Supply

    Check the electrical specification is in accordance with the specification on the appliance data plate. A unique appliance wiring diagram is supplied as a separate document. Page No 20 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 21: Electrical Isolator

    Follow instructions supplied with such legislation/regulatory requirements. panels. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 21 of 56...

  • Page 22: Commissioning And Testing

    • Ensure that fuses are of the correct rating not conform with the above, there is a fault and fuse value. which must be rectified before proceeding Page No 22 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 23: Start Up

    6. The combustion fan will now run and the and rotate clockwise to increase pressure burner will automatically light after about / %CO . Refit cap after adjustment. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 23 of 56...

  • Page 24: Gas Conversion

    Upon completion of conversion recommission and rotate clockwise to increase pressure the heater. Refer to the commissioning section / %CO . Refit cap after adjustment. for more details. Page No 24 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 25 Ignition Controller Program Key Ω 1,000 2,200 3,300 4,700 6,800 10,000 22,000 33,000 Bottom Burner Table 10 : Nominal Combustion Values with service door closed Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 25 of 56...

  • Page 26: Commissioning

    T2A and T2B contacts open, T1 closed Once the slave burner has been isolated, commission the master burner following the commissioning procedure given opposite. Page No 26 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 27 6. Slacken screw in gas valve outlet pressure • Reconnect thermostat connections if test point and attach low range pressure bypassed for commissioning. gauge. Note, offset is a vacuum reading. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 27 of 56...

  • Page 28: Commissioning - Hand Over

    Following flame stabilisation the fan speed will increase to high fire to allow the heat exchanger to warm up quickly. Page No 28 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 29: To Turn The Air Heater Off For Short Periods

    (or follow the instructions of the air handling unit). Gas and electricity must only be turned off in case of emergency or for prolonged periods of shutdown. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 29 of 56...
  • Page 30 Post-purge time This is the time of 255 seconds between burner shut-down and the moment the combustion fan is de-energised. Figure 8 Ignition system timetable Page No 30 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 31: Servicing And Maintenance

    Ignition probe & flame sensor ceramic paper Hex fullnut Hex screw Washer Tube support Burner Tube left support Transition plate - burner gasket Gas pipe bracket bottom Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 31 of 56...
  • Page 32 Ceramic paper gasket with adhesive Spark igniter Ceramic paper gasket with adhesive Flame sensor Ceramic paper gasket with adhesive Turbulator / baffle Ceramic paper gasket with adhesive Page No 32 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 33: Rhc 4036-08, 4050-06, 4060-07, 4075-09 And 4100-12 Component Layout

    Ceramic paper gasket with adhesive Rear shield Taptite screw Tube support 2 Tapitscrew Flame sensor Washer Spark igniter Hex screw Ignition probe and flame sensor ceramic paper Hex fullnut Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 33 of 56...
  • Page 34 2" tube insert Fan trans plate gasket U shaped silicon gasket Burner 2" Tube insert gasket Control box bracket Stainless steel 304 spigot Stainless steel 304 elbow Page No 34 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 35: Rhc21 4125M15 And 4150M18 Component Layout

    Stainless steel 304 90° elbow Hex fullnut Double control box assembly with controller Not used Control box bracket Stainless steel 304 adjustable flue Control box bracket Washer Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 35 of 56...

  • Page 36: Service Procedure

    When cleaning air heaters, wearing of eye protection and a dust face mask is recommended. Page No 36 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 37: Removal And Replacement Of Parts

    RHC21 all models except 4100-12 gas valve fixing screws 8mm nuts 8mm nuts 4. Remove the gas valve / combustion fan assembly from the unit. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 37 of 56...

  • Page 38: Venturi Cleaning And Replacement

    RHC21 4000 all models except 4100-12 gas valve inlet flange assembly. Note that there are two gas valves on RHC21 4125M15 and 4150M18 Throttle Screw RHC21 model 4100-12 venturi Page No 38 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 39: Combustion Fan Cleaning And Replacement

    Fan outlet 7. Follow start up and commissioning flange gasket procedure. 7. Refit remaining items in reverse order. 8. Follow start up and commissioning procedure. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 39 of 56...

  • Page 40: Burner Cleaning And Replacement

    5. Unless wetted, such waste may be dusty and should be properly sealed in containers for disposal. 6. The Material Safety Data Sheet is available from the appliance manufacturer. Page No 40 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 41 Ensure there are no gaps between the chamber insulation and tube inserts. Up to three tube insert spacer gaskets may be needed per tube insert. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 41 of 56...

  • Page 42: Cleaning And Replacement Of Burner Probes

    Flame probe Length of probe = 46.55mm overall 32.95mm to angle 13.79 mm angle to tip Tip deflection away from 0° = 27° Page No 42 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 43: Replacement Of Lc3 Safety Thermostats

    4. Withdraw mounting bracket from heater. Probe mounting bracket gasket x2 Thermostat mounting bracket 11. Refit all parts in reverse order. 12. Follow start up and commissioning procedure. Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 43 of 56...

  • Page 44: Replacement Of Ignition Controller

    7.9 Replacement of ignition transformer 1. Disconnect all electrical connections. 2. Unscrew fixings and remove transformer. 3. Refit in reverse order. 4. Follow start up and commissioning procedure. Page No 44 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 45: Fault Finding

    7. Flame sensor probe bent. time? 8. Integrity of appliance ground connection. 9. Probe leads connected / integrity. 10. Ignition controller. 11. Integrity of chamber insulation. Page 2 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 45 of 56...
  • Page 46 3. LC3 safety thermostat temperature not exceeding 96°C (71°C for models 10 and 20) 4. Lockout reset switch. 5. Heat demand still present. If the heater still fails to operate correctly, contact your local representative. Page No 46 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 47: Parts Listing

    4024-05, 4050-06, 4060-07, 4075-09, 4100- Burner wiring harness single 1031639 12, (TBC for 4036-08) Burner wiring harness double 1031640 40125m15, 4150M18 Collector Box U - Gasket 1031727 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0 Page No 47 of 56...

  • Page 48: User Operating Instructions

    OFF or its lowest setting. Wait at least annually, preferably at the end of the 5 minutes then turn OFF the electrical supply heating season. at the associated local isolator. Page No 48 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 49: Important Note

    • If you have any safety questions reference the servicing and installation of any of our heaters please do not hesitate to contact us for expert advice. Reznor, 4000 Installation EN May 2021 D301334 Issue 0 Page No 49 of 56...

  • Page 50: Erp Tables

    11 ErP table - G20 Page No 50 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 51: Erp Table - G25

    11 ErP table - G25 Reznor, 4000 Installation EN May 2021 D301334 Issue 0 Page No 51 of 56...

  • Page 52: Erp Table - G25.3

    11 ErP table - G25.3 Page No 52 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...

  • Page 53: Handover Document Commissioning Details

    Low Fire CO ....ppm High Fire CO ......ppm Flue Gas Efficiency (net) ....% Flue Gas Temperature ....Supply voltage ........ Supply Amps ....... Signature ............Date ......Reznor, 4000 Installation EN May 2021 D301334 Issue 0 Page No 53 of 56...
  • Page 54 Notes Page No 54 of 56 Reznor, RHC21 4000 Installation EN May 2021 D301334 Issue 0...
  • Page 55 Notes Reznor, 4000 Installation EN May 2021 D301334 Issue 0 Page No 55 of 56...
  • Page 56 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.

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