Reznor RHCLN Guide

RHCLNManualBE(Eng)V2–300517
RHCLN
Installation
Commissioning
Servicing
These appliances meet the following EC Directives
DIR CE 2009/142/EC:GAD
DIR CE 2014/30/EU: EMC
DIR 2014/35/EU: LVD
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.

2


3

Page
Page
1 INTRODUCTION 3
4.2.3 Fitting Combustion Air Inlet For Type C 21
1.1 Basic Information 3 4.3 Electrical Connections 22
1.2 Warranty 4 4.4 Room Thermostat Siting 22
1.3 Disposal Information 5
5COMMISSIONING & TESTING 22
2 TECHNICAL DATA 5
5.1 Preparing For First Start-up 22
2.1 Identification 5 5.2 Recommended Operating Cycle 23
2.2 Dimensional Data & Weights 6
5.3 Electrical Check 23
2.3 Efficiency vs Output 6 5.4 Gas Connection 23
2.4 Internal Pressure Drop Charts 7 5.5 Lighting The Air Heater 23
5.6 Air Heater Gas Pipework 24
3 GENERAL INFORMATION 9
5.7 Adjustments 24
3.1 General 9
3.2 Burner Configuration 11 6
SERVICE & MAINTENANCE 25
3.3 Supply Air Fan Position 14
6.1 Component Identification 25
3.4 Inserting Into Air Handling Unit 15 6.2 Burner/High Limit Reset 26
3.5 Maintenance Clearance 16 6.3 Burner Fan Settings 26
3.6 Combustion Air Supply & Flue
System
16 6.4
6.5
Multi-functional LED
Electrode Positions
27
28
3.7 Condensate Removal 18 6.6 Combustion Analysis 28
3.8 Electrical Supply 20 6.7 Heat exchanger Inspection 29
3.9 Gas Supply 20 6.8 Cleaning The Condense Drain 29
6.9 Cleaning the Burner Tube 30
4 INSTALLATION 21 6.10 Cleaning The Electrodes 30
4.1 Unpacking & Preparation 21 6.11 Cleaning The Flue & Combustion Air 30
4.2 Fitting Combustion Air
Inlet/Flue Pipe
21
6.12
system
Casing Maintenance 30
4.2.1 Fitting The Flue 21
4.2.2 Installing A Grille On
Combustion Air
21 7 GAS CONVERSION 30
HAZARDINTENSITYLEVELS
Failuretocomplycouldresultinminorpersonalinjuryand/orproperty
damage.

Failuretocomplycouldresultinseverepersonalinjuryordeath
and/orpropertydamage.

Failuretocomplywillresultinseverpersonalinjuryordeathand/or
propertydamage.

MustNOTbeperformedunderanycircumstances.
CAUTION
WARNING
DANGER

4
WARNINGS
1.1 Basic Information
The instructions within this manual apply to RHCLN gas fired heater modules. These models are designed for use
within air handling units (AHU) or ducting systems where an air moving fan is present.
The appliances must be installed in accordance with the rules in force. Before installation, check that the local
distribution conditions, nature of gas and pressure and adjustment of the appliance are compatible. A permanent
electricity supply of 230 volts, 50 Hz, single phase is required.
When installed in Great Britain the total installation must comply with the requirements and recommendations of
British Standard BS 6230 “Installation of Gas Fired Forced Convection Air Heaters for Commercial and Industrial
For your safety, if you smell gas:
Do not try to light any appliance
Do not touch any electrical switch, do not use any phone in your building.
Evacuate all personnel & contact your gas supplier immediately.
Do not store or use petrol or other flammable vapours and liquids in the vicinity of the
appliance.
Improper installation, adjustment, alteration, service or maintenance can cause property
damage, injury or death. Read the installation, operation and maintenance instructions
thoroughly before installing or servicing this equipment.
Do not use this appliance if any part has been immersed in water. Immediately call a
qualified service technician to inspect the appliance and replace any gas control that has
been immersed in water.
This appliance is not intended for use by persons (including children) with reduced
sensory or mental capacities or lack of experience and knowledge unless they have
been given supervision or instructions 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.
Should overheating occur or the gas supply fails to shut off, shut off the manual gas
valve to the appliance before shutting off the electrical supply.
Gas fired appliances are not designed for use in hazardous atmospheres containing
flammable vapours or combustible dust, in atmospheres containing chlorinated or
halogenated hydrocarbons or in appliances with airborne silicone substances.
The manual should be kept in a safe place for future reference.
Unauthorised modification of this appliance or departure from use in the manner, for
which it was intended by the manufacturer or installed in a manner contrary to these
instructions, may constitute a hazard and jeopardize all warranties. Deviations should
only be carried out after formal consent has been obtained from the manufacturer.
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 remote supply air fan prematurely
and may damage the heat exchanger, invalidating the warranty.
Use only factory authorized parts when replacement is required.
In case of persisting problems, contact your distributor.
This appliance is supplied without an air moving fan. The ducting system or air handling
unit into which the RHCLN is installed MUST have a suitably sized air movement fan that
is inter-linked with the gas heater module.
WARNING
1INTRODUCTION

5
Space Heating". The installation must also be in accordance with the relevant requirements of “The Gas Safety
(Installation and Use Regulations) and “Amendment regulations 1990” and “Electrical Regulations” (in GB the IEE
Regulations). The requirements of the “Local Building Standards Office”, the premise “Insurance” undertaking and
the “Fire Office” must also be observed.
The modulating pre-mix burner has a modulating range from 100% to 30% full fire rate. The gas valve delivers the
fuel in proportion to the combustion air flow rate in line with the default factory settings. The concentration of carbon
dioxide (CO2), unlike atmospheric burners, is more or less constant throughout the firing range. This will result in a
higher thermal efficiency as the heat output decreases. Perfect mixing of the gas with combustion air combined with
a semi-radiant flame, contributes to a combustion with very low emissions of carbon monoxide (CO) and nitrogen
oxides (NOx).
In the event of reduced combustion air (e.g. obstructions and/or flue or combustion air runs that are too long), the
solenoid valve automatically reduces the gas, keeping the combustion parameters at optimal levels. In the case of
poor combustion air, the solenoid valve closes and no more gas is supplied.
When the external control calls for heat, an electronic control begins the ignition sequence to provide for a safe
start. Under normal conditions the supply air fan motor (by others) runs constantly and after a call for heat it
switches the heater on through 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 handler. The normal operation of RHCLN will then
operate as follows: upon call for heat the pre-mix gas burner fan (1) introduces the optimal combustion air/gas
mixture - dependent upon the modulating valve firing rate (2). Additional combustion air/gas mixing can occur
inside the fan of the pre-mix burner (1), prior to being fed into the burner firing tube. On the external surface of the
burner tube, a radial flame develops once the gas/air mixture is ignited. Combustion products, prior to being
exhausted via the flue, heat up the combustion chamber (3), the rear flue manifold (4), the heat exchanger tubes
(5) and the heat exchanger manifold (6). The electronic control within the RHCLN 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 (supply air/AHU) running to cool down the heat exchanger
The temperature of the combustion products, whilst passing through the heat exchanger (5) falls below dew point,
and retrieves the latent energy contained in the water vapour normally generated during the combustion process.
The condensate produced is collected in the heat exchanger manifold (6) and in turn leaves the appliance via the
condensate connection to an external drain system (by others).
1.2 Warranty
Warranty is void if:
RHCLN heaters are installed in atmospheres containing flammable vapours or atmospheres containing
chlorinated or halogenated hydrocarbons or atmospheres containing any silicone, aluminium oxide, etc.,
that adheres to spark ignition flame sensing probes.
The installation is not in accordance with these instructions.
The maximum air flow through the heat module exceeds that stated in this document.
The required minimum air delivery is not respected.
The inlet temperature exceed/are lower than the working parameters shown in the technical data table.

6
1.3 Disposal Instructions
For disposal methods, refer to the local laws in force relating to special waste.
The unit contains electronic components, therefore cannot be treated as household waste. For disposal methods,
refer to local laws in force relating to special waste.
2.1 Identification
The appliances can be identified by means of:
The technical plate, affixed to the heater, specifying the main technical & performance data
The packaging label, affixed to the outside.
If the technical plate is damaged or lost, request a duplicate to the Technical Assistance Service.
2TECHNICALDATA
1) Natural gas (G20) calorific value 10.48kWh/m3GCV. LPG (G31) calorific value 14.0kWh/kg GCVG20 methane gas
2) Based upon EN 1020 standard, operating on natural gas (G20).


7
2.2 Dimensional Data & Weights
Dimensions & Weight RHCLN 30 40 50 60 90 120
A mm 891 891 1.234 1.234 1.755 1.755
A1 mm 711 711 1054 1054 1575 1575
B mm 450 450 450 450 450 450
C mm 635 635 685 685 840 840
D mm 498 498 538 538 623 623
E mm 818 818 1160 1160 1,680 1,680
F mm 32 32 25 25 33 33
G mm 36 36 36 36 32 32
Ø H Gas connection size 3/4" 3/4" 3/4" 3/4" 3/4" 3/4"
Ø I Flue outlet size mm 80 80 80 80 100 100
NET WEIGHT kg 48 51 62 66 122 129
2.3 Efficiency vs Output

The RHCLN has been designed for the heating of buildings. It features a variable heat output with constant burner
modulation, automatically controlled a 0÷10V signal (by others). This ensures a fast pre-heating of the space as well
as maintaining the required temperature without any significant variance. Resulting in good comfort levels for
personnel.
Thanks to the continuous modulation of the burner, the demand for heat from the space being heated decreases. At
low fire the thermal efficiency can be as high as 106 % (ncv) resulting in lower gas usage. The chart below shows
the relationship between efficiency and the burner output for each RHCLN model
30
30
A1

8
For the purposes of the above chart 1 = RHCLN30, 2 = 40, 3 = 50, 4 = 60, 5 = 90 & 6 = 120
The above example shows that if an RHCLN120 is producing 65kW output (56% full fire rate) the thermal efficiency
would be 104%. Likewise if you were to take an RHCLN90 (line 5) operating at 45kW (50%) that also would be 104%
2.4 Internal Pressure Drop & Temperature Rise Charts
Shown in the charts below are the internal pressure drop (∆p) and temperature rise (∆t) of the appliance when a
given air volume (V) is passed through the unit. Please note that temperature rise is based upon maximum heat
output.
How to use the above chart
Assuming an approximate air volume of 2,750 m³/h, there is:-
‐An internal pressure drop of approx. 32 Pa (intersection of the ∆p curve)
‐A temperature rise of approx. 30 °C (intersection of the ∆t curve)

Thermal Efficiency % (ncv)
Burner Output (kW)
∆t(OC)
V(m3/h)
RHCLN 30
∆p(Pa)

9

V(m3/h)
∆t(OC)
RHCLN 40
V(m3/h)
∆t(OC)
RHCLN 50
V(m3/h)
∆t(OC)
RHCLN 60
∆p(Pa)
∆p(Pa)
∆p(Pa)

10
3.1 General
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 compliance with 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 an uneven and turbulent air flow 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 also provide sufficient space to allow the heater to be serviced. Ensure that the surface onto
which the heater is to be installed is vibration free.
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.
V(m3/h)
∆t(OC)
RHCLN 90
V(m3/h)
∆t(OC)
RHCLN120
3GENERALINFORMATION
∆p(Pa)
∆p(Pa)

11
For correct installation the unit must:
Have minimum safety distances around the appliance, to enable unrestricted airflow & to allow
normal cleaning, control and maintenance operations.
Keep minimum clearance distances to flammable materials.
Allow easy connection and correct run of the flue exhaust system.
Allow easy connection and correct run of the combustion air inlet system.
Allow correct connection to the gas supply.
Provide a suitable route for safe and correct condensate disposal.
Have a local electrical isolator.
Provide easy and safe access to undertake all maintenance operations and inspections.
Have sufficient ventilation to outside air to ensure compliance with local regulations in force
The gas flow rate, pressure & type (i.e G20, G31 etc) are in accordance with the data plate affixed
to the a
pp
liance.
TheheaterMUSTNOTbeinstalled:
Incorrosiveatmospheres
Inconfinedornarrowspaces,wherenoisecreatedbycouldbeamplifiedbyreverberationetc.
In corners or areas where dust, leaves etc can congregate. These items will reduce the
efficiency/operation of the unit if taken into the supply air stream or into the combustion air pipe.
Withinapressurizedspace.
Withinanegativepressureenvironment
External of an
y
buildin
g,
unless incor
p
orated into a suitabl
y
weather
p
roof enclosure.
Iftheinstallationiswithaverticalairflow(uptodown)ITISMANDATORYtoinstalltheappliance
slightlytiltedtowardsthecondensateoutlet(seebelow).
Iftheheaterisinstalledinthehorizontalplane(i.ewithairflowpassingrighttoleftorlefttoright)
ITISMANDATORYtoplacetheapplianceinalevelorslightlytiltedpositiontowardsthe

12
3.2 Burner Configuration
The appliance is capable of being used in three different configurations. The default configuration for air flow passing
from right to left (when looking at the burner). Should you wish an alternative to the default configuration, then please
following the instructions against the relevant configuration shown below.
The temperature probe and deflector must be placed on the outlet side of the heated
air (left side looking at the burner);
The condensate separation siphon must be placed on the left side of the burner.
Horizontal airflow from right to left (default configuration)
The temperature probe and deflector must be placed on the outlet side of the heated air.
On the condensate exhaust fitting, install a 90° (3/4” M to F elbow - not included), then fit the
condensate siphonas shown above.
Horizontal airflow from right to left (default configuration)
Vertical airflow top to bottom

13
Horizontal airflow from left to right
The temperature probe and deflector must be placed on the outlet side of the
heated air (right side looking at the burner)
The condensate siphon must be placed on the left side of the burner (as per default
set-u
p)
.
Two burners stacked
If changing airflow configuration from the default, please remember to make temperature probe &
deflector changes on each burner as detailed in the single burner configuration examples.
Righttoleft(default)Lefttoright

14
Two burners stacked – vertical airflow
If changing airflow configuration from the default, please remember to make temperature probe &
deflector changes on each burner as detailed in the single burner configuration examples.
CONDENSATE siphon MUST be modified when using vertical configuration. See single burner
configuration for details
Two burners mounted in series
If changing airflow configuration
from the default, please
remember to make temperature
probe & deflector changes on
each burner as detailed in the
single burner configuration
examples.
Please ensure the 200mm
minimum distance between
heater faces is adhered to.

15
3.3 Supply Air Fan Position
The fan may be placed upstream or downstream of the heating section. The position of the fan must be such as to
assure an even flow across the whole heat exchanger.
Should the fan be installed downstream (pull through) of the heating section, then the installation of a metal shield in
front of the motor is recommended to provide protection from excessive temperatures.
Two burners mounted in series vertically
Please ensure the 200mm
minimum distance between
heaters is adhered to.
If changing airflow configuration
from the default, please
remember to make temperature
probe & deflector changes on
each burner as detailed in the
single burner configuration
examples.
CONDENSATE siphon MUST
be modified when using vertical
configuration. See single burner
configuration for details
For applications requiring any burner configuration not shown on the previous
pages, please contact your supplier for further details.
>200mm

16
Clearance for nearby components
All components (fans, motors, filters, electrical wires, electric components, etc.) contained with an air handling unit,
or ducting system into which the heating module is inserted, must be placed at a distance to protect from heat
radiation especially in case of fan failure where heat will still build within the heater until the thermal protection switch
activates.
The minimum distances must be:
1.0 m if made of plastic
0.8 m if made of metal
3.4 Inserting Into Air Handling Unit
The heating section is built within a structure that allows for easy insertion into an air handling unit. A flange is
supplied around the heat exchanger element over which supply air is to be passed, this enables a flange on ducting
to be affixed to the heater if needed. Please ensure that supply air ONLY passes through the heat exchanger and a
partition is in place ensuring that the control compartment is not subjected to any positive/negative air pressure.
LEGEND:
1. Air volume path
2. Control compartment

17
Important
When air being passed through the heater section complies with the models
minimum & maximum air flow rates, all of that air must pass through the heater. If the duct or air handling unit casing
is taller and/or wider than the heater, then suitable transition plates must be fitted to ensure smooth passage of air
through the heater.
Example of insertion into an air handling unit or duct system, with sizes exceeding the heating section
Should the air volume exceed the maximum stated in the technical data (page 5), it is possible to fit (by others) either
a side or top air by-pass, through which the excess air volume can be passed. Please ensure that the by-pass duct
is sized so the pressure drop is equal to that of the heater section. For further information see section XX or contact
your supplier.
3.5 Maintenance Clearance
Considerationtothefinalinstallationoftheheater(orairhandlingunitinwhichtheheaterisfitted)mustbe
given,sothataminimumdistanceof1.0mfromtheheatertoanyobstacleisobserved.Failuretocomplywill
preventfullandcorrectmaintenanceoftheheater.When installed within an air handling unit that is located at
ground level, a fence to guard against damage and to protect the public from possible injury should surround the
entire unit.
Minimum distance from the wall:
The base of the air handling unit onto which the heating section is mounted, must be solid and
able to support its weight. The use of suitable structural/stiffening crosspieces is therefore
recommended.
The gas burner section must be securely fixed within the air handling unit to ensure no
movement occurs during transportation of the complete unit.
Access for maintenance of the temperature sensor (located on the outlet side of the burner)
must be provided.
Air tightness of the flue pipe system into the flue outlet spigot is essential and MUST be
checked on a regular basis.

18
3.6 Combustion Air Supply & Flue System
Flue pipe runs may be
horizontal or vertical and
terminate either through the
wall or roof for heaters located
inside a building. Care
should be taken to ensure
that the maximum flue runs
are not exceeded (See
table 1), only approved
concentric terminals should be
used when installing as a type
C appliance.
Model RHCLN heaters may be installed as type B or type C
installation. The heaters are designed to operate safely and efficiently with
either a horizontal or vertical flue system, when installed according to
the specific requirements and instructions. If this unit is replacing an existing
heater, be sure that the flue is of the correct size and that the existing flue
is in good condition.
A correctly sized flue system is required for safe operation of the heater. An incorrectly sized flue system can cause
unsafe conditions and/or create condensation.
The units may be installed as a balanced flue type C heater requiring both a combustion air inlet pipe and a flue pipe
or as a power vented heater type B where the combustion air is taken from the space, where heater is installed,
and only requires a flue pipe exhausting to outdoors.
All products of combustion must be flued to outdoor atmosphere. Each heater installed as a type B appliance must
be fitted with an individual flue pipe. A combustion air inlet opening MUST be fitted into the AHU heater compartment
and provided with a protection grille.
Each heater installed as a type C appliance must be fitted with an individual combustion air/flue pipe system. Type
C2 appliance, with single pipe system for supply of combustion air and evacuation of flue gasses, are not allowed.
For testing, the flue pipe should include a sealable test point. Ideally the test point should be at least 450mm away
from the air heater flue connection socket. However if a concentric flue is attached directly to the connection sockets
then the combustion should be tested through the flue outlet collar via a drilled test point which must be securely
plugged on completion.
The flue must be in accordance with BS6230 or BS5440. Local requirements may apply
in addition to national requirements.
Failure to provide a flue system could result in death, serious injury and/or property
damage.
The products of combustion must be flued to outside atmosphere. Common flues (for
more than one appliance) must not be used.
Single wall flue pipe exposed to cold air or run through unheated areas should be
insulated to avoid condensation.
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 25mm 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 50mm away from any
combustible material.
Table1.E
q
uivalentfluelen
g
ths

19
Combustion air supply
It is important to ensure that there is an adequate fresh air supply at all
times for both combustion and heating
requirements. Modern construction practice means that buildings are
sealed much tighter than in the past. The combustion air supply for a
power vented gas fired air heater (Type B installation) can be affected by
lack of air supply, therefore natural infiltration may not be adequate. Use
of extract fans aggravates this situation. It is important to ensure that there
is an adequate air supply at all times. Reliance on doors and windows is
not allowed. Always ensure that an adequate inlet for fresh air for
combustion is provided sized to suit the total installation of any combustion
apparatus. Fix an access guard (IP 20) into the wall for combustion air and
take appropriate action to ensure that it remains unblocked. See national
installation requirements for aeration & ventilation of buildings.
Models 90 & 120 only (near to the combustion air inlet) it is necessary to install the Venturi tube device already
connected to the gas solenoid valve, to the pressure intake called AIR IN (included in the supply).
Flue extension, if required dia 80 or
100mm (not supplied)
Control compartment panel (not
supplied)
Gas
p
assa
g
e seal
Combustion air inlet protection grille
Teflon sealing ring
dia 80 or 100mm
Aluminium terminal 300mm
long (if AHU mounted on an
external roof). If internally
mounted AHU, then flue
must be extended to outdoor
atmosphere and safely
e
xh
aus
t
ed
.
80
o
r 1
00
mm
d
i
a
Condense drain
A condensation drain must be fitted to both the unit and the flue outlet to properly drain
all condensation.
The condensation drain from the flue must be constructed from non‐corrodible material
not less than 20mm diameter. Copper or copper based alloys must not be used for
condensation drain.
Typical type B Flue installation

1.Combustion air intake
2.Venturi tube device
3.Silicone tube

20
3.7 Condensate Removal
EachRHCLNheatingmoduleisfittedwithacondensatetrapwithaninternalfloatasthe combustion products are
loaded with moisture, some of which will condense out within the flue. No condensate leakage is permitted.
Indoor horizontal flue runs must rise by 1° (17mm per meter) from the appliance to ensure that the condense returns
to the flue
drain.

For the connection of the condensate trap to the condensate disposal system, use a PVC or silicone pipe. It is
recommended that an internal diameter of not less than 20mm is used, however care must be taken to ensure that
the disposal system is suitably sized to handle the volume of condensate produced, especially if more than one
RHCLN module is connected.
Combustion air inlet pipe
Flue products exhaust pipe
Teflon sealing ring dia 80 or 100mm
Flue extension, if required dia 80 or
100mm (not supplied)
Typical type C Flue installation for an internally mounted AHU
The condensate disposal system must be installed in compliance with the European,
National and Local Reference Standards, ensuring the need for a neutralization treatment if
necessary.
When starting-up for the first time, fill the container of the condensate drain syphon with
water.
An incorrectly designed/installed drain will compromise the correct operation of the
appliance, therefore please take into account the following points:
Models designed for outdoor must be equipped with an anti-frost thermostat and electrical
‘Trace heating’ to protect the condense drain system
The total weight of the condensate drain system must not be supported by the heater, and
must be suitably and separately supported.
The condensate discharge system must be inclined suitably. It is forbidden to install pipes that
are levelled and/or not inclined;
The configuration of the condensate discharge system must allow for the easy removal of the
various inspection panels.
The condensate discharge system must be easily removable, for any inspection and/or
maintenance operations.