Reznor EURO-C 4000 RJL User guide

Euro-C 4000-JLGBEN 1/31
0307C4-JLGBEN
Application instructions
EURO-C 4000 RJL
EURO-C 4000 DJL
Jacket-less, Gas fired, Balanced flue, Power vented, Air heater
This document applies when installing into an air handler or as part of an air
handling system
These appliances meet the following EC Directives
Dir. CE/90/396/EEC:GAD
Dir. CE/89/336/EEC:EMC
Dir. CE/73/23/EEC:LVD
Dir. CE/89/392 EEC:MD (annex ll, sub B)
Subject to modifications
Reznor U.K. Limited –Park Farm Road –Folkestone –Kent –
tel [phone] –fax [phone]
Please read this d
ocument carefully prior to commencing building into an air handler

Euro-C 4000-JLGBEN 2/31
EC Declaration of incorporation
(Directive 89/392/EEC (annex ll, Sub B)
Ban on putting into service
Reznor Europe N.V.
J & M Sabbestraat 130
B 8930 Menen
Belgium
Herewith declares that:
Power vented gas fired air heaters type:
EURO-C 4000 RJL or EURO-C 4000 DJL
Models 4011 –4015 –4018 –4024 –4030 –4047 –4060 –4072 &
4100
Are destined to be incorporated in other machines (air-handlers) or to be
combined with other machines (air-handling systems), and is not entirely in
compliance with the machinery directive (89/392/EEC as amended
91/368/EEC, 93/444/EEC, 93/68/EEC
Is in conformity with the provisions of the following other EEC directives :
G.A.D. and E.M.D. and L.V.D.
The following harmonised standards have been applied:
EN1020 –EN 60335-1 and EN 50165
Menen 8th June 2000
Vanryckegem Marnix

Euro-C 4000-JLGBEN 3/31
INDEX:
DECLARATION STATEMENT...................................................................................... 2
1.0 DEFINITIONS .............................................................................................. 4
2.0 BASIC INFORMATION..................................................................................... 4
3.0 PRACTICAL APPLICATION ............................................................................. 11
4.0 LIMITATIONS FOR USE ................................................................................. 12
5.0 BURNER & CONTROLS SECTION...................................................................... 14
6.0 GAS CONNECTION...................................................................................... 15
7.0 ELECTRICAL EQUIPMENT............................................................................... 15
8.0 COMBUSTION CIRCUIT EURO-C RJL .............................................................. 16
9.0 COMBUSTION CIRCUIT EURO-C DJL .............................................................. 21
10.0 PRESSURE DROP INFORMATION ...................................................................... 25
11.0 HEATING SECTION WITH BY-PASS CHANNELS...................................................... 26
12.0 TECHNICAL DATA ...................................................................................... 30

Euro-C 4000-JLGBEN 4/31
1. Definitions
1.1 Jacket-less:
A gas-fired air heater supplied as a
skeleton appliance e.g. without case or
cover.
1.2 Module:
The jacket-less gas fired air heater.
1.3 Constructor:
The undertaking, which builds a module
into another casing. e.g. an air handler
1.4 Appliance;
The end product of the constructor
1.5 Compartment:
The section of an appliance into which
the module is installed
1.6 B22 Appliance:
An appliance where the air for
combustion is taken from within the area
where the gas burner is operated.
1.7 C12 Appliance:
An appliance where the air for
combustion is taken from outdoors via a
duct terminating horizontally from the
appliance.
1.8 C32 Appliance
An appliance where the air for
combustion is taken from outdoors via a
duct terminating from the appliance
vertically.
1.9 Dew point:
The condition, when the temperature is
such that the water vapour in the
combustion products condenses out.
2. Basic information
2.1 The instructions contained in this
document apply to model EURO-C 4000
RJL and/or EURO-C DJL gas fired fan
assisted warm air heaters.
2.2 Models EURO-C 4000 RJL are intended
for use as outdoor (roof top) systems.
Models EURO-C 4000 DJL are intended
for use indoors and may be used as:
B22: Vertically or horizontally flue
heaters
C12: Horizontal vent balanced flue
heaters
C32: Vertical vented balanced flue
heaters
2.3 The gas category for use is II2H3+ (GB & IE)
2.4 All models may only be used when
installed within a closed compartment,
e.g. an air handler.
2.5 Dimensions : we refer to the figures 1, 2
and 3.
All dimensions are in mm (25.4mm= 1
inch)
ATTENTION
ONLY RECOGNIZED AIR HANDLER MANUFACTURERS ARE AUTHORIZED TO BUILD-
IN THE HEATER MODULE. PLEASE CONTACT YOUR DISTRIBUTOR
Note:Manufacturer warranties do not apply in such circumstances.
DANGER
ANY OTHER APPLICATION IS FORBIDDEN AND DANGEROUS. FAILURE TO COMPLY
WILL
RESULT IN SEVERE PERSONAL INJURY OR DEATH AND OR PROPERTY
DAMAGE.

Euro-C 4000-JLGBEN 5/31
Figure 1 : Dimensions EURO-C 4011-15 RJL/DJL
Fig. 1/A
Fig. 1/B

Euro-C 4000-JLGBEN 6/31
Fig. 1/C

Euro-C 4000-JLGBEN 7/31
Figure 2 : Dimensions EURO-C 4018-72 RJL/DJL
Fig. 2/A
Fig. 2/B

Euro-C 4000-JLGBEN 8/31
Fig. 2/C

Euro-C 4000-JLGBEN 9/31
Figure 3 : Dimensions EURO-C 4100 RJL/DJL
Fig. 3/A
Fig. 3/B

Euro-C 4000-JLGBEN 10/31
Fig. 3/C

Euro-C 4000-JLGBEN 11/31
3.0 Practical Application
3.1 Heat exchanger compartment size.
3.1.1 The duct section or air handler compartment must be sized in accordance with the dimensions
given in table 1 with reference to figure 4. Mounting flanges on the modules EURO-C 4000 RJL &
DJL allow easy installation.
Figure 4. Compartment dimensions key reference Table 1.
For horizontal airflow For vertical airflow
Table 1. Dimensions of enclosures (duct channel) for EURO-C 4000 heating modules re. fig 4
Dimension DMODEL Dimension A Dimension B Dimension C Min. Max
4011 310 490 640 315 373
4015 410 490 640 315 373
4018 480 490 640 315 393
4024 480 620 640 315 393
4030 550 620 640 315 393
4036 696 620 640 330 408
4047 836 620 640 330 408
4060 696 950 640 330 408
4072 836 950 640 330 408
4100 900 1800 350 330 408

Euro-C 4000-JLGBEN 12/31
3.1.2 The heating module may only be fitted as shown in figure 5. Alternative attitudes are not
allowed.
Figure 5 Installation possibilities for EURO-C air heater modules
4.0 Limitations for Use
4.1 Heat exchanger compartment
4.1.1 Minimum airflow requirement :
EURO-C 4000 RJL & DJL air heaters may be used for either push through or pull through air
heaters. The minimum airflow duty through the heating section enclosure (see fig. 4 –
table 1) must be observed as indicated in table 2.
Table 2 AIRFLOW DUTY
MODEL Min. air volume required
through enclosure
m3/h
Heat output
100% -1 stage
kW
Heat output
50% -2 stage
kW
Heat output
30% -modulating
kW
4011 1465 10.80 5.40 3.24
4015 1940 14.50 7.25 4.35
4018 2270 18.00 9.00 5.40
4024 2880 24.00 12.00 7.20
4030 3290 29.80 14.90 8.94
4036 5281 35.80 17.90 10.74
4047 6344 46.40 23.20 13.92
4060 8093 60.00 30.00 18.00
4072 9600 72.00 36.00 21.60
4100 16000 98.00 49.00 29.40

Euro-C 4000-JLGBEN 13/31
4.1.2 Maximum airflow
Special attention must be given to ensure
that the temperature rise of the air,
passing through the enclosure (duct
channel) around the heat exchanger
tubes, is high enough to 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 6 indicates the probability of
condensation forming within the tubes
reference :
-the temperature rise of the air
through the enclosure around the
tubes (see table 1-fig. 4).
-the inlet air temperature passing 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 shown in figure 6.
Example
•expected minimum inlet temperature = -5°C
•minimum required temperature rise shown on
the chart = +13°K
Table 2 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 :
0,3423
minimum
T
1000(kW)inputheat
(m³/h)
max
V×
×
=?
Example :
<Tmin = 13K
model 4072 at 100% heat input : 72,00kW
results into Vmax = 16180m³/h
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.
Figure 6 Dew-point occurrence chart (condensation zone)
¦
¦
¦

Euro-C 4000-JLGBEN 14/31
4.2.0 By-pass
For application where the air duty
exceeds that required to maintain the
criteria stated above then, a parallel by-
pass is required to conduct the excess air
around the heat exchanger.
Such a by-pass should be so designed
and constructed so that the air flow
(m³/h) across the enclosure (duct
channel) around the tube is maintained
between the minimum and maximum
figures.
The recommended by-passes per type of
unit are shown in figures 16,17,18 & 19
We refer also to §11.0.
4.3.0 Important remark
The air velocity needs to be equal over
the total area of the heating section so
that even distribution is achieved over
the entire heat exchanger tube assembly.
Attention :
Special attention is necessary assessing
air velocities especially in a push through
system, baffles and or an air-stream
diverter/s may be necessary to ensure an
even distribution of the air-flow.
Part or the whole of the tubes may
become damaged or can be the source of
poor combustion if the air velocity as
recommended above is not applied.
5.0 Burner & controls section
5.1 The following conditions must be
observed when applying the heating
module with its burner controls.
5.1.1 An enclosure containing EURO-C 4000
heating modules shall be so constructed
that it is fully protected against the
rigours of the environment in which it is
intended to operate.
5.1.2 When applied as an RJL (roof top/outdoor
unit) the enclosure into which it is
fitted,must comply with protection grade
IP 45.
5.1.3 Access to compartments enclosing the
burner and its controls must be provided
with panels, doors, etc. that are intended
to be opened only by the use of a tool
(key). Such panels must be designed to
ensure that after repeated removal and
replacement their integrity is not
jeopardised, i.e. seals and insulate etc.
remain serviceable.
5.1.4 Openings from the outside of the air
handler, e.g. gas and electrical services,
shall not be larger than to permit a ball of
16 mm diameter to pass with a pressure
of 5N.
5.1.5 Dimensions (mm) of control cabinet
With reference to figure 4, the
dimensions of the control cabinet must
be in accordance with table 3
Table 3
Type H
(min W (min) D (min) D (max)
4011 369 655 315 373
4015 521 655 315 373
4018 521 655 315 393
4024 626 715 315 393
4030 626 715 315 393
4036 903 715 330 408
4047 903 715 330 408
4060 903 715 330 408
4072 903 715 330 408
4100 1005 680 300 408
Warning
Use of EURO-
C heating modules for
purposes other than those described
above could
result in severe personal
injury or death and cause property
damage.
The manufacturer warranties are void if
departu
re from the intended use is
undertaken.
Warning
This heating module may not be us
ed
where the air handler/heating system in
which it is installed will be used where,
flammable substances/vapours exist or
where the atmosphere contains
chlorinated or haloginated hydrocarbons,
silicones, aluminium oxides, etc.
The manufacturer warranties are void
if
these restrictions are not observed

Euro-C 4000-JLGBEN 15/31
CAUTION
Alterations to the burner and/or its controls, any
other electrical apparatus supplied as part of the
heating module or changing of the settings as
supplied is strictly forbidden to do so is in
contravention of the E.C. gas appliance directive
1990.
5.1.6 Thermal insulation used in the
construction of a heating module
enclosure shall maintain its insulating
properties under the influence of heat
mechanical stress and ageing, it shall be
non-combustible and resistant against
vermin. Ensure that any insulation is
securely fixed and will not obstruct
combustion air pathways.
Asbestos or materials containing
asbestos may not be used.
All materials used in association with
EURO-C 4000 modules must be in
accordance with the combustibility
requirements of ISO 1182 1990.
5.1.7 Where appliances containing EURO-C
4000 modules are intended to be
installed at a height of 1,8 m above floor
level, doors, panels etc. intended to be
removed for servicing shall be provided
with hinges, or restraining devices to
prevent falling from above during
servicing. Access panels must be readily
capable of correct and easy removal and
assembly, this feature is particularly
appropriate to square dimensioned
elements.
NOTE:
Provision must be made to view the burner to
ensure its operation under normal operating
conditions. Viewing ports may be necessary.
Ensure no flammable substances are in the
immediate environment of the heating module.
6.0 Gas Connection (3/4”)
6.1National requirements and regulations for
the installation of gas must be respected
for all countries into which the appliance
is delivered. Gas connections may only
be carried out be appropriately qualified
persons.
6.1.2 Clearances around connections shall be
adequate so as to afford access to allow
the use of tools to connect and
disconnect the gas service connections.
6.1.3 Threads use for gas pipes and fittings
shall comply with ISO 7.1 1994.
6.1.4 Copper pipes and fittings may not be
used. Solder which has a melting point of
less than 450o C neither solder or alloys
containing cadmium shall not be used.
6.1.5 All gas services to the heating module
shall be equipped with an isolation tap
which shall be of the 90oturn type and
shall be provided with a positive stop and
it should be fitted adjacent to the heating
module. Such taps when installed in a
vertical position shall be so that in the
event of a falling handle the valve will be
in the closed condition, the open and
closed positing shall be readily
distinguishable. The valve shall be easy
to operate when required.
7.0 Electrical Equipment
7.1.0 The EURO-C 4000 heating module has
been fully tested prior to leaving the
manufacturer. The constructor shall not
make changes to the wiring supplied with
the module. Electrical connections may
only be made using the terminals
provided and strictly in accordance with
wiring diagram provided with the module.
7.1.1 EURO-C 4000 electrical controls are
phase sensitive 230V 1N 50 Hz. The
appliance must be earthed after the
installation has been completed and earth
continuity test must be carried out.
7.1.2 The electrical equipment of the module
complies with the requirements of: EN
60335-1, EN60730-1 and EN61058-1 or
to relevant amendments. The constructor
must also comply with these
requirements when fitting the module.
7.1.3 The protection of jacket less appliances
conforms to protection code IP 20. The
constructor must ensure that protection
to at least IP 45 is fulfilled and mark his
data/rating plate accordingly.

Euro-C 4000-JLGBEN 16/31
NOTE: IP 45 provides:
a) Personal protection against contact with
electrical components within the
construction;
b) Degree of protection within the construction
against ingress of water.
7.1.4 The constructor shall test and inspect
fully the total appliance prior to supply
including the following:
a) Earth continuity (re: CENELEC 289)
b) Dielectric strain (re: CENELEC 289)
c) Function of all electrical components
and securities and operational
inspection
d) Heat input and test for good and
clean combustion
e) Auxiliary equipment to be supplied
as part of the appliance
f) Soundness of the total gas circuit
8.0 Combustion Circuit EURO-C
4000 RJL
8.1.1 Inlets for combustion air and flue outlets
shall be so designed so that when an
appliance is finally installed their
termination shall be at least 500mm
above deck/ground level.
8.1.2. The heating modules are delivered with
all parts necessary for the construction of
the jacket so that combustion can take
place in a full save manner.
Consequently included with the heating
module are :
-Û100 terminal outlet length 300mm
(PN°60 50712 300)
-90° elbow with sealing ring (dia 100)
(PN 60 50733 100)
-Flue outlet combustion air inlet panel
assembly (PN 81 74076)
-Û100 flue pipe (model 4100 only) (PN
60 20124 500)
-Gas tube sealing ring (PN 06 22783 125)
The 90° elbow, the terminal outlet and
the flue outlet panel assy must be
installed according to figure 7. All
sealing must be correctly placed in the
tubes to avoid flowing back of
combustion products to the burner. As
indicated, the flue outlet panel assy (PN
81 74076) must be integrated in the side
panel of the controls compartment. The
dimensions of the required opening in this
side panel and its position relative to the
mounting flange of the EURO-C 4000
RJL heating module are indicated in
figure 8a & 8b. It is recommended to
properly seal the flue outlet panel assy.
When installing, respect top and bottom
of the flue outlet/combustion air inlet.
The protection cap (PN 60 50712 300)
must be fitted in a horizontal plain.
Remark :
for model EURO-C 4100 RJL, the
position of the flue outlet terminal
(dimension 333,2mm) (fig. 8b) can be
adjusted by reducing the length of the
500mm long flue pipe (PN 60 20124
500).

Euro-C 4000-JLGBEN 17/31
Figure 7. : General arrangement combustion air inlet and flue products outlet
Model 4011-72
Model 4100

Euro-C 4000-JLGBEN 18/31
Figure 8a : models 4011-72
Figure 8b : model 4100

Euro-C 4000-JLGBEN 19/31
Figure 8c : all models
Figure 9a : models 4011-72

Euro-C 4000-JLGBEN 20/31
Figure 9b : model 4100
8.1.3 The protection cap (PN 60 50712 300)
of heavy wall aluminium duct supplied
must be placed so as to fit exactly
between the elbow on the combustion
fan and the outlet terminal.
If required this protection cap must be
cut to length in order to respect the
dimension 75.0mm (fig. 8c / front view).
However, when the depth of the control
compartment exceeds the maximum
value indicated in table 3, a seamless
duct ∅100 of heavy wall aluminium and
a sealing ring are to be used to extend
the length of the protection cap (PN 60
50712 300). The absolute maximum
allowable extension to the protection cap
(std. length 300mm) is 700mm.
8.1.4 Attention must be given to properly seal
the mounting flange of the heating
module (see figure 9).
NOTE:OTHER FLUE ARRANGEMENTS THAN THOSE
DESCRIBED AND SUPPLIED WITH THE HEATING
MODULE ARE NOT PERMITTED
8.1.5 A gas service inlet (PVC) sealing ring is
also provided for the appliance for size R
¾”. The hole size required for the seal ring
in the casing is 50 mm diameter.
All cables and wires passing through the
casing of the burner/controls section
should be via strain relief bushings. It is
recommended that sealing is accomplished
by the use of the sealed ring type.
Connections between the burner module
controls compartment must be effectively
sealed from the appliance air-stream so the
pressure within the combustion circuit
remains at ambient within the
compartment