Thomas&Betts Reznor EURO-C 4000 DJL Technical manual

0008DJL-GBEN 1
0101DJL-GBEN
EURO-C 4000 DJL
Gas-Fired, Balanced-Flue or Power-Vented Unit Heater
INSTRUCTION DOCUMENT
APPLIES FOR: Installation/Commissioning/Servicing
These appliances meet the following EC Directives
DIR CE 90/396/EEC:GAD
DIR CE 89/336/EEC: EMC
DIR 73/23/EEC: LVD
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
.
WARNING:
Improper installation, adjustment, alteration, service, or maintenance can cause property damage,
injury, or death. All work must be carried out by appropriately qualified persons.
Subject to modifications
Reznor Europe N.V. – J&M Sabbestraat 130 – B 8930 Menen – tel [phone] – fax [phone]

0008DJL-GBEN 2
Table of Contents
1.0 INTRODUCTION
1.1 Basic Information
1.2 Warranty
2.0 TECHNICAL DATA
3.0 GENERAL REQUIREMENTS
3.1 Related Documents
3.2 Heater Location
3.3 Minimum airflow duty
3.4 Compartment dimensions
3.5 Maximum airflow conditions
3.6 Combustion air supply & flue system
3.7 Air Supply
3.8 Electrical supply
3.9 Gas supply
4.0 INSTALLATION
4.1 Fitting the combustion air inlet/flue system
4.2 Electrical Connection
4.3 Room Thermostat Siting
4.4 Gas connection
5.0 COMMISSIONING AND TESTING
5.1 Electrical Check
5.2 Gas Connection
5.3 Lighting the Heater
5.3.1 To Turn the Heater ON
5.3.2 To Turn the Heater OFF for Short Periods
5.3.3 To Turn the Heater OFF for Long Periods
5.4 Heater Pipework
5.5 Adjustments
5.6 Options
5.6.1 2 stage burner control
5.6.2 Modureg V7335A 2000 series modulation
system
5.7 Air heater controls & operation
5.8 Handing Over
6.0 SERVICING INSTRUCTIONS
7.0 REMOVAL AND REPLACEMENT OF PARTS
7.1 Main Burner Removal
7.2 Main Burner Injectors
7.3 Ignition System
7.4 Multi functional gas control valve
7.5 Limit Controls
7.6 Combustion Air Control Switch
7.7 Combustion Air Fan
8.0 FAULT FINDING
9.0 PARTS LIST
10.0.GAS CONVERSION
11.0 USERS INSTRUCTIONS
12.0 HEALTH & SAFETY STATEMENT
HAZARD INTENSITY LEVELS
1. DANGER: Failure to comply will result in severe
personal injury or death and/or property damage.
2. WARNING: Failure to comply could result in
severe personal injury or death and/or property
damage.
3. CAUTION: Failure to comply could result in
minor personal injury and/or property damage.
WARNING:
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 fan
prematurely and may damage the heat exchanger,
invalidating the warranty.
1.0 INTRODUCTION
1.1 Basic Information
The instructions in this manual apply to Model
EURO-C 4000 DJL gas-fired/fan-assisted warm air
heaters. These air heater modules are suitable for
indoor air handlers only. When installed where the
height above floor level is greater than 1,8 meters
measured to the underside of the appliance they
may be used as a garage air heater. This appliance
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.
Model EURO-C 4000 DJL heaters are approved for:
Type C12 - horizontal vent for balanced-flue heaters;
Type C32 - vertical vent for balanced-flue heaters;
Type B 22 - vertical vent;
Category II2H3+
These instructions are only valid for the countries
Great Britain (GB) and the Republic of Ireland (IE).
Check that the local distribution conditions of
electricity supply, type of gas and pressure of the
appliance are compatible.

0008DJL-GBEN 3
When installed in Great Britain the total installation
must comply with the requirements and
recommendations of British Standard BS 6230
1991 “Installation of Gas Fired Forced Convection
Air Heaters for Commercial and Industrial 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 premises “Insurance” undertaking and
the “Fire Office” must also be observed.
When the external control calls for heat, an
electronic control begins the ignition sequence to
provide for a safe start. Under normal conditions
the fan motor 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 electronic control 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
running to cool down the heat exchanger
In some applicatins, after approximately 45
seconds, the fan delay relay will turn off the fan (if
wired).
1.2 Warranty
Warranty is void if:
a) Model EURO-C 4000 DJL heaters are installed
in atmospheres containing flammable vapors
or atmospheres containing chlorinated or
halogenated hydrocarbons or atmospheres
containing any silicone, aluminum oxide, etc.,
that adheres to spark ignition flame sensing
probes.
b) The installation is not in accordance with these
instructions.
c) The maximum air flow through the heat
exchanger tubes is not respected (see§ 3.5)
d) The required minimum air delivery is not
respected (see table 3b).
e) The duct dimensions do not comply with the
prescribed dimensions (see fig. 4)
f) The inlet temperature (measured at the heat
exchanger inlet) is lower than the value stated
on the chart (see fig. 5 : dew point occurance
chart).
2.0 TECHNICAL DATA
2.1 Specifications
Table 1 - Model EURO-C 4000 DJL Specifications
Model Heat input Heat
output Gas rate 3Power Consumption
G20 G30 G31
kW gros1kW net2kW m³/h kg/h kg/h kW
4011 13.20 11.91 10.80 1.26 0.96 0.94 0.153
4015 17.60 15.85 14.50 1.68 1.28 1.26 0.153
4018 22.00 19.81 18.00 2.10 1.61 1.57 0.153
4024 29.30 26.38 24.00 2.79 2.14 2.10 0.153
4030 36.60 33.00 29.80 3.49 2.67 2.61 0.153
4036 44.00 39.60 35.80 4.20 3.21 3.14 0.153
4047 56.60 51.00 46.40 5.40 4.13 4.04 0.153
4060 73.30 66.00 60.00 6.99 5.35 5.23 0.153
4072 87.90 79.15 72.00 8.39 6.42 6.28 0.153
4100 122.00 110.00 98.00 11.64 8.91 8.71 0.153
Notes to table 1:
1. GCV (Hs)
2. NCV (Hi)
3. Natural gas G20 gross calorific value 10,48 kW m3@ 15 °C, 1013,25 mbar
Butane gas G30 gross calorific value 13,7 kW/kg
Propane gas G31 gross calorific vale 14,0 kW/kg

0008DJL-GBEN 4
Table 2A : Injector size and burner pressure
G20 natural gas - inlet pressure = 17.5 mbar for UK
20.0 mbar for IE
Injector size
Model Quantity mm marking Burner pressure
(mbar) (1)
4011 3 1.85 1.85 9.00
4015 4 1.85 1.85 8.90
4018 5 1.85 1.85 9.00
4024 5 2.20 220 8.20
4030 6 2.20 220 9.10
4036 8 2.20 220 7.60
4047 10 2.20 220 8.10
4060 8 2.70 270 9.30
4072 10 2.70 270 8.90
4100 12 3.00 300 7.85
Table 2B : Injector size and burner pressure
G30/G31 butane/propane
inlet pressure G30 = 28mbar - inlet pressure G31 = 37mbar
Injector size Burner pressure
(mbar) (1)
Model Quantity mm marking Butane Propane
4011 3 1.00 100 27.9 36.9
4015 4 1.00 100 27.8 36.8
4018 5 1.00 100 27.8 36.9
4024 5 1.20 120 27.8 36.7
4030 6 1.20 120 27.5 36.4
4036 8 1.15 115 27.3 36.3
4047 10 1.20 120 26.7 35.7
4060 8 1.50 150 26.7 35.7
4072 10 1.45 145 25.1 35.1
4100 12 1.55 155 25.0 34.0
(1) with open service door

0008DJL-GBEN 5
2.2. Mounting flange & main dimensions
Figure 1 : Dimensions for model 4011/15
Figure 2 : dimensions for models 4018/24/30/36/47/60/72

0008DJL-GBEN 6
Figure 3 : Dimensions for model 4100
Weights (kg) 4011 4015 4018 4024 4030 4036 4047 4060 4072 4100
unit 20 25 30 31 33 52 55 65 70 110
packaging 12141418182323232340
total 323944495175788893150

0101DJL-GBEN 7
3.0 GENERAL REQUIREMENTS
3.1 Related documents
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 or de-
greasing plants or in areas where there is a fire risk.
3.2 Heater location
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. The location must also
provide sufficient space to allow the heater to be
serviced.
CAUTION: Do not locate the air heater where it
may be exposed to water spry, rain, etc.
Table 3a
Installation clearances (mm)
Model 40..DJL 11,15
18 24,30,3 6,47 60,72 100
To
p
50 150 150
Flue connector 150 150 150
Access
p
anel 500 600 600
Non-access side 50 150 150
Bottom 50 50 50
3.3 Minimum airflow requirement (table 3b)
The minimum airflow duty through the heating
section enclosure (see figure 4) must be observed
as indicated in table 3b
Table 3bMODEL Min. air volume
required (m3/h)
4011 1465
4015 1940
4018 2270
4024 2880
4030 3290
4036 5281
4047 6344
4060 8093
4072 9600
4100 16000
3.4 Compartment dimensions
Figure 4 for horizontal airflow
For vertical airflow
Model Dim A (mm) Dim B (mm) Dim C (mm)
4011 310 490 640
4015 410 490 640
4018 480 490 640
4024 480 620 640
4030 550 620 640
4036 696 620 640
4047 836 620 640
4060 696 950 640
4072 836 950 640
4100 900 1800 350
3.5 Maximum airflow condition
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.

0008DJL-GBEN 8
The chart below indicates the probability of
condensation forming within the tubes reference :
-the temperature rise of the air through the
enclosure (around the tubes) (see figure 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 on page 7.
Example
•expected minimum inlet temperature = -5°C
•minimum required temperature rise shown on
the chart = +13°K
Table 1 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 5 : Dew point occurrence chart (condensation zone)

0008DJL-GBEN 9
3.6 Combustion air supply & flue system
The air heater may be installed as a balanced flue
(Type C) heater requiring both a combustion air
inlet duct and a flue pipe or as a power vented
(Type B) heater, which requires only a flue pipe
exhausting to outdoors. All products of combustion
must be flued to outdoor atmosphere.
Figure 6 : Combustion air and flue pipe sockets
Each heater installed as a type B appliance must be
fitted with an individual flue pipe and the combustion
air inlet socket (IP20) (1). Each heater installed as a
type C appliance must be fitted with an individual
combustion air/flue pipe system. Only systems
specified by the air heater manufacturer may be used.
Common flue and combustion air systems must not be
used.
IMPORTANT: The flue must be installed in accordance
with national and local regulations. Failure to provide
proper fluing could result in death, serious injury
and/or property damage. The air heater must be
installed with a flue to the outside of the building.
Safe operation of any power vented gas apparatus
requires a properly operating flue system, correct
provision for combustion air, and regular maintenance
and inspection.
(1) dia 80 = PN 68 1751201 (EURO-C 4011/15 DJL)
dia 100=PN 02 250090(EURO-C 4018 & 4030 DJL )
dia130 = PN 02 25094 (EURO-C 4036 & 4100 DJL )
3.6.1 Flues for power vented installations
(Type B appliances)
If the air heater is to be installed as a type B appliance,
air for combustion will be taken from within the space
where the heater is installed. Ensure that an adequate
air supply for combustion and ventilation is provided
within the building in accordance with the regulations
& rules in force.
Table 4 shows flue pipe sizes and maximum vent
lengths. The minimum flue length is 0.5 metres.
Table 4 Flue pipe diameters & maximum lengths
Single wall flue pipes are required. All joints must be
sealed to prevent products of combustion from leaking
into the building. An approved flue terminal is required.
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 25 mm 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 50 mm away from any
combustible material.
Single wall flue pipe exposed to cold air or run through
unheated areas must be insulated. Where
condensation is unavoidable, provision must be made
for the condensation to flow freely to a point to which
it can be released, i.e. a drain or gully.
The condensation drain from the flue must be
constructed from non-corrodible material not less than
20 mm diameter. Copper or copper-based alloys must
not be used for condensation drains.
3.6.2 Combustion air inlet pipe & flue pipe for
balanced flue installation (Type C appliances)
Balanced flue air heaters are designed to be fitted with
a combustion air inlet duct that obtains outdoor air
and a flue pipe that exhausts flue products to
outdoors.
Air heaters if fitted with a power venter permitting
either a vertical or horizontal combustion air inlet/flue
pipe system. The heaters must be installed with a
concentric vertical or horizontal flue/air inlet. The
heaters are only approved for use when installed with
the appropriate approved concentric vent terminal. See
table 5.
Both the flue and combustion air pipes must be
sealed. Use gasket sealed seamless aluminum pipe or
equivalent.
Model 40.. DJL 11
15 18 24,30 36,47 60,72,100
Heater socket & mm
pipe dia 80 100 130
Maximum straight m
length 7.5
Equivalent length m
of 90° elbow 1.5

0008DJL-GBEN 10
The flue pipe must include a re-sealable test port to
allow good average sampling of the flue gas mixture
for testing, the port must be at least 450 mm away
from the air heater flue connection socket.
Follow any flue pipe manufacturers installation
instructions for making joints, including connections to
the air heater, for passing through a building element
and for support requirements. If more than one air
heater is being installed in the same place each heater
must have a separate flue system.
Table 5 Combustion air inlet & flue pipe requirements
Model EURO-C 40.. D(JL) 11
15 18,24,30 36,47,60,72,100
Heater socket & pipe dia mm Flue pipe 80 100 130
Inlet pipe 80 100 130
Max. straight length m Flue pipe 9 9 9
Inlet pipe 9 9 9
Inlet pipe 0.75 0.75 0.75
Equivalent length of 45 ° elbow m
Flue pipe 0.75 0.75 0.50
Equivalent length of 90 ° elbow m Flue pipe 1.5 1.5 1.5
inlet pipe 1.5 1.5 1.5
Concentric vertical vent or wall terminal: types : Mugro/Burfix Â
ÂÂ
Â80 - Mugro/Burfix Â
ÂÂ
Â100 - Mugro/Burfix Â
ÂÂ
Â130
Concentric horizontal vent or roof terminal: types : Mugro/Burfix Â
ÂÂ
Â80 - Mugro/Burfix Â
ÂÂ
Â100 - Mugro/Burfix Â
ÂÂ
Â130
3.7 Air supply
It is important to ensure that there is an adequate air
supply at all times for both combustion and heating
requirements. Modern constructions involve the
greater use of insulation, improved vapor barriers, and
weather proofing. This 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. 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.
Fit an access guard to the combustion air inlet and
take appropriate action to ensure that it remains
unblocked.
WARNING: This model air heater is installed as a type
B application and is designed to take air for
combustion from the space in which it is installed. Do
not restrict the combustion air intake.
3.8 Electrical supply
Wiring external to the air heater must be carried out in
accordance with the rules in force and by
appropriately qualified persons.
A constant 230 volt 50 Hertz single phase with
neutral link fused electricity supply is required. All
heaters and controls must be earthed. A lockable
isolator with contact separation of at least 3.0 mm on
all poles should be installed adjacent to the appliance
and within reach of any person working on the heater.
When a number of heaters are to be connected as part
of a single installation each heater must be provided
with a separate isolator.
Ensure that electrical supply cables do not touch the
very hot combustion collector box. The cables must
be fitted on the gas pipe inside the service
compartment. The final connection must be made in
the terminals provided in the control compartment.
Follow the wiring diagram provided with the air heater.
Electrical supply cable conductor size should be 1.5
mm. Fit the cord grip supplied with the heater. The
length of conductors between the cord grip and the
terminals must be such that in the event that the cable
becomes taut the line conductors do so before the
earth conductor.

0008DJL-GBEN 11
3.9 Gas supply
EURO-C 4000 DJL air heaters are designed to operate
on either natural gas (G20) or propane (G31) / butane
(G30) gas. Refer to the specifications in section 2 of
this document and to the data plate for details of
supply pressures.
The gas meter and gas service must be checked by
the supply undertaking to ensure that they are
adequate to deal with the total load of all gas fired
apparatus installed.
Refer also to § 4.4 ‘Gas connection’.
4.0 INSTALLATION
4.1 Fitting the combustion air inlet/flue system
Flue pipe runs may be horizontal or vertical and
terminate either through the wall or roof. See
table 4 for maximum vent length for an appliance
installed as type B or table 5 for maximum lengths
and approved supplied concentric terminals for a
heater installed as a type C appliance.
4.1.1 Fitting the flue pipe
Flue pipes must be sealed. Use seamless, aluminum
pipe or equivalent. Follow pipe manufacturer's
instructions
Table 6 : Flue pipe socket size (Ø mm)
EURO-C 40.. DJL 11
15
18/24/30 36/47/60/72/100
Socket 80 100 130
4.1.2 Installing a guard on the combustion air inlet
pipe for power vent (Type B installations)
When installed as a type B appliance, protect the inlet
by fitting an access guard on the socket. Do not
block this socket as it supplies combustion air for the
burner
The inlet must be provided with a protection gril IP20
(see figure 7b).
4.1.3 Fitting the combustion air inlet pipe for
balanced flue (Type C installations)
The combustion air pipe attaches directly to the
inlet socket.. Air inlet pipes must be sealed. Use
seamless aluminum or equivalent. Follow the pipe
manufacturer's installation instructions. See typical
installations in figures 7a.
Table 7 Air inlet socket size (Ø mm)
Figure 7a :
Figure 7b :
4.2 Electrical connections
The electrical installation may only be carried out
by appropriately qualified persons observing the
rules in force.
All electrical connections should be made in the
heater control compartment.
Screw type terminals are provided. Connections
should be in accordance with the terminal
markings and the wiring diagram affixed to the air
heater or included with this document.
DANGER: THIS APPLIANCE MUST BE EARTHED
EURO-C 40..DJL 11,15 18,24,30 36,47,60,72,100
Socket 80 100 130

0008DJL-GBEN 12
The minimum external controls required for the air
heater are a room thermostat. It is essential the
main input line and neutral to terminals L and N
remains live at all times even when the appliance is
switch off this is to ensure correct operation of the
unit.
An indicator light and burner-reset button are fitted
inside the appliance. To add a remote reset button,
make connections to the terminals in the electric
box as indicated on the wiring diagram.
IMPORTANT: If the reset button requires activating
for any reason the cause should be identified
before resetting. After resetting stay with the
appliance for long enough to ensure that lockout
does not reoccur (suggest 5 minutes).
4.3 Room thermostat siting
The siting of the room thermostat is important. It
should not be fitted on an outside wall.
Avoid location in draughty areas or where it may
be influenced by heat sources e.g. the sun,
process plant, etc. The thermostat or temperature
sensor should be mounted on a vibration free
surface and mounted about 1,5 meters above floor
level Follow the thermostat manufacturers fitting
instructions. The thermostat must be suitable for
switching 230 volts
4.4 Gas connection (gas service connection ¾”)
Connection to a gas network may only be carried
out by appropriately qualified persons. The gas
installation must comply with the rules in force
using materials appropriate for gas installation.
To facilitate servicing, the air heater must be fitted
with an approved gas service tap and union fitting
or union tap adjacent to the appliance.
The inlet gas supply line must be installed so as to
permit the access door to be opened and to allow
removal of the slide out burner assembly.
Figure 8 : gas connection detail” ¾”
5.0 COMMISSIONING & TESTING
Appropriately qualified persons may only carry out
the commissioning and testing.
This section should be read and fully understood
before commencing commissioning and testing.
5.1 Electrical check
After completion of the installation and before
switching on the electrical supply to the appliance,
a qualified electrician must carry out a preliminary
check. The following must be checked:
* Check that electrical cables/wiring do not touch
the ‘hot’ combustion collector box and fix them
all on the gas pipe
* Check that all wiring is connected in
accordance with the appliance circuit diagram;
* Ascertain that the correct fuse value and cable
size has been provided;
* Check to ensure that the appliance is earthen
by conducting an earth continuity test. Connect
a test meter, one lead to the appliance earth
terminal and the other to the mains incoming
earth point at the electrical isolator. A
resistance reading of 1,0 ohm or less must be
indicated. If a higher reading is obtained, check
all cable connections to ensure adequate
security and cleanliness. If problem still exists,
it may be necessary to consult the electricity
supply undertaking;
* Carry out a polarity test. Connect one lead of a
suitable AC voltmeter to earth and connect the
other lead to the live supply terminal (L) at the
air heater. Switch ON the power to the air
heater and check for correct voltage.The same
result should be obtained by connecting the
test leads between live and neutral.
Connect the voltmeter test leads to N and E.
A reading of ±0V should be obtained. If these
tests do not conform with the above, there is a
fault which must be rectified before proceeding
further with the commissioning;
* Check that a suitable thermostat or control
panel has been fitted;
* Ensure that an electrical isolator with two pole
separation with a minimum air break between
poles of 3,0 mm has been fitted adjacent to the
air heater.
5.2 Gas connection
Only persons formally qualified to work on gas
fired apparatus may carry out commissioning and
testing. The whole of the gas service installation
including the meter must be inspected, tested for
soundness and purged in accordance with
appropriate requirements by a qualified person.
CAUTION: Never use a flame for checking gas
soundness.

0008DJL-GBEN 13
5.3 Lighting the air heater
EURO-C 4000 air heaters are all fitted with
automatic spark ignition systems. When adequate
airflow for combustion is proven by an air proving
control and a pre-purge period has elapsed, the
integral igniter and multi-functional gas control
operate. The ignition spark ignites the gas creating
the burner flame, which is detected by a flame rod
sensor. If a burner flame is not detected, the
ignition controller proceeds to lockout and requires
manually resetting. Lockout is indicated by the red
warning light on the air heater.
NOTE: If the first reset is not successful, wait 15
seconds before attempting reset.
5.3.1 To turn the air heater "ON"
The following checks should be carried out before
attempting to light the air heater.
* Ensure that the gas supply to the air heater is
turned ON;
* Ensure that the electrical supply to the air heater
is switched ON;
* If fitted ensure that a time switch is set to an
ON period
* Set room thermostat to call for heat. e.g. above
room ambient temperature (see air handling
system
* Adjust the room thermostat to the required
operating comfort temperature. The air heater
will now start automatically when the room
thermostat calls for heat.
NOTE: If the air heater will not start on initial
start-up, the ignition controller may be in lockout
position and require resetting. This may occur
especially if the appliance has been on stand-by for
a prolonged period.
5.3.2 To turn the air heater "OFF" for short periods
Adjust the room thermostat to its lowest setting or
'OFF'. The fan will continue to run to cool the
heater and then switch OFF automatically (or
follow the instructions of the air handler).
5.3.3 To turn the air heater "OFF" for long periods
Adjust the room thermostat to OFF or its lowest
setting. When the fan has stopped, turn OFF the
gas supply and then switch OFF the electricity
supply to the air heater (or follow the instructions
of the air handler).
5.4 Air heater gas pipework
The soundness of the air heater pipework has been
checked prior to leaving the factory. However
during installation, connections may have been
loosened. Check the soundness of the appliance
pipework using a soapy solution. If any leaks are
found they must be rectified immediately.
Caution: Never use a flame for testing for gas
soundness
5.5 Adjustments
Burner gas pressure adjustment
The gas pressure is set for the required heat input
before the appliance leaves the factory, normally
provided the gas supply to the air heater is in
accordance with the supply pressure described on
the appliance data plate the operating pressure will
not require adjustment. To check the pressure, the
following procedure should be carried out:
* Ascertain from section 1 of this document and
the appliance data plate the correct operating
gas pressure for the air heater;
* Turn the room thermostat control to its lowest
setting (see instructions of the air handler);
* Remove the screw from the outlet pressure test
point of the multi-functional control valve.
Connect a manometer to the test point;
* Adjust the room thermostat to call for heat e.g.
above room ambient temperature;
* Observe the burner gas pressure on the
manometer and compare to the required
pressure (on/off system : tables 2A/2B);
* If necessary, adjust the burner gas pressure.
Remove the cover screw (Honeywell
application) or cover cap (Sit application). Turn
the regulator screw anti-clockwise to decrease
pressure or clockwise to increase pressure;
* Set room thermostat to lowest setting to turn
OFF the burners. Replace the test point screw
(if removed) and with the main burner alight,
test for gas soundness using a soapy solution.
Reset temperature control/room thermostat to
comfort operating level.
Figure 9a :SIT gasvalve
Legend :
①gasvalve SIT 830 Tandem 040
②inlet pressure gas test point
③burner pressure gas test point
④burner pressure regulator cover
⑤burner pressure regulator
}electrical connection 230V

0008DJL-GBEN 14
Figure 9b : HONEYWELL gasvalve
Legend :
①gasvalve HONEYWELL V4601AB
②inlet pressure gas test point
③burner pressure gas test point
④burner pressure regulator cover
⑤burner pressure regulator
}electrical connection 230V
5.6 Options
5.6.1 Two stage burner control
Description
This option provides a 2-stage burner control
system providing 100% & 50% heat input.
Appliances so equipped will only operate in a two
stage manner when connected to a two stage
external control (room thermostat) or duct stat.
Important
Safe operation of the burner is only assured when
the low rate setting is 50% or greater than the
high rate setting. The low rage gas setting
pressure should therefore never be less than 25%
of the normal high rate setting pressure. See table
included in this document.
Nomenclature
This option may only be used in conjunction with
appliances fitted with Honeywell multi-functional
gas controls types VR 4601P.. or type V 4600P..
The valve operator V 4336A.. 3/20 for natural gas
or V 4336A..4/37 for propane gas may be used to
replace the single stage gas regulator already fitted
if conversion is being under taken.
Regulation is possible for the pressure range 3-20
mbar for natural gas and 4-37mbar for propane
gas.
A relay in the burner controls circuit is
necessary to ensure that burner start-up takes
place on high fire rate so that good main burner
cross lighting takes place.
Note:
The maximum gas pressure for all gas type is 60
mbar.
Care should be taken when handling the operator
for the purpose of replacement or exchange.
If upgrading of an existing single stage valve is
being carried out then the gas valve must be
marked accordingly to ensure that replacement
parts for the future are readily identified.
Figure 10 shows in outline view the valve operator
and indicates it's principal components.
Field adjustment & check-out
Important
1. Fitting and adjustment may only be carried
out by qualified persons.
2. Allow time for pre-set pressure to stabilise
before making adjustments i.e. 1 minute.
3. Operate high-low regulator a few times after
adjustment to ensure correct setting.
4. Remove cover cap as indicated in figure 10
Setting (refer to figure 10)
- lever off cover cap as indicated.
- before commencing an adjustment connect a
manometer to the burner pressure test point.
- maximum high rate setting must be adjusted
first after which the minimum low rate setting
can be adjusted. Any adjustment of the
maximum setting influences the minimum rate
setting.
- do not adjust maximum or minimum settings
above or below the pressure stated on the
data plate or in table 8
Adjusting maximum pressure
- energise high-low regulator, set gas control in
operation (light burner) and wait until an
outlet pressure is recorded on pressure gauge.
- use a 6mm hexagon wrench or a 10mm
screw drier to turn adjustment screw for
maximum pressure setting, clockwise to
increase counter clockwise to decrease
pressure until the desired maximum pressure
is obtained.
- check maximum pressure several times

0008DJL-GBEN 15
Figure 10: V 4336A.. Gas valve operator Adjusting minimum pressure setting
- disconnect electrical connection of high-low
regulator.
- set gas control in operation and wait until an
outlet pressure is recorded on the pressure
gauge.
- if minimum pressure setting needs adjusting
use a 3,5mm screw driver to turn adjustment
screw for minimum pressure setting
clockwise to increase counter clockwise to
decrease pressure until desired minimum
pressure is obtained.
- re-connect high-low regulator in circuit.
- check maximum pressure setting, re-adjust if
necessary and check minimum pressure
again. Replace regulator cap when finished.
Note : It is necessary to re-check pressure settings
during routine service and maintenance of the
appliance.
Table 8 : Models High/Low burner gas pressures and low rate consumption values
EURO-C 4000 RJL 4011 4015 4018 4024 4030 4036 4047 4060 4072 4100
nat gas G20 mbar 9.00 8.90 9.00 8.20 9.10 7.60 8.10 9.30 8.90 7.85
butane G30 mbar 27.90 27.80 27.80 28.70 27.50 27.30 26.70 26.70 25.10 25.00
Pressure at 100%
propane G31 mbar 36.90 36.80 36.90 36.70 36.40 36.3 35.70 35.70 35.10 34.00
nat gas G20 mbar 2.25 2.23 2.25 2.05 2.27 1.90 2.03 2.33 2.23 1.96
butane G30 mbar 6.98 6.95 6.95 7.18 6.88 6.83 6.68 6.68 6.28 6.25
Pressure at 50%
propane G31 mbar 9.23 9.20 9.23 9.18 9.10 9.08 8.93 8.93 8.78 8.50
nat gas G20 mbar 0.81 0.80 0.81 0.74 0.82 0.68 0.73 0.74 0.80 0.71
butane G30 mbar 2.51 2.50 2.50 2.58 2.48 2.46 2.40 2.40 2.26 2.25
Burner pressure
Pressure at 30%
propane G31 mbar 3.32 3.31 3.32 3.30 3.28 3.27 3.21 3.21 3.16 3.06
Natural G20 m³/h 0.63 0.84 1.05 1.40 1.75 2.10 2.70 3.50 4.19 5.82
Butane G30 kg/h 0.48 0.64 0.80 1.07 1.34 1.61 2.07 2.68 3.21 4.45
Gas
consumption
at 50% 1
Reference
15°C1013mb Propane G31 kg/h 0.47 0.63 0.79 1.05 1.31 1.57 2.02 2.62 3.14 4.36
1Natural gas G20 gross calorific value 10.48 kWh/m³ at 15°C & 1013 mbar Propane gas G31 gross calorific value 14.0 kg/h
Butane gas G30 gross calorific value 13.70 kg/h Low fire rate must not be reduced below the
values stated above for 50% rating.
Note :
Burner pressures for butane/propane gasses are approximate based on regulated supply pressure :
Calculation burner pressure : burner pressure at 100% input x (load)²
Example 1: type 4072, 50%, nat. gas G20: 8,9mbar x 0,5² = 2,23mbar
Example 2: type 4030, 75%, prop.gas G31: 36,4 mbar x 0,75² = 20,48 mbar

0008DJL-GBEN 16
5.6.2 Modureg V7335A 2000 series modulation
system
Figure 11 : Modureg V7335A
Legend :
1 : Shaft
2 : Adjustment screw (7mm) for maximum
pressure setting
3 : Adjustment screw (9mm) for minimum pressure
setting
4 : “O” ring
5 : 6.3mm AMP terminals
6 : M5 pressure feedback connection
The Modureg V7335A 2000 Series Modulating gas
pressure regulators are an optional addition which
can be used on "Honeywell" Multifunctional gas
controls for modulating the burner gas pressure for
firing over the range 50% to 100% of the nominal
high fire burner rate. Two model types are used
dependant on the gas type. They are identified Grey
cover = Natural gas, outlet pressure range 1,5 -
20,0 mbar. Yellow cover = Propane/Butane gas,
outlet pressure range 4,0 - 37,0 mbar (1)
Caution:
Reznor air heaters must be controlled so that burner
start-up takes place in the high fire (100%) mode.
Modureg gas pressure regulators require to be
powered by a maximum 24 V DC voltage over the
range 15 - 165 mA maximum. Maximum outlet
pressure occurs at the high set point value (high
fire). Minimum outlet pressure occurs at low set
point value (low fire). The power signal may be
obtained from a system amplifier which may be an
integral control within the appliance or, from a
remote control system designed to provide the
required controlling voltages
Adjusting the V7335A Regulator
Refer to figure 11.
To check the minimum or low fire and maximum or
high fire pressures for limits of modulation use the
following procedures.
Fit a manometer to appliance burner pressure test
point.
Important : allow time for gas pressure to stabilise
before making adjustments.
To Set Minimum (low fire) 50% or 30% rate (see
table)
1. Remove regulator cover cap;
2. Disconnect electrical connection to the
regulator coil;
3. Energise operator, set control in operation and
wait until outlet pressure is recorded on
manometer;
4. Use a 9 mm wrench to turn the minimum rate
adjustment screw clockwise to increase or
counter-clockwise to decrease the minimum
pressure setting
The minimum pressure setting must be adjusted
first, because any adjustment of the minimum
pressure setting influences the maximum pressure
setting.
To set Maximum (high fire) 100% rate
1. Follow point 1 above. Connect electrical
connection to the regulator coil and ask for
maximum heat;
2. Using a 7 mm wrench to turn the maximum
adjustment screw clockwise to increase or
counter-clockwise to decrease the maximum
pressure setting to the value stated on the
appliance data plate;
3. Replace cover cap, re-wire coil in circuit;
4. Operate burner several times in high,
intermediate and low-pressure modes and
check performance on the manometer.
FAULT FINDING “MODUREG” OPERATION :
Follow setting procedure for fault finding
1. Minimum or Low Fire unobtainable :
- Ambient temperature too high in location of
regulator max 70°C;
- Check input voltage to coil,
Zero volts is low fire mode, shaft out;
2. Cannot obtain Maximum or High fire :
- Open circuit to regulator coil;
Measure coil resistance = 127 Ω;
- Short circuit between coil and casing;
Check resistance between one terminal and
casing, reading indicates short circuit;
- Low voltage to regulator;
Check for correct voltage range, should
be: 0 - 24 V DC;

0008DJL-GBEN 17
- Low gas supply pressure;
Check natural gas GB = 17.5-20.0
mbar. Push down plunger, burner
pressure should rise to high-fire rate;
3. Erratic operation:
- Fluctuating or pulsating DC voltage ;
Check using meter, if pulsating suspect
input signal, transients, etc ...
4. Minimum rate lower than setting required or
below 1.5mbar :
- Minimum pressure set too low; re-adjust;
- Line supply gas inlet control regulator
faulty or requires adjustment;
Appliance gas tap not fully open
5.7 Air heater controls and operation
Check air heater operation after all adjustments
have been carried out. Set the temperature control
above ambient temperature.
EURO-C 4000 DJL air heaters are fitted with a
pressure sensitive, combustion air safety control
that monitors pressure differential if the combustion
airflow. The control operates with the settings
given in table 9 (settings are for sea level
installations)
When the combustion air safety control closes
verifying airflow, the gas control valve will open
and the burner will light. If the burner does not
light, the ignition controller will lockout and must be
manually reset. The air heater is fitted with a signal
lamp and manual reset button that indicates lock-
out.
NOTE: If the first reset is not successful wait 15
seconds before resetting the igniter.
Table 9 : Combustion air pressure control settings
Model Normal equilibrium
warm (Pascal) Set point 'off' (Pascal)
4011 95 68
4015 90 68
4018 180 130
4024 178 130
4030 180 130
4036 176 130
4047 180 130
4060 174 130
4072 160 130
4100 67 56
Wait approximately 30 seconds after the burner has
lit, the time delay relay will activate the thermal fan
control and will also activate the fan if wired (most
air handlers are equipped with constant running
fans). Continue to operate the air heater for several
minutes to ensure correct operation.
Turn room thermostat to its lowest setting. The
main burners should extinguish while the fan
continues to run to cool the air heater. The fan
delay relay will normally be de-energized and stop
the fan motor in approximately 45 seconds (if
wired).
5.8 Handing over
Upon satisfactory completion of commissioning and
testing, hand the instructions to the user or their
representative. Advise the appropriate person how
to safely use and operate the air heater and
describe the use of appropriate external controls.
Ensure that the person understands how to start
the heater and how to turn it OFF.
Suggest that the instructions are placed close to
the air heater for future reference. In the absence of
an appropriate location fix them to the gas service
meter. Ensure they are not placed where they may
restrict the airflow from the heater or where they
may catch fire from a hot surface. Do not fix them
in the control section.
Advise the person who is resuming responsibility
that for continued safe operation the air heater
should be serviced at least once a year.
6.0 SERVICING INSTRUCTIONS
IMPORTANT:
Only appropriately qualified persons may carry out
servicing and fault finding on this gas fired
equipment.
Before commencing service ensure that both the
gas and the electricity are turned and switched
"OFF" and that the air heater has cooled down.
Inadvertent substitution or replacement of
components similar to those specified or
replacement in a manner contrary to the method
herein described could constitute a hazard and lead
to prosecution.
Reznor EURO-C 4000 DJL air heaters will operate
with a minimum of maintenance. To ensure long life
and satisfactory and safe performance, an air
heater that is operated under normal conditions
should be inspected and cleaned at the start of
each heating season. If the air heater is operated in
an area where unusual amounts of dust, etc are
present in the air, more frequent servicing is
recommended.

0008DJL-GBEN 18
When any service is completed, be sure that
components are reassembled correctly to ensure
that no unsafe condition exists.
Upon completion of the service carry out the
commissioning instructions outlined in section 5 of
this document.
WARNING:
Excessive dirt buildup on the inside of the burner
ports could cause unburned gas to spill out of the
back of the burner tube causing a fire or explosion.
To prevent this occurring, clean all of the burner
ports at least annually.
CAUTION:
When cleaning air heaters, wearing of eye
protection and a dust face mask is recommended.
6.1 Service procedure
The following procedures should be carried out at
least annually:
1. Remove the burner assembly as in section 7.1.
Clean thoroughly, (cleaning the burners requires
an emery cloth, wire brush and a cleaning cloth -
stubborn deposits on burners are best cleaned
using "acetone" as a solvent).
*Check the condition of the ignitor and clean to
remove all deposits. Check the spark gap (3,0
mm).
*Check the sensor - clean as necessary.
*Remove any soot deposits from the burner
with a wire brush. Clean the ports with a
degreaser or acetone. A vacuum cleaner or
compressed air may assist in this cleaning
operation. Wipe the inside of the burner tube
clean (cleaning thoroughly with a degreaser as
recommended will retard future buildup of dirt).
Inspect the burner for any damage or
deterioration. If the burner is damaged or
corroded, replace it.
2. The heat exchanger should remain clean unless
a problem has developed due to poor
combustion. Examine the heat exchanger tubes
internally and externally for any sign of
deterioration. The outside of the tubular heat
exchanger can be cleaned from the front of the
heater with an air jet and/or a flexible brush.
Remove any dust and grease deposits.
The inner surfaces of the heat exchanger can be
reached for cleaning with the burner and
combustion air fan (venter) assemblies removed,
(see figures 12 & 13 and section 7). Clean with
a flue brush or a heavy wire to which wire wool
has been attached. Brush inside each heat
exchanger tube until all foreign material has
been removed. The use of a flashlight is
necessary to carry out this operation.
3. Remove any dirt and/or grease that may have
accumulated on the venter fan motor and its
housing. NOTE: Venter fan motors are lubricated
for life and do not require greasing.
4. The gas multi-functional control valve requires
no field maintenance except cleaning of it's
exterior and checking the condition of the wire
connections. Instructions for testing pressure
are given in section 5.5.
5. Check the flue/combustion air system for
soundness. Reseal/replace any parts that are not
sound.
6. Check all wiring connections. Check wiring for
any signs of damage. Replace any suspect
wiring with an equivalent specification.
7. Check operation of thermal fan control and
control relay.
8. When service is complete carry out full
commissioning procedure as per section 5 of
this document.
7.0 Removal and replacement of
parts
EURO-C 4000 DJL air heaters must only be fitted
with Reznor authorized replacement parts. These
heaters must use certificated spare parts to comply
with legislation.
7.1 Main burner removal
Instructions for burner removal (see figure 10):
1. Turn OFF the gas supply to the air heater.
2. Switch OFF the electricity supply to the air
heater.
3. Open the access door.
4. Disconnect the union in the gas supply outside
of the appliance.
5. Remove gas supply pipe from multi-functional
gas control valve.
6. The burner rack assembly is now visible.
7. At the bottom of the burner rack assembly,
remove the nut that secures the burner rack to
the bolt welded to the burner box bottom. At
the top of the burner rack assembly, remove the
bolt that attaches the burner rack assembly to
the bracket. Lift the burner rack/manifold
assembly upward (to clear the locating weld
pins) and pull the assembly out of the air heater.

0008DJL-GBEN 19
Figure 12
Removing the burner rack/manifold assembly (for
clarity, the heater cabinet & other parts are
notillustrated; do not remove the burner box
assembly from the heater)
Instructions for re-assembly:
1. Reverse the procedure for removal making sure
that all parts are installed correctly. Check that
all components are secure.
2. When lighting, always follow the lighting
instructions on the air heater.
Remember!
After any service work has been carried out, the air
heater must be fully commissioned. See section 5
of this document.
Figure 13 : View of the Control Compartment Legend :
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 Fuseholder with fuse
11 Differential pressure point
12 Combination gas valve with
pressure regulation
13 Manifold & injectors
14 Ignition electrode
15 Relay K1.1 (not for UK/IE)
Relay K1.2 (not applicable on
EURO-C 4000S)
16 Relay main ventilator (not
applied on EURO-C 4000 )
17 Electronic net filter
18 LC3 max limit controller with
manual reset
19 3VA separation transformer
(not for UK/IE)
20 Fan control relay
21 Tube burner

0008DJL-GBEN 20
7.2 Burner injectors
1. Carry out steps 1 to 7 of section 7.1.
2. Unscrew the main burner injectors.
3. Re-fit new injectors.
4. Re-assemble in reverse order.
7.3 Ignition system
To access the ignition system, follow steps 1 to
3 in section 7.1.
Igniter - refer to figure 13 and locate the igniter
(on the side of the burner rack). Disconnect the
wire, remove the screw and the igniter. Clean
with an emery cloth.
Note: Spark gap must be maintained to 3.0 mm
See figure 14a.
IMPORTANT: When re-assembling the earth
wire must remain attached to the igniter
We refer to figure 14b for installing the igniter.
CAUTION: Due to high voltage on the spark
wire and electrode, do not touch when
energized. See hazard levels.
Flame sensor - Refer to figure 13 and locate the
flame sensor. Disconnect the wire, remove the
screw and the flame sensor. Clean with an
emery cloth.
Ignition controller - The enclosed integrated
circuit monitors the operation of the burner
including ignition. Do not attempt to dismantle
the ignition controller. Each heating season lead
wires should be checked for insulation
deterioration and good connections.
Proper operation of the direct spark ignition
system requires a minimum flame current of 1,0
:
::
: A when measured with a micro ammeter.
For further information and checkout procedure
of the direct spark ignition system, refer to the
manufacturers control operating instructions a
copy of which is supplied with the air heater.
Fig. 14a - Igniter assembly
Fig. 14b – Installing the igniter
7.4 Multi-functional gas control valve
1. Ensure gas supply to the air heater is turned OFF.
2. After the air circulation fan has stopped, switch OFF the
electricity supply to the air heater.
3. Mark for future identification and disconnect the wires
connected to the valve.
4. Disconnect the gas service union between the control
valve and the gas service tap. Remove the gas control
valve.
5. Re-fit a replacement valve making all of the
required connections.
6. Carry out complete commissioning procedure prior to
placing the appliance back into service as outlined in
section 5.0.
CAUTION:
The gas control operating valve is the prime safety shut-off.
All gas supply lines must be fee of dirt, scale, etc. before
connecting to the air heater thus ensuring positive closure of
the control valve.
7.5 Thermal overheat (limit) controls
If it is determined that the thermal overheat control needs
replacing, use only Reznor authorized replacements that are
designed for this appliance.
To gain access to the control, open the hinged controls
compartment access door. Refer to figure 13 for control
locations. The control near the top of the air heater is a disc
type control. The lower one is a capillary type one with a
capillary tube that extends into the heat exchanger area. To
remove the controls, disconnect the wires leading to them,
remove the fixing screws and lift clear of the inner-casing
panel. NOTE: The capillary control is fitted to a bracket. With
the bracket removed from the air heater, remove the control
from the bracket.
When replacing the capillary control be careful not to damage
the capillary tube by kinking. Make bends with a generous
radius (±25 mm). When replacing the disc type control never
manually attempt to operate the disc by pushing on the disc.
Doing so will alter the calibration and could be hazardous.