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Thomas & Betts Reznor LDAP 1200 Installation & Operation Manual

Indirect fired, indoor, downflow, packaged heaters
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Table of Contents
Warnings ......................................... 1
Installation/Operation ............... 2-29
Check/Test/Startup .................. 30-31
Accessories ..................................... 32
Maintenance/Service ............... 32-40
Index (by page)
Burners ....................................... 13, 33
Burner Orifice ................................... 35
California Warning Label .................... 2
Clearances ........................................... 6
Installation Codes ............................... 2
Combustion Air .................................... 6
Confined Space .................................... 6
Destratification ................................. 18
Dimensions .......................................... 4
Electrical Connections ..................... 13
Fan ............................................. 20, 36
Fan Control (Destratification) .... 18, 38
Fan Motor .................................... 21, 36
Gas Piping and Pressures ................... 10
Gas Valve ...................................... 21, 37
General ................................................ 2
Hazard Intensity Levels ...................... 2
Heat Exchanger Maintenance ........... 33
High Altitude .................................. 3, 12
High Limit Control ...................... 17, 38
Ignition System ........................... 18, 35
LED Flash Codes ............................... 38
Limit Control .............................. 17, 38
Location (Heater) ................................ 7
Louvers ................................... 3, 10, 32
Maintenance Schedule ................ 32-33
Nozzle (Option) ............................ 3, 32
Pressure Switch
(Combustion Air) ............... 5, 17, 37
Replacement Parts .... See Form P-LDAP
Sound Data ........................................... 8
Startup ................................................ 30
Suspending Heater .............................. 8
Technical Data ..................................... 4
Thermostat (Option) .......................... 14
Throw Data .......................................... 7
Transformer ...................................... 38
Troubleshooting ......................... 38-40
Uncrating and Preparation ................. 3
Valve Outlet Pressure ......................... 12
Vent System Maintenance ................ 38
Venter Motor (Heat Section) ............ 35
Venter Motor (Main) ........................ 36
Venting ............................................... 26
Wall Mounting ..................................... 9
Warranty .............................................. 2
Weights ................................................ 8
Wiring Diagrams .......................... 22-25
CQS
Page
If you smell gas:
1. Open windows.
2. Don't touch electrical switches.
3. Extinguish any open flame.
4. Immediately call your gas supplier.
The use and storage of gasoline or other flammable vapors and
liquids in open containers in the vicinity of this appliance is
hazardous.
WARNING: 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.
WARNING: Gas-fired appliances are not designed for use in
hazardous atmospheres containing flammable vapors or
combustible dust, in atmospheres containing chlorinated or
halogenated hydrocarbons, or in applications with airborne silicone
substances. See Hazard Levels, page 2.
WARNING: Should overheating occur, or the gas supply fail to
shut off, shut off the manual gas valve to the appliance before
shutting off the electrical supply.
WARNING: Do not use this appliance if any part has been under
water. Immediately call a qualified service technician to inspect
the appliance and replace any gas control that has been under water.
Installation/Operation FORM RZ-NA I-LDAP
APPLIES TO:
®
Reznor
Model
LDAP 1200
FOR YOUR SAFETY
FOR YOUR SAFETY
Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 1
Indirect Fired,
Indoor, Downflow,
Packaged Heaters
Model LDAP

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Summary of Contents for Thomas & Betts Reznor LDAP 1200

  • Page 1 Wiring Diagrams ... 22-25 Installation/Operation FORM RZ-NA I-LDAP APPLIES TO: ® Reznor Model LDAP 1200 FOR YOUR SAFETY If you smell gas: 1. Open windows. 2. Don't touch electrical switches. 3. Extinguish any open flame. 4. Immediately call your gas supplier.

  • Page 2: California Warning Label

    Hazard Levels of Warnings in this Manual 1. General 2. Installation Codes Special Installations (Aircraft Hangars/ Repair Garages/ Parking Garages) California Warning Label Massachusetts Requirement 3. Warranty Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 2 HAZARD INTENSITY LEVELS 1. DANGER: Failure to comply will result in severe personal injury or death and/or property damage.

  • Page 3: Uncrating And Preparation

    If installing a Model LDAP 800, repeat Steps 1-5 to change the pressure switch on the second heat section. If installing a Model LDAP 1200, repeat Steps 1-5 to change the pressure switches on the second and third heat sections.

  • Page 4: Technical Data

    Heater Model LDAP 800 One Heater with Two Downflow Heat Sections Model LDAP 1200 One Heater with Three Downflow Heat Sections 7. Dimensions FIGURE 1A - Model LDAP 400 Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 4 Model LDAP Size...
  • Page 5 FIGURE 1B - Model LDAP800 and Model LDAP1200 A Model LDAP1200 with three heat sections is illustrated. A Model LDAP800 has two heat sections. A Model LDAP800 is the same layout as illustrated less the middle heat section. Size inches 1168 1753 inches...

  • Page 6: Combustion Air

    8. Clearances Clearances - Size inches/mm inches mm inches 1200 9. Combustion FIGURE 2 - Definition of Confined Space and Required Openings for Combustion Air Confined Space: A space whose volume is less than 50 cubic feet per 1000 BTUH of the installed appliance input rating Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 6...

  • Page 7: Mounting Height

    10. Heater Location Mounting Height Heater Throw - All Models FIGURE 3 - Model LDAP Air Throw (Heat Mode @ High Speed) - Applies to All Sizes Mounting Height Standard Louvers 30° Nozzle 60° Nozzle 0 = “Rear” of Heater Discharge NOTES: •...

  • Page 8: Weights

    10. Heater Model Location LDAP (cont’d) Size Sound Data 1200 74 0.100 1.000 70 0.064 0.640 67 0.044 0.444 64 0.033 0.327 62 0.025 0.250 µbar = microbar Location Recommendations NOTE: Venting requirements may affect location. Consult requirements in Paragraph 24 before making final determination.

  • Page 9: Wall Mounting

    FIGURE 4A - Suspending the Heater with Rods from the Threaded Nut Retainers “U”-shape Fitting Strut attached to top of heater. Be sure the threaded hanger rods are locked to the heater as illustrated. Recommended maximum hanger rod length is 6 feet (1.8M).

  • Page 10: Gas Piping And Pressures

    11. Installing Heater and Louvers (cont’d) Installing Louvers NOTE: Do not install louvers if installing a nozzle. Follow the instructions shipped with the nozzle. FIGURE 6 - Use Compression Springs to Install Louvers in the Discharge Opening(s) CAUTION: To avoid getting burned, adjust louvers while heater is not operating.
  • Page 11 Model LDAP 400 has one gas valve; Model LDAP 800 has two gas valves; and Model LDAP 1200 has three gas valves. For Natural Gas: When the heater leaves the factory, the combination gas valve(s) is set so that the valve outlet gas pressure for a single stage valve or high fire of a two stage valve is regulated to 3.5"...

  • Page 12: Valve Outlet Pressure

    OUT (counterclockwise) to decrease pressure. 3) If installing a Model LDAP 800, repeat to verify outlet pressure on second valve. If installing a Model LDAP 1200, repeat to verify outlet pressure check on second and third valve. Derate by Valve Outlet Pressure Adjustment for High...

  • Page 13: Electrical Supply And Connections

    Check for leak at the pressure tap fitting. 5. If installing a Model LDAP 800, repeat the adjustment at the second single-stage gas valve. If installing a Model LDAP 1200, repeat the adjustment at the second and third single-stage gas valves.

  • Page 14: Disconnect Switch

    Connections for Reznor optional thermostats are shown in FIGURE 10 for LDAP 400; in FIGURE 11 for LDAP 800; and in FIGURE 12 for LDAP 1200. • Option CL1 - Single-Stage Thermostat, 40-80°F •...
  • Page 15 FIGURE 10 - Thermostat Connections for Model LDAP 400 with Option CL1, CL2, CL3, CL7, or CL18 FIGURE 11 - Thermostat Connections for Model LDAP 800 with Option CL1, CL2, CL3, CL7, or CL18 Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 15...
  • Page 16 15. Thermostat and Connections (cont’d) FIGURE 12 - Thermostat Connections for Model LDAP 1200 with Option CL1, CL2, CL3, CL7, or CL18 Multiple Heater If the heater was ordered with a multiple heater control option, one thermostat can be used to control multiple heaters.

  • Page 17: Limit Control

    16. Combustion Air Proving [Pressure Switch(es)] NOTE: For high altitude, follow instructions in Paragraph 5 to change heat section pressure switch(es). The main combustion air pressure switch (Sizes 800 and 1200 only) does not need to be changed for a high altitude installation.

  • Page 18: Destratification

    18. High Limit Control (cont’d) 19. Adjustable Air Destrati- fication Fan Control 20. Ignition System FIGURE 13 – DSI Integrated Control Module (circuit board) in Each Heat Section Supply Voltage Connections Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 18 the Maintenance Section for information on probable causes . (For location, see FIG- URE 22, page 33.) DANGER: If a manual reset high limit control activates, identify and correct the cause before resetting the switch.
  • Page 19 Normal Heat 1) Call for Heat - The thermostat calls for heat by energizing the “W” terminal. The control checks to see that the limit and high limit switches are closed and the heat section Cycle Operating pressure switch is open and the main combustion air pressure switch (Sizes 800 and Sequence 1200) is open.

  • Page 20: Continuous Fan Operation

    20. Ignition remain energized for an inter-purge period of 10 seconds. The spark and gas valve are then re-energized, and the control initiates another trial for ignition. System If flame is not established on the second trial for ignition, the control de-energizes the gas valve, energizes the fan motor on heat speed, and the heat section venter motor and main (cont’d) venter motor remain energized.

  • Page 21: Fault Modes

    Fault Modes Undesired Flame - If flame is sensed longer than 20 seconds while the gas valve is de- energized, the control shall energize the heat section venter motor, the main venter motor, and the fan motor on heat speed. When flame is no longer sensed, the heat section venter motor and main venter motor will run through postpurge, and the fan motor will run through the selected heat fan off delay time.

  • Page 22: Wiring Diagram

    • FIGURE 15 - Model LDAP 800, page 24. • FIGURE 16 - Model LDAP 1200, page 25. 1. Set thermostat at lowest setting. With Opt CL2 or CL18, set fan switch at “AUTO” position. 2. Turn on the manual gas valve(s).
  • Page 23 Switch Settng Chart for Fan Wiring Black - BK OFF Delay (See SW1 on W.D.) Color Brown - BR TIME Codes Red - R 90 sec Orange - O 120 sec Yellow - Y 160 sec Green - G 45 sec Blue - BL Purple - PR White - W...
  • Page 24 23. Wiring Diagrams (cont’d) FIGURE 15 – Typical Wiring Diagram for Model LDAP 800 (Reference W.D. 189375, Rev 2) Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 24...
  • Page 25 FIGURE 16 – Typical Wiring Diagram for Model LDAP 1200 (Reference W. D. 189376, Rev 2) Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 25...

  • Page 26: Venting Requirements

    24. Venting Venting Requirements 2) Vent Pipe Diameter and Length Venter Model Vent Pipe Outlet LDAP Diameter Diameter Size inches mm inches 1200 Includes one 90° elbow at venter outlet. Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 26 Model LDAP heaters are certified as Category III heaters. WARNING: Each heater requires its own individual vent pipe run and vent cap.
  • Page 27 3) Venter (Flue) Outlet 4) Joints and Sealing FIGURE 17A - Figure 17A - STEP 1 Attaching Double- Slide the Wall (Type-B) Vent double-wall Pipe to the Venter pipe over Outlet the collar A double-wall pipe so that the run is allowed only if collar is at least 75% of the inside the...

  • Page 28: Venting Requirements

    24. Venting (cont’d) Venting Requirements (cont’d) 4) Joints and Sealing (cont’d) FIGURE 17C - Attaching Double-Wall (Type B) Terminal Pipe to a Single Wall or Category III Vent Pipe Run 5) Vent System Support 6) Condensation 7) Vent Terminal (Pipe and Vent Cap) Horizontal Vent Terminal Clearances A vent cap is required.
  • Page 29 FIGURE 18 - Horizontal Vent Terminal NOTE: Read all measurements; drawing is not proportional. FIGURE 19 - Vertical Vent Terminal NOTE: Read all measurements; drawing is not proportional. Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 29...

  • Page 30: Check The Installation Prior To Startup

    25. Check Installation and Startup Check the installation prior to startup: Heater Startup and Warnings: Operating Instructions and Operating Sequence Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 30 Check to be sure that all screws used to hold shipping brackets were re-installed in the heater cabinet.

  • Page 31: Check Installation After Startup

    FIGURE 20 - Gas Valve ON/OFF Control Knob Check installation after startup: Place the "Owner's Envelope" containing the Limited Warranty, this booklet, and any control or optional information in an accessible location near the heater. Follow the instructions on the envelope.

  • Page 32: Optional Accessories

    OPTIONAL ACCESSORIES 26. 4-Way Discharge Louvers, Option CD32 27. Nozzles FIGURE 21A - One heat section with Option CD58, 60° Nozzle Standard individually adjust- able louvers are installed in the nozzle discharge. MAINTENANCE AND SERVICE WARNING: If you turn off the power supply, turn off the gas.

  • Page 33: Heat Exchanger Maintenance

    FIGURE 22 - Location of Controls 29. Heat Exchanger Maintenance 30. Burner Maintenance Burner Removal Instructions (Refer to FIGURE 23.) CAUTION: Use of eye protection is recommended. • Check the wiring for any damaged wire. Replace damaged wiring. (See Paragraph 14 for replacement wiring requirements.) Each section of this heater is equipped with a Patent No.
  • Page 34 30. Burner Maintenance (cont’d) FIGURE 23 - Burner Removal • Size 400 has 1 burner. • Size 800 has 2 burners. • Size 1200 has 3 burners. Inspect and Clean the Burner NOTE: If any of the burner components are damaged or deteriorated, replace the burner assembly.
  • Page 35 31. Burner Orifice(s) 32. Ignition System CAUTION: Due to high voltage on the spark wire and electrode, do not touch when energized. See Hazard Levels, page 2. Ignitor Flame Sensor 33. Heat Section Venter Motor and Wheel 2. Attach the Gas Train - Slide the gas train so that the orifice adapter is through the bracket.
  • Page 36 33. Heat Section Venter Motor and Wheel (cont’d) FIGURE 26 - Venter Wheel Position on Shaft - applies to all heat section venter assemblies 34. Main Venter Motor and Wheel (Models 800 and 1200 only) Venter Motor Main Combustion Air Pressure Switch Venter Housing FIGURE 27- Venter Motor...
  • Page 37 36. Operating Gas Valve(s) WARNING: The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting to the heater to ensure positive closure. See Hazard Levels, page 2. NOTE: Operational pressure settings and instructions for checking pressure settings are in Paragraph 12.

  • Page 38: Troubleshooting

    38. Limit Control 39. High Limit Control 40. Transformer 41. Adjustable Fan Control 42. Vent System 43. Troubleshooting Check the Lights on the DSI Integrated Control Module (Circuit Board) IMPORTANT: When using a multimeter to troubleshoot the 24 volt circuit, place the meter’s test leads into the 5 or 9 pin connectors located on the ignition control.

  • Page 39: General Troubleshooting

    DSI Integrated Control Module Call for Heat (Circuit Board) Trial Troubleshooting Flowchart Is there minimum minimum flame current flame current at the flame at the control sensor? Check connections to Clean Is the flame sensor flame sensor or flame corroded? moisture in bulkhead sensor.

  • Page 40: Troubleshooting

    General Troubleshooting (cont’d) PROBLEM (cont'd) PROBABLE CAUSE (cont'd) 1. Gas pressure too high or too low. Burner cycle on and off 2. Burner not grounded 3. Circuit board not grounded. 4. Faulty integrated circuit board 5. Combustion air proving switch(es) not closing.

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