Thomas & Betts LDAP 1200 User Manual

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Table of Contents

Page

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 V alve......................................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

Indirect Fired,

Indoor , Downflow,

Packaged Heaters

Installation/Operation FORM RZ-NA I-LDAP

APPLIES TO: Model LDAP

CQS

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.

W ARNING: Impr oper 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 .

Reznor

Model

LDAP 1200

FOR YOUR SAFETY

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 1

Hazard Levels of Warnings in this Manual

HAZARD INTENSITY LEVELS

1. DANGER: Failure to comply will result in sever e 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.

1. General

2. Installation Codes

Special Installations (Aircraft Hangars/ Repair Garages/ Parking Garages)

All Model LDAP high bay packaged heaters are design certified by ITS for use in industrial and commercial installations. All models and sizes are available for use with either natural or propane gas. The type of gas, the input rate, and the electrical supply requirement are shown on the heater rating plate. Check the rating plate to determine if the heater is appropriate for the intended installation.

The instructions in this manual apply only to Reznor Installation should be done by a qualified agency in accordance with these instruc-

tions. The qualified service agency installing this heater is responsible for the installation.

These heaters must be installed in accordance with local building codes. In the absence of local codes, in the United States, the heater must be installed in accordance with the National Fuel Gas Code, ANSI Z223.1. A Canadian installation must be in accordance with the CSA B149 Installation Codes. These codes are available from CSA Information Services, 1-800-463-6727. Local authorities having jurisdiction should be consulted before installation is made to verify local codes and installation procedure requirements.

Installations in aircraft hangars should be in accordance with ANSI/NFPA No. 409 (latest edition), Standard for Aircraft Hangars; in public garages in accordance with ANSI/NFPA No. 88A (latest edition), S tandard for Parking S tructures; and for repair garages in accordance with ANSI/NFP A No. 88B (latest edition), S tandard for Repair Garages. In Canada, installations in aircraft hangars should be in accordance with the requirements of the enforcing authorities, and in public garages in accordance with CSA B149 codes.

Model LDAP heaters.

California Warning Label

Massachusetts Requirement

3. Warranty

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 2

If the heater is being installed in the state of California, the installer MUST attach a warning label on the outside of the access door . The California W arning label is shipped in the owner’s envelope along with this manual, the warranty form, and any other paperwork that applies.

If installation is in California, select a location on the heater access panel. Be sure the surface is clean and dry and adhere the label.

If the heater is being installed in the Commonwealth of Massachusetts, this heater must be installed by a licensed plumber or licensed gas fitter.

Refer to the limited warranty information on the Warranty Card in the "Owner's Envelope".

Warranty is void if ...

a. Wiring is not in accordance with the diagram furnished with the heater. b. The heater is installed without proper clearance to combustible materials. c. The heater is connected to a duct system or if the air delivery system is

modified by other than manufacturer-designed accessories.

4. Uncrating and Preparation

This heater was test operated and inspected at the factory prior to crating and was in operating condition. If the heater has incurred any damage in shipment, document the damage with the transporting agency and contact an authorized Reznor Distributor. If you are an authorized Distributor , follow the FOB freight policy procedures as published by Thomas & Betts for Reznor products.

Check the rating plate for the gas specifications and electrical characteristics of the heater to be sure that they are compatible with the gas and electric supplies at the installation site.

MPORTANT: The crate bottom should be removed after the heater is lifted.

I Shipping brackets are attached with cabinet screws. When removing shipping brackets, re-insert ALL screws into the cabinet.

Read this booklet and become familiar with the installation requirements of your particular heater. If you do not have knowledge of local requirements, check with the local gas company or any other local agencies who might have requirements concerning this installation. If the installation is above 2000 ft (610M) elevation, follow the instructions in Paragraph 5 and Paragraph 12.

Before beginning, make preparations for necessary supplies, tools, and manpower. Locate the hardware kit supplied with the heater. The plastic bag contains spring nuts, hex nuts, “U”-shape fittings, lock washers, louvers, and compression springs.

Be sure that all shipped-separate options that were ordered are at the installation site. Shipped-separate items could include a vent cap, louvers, nozzles, hanger kit, a manual shutoff valve, a thermostat, multiple heater controls, high temperature tape, and/or a high altitude kit.

5. High Altitude Operation

Pressure Switch

Instructions for Changing Heat section Pressure

NOTE: Do not change the

main pressure switch located on top of a Size 800 and Size 1200 heater. It is the same for all elevations.

If the heater is being installed at an elevation above 2000 ft (610M), the input rate will have to be derated. This is done by adjusting the outlet pressure of the gas valve and can only be done after the heater is in operation. Follow the instructions in Paragraph 12.

If the heater is being installed at an elevation above 6000 ft (1830M), the heat section pressure switch(es) will need to be changed. If ordered with the heater as Option DJ20, the pressure switch is shipped separately.

High Altit u de Unit Pressure Sw it ch (es)

Start-up Cold Equilibrium Hot Setpoint OFF Setpoint ON

QtySize

400 1 1.75 to 1.45 1.00 to 0.80 0.60 0.78 Lt. Blue 197029 800 2 1.85 to 1.55 1.05 to 0.85 0.60 0.78 Lt. Blue 197029

1200 3 2.35 to 1.85 1.50 to 0.95 0.60 0.78 Lt. Blue 197029

Label Color

Switch

Part No.Differential Pressure (in. w.c.)

Switch(es)

1. In the control compartment of the first heat section, locate the pressure switch.

2. Mark and disconnect the two wires attached to the pressure switch.

3. Mark and disconnect the sensing tubes from the pressure switch.

4. Locate the two screws holding the switch mounting bracket. Remove the screws

(save screws) and the pressure switch.

5. Using the same screws, install the high altitude pressure switch. Attach the

sensing tubes and wires.

6. If installing a Model LDAP 400, the pressure switch change for high altitude is

complete. 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.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 3

6. T echnical Dat a

38

(965mm)

13-1/8

(333mm)

2-5/8

(67mm)

5

(127mm)

9-7/8

(251mm)

43-1/2

(1,105mm)

RIGHT SIDE VIEW

LINE VOLTAGE CONNECTION

DISCONNECTION SWITCH

1 NPT GAS CONNECTION

Model LDAP 400

Model LDAP 800

Model LDAP 1200

One Downflow Heater

One Heater with Two Downflow Heat Sections

One Heater with Three Downflow Heat Sections

Mo del LDAP Size

Input Heating Capa c ity

btuh 400,000 800,000 1,200,000 kw/h 117.1 234.2 351.4

Thermal Efficiency (%) O ut put Heating Capacity

btuh 332,000 664,000 996,000

kw/h 97.2 194.4 291.6 Gas Co nnection (I nches) Vent Connection Diameter (Inches) Contr ol Amps ( 24 volt) Fu ll Load Amps (208 volt) Fu ll Load Amps (230 volt) N orm al Power Consumpti o n @ 2 08V (w a t ts) N orm al Power Consumpti o n @ 2 30V (w a t ts) Discharge Air Temperature Rise (°F)

Air Volum e (Heat @ High Speed)

D ischarge Ai r Opening Are a Outlet Velocity (Heat @ High

Speed) Air Volume (Destratification @ Medium Speed) Outlet Velocity (Destrati ficati on @ Me dium Speed) Air Volume (Destratification @ Low Speed) Outlet Velocity (Destrati ficati on @ L ow S peed)

cfm 5589 11178 16768

/minute

fpm 1521 1521 1521

m/minute 464 464 464

cfm 4650 9300 13950

/minute

fpm 1266 1266 1266

m/minute 386 386 386

cfm 3250 6500 9750

/minute

fpm 885 885 885

m/minute 270 270 270 Fan Motor HP (Qty) Fan Motor RPM Fan Diameter (I nches)

400 800 1200

83 83 83

11-1/41-1/4 68 8

1.0 2.0 3.0

5.6 13.6 19.4

5.5 12.8 18.5 1150 2448 3730 1230 2597 3959

55 55 55

158 317 475

3.67 7.35 11.02

0.34 0.68 1.02

132 263 395

92 184 276

1 (1) 1 (2) 1 (3) 1050 1050 1050

24 24 24

7. Dimensions

FIGURE 1A - Model LDAP 400

30

(762mm)

17-1/8

(435mm)

14-7/8

(378mm)

9-1/8

(232mm)

15-1/4

(387mm)

34-3/8

(873mm)

TOP VIEW

ø 6 FLUE OUTLET

2-1/8 (54mm)

7/8 (22mm)

AIR DESTRATIFICATION FAN CONTROL

28-1/8 (714mm)

HANGER LOCATION 1/2 - 13 FEMALE THREAD

THERMOSTAT CONNECTION

FRONT VIEW

BOTTOM VIEW

DISCHARGE OPENING

9-1/4 (235mm)

1-1/4 (32mm)

23

(584mm)

48-1/2 (1,232mm)

3-1/4 (83mm)

5-5/8 (143mm)

23 (584mm)

NOTE: If an optional nozzle is added to the discharge opening, see dimensions on page 32.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 4

FIGURE 1B - Model LDAP800 and Model LDAP1200

RIGHT SIDE VIEW

LINE VOLTAGE CONNECTION

DISCONNECT SWITCH

1 NPT GAS CONNECTION

38 (965mm)

13-1/8

(333mm)

2-5/8

(67mm)

5

(127mm)

9-7/8

(251mm)

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 A B

HANGER LOCATION 1/2 - 13 FEMALE THREAD

800

11-7/8

(302mm)

1200

inches mm inches mm

46 69

1168 1753

80 103-3/4

2032 2635

14-7/8

(378mm)

COMBUSTION BOX ASSEMBLY

34-3/4

(883mm)

TOP VIEW

34-3/4

(883mm)

ø8 FLUE OUTLET

17-1/8

(435mm)

12

(305mm)

13-3/4 (349mm)

(1,346mm)

7/8 (22mm)

1-5/8

(41mm)

53

28-1/8 (714mm)

AIR DESTRATIFICATION FAN CONTROL

43-1/2 (1,105mm)

46 (1,168mm)

1-1/4 NPT

5-5/8

(143mm)

3-1/4

(83mm)

23

(584mm)

FRONT VIEW

THERMOSTAT CONNECTIONS

11-3/4

(298mm)

23

(584mm)

DISCHARGE OPENING

11-3/4

(298mm)

23

BOTTOM VIEW

1-1/4 (32mm)

23

(584mm)

NOTE: If optional nozzles are added to the discharge openings, see dimensions on page 32.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 5

8. Clearances

(

)

Heaters must be installed so that the clearances in the table are provided for combustion air space, inspection and service, and for proper spacing from combustible construction. Clearance to combustibles is defined as the minimum distance from the heater to a surface or object that is necessary to ensure that a surface temperature of 90°F above the surrounding ambient temperature is not exceeded.

Clearances inches/mm

9. Combustion Air

Size

400 800

1200

Top

inches mm inches mm inches mm inches mm in ches mm inches mm inches mm

12 305 6 152.4 18 457 2 50.8 18 4 57 2 50.8 60 1524 12 305 6 152.4 18 457 2 50.8 18 4 57 2 50.8 60 1524 12 305 6 152.4 18 457 2 50.8 18 4 57 2 50.8 60 1524

This heater must be supplied with the air that enters into the combustion process and is then vented to the outdoors. Sufficient air must enter the equipment location to replace that exhausted through the heater vent system. In the past, the infiltration of outside air assumed in heat loss calculations (one air change per hour) was assumed to be sufficient. However, current construction methods using more insulation, vapor barriers, tighter fitting and gasketed doors and windows, weather-stripping, and/or mechanical exhaust fans may now require the introduction of outside air through wall openings or ducts.

The requirements for combustion and ventilation air depend upon whether the heater is located in a confined or unconfined space. An "unconfined space" is defined as a space whose volume is not less than 50 cubic feet per 1000 BTUH of the installed appliance. Under ALL conditions, enough air must be provided to ensure there will not be a negative pressure condition within the equipment room or space.

Flue

Connector

Front

Access Panel

Rear

Disconnect

Side

Bottom

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

(3)

Confined

Space

(3)

(1)

(2)

W ARNING: A Model LDAP power-vented heater is designed to take combustion air from the space in which the heater is installed and is not designed for connection to outside combustion air intake ducts. Connecting outside air ducts voids the warranty and could cause hazardous operation. See Hazard Levels, page 2.

Combustion Air Requirements for a Heater Located in a Confined Space

Do not install a heater in a confined space without providing wall openings leading to and from the space. Provide openings near the floor and ceiling for ventilation and air for combustion as shown in FIGURE 2, depending on the combustion air source as noted in Items 1, 2, and 3 below.

Add total BTUH of all appliances in the confined space and divide by figures below for square inch free area size of each (top and bottom) opening.

1. Air from inside the building - openings 1 square inch free area per 1000 BTUH. Never less than 100 square inches free area for each opening. See (1) in FIGURE 2.

2. Air from outside through duct - openings 1 square inch free area per 2000 BTUH. See (2) in FIGURE 2.

3. Air direct from outside - openings 1 square inch free area per 4000 BTUH. See (3) in FIGURE 2.

NOTE: For further details on supplying combustion air to a confined space, see the National Fuel Gas Code ANSI Z223.1a (latest edition).

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 6

10. Heater Location

Use the clearances in Paragraph 8; the combustion air requirements in Paragraph 9; the mounting height requirements, throw information, sound data, and location recommendations below; the weights in Paragraph 11; and the venting requirements in Paragraph 24 to determine where to suspend the heater.

CAUTION: Do not locate the heater where it may be exposed to water spray, rain, or dripping water.

Mounting Height

Locate the heater so that it is a minimum of 15 feet (4.6M) above the floor and in compliance with the clearances in Paragraph 8.

WARNING: If touched, the vent pipe and internal heater surfaces that are accessible from outside the heater will cause burns. Suspend the heater a minimum of 15 feet (4.6M) above the floor.

Heater Throw All Models

FIGURE 3 - Model LDAP Air Throw (Heat Mode @ High Speed) - Applies to All Sizes

60° Nozzle

Mounting

Height

Standard Louvers

X Y Z

30° Nozzle

Y Z

60° Nozzle

Y Z

= “Rear” of Heater Discharge

NOTES:

• X = Distance from “0” to beginning

of floor coverage.

• Y = Distance from “0” to end of

floor coverage.

• Length of floor coverage = Y - X.

• Z = Distance from “0” to the point

where the air velocity drops below 50 feet (15.2M) per minute.

• Throws listed are with standard

louvers facing one direction and fully open. Throw pattern changes with louver angle, 2-way louver direction, and or optional 4-way louvers.

Throw (feet and meters)

Sta ndard Lou vers 30° Degree No zzle 60° Degree Nozzle

XYZXYZXYZ

Mounting

Height

(feet) 20 30 40 50

Mounting

6.1

9.1

12.2

15.2

Height

5 55 134 40 90 146 70 125 158

8 53 121 44 86 133 76 119 145 12 49 109 47 81 120 N/A N/A N/A 17 45 96 N/AN/AN/AN/AN/AN/A

Sta ndard Lou vers 30° Degree No zzle 60° Degree Nozzle

XYZXYZXYZ

(Meters)

1.5 16.8 40.8 12.2 27.4 44.5 21.3 38.1 48.2

2.4 16.2 36.9 13.4 26.2 40.5 23.2 36.3 44.2

3.7 14.9 33.2 14.3 24.7 36.6 N/A N/A N/A

5.2 13.7 29.3 N/A N/A N/A N/A N/A N/A

Th row ( f eet )

Th row ( meters)

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 7

10. Heater Location (cont’d)

Sound Data

Model

LDAP

Size

400 800

1200

µbar = microbar Pa = Pascal

20 ft (6.1M) 25 ft (7.6M) 30 ft (9.1M) 35 ft (10.7M) 40 ft (12.2M)

db Pa µbar db Pa µbar db Pa µbar db Pa µbar db Pa µbar

69 0.058 0.580 65 0.037 0.371 62 0.026 0.258 60 0.019 0.189 57 0.015 0.145 72 0.080 0.800 68 0.051 0.512 65 0.036 0.356 62 0.026 0.261 60 0.020 0.200 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

Sound Chart - Model LDAP

DISTANCE

Location Recommendations

NOTE: Venting requirements may affect location. Consult requirements in Paragraph 24 before making final determination.

Hazards of Chlorine

For best results, the heater should be placed with certain rules in mind. In general, a heater should be located from 15-40 feet (4.6-12.2 M) above the floor. If two or more heaters are installed in the same room, a general scheme of air circulation should be maintained for best results.

Suspended heaters are most effective when located as close to the working zone as possible, and this fact should be kept in mind when determining the mounting heights to be used. However, care should be exercised to avoid directing the discharged air directly on the room occupants.

Partitions, columns, counters, or other obstructions should be taken into consideration when locating the heater so that a minimum quantity of airflow will be deflected by such obstacles.

The presence of chlorine vapors in the combustion air of gas-fired heating equipment presents a potential corrosion hazard. Chlorine found usually in the form of freon or degreaser vapors, when exposed to flame will precipitate from the compound, and go into solution with any condensation that is present in the heat exchanger or associated parts. The result is hydrochloric acid which readily attacks all metals including 300 grade stainless steel. Care should be taken to separate those vapors from the combustion process. This may be done by wise location of the heater with regard to exhausters or prevailing wind directions. Chlorine is heavier than air. Keep these facts in mind when determining installation location of the heater in relation to building exhaust systems.

11. Hanging or Mounting the Heater

Weight (lbs/kg)

Size 400 800 1200

lbs 375 805 1195

kg 170 365 542

and

Suspending the Heater

Installing Louvers

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 8

Locate the hardware kit shipped with the heater. The kit contains spring nuts, hex nuts, “U”-shape fittings, and lock washers for suspending the heater. It also includes louvers and the compression springs needed to install them.

When the heater is lifted for suspension, support the bottom of the heater with the crate bottom. If the bottom is not supported, damage could occur. Before hanging or mounting, verify that any screws used for holding shipping brackets were re-installed in the cabinet.

WARNINGS: Check the supporting structure to be used to verify that it has sufficient load carrying capacity to support the weight of the heater . Suspend the heater only fr om the threaded nut retainers or with a manufacturer provided kit. Do NOT suspend from the heater cabinet.

See FIGURE 1A or 1B for the appropriate hanging locations, and install the ½”-13 spring nuts in the strut that is attached to the top of the unit. Comply with the requirements in FIGURE 4A when using threaded rod. If ordered with swivel connectors for 1” pipe, Option CK10, attach the swivels to the spring nuts according to illustration in FIGURE 4B and suspend with 1” pipe.

Before installing the heater, check the supporting structure to be used to verify that it has sufficient loadcarrying capacity to support the weight.

WARNING: All heaters must be level for proper operation. Do not place or add additional weight to the suspended heater. Hazard Levels, page 2.

FIGURE 4A Suspending the Heater with Rods from the Threaded Nut Retainers

1/2”-13 Threaded Rod

Hex Nut

Lockwasher

“U”-shape

Fitting

Spring Nut

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).

W all Mounting

The heater may be attached to a wall. Place supports as shown in FIGURE 5 and comply with all guidelines listed.

FIGURE 4B- Swivel Connectors to Suspend the Heater from 1” Pipe, Option CK10

Pipe Coupling Assembly

Hex Nut

“U”-shape

Fitting

Lockwasher

Spring Nut

Strut

attached to

top of heater.

Be sure the threaded swivel connectors are locked to the heater as illustrated.

Guidelines for Wall Mounting Model LDAP Heaters

 Mounting is the responsibility of the

installer. Verify that the supporting structure has sufficient load-carrying capacity to support the weight. (See weights, page 8.)

 Prior to installation, be sure that the

method of support is in agreement with all local building codes. Check for service platform requirements.

 Maintain a minimum of 2” (51mm)

clearance from the discharge air openings to structural supports. Additional clearance will be required if an optional nozzle is to be field installed.

 Determining the need for installing

vibration or noise isolation is the responsibility of the installer.

 To prevent potential movement, field-

supplied angles must be placed around the perimeter of the heater to anchor it to the structural supports.

 Structural supports must be placed as

shown to prevent damage to the heater.

 All structural supports must be non-

combustible materials.

FIGURE 5 - Wall Mounting

(All structural supports and angles are field supplied.)

All dimensions are measured from centerlines of field-supplied structural supports.

Field-Supplied Mounting Angles (MUST be on all

Model LDAP 800

(2 heat sections)

Front View

34-33/64

(877mm)

34-33/64

(877mm)

34-33/64

(877mm)

Model LDAP 1200

(3 heat sections)

Front View

34-43/64

(881mm)

four sides of the heater.)

Side View

Dimensions are

centerline of the

mounting angles

and apply to all sizes.

34-33/64

(877mm)

(1080mm)

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 9

Model

LDAP 400

(1 heat

section)

Front View

34-11/32

(872mm)

Wall

28-1/4

(718mm)

42-1/2

Airflow direction;

springs are on

the upper end.

Airflow direction;

springs are on the lower end.

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. If adjusting louvers while heater is operating, wear gloves.

After the unit is suspended/mounted, install the air directional louvers or optional nozzle. If an optional nozzle is being installed, follow the instructions included with the nozzle. If a nozzle is not being used, install the louvers in the discharge opening(s). Louvers and springs are in the hardware kit shipped with the heater. Before actually installing the louvers, note the louver curve and determine how the louvers should be positioned to provide the optimal throw pattern. Opening is square so louvers may be installed either horizontal or vertical. Louvers may be installed with the curve all the same direction (either way) or the right half one way and left the other as illustrated in FIGURE 6.

Louver Installation Instructions:

1) With the wider section of the louver facing out of the heater, place one of the compres-

sion springs over the tab on the notched end of a louver. The end of the louver with the spring will fit in any direction in the square opening. How the louver turns depends on which end of the louver is inserted first.

2) Depending on the throw pattern selected, push the louver tab with the spring into a

hole in the discharge opening and insert the louver tab on the other end into the corresponding hole on the opposite side.

3) Continue until all louvers are installed.

Adjust the louvers to provide the

desired throw pattern.

Compression Spring

Wider side of the louver blade must always be facing out of the heater.

Airflow direction depends on how the louvers are installed.

12. Gas Piping

and Pressures

Sizing Gas Supply Line

W ARNING: All components of a gas supply system must be leak tested prior to placing equipment in service. NEVER TEST FOR LEAKS WITH AN OPEN FLAME. Failure to comply could result in personal injury, pr operty damage or death.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 10

WARNING: This appliance is equipped for a maximum gas supply pressure of 1/2 psi, 3.5 kPa, or 14 inches water column. Supply pressure greater than 1/2 psi requires installation of an additional lockup-type service regulator external to the heater.

W ARNING: PRESSURE TESTING SUPPLY PIPING

Test Pressures Above 1/2 PSI: Disconnect the heater and manual valve from the gas supply line which is to be tested. Cap or plug the supply line.

T est Pressur es Below 1/2 PSI: Before testing, close the manual valve on the heater .

Capacity of Piping

Specific Gravity for Natural Gas -- 0.6 (Natural Gas -- 1000 BTU/Cubic Ft)

Specific Gravity for Propane Gas -- 1.6 (Propane Gas -- 2550 BTU/Cubic Ft)

Length Diame te r of Pipe

of 1" 1-1/4" 1-1/2" 2" 2-1/2"

Pipe Natura

20' 350 214 730 445 1100 671 2100 1281 3300 2013 30' 285 174 590 360 890 543 1650 1007 2700 1647 40' 245 149 500 305 760 464 1450 885 2300 1403 50' 215 131 440 268 670 409 1270 775 2000 1220 60' 195 119 400 244 610 372 1105 674 1850 1129 70' 180 110 370 226 560 342 1050 641 1700 1037 80' 170 104 350 214 530 323 990 604

90' 160 98 320 195 490 299 930 567 1500 915 100' 150 92 305 186 460 281 870 531 1400 854 125' 130 79 275 168 410 250 780 476 1250 763 150' 120 73 250 153 380 232 710 433 1130 689 175' 110 67 225 137 350 214 650 397 1050 641 200' 100 61 210 128 320 195 610 372 980 598

Note: When sizing supply lines, consider possibilities of future expansion and increased requirements.

Propane Natural Propane Na t uralPropane NaturalPropane Natural Propane

Refer to National Fuel Gas Code for additional information on line sizing.

- Cubic Feet per Hour based on 0.3" w.c. Pressure Drop

1600

976

Gas Connection Size

Ga s Connection - inches/mm

400

800

1200

Size

inches

Natural

Gas

25.4 25.4

1-1/4 1-1/4

31.8 31.8

1-1/4 1-1/4

31.8 31.8

Propane

Gas

FIGURE 7 - Gas connection is at the pipe nipple that extends outside the cabinet.

IMPORTANT: Two pipe

wrenches are required when installing gas piping. The gas pipe that is supplied with the heater MUST be held with a pipe wrench to prevent damage to the heater.

NOTE: Gas Conversion Kits are available for changing from propane gas to natural gas or natural gas to propane gas. A factory-authorized conversion kit MUST be used.

Valve Outlet or Orifice Pressure Setting

W ARNING: V alve outlet gas pressure must never exceed 3.5" w .c. for natural gas and 10" w .c. for propane gas.

All piping must be in accordance with requirements outlined in the National Fuel Gas Code ANSI/Z223.1a (latest edition) or CSA-B149.1 and B149.2 (See Paragraph

2). Gas supply piping installation should conform with good practice and with local codes. Support gas piping with pipe hangers, metal strapping, or other suitable material; do not rely on the heater to support the gas pipe.

The heater is orificed for operation with natural gas having a heating value of 1000 (± 50) BTUH per cubic ft or propane gas with a heating value of 2500 (± 100) BTUH per cubic ft. If the gas at the installation does not meet these specifications, consult the factory for proper orificing.

Pipe joint compounds (pipe dope) shall be resistant to the action of liquefied petroleum gas or any other chemical constituents of the gas being supplied.

Install a ground joint union and manual shutoff valve upstream of the heater control system, as shown in FIGURE 7. Installation of a trap with a minimum 3" (76mm) drip leg is required.

To connect the gas, the heater is equipped with a nipple that extends outside the cabinet.

Leak-test all connections by brushing on a leak-detecting solution.

Ground

To Gas Valve (inside the cabinet)

Pipe nipple extending

outside the cabinet.

Joint Union

To Gas Valve (inside the cabinet)

Manual shutoff

Drip Leg

Ground

Horizontal Supply

From Gas Supply (horizontal or vertical)

Vertical Supply

Drip

Joint

Union

Leg

Manual shutoff

Measuring valve outlet gas pressure cannot be done until the heater is in operation. It is included in the steps of the "Check-Test-Start" procedure in Paragraph 25. The following warnings and instructions apply. 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" w .c. Low fire on a two-stage valve (Size 400 only) is set to 1.8” w .c. Inlet supply pressure to the heater for natural gas must be a minimum of 5" w.c. or as noted on the rating plate and a maximum of 14" w.c.

For Propane 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 10" w.c. Low fire on a two-stage valve (Size 400 only) is set to 5.0” w.c. Inlet supply pressure to the heater for propane gas must be a minimum of 11" w.c. and a maximum of 14" w.c.

Before attempting to measure or adjust valve outlet gas pressure, the inlet supply pressure must be within the specified range both when the heater is in operation and on standby. Incorrect inlet pressure could cause excessive valve outlet gas pressure immediately or at some future time. If natural gas supply pressure is too high, install a regulator in the supply line before it reaches the heater. If natural gas supply pressure is too low , contact your gas supplier .

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 11

12. Gas

Pressures (cont’d)

Check V alve Outlet Pressure (can only be done after heater is operating)

NOTE: If operating at high altitude, outlet pressure requires adjustment. Follow instructions below.

NOTES: If installation is above 6000 ft (1830M), a high altitude pressure switch is required on each heat section (all sizes). See Paragraph 5. The main combustion air pressure switch (Sizes 800 and 1200 only) does not need to be changed for high

Instructions

1) Locate the 1/8” output pressure tap on the first valve (See FIGURE 8). With

the manual valve turned off to prevent flow to the gas valve, connect a manom-

eter to the 1/8" pipe outlet pressure tap in the valve. NOTE: A manometer (fluid-

filled gauge) is recommended rather than a spring type gauge due to the difficulty

of maintaining calibration of a spring type gauge.

2) Open the manual valve and operate the heater. Measure the outlet pressure of

the gas valve. To measure low-stage pressure on a Size 400 unit equipped with a

two-stage valve, disconnect the wire from the “HI” terminal on the valve. (Be

sure to reconnect wire after testing.)

Normally when operating at sea level, adjustments should not be necessary to the

factory setting(s). (For high altitude settings, see below .) If adjustment is neces-

sary, remove the cap from the adjustment screw(s). Set pressure to correct

settings by turning the regulator screw IN (clockwise) to increase pressure. Turn

regulator screw 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 Altitude Operation

Instructions for High Altitude Derate

1. Determine the required valve outlet pressure for the elevation where the heater

will be operating. If unsure of the elevation, contact the local gas supplier.

Valve Outlet Pressure Settings by Elevation

altitude installation.

FIGURE 8 - Top View of Valves showing Outlet Pressure Tap and Adjustment Locations

Single-Stage Valve

Output

Adjustment

Screw

Inlet

Pressure

Tap

1/8” Output

Pressure Tap

Two -Stage Valve (optional

Feet Meters

0-2000 0-610 3.5 2.0 10.0 5.6 2001-3000 611-915 3.1 1.7 8.8 5.0 3001-4000 916-1220 3.0 1.7 8.5 4.8 4001-5000 1221-1525 2.8 1.6 8.1 4.6 5001-6000 1526-1830 2.7 1.5 7.7 4.4 6001-7000 1831-2135 2.6 1.5 7.4 4.2 7001-8000 2136-2440 2.5 1.4 7.1 4.0 8001-9000 2441-2745 2.4 1.3 6.7 3.8

9001-10000 2746-3045 2.4 1.3 6.7 3.6

Feet Meters

0-2000 0-610 3.5 2.0 10.0 5.6 2001-4500 611-1373 2.8 1.6 8.1 4.6

on Model LDAP 400 only)

Adjust High

Pressure

Output

Inlet

Pressure

Tap

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 12

Adjust Low Pressure Output

1/8” Output

Pressure

Tap

2. Locate the 1/8” output pressure tap on the first valve (See FIGURE 8). Turn

the knob on the top of the valve to “OFF”. Connect a manometer to the 1/8" pipe outlet pressure tap in the valve. Use a water column manometer that is readable to the nearest tenth of an inch.

Single-Stage and Two-Stage High Fire - Turn the knob on the top of the

valve to “ON”. Remove the cap from the pressure adjusting screw and adjust the gas train pressure to the pressure selected from the table above. Adjust pressure by turning the regulator screw IN (clockwise) to increase pressure or OUT (counterclockwise) to decrease pressure.

Two-Stage Low Fire - Disconnect the wire from the “HI” terminal on the gas valve and check the low fire pressure. Turn the regulator screw to adjust the low fire outlet pressure to the “Low Fire” pressure selected from the table. Reconnect the wire to the gas valve.

M anifold Pressure Settings by Altitude for the UNI T ED STATES

Al titude Natural Gas (inches w.c .) Propane Gas (i nc he s w.c .)

Single-Stage and

Two-Sta

Ma nifold Pressure Settings b y Altitude for CANADA

Al titude Natural Gas (inches w.c .) Propane Gas (i nc he s w.c .)

Single-Stage and

Two-Sta

e High Fire

Two-Stage

Low Fire

Two-Stage

Low Fire

Single-Stage and

Two-Stage High Fire

Single-Stage and

Two-Stage High Fire

Two-Stage

Low Fire

Two-Stage

Low Fire

4. Turn up the thermostat. Cycle the burners once or twice to properly seat the

adjustment spring in the valve.

Re-check the pressure(s). When the outlet pressure is right for the installation,

remove the manometer and replace the cap.

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.

6. With the heater operating determine that the inlet pressure to the heater for

natural gas is between 5 and 13.5 inches w.c. and for propane between 10 and

13.5 inches w.c. Take this reading at the inlet pressure tap of the first gas valve. If the inlet pressure is not within the specified range, the inlet pressure must be corrected and Steps 3 - 5 repeated.

7. Find the High Altitude Adjustment label in the plastic bag that contained these

instructions. Using a permanent marker, fill-in the appropriate information from the “BTUH Input & Capacity by Altitude” Table, below. Select a location for the label on the outside of the heater main access panel so that it will be conspicuous to anyone operating or servicing the heater. Be sure the surface is clean and dry and adhere the label.

High Altitude Capacity Changes

BTUH Inputs & Capacities by Altitude in the UNI T ED STATES for Model LDAP

Altitude

Feet Meters

0 - 2000 0 - 610 400000 332000 300000 800000 664000 400000 1200000 996000 400000 2001 - 3000 611 - 915 37600 0 312080 282000 752000 624160 376000 1128000 936240 376000 3001 - 4000 916 - 1220 368000 305440 276000 736000 610880 368000 1104000 916320 368000 4001 - 5000 1221 - 1525 360000 298800 270000 720000 597600 360000 1080000 896400 360000 5001 - 6000 1526 - 1830 352000 292160 264000 704000 584320 352000 1056000 876480 352000 6001 - 7000 1831 - 2135 344000 285520 258000 688000 571040 344000 1032000 856560 344000 7001 - 8000 2136 - 2440 336000 278880 252000 672000 557760 336000 1008000 836640 336000 8001 - 9000 2441 - 2745 328000 272240 246000 656000 544480 328000 984000 816720 328000

9001 - 10000 2746 - 3045 320000 265600 240000 640000 531200 320000 960000 796800 320000

Altitude

Feet Meters

0 - 2000 0 - 610 400000 332000 300000 800000 664000 400000 1200000 996000 400000 2001 - 4500 611 - 1373 360000 298800 270000 720000 597600 360000 1080000 896400 360000

Normal

Input

Normal

Input

13. Burners

The input and/or the capacity of the heater changes with the derate. The tables below list inputs and capacities at altitudes from sea level to 10,000 ft (3045M) for the U.S. and to 4500 ft (1373M) for Canada.

Thermal Output

Capacity

BTUH Inputs & Capacities by Altitude in the CANADA for Mod el LDAP

Thermal Output

Capacity Size 400 Size 800 Size 1200

Each heat section in this heater has a one-piece TCORE

Minimum

Input

Minimum

Input

Normal

Input

Normal

Input

Thermal Output

Cap a city

Size 800 Size 1200Size 400

Thermal Output

Cap a city

Minimum

Input

Minimum

Input

Normal

Input

Normal

Input

Thermal Output

Cap a city

Thermal Output

Cap a city

burner assembly (U.S.

Minimum

Input

Minimum

Input

Patent No. 6,889,686) designed to provide controlled flame stability without lifting or flashback with either natural or propane gas.

The burner can be removed as a unit for inspection or service; see Maintenance Section for removal instructions.

14. Electrical Supply and Connections

Supply Wiring

All electrical wiring and connections, including electrical grounding MUST be made in accordance with the National Electric Code ANSI/NFPA No. 70 (latest edition) or , in Canada, with CSA Standard C22.1. In addition, the installer should be aware of any local ordinances or gas company requirements that might apply.

Check the rating plate on the heater for the supply voltage and current requirements. A dedicated line voltage supply with disconnect switch should be run directly from the main electrical panel to the heater. All external wiring must be within approved

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 13

14. Electrical Supply and Connections (cont’d)

conduit and have a minimum temperature rise rating of 60°C. Conduit must be run so as not to interfere with the heater access panel.

CAUTION: Route wires so that they do not contact the flue wrapper or venter housing. When running electrical conduit, be car eful that it is clear of all access panels.

Supply Wiring (cont’d)

Disconnect Switch

FIGURE 9 - Built-in Disconnect Switch

24V Control Wiring Connections

The heater is equipped with a built-in, non-fusible, lockable disconnect switch (FIGURE 8). If a fusible disconnect is required, it must be field supplied. The built-in

disconnect switch requires copper wiring with ampacity based on 60°C maximum temperature rating at the line side terminals.

WARNING: To prevent injury or death due to electrocution or contact with moving parts, lock disconnect switch open. See Hazard Levels, page 2.

WARNING: If you turn off the power supply , turn off the gas. See Hazard Levels, page 2.

Model LDAP supply wiring enters above and connects directly to the disconnect switch (See FIGURE 1A or 1B in Paragraph 7 and FIGURE 9). A circuit board (See FIGURE 13 in Paragraph 20) is located in the control compartment of each heat section. The circuit boards are polarity sensitive. It is advisable to check the electrical supply to be certain that the black wire is the “hot” wire and that the white wire is the neutral wire. The supply connection made to “L1” on the disconnect switch must be the “hot” wire.

Each heat section in the heater has a terminal strip for 24-volt thermostat connections. The terminal strip is located on the outside of the cabinet at the front of each heat section (See FIGURE 1A or 1B in Paragraph 7). W ires from the terminal strip(s) are factory wired to the circuit board(s).

15. Thermostat and Connections

Use either an optional thermostat available with the heater or a field-supplied 24-volt thermostat. Install according to the thermostat manufacturer's instructions, paying particular attention to the requirements regarding the location of the thermostat.

Make sure that the heat anticipator setting on the thermostat is 0.6 amps (or in accordance with the amperage value noted on the wiring diagram of your heater).

Make thermostat connections at the terminal strip on the front of the heater. The strip has seven terminals, R, G, C, Y1, Y2, W1, and W2. Refer to the wiring diagram on the heater.

IMPORTANT: All heaters MUST be operated by a 24-volt thermostat. Never use a line voltage disconnect switch as a means of operating the heater. Operating by means other than a 24-volt thermostat may result in the high limit control tripping and may cause damage to the heater from excessive heat.

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

• Option CL2 - Single-Stage Thermostat with Fan Switch, 40-80°F

• Option CL3 - Single-Stage Thermostat, 40-90°F

• Option CL7 - Two-Stage Thermostat (for use with optional two-stage gas valve

on Size 400 or for staging heat sections on Sizes 800 and 1200)

• Option CL18 - Two-Stage Thermostat with Fan Switch (for use with optional

two-stage gas valve on Size 400 or for staging heat sections on Sizes 800 and

1200)

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 14

FIGURE 10 - Thermostat Connections for Model LDAP 400 with Option CL1, CL2, CL3, CL7, or CL18

LDAP 400 THERMOSTAT WIRING

FIELD WIRING

NOTES:

1) Set the anticipator at 0.6 amps.

2) Set thermostat first stage anticipator at

0.6 amps and second stage anticipator at

0.2 amps.

3) Jumper thermostat terminals RH to RC.

4) Jumper thermostat terminals RH to RC and G to W1.

5) Set thermostat first stage anticipator at maximum amps and second stage anticipator at 0.6 amps.

LDAP 400 - Thermostat Option CL1, CL2, CL3, CL7 or CL18

WD# 189504 REV. #2

SINGLE STAGE HEATING TWO STAGE HEATING

CL2

W-S23-6 SUBBASE

(OPT CL2) W.R. 1C30-341

(SEE NOTE #1)

CL1 CL3

(SEE NOTE #1)

(OPT CL3) T874F THERMOSTAT OR

(OPT CL1) W.R. 1C30-341 THERMOSTAT

TERMINAL STRIP

SINGLE STAGE HEATING

WITH RECIRCULATION

CL18

(OPT CL18) T874F THERMOSTAT

SEE NOTES #4 & #5)

(

Q674C SUBBASE (SEE NOTES #4 & #5)

CL7

Q674G SUBBASE

(SEE NOTE #5)

(OPT CL7) T874F THERMOSTAT

TERMINAL STRIP

CL18

Q674C SUBBASE

(OPT CL18) T874F THERMOSTAT

(SEE NOTE #2 AND #3)

CL7

Q674G SUBBASE

(SEE NOTE #2)

(OPT CL7) T874F THERMOSTAT

TERMINAL STRIP

FIGURE 11 - Thermostat Connections for Model

CL2

LDAP 800 with Option CL1, CL2, CL3, CL7, or CL18

W-S23-6 SUBBASE

(OPT CL2) W.R. 1C30-341

(SEE NOTE #1)

CL1 CL3

(OPT CL3) T874F THERMOSTAT OR

(OPT CL1) W.R. 1C30-341 THERMOSTAT

(SEE NOTE #1)

LDAP 800 THERMOSTAT WIRING

FIELD WIRING

NOTES:

1) Set the anticipator at 0.6 amps.

2) Set thermostat first stage anticipator at 0.6 amps and second stage anticipator at 0.2 amps.

3) Jumper thermostat terminals RH to RC.

4) Jumper thermostat terminals RH to RC and G to W1.

5) Set thermostat first stage anticipator at maximum amps and second stage anticipator at 0.6 amps.

LDAP 800 - Thermostat Option CL1, CL2, CL3, CL7 or CL18

WD# 189505 REV. #2

TERMINAL STRIP

SINGLE STAGE HEATING

TERMINAL STRIP

UNIT #1

UNIT #2

SINGLE STAGE HEATING

WITH RECIRCULATION

CL18

Q674C SUBBASE

(OPT CL18) T874F THERMOSTAT

(SEE NOTES #4 & #5)

CL7

Q674G SUBBASE

(OPT CL7) T874F THERMOSTAT

(SEE NOTE #5)

TERMINAL STRIP

UNIT #1

TERMINAL STRIP

UNIT #2

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 15

CL18

(OPT CL18) T874F THERMOSTAT

TWO STAGE HEATING

Q674C SUBBASE

(SEE NOTE #2 AND #3)

CL7

Q674G SUBBASE

(OPT CL7) T874F THERMOSTAT

(SEE NOTE #2)

TERMINAL STRIP

UNIT #1

TERMINAL STRIP

UNIT #2

15. Thermostat and Connections (cont’d)

SINGLE STAGE HEATING

WITH RECIRCULATION

CL18

Q674C SUBBASE

(OPT CL18) T874F THERMOSTAT

(SEE NOTES #6 & #7)

CL7

Q674G SUBBASE

(OPT CL7) T874F THERMOSTAT

(SEE NOTE #7)

TERMINAL STRIP

UNIT #1

FIGURE 12 - Thermostat Connections for Model LDAP 1200 with Option CL1, CL2, CL3, CL7, or CL18

SINGLE STAGE HEATING

CL2

W-S23-6 SUBBASE

(OPT CL2) W.R. 1C30-341

(SEE NOTE #1)

CL1 CL3

(OPT CL3) T874F THERMOSTAT OR

(OPT CL1) W.R. 1C30-341 THERMOSTAT

(SEE NOTE #1)

TERMINAL STRIP

UNIT #1

TWO STAGE HEATING

CL18

Q674C SUBBASE

(OPT CL18) T874F THERMOSTAT

NOTE 2

NOTE 3

(SEE NOTE #4 AND #5)

CL7

Q674G SUBBASE

(OPT CL7) T874F THERMOSTAT

(SEE NOTE #4)

TERMINAL STRIP

UNIT #1

LDAP 1200 THERMOSTAT WIRING

FIELD WIRING

FACTORY WIRING

CRIMP TERMINAL

NOTES:

1) Set the anticipator at 0.6 amps.

2) For 400,000 BTUH low fire, do not install this jumper.

3) For 800,000 BTUH low fire, do not install this jumper.

4) Set thermostat first stage anticipator at 0.6 amps and and second stage anticipator at 0.2 amps.

5) Jumper thermostat terminals RH to RC.

6) Jumper thermostat terminals RH to RC and G to W1.

7) Set thermostat first stage anticipator at maximum amps and second stage anticipator at 0.6 amps.

LDAP 1200 - Thermostat Option CL1, CL2, CL3, CL7 or CL18

WD# 189506 REV. #2

TERMINAL STRIP

UNIT #2

TERMINAL STRIP

UNIT #2

TERMINAL STRIP

UNIT #2

TERMINAL STRIP

Multiple Heater Control - Option CL31 and Option CL32

If the heater was ordered with a multiple heater control option, one thermostat can be used to control multiple heaters. The option will control a maximum of six Size 400 heaters, a maximum of three Size 800 heaters, or a maximum of two Size 1200 heaters.

The option includes a 40 VA transformer that replaces the standard transformer in the ”master” heater and a relay assembly that attaches to the “slave” heater. Option CL31 provides for control of two heaters. If control of additional heaters is desired, Option CL32 which is the relay assembly only must be added to each of the “slave” heaters.

The option packages are shipped separately and include complete instructions for installation and wiring.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 16

UNIT #3

TERMINAL STRIP

UNIT #3

TERMINAL STRIP

UNIT #3

16. Combustion Air Proving [Pressure Switch(es)]

The combustion air proving switch is a pressure sensitive switch that monitors air pressure to ensure that proper combustion airflow is available. The switch is a single pole/normally open device which closes when a differential pressure is sensed between the venter housing and the flue collection box. Each section in the heater has a pressure switch. (For switch location, see FIGURE 22, page 33.) In addition, heaters with more than one heat section (Size 800 and Size 1200) have a main pressure switch which senses the negative pressure in the main venter housing.

NOTE: For high altitude, follow instructions in Paragraph 5 to change heat

On startup when the heater is cold, the sensing pressure is at the highest level, and as the heater and flue system warm up, the sensing pressure becomes less. After the system has reached equilibrium (about 20 minutes), the sensing pressure levels off.

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.

Pressure Switch Settings

Sea Level Pressure Switc h Settings (Ap plies to elevatio ns up to 6000ft /1830M)

Main P ressure Switch

St a rt-up Cold

Model

LDAP

400 1 1.80 to 1.50 1.05 to 0.85 0.65 0.83 Yellow 197028 800 -1.30 to -1.00 -0.85 to -0.65 -0.15 -0.33 Gray 205445 2 1.90 to 1.60 1.10 to 0.90 0.65 0.83 Yellow 197028

1200 -1.40 to -0.90 -0.97 to -0.59 -0.15 -0.33 Gray 205445 3 2.40 to 1.90 1.55 to 1.00 0.65 0.83 Yellow 197028

St a rt-up Cold

Model

LDAP

400 1 1.75 to 1.45 1.00 to 0.80 0.60 0.78 Lt. Blue 197029 800 -1.25 to -0.95 -0.80 to -0.60 -0.15 -0.33 Gray 205445 2 1.85 to 1.55 1.05 to 0.85 0.60 0.78 Lt. Blue 197029

1200 -1.35 to -0.85 -0.92 to -0.54 -0.15 -0.33 Gray 205445 3 2.35 to 1.85 1.50 to 0.95 0.60 0.78 Lt. Blue 197029

Equilibrium

Hot

Negative Pressure (in. w.c.) Differential Pressure (in. w.c.)

Main P ressure Switch

Equilibrium

Hot

Negati ve Pressure ( in. w .c.)

If a restriction or excessive flue length or turns cause the sensing pressure to be outside the switch setpoint, the pressure switch will function to shutoff the burner . If the main combustion air pressure switch opens, it will interrupt the electric supply to all gas valves. If a heat section pressure switch opens, it will interrupt the electric supply to the gas valve in that heat section. The burner(s) will remain off until the system has cooled and/or the flue system resistance is reduced.

The Table below lists the approximate water column differential pressure settings of the heat section pressure switch(es) and the negative pressure readings of the main pressure switch.

Heat Section Pressure Sw it ch (es)

Setpoint

High Altitu de Pr essur e Switc h Set tings, Units Abo ve 6000ft/ 1830M

Setpoint

OFF

Setpoint

Label Color

Switch

Part No.

Switch

Part No.

Qty

Start-up

Cold

Start-up

Cold

Equilibrium

Hot

Heat Section Pressure Sw it ch (es)

Equilibrium

Hot

Differential Pressure (in. w.c.)

Setpoint

OFF

Setpoint

OFF

Setpoint

Label Color

Switch

Part No.

Switch

Part No.

DANGER: Safe operation of this heater requir es proper venting flow . NEVER bypass combustion air proving switch(es) or attempt to operate the heater without the venter running and the pr oper flow in the vent system. Hazardous conditions could result. See Hazard Intensity Levels, page 2.

17. Limit Control

Each heat section is equipped with a temperature activated auto reset limit control. The control is factory set and is non-adjustable. If the setpoint is reached, the limit control will interrupt the electric supply to the gas valve in that heat section. This safety device provides protection in the case of motor failure or lack of airflow due to a restriction at the inlet or outlet. (For location, see FIGURE 22, page 33.)

CAUTION: The auto reset limit control will shut down the heater until the cause is corrected. Do not bypass the limit control; hazardous conditions could result. See Hazard Intensity Levels, page

18. High Limit Control

Each heat section is equipped with a temperature activated, manually reset high limit control. The high limit control is located at the top of each heat section. It is factory set and is non-adjustable. If the setpoint is reached, the high limit control acts to interrupt the electric supply to the gas valve in that heat section. If the high limit control activates, identify and correct the cause before resetting the switch. Refer to

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 17

18. High Limit Control (cont’d)

the Maintenance Section for information on probable causes . (For location, see FIGURE 22, page 33.)

DANGER: If a manual reset high limit control activates, identify and correct the cause before r esetting the switch. Never bypass the high limit control; hazardous conditions could result. See Hazard Intensity Levels, page 2.

19. Adjustable Air Destratification Fan Control

20. Ignition

System

An adjustable fan control is located on top of the first heat section. It is adjacent to the circulating air fan and motor and controls the fan motors in all heat sections. The purpose of the fan control is to energize the fan motor(s) when the ambient air temperature around the heater reaches the setting on the control. The fan motor(s) will be de-energized when the fan control is satisfied. The fan(s) re-circulates the heated air near the ceiling down to the floor level (destratification) and improves heat recovery . A call for heat by the thermostat overrides the air destratification fan control.

Set the adjustable fan control for the desired temperature setting for energizing the circulating air fan(s). The fan control setting should be set 5 to 10°F higher than the wall-mounted thermostat setting. The heater is factory wired to energize the fan(s) at medium speed when energized by the adjustable fan control. For lower mounting heights it may be desirable to operate the fan(s) at low speed. Switching the blue (medium speed) and red (low speed) fan motor wires on each heat section will change the fan motor(s) speed. Refer to the wiring diagram for the wire locations.

T o manually override the fan control, the heater may be tuned off at the circuit breaker in the main electrical panel, or a field-installed electrical box with a SPST switch can be located near the wall thermostat with the switch wired in series with the fan control.

The air destratification can also be a benefit in the summer time. Using the fan(s) in the summer time can improve working conditions by alleviating stagnant air conditions and creating a cooling effect for the occupants.

Each heat section in this heater is equipped with a direct spark integrated control module (circuit board). The module monitors the safety devices and controls the operation of the fan and venter motors and the gas valve between heat cycles.

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

Spark

Transformer

Plug

Control

Fuse

Thermostat

Connections

Dip Switch

Fan/Blower

Off

Delay

Status Lights

LED Lights

Normal Heat Cycle Operating Sequence

NOTE: All LED Flash Codes are on page 38.

Swit ch Settng Chart for Fan

OFF Delay (See SW1 on W.D.)

TIME SW1 SW2

90 sec OFF ON 120 sec OFF OFF 160 sec ON OFF

45 sec ON ON

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 pressure switch is open and the main combustion air pressure switch (Sizes 800 and

1200) is open. If the limit or high limit switch is open, the control responds as defined in the “Abnormal Heat Cycle, Limit Switch Operation”. If the heat section pressure switch or main combustion air pressure switch are closed, the control will do four flashes on the green LED and wait indefinitely for the heat section pressure switch or main combustion air pressure switch to open. If the heat section pressure switch and main combustion air pressure switch are open, the control proceeds to prepurge.

2) Prepurge - The control energizes the heat section venter motor and main venter motor (Sizes 800 and 1200) and waits for the heat section pressure switch and main combustion air pressure switch to close. If the heat section pressure switch or main combustion air pressure switch does not close within 30 seconds of the heat section venter motor and main venter motor energizing, the control will do two flashes on the green LED. The control will leave the heat section venter motor and main venter motor energized indefinitely as long as the call for heat remains and the heat section pressure switch or main combustion air pressure switch is open.

When the heat section pressure switch and main combustion air pressure switch are proven closed, the control begins the prepurge time. If flame is present any time while in prepurge, the prepurge time is restarted. If flame is present long enough to cause lockout, the control responds as defined in “Fault Modes, Undesired Flame”.

The control runs the heat section venter motor and main venter motor for a 20 second prepurge time, then proceeds to the ignition trial period.

3) Ignition T rial Period - The control energizes the spark and main gas valve. The venter remains energized. If flame is sensed during the first 16 seconds, the spark is de-energized and the control proceeds to heat fan on delay. If flame has not been sensed during the first 16 seconds, the control de-energizes the spark output and keeps the gas valve energized for an additional one second flame proving period. If flame is not present after the flame proving period, the control de-energizes the gas valve and proceeds with ignition re-tries as specified in “Abnormal Heat Cycle, Ignition Re-try”. If flame is present, the control proceeds to the fan on delay.

4) Fan On Delay - The control waits for 30 seconds from the time the gas valve opened and then energizes the fan motor. The gas valve, heat section venter motor, and main venter motor remain energized. The control proceeds to steady heat mode.

5) Steady Heat - Control inputs are continuously monitored to ensure limit, high limit, heat section pressure switch, and main combustion air pressure switch are closed, flame is established, and the thermostat call for heat remains. When the thermostat call for heat is removed, the control de-energizes the gas valve and begins post-purge and fan off delay timing.

6) Post Purge - The heat section venter motor and main venter motor outputs remain on for a 45 second post-purge period after the thermostat is satisfied.

7) Fan Off Delay - The fan motor is de-energized after a fan off delay as selected by the dip switches. Timing begins when the thermostat is satisfied. Delay times are as in the table on the left. The factory default when shipped is 120 seconds.

Abnormal Heat Cycle Functions

Interrupted Thermostat Call for Heat - If the thermostat demand for heat is removed before the flame is recognized, the control will run the heat section venter motor and main venter motor for the post purge period and de-energize all outputs.

If the thermostat demand for heat is removed after successful ignition, the control will de-energize the gas valve, run the heat section venter motor and main venter motor through post purge, and run the fan motor on heat speed for the selected delay off time.

Ignition Retry - If flame is not established on the first trial for ignition period, the control de-energizes the gas valve and the heat section venter motor and main venter motor

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 19

20. Ignition System (cont’d)

Abnormal Heat Cycle Functions (cont’d)

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.

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 venter motor remain energized. The fan motor is shut of f after the longest selectable fan delay time (160 seconds). When the fan motor de-energizes, the spark and gas valve are re-energized and the control initiates another trial for ignition. (This fan delay is a selfhealing feature for an open auxiliary limit switch).

If flame is not established on the third trial for ignition period, the control de-energizes the gas valve, and the heat section venter motor and main venter motor remain energized for an inter-purge period of 10 seconds. The control then re-energizes the gas valve and spark and initiates another trial for ignition.

If flame is not established on the fourth trial for ignition (initial try plus 3 re-tries), the control de-energizes the gas valve and goes into lockout. The control goes to one flash on the green LED to indicate ignition failure lockout.

Limit and High Limit Switch Operation - The high limit and limit switch are ignored unless a call for heat is present (W energized). If the high limit or limit switch are open and a call for heat is present, the control de-energizes the gas valve and turns the fan motor on heat speed and runs the heat section venter motor and the main venter motor.

When the switch re-closes or the call for heat is lost, the control runs the heat section venter motor and main venter motor through post purge and runs the fan motor through the selected fan off delay. The control will return to normal operation after fan off delay is completed.

Heat Section Pressure Switch (all sizes) and Main Combustion Air Pressure Switch (Sizes 800 and 1200) - If the heat section pressure switch or main combustion air pres-

sure switch opens before the trial for ignition period, the heat section venter motor and main venter motor will run through the heat section pressure switch and main combustion air pressure switch recognition delay (2 seconds), the gas valve will be de-energized, and the heat section venter motor and main venter motor will run through the postpurge time. The control will re-start the heat cycle at the heat section pressure switch and main combustion air pressure switch proving state if the call for heat still exists.

Heat section pressure switch or main combustion air pressure switch opening for less than 2 seconds during the trial for ignition period shall not interrupt the heat cycle. (Gas valve will de-energize while the heat section pressure switch and main combustion air pressure switch is open.)

If the heat section pressure switch or main combustion air pressure switch opens after a successful ignition, the control will de-energize the gas valve. If flame is lost before the end of the 2 second pressure switch recognition delay , the control will respond to the loss of flame. If the heat section pressure switch and main combustion air pressure switch remains open for 2 seconds and the flame remains, the control de-energizes the gas valve, the heat section venter motor and main venter motor runs through postpurge, and the fan motor runs on heat speed through the selected fan off delay. When the fan off delay is over, the fan motor is de-energized, and a heat cycle is begun if the call for heat still exists.

Continuous Fan Operation

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 20

When the thermostat calls for continuous fan (G) without a call for heat, the fan motor is energized after a .25 second delay. NOTE: This brief on delay is to allow the “G” terminal to energize slightly before “Y” and an external changeover relay to switch from “G” to “W” without causing momentary glitches in the fan motor output. The fan remains energized as long as the call for fan remains without a call for heat.

If a call for heat (W) occurs during continuous fan, the fan will de-energize. A call for fan is ignored while in lockout.

Fault Modes

Undesired Flame - If flame is sensed longer than 20 seconds while the gas valve is deenergized, 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. The control will do a soft lockout, but will still respond to open limit and flame. The FLAME (yellow) LED shall flash rapidly when lockout is due to undesired flame.

Gas Valve Relay Fault - If the control senses the gas valve as energized for more than one second when the control is not attempting to energize the gas valve, or the gas valve is sensed as not energized when it is supposed to be energized, then the control will lockout with the green LED off. The control assumes either the contacts of the relay driving the gas valve have welded shut, or the sensing circuit has failed. The heat section venter motor is forced off to open the heat section pressure switch to stop gas flow unless flame is present.

If the gas valve was sensed as closed when it should be open, and has not de-energized after the heat section venter motor and main venter motor was shutoff for 15 seconds, then the heat section venter motor and main venter motor are re-energized to vent the unburned gas.

Lockout

21. Gas V alve(s)

• Size 400 has 1 valve.

• Size 800 has 2 valves.

• Size 1200 has 3 valves.

Soft Lockout - The control shall not initiate a call for heat or call for continuous fan while

in lockout. The control will still respond to an open limit and undesired flame. Lockout shall automatically reset after one hour. Lockout may be manually reset by removing power from the control for more than one second or removing the thermostat call for heat for more than one and less than 20 seconds.

Hard Lockout (Green LED - steady off) - If the control detects a fault on the control board, the status LED will be de-energized, and the control will lockout as long as the fault remains. A hard lockout will automatically reset if the hardware fault clears.

Power Interruption - During a momentary power interruption or at voltage levels below the minimum operating voltage (line voltage or low voltage), the system will self-recover without lockout when voltage returns to the operating range.

Power interruptions of less than 80mS shall not cause the control to change operating states. Power interruptions greater than 80mS may cause the control to interrupt the current operating cycle and re-start. Power interruption during a heat cycle may trip the manual reset high limit switch.

The main operating gas valve(s) is powered by the 24-volt control circuit through the thermostat and safety controls. The gas valve is of the diaphragm type providing regulated gas flow preset at the factory. (For location, see FIGURE 22, page 33.)

WARNING: The operating valve is the prime safety shutoff. All gas supply lines must be free of dirt or scale before connecting the heater to ensure positive closure. See Hazard Levels, page 2.

22 Fan Motor(s)

• Size 400 has 1 fan motor.

• Size 800 has 2 fan motors.

• Size 1200 has 3 fan motors.

Each heat section in the heater has a fan motor. Each fan motor(s) is equipped with thermal overload protection of the automatic reset type. Should the motor(s) refuse to run, it may be because of improper current characteristics. Make certain that the correct voltage is available at the motor(s).

Fan Motor Wiring

White = Neutral Black = High (Heat Speed) Blue = Medium (Destratification Speed, Factory Wired) Red = Low (Optional Destratification Speed, Field Wired)

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 21

23. Wiring Diagrams

• Operating Sequence, Notes, Codes, Keys, etc. for ALL three typical wiring

diagrams (FIGURES 14, 15, and 16 on pages 23, 24, and 25), pages 22-23.

• FIGURE 14 - Model LDAP 400, page 23.

• FIGURE 15 - Model LDAP 800, page 24.

• FIGURE 16 - Model LDAP 1200, page 25.

CAUTION: If any of the original wire as supplied with the appliance must be replaced, it must be replaced with wiring material having a temperature rating of at least 105°C, except for limit control, high limit control, and sensor lead wires which must be 150°C. See Hazard Levels, page 2.

Operating Sequence, Notes, Codes, Keys, etc for ALL three typical wiring diagrams (FIGURES 14, 15, and 16) on pages 23-25.

Operating Sequence

Wiring Diagram NOTES

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 22

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).

3. Turn on power to the heater.

4. Set thermostat at desired setting.

5. Thermostat calls for heat, energizing the venter motor(s).

6. Main combustion air pressure switch (Sizes 800 and 1200) and heat section

pressure switch(es) close, firing heat section(s) (Unit fires at low fire when using two-stage thermostat).

7. Burner flame is sensed, and in 30 seconds the fan motor(s) is energized.

8. High stage of thermostat calls for heat, firing all heat sections at full rate (on

heaters with a two-stage thermostat).

9. With Opt CL2 or CL18, set fan switch at “ON” position for continuous fan

operation.

10.If the flame is extinguished during main burner operation, the integrated

control system closes the main valve of that heat section and must be reset by interrupting power to the control circuit (see lighting instructions).

1. The following controls are field-installed options: Thermostat

2. Dotted wiring installed by others.

3. CAUTION: If any of the original wiring as supplied with the appliance must be

replaced, it must be replaced with wiring material having a temperature rating of at least 105°C, except for sensor lead wire and limit wiring which must be 150°C.

4. Use 18 gauge wire for all wiring on the heater.

5. Line and fan motor branch wire sizes should be of a size to prevent voltage

drops beyond 5% of supply line voltage.

6. Size 400, see thermostat wiring diagram in FIGURE 10, page 15. Size 800, see thermostat wiring diagram in FIGURE 11, page 15. Size 1200, see thermostat wiring diagram in FIGURE 12, page 16.

7. The control transformer has a dual voltage primary. For 230V heaters, the black lead goes to the “240” terminal. Cap the “208” terminal. For 208V heaters, the black lead goes to the 208” terminal. Cap the “240” terminal.

8. When providing or replacing fuses in the fusible disconnect switch, use dual elements time delay fuses and size according to 1.25 times the maximum total input amps.

9. The line side of the lockable disconnect switch must be connected to the incoming power supply such that the voltage between Terminal L1 and Ground is the greater value.

Wiring Color Codes

Black - BK Brown - BR Red - R Orange - O Yellow - Y Green - G

Switch Set tng Ch art for Fan

OFF Delay (See SW1 on W.D.)

TIME SW1 SW2

90 sec OFF ON 120 sec OFF OFF 160 sec ON OFF

45 sec ON ON

Fan Motor Wiring

White = Neutral Black = High (Heat Speed) Blue = Medium (Destratification Speed, Factory Wired) Red = Low (Optional Destratification Speed, Field W ired)

Blue - BL Purple - PR White - W

Key

Terminal Block - Heat Section #1 Terminal Block - Heat Section #2 Terminal Block - Heat Section #3

Factory Wiring Field Wiring

Total Wir e

Len

th 150 ft (46M) 75 ft (23M) 18 Gauge 250 ft (76M) 125 ft (38M) 16 Gauge

350 ft (107M) 175 ft (53M) 14 Gauge

Field Control Wiring

Distance from Unit

to Control

Mi nimum Recommended

Wire Gauge

FIGURE 14 – T ypical Wiring Diagram for Model LDAP 400 (Reference W . D. 189374, Rev 2)

208 OR 230/1/60

See NOTE 6 on Page 22.

HONEYWELL

ALT.

TWO STAGE

GAS VALV E

LOW

HIGH

HONEYWELL

ALT.

SINGLE STAGE

GAS VALV E

GAS VALVE

CUSTOMER'S FUSIBLE DISCONNECT SWITCH (SEE NOTES on page 22.)

GRD

L1 L3

HONEYWELL TWO STAGE GAS VALV E

STG

TERMINAL STRIP

LOCKABLE

MANUAL

RESET

HIGH LIMIT

CONTROL

PRESSURE

LOW

HIGH

ON/OFF

L3 T3

L2 T2

R R

SWITCH

STG

FLAME

STG

ELECTRODE

FLAME

T1L1

LIMIT

CONTROL

GROUND

DISCONNECT

P3-2

P3-3

P3-4

P3-5

P1-8

P1-3

P1-6

P1-5

P1-4

P1-2

P1-7

P3-1

P1-9

ADJUSTABLE

DESTRAT

FAN CONTROL

SEE CHART AT TOP OF PAGE FOR

SWITCH SETTINGS

DSI CONTROL

SW1

LINE VOLTAGE

(SEE NOTE 7 on page 22.)

RBL R

108

NEUTRALL1 SEC COM

FUSE

3.0 AMP ATO OR ATC

NEUTRAL

EAC/BLO

TEST

OK FLAME

LED

NEUTRAL

SPARK

TRANSFORMER

IND

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 23

COM

40 VA. CONTROL

TRANSFORMER

FAN

PERMISSIVE

RELAY CONTACTS

425

SPARK GAP

GRD

SCREW

DESTRAT RELAY

PR B

20uF CAPACITOR

REMOTE MOUNTED

BR/W

FAN

MOTOR

28 CR

3Y1

VENTER

MOTOR

BR/W

4uF CAPACITOR

REMOTE MOUNTED

315CR 1

CONTACTS

GRD

REMOTE DESTRAT RELAY CONTACTS

DESTRAT RELAY COIL 22

REMOTE DESTRAT RELAY COIL 21

2 4

FAN PERMISSIVE RELAY COIL 22 - 23

23. Wiring Diagrams (cont’d)

FIGURE 15 – T ypical W iring Diagram for Model LDAP 800 (Refer ence W.D. 189375, Rev 2)

208 OR 230/1/60

CUSTOMER'S FUSIBLE SWITCH

GRD

G G

SEE NOTE 6 ON PAGE 22.

(SEE NOTES on page 22.)

#1 VENT PERMISSIVE

RELAY CONTACTS

MAIN COMBUSTION AIR

PRESSURE

CBLNO

ADJUSTABLE

FAN CONTROL

TERMINAL STRIP

UNIT #1

DISCONNECT

SWITCH

DESTRAT

MANUAL

RESET

HIGH LIMIT

CONTROL

R2R

PRESSURE

SWITCH

LOCKABLE DISCONNECT

L3 T3

L3 T2

T1L1

LIMIT

CONTROL

#1 HEAT PERMISSIVE

RELAY CONTACTS

GAS VALVE

FLAME

ELECTRODE

FLAME

GROUND

ON/OFF

LINE VOLTAGE

(See NOTE 7 on page 22.)

P3-1

P3-2

P3-3

P3-4

P3-5

P1-8

P1-3

P1-6

P1-5

P1-4

P1-2

P1-7

P1-9

CONTROL

#2 VENT PERMISSIVE

RELAY CONTACTS

2 4

COM

40 VA. CONTROL

TRANSFORMER

SW1

SEC

SEE CHART PAGE 23 FOR

SWITCH SETTINGS

3.0 AMP ATO OR ATC

TEST

FLAME

LED

#1 DSI

LED

FUSE

COM

NEUTRAL

EAC/BLO

IND

NEUTRAL

SPARK

TRANSFORMER

#1 FAN

PERMISSIVE

RELAY CONTACTS

SPARK GAP

LINE VOLTAGE

(See NOTE 7 on page 22.)

GRD

SCREW

#1 DESTRAT

RELAY CONTACTS

20uF CAPACITOR

REMOTE MOUNTED

BR/W

FAN

MOTOR

VENTER MOTOR

BR/W

4uF CAPACITOR

REMOTE MOUNTED

GRD

COM

3BR1

42 CR

40 VA. CONTROL

TRANSFORMER

23 CR

#1 REMOTE DESTRAT

RELAY CONTACTS

MAIN VENTER MOTOR & CAPACITOR

22 CR

1CR33

#1 HEAT

PERMISSIVE RELAY COIL

#2 HEAT PERMISSIVE

RELAY COIL 62

#1 DESTRAT

RELAY COIL 30

#2 DESTRAT RELAY COIL 54

#1 FAN PERMISSIVE RELAY COIL 30 - 31

#1 VENT PERMISSIVE RELAY COIL 13

#1 REMOTE DESTRAT RELAY COIL

The above control wiring is

repeated in the second heat section.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 24

FIGURE 16 – T ypical Wiring Diagram for Model LDAP 1200 (Reference W . D. 189376, Rev 2)

ON/OFF

RELAY CONTACTS

LINE VOLTAGE

PRESSURE

SWITCH

NOC

DESTRAT

MANUAL

RESET

HIGH LIMIT

CONTROL

PRESSURE

SWITCH

TERMINAL STRIP UNIT #1

LOCKABLE

DISCONNECT

L3 T2

COM

40 VA. CONTROL

TRANSFORMER

LIMIT

CONTROL

R R

#1 HEAT PERMISSIVE

RELAY CONTACTS

GAS VALVE

FLAME

ELECTRODE

FLAME

GROUND

SW1

3.0 AMP

TEST

FLAME

LED

ATO OR ATC

COM

FUSE

40 VA. CONTROL

TRANSFORMER

NEUTRAL

EAC/BL

NEUTRAL

SPARK

TRANSFORMER

3BR1

NEUTRALL1 SEC COM

IND

#3 VENT PERMISSIVE

RELAY CONTACTS

PR PR PR

LINE VOLTAGE

(SEE NOTE 7 on page 22.)

O O

RBLR

P3-1

P3-2

P3-3

P3-4

P3-5

P1-8

P1-3

P1-6

P1-5

P1-4

P1-2

P1-7

P1-9

SEE CHART PAGE 23 FOR

#1 DSI

SWITCH SETTINGS

OK LED

CONTROL

LINE VOLTAGE

(SEE NOTE 7 on page 22.)

#1 FAN

PERMISSIVE

RELAY CONTACTS

425

SPARK GAP

RELAY CONTACTS

20uF CAPACITOR

REMOTE MOUNTED

BR/W

MOTOR

3Y1

VENTER MOTOR

BR/W

4uF CAPACITOR

REMOTE MOUNTED

COM

GRD

SCREW

#1 DESTRAT

GRD

FAN

WBK

40 VA. CONTROL

TRANSFORMER

GRD

#1 REMOTE DESTRAT

46 CR

348CR11

3 1

RELAY CONTACTS

PR 2

MAIN

VENTER MOTOR

& CAPACITOR

BR7BR

CUSTOMER'S FUSIBLE

208 OR 230/1/60

GRD

DISCONNECT SWITCH

(SEE NOTES on page 22.)

#1 VENT PERMISSIVE

RELAY CONTACTS

#2 VENT PERMISSIVE

(SEE NOTE 7 on page 22.)

8 7

BL BR

MAIN COMBUSTION AIR

BL O

ADJUSTABLE

FAN CONTROL

See NOTE 6 on Page 22.

#1 HEAT PERMISSIVE RELAY COIL

#2 HEAT PERMISSIVE

RELAY COIL

64 #3 HEAT

PERMISSIVE RELAY COIL 86

#1 DESTRAT

RELAY COIL

#2 DESTRAT RELAY COIL 56

#3 DESTRAT RELAY COIL 78

#1 FAN PERMISSIVE RELAY COIL 34 - 35

#1 VENT PERMISSIVE RELAY COIL 12

#1 REMOTE DESTRAT

RELAY COIL

The above control wiring is

repeated in the second and third heat sections.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 25

24. V enting

Model LDAP heaters are certified as Category III heaters.

WARNING: Each heater requires its own individual vent pipe run and vent cap. Manifolding of vent runs can cause recirculation of combustion products into the building. Failure to comply could result in severe personal injury or death and/or property damage.

Venting must be in accordance with local codes and the National Fuel Gas Code Z223.1 or CSA B149.1 and B149.2, Installation Code for Gas Burning Appliances and Equipment. Local requirements supersede national requirements.

These power-vented heaters are designed to operate safely and efficiently with either a horizontal or vertical vent. Comply with the specific requirements and instructions.

If this heater is replacing an existing heater, be sure that the vent is sized properly for the heater being installed and that the existing vent is in good condition. A properly sized vent system is required for safe operation of the heater. An improperly sized vent system can cause unsafe conditions and/or create condensation. Do not vent into an existing gravity vent or chimney .

Installation should be done by a qualified agency in accordance with these instructions. The qualified service agency installing this system is responsible for the installation.

Venting Requirements

2) V ent Pipe Diameter and Length

1) T ype of Vent Pipe

The type of vent pipe is determined by whether the vent is horizontal or vertical.

Horizontal • Vent pipe approved for a Category III appliance, OR

• Appropriately sealed 26-gauge or heavier galvanized steel or equivalent single-wall pipe

Vertical • Vent pipe approved for a Category III appliance, OR

• Appropriately sealed 26-gauge or heavier galvanized steel or equivalent single-wall pipe

OR, if at least 75% of the equivalent length of the vent run is vertical

• Double-wall (Type B) vent pipe

V ent pipe diameters and maximum vent lengths in the table apply to both Horizontal and Vertical vents. Add all straight sections and equivalent lengths for elbows. The total combined length must not exceed the Maximum V ent Length.

• Use only one diameter of vent pipe on an installation.

• Minimum vent length is 3 feet (1M).

• Minimum of 1 ft (0.3M) of vertical vent required on venter outlet before installing

an elbow.

Model

LDAP

Size

400

800

1200

Includes one 9 0° elbow at venter outl et.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 26

Venter

Outlet

Diameter

inches mminches mm feet M feet M feet M

6152

8203

Vent Pip e Diameter

6 152 45 13.7 15 4.6 7.5 2.3 None 7 178 60 18.3 8 2.4 4 1.2 6" to 7" (152 to 178mm) Increaser 8 203 50 15.2 15 4.6 7.5 2.3 None

10 254 45 13.7 5 1.5 2.5 0.8 8" to 10" (203 to 254mm) Increaser

8 203 50 15.2 15 4.6 7.5 2.3 None

10 254 45 13.7 5 1.5 2.5 0.8 8" to 10" (203 to 254mm) Increaser

Vent Length

Maximum

Eqivalent

Straight Length

for 90° Elbow

Equiv a lent

Straight Length

for 45° Elbow

Field-S upplied Taper Type

Connection Required at the Venter

Outlet

3) V enter (Flue) Outlet

Venter Outlet Attachment Requirements:

Model

LDAP

Size

400 800

1200

Venter O utlet

Diameter

inches mm

6152 8203 8203

Depending on the size of vent pipe as determined in Step No. 2, attach either the vent pipe directly to the venter collar or a taper-type enlarger .

Follow instructions in Requirement No. 4. below to make the connection for the type of pipe being used.

Taper-type Pipe

Airflow

Diameter Increaser

4) Joints and Sealing

FIGURE 17A Attaching DoubleWall (Type-B) Vent Pipe to the Venter Outlet

A double-wall pipe run is allowed only if at least 75% of the vent length is vertical.

Figure 17A - STEP 1

Slide the double-wall pipe over the collar so that the collar is inside the inner pipe.

Provide field-supplied vent pipe as specified in Requirement No. 1.

• If using single wall, 26-gauge or heavier galvanized pipe, secure slip-fit connec-

tions using sheetmetal screws or rivets. Seal pipe joints either with tape suitable for 550°F (such as Option FA1, P/N 98266) or high-temperature silicone sealant.

• If using Category III vent pipe, follow pipe manufacturer's instructions for join-

ing pipe sections. When attaching Category III pipe to the venter outlet or the vent cap, make secure, sealed joints following a procedure that best suits the style of Category III pipe being used.

• If installing a double-wall (T ype B) terminal pipe, follow the instructions in FIG- URE 17C to join the double-wall pipe to a single-wall or Category III vent pipe run. To attach the vent cap, follow instructions in FIGURE 17B.

• If using double-wall (Type B) vent pipe in the vent pipe run (at least 75% of the equivalent vent length must be vertical), follow the pipe manufacturer's instructions for joining pipe sections. For attaching double-wall pipe to the heater, see

FIGURE 17A. To attach the vent cap, see FIGURE 17B.

Figure 17A - STEP 2

DoubleWall Pipe

Venter Collar

To secure the connection, spaced equal distance around the pipe, drill and insert three 3/4” long sheetmetal screws through the pipe and into the collar. Do not over tighten the screws. Fill inside the pipe, around the collar, with silicone sealant being sure there are no gaps.

FIGURE 17B - Attaching Double-Wall (Type B) Pipe to a Vent Cap

Figure 17B - STEP 1

Place a continual 3/8” bead of silicone sealant around the circumference of the vent cap collar. This will prevent any water inside the vent cap from running down the double-wall pipe.

Figure 17B - STEP 2

Insert the collar on the vent cap inside the inner wall of the double-wall pipe. Insert as far as possible. Add additional silicone sealant to fully close any gaps between the vent cap and the double-wall pipe. This is necessary to prevent water from entering the double-wall pipe.

Do STEP 2

immediately

following

STEP 1.

Figure 17B - STEP 3

Secure the vent cap to the double-wall pipe by drilling and inserting a 3/4” long sheetmetal screw into the vent cap collar. Do not over tighten screw.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 27

quip

24. V enting (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

Figure 17C -

On the single-wall pipe or Category III pipe, place a continual 1/4 inch bead of silicone sealant around the circumference.

STEP 1

Do STEP 2 immediately after STEP 1.

SingleW all or Category III Vent Pipe

Figure 17C - STEP 3

Spaced equally around the double-wall

pipe, drill three small holes below the

sealant ring. Insert 3/4 inch long

sheetmetal screws to secure the joint. Do

not over tighten screws.

Figure 17C -

Insert the pipe with the sealant into the inner pipe of the double-wall pipe until the bead of sealant contacts the inner pipe creating a sealed joint.

Double-

Wall Pipe

STEP 2

Vent Pipe with Sealant

5) V ent System Support

6) Condensation

7) V ent T erminal

(Pipe and V ent Cap)

Support horizontal vent runs every six feet (1.8M). Support vertical runs of Type “B” double-wall or Category III vent pipe in accordance with the requirements of the pipe manufacturer. Support single-wall pipe in accordance with accepted industry practices. Do not rely on the heater for support of either horizontal or vertical vent pipe. Use non-combustible supports on vent pipe.

Any length of single-wall vent pipe exposed to cold air or run through an unheated area or an area with an ambient temperature of 45°F or less must be insulated along its entire length with a minimum of 1/2" foil-faced fiberglass, 1-1/2# density insulation. Where extreme conditions are anticipated, install a means of condensate disposal.

The vent terminal pipe must be either Category III vent pipe or double-wall (Type B). Heaters must be equipped with a Reznor vent cap, a Type L Breidert Air-xhauster® vent cap or equivalent. A different style vent cap could cause nuisance problems or unsafe conditions. The vent cap must be the same diameter as the vent pipe.

See the clearance table below and FIGURE 18 for requirements of a horizontal vent terminal. See FIGURE 19 for requirements of vertical vent termination.

Horizontal Vent Terminal Clearances

A vent cap is required. Maintain a minimum clearance of 12 inches (305mm) from the wall to the vent terminal cap for stability under wind conditions.

Products of combustion can cause discoloration of some building finishes and deterioration of masonry materials. Applying a clear silicone sealant that is normally used to protect concrete driveways can protect masonry materials. If discoloration is an esthetic problem, relocate the vent or install a vertical vent.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 28

Structure

Forced air inlet within 10 ft (3.1M) 3 ft (0.9M) above C ombusti on a ir inl e t of another a ppliance 6 ft (1 .8M) Door, window, or gravity air inlet (any bui lding ope ning)

El e c t ric meter , gas me t e r*, gas re gulator*, and relief e

G as regulator * U.S. - 3 ft (0.9M); Canada - 6 ft (1.8M) Adj oining building or par apet 6 ft (1.8M) Adjacent public walkways 7 ft (2.1M) above Grade (ground level) 1 ft (3 05mm ) above** *Do not t erminate the ven t direc tly above a ga s meter or servi c e regula tor. ** C on sider lo cal snow depth conditions. The vent must be at least 6” (15 2m m) higher tha n anticipat e d snow depth.

ment

M inimum Clearances for Vent Termination Location ( all directions unless sp ecified)

4 ft (1.2M) horizontally 4 ft (1.2M) below 1 ft (3 05mm ) above U.S. - 4 ft (1.2M) horizontally Canada - 6 ft (1.8M) horizontally)

FIGURE 18 - Horizontal Vent Terminal

)

NOTE: Read all measurements; drawing is not proportional.

*Follow the instructions in FIGURES 16B and 16C, pages 26 and 27, to join a double-wall vent terminal section to a single-wall vent run and to the vent cap.

Roof or Building Overhang

Wall

12

( 305 mm)

6 (152mm)

minimum

Double-Wall* or Category III

Terminal Vent Pipe

Vent Run (Comply with Requirements No. 1) & 2) on page 25.)

Pitch flue pipe down toward outlet 1/4 per foot for condensate drainage. (NOTE: Slope applies to entire horizontal vent run.)

A clearance thimble is required when flue pipe extends through combustible materials. Follow the requirements of the thimble and/or the vent pipe manufacturer.

FIGURE 19 - Vertical Vent Terminal

NOTE: Read all measurements; drawing is not proportional.

3 ft (1M) minimum

6 ft (1.8M) minimum

Reznor (Option CC1) or Equivalent Vent Cap note positions of vent cap openings (shaded areas)

Parapet or Adjoining Building

6 ft (1.8M)

minimum

Double-Wall* or Category III

Terminal Vent Pipe*

Parapet or Adjoining Building

*Follow the instructions in FIGURES 16B and 16C, pages 26 and 27, to join a doublewall vent terminal section to a single-wall vent run and to the vent cap.

Roof Flashing

6 (152mm) minimum

Reznor (Option CC1) or equivalent vent cap

Vertical flue extension must be 6 (152mm) higher than anticipated snow depth but no less than 2 ft (610mm) above the roof.

Roof pitched from 0 to 45°

A clearance thimble is required when flue pipe extends through combustible materials. Follow the requirements of the thimble and/or the vent pipe manufacturer.

Vent Pipe (Comply with Requirements No. 1

and 2) on page 25.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 29

25. Check

Installation and Startup

Check the installation prior to startup:



 Check to be sure that all screws used to hold shipping brackets were re-installed



in the heater cabinet.



 Check suspension. Heater must be secure and level.

 

 Check clearances from combustibles. Requirements are in Paragraph 8.



 Check vent system to be sure that it is installed according to the instructions in



Paragraph 24.



 Check piping for leaks and proper gas line pressure. Bleed gas lines of trapped



air. See Paragraph 12.



 Check electrical wiring. Be sure all wire gauges are as recommended. Verify that



fusing or circuit breakers are adequate for the load use.



 Check polarity. Verify that line voltage exists between the black “L1” and earth



ground.



 If installed in California, verify that California Warning Label is displayed



Heater Startup and W arnings:

WARNINGS: For your safety, read before operating. If you do not follow these instructions exactly, a fire or explosion may

result causing property damage, personal injury, or loss of life.

• This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner(s). Do not try to light the burner(s) by hand.

• Before operating, smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHA T T O DO IF YOU SMELL GAS

• Open windows.

• Don’t touch electrical switches.

• Extinguish any open flame.

• Immediately call your gas supplier.

• Use only your hand to turn the gas control ON/OFF knob on the gas valve. Never use tools. If the valve ON/OFF knob will not turn by hand, do not try to repair it. Call a qualified service technician. Force or attempted repair may result in a fire or explosion.

• Should overheating occur, or the gas supply fail to shut off, turn off the manual gas valve to the appliance before shutting off the electrical supply.

• Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Operating Instructions and Operating Sequence

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 30

1. Set thermostat at lowest setting.

2. Turn off all electric power to the appliance.

3. This appliance is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand. Open the access door(s) and locate the gas control (ON/OFF) knob on the gas valve(s). (See FIGURE 20.)

4. Turn each gas control knob(s) clockwise to "OFF".

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the

floor. If you smell gas, STOP! and follow the steps in the WARNINGS printed above or on the Operating Label on the heater. If you do not smell gas, proceed to the next step.

6. Turn the gas control knob(s) counterclockwise to "ON".

7. Close the access door(s).

8. Turn on the electric power to the heater.

9. Set the thermostat to the desired setting.

FIGURE 20 - Gas Valve ON/OFF Control Knob

Top View

Gas Control

Knob

(shown in the

ON position)

Gas Flow

Side View

Gas Flow

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.

NOTE: If the appliance does not operate, follow the instructions "To Turn Off Gas to Appliance" printed below (and on the Operating Label on the heater) and call your service technician.

10. Thermostat calls for heat, energizing the venter motor(s).

11. The main combustion air pressure switch (Sizes 800 and 1200) and each heat

section pressure switch close, firing the heater.

12. Burner flame is sensed and in 30 seconds after the gas valve is energized, the

fan motor(s) is energized.

13. If the flame is extinguished during the main burner operation, the integrated

control system closes the main valve and must be reset by interrupting power to the control circuit. (See lighting instructions on the heater.).

TO TURN OFF GAS TO THE APPLIANCE

1) Set thermostat to lowest setting

2) If service is to be performed, turn off all electric power to the appliance.

3) Open the access door(s).

4) Turn the gas control knob(s) clockwise to "OFF". Do not force.

5) Close the access door(s).



Vent System Testing Procedure

1. Seal any unused openings in the venting system.

2. Inspect the venting system for proper size and horizontal pitch, as required in the National Fuel Gas Code, ANSI Z223.1 or CSA B149.1 and B149.2, Installation Code for Gas Burning Appliances and Equipment, and this manual. Determine that there is no blockage or restriction, leakage, corrosion or other deficiencies that could cause an unsafe condition.

3. In so far as practical, close all building doors and windows and all doors between the space where the heater is and other spaces of the building. Turn on exhaust fans so they shall operate at maximum speed. Do not operate a summer exhaust fan.

4. Light the heater following the lighting instructions. Adjust the thermostat for continued operation. Verify that combustion products are venting properly. After determining that the heater vents properly, return doors, windows, and exhaust fans to their previous conditions. If improper venting is observed, the venting system must be corrected.



 With the heater in operation, measure valve outlet gas pressure. If operated at



high altitude, adjust outlet gas pressure for altitude. See information and instructions in Paragraph 12.



 Using the thermostat, turn the heater off and on, pausing two minutes between



each cycle. Observe for smooth ignition.

DANGER: The gas burner in this gas-fir ed equipment is designed and equipped to provide safe controlled complete combustion. However , if the installation does not permit the burner to receive the proper supply of combustion air, complete combustion may not occur. The result is incomplete combustion which produces carbon monoxide, a poisonous gas that can cause death. Safe operation of indirect-fired gas burning equipment requires a properly operating vent system that vents all flue pr oducts to the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING WILL RESULT IN A HEALTH HAZARD WHICH COULD CAUSE SERIOUS PERSONAL INJURY OR DEATH.

Always comply with the combustion air requirements in the installation codes and in Paragraph 9. Combustion air at the burner should be regulated only by manufacturer-provided equipment. NEVER RESTRICT OR OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. Heaters installed in a confined space must be supplied with air for combustion as requir ed by Code and in Paragraph 9 of this heater installation manual. MAINTAIN THE VENT SYSTEM IN STRUCTURALLY SOUND AND PROPER OPERATING CONDITION.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 31

OPTIONAL ACCESSORIES

All Model LDAP heaters have discharge louvers but are available with additional louvers and/or nozzle discharge air options. Optional louver and discharge nozzles are shipped separately for field installation. Model LDAP 800 and 1200 heat sections have independent airflow and do not require the same discharge options. Each package includes illustrated installation instructions.

26. 4-Way Discharge Louvers, Option CD32

27. Nozzles

FIGURE 21A - One heat section with Option CD58, 60° Nozzle

Standard individually adjustable louvers are installed in the nozzle discharge.

Option CD32 consists of additional louvers that are installed perpendicular to the standard individually adjustable louvers. By installing the optional perpendicular louvers, the two sets of louvers can be adjusted to direct airflow in any of the four directions, enabling the installer to select and increase or decrease the coverage area.

Option CD57 is a 30° discharge nozzle. Option CD58 is a 60° discharge nozzle. Option CD59 is a 30° discharge nozzle with 4-way louvers. A nozzle may be installed

at each discharge air opening in any direction. NOTE: Do not install 4-way louvers with a 60° nozzle.

Nozzles should be attached after the unit is suspended. Follow the installation instructions in the nozzle package.

FIGURE 21B Nozzle Dimensions

Option CD58, 60° Nozzle

Option CD57, 30° Nozzle

24-3/8

(618mm)

14-1/8

(360mm)

Option CD59, 30° Nozzle with 4-Way Louvers

16-1/2

(419mm)

MAINTENANCE AND SERVICE

WARNING: If you turn off the power supply, turn off the gas. See Hazard Levels, page 2.

28. Maintenance Schedule

NOTE: If replacement parts are required, use only factory-authorized parts.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 32

The material contained in the MAINTENANCE AND SERVICE Section of this manual is designed to aid a qualified service person in maintaining and servicing this equipment. This heater will operate with a minimum of maintenance. To ensure long life and satisfactory performance, a heater that is operated under normal conditions should be inspected and cleaned at the start of each heating season. If the heater is operating in an area where an unusual amount of dust or soot or other impurities are present in the air, more frequent maintenance is recommended. When any service is completed, be careful to reassemble correctly to ensure that no unsafe conditions are created. When re-lighting, always follow the lighting instructions on the heater.

Maintenance Schedule - The following procedures should be carried out at least annually . Refer to illustrations and follow the instructions in Paragraphs 29-42.

• Clean all dirt, lint, and grease from all combustion air openings and the venter

assemblies.

• Clean all dirt, lint, and grease from all fan blades, fan guards, and motors.

• Check all heat exchangers both internally and externally .

• Check all burners for scale, dust, or lint accumulation. Clean if needed.

• Check gas valve(s) to ensure that gas flow is being shutoff completely.

• Check the vent system for soundness. Clean openings. Replace any parts that

do not appear sound.

• Check the wiring for any damaged wire. Replace damaged wiring. (See

Paragraph 14 for replacement wiring requirements.)

FIGURE 22 - Location of Controls

Venter Motor

24V Thermostat Terminal Board

Destrat Relay

Remote Destrat Relay

Vent Permissive Relay (Models 800 and 1200)

Limit Control

Terminal Boards

Fan

Motor

Heat Section Pressure Switch

Venter Motor Capacitor

Fan Motor Capacitor

High Limit Control and Adjustable Destrat Fan Control

Disconnect Switch

Transformer

Gas Valve

DSI Control (Circuit Board)

Fan Permissive Relay

Flame Sensor

29. Heat Exchanger Maintenance

30. Burner

Maintenance

Burner Removal Instructions (Refer to FIGURE 23.)

CAUTION: Use of eye

protection is

recommended.

Burner Assembly

Ignitor

Heat Permissive Relay (Models 800 and 1200)

Each section of this heater is equipped with a TCORE

Patent No. 6,889,686). Size 400 has one; Size 800 has two; and Size 1200 has three. Remove any external dirt or dust accumulation. V isually check each heat exchanger

for cracks and holes. If a crack or hole is observed, replace the heat exchanger. NOTE: Inspection of the lower portion of the heat exchanger is done with the burner

removed. See the Burner Service section below for information on inspecting the lower portion of the heat exchanger.

Each section of this heater is equipped with a TCORE

6,889,686). Size 400 has one; Size 800 has two; and Size 1200 has three. Inspect each burner/control compartment annually to determine if cleaning is neces-

sary . If there is an accumulation of dirt, dust, and/or lint, clean the compartment and follow the instructions below to remove and clean the burner.

1. Outside the cabinet, shut the gas supply off at the manual valve ahead of the

union.

2. Turn off electric supply.

3. Disconnect the gas supply at the union outside of the cabinet.

4. Remove the access panel.

5. Disconnect the Gas Train and Move It Out of the Way - At the gas valve,

mark and disconnect the wires. Disconnect the union on one or both sides of the gas line inside of the heater. Carefully remove the burner orifice and orifice adapter locking nut. Slide the orifice adapter out through the bracket on the burner.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 33

heat exchanger (U.S.

burner (U.S. Patent No.

30. Burner Maintenance (cont’d)

FIGURE 23 - Burner Removal

• Size 400 has 1 burner.

• Size 800 has 2 burners.

• Size 1200 has 3 burners.

Burner Removal Instructions (cont’d)

6. Remove Burner Assembly

a) Locate the three upper burner body supports. At each support, remove the

one screw that attaches it to the burner shield.

b) Holding the venturi tube, slide the entire burner assembly slightly upward to

disengage the burner from the supports on the bottom. Then rotate the open end of the venturi tube outward toward the access door opening. Carefully pull the burner assembly out of the cabinet.

Disconnect union(s). (On Size 400 or the most downstream heat section in a Size 800 or 1200, there will be one union to disconnect. The first heat section in Sizes 800 and 1200 and the second heat section in Size 1200 will have two unions to disconnect.)

Burner Shield

Burner Body Support -

Remove the three screws attaching the burner assembly to the burner shield.

Inspect and Clean the Burner

NOTE: If any of the burner components are damaged or deteriorated, replace the burner assembly.

Inspect the Lower Portion of the Heat Exchanger (with burner assembly removed)

Gas Valve - Mark and disconnect the wires.

Remove orifice adapter locking nut.

Remove the burner orifice and

Burner

Assembly

With the burner assembly removed, shine a flashlight on the burner ribbons. Look for carbon buildup, scale, dust, lint, and/or anything that might restrict flow through the spaces between the burner ribbons. Holding the burner assembly so that any foreign material will fall away from the burner, use a stif f bristle brush to loosen and remove any foreign material(s). If the burner is excessively dirty, remove one of the burner end caps. Remove the four screws that hold the end cap to the burner housing. Lightly tap the end cap to remove it.

Clean all foreign material from the burner and venturi. After the burner is thoroughly clean, replace the end cap making certain that it is tight against the burner housing.

At the burner flame entrance of each tube, shine a bright light into each heat exchanger section. With the light shining into the heat exchanger, observe the outside for visible light. Repeat this procedure with each heat exchanger section. If any light is observed, replace the heat exchanger.

To remove burner assembly, lift and rotate outward.

slide out through the bracket.

Venturi Tube (part of the burner

assembly)

Re-Install the Burner

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 34

Instructions to Re-Install the Burner (Refer to FIGURE 23.)

1. Attach the Burner Assembly - Holding the venturi tube, slide the entire burner

assembly into position. Align the supports on the bottom with the slots in the burner shield; sliding the supports into the slots. On the top, re-attach each burner body support to the burner shield.

1/8 inch

(3.2mm)

2. Attach the Gas Train - Slide the gas train so that the orifice adapter is through

the bracket. Fasten the gas train to the bracket with the locking nut. Install the gas orifice. Re-connect the wires to the gas valve. Re-connect the union(s) inside of the control compartment.

3. Reconnect the gas supply at the union outside of the cabinet. Turn on the gas

supply and leak test the connections with leak detecting solution.

4. Close the access panel.

5. Turn on the electric. Check for proper operation.

31. Burner Orifice(s)

32. Ignition

System

A burner orifice usually only needs to be replaced when installing a gas conversion kit. If ordering replacement orifice(s) only, give BTUH content and specific gravity of gas, as well as the model and serial number of the heater. When removing or replacing a burner orifice, use two wrenches being careful not to damage the venturi tube and/or the bracket.

DSI Integrated Control Module (circuit board) - See FIGURE 24. The module monitors the operation of the heater including ignition. The only replaceable component is the 3 amp Type ATC or ATO fuse. If the fuse is blown, the problem is most likely an external overload. Correct the problem and replace the fuse.

FIGURE 24 - DSI

Integrated Control

Module (Circuit

Board)

Only replaceable part is a Type ATC or ATO 3 amp fuse (Color Code Violet), P/N 201685

Do not attempt to disassemble the control module. However, each heating season check the lead wires for insulation deterioration and good connections. Size 400 has one control module; Size 800 has two control modules; and Size 1200 has three control modules. Proper operation of the direct spark ignition system requires a minimum flame signal of 1.0 microamps as measured by a microampmeter. For further information and check out procedure on the direct spark ignition system, refer to Paragraph 19 and the Troubleshooting Flow Chart in Paragraph 43.

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

Ignitor - Refer to FIGURE 22 and locate the ignitor. Disconnect the wire; remove the screw and the ignitor. Clean the ignitor assembly with an emery cloth.

Spark gap must be maintained to 1/8". See FIGURE 25.

FIGURE 25 - Ignitor showing required Spark Gap measurement

IMPORTANT: When re-assembling, the brown ground wire must remain attached

to the ignitor.

CAUTION: Due to high voltage on the spark wire and electrode, do not touch when energized. See Hazard Levels, page 2.

Flame Sensor - Refer to FIGURE 22 and locate the flame sensor. Disconnect the

wire; remove the screw and the flame sensor. Clean with an emery cloth.

Remove dirt and grease from the motor casing, the venter housing, and the venter wheel. Venter motor bearings are permanently lubricated. Follow these instructions for replacement of the venter motor and wheel assembly. Keep all hardware removed to be used in re-assembling and installing the replacement parts.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 35

33. Heat Section Venter Motor and Wheel (cont’d)

FIGURE 26 - Venter Wheel Position on Shaft - applies to all heat section venter assemblies

Replacement Instructions

1. Turn off the gas and disconnect the electric power.

2. Open the burner/control compartment access panel.

3. Disconnect the three venter motor wires at the DSI control, capacitor wires at the capacitor, and ground screw (located on the control panel).

4. Holding the venter motor, remove the six screws that attach the venter motor mounting plate to the venter housing. Remove the motor and wheel assembly from the heater.

5. Re-assemble with the replacement venter motor and

wheel assembly. See FIGURE 26.

6. Follow the wiring diagram to connect the venter wires.

7. Replace the access panel. Restore power to the heater and turn on the gas. Light, following the instructions on the lighting instruction plate. Check for proper opera-

7/16 (11mm) inside

tion.

34. Main Venter Motor and Wheel (Models 800 and 1200 only)

The main venter motor and wheel is located on the top of the first heat section of a Model LDAP 800 and 1200. The vent system attaches to the collar on the top of the

Venter Motor

main venter housing. Remove dirt and grease from the motor casing, the venter housing, and the venter

wheel. Venter motor bearings are permanently lubricated. Follow the instructions in Paragraph 33 for replacement of the venter motor and wheel

assembly. Keep all hardware removed to be used in re-assembling and installing the replacement parts. See FIGURE 27 for venter wheel and motor spacing.

Main Combustion Air Pressure

Venter Housing

Switch

FIGURE 27- Venter Motor and Wheel Spacing on Main Venter (Size 800 and

1200)

35. Fan Motor(s), Fan Blades, and Guard(s)

FIGURE 28- Fan Blade Position on the Shaft

Fan Blade

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 36

3

(76mm)

Fan

Motor

Remove dirt and grease from each motor, fan guard, and blades. Use care when cleaning the fan blades to prevent causing misalignment or imbalance. Check that the hub of the fan blades is secure to the shaft. Follow these instructions for replacement of the fan guard, fan motor and/or fan blades. Repeat the procedure for each heater section.

1. If the heater is installed, turn off the gas and disconnect the electric power.

2. Open the access door and disconnect the fan motor wires, capacitor wires at the

capacitor, and ground screw.

3. Remove the assembled parts (the fan guard, the motor and the fan blade).

4. Disassemble and replace whatever parts are needed and reassemble using

whatever part(s) are being replaced and the original parts.

Be sure the fan blade is in the proper position on the shaft; refer to the illustration in FIGURE 28. Position the assembly on the heater. Attach the fan guard. Rotate the fan blade to check for adequate clearance. If adjustment is required, loosen the mounting screws, re-position the fan guard, and tighten the screws.

Wheel

1-1/4 (32mm)

Main Venter

Motor

Screw Flat Washer

Hex Nut

Exhauster Motor Base Assy

Motor Wire and Cable Assy

Rotate the fan blade and re-check for adequate clearance. Repeat this procedure until the assembly is positioned properly .

5. Reconnect the fan motor wires according to the wiring diagram and close the

access panel.

6. When finished with all sections, restore power to the heater and turn on the gas.

Light, following the instructions on the lighting instruction plate. Check for proper operation.

36. Operating Gas V alve(s)

W ARNING: 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.

Carefully remove external dirt accumulation and check the wiring connections. Size 400 has one valve; Size 800 has two valves; Size 1200 has three valves.

The combination gas valve must be checked annually to ensure that the valve is shutting off gas flow completely .

Instructions:

1) Locate the 1/8” NPT pressure tap on the combination valve.

FIGURE 29 - Pressure Tap for Checking Gas Flow Shutoff

Single-Stage Valve

1/8” Outlet

Pressure Tap

2) With the manual valve turned off to prevent flow to the gas valve, connect a manometer to the 1/8” outlet pressure tap in the valve. NOTE: A manometer (fluidfilled gauge) is recommended.

3) Turn the manual valve to the ON position and the heater OFF. Use your finger to fully block the main burner orifice for several seconds. Observe the manometer with the orifice blocked, and if any pressure is indicated, the gas valve is leaking. A

leaking gas valve must be replaced before the heater is placed back in operation.

Two -Stage Valve (optional

on Model LDAP 400 only)

1/8” Outlet

Pressure Tap

37. Combustion Air Pressure Switch(es)

Main Combustion Air Pressure Switch Models 800 and 1200

Heat Section

Pressure

Switch

See FIGURE 22, page 34, for location of the heat section pressure switch. If it is determined that a pressure switch needs replacing, use only the factory-authorized replacement part that is designed for the model and size of heater being serviced.

Size 400 has one pressure switch; Size 800 has two heat section pressure switches and a main combustion air pressure switch; and Size 1200 has three heat section pressure switches and a main combustion air pressure switch. The main combustion air pressure switch is located on the top of the first heat section (see the illustration in Paragraph 34, page 36).

NOTE: A heater operating above 6000 ft elevation requires high altitude heat section pressure switch(es). See Paragraph

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 37

38. Limit Control

If it is determined that the automatic reset limit control needs replacing, use only a factory-authorized replacement part that is designed for the size of heater.

For approximate limit location, see FIGURE 22, page 34.

39. High Limit

Control

40. T ransformer

41. Adjustable

Fan Control

42. Vent System

A manual reset high limit control is located at the top of each heat section. Do not reset high limit control without correcting the problem. If it is determined that the limit control needs replacing, use only a factory-authorized replacement part that is designed for the size of heater.

See FIGURE 22, page 34, for location. Use a voltmeter to verify that there are 24 volts output from the transformer. If the transformer is not functioning, it must be replaced. Use a replacement transformer identical to the factory-installed model.

See FIGURE 22, page 34, for location. Check the wiring connec- tions and the adjustment knob.

If it is determined that the destratification fan control needs replacing, use only a factory-authorized replacement part that is designed for the heater.

Check the complete vent system at least once a year. Inspection should include all joints, seams, and the vent terminal cap. Clean openings. Replace any defective parts.

43. T roubleshooting

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. Do not remove connectors or terminals from the electrical components. Doing so can result in misinterpreted readings due to the ignition control board’s fault mode monitoring circuits.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 38

The integrated circuit board monitors the operation of the heater and includes two LED signal lights that indicate normal operation and various abnormal conditions. If the heater fails to operate properly , check this signal to determine the cause and/or to eliminate certain causes. See operating sequence in Paragraph 19.

Do not attempt to repair the DSI integrated control module; the only field replaceable component is the fuse.

Steady On Nor mal Operation - No call for heat. Stea dy On Flame is sensed. Fast Fl ash Norm al Operati on - Call for heat. Sl ow F lash Weak flame ( c ur r ent bel ow

1 Flash System L oc kout (failed to detec t or

2 Flash Main combustion air pr e ssure

3 Flash Limit or hi gh limit sw itch open. 4 Flash Main combustion air pr e ssure

Ste a dy Off Blown fuse; N o power; or Def ective

Control Status - GREEN L ED Cod es Flame Status - YELLOW LED Codes

1.0 microamps ±50%)

Fast Flash

sustain f lame)

switch or he a t sec tion pressure switch does not cl ose with 30 seconds of vent e r being e ne rgized.

switch or he a t sec tion pressure switch i s closed before venter is energized.

board

U ndesired f lame (valve open and no cal l for heat).

DSI Integrated

prop

)

) Sp

)

prop

)

Control Module (Circuit Board) Trial Troubleshooting Flowchart

Trial for

Ignition

Call for Heat

Is there a

spark across gap at

ignitor?

YES

YES NO

Does gas

ignite?

Check wiring and/or

24VAC transformer

output.

Is there

spark voltage at

control?

Is there

24V P1-2 to power

control?

YES

YESNO

Check high voltage wire

continuity.

Replace control

module.

Is there

minimum flame current

at the control

module?

Check connections to

flame sensor or

moisture in bulkhead

connector.

YES

Replace control

Check gas pressure and

supply voltage. If either

are low, correct and

module.

YES

repeat startup.

Clean flame sensor.

flame current at the flame

YES

Is there minimum

sensor?

Is the flame sensor

corroded?

YES

Is the sensor

located in flame

correctly?

YES

Replace flame

sesnsor.

Repositon flame

sensor.

General T roubleshooting

PROBLEM PROBABLE CAUS E REMEDY Ven ter mo tor will

not start

Burner will 1.

ht 2.

not li

ower to unit.

No 24 volt

Inte

Defective venter motor.

Manual valve not o Ai r in t he Gas pressure too hi gh or too low.

No S

Loose wir e connections. a) Be certain all wire connections are solid.

ow er to int egrate d circuit board.

rated circuit board fuse blown.

ow e r to venter motor.

rated circui t board defective.

en.

as line.

ark:

Transformer failure.

Incorrect spark gap.c

ark cable shorted to ground. d) Replace worn or grounded spark cable.

ark electrode shorted to ground. e) Replace if ceramic spark electrode is cracked or grounded.

Burner not grounded. f) Mak e c e rtain integrated circuit board is grounded to ignitor.

C ircuit board not grounded.

h.) Unit not proper ly grounded. h.) Make c ertain unit is properly fie ld grounded to earth ground and

Integrate d circui t board fuse blown. i) Corr ect cause. Replace fuse (type ATC or ATO, 32V DC , 3 A).

i j.) F a ulty intergr a te d circuit board. j) If 24 volt is available to the integrat ed c ircuit board and all other causes

L oc kout device interru

Combustion air

not c losin

Fault

Main valve not o

combustion a ir proving switch.

ting control circui t by above causes.5. Reset l oc kout by interrupting control at the thermostat or main power.

roving switch

erating.

a) Def ective valve. a) If 24 vol t i s measured at the valve connections and val ve remains

Loose wir e connections

Integrated circuit board does not power main valve.

Loose wir e connections. a) Check and tighten all wiring connections.

a b) F lame sensor gr ounded.

c) Incorrect gas pressure. c) Supply pressure should be 5" - 14" w.c. for natural gas or 11" - 14"

Cr acked ceramic at sensor. d) Repla ce sensor.

Turn on power; check supply fuses or main circuit break e r.

Turn up thermostat; check control transfor mer output.

Corr ect cause. Replace fus e (type ATC or ATO, 32VD C , 3 A).

Tighten connecti ons at ci rcuit board and/or motor ter minals.

Replace intergra t ed ci rcuit bo a rd.

Open manual valve.

Bleed gas line (initial startup only).

Suppl y pressure should be 5" - 14" w. c . for nat ural gas or 11" - 1 4"

w.c. for

Be s ure 24 volts is available.

Maintain spark gap at 1/8".

Make certain integrate d circui t board is grounded to furnace chassis.

erly phased (L1 to hot lead L2 to neutral).

have been eliminated, re

Make sure unit is properly vente d.

R e move obstructions from vent.

Replace faulty tubing to pressure switch.

Repla ce combustion air proving switch.

closed, re

Check and tighten all wiring connections.

) Be certain flame sensor lead is not grounded or insulati on or c e ramic is

not cracked. Repl ace as required.

w.c. for propane gas.

YES NO

Is gas flowing?

Is the ignitor

position correct in the

gas flow?

Replace gas valve.

Reposition spark

ignitor.

Check wiring and

connections to gas

valve.

lace venter m otor. S ee Paragraph 32.

ane gas.

lace board.

lace valve.

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 39

YES

24VAC at the gas

Is there 24VAC from

gas valve output on control

module to chassis?

Replace ignition

control module.

Is there

valve?

General Troubleshooting (cont’d)

)

prop

PROBLEM (cont'd) PROBABLE CAUSE (cont'd) REMEDY (cont'd) Burner cy cle on a nd off

No heat (Heater Operating)

Fa n or venter motor w ill not run

F an or venter motor t u rn s on and off while b urner is operating

F an or venter motor cu t s out on overload

1 . G as pressure too high or too low. 1. Supply pressure should be 5" - 14" w. c . for na t ural ga s or 1 1" - 1 4"

w. c . for propane gas. 2 . Burner not 3 . Circuit bo ard not 4 . Faulty integr a t ed circ uit board 4. If 24 volt is ava ila ble to the integrate d c ircuit board and all other

5 . C ombustion air pr oving swi tc h(es) not closing.

6. Fault 7 . Fl a me sensor grounded. 7 . Be certa in flam e sensor l e ad i s not grounded or insulation or cera mic

8. Cracked ceramic at sensor. 8. Re

9. Incorrect

1. Incorrect valve outlet

2. C

cling on limit control. 2. Check air throughput.

3. Im

1. Circuit o

2. Defective inte

3. Defective motor. 3. Re 1 . Motor overload device cycling on a nd off. 1. Check motor load against motor rating plate. Repl a c e motor if need e d.

1 . Low or hi

2. Defective motor. 2. R e

3. Poor airflow. 3. Clean motor, fan, fan

4. Defective bearin

rounded 2 . Make cert ain int egra t ed c ircuit board i s groun ded t o ignitor.

rounded. 3 . Make cert ain int egra t ed c ircuit board i s grounded to furnace chassis.

causes have been el im inated, replace board.

Make sure unit is properly vented. Remove obstructions from vent. Replace faulty tubing to pressure switch.

combustion air proving switch. 6. Repl ace combustion a ir proving switch.

i s not cracked. R e place as re quired.

lace s ensor.

olarity. 9. R everse l ine volt l ea ds to i ntegra t ed c ircuit board.

re ssure or orif ice. 1. Check valve outlet pressure. See Rating plate for manifold pressure.

er thermostat location or adjustment. 3. See thermostat manufacturer' s i nstructions.

en. 1. C heck wi ri ng and conne ctions.

rated circuit board. 2 . Repl ace board.

lace motor.

h voltage supply. 1. Correct electric supply.

lace motor.

or lubrication. 4. L ub r icate bea rings (motor permitting) or replace motor.

uar d, fil te r, and coils.

FOR SERVICE OR REPAIR, FOLLOW THESE STEPS IN ORDER:

FIRST: Contact the Installer

Name __________________________________________________________ Address_________________________________________________________

__________________________________________________________ __________________________________________________________

Phone _____________________________________

SECOND: Contact the nearest distributor (See Yellow Pages). If no listing,

contact Authorized Factory Representative, 1-800-695-1901 (Press 1).

THIRD: Contact REZNOR

150 McKinley Avenue Mercer, PA 16137 Phone: (724) 662-4400

Model No. _________________________________ Heater Serial No._____________________________ Date of Installation ___________________________

/ Thomas & Betts Corporation

Form RZ-NA-I-LDAP, P/N 207733 (Rev 2), Page 40

(800) 695-1901; www.RezSpec.com

©2005 Thomas & Betts Corporation, All rights reserved. MANUFACTURER OF HEATING, COOLING, AND VENTILATING SYSTEMS Trademark Note: Reznor® and TCORE2® are trademarks of Thomas & Betts. 9/05 Form RZ-NA I-LDAP (Version .2)

Thomas & Betts LDAP 1200 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual