Form I-LDAP (Version A) (Obsoletes Form I-LDAP) Installation/Operation/Maintenance Applies to: Model LDAP, Indirect Fired, Indoor, Downflow, Packaged Heaters Reznor® Model LDAP 1200 ! WARNING: FIRE OR EXPLOSION HAZARD Failure to follow safety warnings exactly could result in serious injury, death, or property damage.
Table of Contents 1.0 General.............................................................. 2-3 1.1 Hazard Labels and Notices...................................... 2 1.2 General Installation Information.............................. 3 1.3 Warranty..................................................................... 3 1.4 Installation Codes..................................................... 3 2.0 Heater Location................................................. 3-6 2.1 General Recommendations..............
1.2 General Installation Information 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.
2.0 Heater Location (cont’d) NOTE: Venting requirements may affect location. Consult requirements in Paragraph 6.3 before making final determination. 2.2 Combustion Air CAUTION: Do not locate the heater where it may be exposed to water spray, rain, or dripping water. 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.
NOTE: For further details on supplying combustion air to a confined space, see the National Fuel Gas Code ANSI Z223.1a (latest edition). 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.
2.0 Heater Location (cont’d) 2.5 Sound Data Sound Chart - Model LDAP Distance Model LDAP 20 ft (6.1M) 25 ft (7.6M) 30 ft (9.1M) 35 ft (10.7M) 40 ft (12.2M) Size db Pa µbar db Pa µbar db Pa µbar db Pa µbar db Pa µbar 400 69 0.058 0.580 65 0.037 0.371 62 0.026 0.258 60 0.019 0.189 57 0.015 0.145 800 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 1200 74 0.100 1.000 70 0.064 0.640 67 0.044 0.444 64 0.033 0.327 62 0.025 0.250 µbar = microbar Pa = Pascal 3.
Instructions for Changing Heat section Pressure Switch(es) 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. 4.0 Clearances and Dimensions 4.1 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.
4.0 Clearances and Dimensions (cont’d) 4.3 Dimensions - Models LDAP 800 and LDAP 1200 FIGURE 3B Model LDAP 1200 with three heat sections. Model LDAP 800 has the same layout minus the middle heat section.
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 from 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.
5.0 Hanging or Mounting the Heater (cont’d) 5.3 Wall Mounting (cont’d) FIGURE 5 - Wall Mounting (All structural supports and angles are field supplied.
WARNING: 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. Test Pressures Below 1/2 PSI: Before testing, close the manual valve on the heater. NOTE: Gas Conversion Kits are available for changing from propane to natural gas or natural gas to propane. A factoryauthorized conversion kit MUST be used.
6.0 Mechanical (cont’d) FIGURE 6 - 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. 6.1.2 Valve Outlet or Orifice Pressure Setting WARNING: Valve outlet gas pressure must never exceed 3.5” w.c. for natural gas and 10” w.c. for propane gas. 6.1 Gas Piping and Pressures (cont’d) 6.1.
CAUTION: DO NOT bottom out the gas valve regulator adjusting screw. This can result in unregulated manifold pressure causing excess overfire and heat exchanger failure. NOTE: If operating at high altitude, outlet pressure requires adjustment. Follow instructions below. Derate by Valve Outlet Pressure Adjustment for High Altitude Operation NOTES: If installation is above 6000 ft (1830M), a high altitude pressure switch is required on each heat section (all sizes). See Paragraph 3.3.
6.0 Mechanical (cont’d) Instructions for High Altitude Derate (cont’d) 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. Re-connect the wire to the gas valve. 4. Turn up the thermostat.
do not require the same discharge options. Each option package includes illustrated installation instructions. 6.2.1 Installing Louvers NOTE: Do not install louvers if installing a nozzle. Follow the instructions shipped with the nozzle. FIGURE 8 - 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.
6.0 Mechanical (cont’d) 6.2 Unit Discharge (cont’d) 6.2.3 Discharge Nozzle Options (cont’d) FIGURE 9B Nozzle Dimensions 6.3 Venting 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.
2) Vent Pipe Diameter and Length Model LDAP Size Venter Outlet Diameter inches mm Vent 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 Vent 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.
6.0 Mechanical (cont’d) 6.3 Venting (cont’d) 4) Joints and Sealing (cont’d) FIGURE 10B - Attaching Double-Wall (Type B) Pipe to a Vent Cap Figure 10B - 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 10B - STEP 2 Insert the collar on the vent cap inside the inner wall of the double-wall pipe. Insert as far as possible.
7) Vent Terminal (Pipe and Vent Cap) The vent terminal pipe must be either Category III vent pipe or double-wall (Type B). Terminate the vent pipe with a Reznor Option CC1 vent cap. 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 FIGURE 11 for requirements of a vertical vent terminal. See FIGURE 12 and the clearance table for requirements of a horizontal vent terminal.
7.0 Electrical and 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. 7.1 Supply Wiring Check the rating plate on the heater for the supply voltage and current requirements.
W1 W R R G G G W1 C 7 Option CL22 TWO STAGE THERMOSTAT Option CL22 G TWO STAGE THERMOSTAT Option CL1 G SINGLE STAGE THERMOSTAT FIGURE 14 Thermostat Connections for Model LDAP 400 with Option CL1 or CL22 W1 W2 R RH RC W2 W2 SINGLE STAGE HEATING WITH RECIRCULATION SINGLE STAGE HEATING C 7 W1 W1 R RH RC W2 W2 C C C Y1 Y1 Y1 Y2 Y2 Y2 TWO STAGE HEATING FIELD WIRING LDAP 400 - CL1, 22 WD# 189504 REV.
7.0 Electrical and Wiring (cont’d) 7.2 24V Control Wiring (cont’d) SINGLE STAGE HEATING SINGLE STAGE HEATING WITH RECIRCULATION G PR W1 W R R R W2 G W1 C PR 7 R RH LDAP 1200 - CL1, 22 WD# 189506 REV. #3 R FACTORY WIRING PR TERMINAL STRIP UNIT #1 R R 1. FOR 400,000 BTUH LOW FIRE DO NOT INSTALL THIS JUMPER.
Gas Valve(s) 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 35.) • Size 400 has 1 valve • Size 800 has 2 valves • Size 1200 has 3 valves. 7.3 Fan Motor(s) 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.
7.
FIGURE 18 – Typical Wiring Diagram for Model LDAP 800 (Reference W.D.
7.0 Electrical and Wiring (cont’d) FIGURE 19 – Typical Wiring Diagram for Model LDAP 1200 (Reference W. D.
8.0 Controls and Operation NOTE: For high altitude, follow instructions in Paragraph 8.3 to change heat section pressure switch(es). The main combustion air pressure switch (Sizes 800 and 1200 only) does not need to be changed for a high altitude installation. Pressure Switch Settings 8.1 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.
8.0 Controls and Operation (cont’d) 8.3 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.
Normal Heat Cycle Operating Sequence NOTE: All LED Flash Codes are on page 41. 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”.
8.0 Controls and Operation (cont’d) Abnormal Heat Cycle Functions (cont’d) 8.5 Ignition System (cont’d) 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 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.
over, the fan motor is de-energized, and a heat cycle is begun if the call for heat still exists. Continuous Fan Operation 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.
9.0 Check Installation and Startup 9.1 Check the installation prior to startup: Check to be sure that all screws used to hold shipping brackets were reinstalled in the heater cabinet. Check suspension. Heater must be secure and level. Check clearances from combustibles. Requirements are in Paragraph 4.1. Check vent system to be sure that it is installed according to the instructions in Paragraph 6.3. Check piping for leaks and proper gas line pressure. Bleed gas lines of trapped air.
FIGURE 21 - Gas Valve ON/OFF Control Knob 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.
9.0 Check Installation and Startup (cont’d) DANGER: The gas burner in this gas-fired 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.
FIGURE 22 - Location of Controls
10.0 Maintenance and Service (cont’d) 10.1.3 Burner Maintenance (cont’d) 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. 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.
Re-Install the Burner Instructions to Re-Install the Burner (Refer to FIGURE 23.) Burner Orifice(s) 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. 10.1.
10.0 Maintenance and Service (cont’d) Flame Sensor 10.1.5 Heat Section Venter Motor and Wheel FIGURE 26 - Venter Wheel Position on Shaft - applies to all heat section venter assemblies 10.1 Maintenance Procedures (cont’d) 10.1.4 Ignition System (cont’d) 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.
10.1.7 Fan Motor(s), Fan Blades, and Guard(s) FIGURE 28 - Fan Blade Position on the Shaft 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.
10.0 Maintenance and Service (cont’d) 10.1 Maintenance Procedures (cont’d) 10.1.8 Operating Gas Valve(s) (cont’d) 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 (fluid-filled 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.
10.2 Troubleshooting Check the Lights on the DSI Integrated Control Module (Circuit Board) IMPORTANT: When using a multimeter to troubleshoot the 24 volt circuit, place the meter’s test leads into the 5 or 9 pin connectors located on the ignition control. 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.
10.2.1 General Troubleshooting PROBLEM Venter motor will not start Burner will not light PROBABLE CAUSE 1. No power to unit. 2. No 24 volt power to integrated circuit board. 3. Integrated circuit board fuse blown. 4. No power to venter motor. 5. Integrated circuit board defective. 6. Defective venter motor. 1. Manual valve not open. 2. Air in the gas line. 3. Gas pressure too high or too low. 4. No Spark: a) Loose wire connections. b) Transformer failure. c) Incorrect spark gap.
APPENDIX Technical Data Model LDAP Size Model LDAP 400 Input Heating Capacity One Downflow Heater Thermal Efficiency (%) Output Heating Capacity Model LDAP 800 One Heater with Two Downflow Heat Sections Model LDAP 1200 One Heater with Three Downflow Heat Sections Index E Abnormal Heat Cycle Functions 30 F A B Burner Removal 35 Burner Service 35 C Check installation after Startup 33 Check Installation and StartUp 32 Clearances 7 Combustion Air 4 Combustion Air Pressure Switch 40 Combustion Air
INSTALLATION RECORD - to be completed by the installer: Installer: Name ________________________________________________________ Company ________________________________________________________ Address ________________________________________________________ ________________________________________________________ ________________________________________________________ Phone _________________________________ Distributor (company from which the unit was purchased): Company _______________
