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Rapid Engineering 2000 Series Installation, Operation & Service Manual

Direct-fired air handler
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FOR YOUR SAFETY
If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in
your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas
supplier after leaving the building.
Follow the gas supplier's
instructions.
8. If you cannot reach your gas
supplier, call the Fire Department.
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clear-
ances to combustibles away from
equipment.
Some objects will catch fire or explode
when placed close to equipment.
Failure to follow these instructions can
result in death, injury or property
damage.
WARNING
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
NOT FOR RESIDENTIAL USE
© 2019 Rapid Engineering LLC
®
Rapid
2000-Series
Direct-Fired Air Handler
Installation, Operation &
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Rapid Engineering LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: +1.616.784.0500
Fax: +1.616.784.0435
www.rapidengineering.com
Service Manual
2010B
Installer
Owner
P/N RP121100NA Rev M 11/19
2005
2010
2020
2030

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Summary of Contents for Rapid Engineering 2000 Series

  • Page 1 NOT FOR RESIDENTIAL USE Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park, MI 49321 Telephone: +1.616.784.0500 Fax: +1.616.784.0435 www.rapidengineering.com P/N RP121100NA Rev M 11/19 © 2019 Rapid Engineering LLC...
  • Page 3 Conçus pour les applications non-résidentielles Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park, MI 49321 Téléphone: +1.616.784.0500 Fax: +1.616.784.0435 www.rapidengineering.com P/N RP121100FC Rev M 11/19 © 2019 Rapid Engineering LLC...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: Air Handler Safety ..........1 16.2 Wiring and Electrical Connections ......44 1.1 Description of Operation ..........1 16.3 Remote Panel ............44 1.2 Inspection and Setup ........... 1 16.4 Motor Current Draw ..........44 1.3 Safety Labels and Their Placement......
  • Page 6 All rights reserved. No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means - graphic, electronic, or mechanical, including Printed in photocopying, recording, taping or information storage and retrieval systems - without the the U.S.A. written permission of Rapid Engineering LLC.

  • Page 7: Section 1: Air Handler Safety

    Cover the air handler to protect it from the Gas-fired equipment is not designed for use in environment. Rapid Engineering LLC will not be held atmospheres containing flammable vapors or dust or responsible for any damages that may occur from atmospheres containing chlorinated or halogenated outdoor storage.

  • Page 8: Safety Labels And Their Placement

    1.3 Safety Labels and Their Placement Product safety signs or labels should be replaced by product user if they are no longer legible. Please contact Rapid Engineering LLC or your RAPID ® independent distributor to obtain replacement signs or labels.

  • Page 9: Section 2: Installer Responsibility

    • To provide access to air handler for servicing. • To provide the owner with a copy of this Rapid Engineering LLC cannot be responsible for Installation, Operation and Service Manual. ensuring that all appropriate safety measures are undertaken prior to installation;...

  • Page 10: National Standards And Applicable Codes

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 2.3 National Standards and Applicable Codes All equipment must be installed in accordance with the latest revision of the applicable standards and national codes. This refers also to the electric, gas and venting installation. Note: Additional standards for installation in public garages, aircraft hangars, etc.

  • Page 11: Section 3: Critical Considerations

    SECTION 3: C RITICAL ONSIDERATIONS SECTION 3: CRITICAL CONSIDERATIONS 3.1 Required Clearances to Combustibles WARNING Clearances are the required distances that combustible objects must be away from the air handler to prevent fire hazards. Combustibles are materials that may catch on fire and include common items such as wood, paper, rubber, fabric, etc.

  • Page 12: Purge Of Supply Duct

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 3.2 Purge of Supply Duct Table 1: Recommended Torque Settings If this heating unit is to be installed indoors, and its outdoor air supply ducted from outdoors, ANSI Standards Z83.4/CSA 3.7, Z83.18 and Z83.25/CSA Bolt Head 3.19 require that all supply duct shall be purged a Grade Marking...

  • Page 13: Section 4: National Standards And Applicable Codes

    SECTION 4: N ATIONAL TANDARDS AND PPLICABLE ODES SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.4 Parking Structures and Repair Garages 4.1 Gas Codes Installation in garages must be in accordance with the following codes: The type of gas appearing on the nameplate must be the type of gas used.

  • Page 14: Section 5: Specifications

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 5: SPECIFICATIONS static pressure is the sum of all accessories and any attached ductwork. See Page 11, Table 5 and Table 6 Estimated weight table applies to both upright and for static pressure accessories. If more external static horizontal units of the same model.
  • Page 15 SECTION 5: S PECIFICATIONS Table 2: Horizontal and Vertical Dimensions DIMENSIONS MODEL 2005 25.3 134.8 168.7 20.8 (in) 25.3 81.7 11.8 10.2 16.0 15.1 32.2 18.0 33.2 40.7 43.5 1K-2K (64.2) (12.0) (342.4) (428.5) (52.8) (7.9) (18.5) (18.5) (cm) (64.3) (207.5) (29.9) (25.9)
  • Page 16 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 4: Performance Heat Output at dBA at Noted External Maximum Motor HP at Minimum Inlet Gas Pressure in wc (mbar) Static Pressure Temperature Airflow 1" ESP with manifold sizes (in wc)** Rise (Btu/h) x Model CFM (m...
  • Page 17 SECTION 5: S PECIFICATIONS Table 5: Estimated Pressure Drop of Accessory Components Inlet Hood with Inlet Hood with Airflow Range Inlet Hood with Filters Filter Section Moisture Limiters Bird Screen Model in wc (mbar) in wc (mbar) in wc (mbar) in wc (mbar) in wc...

  • Page 18: Section 6: Lifting An Air Handler

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 6: LIFTING AN AIR HANDLER • Verify that the lifting lugs are intact undamaged and secured to the air handler. WARNING • Ensure factory-installed hardware is torqued as specified. 4. Prepare the installation location to be ready to accept the air handler (i.e.
  • Page 19 SECTION 6: L IFTING AN ANDLER 6.1.3 Lifting an Upright Air Handler Step 2: Remove the lifting lugs on the inlet end of the air handler and re-install hardware. All air handlers are shipped in the horizontal position. Step 3: Use all four lifting lugs on the discharge end Prior to lifting an upright air handler, the following of the air handler to enable the air handler to be lifted steps must be performed (See Page 13, Figure 4):...

  • Page 20: Section 7: Roof

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: ROOF WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.
  • Page 21 SECTION 7: R FIGURE 5: Roof Curb Assembly ***Cross Brace Caulk required for outside perimeter ***Side panels are split of roof curb at bolted joints. Top Mounting Flange Side Panel End Panel (Inlet or Discharge) Dimensions Weight* Weight** Model (in) 25.9 78.2 22.9...

  • Page 22: Air Handler Mounting To Roof Curb

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.2 Air Handler Mounting to Roof Curb After the curb has been installed, the air handler may be placed on the curb. See Page 16, Figure 6. After the air handler is in place, the installer must fasten the air handler to the curb. This is accomplished by drilling holes down through the floor of the air handler and into the curb.

  • Page 23: Section 8: Legs For Horizontal Mounting

    SECTION 8: L ORIZONTAL OUNTING SECTION 8: LEGS FOR HORIZONTAL MOUNTING WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 24: Section 9: Upright Installation

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 9: UPRIGHT INSTALLATION WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.
  • Page 25 SECTION 9: U PRIGHT NSTALLATION Step 2: Attach the mounting feet to each leg using supplied hardware. See Page 19, Figure 8. FIGURE 8: Step 2...
  • Page 26 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 3: With the top frame upside down, insert and attach the first two legs. Note: All legs are identical and not all the holes will be used on each leg. See Page 20, Figure 9. Step 4: Next attach the horizontal support(s), and repeat process for the other two remaining legs.

  • Page 27: Upright Installation

    SECTION 9: U PRIGHT NSTALLATION Step 5: Attach remaining support braces taking note of the support location to proper orient for your air handler's configuration. See Page 21, Figure 10. FIGURE 10: Step 5 Control Side Return Filter Access 9.2 Upright Installation handler on to the legs.

  • Page 28: Section 10: Filter Section

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: FILTER SECTION WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 29: Filter Section Installation - Horizontal Air Handlers

    SECTION 10: F ILTER ECTION 10.2 Filter Section Installation - Horizontal Air 10.3.2 Filter Installation Handlers Install the proper filters as required for the air 10.2.1 Filter Section Installation handler’s configuration. See Page 23, Table 7. Table 7: Filter Quantities For installation directly onto the inlet of the air Permanent Aluminum Mesh Pleated / Polyester* handler, foam tape (provided by others) must be...

  • Page 30: Section 11: Inlet Hood

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 11: INLET HOOD WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 31: Inlet Hood Assembly

    SECTION 11: I NLET 11.1 Inlet Hood Assembly FIGURE 13: Inlet Hood Roof Left Panel Right Panel Rain Gutter X2 Bottom For an air handler supplied with a filter section a single hood is provided. For an air handler with inlet hood mounted filters, two hoods are provided.

  • Page 32: Inlet Hoods With Filter Rack Assembly

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 11.2 Inlet Hoods with Filter Rack Assembly Step 11.2.1 Seal around the perimeter of the inlet of the air handler with the provided foam gasket tape. Step 11.2.2 Mount the upper inlet hood right and left side (flanges will be facing out), with the bolts and wash- ers provided.
  • Page 33 SECTION 11: I NLET Step 11.2.4 Attach the bottom filter rail for the upper inlet hood to the hood using the provided rivets. Step 11.2.5 Mount the lower inlet hood right and left side (flanges will be facing out), with the bolts and wash- ers provided and the upper edge of these sides to the lower portion of the upper hood with the TEK screws provided.
  • Page 34 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 11.2.6 Attach the bottom filter rail for the lower inlet hood and attach to the left and right side of the hood and to the air handler using the provided TEK screws. Step 11.2.7 Attach the lower hood roof with the provided TEK screws along the left and right side.
  • Page 35 SECTION 11: I NLET Step 11.2.8 Attach the remaining filter rails and the rain gutters to the upper and lower hood sides with the provided rivets. Step 11.2.9 Attach filter retaining latches with the provided rivets. Step 11.2.10 Caulk seam between air handler and inlet hood. Step 11.2.11 Load filters into the inlet hood, checking to see that each filter is in the proper orientation by ver- ifying that the arrow on the side of the filter points in the direction of air flow.
  • Page 36 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 11.3 Inlet Hoods for Air Handler with Filter Section Step 11.3.1 Seal around the perimeter of the inlet of the filter section with the provided foam gasket tape. Step 11.3.2 Attach the left and right side of the inlet hood (flanges facing in) to the top of the inlet hood using the TEK screws provided.
  • Page 37 SECTION 11: I NLET Step 11.4.2 If the hood is attached directly to the unit, fasten to unit with TEK screws and install blocker piece at the bottom. Step 11.4.3 If the unit is equipped with a filter section selected, attach the hood to filter section using TEK screws...
  • Page 38 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Step 11.4.4 Install Mist Limiter media through open face of inlet hood along guide rails. Slide the top of the mist limiter all the way into the top rail. This will provide clearance to lower the bottom of the limiter into the bottom rail.

  • Page 39: Section 12: Dampers

    SECTION 12: D AMPERS SECTION 12: DAMPERS WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices. tices to avoid falling.

  • Page 40: Discharge Damper

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 12.1 Discharge Damper Discharge dampers are shipped loose. Discharge dampers are designed to be mounted downstream of the air handler in ductwork. A qualified contractor/installer must make appropriate allowances for duct connections. To install the discharge damper on an interior wall, drill holes every 8"...

  • Page 41: Section 13: Discharge Heads And Splash Plates

    SECTION 13: D ISCHARGE EADS AND PLASH LATES SECTION 13: DISCHARGE HEADS AND SPLASH PLATES WARNING Crush Hazard Falling Hazard Severe Injury Hazard Cut/Pinch Hazard Use proper lifting Use proper safety Use proper lifting Wear protective gear equipment and equipment and prac- practices and equip- during installation, practices.

  • Page 42: Splash Plate Installation

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 13.2 Splash Plate Installation The splash plate is designed to hang directly from a horizontal air handler with a bottom discharge. Before the splash plate can be installed on the air handler, first drill four holes in the air handler floor. These holes to be centered over the entire blower discharge opening.
  • Page 43 SECTION 13: D ISCHARGE EADS AND PLASH LATES FIGURE 18: Mounting Hole Locations Blower Discharge Centerline Model (in) 24.6 22.5 2005 (cm) 62.5 57.1 (in) 32.1 34.0 2010 (cm) 81.5 86.4 (in) 36.6 36.8 2010B (cm) 93.0 93.4 (in) 40.6 40.3 2020 (cm)

  • Page 44: Section 14: Duct Considerations

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 14: DUCT CONSIDERATIONS Dh: hydraulic diameter H: rectangular duct inside height WARNING W: rectangular duct inside width The air handler is not designed to support the weight of ductwork. Ductwork must be constructed in a fashion that is self-supporting.

  • Page 45: Section 15: Gas Piping

    SECTION 15: G IPING SECTION 15: GAS PIPING regulator and safety shut off valve. Minimum gas pressure as indicated on data plate must be WARNING measured with the burner operating in high fire. Table 8: Gas Manifold Size Model 2005 2010 2010B 2020...
  • Page 46 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 19: ANSI-Compliant Manifold (2005 - 2030) Alternate Inlet Safety Shut Off Valve High Gas Pressure Regulator (Optional) Safety Shut Off Valve Inlet Modulating Valve With Pressure Regulator Manual Gas Valve (Main) Union Manual Gas Valve (Burner) (By Others)
  • Page 47 SECTION 15: G IPING FIGURE 21: XL-Compliant Manifold (2005 - 2030) Vent to Atmosphere Block Valve Alternate With Actuator Inlet Safety Shut High Gas Pressure Regulator (Optional) Off Valve Vent to Atmosphere With Actuator Vent Inlet Valve Vent to Atmosphere Manual Gas Valve (Main) Modulating Valve With...

  • Page 48: Gas Piping

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 15.4 Gas Piping FIGURE 22: Plug Tapping (2005 - 2030) The gas manifold extends through the side of the Manual Gas Modulating Valve control cabinet for models 2005 - 2030. The factory Valve (Burner) piping terminates with a male pipe connection.

  • Page 49: Section 16: Electrical

    SECTION 16: E LECTRICAL SECTION 16: ELECTRICAL DANGER Electrical Shock Hazard Disconnect electric before service. More than one disconnect switch may be required to disconnect electric from equipment. Equipment must be properly grounded. Failure to follow these instructions can result in death or electrical shock.

  • Page 50: Disconnect Fuse Sizing

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 16.1 Disconnect Fuse Sizing The fuse classification must be determined by the service disconnect rating plate and all applicable codes. Fuse sizing is determined by the motor size, control current and supply voltage. Fuses that are being replaced must be replaced with the same type, size and class of fuse that was supplied with the air handler.

  • Page 51: Control Current Draw

    Rapid Engineering LLC. Refer to Page 45, Table 11 for a brief description of each safety device, its location and its switching voltage.
  • Page 52 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 16.6.4 Flame Control 16.6.5 Discharge Temperature Sensor This device will check for both pilot flame and main This device senses the discharge temperature of the flame within the burner. When a flame signal from the air at the blower.
  • Page 53 SECTION 16: E LECTRICAL FIGURE 24: Interconect Wiring 2...

  • Page 54: Interlocks

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 16.7 Interlocks setpoint, after the 5 minute establishing period, the air handler fan will be turned off. If there is a failure of 16.7.1 Carbon Dioxide Interlocks the exhaust fan to activate the field supplied airflow All air handlers that recirculate air from the heated switch, after the 5 minute establishing period, the air space require either a control to limit the temperature...
  • Page 55 SECTION 16: E LECTRICAL 16.8.9 Single Point Connection 16.8.10 Service Receptacle Powered by Others (Wired) When a variable frequency drive or auxiliary motor starter (both used for controlling an exhaust fan) or This option provides a service receptacle. It includes an enclosure heater or ground fault interrupt (GFI) ground-fault interrupter (GFI) receptacle mounted on receptacle are ordered, the installer/service...

  • Page 56: Section 17: Sequence Of Operation

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 17: SEQUENCE OF OPERATION 17.1.2 Fixed Recirculation (FR) Style The FR style air handler has a constant speed DANGER blower that is designed to deliver a constant volume of air to the heated space. In all cases, however, the air being delivered directly over the burner for combustion must always be 100% outside air.
  • Page 57 SECTION 17: S EQUENCE OF PERATION FIGURE 25: Air Handler Styles MUA - MAKE UP AIR (All Models) FR - FIXED RETURN (All Models) AM - AIR MANAGEMENT (All Models) VAV - VARIABLE AIR VOLUME (All Models) Floating Damper Floating Damper Table 12: Configuration Chart Air Handler Air Flow...

  • Page 58: Hvac Remote Panels And Panel Options

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 17.2 HVAC Remote Panels and Panel Options The remote panel should be mounted in the conditioned space in a convenient location for controlling the air handler. Do not locate a remote panel that contains temperature sensing equipment in an area directly affected by the air handler or another heat source as it may interfere with the operation of the air handler.
  • Page 59 SECTION 17: S EQUENCE OF PERATION Selectrastat dial. The 7-day programmable touchscreen thermostat provides nighttime setback for unoccupied space heating. AUTO/WINTER Mode: Occupied time: Blower and burner cycle operate continuously to maintain a constant space temperature as selected on the Selectrastat dial. The burner flame fully modulates and varies the discharge air temperature to maintain the space temperature.

  • Page 60: Infinitypro

    Each BMS input is capable of receiving a For optimum efficiency, Rapid Engineering LLC 4-20mA or 0 - 10VDC from the control system. On all suggests to limit the discharge temperature to 160 °F.
  • Page 61 SECTION 17: S EQUENCE OF PERATION located on the programmer module, are as follows. • Terminal #3 powers up the equipment's pilot gas They are listed in the order you will find them on the solenoid valve which opens allowing gas to flow. flame safeguard and is also the order in which they •...
  • Page 62 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL equal to or over 1M BTU, certain sequences must be and the flame safeguard will need to be manu- provided in the flame safeguard control. There is a ally reset. specified time for pre-purge, trial for ignition, and non The M4RT1 has a series of 8 jumpers that are used recycle.
  • Page 63 SECTION 17: S EQUENCE OF PERATION Pilot Trial for Ignition • At the same time that the contact in step b closes, the electronic network opens a contact, which • Jumpers JP6 and JP7 are used by the factory powers terminal #4. This shuts off the power to only to select the PTFI for the M4RT1.

  • Page 64: Section 18: Direct Fired Burner

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 18: DIRECT FIRED BURNER WARNING DANGER Explosion Hazard Carbon Monoxide Hazard Burn Hazard Electrical Shock Hazard Leak test all compo- Heaters installed Allow heater to cool Disconnect electric nents of gas piping unvented must be before service.

  • Page 65: Direct Fired Burner Ignition

    A high voltage arc is generated between the spark rod and the pilot gas tube. The The burner that is used in the Rapid Engineering gas flowing out the ports in the pilot gas tube is LLC unit is equipped with a pilot assembly. The pilot ignited by this arc.

  • Page 66: Direct Fired Burner Flame Proving (Flame Rod)

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 18.2 Direct Fired Burner Flame Proving (Flame Rod) The flame rod in the burner is constructed of a material that produces a signal when heated. This signal is measured as a direct current micro amp. The path of the signal is from the flame rod to the burner.

  • Page 67: Section 19: Direct Fired Process Air Heaters

    SECTION 19: D IRECT IRED ROCESS EATERS SECTION 19: DIRECT FIRED PROCESS AIR HEATERS DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 68: Direct Fired Process Air Heater Models

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL the process air heater in compliance with: 4. Instructions must be provided to require peri- odic inspection and cleaning of the recircula- United States: Refer to NFPA 86 - latest revision, tion air duct. The installer must supply this Ovens and Furnaces /ANSI Z83.25 - latest revision, information.

  • Page 69: Installer's Responsibility For Process Heaters Connected To Paint Booths

    Heater's airflow. B. 90/10 Recirculation Process Heaters • The installer must ensure that the Outside Air Damper, when supplied by Rapid Engineering LLC, is set to provide proper airflow for combustion and to make sure the recirculation air is properly diluted during the bake cycle mode.

  • Page 70: Section 20: Start-Up Procedures

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 20: START-UP PROCEDURES DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 71: Installation Of Recirculating Air Handler

    /h) of outside air per 1,000 Btu/h (0.293 kW). installation and service of equipment sold and Before installation, check that the local distribution supplied by Rapid Engineering LLC and conform to condition, nature of gas and pressure, and the ®...

  • Page 72: Electrical

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 20.2.2 Belt Tension 20.3 Electrical • Belt tension should be checked with a belt-tension Check motor starter for proper overload set- tings. The overload setting should meet full gauge when one is available. Follow the belt load amps (FLA) of motor.

  • Page 73: Gas Piping And Initial Pressure Settings

    SECTION 20: S TART ROCEDURES adjustment. 20.5 Gas Piping and Initial Pressure Settings Perform a pressure test on all gas supply lines to the air handler per applicable codes. Table 16: Motor Sheave Drive Torque Make sure to isolate all gas controls before Specifications pressure testing the system.
  • Page 74 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 5. Adjust air handler high fire gas pressure. • Reconnect any wires that were removed for adjustment. • Determine the high fire gas pressure by adding the manifold pressure for maximum Maximum discharge temperature is 160° F input (from the rating plate) and the burner (71°...

  • Page 75: Safety Shut Off Valve Check

    SECTION 20: S TART ROCEDURES Set BMS to max fire or remove input wires from Remove from terminal SC11 Signal terminals #6 and #5 and #1 on the Conditioner connect a 9VDC battery to signal conditioner the signal conditioner Remove wire from ter- Disconnect selector ribbon Series 94 minal #2 on the ampli-...
  • Page 76 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 34: MR 212 Valve SIDE VIEW NOTE: For high fire adjustment, turn clockwise to increase manifold pressure; turn counter clockwise to decrease manifold pressure. Inlet Pressure Outlet Pressure (Burner Pressure)
  • Page 77 SECTION 20: S TART ROCEDURES FIGURE 35: M611 Valve NOTE: Modulating only. Gas Inlet Low Fire Adjustment Gas Outlet (under cap) FIGURE 36: Regulator (2005) Regulator Adjustment Below (High Fire Adjustment Cap) Gas Flow Gas Flow Outlet Pressure Inlet Pressure Tap-1/8 NPT Tap-1/8 NPT...

  • Page 78: Section 21: Maintenance

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 21: MAINTENANCE DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 79: General

    OSHA regulations and allow ample installation and service of equipment sold and time for the air handler to cool. After maintenance is supplied by Rapid Engineering LLC and conform to performed or air handler is serviced, the air handler ®...
  • Page 80 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Drive Belts and Sheaves Check for belt ride in the groove. In multiple groove drives, belt ride should be uniform. Check groove wear area for wear. Side wall of groove should be straight, not dished out.
  • Page 81 Repeat this same operation after 1 week of service. Consult Rapid Engineering LLC or the motor manufacturer for further recommendations on grease compatibility.

  • Page 82: Manifold And Controls

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 21.4 Manifold and Controls Manifold Periodically check gas control assembly and internal and external piping for leaks. Relief vent lines to outdoors on gas controls should be checked to ensure against blockage caused by insects or any other substance. Clean as required.

  • Page 83: Optional Equipment

    Replace filters with filters of equal specification when they appear dirty. NOTE: When using Rapid Engineering LLC supplied disposable polyester fil- ters, they must be inserted with the white media side facing the inlet of filter section. When using Rapid Engineering LLC supplied permanent aluminum mesh or disposable filters, they must be inserted with the arrow on the filter pointing in the direction of airflow (toward the air handler).

  • Page 84: Section 22: Replacement Parts

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 22: REPLACEMENT PARTS WARNING DANGER Electrical Shock Hazard Explosion Hazard Carbon Monoxide Hazard Fire Hazard ® Use only genuine RAPID replacement parts per this installation, operation and service manual. Failure to follow these instructions can result in death, electric shock, injury or property damage. WARNING WARNING Severe Injury Hazard...
  • Page 85 SECTION 22: R EPLACEMENT ARTS Table 21: Control Panel Spare Parts Description Models Part Number Pressure Switch Hi/Low Airflow All models 28892 Maxitrol 1014U (Temp Control Amp) 07432 Maxitrol 1044 (Temp Control Amp) 07431 Mixing Tube All models 07380 Discharge Air Sensor 1014 07337 Discharge Air Sensor 1044 07433...
  • Page 86 2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 23: Blower Spare Parts Model 2005 2010 2010B 2020 2030 1000-2000 CFM 2000-5000 CFM Blower 62924 62923 P-000315 P-000316 P-000317 P-000318 Bearing P-000627 P-000630 P-000633 P-000636 Shaft P-000628 P-000631 P-000634 P-000637 Wheel P-000629 P-000632...
  • Page 87 SECTION 22: R EPLACEMENT ARTS 208/3/60 Overload 28709 28708 28708 28711 28712 28713 28714 28716 28717 28718 28719 28720 28720 Starter 33810 33810 33810 33811 33812 33813 33814 33816 33817 33818 33819 33819 33820 Fuse 25120 25094 25094 25095 25096 25116 25100 25121...

  • Page 88: Section 23: Troubleshooting

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 23: TROUBLESHOOTING DANGER Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service. Do not enter equipment while in operation. More than one disconnect switch may be Equipment may start automatically. required to disconnect electric from equipment.

  • Page 89: Initial Checks

    SECTION 23: T ROUBLESHOOTING 23.1 Initial Checks When encountering any abnormal operation or fault conditions of the equipment, all troubleshooting should start with the following initial checks. If a problem is discovered in these initial checks it must be corrected before moving on in the trouble shooting.

  • Page 90: Burner

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 23.3 Burner PROBLEM POSSIBLE CAUSE SOLUTION Auxiliary contact not closed. Properly mount contact or replace Flame control Burner/winter switch closed? Replace switch does not try for ignition High temp limit switch tripped? Manually reset or replace Check blower operation Reconnect tubes to pressure switch...

  • Page 91: Temperature Controls

    Burner (continued) PROBLEM POSSIBLE CAUSE SOLUTION Manual shut off valve closed Open manual shut off valve Check wiring from burner control to SSOV Safety Shut Off Valve not operating. Is there Verify inlet gas pressure positive gas pressure downstream of SSOV? Replace SSOV Verify minimum gas supply pressure as per data No main flame...

  • Page 92: A1014 Amplifier - Field Checklist

    23.5 A1014 Amplifier - Field Checklist SYMPTOM POSSIBLE CAUSE No Gas Flow 1. Modulating valve improperly installed. Continuous Low Fire (electronics problem). 2. Short circuit or no voltage to the amplifi er. 3. Open circuit in TD114. Remote Temperature Selector circuit or wiring. 4.
  • Page 93 SECTION 23: T ROUBLESHOOTING FIELD TEST REMEDY 1. Arrow on side of Valve should point in direction of gas fl ow. 1. Install properly. 2. Check for 24VAC at amplifi er terminals 7 & 8. 2. Prove the power source. 3.

  • Page 94: A44 Amplifier - Field Service Checklist

    2000 I ERIES NSTALLATION PERATION AND ERVICE ANUAL 23.6 A44 Amplifier - Field Service Checklist SYMPTOM POSSIBLE CAUSE No gas fl ow. 1. Valve improperly installed. Continuous low fi re (electronics ok). 2. Open circuit in modulator coil. 3. Plunger missing, jammed or improperly installed. 4.
  • Page 95 SECTION 23: T ROUBLESHOOTING FIELD TEST REMEDY 1. Arrow on side of valve should point in direction of gas fl ow. 1. Install properly. 2. Remove wires connected to amplifi er terminals 6 & 7 and mea- 2. If proper resistance values are not observed, replace modulator head or sure resistance.

  • Page 96: Section 24: Rapid

    Phone: __________________________________ Phone: __________________________________ Fax: ____________________________________ Fax: ____________________________________ Notice: Please return a completed copy to Rapid Engineering LLC. If this document is not returned, the manufacturing date will be used as the warranty start date. WARNING Explosion Hazard Falling Hazard...
  • Page 97 ® independent according to the rating plate inlet gas pressure specifica- tions. distributor or Rapid Engineering LLC for a manual. Fuel Type: _______ Pressure: ___________. Only after performing steps 1-3, open the main gas valve At Start-up: and close the manual gas valve downstream of the MR Verify proper belt tension and sheave alignment per instructions on Page 65, Section 20.2.1.

  • Page 98: Section 25: The Rapid

    1100 Seven Mile Road NW Comstock Park, MI 49321 Rapid Engineering LLC will require the part in question to be returned to the factory. Rapid Engineering LLC will, at Telephone: +1.616.784.0500 its sole discretion, repair or replace after determining the Fax: +1.616.784.0435...
  • Page 99 SECTION 25: T RAPID ® 2000-S ERIES ARRANTY...
  • Page 100 This product is not approved for residential use. © 2018 Rapid Engineering LLC - All rights reserved. No part of this work covered by the copyrights herein my be reproduced or copied in any form or by any means – graphic, electronic, or mechanical, including photcopying, recording, taping, or information storage and retrieval systems –...
  • Page 101 All information contained in this document is subject to change without notice.

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