Table of Contents
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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
CANADA: 100% OUTSIDE AIR ONLY
© 2015 Rapid Engineering LLC
Rapid
Direct, Gas-Fired, Industrial
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: +1.616.784.1910
Toll Free: 800.536.3461
www.rapidengineering.com
®
2000-Series
Air Handler
Service Manual
Installer
Owner
P/N RP121100NA Rev C 08/15
2005
2010
2010B
2020
2030
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Table of Contents
Related Manuals for Rapid 2010
Summarization of Contents
Air Handler Safety
Description of Operation
Details the direct, gas-fired, fresh-air handler design and operating capabilities, including temperature ranges.
Inspection and Setup
Instructions for inspecting the air handler upon receipt, checking fuel/electrical specs, and verifying for damage or proper clearances.
Safety Labels and Their Placement
Guidance on replacing illegible safety labels and instructions for their placement on the equipment.
California Proposition 65
Requirements for warning labels in accordance with California Proposition 65 for equipment placement.
Label Placement
Diagrams illustrating the specific locations for safety and informational labels on various air handler models.
Installer Responsibility
Wall Tag
Information on the availability and placement of a laminated wall tag for safety instructions and clearances.
Corrosive Chemicals
Warning about identifying and avoiding corrosive chemicals and halogenated hydrocarbons to prevent equipment damage.
National Standards and Applicable Codes
Requirement to install equipment in accordance with the latest revision of applicable national and local codes.
Required Equipment
List of tools and equipment necessary for the safe installation and start-up of the air handler.
Critical Considerations
Required Clearances to Combustibles
Specifies minimum distances from combustible materials to prevent fire hazards and ensure safety.
Purge of Supply Duct
Requirement for purging the supply duct with fresh air before ignition attempts, as per ANSI standards.
Hardware
Guidance on torque settings for hardware and notes on inlet hood installation for moisture entrainment prevention.
National Standards and Applicable Codes
Gas Codes
References for national and local codes governing gas piping installation, including NFPA and CSA standards.
Installation Codes
References for installation codes related to air conditioning and ventilating systems, specifically NFPA 90A.
Aircraft Hangars
Codes and standards applicable for installation in aircraft hangars, referencing NFPA 409.
Parking Structures and Repair Garages
Applicable codes for installation in garages, referencing NFPA 88A and NFPA 30A.
Electrical
References for national electrical codes, including NEC and Canadian Electrical Code for wiring connections.
Venting
Requirements for venting installation according to the manual and national fuel gas codes (NFPA 54/ANSI Z223.1).
High Altitude
Information on approved installation altitudes and requirements for installations above specified limits.
Lifting an Air Handler
Lifting an Air Handler
Covers preparation, safety precautions, and procedures for lifting both horizontal and upright air handler models.
Lifting an Upright Air Handler (2005 - 2030)
Step-by-step instructions for lifting an upright air handler into its final position.
Roof Curb
Roof Curb Assembly and Installation
Instructions for assembling and installing the roof curb, including torque specifications and weatherproof sealing.
Air Handler Mounting to Roof Curb
Procedure for placing and fastening the air handler onto the installed roof curb.
Upright Stand
Upright Stand Installation
Steps for securely attaching the upright stand to a concrete slab or floor.
Attaching Air Handler to Stand
Procedure for mounting the air handler onto the stand, including foam tape application and securing hardware.
Legs
Leg Mounting
Information on using legs for mounting air handlers on concrete slabs or floors, available for horizontal configurations.
Leg Mounting - Horizontal Air Handler (2005 - 2030)
Detailed steps for attaching legs to the air handler and securing them to a concrete slab.
Indoor Suspension Mounting - Horizontal Air Handler
Suspension Kit Assembly and Installation
Instructions for assembling and installing suspension kits for horizontal air handlers (models 2005-2010B).
Filter Section
Filter Section (2005)
Details on the filter section for the 2005 model, including part numbers and dimensions.
Filter Section Assembly (2010 and 2010B)
List of parts and quantities for assembling the filter section for 2010 and 2010B models.
Filter Section Assembly (2020 and 2030)
List of parts and quantities for assembling the filter section for 2020 and 2030 models.
Filter Section Support Assembly
Information on the filter section support assembly for models 2010-2030 when an inlet hood is also present.
Filter Section Installation - Horizontal Air Handlers
Procedures for installing filter sections onto horizontal air handlers for 2005 and 2010-2030 models.
Filter Section Installation - Upright Air Handlers
Procedures for installing filter sections onto upright air handlers for 2005 and 2010-2030 models.
Inlet Hood
Inlet Hood Assembly (2005)
List of parts and quantities for assembling the inlet hood for the 2005 model.
Inlet Hood Assembly (2010 and 2010B)
List of parts and quantities for assembling the inlet hood for 2010 and 2010B models.
Inlet Hood Assembly (2020 and 2030)
List of parts and quantities for assembling the inlet hood for 2020 and 2030 models.
Inlet Hood Installation
Instructions for installing the inlet hood onto an exterior wall or directly to the air handler.
Dampers
Discharge Damper
Details on the motorized discharge damper, its dimensions, and mounting recommendations.
Inlet Damper
Information on factory-mounted inlet dampers, their configurations, and dimensions for various models.
Discharge Heads and Splash Plates
One-Way and Three-Way Discharge Head Installation
Instructions for installing discharge heads, including mounting to air handlers or interior walls.
Splash Plate Installation
Procedure for installing the splash plate, including drilling holes and attaching hanger rods.
Duct Considerations
Inlet Duct Work
Guidelines for inlet duct dimensions and ensuring it supplies only fresh air to the handler.
Return Duct Work
Guidelines for return duct dimensions, emphasizing it must supply only fresh air to the handler.
Discharge Duct Work
Recommendations for minimum discharge duct sizes and connection dimensions based on model.
Gas Piping
Gas Manifolds
Information on available gas manifold options and compliance with relevant codes.
Gas Piping and Pressures
Details on manifold pressure ratings and requirements for high pressure gas regulators.
Gas Manifold Venting
Requirement to pipe vent valves to the atmosphere outside the structure per applicable codes.
Gas Piping
Guidelines for gas supply piping, compliance with codes, and ensuring accessibility.
Pressure Test Ports
Location and purpose of pressure test ports for measuring manifold and burner gas pressures.
Line Pressure Test - Leak Testing
Procedures for line pressure testing, including isolation of the air handler during testing.
Electrical
Wiring and Electrical Connections
Compliance requirements for electrical wiring and connections with National Electrical Code and local ordinances.
Remote Panel
Wiring instructions for remote panels, including wire gauge sizes and mounting distance considerations.
Motor Current Draw
Guidance on referring to the rating plate for motor current requirements and potential adjustments.
Control Current Draw
Specifies the maximum current draw for air handler controls and accessories.
Safety Systems
Description of various safety systems including limit switches, pressure switches, and flame controls.
Additional Control Wiring
Details on optional control wiring for different air handler styles like VAV, AM, FR, and MUA.
Carbon Dioxide Interlocks
Requirements for CO2 sensors or temperature limit controls when recirculating air.
Control Options
Overview of various control options such as mild weather stat, low temp limit, failsafe interlocks, and motorized dampers.
Optional Exhaust Motor Starters, Variable Frequency Drives
Wiring diagrams for optional exhaust motor starters and variable frequency drives.
Disconnect Fuse Sizing
Guidance on determining the correct fuse classification based on motor size, control current, and supply voltage.
Sequence of Operation
Air Handler Configuration
Describes the four main air handler configurations: MUA, FR, AM, and VAV styles.
HVAC Remote Panels and Panel Options
Guidance on mounting remote panels and descriptions of Basic II, SDC, DTC, and BMS-Ready panel options.
Basic Air Handler Sequence of Operation
General sequence of operation for the air handler, including fan, burner, and flame control functions.
Start-Up Procedures
Installation of Recirculating Air Handler
Installation steps specific to recirculating air handlers, including CO2 sensor and temperature rise limiting.
Mechanical
Procedures related to mechanical aspects like outside air requirements, sheave alignment, belt tension, and air temperature sensing.
Electrical
Checks for motor starters, supply voltage, fan rotation, system current draw, and VFD programming.
Airflow
Procedures for verifying airflow using differential pressure measurements and adjusting blower speed via sheaves.
Gas Piping and Initial Pressure Settings
Steps for performing pressure tests, verifying supply pressure, setting gas pressure, and checking pilot pressure.
Safety Shut Off Valve Check
Procedure for verifying gas soundness of Safety Shut Off Valves (SSOV) after initial start-up.
Temperature Control System Calibration
Information on calibrating temperature control systems and referring to product information sheets.
Maintenance
General
General maintenance overview, including lockout procedures and annual inspection recommendations.
Unit Exterior
Maintenance for the unit exterior, including touch-ups, periodic painting, and inspection of caulk and warning labels.
Blower Section
Maintenance for the blower section, including inspecting the blower wheel, cleaning, and checking for vibration.
Drive Belts and Sheaves
Procedures for checking belt ride, wear, alignment, tension, and replacement guidelines.
Blower Bearing Lubrication
Guidance on lubricating blower pillow block bearings and recommended lubricants.
Motors
Inspection and lubrication intervals for motors based on NEMA frame size and motor horsepower.
Instructions for Lubricating
Detailed steps for lubricating motors, emphasizing clean fittings and avoiding over-greasing.
Manifold and Controls
Maintenance checks for the manifold, air flow switch, electric components, and temperature sensors.
Burner
Annual inspection procedures for the burner and its components, including cleaning the UV scanner and igniter.
Optional Equipment
Maintenance guidelines for optional equipment such as dampers and filters, including cleaning and replacement.
Troubleshooting
Initial Checks
Initial checks to perform when encountering abnormal operation or fault conditions.
Motor and Blower
Troubleshooting guide for motor and blower issues, listing possible causes and solutions.
Burner
Troubleshooting guide for burner issues, covering flame control, lockout, pilot flame, and gas supply.
Temperature Controls
Guidance for troubleshooting temperature control amplifier problems, referring to specific checklists.
22.5A1014 Amplifier - Field Checklist
A checklist for diagnosing symptoms related to the A1014 amplifier.
22.6A44 Amplifier - Field Service Checklist
A checklist for diagnosing symptoms related to the A44 amplifier.
Rapid® 2000-Series Start-Up Procedures
Receiving Inspection
Steps for inspecting the installation site, handling, packing list, and initial component checks.
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