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 2030
Summarization of Contents
SECTION 1: AIR HANDLER SAFETY
1.1 Description of Operation
Overview of the direct-fired gas-fired air handler's function and design for industrial use.
1.2 Inspection and Setup
Instructions for inspecting the unit upon receipt and preparing it for installation.
1.3 Safety Labels and Their Placement
Guidance on the importance and placement of safety signs and labels on the equipment.
1.4 California Proposition 65
Requirements for warning labels regarding Proposition 65 in California.
1.5 Label Placement
Diagrams illustrating the correct placement of various safety and informational labels.
SECTION 2: INSTALLER RESPONSIBILITY
2.1 Wall Tag
Information about the laminated wall tag for safety reminders and clearance importance.
2.2 Corrosive Chemicals
Warning about corrosive chemicals and their effect on air handler components.
2.3 National Standards and Applicable Codes
Requirement to install equipment according to national codes and standards.
2.4 Required Equipment
List of tools and equipment necessary for installation and start-up.
SECTION 3: CRITICAL CONSIDERATIONS
3.1 Required Clearances to Combustibles
Specifies minimum distances from the air handler to combustible materials for fire prevention.
3.2 Purge of Supply Duct
Requirement for purging the supply duct with fresh air before ignition attempts.
3.3 Hardware
Guidance on using and torquing hardware, including specific notes on inlet hood installation.
SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES
4.1 Gas Codes
References for national and local codes governing gas piping installation.
4.2 Installation Codes
Standards applicable to the installation of air conditioning and ventilating systems.
4.3 Aircraft Hangars
Codes specific to installing air handlers in aircraft hangars.
4.4 Parking Structures and Repair Garages
Codes applicable to installation in garages and parking structures.
4.5 Electrical
Standards for electrical connections and wiring.
4.6 Venting
Requirements for proper installation of the venting system.
4.7 High Altitude
Information on approved installation altitudes and factory consultation.
SECTION 6: LIFTING AN AIR HANDLER
6.1 Lifting an Air Handler
Procedures and safety precautions for safely lifting and preparing the air handler for installation.
6.1.3 Lifting an Upright Air Handler (2005 - 2030)
Step-by-step guide for lifting air handlers in the upright configuration.
SECTION 7: ROOF CURB
7.1 Roof Curb Assembly and Installation
Instructions for assembling and installing the roof curb for unit mounting.
7.2 Air Handler Mounting to Roof Curb
Guidance on placing and securing the air handler onto the installed roof curb.
SECTION 8: UPRIGHT STAND
8.1 Upright Stand Installation
Steps for securely installing the upright stand onto a concrete slab or floor.
8.2 Attaching Air Handler to Stand
Procedure for mounting the air handler onto the installed upright stand.
SECTION 9: LEGS
9.1 Leg Mounting
Instructions for using legs to mount the air handler on a concrete slab or floor.
9.2 Leg Mounting - Horizontal Air Handler (2005 - 2030)
Specific steps for mounting legs to horizontal air handlers.
SECTION 10: INDOOR SUSPENSION MOUNTING - HORIZONTAL AIR HANDLER
10.1 Suspension Kit Assembly and Installation
Guidance on assembling and installing the suspension kit for horizontal units.
SECTION 11: FILTER SECTION
11.1 Filter Section (2005)
Details on the filter section assembly for the 2005 model.
11.2 Filter Section Assembly (2010 and 2010B)
Instructions for assembling the filter section for 2010 and 2010B models.
11.3 Filter Section Assembly (2020 and 2030)
Assembly instructions for the filter section of 2020 and 2030 models.
11.4 Filter Section Support Assembly
Information on the support assembly for filter sections, especially when used with inlet hoods.
11.5 Filter Section Installation - Horizontal Air Handlers
Procedures for installing the filter section onto horizontal air handlers.
11.6 Filter Section Installation - Upright Air Handlers
Procedures for installing the filter section onto upright air handlers.
SECTION 12: INLET HOOD
12.1 Inlet Hood Assembly (2005)
Steps for assembling the inlet hood for the 2005 model.
12.2 Inlet Hood Assembly (2010 and 2010B)
Instructions for assembling the inlet hood for 2010 and 2010B models.
12.3 Inlet Hood Assembly (2020 and 2030)
Assembly procedures for the inlet hood for 2020 and 2030 models.
SECTION 13: DAMPERS
13.1 Discharge Damper
Guidelines for installing motorized discharge dampers.
13.2 Inlet Damper
Information regarding the factory-mounted motorized inlet dampers.
SECTION 14: DISCHARGE HEADS AND SPLASH PLATES
14.1 One-Way and Three-Way Discharge Head Installation
Instructions for installing discharge heads, including mounting and support.
14.2 Splash Plate Installation
Procedure for installing the splash plate for bottom discharge units.
SECTION 15: DUCT CONSIDERATIONS
15.1 Inlet Duct Work
Requirements for inlet ductwork size and airflow.
15.2 Return Duct Work
Requirements for return ductwork size and airflow.
15.3 Discharge Duct Work
Recommendations for discharge ductwork sizing and installation.
SECTION 16: GAS PIPING
16.1 Gas Manifolds
Compliance requirements and options for gas manifolds.
16.2 Gas Piping and Pressures
Specifications for gas piping connections and pressure limits.
16.3 Gas Manifold Venting
Requirements for venting gas manifolds and regulators to the atmosphere.
16.4 Gas Piping
General guidelines and codes for gas piping installation.
16.5 Pressure Test Ports
Location and use of pressure test ports for manifold and burner pressure.
16.6 Line Pressure Test - Leak Testing
Procedures for performing line pressure tests and leak detection.
SECTION 17: ELECTRICAL
17.1 Wiring and Electrical Connections
Standards and codes for electrical wiring and connections.
17.2 Remote Panel
Instructions for wiring and mounting the remote control panel.
17.5 Safety Systems
Overview of essential safety devices for proper air handler operation.
17.8 Control Options
Description of various optional controls for air handler functionality.
17.9 Optional Exhaust Motor Starters, Variable Frequency Drives
Wiring diagrams for optional exhaust motor starters and VFDs.
17.10 Disconnect Fuse Sizing
Guidelines for selecting appropriate fuse sizes for disconnects.
SECTION 18: SEQUENCE OF OPERATION
18.1 Air Handler Configuration
Description of the four available air handler configuration styles.
18.2 HVAC Remote Panels and Panel Options
Information on selecting and mounting remote panels and their functions.
18.3 Basic Air Handler Sequence of Operation
Detailed operational sequence for the air handler's primary functions.
SECTION 19: START-UP PROCEDURES
19.1 Installation of Recirculating Air Handler
Steps for installing air handlers that recirculate room air.
19.2 Mechanical
Mechanical checks and adjustments required before operation.
19.3 Electrical
Electrical checks including motor starters, voltage, rotation, and current.
19.5 Gas Piping and Initial Pressure Settings
Procedures for gas piping connection and setting initial pressures.
SECTION 20: MAINTENANCE
20.1 General
General maintenance guidelines and schedule for the air handler.
20.2 Unit Exterior
Procedures for cleaning and inspecting the exterior of the unit.
20.3 Blower Section
Maintenance tasks for the blower section, including wheel and belt checks.
Motors
Inspection and lubrication procedures for the unit's motors.
20.4 Manifold and Controls
Maintenance checks for the gas manifold, air flow switch, and electrical components.
20.5 Burner
Annual inspection and cleaning procedures for the burner assembly.
20.6 Optional Equipment
Maintenance recommendations for optional dampers and filters.
SECTION 21: REPLACEMENT PARTS
Control Panel
List of replacement parts for the control panel components.
Power Panel
List of replacement parts for the power panel components.
Manifold Components
List of replacement parts for gas manifold components.
SECTION 22: TROUBLESHOOTING
22.1 Initial Checks
Initial troubleshooting steps to perform before diagnosing specific issues.
22.2 Motor and Blower
Troubleshooting guide for motor and blower operational problems.
22.3 Burner
Troubleshooting steps for burner ignition and flame issues.
22.4 Temperature Controls
Guidance for troubleshooting temperature control system issues.
22.5A1014 Amplifier - Field Checklist
Field checklist for diagnosing problems with the A1014 amplifier.
22.6A44 Amplifier - Field Service Checklist
Field service checklist for diagnosing issues with the A44 amplifier.
SECTION 23: RAPID® 2000-SERIES START-UP PROCEDURES
Receiving Inspection
Steps for inspecting the unit and installation site prior to start-up.
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