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 2020
Summarization of Contents
Section 1: Air Handler Safety
1.1 Description of Operation
Details the direct, gas-fired, fresh-air air handler's function and operating parameters.
1.2 Inspection and Setup
Provides instructions for inspecting the air handler upon receipt and preparing for installation.
1.3 Safety Labels and Their Placement
Explains the importance and location of safety labels on the air handler.
1.4 California Proposition 65
Addresses the requirement for Proposition 65 warning labels on the equipment.
1.5 Label Placement
Illustrates the specific locations for various safety and identification labels on models.
Section 2: Installer Responsibility
2.1 Wall Tag
Describes the laminated wall tag for safety reminders and clearance importance.
2.2 Corrosive Chemicals
Highlights the installer's responsibility to identify and avoid corrosive chemicals.
2.3 National Standards and Applicable Codes
Lists national and local codes applicable to installation, gas, and venting.
2.4 Required Equipment
Details the tools and equipment necessary for safe installation and start-up.
Section 3: Critical Considerations
3.1 Required Clearances to Combustibles
Specifies minimum distances from the air handler to combustible materials.
3.2 Purge of Supply Duct
Mandates purging the supply duct with fresh air before ignition attempts.
3.3 Hardware
Provides guidelines for proper torque settings for all hardware used in installation.
Section 4: National Standards and Applicable Codes
4.1 Gas Codes
References NFPA 54/ANSI Z223.1 and CSA B149.1 for gas piping installation.
4.2 Installation Codes
References NFPA 90A for air conditioning and ventilating systems installation.
4.3 Aircraft Hangars
Lists codes for installation in aircraft hangars, including NFPA 409.
4.4 Parking Structures and Repair Garages
Specifies codes for installation in garages, such as NFPA 88A and NFPA 30A.
4.5 Electrical
References National Electrical Code® (NFPA 70) and Canadian Electrical Code.
4.6 Venting
Outlines requirements for venting installation, referencing NFPA 54/ANSI Z223.1.
4.7 High Altitude
Provides approved installation altitudes and requirements for higher elevations.
Section 5: Specifications
Table 8: 2000-Series Selection Guide
Provides airflow, motor HP, static pressure, heat output, and gas pressure data.
Table 9: Estimated Pressure Drop of Accessory Components
Lists estimated pressure drops for various optional accessory components.
Section 6: Lifting an Air Handler
Preparing to Lift the Air Handler
Details essential steps before lifting the air handler, including inspection.
Lifting a Horizontal Air Handler (All Models)
Provides instructions for safely lifting horizontal air handler units.
Lifting an Upright Air Handler (2005 - 2030)
Outlines the procedure for lifting air handlers into an upright position.
Section 7: Roof Curb
Roof Curb Assembly and Installation
Guides on assembling and installing the roof curb for the air handler.
Air Handler Mounting to Roof Curb
Details the process of securely mounting the air handler onto the installed roof curb.
Section 8: Upright Stand
Upright Stand Installation
Provides instructions for securing the upright stand to a concrete slab or floor.
Attaching Air Handler to Stand
Guides on how to safely place and secure the air handler onto the stand.
Section 9: Legs
Leg Mounting
Explains using legs for mounting air handlers on concrete slabs or floors.
Leg Mounting - Horizontal Air Handler (2005 - 2030)
Details the mounting procedure for legs on horizontal air handlers.
Section 10: Indoor Suspension Mounting - Horizontal Air Handler
Suspension Kit Assembly and Installation
Provides instructions for assembling and installing suspension kits for horizontal units.
Section 11: Filter Section
Filter Section Assembly
Covers assembly procedures for filter sections for various models (2005, 2010/2010B, 2020/2030).
Filter Section Support Assembly
Details the assembly of supports for filter sections, especially for 2010-2030 models.
Filter Section Installation
Provides instructions for installing filter sections onto horizontal and upright air handlers.
Section 12: Inlet Hood
Inlet Hood Assembly
Covers assembly procedures for inlet hoods for models 2005, 2010/2010B, and 2020/2030.
Inlet Hood Installation
Details installation methods for inlet hoods onto walls or air handlers.
Section 13: Dampers
Discharge Damper
Provides information on the installation of motorized discharge dampers.
Inlet Damper
Describes the factory-mounted motorized inlet dampers for various models.
Section 14: Discharge Heads and Splash Plates
One-Way and Three-Way Discharge Head Installation
Guides on installing discharge heads for models 2005-2030.
Splash Plate Installation
Details the installation process for splash plates on horizontal air handlers.
Section 15: Duct Considerations
Inlet Duct Work
Specifies requirements for inlet duct dimensions and airflow.
Return Duct Work
Specifies requirements for return duct dimensions and airflow.
Discharge Duct Work
References tables for minimum discharge duct sizes and recommendations.
Section 16: Gas Piping
Gas Manifolds
Describes the available gas manifold options and compliance requirements.
Gas Piping and Pressures
Outlines supply pressure limits and requirements for gas piping.
Gas Manifold Venting
Covers requirements for venting gas controls to the atmosphere.
Pressure Test Ports
Details the location and purpose of pressure test ports for manifold and burner.
Line Pressure Test - Leak Testing
Provides guidelines for conducting line pressure tests and leak detection.
Section 17: Electrical
Wiring and Electrical Connections
Specifies compliance with electrical codes and wiring practices.
Remote Panel Configuration
Details wiring, mounting distance, and low voltage wiring for remote panels.
Motor and Control Current Draw
Provides information on current draw requirements for motors and controls.
Safety Systems Overview
Highlights the importance of safety systems for proper air handler performance.
Additional Control Wiring
Describes optional control wiring for various air handler styles (MUA, FR, AM, VAV).
Carbon Dioxide Interlocks
Explains CO2 sensor requirements for recirculating air handlers.
Control Options
Details various optional controls like outside air stats and limits.
Exhaust Motor Starters and VFDs
Covers wiring for optional exhaust motor starters and variable frequency drives.
Disconnect Fuse Sizing
Provides guidance on selecting appropriate fuse sizes for disconnects.
Section 18: Sequence of Operation
Air Handler Configuration
Describes the four available air handler configurations (MUA, FR, AM, VAV).
HVAC Remote Panels and Panel Options
Details the use and mounting of remote panels and their options.
Basic Air Handler Sequence of Operation
Explains the operational sequence for basic air handler functions, including flame control.
Section 19: Start-Up Procedures
Installation of Recirculating Air Handler
Provides specific installation guidelines for recirculating air handler types.
Mechanical Checks
Covers mechanical checks including sheave alignment, belt tension, and air temperature sensing.
Electrical Checks
Details critical electrical checks for proper start-up.
Airflow Checks
Explains how to verify proper airflow using differential pressure measurements.
Burner Pressure Checks
Guides on measuring and adjusting burner pressure for optimal performance.
Gas Piping and Initial Pressure Settings
Details gas pressure testing, supply pressure verification, and pilot pressure settings.
Section 20: Maintenance
General Maintenance
Provides general guidelines for maintenance, including inspections and cleaning.
Unit Exterior Maintenance
Covers cleaning, painting, and inspection of exterior components and labels.
Blower Section Maintenance
Details inspection and cleaning of the blower wheel, belts, sheaves, and bearings.
Manifold and Controls Maintenance
Outlines periodic checks for gas leaks, air flow switches, and electric components.
Burner Maintenance
Provides instructions for annual burner inspection, cleaning, and component checks.
Optional Equipment Maintenance
Covers maintenance for dampers and filters, including cleaning and replacement.
Section 21: Replacement Parts
Control Panel Parts
Lists available replacement parts for control panels and associated components.
Power Panel Parts
Details replacement parts for power panels, including disconnects and contactors.
Manifold Components
Lists components for gas manifolds, including valves and regulators.
Blower Parts
Lists replacement parts for the blower assembly, including bearings and wheels.
Remote Panel Parts
Lists available replacement parts for remote panels and accessories.
V-Belt Parts
Provides a list of available V-belt part numbers for various sizes.
Section 22: Troubleshooting
Initial Checks
Provides essential initial checks for identifying operational or fault conditions.
Motor and Blower Troubleshooting
Lists common problems, causes, and solutions for motor and blower issues.
Burner Troubleshooting
Addresses common burner problems such as no ignition or flame loss.
Temperature Controls Troubleshooting
Guides on troubleshooting issues related to temperature control systems.
A1014 Amplifier - Field Checklist
Provides a checklist for diagnosing issues with the A1014 amplifier.
A44 Amplifier - Field Service Checklist
Offers a service checklist for diagnosing problems with A44 amplifiers.
Section 23: RAPID® 2000-Series Start-Up Procedures
Receiving Inspection
Details steps for inspecting the installation site and air handler upon receipt.
At Start-up Procedures
Provides a comprehensive checklist for commissioning the air handler.
Section 24: The RAPID® 2000-Series Warranty
Rapid Engineering LLC Will Pay For
Outlines what the warranty covers, including replacement parts for defects.
Rapid Engineering LLC Will Not Pay For
Lists exclusions from warranty coverage, such as labor and misuse.
Warranty is Void If
Specifies conditions under which the product warranty becomes void.
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