Rapid 4040 Installation, Operation & Service Manual
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Rapid 4040 Installation, Operation & Service Manual

Rapid 4000 series 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
CANADA: 100% OUTSIDE AIR ONLY
© 2018 Rapid Engineering LLC
®
Rapid
4000-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
4024
4036
4040
4044
4049
Installer
Owner
P/N RP140000NA Rev A 03/18
4054
4060
4066
4073
4080
4089

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  • 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 CANADA: 100% OUTSIDE AIR ONLY P/N RP140000NA Rev A 03/18 © 2018 Rapid Engineering LLC...

  • Page 3: Table Of Contents

    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 photocopying, recording, taping or information storage and retrieval systems - without the Printed in written permission of Rapid Engineering LLC. the U.S.A.
  • Page 5 There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the property of their respective owners. Rapid Engineering LLC is not sponsored by or affiliated with any of the trademark or registered...
  • Page 7 TABLE OF FIGURES Figure 44: Service Platform for a Horizontal Air Handler..56 Figure 45: Vertical Air Handler with Duct Sleeves and Discharge Figure 1: 4024 - 4049..............3 Head ..................58 Figure 2: 4054 and 4089............4 Figure 46: One-Way Discharge Head ........59 Figure 3: 4000-Series Interior ...........

  • Page 9: Section 1: Air Handler Safety

    For additional copies of the Installation, Operation separately on another truck. Check the bill of lading and Service Manual, please contact Rapid for information. Engineering LLC. Gas-fired appliances are not designed for use in...

  • Page 10: Temporary Storage

    Air handlers built for indoor installation are not weatherized. Rapid Engineering LLC will not be held responsible for any damage that may occur from outdoor storage. 1.4 Safety Labels and Their Placement Product safety signs or labels should be replaced by product user if they are no longer legible.

  • Page 11: Label Placement

    Item Part Number Description 19305 Label Shock Hazard 19304 Label Severe Injury Hazard 19307 Label Crush Hazard 19308 Label Fire Hazard 19309 Label Falling Hazard 19306 Label Burn Hazard 91040039 Rapid Logo Label 91070015 Proposition 65 Label 3 of 154...

  • Page 12: Figure 2: 4054 And 4089

    Item Part Number Description 19305 Label Shock Hazard 19304 Label Severe Injury Hazard 19307 Label Crush Hazard 19308 Label Fire Hazard 19309 Label Falling Hazard 19306 Label Burn Hazard 91040039 Rapid Logo Label 91040015 Proposition 65 Label 4 of 154...

  • Page 13: Figure 3: 4000-Series Interior

    Label - Rotation Label - High Voltage Label - Caution Don’t Overtighten Belt Label - Alignment Guide Label - Rapid Factory Direct Parts Information Label - Bearing Lube Chart Label - Gas Type Label - Outdoor Temp Sensor Label - Min/Max Gas Pressures Required...

  • Page 14: Section 2: Installer Responsibility

    Engineering LLC recommends the installer contact a local building inspector or Fire Marshal Rapid Engineering LLC cannot be responsible for for guidance. ensuring that all appropriate safety measures are • To use the information given in a layout drawing undertaken prior to installation;...
  • Page 15 SECTION 2: I NSTALLER ESPONSIBILITY the air handler and accessories may be placed in a safe manner. The qualified installer or service technician is responsible for having the appropriate equipment for the safe installation and start-up of an industrial air handler.

  • Page 16: Section 3: Critical Considerations

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 3: CRITICAL CONSIDERATIONS • Locate the air handler so that the air intakes are not too close to any exhaust fan outlets, gasoline WARNING storage or other contaminants that could potentially cause dangerous situations. •...

  • Page 17: Section 4: National Standards And Applicable Codes

    SECTION 4: N ATIONAL TANDARDS AND PPLICABLE ODES SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES 4.5 Electrical 4.1 Gas Codes Electrical connection to air handler must be in accordance with the following codes: The type of gas appearing on the nameplate must be the type of gas used.

  • Page 18: Section 5: Specifications

    Outdoor duct sizes vary. Control enclosure can be located on left or right side of unit. (Shown on right side in drawings.) Consult Rapid Engineering LLC for additional information.

  • Page 19: Table 2: 4000 Am Dimensions

    RD/LD BD/UD ELECTRICAL CONNECTION CONNECTION RIGHT SIDE VIEW FRONT VIEW Table 2: 4000 AM Dimensions Air Handler 4024 4036 4040 4044 4049 4054 4060 112 120 4066 4073 112 120 4080 131 112 171 131 138 4089 131 112 177...

  • Page 20: Table 3: 4000 Am Approximate Shipping Weights

    Table 3: 4000 AM Approximate Shipping Weights Horizontal Service Platforms Model 1,254 1,289 4024 2,110 2,129 4036 2,427 1,012 2,443 4040 2,783 1,122 2,816 4044 3,114 1,230 3,150 4049 2,383 1,671 1,597 1,150 2,373 1,754 4054 2,673 1,936 1,707 1,157...

  • Page 21: Table 4: 4000 Mua Dimensions

    SECTION 5: S PECIFICATIONS FIGURE 6: 4000 MUA Vertical Model Dimensions RD/LD BD/UD ELECTRICAL CONNECTION CONNECTION RIGHT SIDE VIEW FRONT VIEW Table 4: 4000 MUA Dimensions Air Handler 4024 4036 4040 4044 4049 4054 4060 4066 4073 4080 4089 13 of 154...

  • Page 22: Table 5: 4000 Mua Approximate Shipping Weights

    ELECTRICAL RIGHT SIDE VIEW CONNECTION Table 5: 4000 MUA Approximate Shipping Weights Model 1,325 1,360 4024 2,110 2,129 4036 2,530 2,546 4040 2,783 2,816 4044 4049 3,305 1,126 3,341 2,518 1,695 1,150 2,508 1,760 4054 2,808 1,973 1,627 2,798 2,076...

  • Page 23: Table 6: 4000 Fr Dimensions

    ELECTRICAL CONNECTION S x P (Optional) (Optional) (Optional) CONNECTION (Optional) (Optional) RIGHT SIDE VIEW FRONT VIEW Table 6: 4000 FR Dimensions Air Handler 4024 4036 4040 32.5 4044 35.5 4049 43.5 4054 4060 4066 4073 4080 4089 15 of 154...

  • Page 24: Table 7: 4000 Fr Approximate Shipping Weights

    GAS CONNECTION CONNECTION (Optional) Table 7: 4000 FR Approximate Shipping Weights Model 4024 1,245 1,230 2,055 2,054 4036 2,354 2,360 4040 2,716 2,704 4044 3,034 3,017 4049 2,383 1,470 2,373 1,553 4054 2,673 1,712 2,663 1,805 4060 2,961 1,847 3,129...

  • Page 25: Table 8: 4000 Vav Dimensions

    FIGURE 10: 4000 VAV Vertical Model Dimensions 20% to 100% Air ELECTRICAL CONNECTION CONNECTION RIGHT SIDE VIEW FRONT VIEW Table 8: 4000 VAV Dimensions Air Handler 4024 4036 4040 4044 4049 4054 4060 4066 4073 4080 4089 17 of 154...

  • Page 26: Table 9: 4000 Vav Approximate Shipping Weights

    ELECTRICAL CONNECTION 20% to 100% AI R Table 9: 4000 VAV Approximate Shipping Weights Model 1,564 1,589 4024 2,585 2,627 4036 4040 2,982 3,033 3,413 3,470 4044 3,804 3,870 4049 2,953 2,061 1,150 2,943 2,144 4054 3,333 2,396 1,157 3,323 2,489...

  • Page 27: Table 10: Dimensions

    32.5 17.1 22.1 25.6 28.9 31.7 32.1 35.0 18.4 23.8 27.6 31.1 34.1 34.6 37.5 19.7 25.5 29.5 33.3 36.6 37.0 40.0 21.1 27.2 31.5 35.6 39.0 39.5 NOTE: Rapid Engineering LLC's standard media thickness equals 12". 19 of 154...

  • Page 28: Table 12: Air Density Ratio

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 12: Air Density Ratio Density Ratio for Stated Elevation (ft/in HG) Temperature 1,000/ 2,000/ 3,000/ 4,000/ 5,000/ 6,000/ 7,000/ 8,000/ 9,000/ 10,000/ (°F) 29.92 28.86 26.82 26.82 25.84 24.90 23.98 23.09 22.22 21.39 20.58 68°...

  • Page 29: Table 13: Dimensions

    SECTION 5: S PECIFICATIONS FIGURE 13: Mechanical Cooling BD/UD PLAN VIEW ENERGY EVAPORATIVE FILTER COIL SECTION RECOVERY INLET PLENUM INLET HOOD FAN SECTION BURNER SECTION COOLER SECTION (OPTIONAL) SECTION (OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL) (OPTIONAL) LD/RD ELECTRICAL GAS CONNECTION CONNECTION RIGHT SIDE VIEW Table 13: Dimensions Airflow - Cubic Compatible...

  • Page 30: Table 15: Dimensions

    Minute (CFM) Hood Hood Section Housing 4024 4024 4,000-7,000 1,000 7,001-15,000 1,900 4036 4036 15,001-20,000 2,000 4040 20,001-25,000 2,700 4040 4044 25,001-30,000 2,900 4044 4049 30,001-35,000 4,800 1,280 4049 4054 35,001-40,000 5,000 1,490 4054 4060 40,001-50,000 5,800 1,673 1,050 4060...

  • Page 31: Table 16: Energy Recovery

    546.64 / 1,272.52 26,000 0.90 0.96 509.47 / 1,267.47 568.50 / 1,323.44 27,000 0.96 1.03 529.06 / 1,316.14 590.37 / 1,374.35 4040 4044 28,000 1.03 1.10 548.66 / 1,364.80 612.23 / 1,425.25 29,000 1.10 1.17 568.25 / 1,413.45 634.10 / 1,476.15 30,000 1.17...

  • Page 32: Table 17: Fan Selection Chart

    9.2 10.2 11.1 20,000 4036 2,451 8.7 10.1 10.4 11.3 12.2 13.1 20,000 4040 1,745 9.5 10.6 11.7 12.8 20,000 4044 1,429 9.5 10.6 11.7 12.8 22,500 4036* 2,757 9.8 10.7 11.6 12.5 13.5 14.5 15.5 22,500 4040 1,964 9.4 10.3 11.4 12.4 13.4 14.5...

  • Page 33: Table 18: Fan Selection Chart (Continued)

    For external static pressure greater than 2", contact your local representative or Rapid Engineering LLC. For operation in altitudes exceeding 2000' above sea level, contact the factory. The recommended motor horsepowers shown for the Fan Selection Chart in the 0 in. wc external static pressure column include fan and burner static pressures only (internal equipment static pressure).

  • Page 34: Table 19: Static Pressure Drops For Options

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Table 19: Static Pressure Drops for Options Description in wc Cooling Coil Section 0.10 Cooling Coil Damper - Inlet 0.05 Damper - Low Leak 0.05 Damper - Discharge 0.10 Damper - Discharge, Low Leak 0.10 Supply Air End Discharge Plate...

  • Page 35: Section 6: Lifting An Air Handler (Rigging)

    SECTION 6: L IFTING AN ANDLER IGGING SECTION 6: LIFTING AN AIR HANDLER 6.1 Preparing to Lift the Air Handler (RIGGING) Prior to lifting the air handler, the following steps must WARNING be performed: Remove all packaging or banding that attached the air handler to the skid and ensure that the air handler is no longer bound to a skid or truck bed.

  • Page 36: Lifting A Horizontal Air Handler

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 6.2 Lifting a Horizontal Air Handler FIGURE 15: Lifting a Horizontal Air Handler Filter Section and Options (Model 4024 - 4049) CRANE OR HELICOPTER CABLE LIFTING SLINGS SPREADER BAR END VIEW INLET BURNER FILTER FILTER MIX BOX PLENUM...

  • Page 37: Lifting An Vertical Air Handler

    SECTION 6: L IFTING AN ANDLER IGGING 6.3 Lifting an Vertical Air Handler FIGURE 17: Lifting an Vertical Air Handler (All Models) NOTE: SHEET METAL CHANNEL OR ANGLE IRON FRAME MUST BE ALIGNED ON ALL SECTIONS BASE FRAME WOODEN BLOCKS INLET BASE FRAME Shipping Position:...

  • Page 38: Figure 18: Lifting An Vertical Air Handler With Filter Section And Mixing Box

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 18: Lifting an Vertical Air Handler with Filter Section and Mixing Box LIFTING LUGS LIFTING LUGS SHEETMETAL CHANNEL SHEETMETAL CHANNEL OR ANGLE IRON FRAME OR ANGLE IRON FRAME N & I O N MUST BE ALIGNED ON MUST BE ALIGNED ON I O N...

  • Page 39: Upright Assembly Alignment

    SECTION 6: L IFTING AN ANDLER IGGING 6.4 Upright Assembly Alignment FIGURE 19: Inlet Alignment 5/8 X 2 3/4 THREADED ROD ALIGNMENT PIN APPLY ROPE CAULKING AROUND FAN SECTION INLET FRAME PERIMETER OF FRAME. OR BURNER INLET FRAME WITH 7/8" CLEARANCE HOLE. DETAIL: FMB DISCH./BURNER DISCH.

  • Page 40: Section 7: Air Handler Assembly

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 7: AIR HANDLER ASSEMBLY 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 41: Caulking The Air Handler

    SECTION 7: A ANDLER SSEMBLY 7.1 Caulking the Air Handler FIGURE 20: Caulking Air Handler Joints "A" Type Joint 3/8" x 3/4" STRIP OF CAULKING (PROVIDED BY MANUFACTURER) CAULK AFTER ASSEMBLY HOUSING SKIN HOUSING SKIN (CAULK PROVIDED BY OTHERS) TYPICAL VERTICAL JOINT TYPICAL VERTICAL JOINT CAULK EACH VERTICAL JOINT CAULK EACH VERTICAL EXTERIOR JOINT...

  • Page 42: Caulking A Horizontal Air Handler

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 7.2 Caulking a Horizontal Air Handler FIGURE 21: Caulking a Standard Horizontal Air Handler APPLY 3" (78.7 cm) ROOF TAPE TO ALL NOTE: Failure to properly caulk the air ROOF JOINTS. COMPONENTS MAY handler joints will allow water to VARY AS SHOWN BELOW.

  • Page 43: Caulking An Vertical Air Handler

    SECTION 7: A ANDLER SSEMBLY 7.3 Caulking an Vertical Air Handler FIGURE 22: Caulking a Standard Vertical Air Handler SHEETMETAL CHANNEL OR ANGLE IRON FRAME MUST BE ALIGNED ON ALL SECTIONS. LIFTING LUGS "A" TYPE JOINT: "A" SEAL WITH HEAVY BEAD OF CALUKING Ó...

  • Page 44: Figure 23: Assembling Optional Discharge / Supply And Return Sleeves

    FIGURE 23: Assembling Optional Discharge / Supply and Return Sleeves. NOTE:DISCHARGE AND RETURN AIR SLEEVE'S ARE A OPTION AND CAN BE PURCHASED THRU RAPID, SEE CHART FOR ACTUAL OD OF DUCTS IF BEING BUILT AND INSTALLED BY SERVICE CONTRACTOR. 2" FLANGE ON BOTH ENDS OF DISCHARGE DUCT 3'-4"...

  • Page 45: Accessory Connections

    SECTION 7: A ANDLER SSEMBLY 7.4 Accessory Connections FIGURE 24: Electrically Connecting Joined Sections Filter Burner Inlet Hood Mixbox Section Fan Section LEFT SIDE VIEW NOTE: TYPICALLY 6 THHN CONDUCTORS AND 1 SHIELDED CABLE NOTE: TYPICALLY 2 1/2" CONDUIT TYP. THHN CONDUCTORS AND 1 SHIELDED CONTROL...

  • Page 46: Figure 26: Installing Pressure Transmitter Tubing For Am And Vav

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 26: Installing Pressure Transmitter Tubing for AM and VAV OUTDOOR INSTALLATION INDOOR INSTALLATION PROTECT TUBING OPENING FROM THE WIND. (Installed by others.) BUILDING WALL AIR HANDLER OR ROOF MODUS OUTSIDE AIR DUCT RETURN AIR DAMPER BLADE 5/16"...

  • Page 47: Figure 28: Conductivity Control And Freeze Protection (Evaporative Cooling Package #2)

    SECTION 7: A ANDLER SSEMBLY FIGURE 28: Conductivity Control and Freeze Protection (Evaporative Cooling Package #2) HEADER EVAPORATIVE COOLING MODULE FLOAT VALVE & MAKE-UP CONN. UNION MANUAL SHUT-OFF VALVE CONDUCTIVITY CONTROL OVERFLOW CONN. WATER FLOW ADJUSTMENT VALVE DRAIN CONN. VACUUM BREAKER WATER LEVEL Notes Makeup line must be installed...

  • Page 48: Figure 30: Evaporative Cooling Trap Detail

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 30: Evaporative Cooling Trap Detail 40 of 154...

  • Page 49: Section 8: Roof Curb

    Guard drawing on Page 40, Figure 30. NOTE: Before installation, verify that you have the correct roof curb and all required assembly brackets. If any components are missing, contact Rapid Engineering LLC or your RAPID ® independent *Curb add required only when an inlet plenum is representative.

  • Page 50: Figure 31: Roof Curb

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 31: Roof Curb NOTE: Adapter shown for models 4024 through 4089 horizontal AM, FMB and MUA. 42 of 154...

  • Page 51: Figure 32: Roof Curb Installation

    SECTION 8: R FIGURE 32: Roof Curb Installation DO NOT TWIST OR BEND FRAME 2" LAG BOLT OPTIONAL 4024-4049: 4" UNIT CURB ANGLE 4054-4066: 6" UNIT CURB ANGLE ¥ MODELS 4024-4049: 4 x 2 Sheetmetal Formed Channel ¥ MODEL 4073: 3 x 3 x 3/16 Angle Iron ¥...

  • Page 52: Figure 33: Roof Curb Assembly With Brackets

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 33: Roof Curb Assembly with Brackets 1. Refer to the assembly drawings shipped with the curb. 2. Curb length can vary by options selected. 3. Verify overall assembly dimensions before roofing. DETAIL 1 DETAIL 2 4.

  • Page 53: Figure 34: Duct Support Adapter

    SECTION 8: R FIGURE 34: Duct Support Adapter NOTE: GASKET SPONGE REQUIRED ON TOP SIDE OF FLANGE PERIMETER. MATERIAL TO BE ALUMINIZED 20ga. STEEL B (OD) B (OD) A (OD) A (OD) E (ID) E (ID) F (ID) F (ID) G (ID) G (ID) DETERMINED...

  • Page 54: Section 9: Indoor Suspension Mounting - Horizontal Air Handler

    Threaded rod is provided by others. Minimum threaded rod size is ¾". NOTE: Check to be sure all required components are present. If there are any missing, contact Rapid Engineering LLC or your RAPID ®...

  • Page 55: Figure 35: Indoor Suspension

    4036 NOTES: 1. CONSULT FACTORY FOR DIMENSIONS WHEN USING 4040 A 3V4 OR 4" MANIFOLD. 4044 2. ALL DIMENSIONS & WEIGHTS ARE SUBJECT TO CHANGE WITHOUT NOTICE & SHOULD NOT BE USED FOR 4049 CONSTRUCTION UNLESS CERTIFIED. 4054 3. ACCESSORIES MAY VARY BY INDIVIDUAL ORDER. CONSULT FACTORY 4060 FOR ADDITIONAL INFORMATION.

  • Page 56: Section 10: Leg Mounting

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 10: LEG 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 57: Figure 36: Assembling Legs For Horizontal Air Handlers

    SECTION 10: L OUNTING FIGURE 36: Assembling Legs for Horizontal Air Handlers RIGHT ACCESS CONTROLS DOOR A I R CURB ANGLE 1/2"x 1-5/8" SLOTTED HOLES MANUFACTURER PROVIDES FOR EACH LEG: FOR MODEL 4024-4066 CORNER SUPPORT LEGS (12) - 3/8 X 1" BOLTS 4 - REQUIRED (12) - 3/8 FLANGE NUTS (12) - 3/8 FLAT WASHERS...

  • Page 58: Figure 37: Assembly Legs And Rainskirt For Upright Air Handlers

    DIMENSION A TOP AND BOTTOM PLATES OPTIONAL NOTE - BOLT ON OUTSIDE OF LEG SECTION (s) RAPID PROVIDES FOR EACH LEG (12) - 3/8 X 1" BOLTS (8) - 3/8 FLANGE NUTS STANDARD LEG SIZES (12) - 3/8 WASHERS DIM. A 24"...

  • Page 59: Section 11: Filter Section

    All filter sections are shipped assembled. Models 4024-4049 ship attached to the base unit. Models 4054- 4089 shipped loose and required field assembly to base unit. NOTE: Check to be sure that all required components are present. If any are missing, contact Rapid Engineering LLC or your RAPID ®...

  • Page 60: Section 12: Inlet Hoods

    Failure to follow these instructions can result in death, injury or property damage. Inlet hoods are shipped unassembled and must be assembled prior to installation. NOTE: Check to be sure that all required components are present. If any are missing, contact Rapid Engineering LLC or your RAPID ®...

  • Page 61: Figure 40: Inlet Hood Without Filters (4054-4089)

    (2) All parts mounted to inlet end to be attached with 3/8" bolt and flat washers. Rapid recommends assembling (3) All other parts bolted together inlet hood parts to the air with 5/16" bolts, flat washer, handler in the following and lock nut.

  • Page 62: Figure 42: Inlet Hood With Moisture Limiter

    9. Seal all joints of inlet hood and perimeter of mist eliminator to inlet hood 100% with caulking. NOTE: 1. Inlet hood framing side (item #2) not shown. 2. All dimensions are in inches. Model 4024 4036 4040 4044 4049 4054 4060 4066 4073 4080/4089 Quantity of...

  • Page 63: Section 13: Service Platform

    SECTION 13: S ERVICE LATFORM SECTION 13: SERVICE PLATFORM 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 64: Figure 44: Service Platform For A Horizontal Air Handler

    NSTALLATION PERATION AND ERVICE ANUAL FIGURE 44: Service Platform for a Horizontal Air Handler SIDE RAILING 4 PCS ASSEMBLY SPLICE LOCATED ON 4044-4089 MODELS ONLY SUPPORT CHANNEL SIDE RAILING FIELD ASSEMBLY FIELD JOINT WHEN REQUIRED HOLES FOR 3/8" BOLTS SUPPORT ROD HOLES...

  • Page 65: Section 14: Discharge Accessories

    SECTION 14: D ISCHARGE ACCESSORIES SECTION 14: DISCHARGE ACCESSORIES 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 66: Figure 45: Vertical Air Handler With Duct Sleeves And Discharge Head

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 45: Vertical Air Handler with Duct Sleeves and Discharge Head DETAIL B DETAIL A SUPPORT BY OTHERS AIR HANDLER DETAIL C ALTERNATE SUPPORT BY 1/4-20 x 1" BOLTS OTHERS (12" O.C.) 2" DISCHARGE HEAD (SUPPLY AIR AND...

  • Page 67: Figure 46: One-Way Discharge Head

    Model DETAIL A 4024 24.25 33.25 TYPICAL ASSEMBLY 4036 29.25 51.25 END VIEW RIGHT SIDE VIEW 2” 4040 37.25 54.25 AIR HANDLER 4044 40.25 60.25 HOUSING 4049 43.25 67.25 SELF TAPPING 4054 47.25 76.25 DISCHARGE SCREWS HEAD 4060 52.25 85.25 4066 54.25...

  • Page 68: Figure 47: Three-Way Discharge Head

    FIGURE 47: Three-Way Discharge Head (TYPICAL) PLAN VIEW Model 4024 24.4 20.3 29.3 SIDE VIEW 4036 29.4 25.3 47.3 4040 37.4 33.3 50.3 4044 40.4 36.3 56.3 4049 43.4 39.3 63.3 4054 47.4 43.3 72.3 4060 52.4 48.3 81.3 4066 54.4...

  • Page 69: Figure 48: Four-Way Discharge Head

    4066 96 104 58 54.3 95.3 4073 96 112 58 54.3 103.3 4080 112 131 58 64.3 120.3 AIR HANDLER DUCT 4089 112 131 58 64.3 120.3 NOT SUPPLIED BY 12" RAPID ENGINEERING LLC. 12" TYPICAL TYPICAL 61 of 154...
  • Page 70 32 1/4 4 7/8 5 3/8 32 x 47 4040 33 1/4 35 1/4 5 7/8 6 3/8 35 x 50 4044 36 1/4 35 1/4 5 7/8 6 3/8 35 x 56 4049 39 1/4 40 1/4 5 7/8...

  • Page 71: Splash Plate Installation

    SUPPORT RODS (BY OTHERS) DISCHARGE PLATE 2” TYPICAL 2” 1¾” TYPICAL 4 CORNERS CENTER HOLES ON 60 THRU 89 ” HOLES Weight Model (min.) (max.) (lbs) 4024 4036 4040 4044 4049 4054 4060 4066 4073 4080 4089 63 of 154...

  • Page 72: Section 15: Vibration Isolation

    VENDOR # 29875 4024 RH – 2, GRAY 20888 RH – 3, GREEN 4036 20888 4040 RH – 3, GREEN 4044 RH – 3, GRAY 20817 4049 20817 RH – 3, GRAY 4054 46212 RH – 4, GREEN 4060 46212 RH –...

  • Page 73: Figure 52: Curb Mounted

    SECTION 15: V IBRATION SOLATION FIGURE 52: Curb Mounted Roof Curb Roof Curb 65 of 154...

  • Page 74: Figure 53: Platform Mounting On Vibration Isolators

    REQ’D FOR VENDOR # MODEL 4024 R – 3, RED 4036 R – 3, GREEN 4040 R – 3, GREEN 4044 R – 3, GRAY D = DIA. 4049 R – 3, GRAY 2 PL. 4054 R – 4, BLACK 4060 R –...

  • Page 75: Figure 54: Vibration Isolation Platform Locations

    37 3/8 NOTE: ALL DIMENSIONS AND WEIGHTS 4036 55 3/8 ARE SUBJECT TO CHANGE 4040 60 3/8 WITHOUT NOTICE AND SHOULD 66 3/8 4044 NOT BE USED FOR CONSTRUCTION 4049 73 3/8 UNLESS CERTIFIED. 4054 82 3/8 NOTE: 4060 91 3/8...

  • Page 76: Section 16: Cooling Specifications

    5-6 Air Changes per NOTE: Moisture limiter pressure drop is added for Hour (AC/Hr) for the entire volume. This will vary by face velocities greater than 600 Feet per Minute application. (FPM). Rapid Engineering LLC's standard media thickness equals 12". 68 of 154...

  • Page 77: Section 17: Duct Considerations

    SECTION 17: D ONSIDERATIONS SECTION 17: DUCT CONSIDERATIONS The air handler is not designed to support the weight WARNING of ductwork. Ductwork must be constructed in a fashion that is self-supporting. Ductwork should be straight, elbows should be minimal and any transitions should be gradual.

  • Page 78: Section 18: Gas Piping

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 18: GAS PIPING Minimum gas pressure as indicated on data plate must be measured with the burner operating in high WARNING fire. Minimum inlet gas pressure is determined by gas train size and BTU/h rating. Explosion Hazard Leak test all components of gas piping before operation.

  • Page 79: Table 27: Manifold Component Identification

    SECTION 18: G IPING Table 27: Manifold Component Identification Item Component Identification Leg Trap (by others) Lockable Manual Shut-Off Valve (by others) High Gas Pressure Regulator (by others) if gas pressure is over 5 P.S.I. Pilot Gas Cock Primary Safety Shut Off Valve and Actuator Vent Valve and Piping Block Valve and Actuator Plug Cock...

  • Page 80: Figure 56: Fm Gas Manifold

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 56: FM Gas Manifold ALTERNATE VENT OUTSIDE INLET VENT LIMITER INLET * INTEGRAL VENT LIMITER * INTEGRAL VENT LIMITER BY OTHERS VENT LIMITER ALL VENT PIPING TO OUTSIDE BY OTHERS BY OTHERS 72 of 154...

  • Page 81: Figure 57: Xl Insurance Gas Manifold

    SECTION 18: G IPING FIGURE 57: XL Insurance Gas Manifold ALTERNATE INLET VENT OUTSIDE VENT LIMITER VENT OUTSIDE INLET * INTEGRAL VENT LIMITER * INTEGRAL VENT LIMITER BY OTHERS VENT LIMITER BY OTHERS ALL VENT PIPING TO OUTSIDE BY OTHERS 73 of 154...

  • Page 82: Gas Piping

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 18.3 Gas Piping The gas manifold connection extends through the side of the control enclosure for vertical equipment and through the bottom for horizontal equipment. The factory piping terminates with a male pipe connection in the primary gas valve.

  • Page 83: Section 19: Electrical

    SECTION 19: E LECTRICAL SECTION 19: 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 84: Disconnect Fuse Sizing

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.1 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 85: Control Current Draw

    Rapid Engineering LLC. Refer to Page 81, Table 31 for a brief description of each On the low gas pressure switch side, this switch safety device, its location and its switching voltage.
  • Page 86 If a pilot flame is not present, the electrical signal cannot be sent and the pilot burner gas valve will ® Your Rapid direct fired air handler was built custom close. The relay is equipped with a 10-second trial for to meet your needs.

  • Page 87: Interlocks

    SECTION 19: E LECTRICAL 19.7 Interlocks setpoint, after the 5 minute establishing period, the air handler fan will be turned off. If there is a failure of 19.7.1 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 88 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.8.9 Service Receptacle Powered by Others (Wired) This option provides a service receptacle. It includes ground-fault interrupter (GFI) receptacle mounted on the interior or exterior of the control enclosure. Power to the receptacle is supplied by the installer. 19.8.10 Room Override Stat For use with Standard Discharge Control remote.

  • Page 89: Safety Systems

    Rapid Engineering LLC. Refer to Page 81, Table 31 for a brief description of each safety device, its location and its switching voltage.

  • Page 90: Remote Panels

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.10 Remote Panels 19.10.1 Basic Remote FIGURE 58: Basic Remote MOTOR FLA TAKEN FROM N.E.C FEEDER PROTECTION POWER SUPPLY SIZING BY OTHERS. REFER TO NAMEPLATE FOR ACTUAL FLA ____V___PH___HZ REF: N.E.C. TABLE 430-152 35.1 ____FLA DISC SW...

  • Page 91: Figure 59: Basic Remote (Continued)

    SECTION 19: E LECTRICAL FIGURE 59: Basic Remote (Continued) IGNITION TRANSFORMER FLAME RELAY SOL.-1 PILOT VALVE SOLENOID SOL.-2 VENT VALVE PRIMARY SHUT-OFF VALVE BURNER ON FR-1 VALVES OPEN LOW VOLTAGE AMPLIFIER 40VA TRANSFORMER 3 2 1 24VAC SERIES 14A BASIC REMOTE 83 of 154...

  • Page 92: Figure 60: Standard Discharge Remote

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.10.2 Standard Discharge Control Remote FIGURE 60: Standard Discharge Remote MOTOR FLA TAKEN FROM N.E.C FEEDER PROTECTION POWER SUPPLY SIZING BY OTHERS. REFER TO NAMEPLATE FOR ACTUAL FLA ____V___PH___HZ REF: N.E.C. TABLE 430-250 15.1 ____FLA DISC SW...

  • Page 93: Figure 61: Standard Discharge Remote (Continued)

    SECTION 19: E LECTRICAL FIGURE 61: Standard Discharge Remote (Continued) IGNITION TRANSFORMER FLAME RELAY SOL.-1 PILOT VALVE SOLENOID PRIMARY SHUT-OFF VALVE LT-2 BURNER ON FR-1 VALVES OPEN LOW VOLTAGE AMPLIFIER TRANSFORMER 3 2 1 24VAC 85 of 154...

  • Page 94: Figure 62: Deluxe Room Control Remote

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.10.3 Deluxe Room Control Remote FIGURE 62: Deluxe Room Control Remote MOTOR FLA TAKEN FROM N.E.C FEEDER PROTECTION POWER SUPPLY SIZING BY OTHERS. REFER TO NAMEPLATE FOR ACTUAL FLA ____V___PH___HZ REF: N.E.C. TABLE 430-250 22.1 ____FLA DISC SW...

  • Page 95: Figure 63: Deluxe Room Control Remote (Continued)

    SECTION 19: E LECTRICAL FIGURE 63: Deluxe Room Control Remote (Continued) IGNITION TRANSFORMER FLAME RELAY SOL.-1 PILOT VALVE SOLENOID PRIMARY SHUT-OFF VALVE LT-2 BURNER ON FR-1 VALVES OPEN LOW VOLTAGE AMPLIFIER TRANSFORMER 3 2 1 24VAC 87 of 154...

  • Page 96: Figure 64: Standard Room Control Remote

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.10.4 Standard Room Control Remote FIGURE 64: Standard Room Control Remote MOTOR FLA TAKEN FROM N.E.C FEEDER PROTECTION POWER SUPPLY SIZING BY OTHERS. REFER TO NAMEPLATE FOR ACTUAL FLA ____V___PH___HZ REF: N.E.C. TABLE 430-250 79.7 ____FLA M1 OL...

  • Page 97: Figure 65: Standard Room Control Remote (Continued)

    SECTION 19: E LECTRICAL FIGURE 65: Standard Room Control Remote (Continued) IGNITION TRANSFORMER FLAME RELAY SOL.-1 PILOT VALVE SOLENOID SOV1 PRIMARY SHUT-OFF VALVE LT-2 BURNER ON SOV2 FR-1 VALVES OPEN LOW VOLTAGE AMPLIFIER TRANSFORMER 3 2 1 24VAC 89 of 154...

  • Page 98: Ddc-Ready Controls

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.11 DDC-Ready Controls FIGURE 66: DDC-Ready Controls MOTOR FLA TAKEN FROM N.E.C FEEDER PROTECTION POWER SUPPLY SIZING BY OTHERS. REFER TO NAMEPLATE FOR ACTUAL FLA ____V___PH___HZ REF: N.E.C. TABLE 430-152 29.7 ____FLA DISC SW M1 OL SUPPLY FAN MOTOR...

  • Page 99: Figure 67: Ddc-Ready Controls (Continued)

    SECTION 19: E LECTRICAL FIGURE 67: DDC-Ready Controls (Continued) HIGH HIGH TEMP AIRFLOW GAS PRS. GAS PRS. LIMIT AFS1 SWITCH SWITCH PS-2 PS-1 SAFETIES MANUAL MANUAL RESET MANUAL RESET AIRFLOW RESET AFS2 OA STAT TH-2 FR-1 RM7897C JUMPER IGNITION TRANSFORMER BURNER FAILURE CR67 RELAY...

  • Page 100: Intelligent Control Systems

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL Your RAPID ® Air Handler may be equipped with one of the following DDC control offerings. If so, a separate manual providing wiring, operation and trouble shooting information, specific to that control offering, will also accompany this document.

  • Page 101: Figure 68: Air Handler Styles

    SECTION 19: E LECTRICAL FIGURE 68: Air Handler Styles MUA - MAKE UP AIR (All Models) FR - FIXED RETURN (All Models) Optional Motorized Inlet Damper Optional Motorized Inlet Damper Outside Air Bottom Bottom Bottom Return Air Discharge Discharge 100% Return Outside Air AM -AIR MANAGEMENT (All Models)

  • Page 102: Hvac Remote Panels And Panel Options

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.13 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 103 SECTION 19: E LECTRICAL to maintain the space temperature set on the 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.

  • Page 104: Basic Air Handler Sequence Of Operation

    Discharge temperature must be shut off and turned back on. monitoring and modulation valve adjustment are completed by the customer supplied control system. For optimum efficiency, Rapid Engineering LLC FIGURE 69: Fireye ® M4RT1 suggests to limit the discharge temperature to 160 °F.
  • Page 105 SECTION 19: E LECTRICAL Operating Control - This indicator is on when • This lasts for 10 seconds. This cycle is called trial power is present at terminals #1 and #7 of the for ignition. During this time period, the PTFI LED flame safeguard.

  • Page 106: Table 33: Jumper Settings

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL The M4RT1 has a series of 8 jumpers that are used to configure the Purge timing, Pilot Trial for Ignition Timed pre-purge (PTFI) timing, and recycle or non-recycle operation. This must be a separate purge from the rest of See Page 98, Figure 70.
  • Page 107 SECTION 19: E LECTRICAL 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 108: Honeywell Rm7890 Flame Safeguard

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 19.15 Honeywell ® RM7890 Flame Safeguard 100 of 154...
  • Page 109 SECTION 19: E LECTRICAL 101 of 154...
  • Page 110 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 102 of 154...
  • Page 111 SECTION 19: E LECTRICAL 103 of 154...
  • Page 112 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 104 of 154...
  • Page 113 SECTION 19: E LECTRICAL 105 of 154...
  • Page 114 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 106 of 154...
  • Page 115 SECTION 19: E LECTRICAL 107 of 154...
  • Page 116 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 108 of 154...
  • Page 117 SECTION 19: E LECTRICAL 109 of 154...
  • Page 118 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 110 of 154...
  • Page 119 SECTION 19: E LECTRICAL 111 of 154...

  • Page 120: Section 20: Direct Fired Burner

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 20: 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 121: Figure 71: Midco Hma-2A Burner

    SECTION 20: D IRECT IRED URNER FIGURE 71: Midco HMA-2A Burner 113 of 154...
  • Page 122 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 114 of 154...

  • Page 123: 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 124: Direct Fired Burner Flame Proving (Flame Rod)

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 20.2 Direct Fired Burner Flame Proving (Flame Figure 72. Rod) NOTE: For the flame rod to produce this signal its The flame rod in the burner is constructed of a position in relation to the grounding rod, pilot and material that produces a signal when heated.
  • Page 125 SECTION 20: D IRECT IRED URNER 117 of 154...
  • Page 126 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 118 of 154...

  • Page 127: Honeywell Uv Flame Detector

    SECTION 20: D IRECT IRED URNER 20.3 Honeywell UV Flame Detector 119 of 154...

  • Page 128: Honeywell Uv Flame Detector (Continued)

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 20.4 Honeywell UV Flame Detector (Continued) 120 of 154...

  • Page 129: Section 21: Start-Up Procedures

    SECTION 21: S TART ROCEDURES SECTION 21: 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 130: 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 131: Electrical

    SECTION 21: S TART ROCEDURES 21.2.2 Belt Tension 21.3 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 132: Gas Piping And Initial Pressure Settings

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL adjustment. 21.5 Gas Piping and Initial Pressure Settings Perform a pressure test on all gas supply lines to the air handler per applicable codes. Table 35: Motor Sheave Drive Torque Make sure to isolate all gas controls before Specifications pressure testing the system.

  • Page 133: Table 37: Burner Mode By Amplifier Type

    SECTION 21: S TART ROCEDURES 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 134: Safety Shut Off Valve Check

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 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...

  • Page 135: Figure 77: Mr 212 Valve

    SECTION 21: S TART ROCEDURES FIGURE 77: 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) 127 of 154...

  • Page 136: Figure 78: M611 Valve

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 78: M611 Valve NOTE: Modulating only. Gas Inlet Low Fire Adjustment Gas Outlet (under cap) FIGURE 79: 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 137: Section 22: Maintenance

    SECTION 22: M AINTENANCE SECTION 22: 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 138: 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 139 SECTION 22: M AINTENANCE 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. Bottom of groove should show no signs of belt contact.

  • Page 140: Manifold And Controls

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 22.4 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 141: Table 39: Motor Lubrication Intervals

    Using the instructions for lubrication, open grease outlet and purge the sys- tem as much as possible of the old or unwanted grease. Repeat this same operation after 1 week of service. Consult Rapid Engineering LLC or the motor manufacturer for further rec- ommendations on grease compatibility.

  • Page 142: 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...

  • Page 143: Section 23: Replacement Parts

    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...

  • Page 144: Section 24: Troubleshooting

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL SECTION 24: 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 145: Initial Checks

    SECTION 24: T ROUBLESHOOTING 24.1 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 146: Burner

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 24.3 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 Low airflow pressure switch contacts not made.

  • Page 147: Temperature Controls

    SECTION 24: T ROUBLESHOOTING 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 148: A1014 Amplifier - Field Checklist

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 24.5 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 149 SECTION 24: 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 150: Figure 80: Rm7897C Flame Control

    4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL FIGURE 80: RM7897C Flame Control LINE VOLTAGE ALARM MASTER SWITCH BURNER CONTROLLER / LIMITS RUNNING INTERLOCK (INC. AIRFLOW SWITCH) 10SEC. INTERUPTED PILOT / IGNITION MAIN VALVE PRE-IGNITION INTERLOCK IGNITION FLAME DETECTOR Initiate Pilot Flame Main Flame (Initial Prepurge...

  • Page 151: Section 25: Rapid

    Field start-up should be performed by a qualified technician. The technician is responsible for assuring that all of the items on this checklist are properly installed and operating. Upon completion, a copy of this form should be returned to Rapid Engineering LLC using the contact information listed in the header. WARNING...
  • Page 152 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL C. General Inspection- Burner Inspection __ No obstructions to the burner. __ Spark igniter is secured and tight. __ UV scanner is secured and finger tight. Comments ___________________________________________________________________________ D. General Inspection- Temperature Control Operation __ For conventional controls, temperature sensor wiring is shielded cable or standard wiring in a separate circuit.
  • Page 153 SECTION 25: RAPID ® 4000-S ERIES TART ROCEDURES G. Operational Checks- Fan Operation __ Fan rotation is correct. (See rotation sticker in the unit.) __ Check and record the following: Volts (Fan Off) Phase 1-2 ___ Phase 2-3 ___ Phase 1-3 ___...
  • Page 154 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL I. Operational Checks: Temperature Control Operation, Conventional Controls Minimum discharge air temp setpoint (°F) __________________________________________________ Maximum discharge air temp setpoint (°F) __________________________________________________ ___ Low temperature limit switch opens. ___ All circuit check lights illuminate properly. ___ The time clock controls operate properly (if applicable).
  • Page 155 SECTION 25: RAPID ® 4000-S ERIES TART ROCEDURES L. Operational Checks: Special Controls (List any other special controls specific to this air handler.) Comments ___________________________________________________________________________ M. Operational Checks: Miscellaneous ___ Documentation (Installation, Operation and Service Manual and electrical prints) inside the main control panel.

  • Page 156: Section 26: Rapid

    Field start-up should be performed by a qualified technician. The technician is responsible for assuring that all of the items on this checklist are properly installed and operating. Upon completion, a copy of this form should be returned to Rapid Engineering LLC using the contact information listed in the header WARNING...
  • Page 157 SECTION 26: RAPID ® 4000-S ERIES TART ROCEDURES VAPORATIVE OOLER D. Conductivity Control (Control Package #2) A conductivity controller monitors the electrical conductance of the cooling water. If the conductivity of the cooling water exceeds the front panel setpoint, the controller activates a "blowdown" process. During this process, some of the highly conductive water is drained from the sump and fresh water is added to dilute the concentrated water.
  • Page 158 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL APPENDIX I: BURNER FIRING RATE CALIBRATION High fire adjustments NOTE: THE MODULATING/REGULATOR VALVE IS LOCATED ON THE GAS TRAIN. SEE GAS TRAIN DRAWING FOR LOCATION OF VALVE. In order to set the High Fire gas pressure correctly, three terms must be understood. They are: 1.

  • Page 159: Section 27: 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: +1.616.784.0500...
  • Page 160 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 152 of 154...
  • Page 161 SECTION 27: T RAPID ® 4000-S ERIES ARRANTY 153 of 154...
  • Page 162 4000-S ERIES NSTALLATION PERATION AND ERVICE ANUAL 154 of 154...

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