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Rapid 2010B manual available for free PDF download: Installation, Operation & Service Manual
Rapid 2010B Installation, Operation & Service Manual (162 pages)
Direct, Gas-Fired, Industrial Air Handler
Brand:
Rapid
| Category:
Air Handlers
| Size: 9.26 MB
Table of Contents
Table of Contents
5
Table of Contents
11
SECTION 1: Air Handler Safety
11
Description of Operation
11
Inspection and Setup
11
Safety Labels and Their Placement
12
California Proposition 65
12
Label Placement
13
Figure 1: 2005
13
Figure 2: 2010 and 2010B
13
Figure 3: 2020 and 2030
14
Figure 4: 2000-Series Interior
15
SECTION 2: Installer Responsibility
16
Wall Tag
16
Corrosive Chemicals
16
National Standards and Applicable Codes
17
Required Equipment
17
SECTION 3: Critical Considerations
18
Required Clearances to Combustibles
18
Purge of Supply Duct
19
Hardware
19
Table 1: Recommended Torque Settings
19
SECTION 4: National Standards and Applicable Codes
20
Gas Codes
20
Installation Codes
20
Aircraft Hangars
20
Parking Structures and Repair Garages
20
Electrical
20
Venting
20
High Altitude
20
SECTION 5: Specifications
21
Figure 5: 2005 Upright Model Dimensions
21
Table 2: 2005 Dimensions
21
Figure 6: 2005 Horizontal Model Dimensions
22
Table 3: 2005 Weights
22
Table 4: Motor Weights
22
Figure 7: 2010, 2010B, 2020 and 2030 Upright Model Dimensions
23
Table 5: 2010, 2010B, 2020 and 2030 Dimensions
23
Figure 8: 2010, 2010B, 2020 and 2030 Horizontal Model Dimensions
24
Table 6: 2010, 2010B, 2020 and 2030 Weights
24
Table 7: Motor Weights
24
Table 8: 2000-Series Selection Guide
25
Table 9: Estimated Pressure Drop of Accessory Components
26
SECTION 6: Lifting an Air Handler
27
Lifting an Air Handler
27
Figure 9: Lifting a Horizontal Air Handler
27
Figure 10: Lifting an Upright Air Handler (2005 - 2030)
28
SECTION 7: Roof Curb
29
Roof Curb Assembly and Installation
29
Air Handler Mounting to Roof Curb
30
Figure 11: Roof Curb Assembly
30
Figure 12: Curb Mounting
31
SECTION 8: Upright Stand
32
Upright Stand Installation
32
Attaching Air Handler to Stand
32
Figure 13: Upright Stand Detail (2005)
32
Figure 14: Upright Stand Detail (2010 - 2030)
32
Figure 15: Stand Shim (2010B - 2030)
33
Figure 16: Upright Stand Mounting Detail
33
SECTION 9: Legs
34
Leg Mounting
34
Leg Mounting - Horizontal Air Handler (2005 - 2030)
34
Figure 17: Leg Mounting Holes (2005 - 2030)
34
Figure 18: Stud Positioning
35
Figure 19: Leg Bolt Detail
35
SECTION 10: Indoor Suspension Mounting - Horizontal Air Handler
36
Suspension Kit Assembly and Installation
36
Figure 20: Indoor Suspension (2005)
37
Figure 21: Indoor Suspension (2010 and 2010B)
38
SECTION 11: Filter Section
39
Filter Section (2005)
39
Filter Section Assembly (2010 and 2010B)
40
Filter Section Assembly (2020 and 2030)
44
Filter Section Support Assembly
51
Figure 22: Filter Section Support Assembly
52
Filter Section Installation - Horizontal Air Handlers
53
Filter Section Installation - Upright Air Handlers
53
Figure 23: Filter Section Installation on Horizontal Air Handler (2010 - 2030)
53
SECTION 12: Inlet Hood
54
Inlet Hood Assembly (2005)
54
Figure 24: Inlet Hood Assembly (2005)
54
Inlet Hood Assembly (2010 and 2010B)
55
Inlet Hood Assembly (2020 and 2030)
64
Inlet Hood Installation
74
Figure 25: Inlet Hood Positioning
74
SECTION 13: Dampers
75
Discharge Damper
76
Figure 26: Motorized Discharge Damper (2005 - 2030)
76
Inlet Damper
77
Figure 27: Motorized Inlet Damper (2005 - 2010B)
77
Figure 28: Motorized Inlet Damper (2020 and 2030)
78
SECTION 14: Discharge Heads and Splash Plates
79
One-Way and Three-Way Discharge Head Installation
79
Figure 29: Three-Way Discharge Head (2005 - 2030)
79
Splash Plate Installation
80
Figure 30: Splash Plate
80
Figure 31: Hole Location (2005 - 2030)
81
SECTION 15: Duct Considerations
82
Inlet Duct Work
82
Return Duct Work
82
Discharge Duct Work
82
Table 10: Minimum Recommended Duct Size
83
Table 11: Discharge Duct Size Recommendations to Connect to Heater (for BD/RD)
83
SECTION 16: Gas Piping
84
Gas Manifolds
84
Gas Piping and Pressures
84
Gas Manifold Venting
84
Table 12: Gas Manifold Size
84
Figure 32: ANSI/FM/XL-Compliant Manifolds (2005)
85
Figure 33: ANSI-Compliant Manifold (2010 - 2030)
85
Figure 34: FM-Compliant Manifold (2010 - 2030)
86
Figure 35: XL-Compliant Manifold (2010 - 2030)
86
Gas Piping
87
Pressure Test Ports
87
Line Pressure Test - Leak Testing
87
Figure 36: Plug Tapping (2005)
87
Figure 37: Plug Tapping (2010 - 2030)
87
SECTION 17: Electrical
88
Wiring and Electrical Connections
88
Remote Panel
88
Motor Current Draw
88
Control Current Draw
88
Safety Systems
88
Table 13: Control Voltage Wiring for All Control Systems
88
Table 14: Full Load Current Draw
89
Table 15: Safety Systems
89
Figure 38: Wiring Diagram Key
90
Figure 39: Basic Remote Wiring Diagram (2005)
91
Figure 40: Standard Discharge Control Remote (SDC) Wiring
92
Figure 41: Deluxe Temperature Control Remote (DTC) Wiring
93
Figure 42: Basic Remote Wiring Diagram (2010 - 2030)
94
Figure 43: Standard Discharge Control Remote (SDC) Wiring Diagram (2010 - 2030)
95
Figure 44: Deluxe Temperature Control Remote (DTC) Wiring Diagram (2010 - 2030)
96
Figure 45: BMS-Ready Control MUA Style (2005)
97
Figure 46: BMS-Ready Control MUA/FR Style Units (2010 - 2030)
98
Additional Control Wiring
100
Figure 48: Additional Control Wiring for VAV Style (2010 and 2010B)
100
Figure 49: Additional Control Wiring for VAV Style (2020 - 2030)
101
Figure 50: BMS-Ready Control for VAV Style (2010 and 2010B)
102
Figure 51: BMS-Ready Control for VAV Style (2020 - 2030)
103
Figure 52: BMS-Ready Control for VAV Style with Inlet Damper (2020 - 2030)
104
Figure 53: Additional Control Wiring for VAV Style with Inlet Damper (2020 - 2030)
105
Figure 54: am Style for 2010 and 2010B
106
Figure 55: am Style for 2020 - 2030
106
Carbon Dioxide Interlocks
107
Control Options
107
Figure 56: CO2 Sensor Interlock for FR and MUA Style
107
Figure 57: CO2 Sensor Interlock for am and VAV Style (2010 and 2010B)
107
Figure 58: CO2 Sensor Interlock for am and VAV Style (2020 and 2030)
107
Figure 59: CO Sensor Interlock for FR and MUA
108
Figure 60: CO Sensor Interlock for am and VAV
108
Figure 61: CO Sensor Interlock for am and VAV with Photohelic
108
Figure 62: CO Sensor Interlock for am with Building Pressure
108
Optional Exhaust Motor Starters, Variable Frequency Drives
113
Figure 63: J-1000 1 Pot 7.5HP or Less
113
Figure 64: V-1000 1 Pot 10-25HP
113
Figure 65: P7 1 Pot 30HP or more
114
Figure 66: J-1000 VFD 7.5HP or Less with Photohelic
114
Figure 67: V-1000 VFD 10 to 25HP with Photohelic
115
Disconnect Fuse Sizing
116
Figure 68: P7 30HP or more with Photohelic
116
Table 16: Minimum and Maximum Fuse Size by Motor Size and Supply Voltage
116
Figure 69: Single Exhaust Starter
117
Figure 70: Two Exhaust Starter
117
SECTION 18: Sequence of Operation
118
Air Handler Configuration
118
Figure 71: Air Handler Styles
119
Table 17: Configuration Chart
119
HVAC Remote Panels and Panel Options
120
Basic Air Handler Sequence of Operation
122
Figure 72: Honeywell Safeguard Jumpers
122
Table 18: Factory Preset Schedule on TH8110 Thermostat
122
Table 19: Site-Configuration Jumper Options
122
Figure 73: S8600 Flame Control (2005)
123
Figure 74: RM7890 Flame Control (2010 and 2010B)
124
Figure 75: RM7897 Flame Control (2020 - 2030)
125
SECTION 19: Start-Up Procedures
126
Installation of Recirculating Air Handler
127
Mechanical
127
Figure 76: Sheave Alignment
127
Electrical
128
Airflow
128
Figure 77: Belt Tension
128
Table 20: Deflection Force B and BX Belts (in Lbs)
128
Gas Piping and Initial Pressure Settings
129
Figure 78: Honeywell Flame Module
129
Table 21: Motor Sheave Drive Torque Specifications
129
Table 22: Motor and Blower Bushing Torque Specifications
129
Safety Shut off Valve Check
131
Temperature Control System Calibration
131
Table 23: Burner Mode by Amplifier Type
131
Table 24: Maximum Temperature Rise
131
Figure 79: MR 212 Valve (2010 - 2030)
132
Figure 80: M611 Valve (2005)
133
Figure 81: Regulator (2005)
133
SECTION 20: Maintenance
134
General
135
Unit Exterior
135
Blower Section
135
Table 25: Motor Lubrication Intervals
137
Manifold and Controls
138
Burner
138
Figure 82: 6" (15.3 CM) Straight Cast Iron
139
Figure 83: 12" (30.5 CM) Straight Cast Iron
139
Figure 84: 12" (30.5 CM) Tee Cast Iron
139
Table 26: Burner Selections
139
Optional Equipment
140
SECTION 21: Replacement Parts
141
Figure 85: Control Panel Layouts
141
Figure 86: Power Panel Layout
142
Table 27: Control Panel
142
Table 28: Power Panel
143
Figure 87: Blower Layout
144
Table 29: Manifold Components
144
Table 30: Blower
144
Table 31: Remote Panel
145
Table 32: V-Belt
145
SECTION 22: Troubleshooting
146
Initial Checks
147
Motor and Blower
147
Burner
148
Temperature Controls
149
A1014 Amplifier - Field Checklist
150
A44 Amplifier - Field Service Checklist
152
SECTION 23: RAPID ® 2000-Series Start-Up Procedures
155
SECTION 24: the RAPID ® 2000-Series Warranty
157
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