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Rapid 4060 manual available for free PDF download: Installation, Operation & Service Manual
Rapid 4060 Installation, Operation & Service Manual (162 pages)
Rapid 4000 Series Direct-Fired Air Handler
Brand:
Rapid
| Category:
Air Handlers
| Size: 9.81 MB
Table of Contents
Table of Contents
3
Table of Contents
9
SECTION 1: Air Handler Safety
9
Description of Operation
9
Inspection and Setup
9
Temporary Storage
10
Safety Labels and Their Placement
10
California Proposition 65
10
Label Placement
11
Figure 1: 4024 - 4049
11
Figure 2: 4054 and 4089
12
Figure 3: 4000-Series Interior
13
SECTION 2: Installer Responsibility
14
Corrosive Chemicals
14
National Standards and Applicable Codes
14
Required Equipment
14
SECTION 3: Critical Considerations
16
Required Clearances to Combustibles
16
Hardware
16
Table 1: Recommended Torque Settings
16
SECTION 4: National Standards and Applicable Codes
17
Gas Codes
17
Installation Codes
17
Aircraft Hangars
17
Parking Structures and Repair Garages
17
Electrical
17
Venting
17
High Altitude
17
SECTION 5: Specifications
18
Table 2: 4000 am Dimensions
19
Figure 4: 4000 am Vertical Model Dimensions
19
Table 3: 4000 am Approximate Shipping Weights
20
Figure 5: 4000 am Horizontal Model Dimensions
20
Table 4: 4000 MUA Dimensions
21
Figure 6: 4000 MUA Vertical Model Dimensions
21
Table 5: 4000 MUA Approximate Shipping Weights
22
Figure 7: 4000 MUA Horizontal Model Dimensions
22
Table 6: 4000 FR Dimensions
23
Figure 8: 4000 FR Vertical Model Dimensions
23
Table 7: 4000 FR Approximate Shipping Weights
24
Figure 9: 4000 FR Horizontal Model Dimensions
24
Table 8: 4000 VAV Dimensions
25
Figure 10: 4000 VAV Vertical Model Dimensions
25
Table 9: 4000 VAV Approximate Shipping Weights
26
Figure 11: 4000 VAV Horizontal Model Dimensions
26
Table 10: Dimensions
27
Table 11: Leaving Dry Bulb Temperature Drop (Average)
27
Figure 12: Evaporative Cooling
27
Table 12: Air Density Ratio
28
Table 13: Dimensions
29
Table 14: Estimated Tons of Cooling
29
Figure 13: Mechanical Cooling
29
Table 15: Dimensions
30
Figure 14: Energy Recovery
30
Table 16: Energy Recovery
31
Table 17: Fan Selection Chart
32
Table 18: Fan Selection Chart (Continued)
33
Table 19: Static Pressure Drops for Options
34
SECTION 6: Lifting an Air Handler (Rigging)
35
Preparing to Lift the Air Handler
35
Lifting a Horizontal Air Handler
36
Figure 15: Lifting a Horizontal Air Handler Filter Section and Options (Model 4024 - 4049)
36
Figure 16: Lifting a Horizontal Air Handler with Options (Model 4054 - 4089)
36
Lifting an Vertical Air Handler
37
Figure 17: Lifting an Vertical Air Handler (All Models)
37
Figure 18: Lifting an Vertical Air Handler with Filter Section and Mixing Box
38
Upright Assembly Alignment
39
Figure 19: Inlet Alignment
39
SECTION 7: Air Handler Assembly
40
Caulking the Air Handler
41
Figure 20: Caulking Air Handler Joints
41
Caulking a Horizontal Air Handler
42
Figure 21: Caulking a Standard Horizontal Air Handler
42
Caulking an Vertical Air Handler
43
Figure 22: Caulking a Standard Vertical Air Handler
43
Figure 23: Assembling Optional Discharge / Supply and Return Sleeves
44
Accessory Connections
45
Figure 24: Electrically Connecting Joined Sections
45
Figure 25: Installing Cooling Coil Section
45
Figure 26: Installing Pressure Transmitter Tubing for am and VAV
46
Figure 27: Typical Freeze Protection (Evaporative Cooling Package #1)
46
Figure 28: Conductivity Control and Freeze Protection (Evaporative Cooling Package #2)
47
Figure 29: Protection and Auto-Flush (Evaporative Cooling Package #3)
47
Figure 30: Evaporative Cooling Trap Detail
48
SECTION 8: Roof Curb
49
Roof Curb Assembly and Installation
49
Table 20: Roof Curbs (Availability Based on Style)
49
Figure 31: Roof Curb
50
Figure 32: Roof Curb Installation
51
Figure 33: Roof Curb Assembly with Brackets
52
Figure 34: Duct Support Adapter
53
SECTION 9: Indoor Suspension Mounting - Horizontal Air Handler
54
Suspension Mounting Assembly and Instructions
54
Figure 35: Indoor Suspension
55
SECTION 10: Leg Mounting
56
Figure 36: Assembling Legs for Horizontal Air Handlers
57
Figure 37: Assembly Legs and Rainskirt for Upright Air Handlers
58
SECTION 11: Filter Section
59
Figure 38: Filter Section Support Assembly
59
SECTION 12: Inlet Hoods
60
Inlet Hood Assembly
60
Figure 39: Inlet Hood Without Filters (4024-4049)
60
Figure 40: Inlet Hood Without Filters (4054-4089)
61
Figure 41: Inlet Hood with Permanent Filters
61
Figure 42: Inlet Hood with Moisture Limiter
62
SECTION 13: Service Platform
63
Service Platform
63
Figure 43: Service Platform for an Vertical Air Handler
63
Figure 44: Service Platform for a Horizontal Air Handler
64
SECTION 14: Discharge Accessories
65
One-Way, Three-Way and Four-Way Discharge Head Installation
65
Figure 45: Vertical Air Handler with Duct Sleeves and Discharge Head
66
Figure 46: One-Way Discharge Head
67
Figure 47: Three-Way Discharge Head
68
Figure 48: Four-Way Discharge Head
69
Splash Plate Installation
71
Figure 50: Discharge Plate
71
SECTION 15: Vibration Isolation
72
Figure 51: Suspended
72
Figure 52: Curb Mounted
73
Figure 53: Platform Mounting on Vibration Isolators
74
Figure 54: Vibration Isolation Platform Locations
75
SECTION 16: Cooling Specifications
76
Evaporative Cooling
76
Table 21: Formulas
76
Table 22: Abbreviations
76
Table 23: Evaporation Rate
76
Table 24: Suggested Air Changes Per Hour (Air Change Method)
76
Table 25: Saturation Efficiency at Stated Media Depth
76
Table 26: Static Pressure Drop (in Wc) at Stated Media Depth
76
SECTION 17: Duct Considerations
77
Inlet Air Duct
77
Return Air Duct
77
Supply Air Duct Work
77
SECTION 18: Gas Piping
78
Gas Manifolds
78
Gas Piping and Pressures
78
Table 27: Manifold Component Identification
79
Figure 55: Standard Gas Manifold
79
Figure 56: FM Gas Manifold
80
Figure 57: XL Insurance Gas Manifold
81
Gas Piping
82
Pressure Test Ports
82
SECTION 19: Electrical
83
Disconnect Fuse Sizing
84
Wiring and Electrical Connections
84
Remote Panel
84
Motor Current Draw
84
Table 28: Minimum and Maximum Fuse Size by Motor Size and Supply Voltage
84
Table 29: Control Voltage Wiring for All Control Systems
84
Control Current Draw
85
Safety Systems
85
Table 30: Safety Systems
85
Interlocks
87
Control Options
87
Safety Systems
89
Table 31: Safety Systems
89
Remote Panels
90
Figure 58: Basic Remote
90
Figure 59: Basic Remote (Continued)
91
Figure 60: Standard Discharge Remote
92
Figure 61: Standard Discharge Remote (Continued)
93
Figure 62: Deluxe Room Control Remote
94
Figure 63: Deluxe Room Control Remote (Continued)
95
Figure 64: Standard Room Control Remote
96
Figure 65: Standard Room Control Remote (Continued)
97
DDC-Ready Controls
98
Figure 66: DDC-Ready Controls
98
Figure 67: DDC-Ready Controls (Continued)
99
Intelligent Control Systems
100
Figure 68: Air Handler Styles
101
HVAC Remote Panels and Panel Options
102
Basic Air Handler Sequence of Operation
104
Table 32: Factory Preset Schedule on TH8110 Thermostat
104
FIGURE 69: Fireye M4RT1
104
Table 33: Jumper Settings
106
Figure 70: Jumper Locations
106
Honeywell RM7890 Flame Safeguard
108
SECTION 20: Direct Fired Burner
120
Figure 71: Midco HMA-2A Burner
121
Direct Fired Burner Ignition
123
Figure 72: Spark Rod Dimensions
123
Direct Fired Burner Flame Proving (Flame Rod)
124
Figure 73: Maxon NPLE Burner
124
Honeywell UV Flame Detector
127
Honeywell UV Flame Detector (Continued)
128
SECTION 21: Start-Up Procedures
129
Installation of Recirculating Air Handler
130
Mechanical
130
Figure 74: Sheave Alignment
130
Electrical
131
Airflow
131
Table 34: Deflection Force B and BX Belts (in Lbs)
131
Figure 75: Belt Tension
131
Gas Piping and Initial Pressure Settings
132
Table 35: Motor Sheave Drive Torque Specifications
132
Table 36: Motor and Blower Bushing Torque Specifications
132
Figure 76: Fireye Flame Module
132
Table 37: Burner Mode by Amplifier Type
133
Safety Shut off Valve Check
134
Temperature Control System Calibration
134
Table 38: Maximum Temperature Rise
134
Figure 77: MR 212 Valve
135
Figure 78: M611 Valve
136
Figure 79: Regulator (2005)
136
SECTION 22: Maintenance
137
General
138
Unit Exterior
138
Blower Section
138
Manifold and Controls
140
Burner
140
Table 39: Motor Lubrication Intervals
141
Optional Equipment
142
SECTION 23: Replacement Parts
143
SECTION 24: Troubleshooting
144
Initial Checks
145
Motor and Blower
145
Burner
146
Temperature Controls
147
A1014 Amplifier - Field Checklist
148
Figure 80: RM7897C Flame Control
150
Section 25: Rapid
151
4000-Series Start-Up Procedures
151
Section 26: Rapid
156
4000-Series Start-Up Procedures Evaporative Cooler
156
Evaporative Cooler
159
SECTION 27: the RAPID
159
4000-Series Warranty
159
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