Rapid 4044 Manual

NOT FOR RESIDENTIAL USE

WARNING

Installation must be done by a contractor qualified

in the installation and service of gas-fired heating

equipment or your gas supplier.

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.

Installer

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.

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

WARNING

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.

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.

CANADA: 100% OUTSIDE AIR ONLY

Rapid®4000-Series

Direct-Fired Air Handler

Installation, Operation &

Service Manual

4024

4036

4040

4044

4049

4054

4060

4066

4073

4080

4089

P/N RP140000NA RevA 03/18

TABLE OF CONTENTS

SECTION 1: Air Handler Safety.............................................. 1

1.1 Description of Operation............................................... 1

1.2 Inspection and Setup ................................................... 1

1.3 Temporary Storage....................................................... 2

1.4 Safety Labels and Their Placement .............................2

1.5 California Proposition 65 ..............................................2

1.6 Label Placement .......................................................... 3

SECTION 2: Installer Responsibility ..................................... 6

2.1 Corrosive Chemicals.................................................... 6

2.2 National Standards and Applicable Codes .................. 6

2.3 Required Equipment .................................................... 6

SECTION 3: Critical Considerations ..................................... 8

3.1 Required Clearances to Combustibles......................... 8

3.2 Hardware ..................................................................... 8

SECTION 4: National Standards and Applicable Codes ..... 9

4.1 Gas Codes................................................................... 9

4.2 Installation Codes ........................................................ 9

4.3 Aircraft Hangars ........................................................... 9

4.4 Parking Structures and Repair Garages ...................... 9

4.5 Electrical ...................................................................... 9

4.6 Venting......................................................................... 9

4.7 High Altitude ................................................................ 9

SECTION 5: Specifications .................................................. 10

SECTION 6: Liftingan Air Handler (Rigging)...................... 27

6.1 Preparing to Lift the Air Handler.................................27

6.2 Lifting a Horizontal Air Handler ..................................28

6.3 Lifting an Vertical Air Handler ....................................29

6.4 Upright Assembly Alignment...................................... 31

SECTION 7: Air Handler Assembly...................................... 32

7. 1 C a ulking the Air Handler............................................. 33

7. 2 C a ulking a Horizontal Air Handler............................... 34

7. 3 C a ulking an Vertical Air Handler................................. 35

7.4 Accessory Connections.............................................. 37

SECTION 8: Roof Curb ......................................................... 41

8.1 Roof Curb Assembly and Installation......................... 41

SECTION 9: Indoor Suspension Mounting-

Horizontal Air Handler .................................... 46

9.1 Suspension Mounting Assembly and Instructions ..... 46

SECTION 10: LegMounting................................................. 48

SECTION 11: Filter Section .................................................. 51

SECTION 12: Inlet Hoods ..................................................... 52

12.1 Inlet Hood Assembly ................................................ 52

SECTION 13: Service Platform............................................. 55

13.1 Service Platform ...................................................... 55

SECTION 14: Discharge accessories .................................. 57

14.1 One-Way, Three-Way and Four-Way Discharge

Head Installation ...................................................... 57

14.2 Splash Plate Installation........................................... 63

SECTION 15: Vibration Isolation.......................................... 64

SECTION 16: CoolingSpecifications .................................. 68

16.1 Evaporative Cooling ................................................. 68

SECTION 17: Duct Considerations...................................... 69

17.1 Inlet Air Duct ............................................................. 69

17.2 Return Air Duct ......................................................... 69

17.3 Supply Air Duct Work ............................................... 69

SECTION 18: Gas Piping...................................................... 70

18.1 Gas Manifolds.......................................................... 70

18.2 Gas Piping and Pressures ....................................... 70

18.3 Gas Piping ................................................................74

18.4 Pressure Test Ports...................................................74

SECTION 19: Electrical......................................................... 75

19.1 Disconnect Fuse Sizing .......................................... 76

19.2 Wiring and Electrical Connections ........................... 76

19.3 Remote Panel .......................................................... 76

19.4 Motor Current Draw................................................. 76

19.5 Control Current Draw............................................... 77

19.6 Safety Systems........................................................ 77

19.7 Interlocks ................................................................. 79

19.8 Control Options........................................................ 79

19.9 Safety Systems........................................................ 81

19.10 Remote Panels ...................................................... 82

19.11 DDC-Ready Controls ............................................. 90

19.12 Intelligent Control Systems .................................... 92

19.13 HVAC Remote Panels and Panel Options ............. 94

19.14 Basic Air Handler Sequence of Operation ............. 96

19.15 Honeywell®RM7890 Flame Safeguard................ 100

SECTION 20: Direct Fired Burner .......................................112

20.1 Direct Fired Burner Ignition.....................................115

20.2 Direct Fired Burner Flame Proving (Flame Rod) ....116

20.3 Honeywell UV Flame Detector ...............................119

20.4 Honeywell UV Flame Detector (Continued)........... 120

SECTION 21: Start-up Procedures .................................... 121

21.1 Installation of Recirculating Air Handler ................. 122

21.2 Mechanical............................................................. 122

21.3 Electrical ................................................................ 123

21.4 Airflow.................................................................... 123

21.5 Gas Piping and Initial Pressure Settings ................ 124

21.6 Safety Shut Off Valve Check .................................. 126

21.7 Temperature Control System Calibration................ 126

SECTION 22: Maintenance................................................. 129

22.1 General.................................................................. 130

22.2 Unit Exterior........................................................... 130

22.3 Blower Section...................................................... 130

22.4 Manifold and Controls............................................ 132

22.5 Burner................................................................... 132

22.6 Optional Equipment............................................... 134

SECTION 23: Replacement Parts ...................................... 135

SECTION 24: Troubleshooting.......................................... 136

24.1 Initial Checks ......................................................... 137

24.2 Motor and Blower ................................................. 137

24.3 Burner................................................................... 138

24.4 Temperature Controls ........................................... 139

24.5 A1014 Amplifier - Field Checklist .......................... 140

SECTION 25: RAPID®4000-Series Start-Up Procedures. 143

SECTION 26: RAPID®4000-Series Start-Up Procedures

Evaporative Cooler ............................................................. 148

SECTION 27: The RAPID®4000-Series Warranty............. 151

Rapid Engineering LLC

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

written permission of Rapid Engineering LLC.

Printed in

the U.S.A.

LIST OF TABLES

Table 1: Recommended Torque Settings................................. 8

Table 2: 4000 AM Dimensions ............................................... 11

Table 3: 4000 AM Approximate Shipping Weights................. 12

Table 4: 4000 MUA Dimensions............................................. 13

Table 5: 4000 MUA Approximate Shipping Weights .............. 14

Table 6: 4000 FR Dimensions................................................ 15

Table 7: 4000 FR Approximate Shipping Weights.................. 16

Table 8: 4000 VAV Dimensions.............................................. 17

Table 9: 4000 VAV Approximate Shipping Weights ............... 18

Table 10: Dimensions............................................................. 19

Table 11: Leaving Dry Bulb Temperature Drop (Average) ..... 19

Table 12: Air Density Ratio..................................................... 20

Table 13: Dimensions............................................................. 21

Table 14: Estimated Tons of Cooling ..................................... 21

Table 15: Dimensions............................................................. 22

Table 16: Energy Recovery.................................................... 23

Table 17: Fan Selection Chart................................................ 24

Table 18: Fan Selection Chart (continued)............................. 25

Table 19: Static Pressure Drops for Options.......................... 26

Table 20: Roof Curbs (availability based on style) ................. 41

Table 21: Formulas................................................................. 68

Table 22: Abbreviations.......................................................... 68

Table 23: Evaporation Rate.................................................... 68

Table 24: Suggested Air Changes Per Hour

(Air Change Method) .............................................. 68

Table 25: Saturation Efficiency at Stated Media Depth.......... 68

Table 26: Static Pressure Drop (in wc) at Stated

Media Depth ........................................................... 68

Table 27: Manifold Component Identification ......................... 71

Table 28: Minimum and Maximum Fuse Size by Motor

Size and Supply Voltage ........................................ 76

Table 29: Control Voltage Wiring For All Control Systems..... 76

Table 30: Safety Systems....................................................... 77

Table 31: Safety Systems....................................................... 81

Table 32: Factory Preset Schedule on TH8110 Thermostat .. 96

Table 33: Jumper Settings...................................................... 98

Table 34: Deflection Force B and BX Belts (in lbs) .............. 123

Table 35: Motor Sheave Drive Torque Specifications .......... 124

Table 36: Motor and Blower Bushing Torque Specifications 124

Table 37: Burner Mode by Amplifier Type............................ 125

Table 38: Maximum Temperature Rise ................................ 126

Table 39: Motor Lubrication Intervals ................................... 133

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

trademark owners, and makes no representations about them, their owners, their products or services.

TABLE OF FIGURES

Figure 1: 4024 - 4049................................................................ 3

Figure 2: 4054 and 4089........................................................... 4

Figure 3: 4000-Series Interior ................................................... 5

Figure 4: 4000 AM Vertical Model Dimensions ....................... 11

Figure 5: 4000 AM Horizontal Model Dimensions................... 12

Figure 6: 4000 MUA Vertical Model Dimensions..................... 13

Figure 7: 4000 MUA Horizontal Model Dimensions ................ 14

Figure 8: 4000 FR Vertical Model Dimensions........................ 15

Figure 9: 4000 FR Horizontal Model Dimensions ................... 16

Figure 10: 4000 VAV Vertical Model Dimensions.................... 17

Figure 11: 4000 VAV Horizontal Model Dimensions ................ 18

Figure 12: Evaporative Cooling...............................................19

Figure 13: Mechanical Cooling................................................ 21

Figure 14: Energy Recovery ...................................................22

Figure 15: Lifting a Horizontal Air Handler Filter Section and

Options (Model 4024 - 4049) ................................. 28

Figure 16: Lifting a Horizontal Air Handler with Options (Model

4054 - 4089) .......................................................... 28

Figure 17: Lifting an Vertical Air Handler (All Models)............. 29

Figure 18: Lifting an Vertical Air Handler with Filter Section and

Mixing Box ............................................................. 30

Figure 19: Inlet Alignment .......................................................31

Figure 20: Caulking Air Handler Joints.................................... 33

Figure 21: Caulking a Standard Horizontal Air Handler........... 34

Figure 22: Caulking a Standard Vertical Air Handler............... 35

Figure 23: Assembling Optional Discharge / Supply and Return

Sleeves. ................................................................. 36

Figure 24: Electrically Connecting Joined Sections ................ 37

Figure 25: Installing Cooling Coil Section ............................... 37

Figure 26: Installing Pressure Transmitter Tubing for AM and VAV

Figure 27: Typical Freeze Protection (Evaporative Cooling

Package #1) ........................................................... 38

Figure 28: Conductivity Control and Freeze Protection

(Evaporative Cooling Package #2).........................39

Figure 29: Protection and Auto-Flush (Evaporative Cooling

Package #3) ........................................................... 39

Figure 30: Evaporative Cooling Trap Detail.............................40

Figure 31: Roof Curb............................................................... 42

Figure 32: Roof Curb Installation ............................................ 43

Figure 33: Roof Curb Assembly with Brackets........................ 44

Figure 34: Duct Support Adapter ............................................ 45

Figure 35: Indoor Suspension................................................. 47

Figure 36: Assembling Legs for Horizontal Air Handlers......... 49

Figure 37: Assembly Legs and Rainskirt for Upright Air Handlers

Figure 38: Filter Section Support Assembly............................ 51

Figure 39: Inlet Hood without Filters (4024-4049) ................... 52

Figure 40: Inlet Hood without Filters (4054-4089) ................... 53

Figure 41: Inlet Hood with Permanent Filters .......................... 53

Figure 42: Inlet Hood with Moisture Limiter............................. 54

Figure 43: Service Platform for an Vertical Air Handler ..........55

Figure 44: Service Platform for a Horizontal Air Handler........ 56

Figure 45: Vertical Air Handler with Duct Sleeves and Discharge

Head ....................................................................................... 58

Figure 46: One-Way Discharge Head .................................... 59

Figure 47: Three-Way Discharge Head.................................. 60

Figure 48: Four-Way Discharge Head.................................... 61

Figure 49: 120° Discharge Head Horizontal Bottom Supply Air62

Figure 50: Discharge Plate ..................................................... 63

Figure 51: Suspended ............................................................ 64

Figure 52: Curb Mounted........................................................ 65

Figure 53: Platform Mounting on Vibration Isolators............... 66

Figure 54: Vibration Isolation Platform Locations ................... 67

Figure 55: Standard Gas Manifold .......................................... 71

Figure 56: FM Gas Manifold ................................................... 72

Figure 57: XL Insurance Gas Manifold ................................... 73

Figure 58: Basic Remote ........................................................ 82

Figure 59: Basic Remote (Continued)..................................... 83

Figure 60: Standard Discharge Remote.................................. 84

Figure 61: Standard Discharge Remote (Continued).............. 85

Figure 62: Deluxe Room Control Remote .............................. 86

Figure 63: Deluxe Room Control Remote (Continued)........... 87

Figure 64: Standard Room Control Remote ........................... 88

Figure 65: Standard Room Control Remote (Continued) ....... 89

Figure 66: DDC-Ready Controls............................................. 90

Figure 67: DDC-Ready Controls (Continued)......................... 91

Figure 68: Air Handler Styles.................................................. 93

Figure 69: Fireye®M4RT1 ..................................................... 96

Figure 70: Jumper Locations .................................................. 98

Figure 71: Midco HMA-2A Burner..........................................113

Figure 72: Spark Rod Dimensions.........................................115

Figure 73: Maxon NPLE Burner.............................................116

Figure 74: Sheave Alignment ............................................... 122

Figure 75: Belt Tension ........................................................ 123

Figure 76: Fireye Flame Module........................................... 124

Figure 77: MR 212 Valve....................................................... 127

Figure 78: M611 Valve .......................................................... 128

Figure 79: Regulator (2005).................................................. 128

Figure 80: RM7897C Flame Control..................................... 142

SECTION 1: AIR H ANDLER S AFETY

1 of 154

SECTION 1: AIR HANDLER SAFETY

Yo ur Safety is Important to Us!

This symbol is used throughout

the manual to notify youof

possible fire, electrical or burn

hazards. Please pay special

attention when reading and

following the warnings in these

sections.

Installation, service and, at a minimum, annual

inspection of air handlers must be done by a

contractor qualified in the installation and service of

gas-fired heating equipment.

Read this manual carefully before installation,

operation or service of this equipment.

This air handler is designed for heating non-

residential indoor spaces. Do not install in residential

spaces. These instructions, the layout drawing, local

codes and ordinances and applicable standards that

apply to gas piping, electrical wiring, ventilation, etc.

must be thoroughly understood before proceeding

with the installation.

Protective gear is to be worn during installation,

operation and service. Thin sheet metal parts have

sharp edges. To prevent injury, the use of work

gloves is recommended.

Before installation, check that the local distribution

conditions, nature of gas and pressure and

adjustment of the appliance are compatible.

The equipment must be applied and operated under

the general concepts of reasonable use and installed

using the best building practices.

This appliance is not intended for use by persons

(including children) with reduced physical, sensory or

mental capabilities, or lack of experience and

knowledge, unless they have been given supervision

or instruction concerning use of the appliance by a

person responsible for their safety.

Children should be supervised to ensure that they do

not play with the appliance.

For additional copies of the Installation, Operation

and Service Manual, please contact Rapid

Engineering LLC.

Gas-fired appliances are not designed for use in

atmospheres containing flammable vapors or dust or

atmospheres containing chlorinated or halogenated

hydrocarbons. Recirculated room air may be

hazardous if containing flammable solids, liquids,

and gases; explosive materials; and/or substances

which may become toxic when exposed to heat (i.e.

refrigerants, aerosols, etc.).

1.1 Description of Operation

This air handler is a direct-fired, electric, steam, hot

water and/or energy recovery heated fresh air

appliance. It is designed for indoor or outdoor

installation with fresh outdoor air delivered to the

burner. Air handlers are designed to operate in

temperatures as lowas -30 °F (-34 °C) variable

frequency drive is only approved for applications

15 °F (-9 °C) and above, unless a control enclosure

heater is installed. The air handler is factory-tested

and may be designed to operate using natural gas or

LPG (check the air handler's rating plate for

information on the appropriate gas). The heat will

modulate to maintain the selected supply air

temperature or room air temperature, depending on

the selected controls. See Page 92, Section .

The air handler may be provided with several

different controls and options to meet various

application requirements. Be sure to read this entire

manual before installation and start-up.

1.2 Inspection and Setup

The air handler may ship in multiple sections based

upon the configuration selected. The air handler was

inspected and operated prior to shipment.

Immediately upon receipt of the air handler, check

the fuel and electrical requirements of the air handler

and verify that they match the fuel and electrical

supply available. Verify that the specifications on the

air handler rating plate match the order. Check the air

handler for any damage that may have occurred

during shipment. If any damage is found, file a claim

with the transporting agency. Do not refuse

shipment. Check the installation location to ensure

proper clearances to combustibles. See Page 8,

Section 3.1.

Any small options which do not come attached to the

air handler will be found inside the air handler.

Larger accessories (i.e. legs, stand, filter section,

inlet hood) may either ship with the air handler or

separately on another truck. Check the bill of lading

for information.

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

2 of 154

1.3 Temporary Storage

If the air handler must be temporarily stored (ie. job

site is not ready for installation of the air handler), the

following procedure should be performed. After

unloading unit from truck, place on a flat clean

surface in a protected area. The air handler should

be set on 4" x 4" (10 cm x 10 cm) pieces of timber to

elevate unit off the ground. Cover air handler with a

tarp or weatherproof material to ensure protection

from the environment. Manually rotate the fan wheel

every 15 days to eliminate grease from settling in the

fan bearings and creating flat spots on the shaft.

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. Please

contact Rapid Engineering LLC or your RAPID®

independent distributor to obtain replacement signs

or labels. See Page 3, Figure 1 through Page 5,

Figure 3.

1.5 California Proposition 65

In accordance with California Proposition 65 require-

ments, a warning label must be placed in a highly

visible location on the outside of the equipment (i.e.,

near equipment's serial plate). See label placement

drawing on Page 3, Figure 1 through Page 5, Figure

3for label location. Avoid placing labels on areas

with extreme heat, cold, corrosive chemicals or other

elements. To order additional labels, please contact

Rapid Engineering LLC or your RAPID®independent

distributor.

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