Rapid 2005 Installation, Operation & Service Manual Download

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Summary of Contents for 2005

Page 1: ...0 Fax 1 616 784 1910 Toll Free 800 536 3461 www rapidengineering com 2015 Rapid Engineering LLC WARNING FOR YOUR SAFETY If you smell gas 1 Open windows 2 DO NOT try to light any appliance 3 DO NOT use...

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Page 3: ...fra s 800 536 3461 www rapidengineering com 2015 Rapid Engineering LLC AVERTISSEMENT POUR VOTRE SECURITE Si vous sentez une odeur de gaz 1 Ouvrir les fen tres 2 N essayer pas d allumer un appareil 3 N...

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Page 5: ...Hood Installation 64 SECTION 13 Dampers 65 13 1 Discharge Damper 66 13 2 Inlet Damper 67 SECTION 14 Discharge Heads and Splash Plates 69 14 1 One Way and Three Way Discharge Head Installation 69 14 2...

Page 6: ...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...

Page 7: ...ure 44 Deluxe Temperature Control Remote DTC Wiring Diagram 2010 2030 86 Figure 45 BMS Ready Control MUA Style 2005 87 Figure 46 BMS Ready Control MUA FR Style Units 2010 2030 88 Figure 47 BMS Ready C...

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Page 9: ...ble 18 Factory Preset Schedule on TH8110 Thermostat 112 Table 19 Site Configuration Jumper Options 112 Table 20 Deflection Force B and BX Belts in lbs 118 Table 21 Motor Sheave Drive Torque Specificat...

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Page 11: ...genated 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 refri...

Page 12: ...3 Figure 1 through Page 4 Figure 3 1 4 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 o...

Page 13: ...11 91010431 Label Improper Installation 12 91070015 Label Proposition 65 2 4 6 1 4 5 2 6 7 2 7 2 4 4 x 1 7 x 3 ON SHRINK WRAP 7 AIR FLOW AIR FLOW AIR FLOW AIR FLOW 5 5 5 8 ON SHRINK WRAP BY CONTROL EN...

Page 14: ...ED AT THE BOTTOM CENTER OF THE CONTROL ENCLOSURE 10 LOCATED OVER THE REGULATOR VENTS 11 11 12 12 Item Part Number Description 1 91070001 Label Shock Hazard 2 91070002 Label Severe Injury Hazard 3 9107...

Page 15: ...2030 7 9 2005 CONTROL ENCLOSURE DOOR 13 PLACE INSIDE ITEM 9 11 or 12 NAMEPLATE 3 MOTOR 4 3 BLOWER HIGH TEMP LIMIT SWITCH DISCHARGE SENSOR 6 REMOTE BOX RIGHT SIDE TERMINAL RAIL REMOTE BOX 10X10 INTERNA...

Page 16: ...l near the heater e g thermostat or control system A copy of the wall tag P N 91040118 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near the heater Kn...

Page 17: ...for supplying or arranging for the appropriate lifting equipment so that the air handler and accessories may be placed in a safe manner The qualified installer or service technician is responsible fo...

Page 18: ...sitive material equipment and workstations Clearances to combustibles do not denote clearances for accessibility Minimum clearance for access is 48 122 cm Minimum clearance for accessibility applies t...

Page 19: ...the appropriate duration to meet this requirement 3 3 Hardware Unless otherwise specified all hardware must be torqued to settings on Page 9 Table 1 Note Inlet hood opening shall not be installed wit...

Page 20: ...in garages must be in accordance with the following codes United States Refer to Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Ga...

Page 21: ...GURE 5 2005 Upright Model Dimensions Table 2 2005 Dimensions Legend BD Bottom Discharge OA Outside Air CE Control Enclosure RA Return Air optional GC Gas Connection RD Right Discharge ED End Discharge...

Page 22: ...LTER SECTION OPTIONAL INLET HOOD OPTIONAL Customer Supplied Duct Location See page 73 Table 11 Filter Access Filter Access S AA BB BB Y Z GC OH Model Air Handler Stand Inlet Hood Splash Plate Filter S...

Page 23: ...3 0 7 6 10 0 25 4 3 4 8 6 56 4 143 2 37 2 94 5 34 0 86 3 38 8 98 6 28 8 73 2 28 6 72 6 1 5 3 8 1 1 2 8 41 0 104 1 0 5 1 3 6 5 16 5 25 3 64 3 9 5 24 1 25 3 64 3 2020 in cm 1 5 3 8 3 9 9 9 26 5 67 3 6 0...

Page 24: ...2020 lb 1400 230 60 220 190 210 150 120 26 N A 340 kg 638 104 3 27 2 99 8 86 2 95 3 68 54 4 11 8 154 2 2030 lb 1650 300 60 270 240 260 160 160 26 N A 365 kg 748 4 136 1 27 2 122 5 108 9 117 9 72 6 72...

Page 25: ...2010B 5 5 5 5 5 59 62 66 756 605 7 17 5 1 25 32 8 000 13 600 2010B 5 5 5 5 5 60 63 66 864 691 7 17 5 1 25 32 9 000 15 300 2010B 7 5 7 5 7 5 7 5 7 5 61 64 67 972 778 7 17 5 1 25 32 10 000 17 000 2010B...

Page 26: ...10 0 25 0 05 0 12 18 000 25 000 30 600 42 500 0 40 1 0 0 50 1 25 0 10 0 25 0 05 0 12 2030 25 000 30 000 42 500 51 000 0 35 0 87 0 75 1 87 0 10 0 25 0 05 0 12 32 500 40 000 55 200 68 000 0 40 1 0 0 85...

Page 27: ...ide the control enclosure 3 Inspect the air handler to Verify that there is no damage as a result of shipping Ensure that it is appropriately rated for the utilities available at the installation site...

Page 28: ...ar across the long axis Lift the air handler off the skid and place it on a flat clean dry surface Step 2 Remove the lifting lugs on the inlet end of the air handler and re install hardware Step 3 Use...

Page 29: ...easurements are within 1 8 3 mm of each other To ensure a weatherproof seal between the air handler and the curb the curb must be level with no twist from end to end Shim level as required and secure...

Page 30: ...After the curb has been installed the air handler may be placed on the curb There must be a 1 8 3 cm x 2 5 1 cm neoprene closed cell adhesive back gasket supplied by others between the top of the curb...

Page 31: ...SECTION 7 ROOF CURB 21 of 147 FIGURE 12 Curb Mounting Air Handler Roof Curb Fastening Detail...

Page 32: ...the mounting stand must be removed and saved for re installation to secure the air handler to the stand Lift the air handler on to the mounting stand See Page 17 Section 6 1 for safe lifting practice...

Page 33: ...er Control Enclosure Side B Model Part Number Height A B Weight lbs Weight kg 2005 in cm 94000 3 30 0 76 2 27 1 68 9 22 8 57 8 75 0 34 0 2010 and 2010B in cm 91000 2 53 0 134 6 27 8 70 5 39 3 99 7 160...

Page 34: ...n the inside of the corner and attach with the previously removed hardware Missing hardware needs to be added at each bolt location The required hardware is a 5 16 18 x 1 grade 5 bolt a 5 16 flat wash...

Page 35: ...W 38 8 98 5 10 8 27 4 9 5 24 1 26 0 11 8 2010 and 2010B in cm 77040 301 W 71 0 180 3 23 5 59 7 9 5 24 1 26 0 11 8 2020 in cm 77040 301 W 95 0 241 3 35 0 88 9 9 5 24 1 26 0 11 8 2030 in cm 77040 301 W...

Page 36: ...leted reinstall hardware See Page 27 Figure 20 On model 2010 and 2010B drilling holes down through the floor of the air handler and into the suspension frame At least three 12 sheet metal screws suppl...

Page 37: ...Angle to secure unit in position Suspension Angle Clip Double 1 2 Hex Nuts on Bottom Side of Angle for height adjustment 5 8 for 1 2 Threaded Rod 1 4 Bolt Clip to angle and to unit sideskin floor Desc...

Page 38: ...hreaded Rod and Nuts Not Supplied by manufacturer Nuts and bolts provided Provided by others Description Part Number Qty 2010 and 2010B Suspension Kit 77046 301 Suspension Sides 77047 103 2 Suspension...

Page 39: ...s are present If any are missing contact your RAPID independent distributor 11 1 Filter Section 2005 Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment...

Page 40: ...1 23629 4 N A Permanent Aluminum Mesh Filters 20 x 20 x 1 20628 N A 8 Insulated Access Cover 77401 002 W 1 1 Header Panel 77402 002 W 1 1 Right Panel 77403 001 W 1 1 Left Panel 77403 002 W 1 1 Channel...

Page 41: ...crews on each side as shown Description Part Number Left Panel 77403 002 W Right Panel 77403 001 W End Panel 77406 002 W TEK Screw 13404 Supports Insert Screws Insert Screws Make sure that the bottom...

Page 42: ...loose end of upper filter channel to stiffener attach loose end of lower filter channels to header piece On the inlet of the filter section rivnuts P N 91120106 are factory installed With additional...

Page 43: ...ng the inlet and the blue side is facing the discharge end Description Part Number Permanent Aluminum Mesh Filters 20628 Disposable Polyester Filters 23629 Insulated Access Cover Install cage nuts int...

Page 44: ...HMS Bolt 27000 6 6 Fastener Rivnut 3 8 16 91120106 14 14 Spacer Hinge Filter 13205032 8 8 Gasket Door Filter 13205035 11 11 2030 Filter Section Description Part Number Permanent Aluminum Mesh Filters...

Page 45: ...or each assembly at the begining of the instructions Step 11 3 1 Top Panel Side Left Panel Top Panel Side Panel For Model 2020 On a flat clean and dry surface attach the top panel and side panel of th...

Page 46: ...2020 Attach the bottom panel with five TEK self tapping screws Attach the right panel with five TEK self tapping screws on each side For Model 2030 Attach the bottom panel with seven TEK self tapping...

Page 47: ...lter rail to the top panel with five TEK self tapping screws Line up filter rail holes with provided holes near the discharge end of the filter section panel For Model 2030 Attach the side filter rail...

Page 48: ...h the side filter rail to the bottom panel with five TEK self tapping screws Line up filter rail holes with provided holes near the discharge end of the filter section panel For Model 2030 Attach the...

Page 49: ...0 TEK Screw 13404 Load filters into the filter section Check that each filter in in the proper orientation For permanent aluminum mesh filters Verify the arrow on the side of the filter points in the...

Page 50: ...access opening from the hinges Place a washer on a 20 bolt and insert it into one of the three bolt holes on the door panel Place a push nut on to the bolt from the inside of the door panel to keep th...

Page 51: ...0 and 2010B 2020 2030 77412 001 77412 002 77412 003 Quantity Quantity Quantity Filter Box Support Base 2010 and 2010B 77408001 1 N A N A Filter Box Support Base 2020 77408002 N A 1 N A Filter Box Supp...

Page 52: ...he air handler as described on Page 43 Section 11 5 Step 4 Line up the support extension P N 77410001 with the left support leg P N 77409001 and select the appropriate height alignment Attach the supp...

Page 53: ...ion Additional TEK screws may be used along the bottom flange of the filter section to seal the bottom seam Caulk provided by others the side and bottom seams between the filter section and air handle...

Page 54: ...2 1 Inlet Hood Assembly 2005 FIGURE 24 Inlet Hood Assembly 2005 Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Sever...

Page 55: ...1 2 2 2 Drip Rail 13505092 2 2 2 TEK Screw 13404 82 105 92 5 16 18 x 1 Bolt HHCS Grade 5 20507 5 5 5 5 16 Flat Washer 95211600 5 5 5 5 16 Nut Flange 20509 5 5 5 Permanent Filter 20 x 20 x 1 20628 6 N...

Page 56: ...to the inlet of the filter section with the angles opening towards the inside of the filter section Upright mounts P N 13505090 are attached with five 3 8 16 bolts P N 20517 and flat washers P N 2051...

Page 57: ...the panels break inward Description Part Number Left Panel 13505080 Right Panel 13505081 TEK Screw 13404 Screws Bottom Rail Attach the bottom panel to the bottom attaching flange with five TEK self t...

Page 58: ...Panel 13505076 13505096 TEK Screw 13404 Top Front Panel Top Inner Filter Rail Top Front Panel Bottom Rail Right Panel Left Panel Top Inner Filter Rail SIDE VIEW REVERSE INLET VIEW Attach the top inner...

Page 59: ...head cap screws 5 16 washers and 5 16 flange nuts at the J bend joint Ensure that the side tabs of the roof panel are to the outside of the side panels and that the J bend interlocks with the front r...

Page 60: ...low for maximum clearance for the filters Attach the snap fastener with one TEK self tapping screw each First remove the washer as the washer will restrict the snap fastener making it difficult to ope...

Page 61: ...idewall panels Apply caulk to the drip rails before attaching to the side panels NOTE Double sided filter rails or snap fasteners are not required for inlet hood with moisture limiter Description Part...

Page 62: ...Side Cover ML 13505099 TEK Screw 13404 10 24 x Bolt 27000 10 24 Nut 26098 Inner Support Rail Moisture Limiter Side Cover Place the moisture limiter inner support rail under the top flange of the moist...

Page 63: ...t Rail Place the moisture limiter frame side cover in order to have the flange at the top overlap the top of the frame Attach to the inlet hood rain gutter using eight TEK screws Attach to the bottom...

Page 64: ...l 1 13X05081 1 1 1 Left Side Panel 2 13X05082 1 1 1 Right Side Panel 2 13X05083 1 1 1 Left Side Panel 3 13X05084 1 1 1 Right Side Panel 3 13X05085 1 1 1 Upright Mount 13X05090 2 2 2 Horizontal Mount 1...

Page 65: ...f the filter section with the angles opening towards the inside of the filter section Upright mounts P N 13X05090 are attached with seven 3 8 16 bolts P N 20517 and flat washers P N 20515 each the rec...

Page 66: ...5081 TEK Screws 13404 Bottom Rail For Model 2020 Attach the bottom panel to the bottom mounting flange with seven TEK self tapping screws Attach to each side panel with two TEK self tapping screws For...

Page 67: ...washer 5 16 flange nut Description Part Number Left Side Panel 2 13205082 13305082 Right Side Panel 2 13205083 13305083 Left Side Panel 3 13205084 13305084 Right Side Panel 3 13205085 13305085 5 16 1...

Page 68: ...p inner filter rail to the inside of the top front panel using five TEK self tapping screws For Model 2030 Attach top inner filter rail to the inside of the top front panel using six TEK self tapping...

Page 69: ...h side seven TEK self tapping screws to the top mounting flange and with six 5 16 18 x 1 bolts 5 16 washers and 5 16 flange nuts at the J bend joint For Model 2030 Attach top back panel with five TEK...

Page 70: ...h the double sided filter rails horizontally to the face of the inlet hood using two 10 24 x bolts and 10 24 nuts on each side When attaching the filter rails insert the bolt from the inside of the fi...

Page 71: ...rails are positioned above the filter clips using the provided holes in the sidewall panels Attach drip rail to right side of inlet hood starting with the lower drip rail using five TEK self tapping s...

Page 72: ...e air handler when installed in the proper orientation Once filters are installed close snap fasteners installed previously See Page 60 Step 12 3 9 to hold filters in place Description Size Part Numbe...

Page 73: ...r of the frame using two 10 24 x bolts and 10 24 nuts Description Part Number Inner Support Rail 13205097 13305097 TEK Screw 13404 10 24 x 1 2 Bolt 27000 10 24 Nut 26098 Moisture Limiter Media For Mod...

Page 74: ...hood and the air handler wall panel NOTE After installing the inlet hood all hardware must be tightened with a torque wrench The roof side and bottom seams must be caulked supplied by others 12 4 3 In...

Page 75: ...ty equipment and prac tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment Equipment and accessories are heavy Cut Pinch Hazard Wear protective gear during installat...

Page 76: ...o the air handler FIGURE 26 Motorized Discharge Damper 2005 2030 C E C D A B C C F NOTE 1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 NUMBER OF LOUVERS WILL VARY 3 MOU...

Page 77: ...nlet Damper 2005 2010B C E C D A B C C F NOTE 1 CONTRACTOR INSTALLER MUST MAKE APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS 2 NUMBER OF LOUVERS WILL VARY 3 MOUNTED UPSTREAM OF AIR HANDLER MOUNTS DIRECT...

Page 78: ...REAM OF AIR HANDLER MOUNTS DIRECTLY TO AIR HANDLER PRE INSTALLED UPPER DAMPER LOWER DAMPER A C B D C A E E E E E E AIR FLOW AIR FLOW Model A B C D E 2020 in 47 3 24 4 2 0 29 5 1 5 cm 120 0 63 0 5 1 74...

Page 79: ...ior wall drill holes every 8 20 5 cm in the flanges on all four sides of the discharge heads to accommodate lag bolts supplied by others Sheet metal supplied by others may be required See Page 69 Figu...

Page 80: ...n through a hole located in each corner of the splash plate Next feed a flanged nut onto the rod below the splash plate See Page 70 Figure 30 The hanger rods should be attached to the air handler in t...

Page 81: ...ARGE HEADS AND SPLASH PLATES 71 of 147 FIGURE 31 Hole Location 2005 2030 A B Model 2005 2010 and 2010B 2020 2030 A in cm 19 5 49 5 41 5 105 4 51 3 130 2 51 25 130 2 B in cm 22 5 57 2 41 5 105 4 51 3 1...

Page 82: ...inches Dh 2 H W H W Dh hydraulic diameter H rectangular duct inside height W rectangular duct inside width The air handler is not designed to support the weight of ductwork Ductwork must be construct...

Page 83: ...BD RD NOTE Dimension clearance to clear blower mounting bolts Model Height Width 2005 in cm 14 35 6 15 6 39 7 2010 and 2010B in cm 24 61 0 24 61 0 2020 in cm 32 81 3 32 81 3 2030 in cm 38 96 5 38 96 5...

Page 84: ...enting Vent valves fitted on XL compliant manifolds must be piped to the atmosphere outside the structure and in accordance with applicable codes This is the responsibility of the installer 16 3 1 Mai...

Page 85: ...anifolds Manual Gas Valve Burner Manual Gas Valve Main Combination Valve Manual Gas Valve Pilot Vent to Atmosphere FM and XL Manifold Union By Others NOTE Vent valves must be piped to the atmosphere o...

Page 86: ...Safety Shut Off Valve NOTE Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes Alternate Inlet Inlet By Others Manual Gas High Gas Pressure Regula...

Page 87: ...as pressure during burner setup 16 5 1 Manifold Inlet Gas Pressure The pressure port for measuring manifold inlet pressure is located on the inlet side of the first safety shutoff valve Refer to the u...

Page 88: ...ematic For wire gauge sizes see Page 78 Table 13 All power supply and motor wiring must be minimum type THWN with a 167 F 75 C temperature rise 17 2 1 Remote Panel Mounting Distance If the interconnec...

Page 89: ...bove 2 500 MBH and XL compliant gas trains and are also available as an option on the others The function of the gas pressure switches is to protect against insufficient lack of gas pressure and exces...

Page 90: ...temperature limit switch will turn the burner off BMS ready air handlers do not come equipped with this sensor and must be field supplied 17 5 6 Positive Low Fire Start This feature forces the burner...

Page 91: ...0VAC 2 M1 OL M1 OL 9C MV MV PV PV GND 24V GND 24V SPARK SENSE CR2 S8600B SSOV MV MV PV 40VA 120VAC 24VAC X2 X1 2 SAFETY SHUTOFF VALVE PILOT VALVE CONTROL IGNITION 13 SP FR L 12 BURNER ON LIGHT CR2 9C...

Page 92: ...R X1 16 20VA X2 MTR 250VA M1 X2 X1 H2 H1 H3 3A H4 T1 4 MOTOR 2 FAN ON L M1 MOTOR STARTER FAN ON BLOWER 120vac 120VAC 2 M1 OL M1 OL 9C MV MV PV PV GND 24V GND 24V SPARK SENSE CR2 S8600B SSOV MV MV PV 4...

Page 93: ...X1 H2 H1 H3 3A H4 T1 4 MOTOR 2 FAN ON L M1 MOTOR STARTER FAN ON BLOWER 120vac 120VAC 2 M1 OL M1 OL 9C MV MV PV PV GND 24V GND 24V SPARK SENSE CR2 S8600B SSOV MV MV PV 40VA 120VAC 24VAC X2 X1 2 SAFETY...

Page 94: ...24VAC X2 T3 9 2 F G 12 10 6 8 3 SP 11 SSOV BURNER ON A T2 PV FUSABLE DISCONNECT M1 1 L1 BURNER ON OFF 4 H1 FAN OFF ON H3 H2 X1 X2 H4 T1 250VA L3 L2 M1 FAN ON MOTOR STARTER FAN ON A 3A M1 M1 OL 2 MOTOR...

Page 95: ...20VA X2 BURNER ON SSOV A SP T2 PV CONTROL SAFETY SHUTOFF BURNER ON VALVE PILOT VALVE TRANSFORMER IGNITION IGNITION 3A 250VA M1 X1 X2 H1 H2 H3 H4 T1 4 M1 OL MTR MOTOR FAN ON A M1 M1 OL 2 MOTOR STARTER...

Page 96: ...Y CONNECTION T1 TRANSFORMER MOTOR AUTO 32 CR1 SUMMER M1 OFF ON 3A FUSABLE DISCONNECT L1 1 31 X2 X1 H1 3 AMP H3 H2 H4 FAN ON M1 4 A FAN ON M1 OL MOTOR STARTER T1 250VA H4 COMMON 2 L3 L2 BLOWER OL M1 MT...

Page 97: ...H HI PRES SWITCH C NO C NC NC 3 PHASE ONLY BURNER ON RELAY 24VAC WIRES GROUNDED AT CONTROL PANEL PRIMARY CONNECTION T1 TRANSFORMER H4 COMMON H2 230 USE 3 0 AMP BREAKER H3 208 USE 4 0 AMP BREAKER H1 46...

Page 98: ...SWITCH BEFORE CONNECTING POWER 4 ON OFF 1 2 3 O O O THREE POSITION DIP SWITCH ON SC11 B 4 20mA ALL POSITIONS ON OFF ALL POSITIONS 0 10 VDC R3 HI TEMP LIMIT HLS MANUAL RESET 8 8A 9 LOW PRES SWITCH 0 3...

Page 99: ...OL MTR 120vac 4 20MA Input Signal FAN R2 R1 R1 R2 COIL CONN BY OTHERS COIL CONN BY OTHERS RELAY R1 AND R2 VOLTAGE IS OR 0 10VDC Signal SET DIP SWITCH BEFORE CONNECTING POWER BURNER LOCKOUT CONTACT CO...

Page 100: ...additional AM style wiring for models 2020 and 2030 See Page 96 Figure 55 FIGURE 48 Additional Control Wiring for VAV Style 2010 and 2010B PHOTOHELIC 1 LOCATED INSIDE CONTROL ENCLOSURE CONTROLS DIFFE...

Page 101: ...N S3 UP TO 25HP 30HP AND UP B C A VFD TERMINALS VFD PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 C1 01 20 ACCEL TIME SEC C1 02 20 D...

Page 102: ...S3 S5 SN S3 UP TO 25HP 30HP AND UP B C A VFD TERMINALS VFD PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 C1 01 20 ACCEL TIME SEC C1...

Page 103: ...P TO 25HP 30HP AND UP B C A VFD TERMINALS VFD PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 C1 01 20 ACCEL TIME SEC C1 02 20 DECEL T...

Page 104: ...HP OR LESS S4 SC S3 S5 SN S3 UP TO 25HP 30HP AND UP B C A VFD TERMINALS VFD PROGRAM PARAMTERS 30HP OR MORE B1 02 1 C1 01 25 C1 02 25 D2 02 50 D4 01 1 E1 01 VOLTS E2 01 AMP H1 03 10 H1 05 11 C1 01 20 A...

Page 105: ...MOTOR STARTER OVERLOAD AND M1 AUXILIARY CONTACT IS REPLACED WITH RM1 RELAY RM1 RM1 2 4 3D 3A VFD PROGRAM PARAMTERS 25HP OR LESS S4 SC S3 S5 SN S3 UP TO 25HP 30HP AND UP B C A VFD TERMINALS VFD PROGRA...

Page 106: ...LATING POSITION Damper Switch DM2 0 25 25 PHOTOHELIC BUILDING PRESSURE BLDG PHOTOHELIC PNEUMATIC DIAGRAM Part Number Description Models AM AM Control Wiring 2010 and 2010B MODULATING DAMPER MOTOR ADJU...

Page 107: ...Diagram CO2 Sensor Wiring By Others Modulating Regulating Valve This Replaces The MRV Wiring Part Number Description Models 13205105 CO2 Sensor Interlock FR and MUA CO2 Sensor Wiring By Others 2 CO2 S...

Page 108: ...or AM and VAV FIGURE 61 CO Sensor Interlock for AM and VAV with Photohelic FIGURE 62 CO Sensor Interlock for AM with Building Pressure LOW LIMIT SWITCH 2 3A LT RED YELLOW 3A LT 3B SET AT 5 MIN SET AT...

Page 109: ...safe interlock set the fan switch to off and then on again The air handler will return to the normal sequence of operations 3C AFS 3 TD5 TIMING RELAY TD5 21 3D CR3 CR3 LOW PRESSURE SWITCH 0 3 in w c 2...

Page 110: ...e for the control components This option is intended for extremely cold climates but recommended for installations below 15 F 9 C The air handler controls are rated to perform at temperatures as low a...

Page 111: ...ximum switching capacity on the normally open contact is 8A and for the booth light relay P N 80916 2 15A 17 8 9 Smoke Detector A smoke detector interlock allows for the air handler to operate based o...

Page 112: ...s additional thermostat capability based on room temperature The thermostat senses room temperature and resets the discharge air to a higher temperature whenever the temperature falls below settings i...

Page 113: ...TH REMOTE POT ONLY WIRES GOING INTO VFD MUST BE SHIELDED AND ONE END GROUNDED OPTIONAL WIRING REQUIRED FOR REMOTE POT AC X3 X2 X1 A1 V WIRES CONNECTED TO CONTROL PANEL 2 3C 35 SHIELDED X1 X2 X3 WITH R...

Page 114: ...SN S1 X3 S3 X1 X2 A1 50 LOAD SIDE OUT 3 T 52 AC V 50 R1 R2 S5 53 53 R4B 6 7 1 2 3 PRESET TO 1 MINUTE 55 56 TIMER DELAY ON BREAK R2B 1 2 57 35 2 CURE RELAY R4B 2 RELAY R1 MOTOR OL VFD EXHAUST MOTOR S T...

Page 115: ...ON VFD PANEL INSIDE CONTROL ENCLOSURE PHOTOHELIC LOCATED INSIDE SEPARATE REMOTE ENCLOSURE PRESET AT 0 1 LOW AND 0 3 HIGH CONTROLS BOOTH PRESSURE 2 RELAY R1 MOTOR OL VFD EXHAUST MOTOR S T1 T2 T3 S1 S4...

Page 116: ...3 60 230 1 60 2 1 5 7 3 10 2 6 9 9 6 3 4 4 8 2 6 3 6 13 3 18 6 3 2 2 10 1 14 2 9 3 13 0 4 6 6 5 3 7 5 2 17 3 24 2 5 3 7 15 4 21 6 15 1 21 1 7 5 10 6 6 1 8 5 24 3 34 0 7 5 5 6 23 1 32 4 21 3 29 8 10 6...

Page 117: ...wo Exhaust Starter EXHAUST 1 SINGLE EXHAUST STARTER 2 P N 061XX M2 M2 OL 3C EXHAUST 2 EXHAUST 1 R4 65 TR3 67 M3 TR3 M3 OL TWO EXHAUST STARTERS 1 DROPS OUT IN CURE 2 P N 061XX TR SEQUENCE 1 TR2 2 TR3 3...

Page 118: ...is brought into the space to satisfy the pressure setpoint Most installations require a setpoint of 0 02 in wc to 0 03 in wc to achieve adequate pressure control in the building space 5 16 diameter t...

Page 119: ...able ratio of 20 outside air and 80 return air to 100 out side air and 0 return air Constant Building Pressure Controls Outside Return Air Ratio Variable Air Volume VAV 100 Outside Air Variable 50 100...

Page 120: ...motor via the M1 motor starter BURNER ON indicator Indicates that the unit has supplied power to open the main gas safety shut off valve 18 2 2 Standard Discharge Control SDC Remote This control is t...

Page 121: ...cupied time Blower and burner cycle operate continuously to maintain a constant space temperature as selected on the Selectrastat dial The burner flame fully modulates and varies the discharge air tem...

Page 122: ...ame control module will execute the burner ignition sequence Once the pilot flame is ignited and sensed by the UV scanner the flame control module will open the safety shutoff valve to ignite the main...

Page 123: ...t s optional Close Main Gas Valve and Pilot Gas Valve Close Main Gas Valve and Pilot Gas Valve Run Flame Lost Call for Heat ends YES NO NO Flame Stabilization 2 seconds Open Main Gas Valve Close Pilot...

Page 124: ...ON INTERLOCK L1 L2 MASTER SWITCH LED Display Initiate Initial Powerup Only Standby Safe Start Pilot Flame Establishing Period 10 Sec Main Flame Establishing Period Run Standby Power Power Power Power...

Page 125: ...isplay Initiate Initial Powerup only Standby Prepurge 7 Sec Pilot Flame Establishing Period 10 Sec Main Flame Establishing Period Run Postpurge Standby Power Power Power Pilot Flame Main Alarm Power P...

Page 126: ...se instructions can result in death electrical shock or injury Explosion Hazard Leak test all compo nents of equipment gas piping before operation Gas can leak if piping is not installed properly Do n...

Page 127: ...of this sensor must be wired in as per the CO2 interlock diagram maintaining the room concentration of CO2 below 5 000 ppm Select the CO2 interlock diagram based on air handler configuration and mode...

Page 128: ...plicable compare all variable frequency drive VFD programming parameters with specifications provided on electrical drawing 19 4 Airflow The air flow switches are factory calibrated safety devices for...

Page 129: ...ched to the 1 8 tap It will be used later to check high fire gas pressure 19 5 Gas Piping and Initial Pressure Settings 1 Perform a pressure test on all gas supply lines to the air handler per applica...

Page 130: ...it into high fire Measure the recirculation temperature rise and compare it to Page 121 Table 24 The resistor on the reduced flow switch mounted inside the control enclosure may need adjustment until...

Page 131: ...yle at minimum airflow Amplifier Type High Fire Mode Low Fire Mode Series 14 Remove wire 45 from ter minal 4 on the amplifier Remove wire 16 from terminal 8 on the amplifier Series 44 Remove wires 40...

Page 132: ...ire Adjustment loosen locking screw before adjustment High Fire Adjustment Cap Modulator Wire 48 and 49 or 49A TOP VIEW cover removed Inlet Pressure Outlet Pressure Tap Tap Burner Pressure SIDE VIEW N...

Page 133: ...611 Valve 2005 FIGURE 81 Regulator 2005 Low Fire Adjustment under cap Gas Inlet Gas Outlet NOTE Modulating only IN PSI 2 OFF ON Outlet Pressure Tap 1 8 NPT Inlet Pressure Tap 1 8 NPT Regulator Adjustm...

Page 134: ...l components of equipment gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with equipment connected DANGER Failure to follow these inst...

Page 135: ...Section 19 2 2 Though belts were properly adjusted at the factory they will stretch after the first few hours of operation First 100 Hours of Operation Re check belt tension and adjust if necessary An...

Page 136: ...spider bracket bearings are pre lubricated and do not require any re lubrication during their entire service life Blowers that use pillow block bearings should be re lubricated per the chart below The...

Page 137: ...grease capacity recommen dations as capacities vary by motor Relubrication intervals are specified in the table above After relubricating allow motor to run for 10 minutes before replacing relief hard...

Page 138: ...st part the burner is self cleaning However if the application is extremely dirty or dusty it may become neces sary to periodically clean the burner Inspect and clean the burner in accor dance with th...

Page 139: ...able 26 Burner Selections Model Burner Length Style Qty Drill Size 2005 6 15 3 cm 6 15 3 cm Straight 1 47 2010 1 ft 30 5 cm 12 30 5 cm Straight 1 47 2010B 2 ft 61 cm 12 30 5 cm Straight 2 47 2020 3 5...

Page 140: ...nkages and check dampers for proper operation See Page 65 Section 13 Filters Filters should be checked for dirt restriction on a monthly basis or as required Replace filters with filters of equal spec...

Page 141: ...instructions can result in death electric shock injury or property damage Explosion Hazard DANGER Electrical Shock Hazard Fire Hazard WARNING Severe Injury Hazard Use proper lifting practices and equ...

Page 142: ...s 90407219 Belimo LF120 S US 2005 and 2030 07097 Belimo NF120 S US 2010 and 2030 07095 Actuator 90 in Lb Floating 2020 and 2030 90667110 Actuator 90 in Lb 4 20mA 2020 and 2030 90667120 Actuator 90 in...

Page 143: ...scription 2005 2030 2HP 3HP 5HP 7 5HP 10HP 15HP 20HP 25HP 30HP 460 3 60 Disconnect 08039 08037 Contactor 90600200 90600205 90600210 Aux Contact N A 90447000 Overload 90446005 90446005 90446015 9044602...

Page 144: ...490 3 07500 3 07500 3 Regulator 07185 Pilot Regulator 07552 07552 07552 07552 07552 Pilot Solenoid 07523 07522 07522 07522 07522 Manual Gas Valve Main 62019 62021 62034 62035 62023 Manual Gas Valve Pi...

Page 145: ...h Timer DTC 90425111 Amber Status Light All 18663 Temperature Selector Basic Remote SDC 07345 Thermostat SDC 83200052 20VA Transformer DTC 90436900 Terminal Block All 91300121 Description Part Number...

Page 146: ...ult in death electrical shock or injury Falling Hazard Use proper safety equipment and practices to avoid falling Do not use any part of equipment as support WARNING Failure to follow these instructio...

Page 147: ...switch is OFF Turn disconnect to ON Blown fuse s in disconnect Replace fuse s Blown fuse s breaker tripped in control transformer Replace fuse s reset breaker with disconnect off Fan switch on Power o...

Page 148: ...eutral or 6 and L2 neutral for RM7890A 5 and L2 neutral or 7 and L2 neutral for RM7897C of the burner control base Verify wiring Flame control defect Replace Burner Lockout Failure to ignite pilot or...

Page 149: ...mplifiers Series 44 Amplifiers are supplied on units equipped with DTC remote panels If problems persist after performing the troubleshooting procedure and the temperature control amplifier troublesho...

Page 150: ...1 Open circuit in TS114 TS10765 Discharge or Inlet Air Sensor Circuit or wirin 12 Jumper not connected across amplifier terminals 2 and 3 F Continuous High Fire electronics ok 13 Foreign object holdin...

Page 151: ...ure drop of the valve see Maxitrol capacity chart 16 Read manifold pressure using manometer and compare with recommen dation of equipment manufacturer 15 Increase inlet pressure if possible 16 See val...

Page 152: ...Temperature 14 Improper TS144 location 15 Incorrect discharge air temperature calibrations G Continuous High Fire electronics ok 16 Foreign material holding valve open 17 Plunger jammed H Continuous H...

Page 153: ...e air temperature 15 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS Sections IV in Maxitrol product information sheet 14 Move TS144 to location where average temperature can be sensed 15...

Page 154: ...B SERIES INSTALLATION OPERATION AND SERVICE MANUAL 144 of 147...

Page 155: ...sheaves set screws and bearing collars Make sure they are tight OK ____ Loose ____ Specify 5 Compare voltage on unit rating plate to job site voltage Job Site Voltage ______ ____ _____ 6 Compare gas t...

Page 156: ...d blowers on ______________ in wc mbar Gas Piping and Initial Pressure Setting Page 77 Section 16 4 1 Perform a pressure test on all gas supply lines to air han dler per local codes OK _____ 2 Verify...

Page 157: ...plate and or serial number are removed defaced modified or altered in any way The ownership of the RAPID 2000 Series is moved or transferred This warranty is non transferable Rapid Engineering LLC is...

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Page 159: ...e __________ Type of Installation check one o Automotive o Manufacturing o Warehouse o Recreational o Aircraft o Public Building o Of ce o Retail o Agricultural o Other______________ Mail or Fax to Ra...

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Rapid 2005, Installation, Operation & Service Manual

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