Rapid 2005, Installation, Operation & Service Manual

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TABLE OF CONTENTS
SECTION 1: Air Handler Safety.............................................. 1
1.1 Description of Operation............................................... 1
1.2 Inspection and Set
u p ................................................... 1
1.3 Safety Labels and Their Placement ............................. 2
1.4 California Proposition 65 .............................................. 2
1.5 Label Placement .......................................................... 3
SECTION 2: Installer Responsibility ..................................... 6
2.1 Wall Tag ....................................................................... 6
2.2 Corrosi
v e Chemicals.................................................... 6
2.3 National Standards and Applicable Codes .................. 7
2.4 Req
u ired Eq u ipment .................................................... 7
SECTION 3: Critical Considerations ..................................... 8
3.1 Req u ired Clearances to Comb u stibles......................... 8
3.2 P u rge of S u pply D u ct ................................................... 9
3.3 Hard w are ..................................................................... 9
SECTION 4: National Standards and Applicable Codes ... 10
4.1 Gas Codes................................................................. 10
4.2 Installation Codes ...................................................... 10
4.3 Aircraft Hangars ......................................................... 10
4.4 Parking Str
u ct u res and Repair Garages .................... 10
4.5 Electrical .................................................................... 10
4.6 Venting....................................................................... 10
4.7 High Altit
u de .............................................................. 10
SECTION 5: Specifications .................................................. 11
SECTION 6: Liftin
g an Air Handler ...................................... 17
6.1 Lifting an Air Handler ................................................. 17
SECTION 7: Roof Curb ......................................................... 19
7.1 Roof C u rb Assembly and Installation ......................... 19
7.2 Air Handler Mo u nting to Roof C u rb ............................ 20
SECTION 8 : Upri g ht Stand ................................................... 22
8.1 Upright Stand Installation........................................... 22
8.2 Attaching Air Handler to Stand................................... 22
SECTION 9: Le g s .................................................................. 24
9.1 Leg Mo u nting ............................................................. 24
9.2 Leg Mo u nting - Horizontal Air Handler
(2005 - 2030) ............................................................ 24
SECTION 10: Indoor Suspension Mountin g - Horizontal
Air Handler .................................................. 26
10.1 S u spension Kit Assembly and Installation ............... 26
SECTION 11: Filter Section .................................................. 29
11.1 Filter Section (2005) ................................................. 29
11.2 Filter Section Assembly (2010 and 2010B) ............... 30
11.3 Filter Section Assembly (2020 and 2030) ................. 34
11.4 Filter Section S
u pport Assembly............................... 41
11.5 Filter Section Installation - Horizontal Air Handlers... 43
11.6 Filter Section Installation - Upright Air Handlers ....... 43
SECTION 12: Inlet Hood ....................................................... 44
12.1 Inlet Hood Assembly (2005) .................................... 44
12.2 Inlet Hood Assembly (2010 and 2010B) ................... 45
12.3 Inlet Hood Assembly (2020 and 2030) .................... 54
12.4 Inlet Hood Installation .............................................. 64
SECTION 13: Dampers ......................................................... 65
13.1 Discharge Damper ................................................... 66
13.2 Inlet Damper ............................................................ 67
SECTION 14: Dischar g e Heads and Splash Plates ............ 69
14.1 One-Way and Three-Way Discharge Head
Installation ................................................................ 69
14.2 Splash Plate Installation........................................... 70
SECTION 15: Duct Considerations...................................... 72
15.1 Inlet D u ct Work ........................................................ 72
15.2 Ret u rn D u ct Work .................................................... 72
15.3 Discharge D u ct Work ............................................... 72
SECTION 16: Gas Pipin g .......................................................74
16.1 Gas Manifolds...........................................................74
16.2 Gas Piping and Press
u res ........................................74
16.3 Gas Manifold Venting................................................74
16.4 Gas Piping ............................................................... 77
16.5 Press
u re Test Ports.................................................. 77
16.6 Line Press u re Test - Leak Testing............................ 77
SECTION 17: Electrical......................................................... 7 8
17.1 Wiring and Electrical Connections............................ 78
17.2 Remote Panel........................................................... 78
17.3 Motor C
u rrent Dra w .................................................. 78
17.4 Control C u rrent Dra w ................................................ 78
17.5 Safety Systems......................................................... 78
17.6 Additional Control Wiring .......................................... 90
17.7 Carbon Dioxide Interlocks ........................................ 97
17.8 Control Options ........................................................ 97
17.9 Optional Exha
u st Motor Starters, Variable
Freq u ency Dri v es.................................................. 103
17.10 Disconnect F u se Sizing ........................................ 106
SECTION 1 8 : Se q uence of Operation ............................... 10 8
18.1 Air Handler Config u ration ...................................... 108
18.2 HVAC Remote Panels and Panel Options .............. 110
18.3 Basic Air Handler Seq
u ence of Operation ..............112
SECTION 19: Start-up Procedures .....................................116
19.1 Installation of Recirc u lating Air Handler ..................117
19.2 Mechanical .............................................................117
19.3 Electrical .................................................................118
19.4 Airflo
w .....................................................................118
19.5 Gas Piping and Initial Press u re Settings.................119
19.6 Safety Sh u t Off Val v e Check.................................. 121
19.7 Temperat u re Control System Calibration ............... 121
SECTION 20: Maintenance................................................. 124
20.1 General.................................................................. 125
20.2 Unit Exterior........................................................... 125
20.3 Blo
w er Section....................................................... 125
20.4 Manifold and Controls............................................ 128
20.5 B
u rner.................................................................... 128
20.6 Optional Eq u ipment ............................................... 130
SECTION 21: Replacement Parts ...................................... 131
SECTION 22: Troubleshootin
g .......................................... 136
22.1 Initial Checks ......................................................... 137
22.2 Motor and Blo
w er .................................................. 137
22.3 B u rner.................................................................... 138
22.4 Temperat u re Controls ............................................ 139
22.5 A1014 Amplifier - Field Checklist ........................... 140
22.6 A44 Amplifier - Field Ser
v ice Checklist.................. 142
SECTION 23: RAPID ® 2000-Series Start-Up Procedures. 145
SECTION 24: The RAPID
®
2000-Series Warranty............. 147