Rapid 2005 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: [phone]
Fax: [phone]
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 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®2000-Series
Direct, Gas-Fired, Industrial
Air Handler
Installation, Operation &
Service Manual
2005
2010
2010B
2020
2030
P/N RP121100NA RevC 08/15

Conçus pour les applications non-résidentielles
Canada: seulement avec
100% d’air externe
ATTENTION
Linstallation doit être effectuée par un installateur
éprouvé/contractant qualifié dans linstallation et la
maintenance du syst me de chauffage par infrarouge
activé au gaz.
Linstallation, lajustement, laltération, le démarrage
ou lentretien inadéquat peuvent causer la mort, des
blessures ou des dégâts matériels. Lire enti rement
le manuel dinstallation, dopération et dentretien
avant linstallation ou l'entretien de cet équipement.
Installateur
Prenez le temps de lire et comprendre ces instructions
avant toute installation.
Linstallateur doit remettre au propriétaire
un exemplaire de ce manuel.
Propriétaire
Gardez ce manuel dans un endroit sûr pour
fournir des informations au réparateur
en cas de besoin.
Rapid Engineering LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Téléphone: +1.616.784.0500
Fax: [phone]
Numéro sans fraís: 800.536.3461
www.rapidengineering.com
© 2015 Rapid Engineering LLC
AVERTISSEMENT
POUR VOTRE SECURITE
Si vous sentez une odeur de gaz:
1. Ouvrir les fenêtres.
2. N’essayer pas d’allumer un appareil.
3. N’utiliser pas d’interrupteurs
électriques.
4. N’utiliser pas de téléphone dans votre
bâtiment.
5. Eteindre flamme nue.
6. Quitter le bâtiment.
7. Après avoir quitté le bâtiment, appelez
immédiatement votre fournisseur local
de gaz.
Suivre les instructions du fournisseur
de gaz.
8. Si vous ne pouvez pas joindre votre
fournisseur de gaz, appeler le service
d’incendie.
Risque d’incendie
Garder tous les objets, liquides ou vapeurs
inflammables à la distance minimale de
l’unité de chauffage requise avec les
matériaux combustibles.
Certains objets prendront feu ou exploseront
s’ils sont placés à proximité de l’unité de
chauffage.
Le non respect de ces instructions peut
entraîner la mort, des blessures corporelles
ou des dommages matériels.
Rapid®2000-Series
L’appareil de traitment de l’air à
combustion directe, au gaz pour
les applications industrielles
Manuel d'installation,
d'opération,
et d'entretien
2005
2010
2010B
2020
2030
P/N RP121100FC RevC 08/15

TABLE OF CONTENTS
SECTION 1: Air Handler Safety.............................................. 1
1.1 Description of Operation............................................... 1
1.2 Inspection and Setup ................................................... 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 Corrosive Chemicals.................................................... 6
2.3 National Standards and Applicable Codes .................. 7
2.4 Required Equipment .................................................... 7
SECTION 3: Critical Considerations ..................................... 8
3.1 Required Clearances to Combustibles......................... 8
3.2 Purge of Supply Duct ................................................... 9
3.3 Hardware ..................................................................... 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 Structures and Repair Garages .................... 10
4.5 Electrical .................................................................... 10
4.6 Venting....................................................................... 10
4.7 High Altitude .............................................................. 10
SECTION 5: Specifications .................................................. 11
SECTION 6: Liftingan Air Handler ...................................... 17
6.1 Lifting an Air Handler ................................................. 17
SECTION 7: Roof Curb ......................................................... 19
7. 1 R o o f C urb Assembly and Installation ......................... 19
7.2 Air Handler Mounting to Roof Curb ............................ 20
SECTION 8: Upright Stand ................................................... 22
8.1 Upright Stand Installation........................................... 22
8.2 Attaching Air Handler to Stand...................................22
SECTION 9: Legs .................................................................. 24
9.1 Leg Mounting............................................................. 24
9.2 Leg Mounting - Horizontal Air Handler
(2005 - 2030) ............................................................ 24
SECTION 10: Indoor Suspension Mounting- Horizontal
Air Handler .................................................. 26
10.1 Suspension 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 Support 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: Discharge 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 Duct Work ........................................................ 72
15.2 Return Duct Work .................................................... 72
15.3 Discharge Duct Work ............................................... 72
SECTION 16: Gas Piping.......................................................74
16.1 Gas Manifolds...........................................................74
16.2 Gas Piping and Pressures ........................................74
16.3 Gas Manifold Venting................................................74
16.4 Gas Piping ............................................................... 77
16.5 Pressure Test Ports.................................................. 77
16.6 Line Pressure Test - Leak Testing............................ 77
SECTION 17: Electrical......................................................... 78
17.1 Wiring and Electrical Connections............................ 78
17.2 Remote Panel........................................................... 78
17.3 Motor Current Draw.................................................. 78
17.4 Control Current Draw................................................ 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 Exhaust Motor Starters, Variable
Frequency Drives.................................................. 103
17.10 Disconnect Fuse Sizing ........................................ 106
SECTION 18: Sequence of Operation ............................... 108
18.1 Air Handler Configuration ...................................... 108
18.2 HVAC Remote Panels and Panel Options ..............110
18.3 Basic Air Handler Sequence of Operation..............112
SECTION 19: Start-up Procedures .....................................116
19.1 Installation of Recirculating Air Handler..................117
19.2 Mechanical .............................................................117
19.3 Electrical .................................................................118
19.4 Airflow.....................................................................118
19.5 Gas Piping and Initial Pressure Settings.................119
19.6 Safety Shut Off Valve Check.................................. 121
19.7 Temperature Control System Calibration ............... 121
SECTION 20: Maintenance................................................. 124
20.1 General.................................................................. 125
20.2 Unit Exterior........................................................... 125
20.3 Blower Section....................................................... 125
20.4 Manifold and Controls............................................ 128
20.5 Burner.................................................................... 128
20.6 Optional Equipment............................................... 130
SECTION 21: Replacement Parts ...................................... 131
SECTION 22: Troubleshooting.......................................... 136
22.1 Initial Checks ......................................................... 137
22.2 Motor and Blower .................................................. 137
22.3 Burner.................................................................... 138
22.4 Temperature Controls ............................................ 139
22.5 A1014 Amplifier - Field Checklist ........................... 140
22.6 A44 Amplifier - Field Service Checklist.................. 142
SECTION 23: RAPID®2000-Series Start-Up Procedures. 145
SECTION 24: The RAPID®2000-Series Warranty............. 147

© 2015
Rapid Engineering LLC
All rights reserved. No part of this work covered 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 - without the
written permission of Rapid Engineering LLC.
Printed in
the U.S.A.

TABLE OF FIGURES
Figure 1: 2005........................................................................... 3
Figure 2: 2010 and 2010B .........................................................3
Figure 3: 2020 and 2030........................................................... 4
Figure 4: 2000-Series Interior ................................................... 5
Figure 5: 2005 Upright Model Dimensions.............................. 11
Figure 6: 2005 Horizontal Model Dimensions ......................... 12
Figure 7: 2010, 2010B, 2020 and 2030 Upright Model
Dimensions ........................................................... 13
Figure 8: 2010, 2010B, 2020 and 2030 Horizontal Model
Dimensions............................................................ 14
Figure 9: Lifting a Horizontal Air Handler................................17
Figure 10: Lifting an Upright Air Handler (2005 - 2030)........... 18
Figure 11: Roof Curb Assembly .............................................. 20
Figure 12: Curb Mounting ....................................................... 21
Figure 13: Upright Stand Detail (2005) ...................................22
Figure 14: Upright Stand Detail (2010 - 2030)........................22
Figure 15: Stand Shim (2010B - 2030).................................... 23
Figure 16: Upright Stand Mounting Detail ............................... 23
Figure 17: Leg Mounting Holes (2005 - 2030) ........................24
Figure 18: Stud Positioning ..................................................... 25
Figure 19: Leg Bolt Detail .......................................................25
Figure 20: Indoor Suspension (2005) ..................................... 27
Figure 21: Indoor Suspension (2010 and 2010B) ....................28
Figure 22: Filter Section Support Assembly............................ 42
Figure 23: Filter Section Installation on Horizontal Air
Handler (2010 - 2030)...........................................43
Figure 24: Inlet Hood Assembly (2005)................................... 44
Figure 25: Inlet Hood Positioning............................................64
Figure 26: Motorized Discharge Damper (2005 - 2030).......... 66
Figure 27: Motorized Inlet Damper (2005 - 2010B) ................. 67
Figure 28: Motorized Inlet Damper (2020 and 2030) .............. 68
Figure 29: Three-Way Discharge Head
(2005 - 2030) ..........................................................................69
Figure 30: Splash Plate........................................................... 70
Figure 31: Hole Location (2005 - 2030) ..................................71
Figure 32: ANSI/FM/XL-Compliant Manifolds (2005) .............. 75
Figure 33: ANSI-Compliant Manifold (2010 - 2030)................. 75
Figure 34: FM-Compliant Manifold (2010 - 2030).................... 76
Figure 35: XL-Compliant Manifold (2010 - 2030)..................... 76
Figure 36: Plug Tapping (2005) ..............................................77
Figure 37: Plug Tapping (2010 - 2030) ...................................77
Figure 38: Wiring Diagram Key ............................................... 80
Figure 39: Basic Remote Wiring Diagram (2005).................... 81
Figure 40: Standard Discharge Control Remote (SDC) Wiring
Diagram (2005)...................................................... 82
Figure 41: Deluxe Temperature Control Remote (DTC) Wiring
Diagram (2005)...................................................... 83
Figure 42: Basic Remote Wiring Diagram (2010 - 2030) ......... 84
Figure 43: Standard Discharge Control Remote (SDC) Wiring
Diagram (2010 - 2030) ........................................... 85
Figure 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 Control AM Style Units (2010 - 2010B)89
Figure 48: Additional Control Wiring for VAV Style (2010 and
2010B).................................................................... 90
Figure 49: Additional Control Wiring for VAV Style
(2020 - 2030) ........................................................ 91
Figure 50: BMS-Ready Control for VAV Style
(2010 and 2010B) ................................................ 92
Figure 51: BMS-Ready Control for VAV Style (2020 - 2030) .. 93
Figure 52: BMS-Ready Control for VAV Style with Inlet Damper
(2020 - 2030)......................................................... 94
Figure 53: Additional Control Wiring for VAV Style with Inlet
Damper (2020 - 2030) ........................................... 95
Figure 54: AM Style for 2010 and 2010B................................. 96
Figure 55: AM Style for 2020 - 2030....................................... 96
Figure 56: CO2 Sensor Interlock for FR and MUA Style ........ 97
Figure 57: CO2 Sensor Interlock for AM and VAV Style
(2010 and 2010B) ............................................... 97
Figure 58: CO2 Sensor Interlock for AM and VAV Style
(2020 and 2030) ................................................. 97
Figure 59: CO Sensor Interlock for FR and MUA ................... 98
Figure 60: CO Sensor Interlock for AM and VAV ................... 98
Figure 61: CO Sensor Interlock for AM and VAV with
Photohelic ........................................................... 98
Figure 62: CO Sensor Interlock for AM with Building
Pressure ............................................................. 98
Figure 63: J-1000 1 Pot 7.5HP or Less ................................. 103
Figure 64: V-1000 1 Pot 10-25HP ......................................... 103
Figure 65: P7 1 Pot 30HP or More........................................ 104
Figure 66: J-1000 VFD 7.5HP or Less with Photohelic ......... 104
Figure 67: V-1000 VFD 10 to 25HP with Photohelic.............. 105
Figure 68: P7 30HP or More with Photohelic........................ 106
Figure 69: Single Exhaust Starter......................................... 107
Figure 70: Two Exhaust Starter ............................................ 107
Figure 71: Air Handler Styles................................................ 109
Figure 72: Honeywell Safeguard Jumpers ........................... 112
Figure 73: S8600 Flame Control (2005) ................................113
Figure 74: RM7890 Flame Control (2010 and 2010B) ............114
Figure 75: RM7897 Flame Control (2020 - 2030) ..................115
Figure 76: Sheave Alignment ............................................... 117
Figure 77: Belt Tension ........................................................ 118
Figure 78: Honeywell Flame Module .................................... 119
Figure 79: MR 212 Valve (2010 - 2030) ................................ 122
Figure 80: M611 Valve (2005) ............................................... 123
Figure 81: Regulator (2005).................................................. 123
Figure 82: 6" (15.3 cm) Straight Cast Iron ............................ 129
Figure 83: 12" (30.5 cm) Straight Cast Iron .......................... 129
Figure 84: 12" (30.5 cm) Tee Cast Iron ................................ 129
Figure 85: Control Panel Layouts.......................................... 131
Figure 86: Power Panel Layout ............................................. 132
Figure 87: Blower Layout ...................................................... 134

LIST OF TABLES
Table 1: Recommended Torque Settings................................. 9
Table 2: 2005 Dimensions...................................................... 11
Table 3: 2005 Weights ........................................................... 12
Table 4: Motor Weights .......................................................... 12
Table 5: 2010, 2010B, 2020 and 2030 Dimensions ............... 13
Table 6: 2010, 2010B, 2020 and 2030 Weights ..................... 14
Table 7: Motor Weights .......................................................... 14
Table 8: 2000-Series Selection Guide.................................... 15
Table 9: Estimated Pressure Drop of Accessory
Components ............................................................. 16
Table 10: Minimum Recommended Duct Size ....................... 73
Table 11: Discharge Duct Size Recommendations to
Connect to Heater (for BD/RD)............................. 73
Table 12: Gas Manifold Size .................................................. 74
Table 13: Control Voltage Wiring For All Control Systems..... 78
Table 14: Full Load Current Draw.......................................... 79
Table 15: Safety Systems....................................................... 79
Table 16: Minimum and Maximum Fuse Size by Motor Size
and Supply Voltage............................................. 106
Table 17: Configuration Chart .............................................. 109
Table 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 Specifications .......... 119
Table 22: Motor and Blower Bushing Torque
Specifications...................................................... 119
Table 23: Burner Mode by Amplifier Type............................ 121
Table 24: Maximum Temperature Rise ................................ 121
Table 25: Motor Lubrication Intervals ................................... 127
Table 26: Burner Selections ................................................. 129
Table 27: Control Panel........................................................ 132
Table 28: Power Panel ......................................................... 133
Table 29: Manifold Components........................................... 134
Table 30: Blower .................................................................. 134
Table 31: Remote Panel....................................................... 135
Table 32: V-Belt.................................................................... 135
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.