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.

SECTION 1: AIR HANDLER SAFETY
1 of 147
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 in accordance to the
Occupational Safety and Health Administration
(OSHA). Gear must be in accordance to NFPA 70E,
latest revision when working with electrical
components. 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 piece of equipment 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
equipment by a person responsible for their safety.
Children should be supervised to ensure that they do
not play with the equipment.
For additional copies of the Installation, Operation
and Service Manual, please contact Rapid
Engineering LLC.
Gas-fired equipment is 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, gas-fired, fresh-air piece
of equipment. 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). The air
handler is factory-tested to fire with natural gas or
LPG (check the air handler's rating plate for
information on the appropriate gas). The burner
flame will modulate to maintain the selected
discharge air temperature or room air temperature,
depending on the selected controls. See Page 110,
Section 18.2. For maximum temperature rise, See
Page 121, Table 24.
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 is shipped fully assembled. The air
handler was inspected and operated prior to
shipment. Immediately upon receipt of the air
handler, check the fuel and electrical characteristics
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 (i.e. remote panel) 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. Check the bill of lading for information.
If the air handler must be temporarily stored (i.e. job
site is not ready for installation of the air handler), the
air handler should be set on 4" x 4" (10 cm x 10 cm)
pieces of timber on the ground in a protected area.
Cover the air handler to protect it from the
environment. Rapid Engineering LLC will not be held
responsible for any damages that may occur from

B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
2 of 147
outdoor storage.
1.3 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 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 of the equipment (i.e.,
near equipment's serial plate). See label placement
drawing on Page 3, Figure 1 through Page 4, 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.

SECTION 1: AIR HANDLER SAFETY
3 of 147
1.5 Label Placement
FIGURE 1: 2005
FIGURE 2: 2010 and 2010B
AIR FLOW AIR FLOW
AIR FLOW
AIR FLOW
CONTROL ENCLOSURE
CONTROL ENCLOSURE
1
7
1
7
2
2
4
2
4
3ON SHRINK WRAP
4
5
5
6
2
46
8ON SHRINK WRAP BY CONTROL ENCLOSURE
9
10
9
10
11
11
12
12
Item Part Number Description
1 91070001 Label Shock Hazard
2 91070002 Label Severe Injury Hazard
3 91070003 Label Crush Hazard
4 91070004 Label Fire Hazard
5 91070005 Label Falling Hazard
6 91070006 Label Burn Hazard
7 19205 Label 2000-Series
8 91010100 Label Manual Location
9 19030 Label Recommended Entry
10 91010427 Label Vent to Outdoors
11 91010431 Label Improper Installation
12 91070015 Label Proposition 65
2
46
1
45
2
6
7
2
7
2
4
4
x
1
7
x
3ON SHRINK WRAP
7
AIR FLOW AIR FLOW
AIR FLOW AIR FLOW
55
5
8ON SHRINK WRAP
BY CONTROL ENCLOSURE
9
10
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
LOCATED OVER THE
REGULATOR VENTS
9
10
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
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 91070003 Label Crush Hazard
4 91070004 Label Fire Hazard
5 91070005 Label Falling Hazard
6 91070006 Label Burn Hazard
7 19205 Label 2000-Series
8 91010100 Label Manual Location
9 19030 Label Recommended Entry
10 91010427 Label Vent to Outdoors
11 91010431 Label Improper Installation
12 91070015 Label Proposition 65

B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
4 of 147
FIGURE 3: 2020 and 2030
x
x
4
5
3ON SHRINK WRAP
7
1
2
46
7
1
24
6
2
2
4
AIR FLOW AIR FLOW
AIR FLOW AIR FLOW
5 5
5
8ON SHRINK WRAP BY CONTROL ENCLOSURE
9
10
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
LOCATED OVER THE
REGULATOR VENTS
9
LOCATED 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 91070003 Label Crush Hazard
4 91070004 Label Fire Hazard
5 91070005 Label Falling Hazard
6 91070006 Label Burn Hazard
7 19205 Label 2000-Series
8 91010100 Label Manual Location
9 19030 Label Recommended Entry
10 91010427 Label Vent to Outdoors
11 91010431 Label Improper Installation
12 91070015 Label Proposition 65

SECTION 1: AIR HANDLER SAFETY
5 of 147
FIGURE 4: 2000-Series Interior
5
GROUND
LUG ON
BURNER
END RS
PANEL
NOTE:-LABEL 3, 4, AND 10 MUST BE ORIENTATED
SO THAT IT CAN BE READ FROM TOP-LEFT
TO BOTTOM-RIGHT WHEN THE AIR HANDLER
IS INSTALLED AT THE JOB SITE.
-LABEL 15 IS USED ANY TIME THERE IS A
GFI OUTLET THAT
IS POWERED BY OTHERS. TO BE POSITIONED
NEXT TO LABEL 8 AND/OR 14.
8 or 14
2005 MOUNT
ON ENCL FLOOR
UNDER VFD/AUX
MOTOR STARTER
15
8 AND/OR 14
2010-2030 SPLASH PLATE MOUNTED
ON CONTROL ENCLOSURE BOTTOM PANEL
2005 CONTROL ENCLOSURE FLOOR UNDER
VFD/AUX MOTOR STARTER
15
16
1 OR 2
SAFETY
SHUTOFF
VALVE
IGNITION
TRANSFORMER
TRANSFORMER
40VA
AMPLIFIER
AIRFLOW
SWITCH
0.32INW.C.
R6
AIRFLOW
SWITCH
1.40INW.C. 10
7
9
SPLASH PLATE MOUNTED
ON CONTROL ENCLOSURE
DOOR
CONTROL ENCLOSURE DOOR
11 or 12
13 PLACE INSIDE ITEM #9
2010-2030
7
9
2005 CONTROL ENCLOSURE DOOR
13 PLACE INSIDE ITEM #9
11 or 12
NAMEPLATE
3MOTOR
4
3
BLOWER
HIGH TEMP LIMIT SWITCH DISCHARGE SENSOR
6
REMOTE BOX
RIGHT SIDE
TERMINAL RAIL
REMOTE BOX 10X10 INTERNAL
10
11
REMOTE BOX
LEFT SIDE
16
10
TERMINAL RAIL
REMOTE BOX 12x16 INTERNAL
6
REMOTE BOX
RIGHT SIDE
11 or 12
REMOTE BOX
LEFT SIDE
16
Item Part Number Description Qty.
1 19024 Label - Propane Gas 1
2 19025 Label - Natural Gas 1
3 19162 Label - Rotation 1
4 19161 Label - High Temperature Limit 1
5 19100 Label - Ground 1
6 91070009 Label - Electric Shock Hazard (Mini) 1
7 91010444 Label - 2000-Series Rating Plate 1
8 91010443 Label - 2000-Series Exhaust Fan Motor Control 1
9 90911300 9½" x 13" Clear Pouch 1
10 91010445 Label - 2000-Series Wire Connection Control Panel/
Remote Panel 2
11 91010446 Label - ETL Certification Without Recirculation Z83.4 2
12 91010447 Label - ETL Certification With Recirculation Z83.18 2
13 80XXX Wiring Diagram - Varies by Order 2
14 91040128 Label - Auxiliary Motor Starter 1
15 91010448 Label - Shock Hazard GFI 1

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SECTION 2: INSTALLER RESPONSIBILITY
The installer is responsible for the following:
• To install and commission the air handler, as well
as the gas and electrical supplies, in accordance
with applicable specifications and codes. Rapid
Engineering LLC recommends the installer
contact a local building inspector or Fire Marshal
for guidance.
•Touse the information given in a layout drawing
and in the manual together with the cited codes
and regulations to perform the installation.
• To install the heater in accordance with the
clearances to combustibles.
•Tofurnish all needed materials not furnished as
standard equipment.
• To plan location of supports.
• To provide access to
air handler for servicing.
• To provide the owner with a copy of this
Installation, Operation and Service Manual.
• To never use heater as support for a ladder or
other access equipment and never hang or
suspend anything from heater.
•Toensure there is adequate air circulation around
the air handler and to supply air for combustion,
ventilation and distribution in accordance with
local codes.
• To assemble or install any accessories or
associated duct work using best building
practices.
• To properly size supports and hanging materials.
• To ensure heater is placed in an approved
application.
2.1 Wall Tag
A laminated wall tag is available for the heater as a
permanent reminder of the safety instructions and
the importance of the required clearances to
combustibles. Please contact Rapid Engineering LLC
or your RAPID®independent distributor to obtain the
wall tag. Affix the tag on a wall 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, youmay
affix this copy on the wall near the heater.
Knowyour model number and installed configuration.
Model number and installed configuration are found
on the rating plate and in the Installation, Operation
and Service Manual. See Page 3, Figure 1 through
Page 4, Figure 3.
2.2 Corrosive Chemicals
Rapid Engineering LLC cannot be responsible for
ensuring that all appropriate safety measures are
undertaken prior to installation; this is entirely the
responsibility of the installer. It is essential that the
contractor, the sub-contractor, or the owner identifies
the presence of combustible materials, corrosive
chemicals or halogenated hydrocarbons* anywhere
in the premises.
* HalogenatedHydrocarbons are a family of chemical
compounds characterized by the presence of halogen elements
(fluorine, chlorine, bromine, etc.). These compounds are
frequently used in refrigerants, cleaning agents, solvents, etc. If
these compounds enter the air supply of the burner, the life span
of the air handler components will be greatly reduced. The loca-
tion of the outside air supply must be carefully chosen to supply
outside air, free of these compounds, to the burners whenever
the presence of these compounds is suspect. Warranty will be
invalid if the air handler is exposed to halogenated hydrocar-
bons.
WARNING
Explosion Hazard
Equipment must have access to
uncontaminated air at all times.
Failure to follow these instructions can result
in death, injury or property damage.
CAUTION
Product Damage Hazard
Do not use equipment in area containing
corrosive chemicals.
Refer to appropriate Material Safety Data
Sheets (MSDS).
Failure to follow these instructions can result
in product damage.

SECTION 2: INSTALLER RESPONSIBILITY
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2.3 National Standards and Applicable Codes
All equipment must be installed in accordance with
the latest revision of the applicable standards and
national codes. This refers also to the electric, gas
and venting installation. Note: Additional standards
for installation in public garages, aircraft hangars, etc.
may be applicable.
2.4 Required Equipment
When lifting of the equipment is required, the
installing contractor is responsible 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 for having the appropriate equipment for
the safe installation and start-up of a direct-fired air
handler. Tools required to commission the equipment
include, but are not limited to, the following:
• Various screwdriver types and sizes
• Various adjustable wrenches
• Torque wrenches
• Pipe wrenches sized appropriately for the gas
train components
• Drill motor and various drills
• U-tube manometer or gas pressure gauge
• Volt meter
• Clamp style ammeter
• Belt tension gauge
• Caulk (non-silicone)

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SECTION 3: CRITICAL CONSIDERATIONS 3.1 Required Clearances to Combustibles
Clearances are the required distances that
combustible objects must be away from the air
handler to prevent fire hazards. Combustibles are
materials that may catch on fire and include common
items such as wood, paper, rubber, fabric, etc.
Maintain clearances to combustibles at all times
for safety.
Check the clearances on each air handler being
installed to make sure the product is suitable for your
application and the clearances are maintained.
Clearances to combustibles for models 2005-
2030 are 12" (30.5 cm) on the control enclosure side
and 6" (15.2 cm) on all other surfaces. Read and
followthe safety guidelines below:
• Locate the air handler so that the air intakes are
not too close to any exhaust fan outlets, gasoline
storage, propane tanks or other contaminants that
could potentially cause dangerous situations.
• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or
vapors away from this air handler or any other
piece of
equipment .
• Maintain clearances from heat sensitive 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 to the control enclosure, blower
access panel and filter access panel (when
equipped).
The stated clearances to combustibles represent a
surface temperature of 90° F (50° C) above room
temperature (90° F [50° C] plus ambient
temperature). Building materials with a lowheat
tolerance (i.e. plastics, vinyl siding, canvas, tri-ply,
etc.) may be subject to degradation at lower
temperatures. It is the installer’s/owner’s
responsibility to assure that adjacent materials are
protected from degradation.
•Maintain clearances from vehicles parked belowthe
air handler. See Page 10, Section 4.4.
WARNING
Fire Hazard
Keep all flammable objects, liquids and
vapors the minimum required clearances 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.
WARNING
Explosion Hazard
Fresh air supply duct and burner housing
must be purged with fresh air four times
before every ignition.
Explosive vapors will ignite if not evacuated
before ignition attempt.
Failure to follow these instructions can result
in death, injury or property damage.

SECTION 3: CRITICAL C ONSIDERATIONS
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3.2 Purge of Supply Duct
If this heating unit is to be installed indoors, and its
outdoor air supply ducted from outdoors, ANSI
Standards Z83.18 and Z83.4 require that all supply
duct shall be purged a minimum of four times prior to
any ignition attempt. If the volume of the outdoor air
supply duct exceeds the heating unit’s ability to
complete the required four air changes prior to
ignition, youmust contact the factory to purchase an
extended purge card of 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 with
inlet opening facing into the prevailing wind direction
in order to help prevent the possibility of moisture
entrainment.
Table 1: Recommended Torque Settings
Bolt Head
Grade Marking
Nut Grade
Marking
Bolt Size Grade 2 Grade 5
10-24 27 in•lb 42 in•lb
1/4-20 65 in•lb 101 in•lb
5/16-18 11 ft•lb 17 ft•lb
3/8-16 19 ft•lb 30 ft•lb
Bolt Head
Grade Marking
Nut Grade
Marking
Bolt Size Grade 8.8Grade 10.9
M5 6Nm 9Nm
M6 10Nm 15Nm
M8 25Nm 35Nm
M10 50Nm 75Nm
M12 85Nm 130Nm
M16 215Nm 315Nm
8.8
10.9
8.8 10.9

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SECTION 4: NATIONAL STANDARDS AND
APPLICABLE CODES
4.1 Gas Codes
The type of gas appearing on the nameplate
must be the type of gas used. Installation must
comply with national and local codes and
requirements of the local gas company.
United States: Refer to NFPA 54/ANSI Z223.1 -
latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1- latest revision,
Natural Gas and Propane Installation Code.
4.2 Installation Codes
Installations must be made in accordance with
the Standard for the Installation of Air-
Conditioning and Ventilating Systems, NFPA
90A - latest revision for the installation of air
conditioning and ventilating systems.
4.3 Aircraft Hangars
Installation in aircraft hangars must be in
accordance with the following codes:
United States: Refer to Standard on Aircraft
Hangars, NFPA 409 - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code, Standard CSA B149.1 - latest
revision.
4.4 ParkingStructures and Repair Garages
Installation 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 Garages, NFPA 30A - latest revision.
Canada: Refer to Natural Gas and Propane
Installation Code, Standard CSA B149.1 - latest
revision.
4.5 Electrical
Electrical connection to air handler must be in
accordance with the following codes:
United States: Refer to National Electrical
Code®, NFPA 70 - latest revision. Wiring must
conform to the most current National Electrical
Code®, local ordinances, and any special
diagrams furnished.
Canada: Refer to Canadian Electrical Code,
CSA C22.1 Part 1 - latest revision.
4.6 Venting
The venting must be installed in accordance
with the requirements within this manual and
the following codes:
United States: Refer to NFPA 54/ANSI Z223.1-
latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision,
Natural Gas and Propane Installation Code.
4.7 High Altitude
These air handlers are approved for
installations up to 2000' (609.6 m) (in the US)
and 4500' (1371.6 m) (in Canada) without
modification. Consult factory if US installation is
above 2000
' (609.6 m) or Canadian installation
is above 4500
' (1371.6 m).