Rapid 4044 Manual

NOT FOR RESIDENTIAL USE
WARNING
Installation must be done by a contractor qualified
in the installation and service of gas-fired heating
equipment or your gas supplier.
Improper installation, adjustment, alteration, service
or maintenance can result in death, injury or
property damage. Read the Installation, Operation
and Service Manual thoroughly before installing or
servicing this equipment.
Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Rapid Engineering LLC
1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: [phone]
Fax: [phone]
www.rapidengineering.com
© 2018 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®4000-Series
Direct-Fired Air Handler
Installation, Operation &
Service Manual
4024
4036
4040
4044
4049
4054
4060
4066
4073
4080
4089
P/N RP140000NA RevA 03/18

TABLE OF CONTENTS
SECTION 1: Air Handler Safety.............................................. 1
1.1 Description of Operation............................................... 1
1.2 Inspection and Setup ................................................... 1
1.3 Temporary Storage....................................................... 2
1.4 Safety Labels and Their Placement .............................2
1.5 California Proposition 65 ..............................................2
1.6 Label Placement .......................................................... 3
SECTION 2: Installer Responsibility ..................................... 6
2.1 Corrosive Chemicals.................................................... 6
2.2 National Standards and Applicable Codes .................. 6
2.3 Required Equipment .................................................... 6
SECTION 3: Critical Considerations ..................................... 8
3.1 Required Clearances to Combustibles......................... 8
3.2 Hardware ..................................................................... 8
SECTION 4: National Standards and Applicable Codes ..... 9
4.1 Gas Codes................................................................... 9
4.2 Installation Codes ........................................................ 9
4.3 Aircraft Hangars ........................................................... 9
4.4 Parking Structures and Repair Garages ...................... 9
4.5 Electrical ...................................................................... 9
4.6 Venting......................................................................... 9
4.7 High Altitude ................................................................ 9
SECTION 5: Specifications .................................................. 10
SECTION 6: Liftingan Air Handler (Rigging)...................... 27
6.1 Preparing to Lift the Air Handler.................................27
6.2 Lifting a Horizontal Air Handler ..................................28
6.3 Lifting an Vertical Air Handler ....................................29
6.4 Upright Assembly Alignment...................................... 31
SECTION 7: Air Handler Assembly...................................... 32
7. 1 C a ulking the Air Handler............................................. 33
7. 2 C a ulking a Horizontal Air Handler............................... 34
7. 3 C a ulking an Vertical Air Handler................................. 35
7.4 Accessory Connections.............................................. 37
SECTION 8: Roof Curb ......................................................... 41
8.1 Roof Curb Assembly and Installation......................... 41
SECTION 9: Indoor Suspension Mounting-
Horizontal Air Handler .................................... 46
9.1 Suspension Mounting Assembly and Instructions ..... 46
SECTION 10: LegMounting................................................. 48
SECTION 11: Filter Section .................................................. 51
SECTION 12: Inlet Hoods ..................................................... 52
12.1 Inlet Hood Assembly ................................................ 52
SECTION 13: Service Platform............................................. 55
13.1 Service Platform ...................................................... 55
SECTION 14: Discharge accessories .................................. 57
14.1 One-Way, Three-Way and Four-Way Discharge
Head Installation ...................................................... 57
14.2 Splash Plate Installation........................................... 63
SECTION 15: Vibration Isolation.......................................... 64
SECTION 16: CoolingSpecifications .................................. 68
16.1 Evaporative Cooling ................................................. 68
SECTION 17: Duct Considerations...................................... 69
17.1 Inlet Air Duct ............................................................. 69
17.2 Return Air Duct ......................................................... 69
17.3 Supply Air Duct Work ............................................... 69
SECTION 18: Gas Piping...................................................... 70
18.1 Gas Manifolds.......................................................... 70
18.2 Gas Piping and Pressures ....................................... 70
18.3 Gas Piping ................................................................74
18.4 Pressure Test Ports...................................................74
SECTION 19: Electrical......................................................... 75
19.1 Disconnect Fuse Sizing .......................................... 76
19.2 Wiring and Electrical Connections ........................... 76
19.3 Remote Panel .......................................................... 76
19.4 Motor Current Draw................................................. 76
19.5 Control Current Draw............................................... 77
19.6 Safety Systems........................................................ 77
19.7 Interlocks ................................................................. 79
19.8 Control Options........................................................ 79
19.9 Safety Systems........................................................ 81
19.10 Remote Panels ...................................................... 82
19.11 DDC-Ready Controls ............................................. 90
19.12 Intelligent Control Systems .................................... 92
19.13 HVAC Remote Panels and Panel Options ............. 94
19.14 Basic Air Handler Sequence of Operation ............. 96
19.15 Honeywell®RM7890 Flame Safeguard................ 100
SECTION 20: Direct Fired Burner .......................................112
20.1 Direct Fired Burner Ignition.....................................115
20.2 Direct Fired Burner Flame Proving (Flame Rod) ....116
20.3 Honeywell UV Flame Detector ...............................119
20.4 Honeywell UV Flame Detector (Continued)........... 120
SECTION 21: Start-up Procedures .................................... 121
21.1 Installation of Recirculating Air Handler ................. 122
21.2 Mechanical............................................................. 122
21.3 Electrical ................................................................ 123
21.4 Airflow.................................................................... 123
21.5 Gas Piping and Initial Pressure Settings ................ 124
21.6 Safety Shut Off Valve Check .................................. 126
21.7 Temperature Control System Calibration................ 126
SECTION 22: Maintenance................................................. 129
22.1 General.................................................................. 130
22.2 Unit Exterior........................................................... 130
22.3 Blower Section...................................................... 130
22.4 Manifold and Controls............................................ 132
22.5 Burner................................................................... 132
22.6 Optional Equipment............................................... 134
SECTION 23: Replacement Parts ...................................... 135
SECTION 24: Troubleshooting.......................................... 136
24.1 Initial Checks ......................................................... 137
24.2 Motor and Blower ................................................. 137
24.3 Burner................................................................... 138
24.4 Temperature Controls ........................................... 139
24.5 A1014 Amplifier - Field Checklist .......................... 140
SECTION 25: RAPID®4000-Series Start-Up Procedures. 143
SECTION 26: RAPID®4000-Series Start-Up Procedures
Evaporative Cooler ............................................................. 148
SECTION 27: The RAPID®4000-Series Warranty............. 151
© 2018
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.

LIST OF TABLES
Table 1: Recommended Torque Settings................................. 8
Table 2: 4000 AM Dimensions ............................................... 11
Table 3: 4000 AM Approximate Shipping Weights................. 12
Table 4: 4000 MUA Dimensions............................................. 13
Table 5: 4000 MUA Approximate Shipping Weights .............. 14
Table 6: 4000 FR Dimensions................................................ 15
Table 7: 4000 FR Approximate Shipping Weights.................. 16
Table 8: 4000 VAV Dimensions.............................................. 17
Table 9: 4000 VAV Approximate Shipping Weights ............... 18
Table 10: Dimensions............................................................. 19
Table 11: Leaving Dry Bulb Temperature Drop (Average) ..... 19
Table 12: Air Density Ratio..................................................... 20
Table 13: Dimensions............................................................. 21
Table 14: Estimated Tons of Cooling ..................................... 21
Table 15: Dimensions............................................................. 22
Table 16: Energy Recovery.................................................... 23
Table 17: Fan Selection Chart................................................ 24
Table 18: Fan Selection Chart (continued)............................. 25
Table 19: Static Pressure Drops for Options.......................... 26
Table 20: Roof Curbs (availability based on style) ................. 41
Table 21: Formulas................................................................. 68
Table 22: Abbreviations.......................................................... 68
Table 23: Evaporation Rate.................................................... 68
Table 24: Suggested Air Changes Per Hour
(Air Change Method) .............................................. 68
Table 25: Saturation Efficiency at Stated Media Depth.......... 68
Table 26: Static Pressure Drop (in wc) at Stated
Media Depth ........................................................... 68
Table 27: Manifold Component Identification ......................... 71
Table 28: Minimum and Maximum Fuse Size by Motor
Size and Supply Voltage ........................................ 76
Table 29: Control Voltage Wiring For All Control Systems..... 76
Table 30: Safety Systems....................................................... 77
Table 31: Safety Systems....................................................... 81
Table 32: Factory Preset Schedule on TH8110 Thermostat .. 96
Table 33: Jumper Settings...................................................... 98
Table 34: Deflection Force B and BX Belts (in lbs) .............. 123
Table 35: Motor Sheave Drive Torque Specifications .......... 124
Table 36: Motor and Blower Bushing Torque Specifications 124
Table 37: Burner Mode by Amplifier Type............................ 125
Table 38: Maximum Temperature Rise ................................ 126
Table 39: Motor Lubrication Intervals ................................... 133
There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the
property of their respective owners. Rapid Engineering LLC is not sponsored by or affiliated with any of the trademark or registered
trademark owners, and makes no representations about them, their owners, their products or services.

TABLE OF FIGURES
Figure 1: 4024 - 4049................................................................ 3
Figure 2: 4054 and 4089........................................................... 4
Figure 3: 4000-Series Interior ................................................... 5
Figure 4: 4000 AM Vertical Model Dimensions ....................... 11
Figure 5: 4000 AM Horizontal Model Dimensions................... 12
Figure 6: 4000 MUA Vertical Model Dimensions..................... 13
Figure 7: 4000 MUA Horizontal Model Dimensions ................ 14
Figure 8: 4000 FR Vertical Model Dimensions........................ 15
Figure 9: 4000 FR Horizontal Model Dimensions ................... 16
Figure 10: 4000 VAV Vertical Model Dimensions.................... 17
Figure 11: 4000 VAV Horizontal Model Dimensions ................ 18
Figure 12: Evaporative Cooling...............................................19
Figure 13: Mechanical Cooling................................................ 21
Figure 14: Energy Recovery ...................................................22
Figure 15: Lifting a Horizontal Air Handler Filter Section and
Options (Model 4024 - 4049) ................................. 28
Figure 16: Lifting a Horizontal Air Handler with Options (Model
4054 - 4089) .......................................................... 28
Figure 17: Lifting an Vertical Air Handler (All Models)............. 29
Figure 18: Lifting an Vertical Air Handler with Filter Section and
Mixing Box ............................................................. 30
Figure 19: Inlet Alignment .......................................................31
Figure 20: Caulking Air Handler Joints.................................... 33
Figure 21: Caulking a Standard Horizontal Air Handler........... 34
Figure 22: Caulking a Standard Vertical Air Handler............... 35
Figure 23: Assembling Optional Discharge / Supply and Return
Sleeves. ................................................................. 36
Figure 24: Electrically Connecting Joined Sections ................ 37
Figure 25: Installing Cooling Coil Section ............................... 37
Figure 26: Installing Pressure Transmitter Tubing for AM and VAV
38
Figure 27: Typical Freeze Protection (Evaporative Cooling
Package #1) ........................................................... 38
Figure 28: Conductivity Control and Freeze Protection
(Evaporative Cooling Package #2).........................39
Figure 29: Protection and Auto-Flush (Evaporative Cooling
Package #3) ........................................................... 39
Figure 30: Evaporative Cooling Trap Detail.............................40
Figure 31: Roof Curb............................................................... 42
Figure 32: Roof Curb Installation ............................................ 43
Figure 33: Roof Curb Assembly with Brackets........................ 44
Figure 34: Duct Support Adapter ............................................ 45
Figure 35: Indoor Suspension................................................. 47
Figure 36: Assembling Legs for Horizontal Air Handlers......... 49
Figure 37: Assembly Legs and Rainskirt for Upright Air Handlers
50
Figure 38: Filter Section Support Assembly............................ 51
Figure 39: Inlet Hood without Filters (4024-4049) ................... 52
Figure 40: Inlet Hood without Filters (4054-4089) ................... 53
Figure 41: Inlet Hood with Permanent Filters .......................... 53
Figure 42: Inlet Hood with Moisture Limiter............................. 54
Figure 43: Service Platform for an Vertical Air Handler ..........55
Figure 44: Service Platform for a Horizontal Air Handler........ 56
Figure 45: Vertical Air Handler with Duct Sleeves and Discharge
Head ....................................................................................... 58
Figure 46: One-Way Discharge Head .................................... 59
Figure 47: Three-Way Discharge Head.................................. 60
Figure 48: Four-Way Discharge Head.................................... 61
Figure 49: 120° Discharge Head Horizontal Bottom Supply Air62
Figure 50: Discharge Plate ..................................................... 63
Figure 51: Suspended ............................................................ 64
Figure 52: Curb Mounted........................................................ 65
Figure 53: Platform Mounting on Vibration Isolators............... 66
Figure 54: Vibration Isolation Platform Locations ................... 67
Figure 55: Standard Gas Manifold .......................................... 71
Figure 56: FM Gas Manifold ................................................... 72
Figure 57: XL Insurance Gas Manifold ................................... 73
Figure 58: Basic Remote ........................................................ 82
Figure 59: Basic Remote (Continued)..................................... 83
Figure 60: Standard Discharge Remote.................................. 84
Figure 61: Standard Discharge Remote (Continued).............. 85
Figure 62: Deluxe Room Control Remote .............................. 86
Figure 63: Deluxe Room Control Remote (Continued)........... 87
Figure 64: Standard Room Control Remote ........................... 88
Figure 65: Standard Room Control Remote (Continued) ....... 89
Figure 66: DDC-Ready Controls............................................. 90
Figure 67: DDC-Ready Controls (Continued)......................... 91
Figure 68: Air Handler Styles.................................................. 93
Figure 69: Fireye®M4RT1 ..................................................... 96
Figure 70: Jumper Locations .................................................. 98
Figure 71: Midco HMA-2A Burner..........................................113
Figure 72: Spark Rod Dimensions.........................................115
Figure 73: Maxon NPLE Burner.............................................116
Figure 74: Sheave Alignment ............................................... 122
Figure 75: Belt Tension ........................................................ 123
Figure 76: Fireye Flame Module........................................... 124
Figure 77: MR 212 Valve....................................................... 127
Figure 78: M611 Valve .......................................................... 128
Figure 79: Regulator (2005).................................................. 128
Figure 80: RM7897C Flame Control..................................... 142

SECTION 1: AIR H ANDLER S AFETY
1 of 154
SECTION 1: AIR HANDLER SAFETY
Yo ur Safety is Important to Us!
This symbol is used throughout
the manual to notify youof
possible fire, electrical or burn
hazards. Please pay special
attention when reading and
following the warnings in these
sections.
Installation, service and, at a minimum, annual
inspection of air handlers must be done by a
contractor qualified in the installation and service of
gas-fired heating equipment.
Read this manual carefully before installation,
operation or service of this equipment.
This air handler is designed for heating non-
residential indoor spaces. Do not install in residential
spaces. These instructions, the layout drawing, local
codes and ordinances and applicable standards that
apply to gas piping, electrical wiring, ventilation, etc.
must be thoroughly understood before proceeding
with the installation.
Protective gear is to be worn during installation,
operation and service. Thin sheet metal parts have
sharp edges. To prevent injury, the use of work
gloves is recommended.
Before installation, check that the local distribution
conditions, nature of gas and pressure and
adjustment of the appliance are compatible.
The equipment must be applied and operated under
the general concepts of reasonable use and installed
using the best building practices.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory or
mental capabilities, or lack of experience and
knowledge, unless they have been given supervision
or instruction concerning use of the appliance by a
person responsible for their safety.
Children should be supervised to ensure that they do
not play with the appliance.
For additional copies of the Installation, Operation
and Service Manual, please contact Rapid
Engineering LLC.
Gas-fired appliances are not designed for use in
atmospheres containing flammable vapors or dust or
atmospheres containing chlorinated or halogenated
hydrocarbons. Recirculated room air may be
hazardous if containing flammable solids, liquids,
and gases; explosive materials; and/or substances
which may become toxic when exposed to heat (i.e.
refrigerants, aerosols, etc.).
1.1 Description of Operation
This air handler is a direct-fired, electric, steam, hot
water and/or energy recovery heated fresh air
appliance. It is designed for indoor or outdoor
installation with fresh outdoor air delivered to the
burner. Air handlers are designed to operate in
temperatures as lowas -30 °F (-34 °C) variable
frequency drive is only approved for applications
15 °F (-9 °C) and above, unless a control enclosure
heater is installed. The air handler is factory-tested
and may be designed to operate using natural gas or
LPG (check the air handler's rating plate for
information on the appropriate gas). The heat will
modulate to maintain the selected supply air
temperature or room air temperature, depending on
the selected controls. See Page 92, Section .
The air handler may be provided with several
different controls and options to meet various
application requirements. Be sure to read this entire
manual before installation and start-up.
1.2 Inspection and Setup
The air handler may ship in multiple sections based
upon the configuration selected. The air handler was
inspected and operated prior to shipment.
Immediately upon receipt of the air handler, check
the fuel and electrical requirements of the air handler
and verify that they match the fuel and electrical
supply available. Verify that the specifications on the
air handler rating plate match the order. Check the air
handler for any damage that may have occurred
during shipment. If any damage is found, file a claim
with the transporting agency. Do not refuse
shipment. Check the installation location to ensure
proper clearances to combustibles. See Page 8,
Section 3.1.
Any small options which do not come attached to the
air handler will be found inside the air handler.
Larger accessories (i.e. legs, stand, filter section,
inlet hood) may either ship with the air handler or
separately on another truck. Check the bill of lading
for information.

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
2 of 154
1.3 Temporary Storage
If the air handler must be temporarily stored (ie. job
site is not ready for installation of the air handler), the
following procedure should be performed. After
unloading unit from truck, place on a flat clean
surface in a protected area. The air handler should
be set on 4" x 4" (10 cm x 10 cm) pieces of timber to
elevate unit off the ground. Cover air handler with a
tarp or weatherproof material to ensure protection
from the environment. Manually rotate the fan wheel
every 15 days to eliminate grease from settling in the
fan bearings and creating flat spots on the shaft.
Air handlers built for indoor installation are not
weatherized.
Rapid Engineering LLC will not be held responsible
for any damage that may occur from outdoor storage.
1.4 Safety Labels and Their Placement
Product safety signs or labels should be replaced by
product user if they are no longer legible. Please
contact Rapid Engineering LLC or your RAPID®
independent distributor to obtain replacement signs
or labels. See Page 3, Figure 1 through Page 5,
Figure 3.
1.5 California Proposition 65
In accordance with California Proposition 65 require-
ments, a warning label must be placed in a highly
visible location on the outside of the equipment (i.e.,
near equipment's serial plate). See label placement
drawing on Page 3, Figure 1 through Page 5, Figure
3for label location. Avoid placing labels on areas
with extreme heat, cold, corrosive chemicals or other
elements. To order additional labels, please contact
Rapid Engineering LLC or your RAPID®independent
distributor.

SECTION 1: AIR H ANDLER S AFETY
3 of 154
1.6 Label Placement
FIGURE 1: 4024 - 4049
BDBD
OAOA
7
11
7
VERTICAL CONTROL SIDE VERTICAL OPP. CONTROL SIDE
HORIZONTAL OPP. CONTROL SIDE HORIZONTAL CONTROL SIDE
3ON SHRINK WRAP
1
1
2
4
4
44
5
6
6
2
5
IF USED.
2
5
2
5
Item Part Number Description
1 19305 Label Shock Hazard
2 19304 Label Severe Injury Hazard
3 19307 Label Crush Hazard
4 19308 Label Fire Hazard
5 19309 Label Falling Hazard
6 19306 Label Burn Hazard
7 91040039 Rapid Logo Label
8 91070015 Proposition 65 Label

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
4 of 154
FIGURE 2: 4054 and 4089
BD
BD
OA
LIFTING RINGS
OA
LIFTING RINGS
VERTICAL CONTROL SIDE VERTICAL OPP. CONTROL SIDE
HORIZONTAL OPP. CONTROL SIDE HORIZONTAL CONTROL SIDE
ACCESS DOOR
GAS CONNECTION
6 x 2 x 12GA
CHANNEL BASE FRAME
DISCONNECT
RC
Curb Channel
2 x 6
6 x 2 x 12GA
CHANNEL BASE FRAME
ON SHRINK WRAP
IF USED.
Curb Channel
2 x 6
Access Door
(18 x 30)
LA
Elec Conn.
Gas Conn.
RC
Disconnect Disconnect
INLET
BR BR
BD EXH BD
EXH
3
6
5
4
2
1
1
2
5
4
25
4
46
2
5
7
7
77
BURNER FAN
FAN BURNER
BURNER
FAN
BURNER
FAN
Item Part Number Description
1 19305 Label Shock Hazard
2 19304 Label Severe Injury Hazard
3 19307 Label Crush Hazard
4 19308 Label Fire Hazard
5 19309 Label Falling Hazard
6 19306 Label Burn Hazard
7 91040039 Rapid Logo Label
8 91040015 Proposition 65 Label

SECTION 1: AIR H ANDLER S AFETY
5 of 154
FIGURE 3: 4000-Series Interior
1
CONE PLATE
12 13
2
12
MOTOR & MOTOR COOLING DUCT
INSIDE
CONTROL ENCLOSURE
89
7
7
9
2
CONTROL ENCLOSURE DOOR
PROP 65 LABEL
RATING TAG
ELECTRICAL PRINT
RH INSIDE WALL
CONTROL ENCLOSURE
LH INSIDE WALL
CONTROL ENCLOSURE
11
10
3
4
5
6
2
Item Part Number Description Qty.
1 Label - Rotation 2
2 Label - High Voltage 2
3 Label - Caution Don’t Overtighten Belt 1
4 Label - Alignment Guide 1
5 Label - Rapid Factory Direct Parts Information 1
6 Label - Bearing Lube Chart 1
7 Label - Gas Type 3
8 Label - Outdoor Temp Sensor 1
9 Label - Min/Max Gas Pressures Required 1
10 Label - Regulator Model Number 1
11 Label - Regulator/Internal Relief Required 1
12 Label - Notice To Installer 1
13 Label - Caution YellowWire Not Diffused 1
14 91070015 Proposition 65 Label 1

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
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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 air handler in accordance with
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.
•Tonever use air handler 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 air handler is placed in an approved
application.
• To provide building pressure relief/dampers fans
to prevent over pressurization of a building, if
needed.
2.1 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.
* Halogenated Hydrocarbons 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.
2.2 National Standards and Applicable Codes
All appliances 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 installations in public garages, aircraft hangars,
etc. may be applicable.
2.3 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
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 R ESPONSIBILITY
7 of 154
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 an industrial 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 drill bits and runners
• U-tube manometer or gas pressure gauge
• Volt meter
• Clamp style ammeter
• Belt tension gauge
• Thermometer

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
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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 all models are 6"(15.2
cm) on all 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 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
appliance.
• 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, fan
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 responsibility to
assure that adjacent materials are protected from
degradation.
•Maintain clearances from vehicles parked belowthe
air handler. See Page 9, Section 4.4.
3.2 Hardware
Unless otherwise specified, all hardware must be
torqued to settings on Page 8, Table 1.
Table 1: Recommended Torque Settings
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. 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

SECTION 4: NATIONAL STANDARDS AND A PPLICABLE CODES
9 of 154
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 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).

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
10 of 154
SECTION 5: SPECIFICATIONS
Dimension and estimated weight tables apply to both vertical and horizontal units of the same style.
All dimensions are in inches and all weights are in pounds, but are subject to change without notice.
Dimensions apply to both horizontal and vertical units. Filters and legs are shipped loose. Control enclosure
for 3" or smaller manifolds is 57"H x 57"W x 25"D. (B dimension of model 4024 cabinet is approximately 20"
smaller than the control enclosure. Model 4049 control enclosure is 57"H x 57"W x 20"D.) To minimize water
entrainment, an inlet hood with drift eliminator or inlet plenum is recommended. Outdoor duct sizes vary.
Control enclosure can be located on left or right side of unit. (Shown on right side in drawings.) Consult Rapid
Engineering LLC for additional information.
All industrial air handlers are built based on customer specific static pressure.
All ductwork and connections must be sized per SMACNA (Sheet Metal and Air Conditioning Contractors’
National Association).
The legend belowdetails abbreviations used in this section and applies to Page 11, Figure 4 through Page
18, Figure 11.
* Models 4054 - 4089
** Models 4080 - 4089
*** Models 4024 - 4073
Legend
OA = Outside Air
CE = Control Enclosure
BD = Bottom Discharge
LD = Left Discharge
RD = Right Discharge
UD = Up Discharge
BR = Bottom Return
RR = Right Return
LR = Left Return
ER = End Return
FJ = Field Joint *
AD1 = Access Door **
AD2 = Access Door ***

SECTION5:SPECIFICATIONS
11 of 154
FIGURE 4: 4000 AM Vertical Model Dimensions
Table 2: 4000 AM Dimensions
Model
Air Handler
Base Frame
Formed Channel
Base Frame
Structural Angle
Filter Section Width
Filter Mixbox Length
Filter Mixbox Length
With Side Return
Discharge Length
Discharge Width
Return Air Length
Return Air Length
Return Air Width
Return Air Height Discharge Height
Filter Length
Plenum Width
Plenum Length
Inlet Hood Length
Minimum LegHeight
Plenum Height
Width
Height
Length
ABCDEFGHH1J K L M NN1PP1QRR1ST V X Y ZAABB
4024 40 40 109 - 4 - 62 62 62 4 5.5 20 29 18 27 32 22 34 4 2 3 10 30 40 60 48 36 40
4036 58 58 120 - 4 - 62 66 77 5 5.5 25 47 26 41 50 32 50 4 2 3 4 30 63 77 72 36 63
4040 63 63 130 - 4 - 81 68 77 6 6.5 33 50 30 41 55 40 53 4 2 3 4 30 63 77 84 36 63
4044 69 69 137 - 4 - 81 70 79 6 6.5 36 56 32 43 61 46 59 4 2 3 4 30 76 84 84 36 76
4049 76 76 140 - 4 - 81 72 80 6 6.5 39 63 34 44 68 53 66 4 2 3 4 30 76 84 84 36 76
4054 85 85 144 86 58 6 - 100 77 90 6 6.5 43 72 39 55 77 55 75 4 2 3 4 30 94 77 96 48 94
4060 94 94 154 90 64 6 - 100 77 85 6 6.5 48 81 38 50 86 65 84 4 2 3 4 30 94 77 96 48 94
4066 104 96 158 94 64 6 - 119 84 100 6 6.5 50 91 45 65 96 67 90 4 2 3 4 30 112 120 96 48 96
4073 112 96 163 94 69 - 3 119 84 107 6 6.5 50 99 44 72 104 64 90 4 2 3 4 30 112 120 96 48 96
4080131 112 171 75 96 - 4 139 94 112 6 7.5 60 116 48 77 123 76 106 4 2 3 4 30 131 138 96 48 112
4089131 112 177 81 96 - 4 139 94 112 6 7.5 60 116 48 77 123 76 106 4 2 3 4 30 131 138 96 48 112
B
F
Q
BD RD/LD
BR
CE
FJ
S
A
MK KJ
LD
L
D
C
E
N
T
R
P
R
CE
BR
BD/UD
G
BR
V
V
H
N
T
RPR
OA
OA
BR
ELECTRICAL
CONNECTION
GAS
CONNECTION
UD RD
AA
FJ
AD2
AD1
FAN SECTIONBURNER SECTION
SERVICE
PLATFORM
(OPTIONAL)
FILTER
SECTION
(OPTIONAL)
FILTER MIX BOX
(OPTIONAL) OR
LEGS
(OPTIONAL)
RAIN SKIRT
(STANDARD FOR
OUTDOOR EQUIPMENT)
FRONT VIEW
RIGHT SIDE VIEW
AD2
AD1

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
12 of 154
FIGURE 5: 4000 AM Horizontal Model Dimensions
Table 3: 4000 AM Approximate ShippingWeights
OA
B
F
BD
UD
LD/RD
Q
S
ELECTRICAL
CONNECTION
GAS CONNECTION
BR
CE
VLR
N
RR
T
H & (H1)
G
VY
X
Z
A
OA
RD
BD/UD BR BR
AM
K
K
JL
DE
C
NT
R
CE R
FJ
N1
R1
S
P1
RR/LR
P
LD
BR
FJ
AD1
AD2
AD1
AD2
PLAN VIEW
RIGHT SIDE VIEW
FAN SECTION BURNER SECTION
COIL SECTION
(OPTIONAL)
EVAPORATIVE
COOLER
(OPTIONAL)
ENERGY
RECOVERY
SECTION
(OPTIONAL)
FILTER
SECTION
(OPTIONAL)
FILTER MIX BOX
(OPTIONAL)
OR INLET PLENUM
(OPTIONAL)
INLET HOOD
(OPTIONAL)
OR
See Page 21, Figure 14 Energy recovery section for dimensions
See Page 19,Figure 12 Evaporative cooler section for dimensions
See Page 20, Figure 13 for coil section for dimensions
BB
R
R
P
Model
Horizontal
Fan Section
Horizontal
Burner Section
Horizontal Service Platforms
Filter Section
Filter Mixbox
Inlet Hood
Inlet Plenum
Vertical
Service Platform
Vertical
Fan Section
Vertical
Burner Section
Basic
With
Outside Air
Add
With
Filter Mix Box
Add
4024 1,254 475 70 190 320 611 80 343 340 1,289
4036 2,110 520 70 205 465 843 135 657 430 2,129
4040 2,427 606 69 209 525 1,012 210 661 470 2,443
4044 2,783 630 70 215 600 1,122 226 866 500 2,816
4049 3,114 650 68 230 640 1,230 248 870 525 3,150
4054 2,383 1,671 675 66 235 685 1,597 370 1,150 580 2,373 1,754
4060 2,673 1,936 710 70 240 760 1,707 395 1,157 600 2,663 2,029
4066 2,961 2,126 735 65 275 875 2,084 410 1,635 620 3,129 2,228
4073 4,219 2,332 760 65 275 1,125 2,220 425 2,052 630 4,553 2,541
40803,667 4,790 805 70 310 1,400 2,776 590 2,128 720 4,002 4,924
40894,101 4,849 820 70 310 1,400 2,776 590 2,128 720 4,503 4,983