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Rapid 4044, Installation, Operation & Service Manual

The Gardena 4044 Operating Instructions Manual is an essential resource for getting the most out of your Gardena 4044 product. This comprehensive manual provides clear, step-by-step instructions on how to operate and maintain your device. Download it for free from 88.208.23.73:8080 to ensure a smooth and hassle-free user experience.

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TABLE OF CONTENTS
SECTION 1: Air Handler Safety.............................................. 1

1.1 Description of Operation............................................... 1
1.2 Inspection and Set

u

p ................................................... 1

1.3 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 Corrosi

v

e Chemicals.................................................... 6

2.2 National Standards and Applicable Codes .................. 6
2.3 Req

u

ired Eq

u

ipment .................................................... 6

SECTION 3: Critical Considerations .....................................

8

3.1 Req

u

ired Clearances to Comb

u

stibles......................... 8

3.2 Hard

w

are ..................................................................... 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 Str

u

ct

u

res and Repair Garages ...................... 9

4.5 Electrical ...................................................................... 9
4.6 Venting......................................................................... 9
4.7 High Altit

u

de ................................................................ 9

SECTION 5: Specifications .................................................. 10
SECTION 6: Liftin

g

 an Air Handler (Ri

gg

in

g

)...................... 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 Ca

u

lking the Air Handler............................................. 33

7.2 Ca

u

lking a Horizontal Air Handler............................... 34

7.3 Ca

u

lking an Vertical Air Handler................................. 35

7.4 Accessory Connections.............................................. 37

SECTION 

8

: Roof Curb ......................................................... 41

8.1 Roof C

u

rb Assembly and Installation......................... 41

SECTION 9: Indoor Suspension Mountin

g

 -

                     Horizontal Air Handler  .................................... 46

9.1 S

u

spension Mo

u

nting Assembly and Instr

u

ctions ..... 46

SECTION 10: Le

g

 Mountin

g

................................................. 4

8

SECTION 11: Filter Section .................................................. 51
SECTION 12: Inlet Hoods ..................................................... 52

12.1 Inlet Hood Assembly ................................................ 52

SECTION 13: Service Platform............................................. 55

13.1 Ser

v

ice Platform ...................................................... 55

SECTION 14: Dischar

g

e accessories .................................. 57

14.1 One-Way, Three-Way and Fo

u

r-Way Discharge

        Head Installation ...................................................... 57
14.2 Splash Plate Installation........................................... 63

SECTION 15: Vibration Isolation.......................................... 64
SECTION 16: Coolin

g

 Specifications .................................. 6

8

16.1 E

v

aporati

v

e Cooling ................................................. 68

SECTION 17: Duct Considerations...................................... 69

17.1 Inlet Air D

u

ct ............................................................. 69

17.2 Ret

u

rn Air D

u

ct ......................................................... 69

17.3 S

u

pply Air D

u

ct Work ............................................... 69

SECTION 1

8

: Gas Pipin

g

...................................................... 70

18.1 Gas Manifolds.......................................................... 70
18.2 Gas Piping and Press

u

res ....................................... 70

18.3 Gas Piping ................................................................74
18.4 Press

u

re Test Ports...................................................74

SECTION 19: Electrical......................................................... 75

19.1  Disconnect F

u

se Sizing .......................................... 76

19.2 Wiring and Electrical Connections ........................... 76
19.3 Remote Panel .......................................................... 76
19.4 Motor C

u

rrent Dra

w

................................................. 76

19.5 Control C

u

rrent Dra

w

............................................... 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 Seq

u

ence of Operation ............. 96

19.15 Honey

w

ell

®

 RM7890 Flame Safeg

u

ard................ 100

SECTION 20: Direct Fired Burner .......................................112

20.1 Direct Fired B

u

rner Ignition.....................................115

20.2 Direct Fired B

u

rner Flame Pro

v

ing (Flame Rod) ....116

20.3 Honey

w

ell UV Flame Detector ...............................119

20.4 Honey

w

ell UV Flame Detector (Contin

u

ed)........... 120

SECTION 21: Start-up Procedures .................................... 121

21.1 Installation of Recirc

u

lating Air Handler ................. 122

21.2 Mechanical............................................................. 122
21.3 Electrical ................................................................ 123
21.4 Airflo

w

.................................................................... 123

21.5 Gas Piping and Initial Press

u

re Settings ................ 124

21.6 Safety Sh

u

t Off Val

v

e Check .................................. 126

21.7 Temperat

u

re Control System Calibration................ 126

SECTION 22: Maintenance................................................. 129

22.1 General.................................................................. 130
22.2 Unit Exterior........................................................... 130
22.3  Blo

w

er Section...................................................... 130

22.4 Manifold and Controls............................................ 132
22.5  B

u

rner................................................................... 132

22.6 Optional Eq

u

ipment ............................................... 134

SECTION 23: Replacement Parts ...................................... 135
SECTION 24: Troubleshootin

g

.......................................... 136

24.1 Initial Checks ......................................................... 137
24.2  Motor and Blo

w

er ................................................. 137

24.3  B

u

rner................................................................... 138

24.4  Temperat

u

re 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 ............................................................. 14

8

SECTION 27: The RAPID

®

 4000-Series Warranty............. 151

© 201

8

 

Rapid Engineering LLC

All rights reserved. 

N

o part of this work covered 

b

y the copyrights herein may 

b

e reproduced 

or copied in any form or 

b

y 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.

Summary of Contents for 4044

Page 1: ...0500 Fax 1 616 784 0435 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 switche...

Page 2: ......

Page 3: ...ing 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 Connecti...

Page 4: ......

Page 5: ...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 Maximu...

Page 6: ......

Page 7: ...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 Sect...

Page 8: ......

Page 9: ...ed 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...

Page 10: ...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 replace...

Page 11: ...PP CONTROL SIDE HORIZONTAL CONTROL SIDE 3 ON SHRINK WRAP 1 1 2 4 4 4 4 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 Labe...

Page 12: ...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 2 5 4 4 6...

Page 13: ...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...

Page 14: ...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 corrosi...

Page 15: ...tion 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 T...

Page 16: ...bility 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...

Page 17: ...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 Garag...

Page 18: ...od 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...

Page 19: ...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...

Page 20: ...il 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 Ve...

Page 21: ...63 4044 69 69 137 4 81 3 6 6 5 36 56 59 36 30 76 84 84 76 4049 76 76 140 4 81 3 6 6 5 39 63 66 36 30 94 77 84 76 4054 85 85 144 86 58 6 100 3 6 6 5 43 72 75 48 30 94 77 96 94 4060 94 94 154 90 64 6 1...

Page 22: ...27 2 798 2 076 4066 3 036 2 159 875 410 1 635 3 204 2 234 4073 4 525 2 361 1 125 425 2 052 4 859 2 441 4080 3 667 4 790 1 400 590 2 128 4 002 4 624 4089 4 101 5 210 1 400 590 2 128 4 503 5 044 C D E A...

Page 23: ...6 5 36 56 30 61 59 4 32 4 45 35 5 39 36 3 4049 76 76 140 4 16 36 6 6 5 39 63 30 68 66 4 34 4 45 39 42 36 3 4054 85 85 144 86 58 6 16 36 6 6 5 43 72 30 77 75 4 39 4 45 43 5 46 48 3 4060 94 94 154 90 6...

Page 24: ...A x W X F I L T E R S Outdoor Air Duct Sleeve Filtered Inlet Hood Louver Duct Louver Model Horizontal Fan Section Horizontal Burner Section Filter Section Inlet Hood Vertical Fan Section Vertical Burn...

Page 25: ...63 77 84 63 4044 69 102 137 4 16 36 6 6 5 35 56 30 76 84 84 76 4049 76 109 140 4 16 36 6 6 5 40 63 30 76 84 84 76 4054 85 124 144 86 58 6 16 48 6 6 5 40 72 30 94 77 96 94 4060 94 138 154 90 64 6 20 4...

Page 26: ...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 Model Horizontal Fan Section Horizontal...

Page 27: ...000 4036 ECM36D 13 700 58 58 4036 ECM40 12 000 4036 4040 ECM40D 16 600 63 63 4036 ECM44 14 500 4036 4040 ECM44D 19 600 69 69 4036 4040 ECM49 17 700 4036 4049 ECM49D 24 300 76 76 4036 4049 ECM54 23 00...

Page 28: ...25 84 5 000 24 90 6 000 23 98 7 000 23 09 8 000 22 22 9 000 21 39 10 000 20 58 68 1 00 0 97 0 93 0 90 0 87 0 84 0 80 0 77 0 75 0 72 0 69 70 1 00 0 96 0 93 0 90 0 86 0 83 0 80 0 77 0 74 0 71 0 69 72 1...

Page 29: ...61 523 110 65 72 20 001 27 500 36 44 50 138 2 52 5 35 x 108 381 524 116 80 78 27 501 30 000 40 49 69 150 2 61 2 39 x 113 449 490 121 90 78 30 001 35 000 49 60 75 175 2 70 0 41 x 123 428 500 131 96 84...

Page 30: ...ons Estimated Weights Length Width Height Module Inlet Hood Exhaust Fan Exhaust Hood Downturn Section Filter Housing MUA AM A B C 4024 4024 4 000 7 000 109 58 69 1 000 150 400 150 250 225 4036 4036 7...

Page 31: ...299 55 586 72 1 356 99 24 000 1 02 1 09 61 59 548 66 1 355 95 612 23 1 415 99 25 000 1 10 1 17 61 59 571 52 1 412 35 637 74 1 474 99 4040 4044 25 001 0 83 0 89 61 60 489 87 1 218 80 546 64 1 272 52 2...

Page 32: ...27 500 4049 1 612 7 5 10 10 15 15 15 20 20 20 10 0 11 0 12 1 13 1 14 2 15 4 16 5 17 7 18 9 83 30 000 4040 2 618 15 15 20 20 20 20 25 25 25 8 1 9 1 10 3 11 4 12 6 13 9 15 1 16 4 17 7 81 30 000 4044 2...

Page 33: ...30 4 33 0 35 6 38 2 40 9 43 5 46 4 85 70 000 4073 2 036 25 30 30 40 40 40 50 50 50 24 5 27 1 29 8 32 7 35 6 38 5 41 5 44 5 47 6 81 70 000 4080 1 448 25 25 30 30 40 40 40 50 CF 20 7 23 6 26 6 29 5 32...

Page 34: ...r Discharge Low Leak 0 10 Supply Air End CF Discharge Plate 0 05 Discharge Head One Way 0 10 Discharge Head Three Way 0 10 Discharge Head Four Way 0 05 Horizontal Inlet Hood 0 00 Horizontal Inlet Plen...

Page 35: ...be performed 1 Remove all packaging or banding that attached the air handler to the skid and ensure that the air handler is no longer bound to a skid or truck bed 2 Remove all packaging or blockers 3...

Page 36: ...Horizontal Air Handler with Options Model 4054 4089 LIFTING SLINGS END VIEW CL CR CRANE OR HELICOPTER CABLE FAN SECTION BURNER SECTION FILTER SECTION FILTER MIX BOX OR TRANS EVAP FILTER SECTION INLET...

Page 37: ...bolts A B 4 places 2 Lift off truck 3 Place on a clean flat dry surface free from water mud etc Turning Position 4 Remove eye bolts B 2 places 5 Attached eye bolts from B to corner C 2 places 6 Attach...

Page 38: ...CT SECTION MIX BOX SECTION BURNER SECTION FAN LEGS 4 required REMOVE LIFTING EYE BOLTS AFTER SETTING SECTION SHEETMETAL CHANNEL OR ANGLE IRON FRAME MUST BE ALIGNED ON ALL SECTIONS Model 4024 4049 Mode...

Page 39: ...IGNMENT DETAIL FOR UPRIGHTS MODELS 49 89 ONLY 5 8 X 2 3 4 THREADED ROD ALIGNMENT PIN FAN SECTION INLET FRAME OR BURNER INLET FRAME WITH 7 8 CLEARANCE HOLE FMB DISCH BURNER DISCH SECTION FRAME 5 8 11 F...

Page 40: ...ion See Page 33 Figure 7 1 through Page 35 Figure 22 NOTE After the equipment sections are set together if shipped separately connection of the electrical conductors between the sections is required T...

Page 41: ...Y OF CAULKING THE 3 78 7 cm ROOF TAPE A Type Joint B Type Joint CAULK PROVIDED BY OTHERS 3 8 x 3 4 STRIP OF CAULKING PROVIDED BY MANUFACTURER TYPICAL VERTICAL JOINT AFTER ASSEMBLY CAULK EACH VERTICAL...

Page 42: ...N E R S E C T I O N F I L T E R B P L E N U M I N L E T M I X B O X S E C T I O N B A B B A I N L E T P L E N U M A INLET F I L T E R S E C T I O N B U R N E R F A N S E C T I O N S E C T I O N B B B...

Page 43: ...HEETMETAL CHANNEL OR ANGLE IRON FRAME MUST BE ALIGNED ON ALL SECTIONS RAIN SKIRT ON OUTDOOR AIR HANDLER A A A A LEGS A LIFTING LUGS A A FIELD ATTACHMENT A A RAIN SKIRT ON OUTDOOR AIR HANDLER FIELD ATT...

Page 44: ...X B OD SELF TAPPING SCREWS EVERY 6 8 C D AIR HANDLER HOUSING RETURN AIR SLEEVE CAULKING FLANGE NOTE TEK SCREW RETURN SLEEVE TO INSIDE OF AIR HANDLER RETURN AIR FLANGE RETURN AIR DAMPER SELF TAPPING SC...

Page 45: ...THHN CONDUCTORS AND 1 SHIELDED CABLE NOTE TYPICALLY 2 THHN CONDUCTORS AND 1 SHIELDED CABLE DETAIL B Inlet Hood Legend OA Outside Air BR Bottom Return BD Bottom Discharge LC Left Controls DUAL PERFORA...

Page 46: ...AND RETURN AIR OPENINGS INDOOR INSTALLATION OUTDOOR INSTALLATION Factory furnished piping devices Field furnished piping devices HEADER UNION BLEED OFF VALVE WATER LEVEL Notes Legend 1 2 3 4 EVAPORAT...

Page 47: ...n a non freeze location Makeup line must be installed with no traps or sages above the roof line WATER FLOW ADJUSTMENT VALVE Factory furnished piping devices Field furnished piping devices Notes HEADE...

Page 48: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 40 of 154 FIGURE 30 Evaporative Cooling Trap Detail...

Page 49: ...r and the curb the curb must be level with no twist from end to end Shim level as required and secure curb to roof deck using best building practices The curb is self flashing Install roofing material...

Page 50: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 42 of 154 FIGURE 31 Roof Curb NOTE Adapter shown for models 4024 through 4089 horizontal AM FMB and MUA...

Page 51: ...THERS ROOFING BY OTHERS COUNTER FLASHING BY OTHERS ROOF INSULATION BY CONTRACTOR SILICONE CAULK BY OTHERS TYPICAL CURB INSTALLATION ROOF CURB CHANNEL UNIT CURB ANGLE MODEL 4073 3 x 3 x 3 16 Angle Iron...

Page 52: ...AT WASHERS LOCK WASHERS FLANGE NUTS CORNER CONNECTION 7 BOLTS FLAT WASHERS LOCK WASHERS FLANGE NUTS 1 Refer to the assembly drawings shipped with the curb 2 Curb length can vary by options selected 3...

Page 53: ...1 3 56 2 56 INLET SIDE ASM SIZE A 24 38 00 36 56 00 40 61 00 44 67 00 49 74 00 54 83 00 60 92 00 66 102 00 73 109 00 80 128 00 89 436126 436184 BOTTOM DISCHARGE DUCT ADAPTER 436196 436208 436220 43623...

Page 54: ...ame is secure the air handler may be mounted See Page 27 Section 6 1 for safe lifting practices Crush Hazard Check blower assembly per maintenance section Lack of blower assembly maintenance can cause...

Page 55: ...ONLY NOTES 1 CONSULT FACTORY FOR DIMENSIONS WHEN USING A 3V4 OR 4 MANIFOLD 2 ALL DIMENSIONS WEIGHTS ARE SUBJECT TO CHANGE WITHOUT NOTICE SHOULD NOT BE USED FOR CONSTRUCTION UNLESS CERTIFIED 3 ACCESSO...

Page 56: ...erings Horizontal 4024 4049 require a minimum quantity of four legs Horizontal 4054 4089 require a minimum quantity of eight legs For every additional section ie mix box coil etc beyond the basic hori...

Page 57: ...NUFACTURER PROVIDES FOR EACH LEG 12 3 8 X 1 BOLTS FOR MODEL 4024 4066 12 3 8 FLANGE NUTS 12 3 8 FLAT WASHERS CURB ANGLE ON UNIT SECTION VIEW A A Models 4024 4066 HORIZONTAL LEG NOTE Leg mounts to unde...

Page 58: ...EG SIZES 60 72 48 36 24 96 RAPID PROVIDES SHEETMETAL CHANNEL OR ANGLE IRON FRAME TOWARD BUILDING NOTE RAIN SKIRT WITH OUTDOOR AIR HANDLERS ONLY CAUTION SHORTENING THE LEGS MAY RESULT IN HIGH INLET AIR...

Page 59: ...ctices Falling Hazard Use proper safety equipment and prac tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment Equipment and accessories are heavy Cut Pinch Hazard...

Page 60: ...equip ment Equipment and accessories are heavy Cut Pinch Hazard Wear protective gear during installation operation and service Edges are sharp WARNING Failure to follow these instructions can result...

Page 61: ...0 1 77500 49 MODEL 80 89 EXPLODED VIEW ASSEMBLY INSTRUCTIONS ASSEMBLE INLET HOOD PARTS LISTED IN EXPLODED VIEW 7 8 9 14 TO AIR HANDLER WITH 3 8 FLAT WASHERS AND 3 8 X 1 BOLTS BUTYL ROPE CAULKING IS SU...

Page 62: ...nd center channel piece see detail C for model 4080 4089 only 2 If inlet hood is currently mounted remove corner brackets Bolt floor items 1 and 3 to bottom of the inlet frame and sides of hood 3 Tek...

Page 63: ...S 3 4 NUTS MODEL 4073 4089 ANGLE IRON MODEL 4024 4066 SHTMTL CHANNEL RAILING CONTROLS Side Railing Field Assembly ACCESS SIDE RAILING SIZES 4049 4089 TEK SCREW IN FIELD FRONT GRATING Two Front Rails o...

Page 64: ...HANNEL 3 8 BOLTS SAFETY CHAIN FRONT RAILING SWAY TAB SUPPORT RODS DOUBLE NUTTED LIFTING EYE AIR HANDLER SUPPORT CHANNEL ACCESS SIDE RAILING SIDE RAILING FIELD ASSEMBLY HOLES FOR 3 8 BOLTS SUPPORT ROD...

Page 65: ...be installed on horizontal or vertical air handlers To install the discharge head on an interior wall drill holes in the flanges on all four sides of the discharge heads to accommodate lag bolts suppl...

Page 66: ...IR HANDLER DETAIL B TYPICAL ASSEMBLY 2 SELF TAPPING SCREWS ALTERNATE SUPPORT BY OTHERS SUPPORT BY OTHERS INLET DETAIL A DETAIL B DETAIL C MODELS 4024 4089 AIR HANDLER HOUSING RETURN AIR SLEEVE CAULK J...

Page 67: ...ICAL ASSEMBLY 2 SELF TAPPING SCREWS AIR HANDLER HOUSING DISCHARGE HEAD END VIEW RIGHT SIDE VIEW Model A C D E F G 4024 40 24 25 33 25 2 40 3 5 4036 58 29 25 51 25 3 58 3 5 4040 63 37 25 54 25 4 63 4 5...

Page 68: ...G 4024 44 25 24 4 14 20 3 29 3 2 1 4036 62 30 29 4 22 25 3 47 3 2 1 4040 65 31 37 4 23 33 3 50 3 2 1 4044 71 32 40 4 26 36 3 56 3 2 1 4049 78 34 43 4 28 39 3 63 3 2 1 4054 82 37 47 4 32 43 3 72 3 2 1...

Page 69: ...C ROOF B D F F F F AIR HANDLER 12 TYPICAL 12 TYPICAL RIGHT SIDE VIEW END VIEW Model A B C D E F 4024 40 40 46 24 3 33 3 2 4036 58 58 46 29 3 51 3 2 4040 63 63 46 37 3 54 3 2 4044 69 69 46 40 3 60 3 2...

Page 70: ...8 63 6 3 8 31 73 39 35 x 50 140 4044 69 36 1 4 35 1 4 5 7 8 69 6 3 8 33 73 36 35 x 56 180 4049 76 39 1 4 40 1 4 5 7 8 76 6 3 8 33 78 36 40 x 63 190 4054 85 43 1 4 40 1 4 5 7 8 85 6 3 8 39 89 39 40 x 7...

Page 71: ...supply fan is in operation To attach all of the hanger rods to the splash plate start by threading a flanged nut onto each hanger rod Then slip each hanger rod down through a hole located in each corn...

Page 72: ...OLATOR SUPPORT ROD TO UNIT BY OTHERS L A H NOTE ALL DIMENSIONS AND WEIGHTS ARE SUBJECT TO CHANGE WITHOUT NOTICE AND SHOULD NOT BE USED FOR CONSTRUCTION UNLESS CERTIFIED TYPE L W H A D RH2 RH3 RH4 3 3...

Page 73: ...SECTION15 VIBRATION ISOLATION 65 of 154 FIGURE 52 Curb Mounted Roof Curb Roof Curb...

Page 74: ...TRUCTION UNLESS CERTIFIED TYPE A B C D E H R 3 R 4 3 3 8 4 1 4 5 1 2 6 1 2 4 1 8 5 9 16 9 16 1 2 5 8 1 3 4 1 3 4 H B C D DIA 2 PL E NC TAP A ISOLATORS REQ D FOR MODEL VENDOR AIR H AN D LER AIR H AN D...

Page 75: ...109 120 130 137 140 144 154 158 163 171 177 103 114 124 131 134 138 148 152 157 165 171 3 3 3 3 3 3 3 3 3 3 3 62 66 68 70 72 77 77 84 84 94 94 58 64 64 69 90 90 80 84 88 88 75 81 37 3 8 55 3 8 60 3 8...

Page 76: ...ression ODB OWB 4 Evaporation Rate GPH CFM x WBD x SE 8050 5 Bleed off Rate approximately 20 of evaporation rate 6 Recirculation Rate approximately 3 times evaporation rate Abbreviations CFM Cubic Fee...

Page 77: ...he options ordered with the air handler flanges either external or internal may be provided to facilitate connection of ductwork In cases where flanges are not provided flat surfaces on the exterior s...

Page 78: ...suitable for connection to supply pressure of up to 5 p s i maximum for all manifold types When gas supply exceeds the above listed maximum gas pressures an additional high pressure gas regulator wil...

Page 79: ...er 5 P S I D Pilot Gas Cock E Primary Safety Shut Off Valve and Actuator F Vent Valve and Piping G Block Valve and Actuator H Plug Cock J Modulator Valve Gas Pressure Regulator K Low Gas Pressure Swit...

Page 80: ...RVICE MANUAL 72 of 154 FIGURE 56 FM Gas Manifold VENT OUTSIDE A ALTERNATE INLET INLET BY OTHERS D M B C K E G H J N P R S L BY OTHERS INTEGRAL VENT LIMITER INTEGRAL VENT LIMITER VENT LIMITER VENT LIMI...

Page 81: ...57 XL Insurance Gas Manifold ALL VENT PIPING TO OUTSIDE BY OTHERS VENT OUTSIDE F VENT OUTSIDE A ALTERNATE INLET INLET BY OTHERS D B C K E G H J N P R S M L BY OTHERS INTEGRAL VENT LIMITER INTEGRAL VE...

Page 82: ...ng does not restrict accessibility to the air handler or its removable access doors Lockable manual shut off valve must be added by the installer in compliance with Occupational Safety and Health Admi...

Page 83: ...not supplied Note Spark testing or shorting of the control wires by any means will render the transformers inoperative Each unit is equipped with a fused rotary disconnect The rotary disconnects are...

Page 84: ...electrical schematic For wire gauge sizes see Page 76 Table 29 All power supply and motor wiring must be minimum type THWN with a 167 F 75 C temperature rise 19 3 1 Remote Panel Mounting Distance If t...

Page 85: ...er velocity volume for combustion the switch closes When the switch closes it permits the flame safeguard relay to begin ignition This switch is factory set at 0 32 in wc 0 8 mbar The high velocity pr...

Page 86: ...ame safeguard relay will lockout it will reset upon power restoration See the Trouble Shooting Guide Page 136 Section 24 19 6 5 Discharge Temperature Sensor This device senses the discharge temperatur...

Page 87: ...switch and the exhaust fan interlock If the air handler s discharge temperature falls to the predetermined low temperature limit setpoint after the 5 minute establishing period the air handler fan wi...

Page 88: ...e is supplied by the installer 19 8 10 Room Override Stat For use with Standard Discharge Control remote This option provides additional thermostat capability based on room temperature The thermostat...

Page 89: ...ion and service of gas fired heating equipment using only components that are sold and supplied by Rapid Engineering LLC Refer to Page 81 Table 31 for a brief description of each safety device its loc...

Page 90: ...HZ ____FLA 460 L2 L1 L3 60 35 1 3 F1 F1 DISC SW F1 34 0 1800 25 SUPPLY FAN MOTOR ____HP ____FLA ____RPM MTR T3 T2 1 T1 A A FAN ON LIGHT LT MOTOR FLA TAKEN FROM N E C REFER TO NAMEPLATE FOR ACTUAL FLA...

Page 91: ...IFIER SP T2 TRANSFORMER IGNITION G F 9 8 L2 7 6 FR 1 10 5 SOL 1 VALVE BURNER ON FLAME RELAY PILOT VALVE SOLENOID PRIMARY SHUT OFF 20 A A LT VALVES OPEN 52 52 2 41 43 45 44 49 46 35 36 18 24VAC 40VA 80...

Page 92: ...60 15 1 3 F1 F1 DISC SW F1 14 0 1800 10 SUPPLY FAN MOTOR ____HP ____FLA ____RPM MTR T3 T2 1 T1 A A FAN ON LIGHT LT 1 MOTOR FLA TAKEN FROM N E C REFER TO NAMEPLATE FOR ACTUAL FLA H3 H4 460VAC AFS2 HI R...

Page 93: ...3 LOW VOLTAGE TRANSFORMER AMPLIFIER SP T2 TRANSFORMER IGNITION G F 9 8 L2 7 6 FR 1 10 5 SOL 1 VALVE BURNER ON FLAME RELAY PILOT VALVE SOLENOID PRIMARY SHUT OFF 20 A A LT 2 VALVES OPEN 52 52 2 41 43 45...

Page 94: ...L2 L1 L3 60 22 1 3 F1 F1 DISC SW F1 21 0 1800 15 SUPPLY FAN MOTOR ____HP ____FLA ____RPM MTR T3 T2 1 T1 A A FAN ON LIGHT LT 1 MOTOR FLA TAKEN FROM N E C REFER TO NAMEPLATE FOR ACTUAL FLA H3 H4 460VAC...

Page 95: ...VOLTAGE TRANSFORMER AMPLIFIER SP T2 TRANSFORMER IGNITION G F 9 8 L2 7 6 FR 1 10 5 SOL 1 VALVE BURNER ON FLAME RELAY PILOT VALVE SOLENOID PRIMARY SHUT OFF 20 A A LT 2 VALVES OPEN 52 52 41 43 45 44 49 4...

Page 96: ...PLY FAN MOTOR ____HP ____FLA ____RPM MTR T3 T2 1 T1 A A FAN ON LIGHT LT 1 MOTOR FLA TAKEN FROM N E C REFER TO NAMEPLATE FOR ACTUAL FLA H3 H4 460VAC AFS2 HI RESET MANUAL LIMIT HIGH TEMP AIRFLOW AIRFLOW...

Page 97: ...VOLTAGE TRANSFORMER AMPLIFIER SP T2 TRANSFORMER IGNITION G F 9 8 L2 7 6 FR 1 10 5 SOL 1 VALVE BURNER ON FLAME RELAY PILOT VALVE SOLENOID PRIMARY SHUT OFF 20 A A LT 2 VALVES OPEN 52 52 2 41 43 45 44 49...

Page 98: ...PPLY FAN MOTOR ____HP ____FLA ____RPM MTR T3 T2 1 T1 MOTOR FLA TAKEN FROM N E C REFER TO NAMEPLATE FOR ACTUAL FLA H3 H2 FAN START STOP INTERLOCK BURNER START STOP INTERLOCK CR98 CR93 1 2 12 16 18 15 X...

Page 99: ...7897C BU R TH 2 OA STAT CR93 24 VAC COIL YELLOW WIRE POWERED BY OTHERS FAN START STOP INTERLOCK CR98 24 VAC COIL YELLOW WIRE POWERED BY OTHERS BURNER START STOP INTERLOCK 10 AMPS MAX BURNER FAILURE IN...

Page 100: ...equipped with one of the following DDC control offerings If so a separate manual providing wiring operation and trouble shooting information specific to that control offering will also accompany this...

Page 101: ...t Damper Bottom Return 20 Outside Air 80 Return Air Bottom Discharge Bottom Discharge Bottom Return 20 Outside Air 80 Combined Outside Air and Bypass Air Bottom Discharge 20 Outside Air 80 Combined Ou...

Page 102: ...ting ON WINTER Mode The air handler blower and burner operate continuously to provide heated air When the air handler is operating air is being discharged at the setpoint on the discharge temperature...

Page 103: ...dulates and varies the discharge air temperature to maintain the space temperature ON SUMMER Mode Only the blower operates continuously to provide unheated air The burner remains off regardless of tem...

Page 104: ...ain flame When the safety shutoff is opened 115 VAC is applied to the Burner On light and T3 transformer the secondary side supplies 24 VAC to the temperature control amplifier The temperature control...

Page 105: ...is cycle is called trial for ignition During this time period the PTFI LED is illuminated When the flame sensor detects a pilot flame the signal is sent back to the safeguard control The electronic ne...

Page 106: ...s of 8 jumpers that are used to configure the Purge timing Pilot Trial for Ignition PTFI timing and recycle or non recycle operation See Page 98 Figure 70 Purge Timing Jumpers JP1 through JP5 are used...

Page 107: ...powers up terminal 3 and terminal 4 in the safeguard control Terminal 3 powers up the equipment s pilot gas solenoid valve which opens allowing gas to flow Terminal 4 powers up the ignition module cre...

Page 108: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 100 of 154 19 15 Honeywell RM7890 Flame Safeguard...

Page 109: ...SECTION19 ELECTRICAL 101 of 154...

Page 110: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 102 of 154...

Page 111: ...SECTION19 ELECTRICAL 103 of 154...

Page 112: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 104 of 154...

Page 113: ...SECTION19 ELECTRICAL 105 of 154...

Page 114: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 106 of 154...

Page 115: ...SECTION19 ELECTRICAL 107 of 154...

Page 116: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 108 of 154...

Page 117: ...SECTION19 ELECTRICAL 109 of 154...

Page 118: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 110 of 154...

Page 119: ...SECTION19 ELECTRICAL 111 of 154...

Page 120: ...he arrangement and shape of the air holes in the baffles that surround the burner provide the proper amount of air for proper combustion for all of the firing rates WARNING Failure to follow these ins...

Page 121: ...SECTION 20 DIRECT FIRED BURNER 113 of 154 FIGURE 71 Midco HMA 2A Burner...

Page 122: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 114 of 154...

Page 123: ...k Rod Dimensions The gas supplied to the pilot gas tube should be 3 1 2 wc for natural gas and between 9 to 11 wc for propane or LP The difference between the two fuels is that a restricting orifice i...

Page 124: ...not recessed more than 1 8 At this setting the flame rod will be enveloped by the pilot or main flame It will be glowing bright red along at least 50 of its length See Page 115 Figure 72 NOTE For the...

Page 125: ...SECTION 20 DIRECT FIRED BURNER 117 of 154...

Page 126: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 118 of 154...

Page 127: ...SECTION 20 DIRECT FIRED BURNER 119 of 154 20 3 Honeywell UV Flame Detector...

Page 128: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 120 of 154 20 4 Honeywell UV Flame Detector Continued...

Page 129: ...tions can result in death electrical shock or injury Explosion Hazard Leak test all compo nents of equipment gas piping before operation Gas can leak if piping is not installed properly Do not high pr...

Page 130: ...rer s recommendations The normally closed contacts of this sensor must be wired in as per the CO2 interlock diagram maintaining the room concentration of CO2 below 5 000 ppm Select the CO2 interlock d...

Page 131: ...ompare all variable frequency drive VFD programming parameters with specifications provided on electrical drawing 21 4 Airflow The air flow switches are factory calibrated safety devices for burner ai...

Page 132: ...re 21 5 Gas Piping and Initial Pressure Settings 1 Perform a pressure test on all gas supply lines to the air handler per applicable codes Make sure to isolate all gas controls before pressure testing...

Page 133: ...nside the control enclosure may need adjustment until recirculation temperature rise is obtained Return unit to normal operating conditions Reconnect any wires that were removed for adjustment 7 Maxim...

Page 134: ...tem calibration If the temperature control system should require field calibration refer to the provided temperature control amplifier product information sheet Table 38 Maximum Temperature Rise SC11...

Page 135: ...djustment loosen locking screw before adjustment High Fire Adjustment Cap Modulator TOP VIEW cover removed Inlet Pressure Outlet Pressure Tap Tap Burner Pressure SIDE VIEW NOTE For high fire adjustmen...

Page 136: ...54 FIGURE 78 M611 Valve FIGURE 79 Regulator 2005 Low Fire Adjustment under cap Gas Inlet Gas Outlet NOTE Modulating only IN PSI 2 OFF ON Outlet Pressure Tap 1 8 NPT Inlet Pressure Tap 1 8 NPT Regulato...

Page 137: ...f equipment gas piping before operation Gas can leak if piping is not installed properly Do not high pressure test gas piping with equipment connected DANGER Failure to follow these instructions can r...

Page 138: ...Check belts and adjust as required See Page 123 Section 21 2 2 Though belts were properly adjusted at the factory they will stretch after the first few hours of operation First 100 Hours of Operation...

Page 139: ...cation Blowers with spider bracket bearings are pre lubricated and do not require any re lubrication during their entire service life Blowers that use pillow block bearings should be re lubricated per...

Page 140: ...ors as required See Page 123 Section 21 2 3 An annual inspection of the burner and components must be made to ensure proper and safe operation For the most part the burner is self cleaning However if...

Page 141: ...grease capacity recommendations as capacities vary by motor Relubrication inter vals are specified in the table above After relubricating allow motor to run for 10 minutes before replacing relief hard...

Page 142: ...d for dirt restriction on a monthly basis or as required Replace filters with filters of equal specification when they appear dirty NOTE When using Rapid Engineering LLC supplied disposable polyester...

Page 143: ...placement parts per this installation operation and service manual Failure to follow these instructions can result in death electric shock injury or property damage Explosion Hazard DANGER Electrical...

Page 144: ...esult in death electrical shock or injury Falling Hazard Use proper safety equipment and practices to avoid falling Do not use any part of equipment as support WARNING Failure to follow these instruct...

Page 145: ...g plate for reversing instructions 24 2 Motor and Blower PROBLEM POSSIBLE CAUSE SOLUTION Motor does not operate Main disconnect switch is OFF Turn disconnect to ON Blown fuse s in disconnect Replace f...

Page 146: ...pressure switch Manual reset Verify gas pressure Optional Low gas pressure switch Manual reset Verify gas pressure Flame control defect Replace Burner Lockout Failure to ignite pilot or main flame Fla...

Page 147: ...mplifiers Series 44 Amplifiers are supplied on units equipped with DTC remote panels If problems persist after performing the troubleshooting procedure and the temperature control amplifier troublesho...

Page 148: ...11 Open circuit in TS114 TS10765 Discharge or Inlet Air Sensor Circuit or wirin 12 Jumper not connected across amplifier terminals 2 and 3 F Continuous High Fire electronics ok 13 Foreign object hold...

Page 149: ...ressure drop of the valve see Maxitrol capacity chart 16 Read manifold pressure using manometer and compare with recommen dation of equipment manufacturer 15 Increase inlet pressure if possible 16 See...

Page 150: ...LED Display Initiate Initial Powerup only Standby Prepurge 7 Sec Pilot Flame Establishing Period 10 Sec Main Flame Establishing Period Run Postpurge Standby Power Power Power Pilot Flame Main Alarm P...

Page 151: ...rcle one Natural Gas Propane __ For indoor air handlers only the vent lines are piped outdoors __ All vent caps are installed Vent line must be run separately Do not combine with other vent lines Comm...

Page 152: ...operly weather sealed __ All hardware is tight and secure __ All damper linkage is tight __ Filters are installed properly Aluminum mesh w arrow in the direction of the airflow Polyester w the white s...

Page 153: ..._________________________________________ ___ Low re gas pressure produces a minimum continuous ribbon of flame Burner High Fire Gas Pressure in w c ___________________________________________________...

Page 154: ...rature ____________ Temp on PC after calibration ____________ Discharge Air Measured Temperature ____________ Temp on PC after calibration ____________ Minimum discharge air temp setpoint F __________...

Page 155: ...he main control panel ___ There is no noticeable vibration ___ Remote Control Station s operate s properly ___ Connected network hardware and software operate properly ___ Explained the unit operation...

Page 156: ..._ Evap enable relay located in main electrical panel energizes evaporative cooler The fill valve energizes and sump begins filling ___ The outside air freeze stat is set at 45 F ___ When the outside a...

Page 157: ...ng the simulator button on the conductivity controller while the evaporative cooler is in operation This will open the blowdown contact de energizing the timer and open the sump drain valve When the s...

Page 158: ...ire Gas Pressure Is measured with a manometer connected in the same place as above The fan must be ON and the burner forced to high fire The desired high fire gas pressure being adjusted in Step 3 bel...

Page 159: ...modified or altered in any way The ownership of the RAPID 4000 Series is moved or transferred This warranty is non transferable Rapid Engineering LLC is not permitted to inspect the damaged equipment...

Page 160: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 152 of 154...

Page 161: ...SECTION 27 THE RAPID 4000 SERIES WARRANTY 153 of 154...

Page 162: ...4000 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 154 of 154...

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