Rapid 7500 136, Installation, Operation & Service Manual

Page 1: ...ight 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 fuel supplier after leavi...

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Page 3: ...ngineering LLC AVERTISSEMENT POUR VOTRE SECURITE Si vous sentez une odeur de gaz 1 Ouvrez les fen tres 2 N essayez pas d allumer un appareil 3 N utilisez pas d interrupteurs lectriques 4 N utilisez pa...

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Page 5: ...Line Pressure Test Leak Testing 44 SECTION 12 Oil Piping For Oil Fired Air Turnover Units 45 12 1 Oil Piping and Pressures 45 12 2 Line Pressure Test Leak Testing 46 12 3 Pressure Test Ports 46 12 4 O...

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Page 7: ...38 Wiring Diagram Key 55 Figure 39 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and On Off Burner with Input Less Than 1 566 MBH 458 9 kW 56 Figure 4...

Page 8: ...liant Manifold and High Low Off Burner with Input Less Than 1 000 MBH 293 1 kW 85 Figure 69 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and High Low...

Page 9: ...9 Low Fire Adjustment for Fully Modulating Burner with Stop Screw Adjustment 110 Figure 90 Oil Pressure Adjustments for On Off Burner 110 Figure 91 Oil Pressure Adjustment High Low Off Burner with Sun...

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Page 11: ...on Performance Information 18 Table 11 Estimated Shipping Weights All Models 19 Table 12 Base Section Mounting Dimensions 23 Table 13 Combustion Air Duct Collar Sizing 34 Table 14 Gas Manifold Size 38...

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Page 13: ...posed to heat i e refrigerants aerosols etc 1 1 Description of Operation This air turnover unit is an indirect gas and or oil fired appliance It is designed for indoor installation The air turnover un...

Page 14: ...near equipment s serial plate See label placement drawings on Page 2 Figure 1 through Page 5 Figure 5 for label location Avoid placing label on areas with extreme heat cold corrosive chemicals or oth...

Page 15: ...IGURE 2 Upper Sections Item Part Number Description 1 91040039 Logo Label 2 91070001 Electric Shock Hazard Label 3 91070004 Fire Hazard Label 4 91070005 Fall Hazard Label 5 91070006 Burn Hazard Label...

Page 16: ...tallation Manual Enclosed Label 3 831 006 36 Gas Fired or 831 006 48 Oil Fired or 831 006 60 Combo Gas Oil Fired Serial Data Plate 4 N A Electrical Schematic 5 91070016 California Proposition 65 Label...

Page 17: ...1 AIR TURNOVER UNIT SAFETY 5 of 143 FIGURE 5 Remote Panel Item Part Number Description 1 91070032 English Spanish Electric Shock Hazard Label mini 2 91070033 English French Electric Shock Hazard Labe...

Page 18: ...he air turnover unit and to supply air for combustion ventilation and distribution in accordance with local codes The burners used on the air turnover units require pressure neutral air for proper com...

Page 19: ...nd Materials 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 turnover unit and acces...

Page 20: ...air turnover unit or any other appliance Maintain clearances from heat sensitive material equipment and workstations Clearances to combustibles do not denote clearances for accessibility Minimum clear...

Page 21: ...test revision Installation Code for Oil Burning Equipment for oil units In aircraft storage and servicing areas air turnover units shall be installed at least 10 3 m above the upper surface of wings o...

Page 22: ...th 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 diagram...

Page 23: ...t exchanger and smaller flue located on right side of unit for 1 250 MBH heat exchanger and larger Dimensions D and F may vary within a model depending on heat exchanger size ex 45 450 MBH heat exchan...

Page 24: ...3 3 3 255 1 476 4 16 000 27 184 3 1 motor 2 2 1 motor 240 70 3 750 219 8 14 to 43 7 7 to 23 8 3 300 1 496 9 154 14 000 23 786 3 1 motor 2 2 1 motor 240 70 3 450 131 9 16 to 30 8 8 to 16 6 3 880 1 759...

Page 25: ...on All Models A M M B K C G D H F F K J CONTROL PANEL INSPECTION AND RELIEF PORT SPLIT FOR SHIPMENT N K LIFTING ANGLES E DA DA RA RA RA RA END VIEW FRONT VIEW DA DA EXTERIOR FILTER RACKS DISCHARGE PLE...

Page 26: ...1 9 22 to 42 12 1 to 23 3 3 455 1 567 2 16 000 27 184 5 1 motor 3 7 1 motor 240 70 3 750 219 8 14 to 43 7 7 to 23 8 3 470 1 574 0 154 14 000 23 786 3 1 motor 2 2 1 motor 240 70 3 450 131 9 16 to 30 8...

Page 27: ...Models A K B C E D F SPLIT FOR SHIPMENT H LIFTING ANGLES G M L K H H END VIEW FRONT VIEW DA DA RA RA RA RA DA DA DISCHARGE PLENUM EXTENSIONS OPTIONAL PROPELLER FAN SECTION EXTERIOR FILTER RACKS COILS...

Page 28: ...9 000 15 291 3 1 motor 2 2 1 motor 2 505 1 136 2 12 000 20 388 5 1 motor 3 7 1 motor 2 520 1 143 1 148 10 000 16 990 3 1 motor 2 2 1 motor 3 455 1 567 2 16 000 27 184 5 1 motor 3 7 1 motor 3 470 1 57...

Page 29: ...T INSPECTION AND RELIEF PORT K LIFTING ANGLES LIFTING ANGLES J P E L M N M L CONTROL PANEL F F Q END VIEW FRONT VIEW DA DA RA RA RA RA DA DA HEAT EXCHANGER SECTION DISCHARGE PLENUM EXTENSIONS OPTIONAL...

Page 30: ...10 000 16 990 5 1 motor 3 7 1 motor 240 70 3 450 131 9 22 to 42 12 1 to 23 3 3 455 1 567 2 16 000 27 184 7 5 1 motor 5 6 1 motor 240 70 3 750 219 8 14 to 43 7 7 to 23 8 3 470 1 574 0 154 14 000 23 786...

Page 31: ...154 2 2 Oil Burner Input GPH Input LPH 2 5 4 5 9 5 17 0 4 6 6 7 17 1 25 4 6 8 8 9 25 5 33 7 9 0 13 4 33 8 50 7 13 5 17 9 50 8 67 8 18 0 22 0 67 9 83 3 22 1 36 0 83 4 136 3 Weight lb kg 125 56 7 125 56...

Page 32: ...lation site Verify that the lifting lugs are intact undamaged and secured to the air turnover unit Ensure factory installed hardware is torqued as specified 4 Prepare the installation location to be r...

Page 33: ...SECTION 6 LIFTING AN AIR TURNOVER UNIT 21 of 143 FIGURE 10 Lifting an Air Turnover Unit Base Section...

Page 34: ...lace See Page 21 Figure 10 To assemble use the supplied hardware and bolt the sections together through the pre drilled holes Supplied hardware must be torqued to recommended specifications on Page 8...

Page 35: ...ng Dimensions Model A B 136 in cm 48 75 123 8 66 167 6 148 in cm 58 75 149 2 78 198 1 154 in cm 70 75 179 7 91 231 1 236 in cm 48 75 123 8 96 243 8 242 in cm 53 75 136 5 106 269 2 248 in cm 58 75 149...

Page 36: ...7500 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 24 of 143 FIGURE 12 Air Turnover Unit Sections Schematic...

Page 37: ...URE 13 Air Turnover Unit Assembly Model Quantity of 1 2 Nuts Bolts Flat Lock Washers Base Section to Burner Heat Exchanger Section Burner Heat Exchanger Section to Discharge Head 136 6 6 148 6 6 154 6...

Page 38: ...panels and end panels around the frame with flanges facing up Step 8 1 2 Attach the side panels to each other using supplied drill screws through the pilot holes Repeat on the opposite side Crush Haz...

Page 39: ...ot holes Repeat on the opposite side Step 8 1 4 Attach the end panels to each other using supplied drill screws through the pilot holes Repeat on the opposite side Attach the end panel assemblies to t...

Page 40: ...to this frame using the supplied drill screws 8 2 Discharge Extension Installation The discharge extensions are designed for mounting to the cabinet of the air turnover unit each other and the dischar...

Page 41: ...SECTION 8 DISCHARGE EXTENSIONS 29 of 143 FIGURE 14 Discharge Extension Installation Model Quality of 1 2 Nuts Bolts Flat Lock Washers 136 6 148 6 154 6 236 6 242 6 248 6 254 6 260 8 272 8...

Page 42: ...ng On equipment with a high turndown burner it is recommended to insulate single wall vent pipes Insulation must have a minimum temperature rating of 1000 F 537 8 C Maximum vent pipe length horizontal...

Page 43: ...ll be non corrosive and can handle the high heat A P Trap is preferred and should be constructed using Page 31 Figure 15 as a guideline FIGURE 15 Condensate Drain The condensate should be piped into t...

Page 44: ...hed by an integrally mounted motor driven combustion air fan and is controlled by a multi louvered damper assembly The combustion air then discharges into the burner blast tube assembly High turbulenc...

Page 45: ...rners are preset at the factory for proper operation and firing rate If field re adjustment of ignition electrodes or flame rod is required refer to Page 33 Figure 18 through Page 36 Figure 21 for the...

Page 46: ...air duct A drain connection is required in the lowest point of the duct or the duct must be pitched a minimum of a 0 25 6 cm per foot 30 5 cm away from the burner for condensate drainage Duct Sizing S...

Page 47: ...ould be lined up with the hole in the backside of pilot housing so that the blower air passing through this hole will cause the arc to flag or move around Normal spark gap should be 1 16 1 6 mm 3 32 2...

Page 48: ...7500 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 36 of 143 FIGURE 21 Type C Burner with Ignition Electrode Oil...

Page 49: ...folds Factory Mutual FM Underwriters Laboratories UL Compliant XL Insurance former Industrial Risk Insurers IRI Compliant 11 2 Gas Piping and Pressures The air turnover unit is equipped with a gas man...

Page 50: ...8 0 242 300 88 630 185 1 00 7 0 631 186 938 275 1 00 10 0 939 276 1 250 366 1 25 8 0 1 251 367 1 565 459 1 50 10 0 248 300 88 630 185 1 00 7 0 631 186 938 275 1 00 10 0 939 276 1 250 366 1 25 8 0 1 25...

Page 51: ...AS FIRED AIR TURNOVER UNITS 39 of 143 FIGURE 22 Manifold Diagram for Gas Fired Air Turnover Unit with any FM Compliant Manifold XL Compliant Manifold Rated for Less Than 1 000 MBH 293 kW and with On O...

Page 52: ...TION OPERATION AND SERVICE MANUAL 40 of 143 FIGURE 23 Manifold Diagram for Gas Fired Air Turnover Unit with any FM Compliant Manifold XL Compliant Manifold Rated for Less Than 1 000 MBH 293 kW and wit...

Page 53: ...S PIPING FOR GAS FIRED AIR TURNOVER UNITS 41 of 143 FIGURE 24 Manifold Diagram for Gas Fired Air Turnover Unit with XL Compliant Manifold Rated for More Than 1 000 MBH 293 kW and with On Off or High L...

Page 54: ...RIES INSTALLATION OPERATION AND SERVICE MANUAL 42 of 143 FIGURE 25 Manifold Diagram for Gas Fired Air Turnover Unit with XL Compliant Manifold Rated for More Than 1 000 MBH 293 kW and with Modulating...

Page 55: ...in the pilot take off tee The manual main gas shutoff valve is shipped loose for field installation Be sure that the fuel supply pipe connected at this point is large enough to ensure the proper gas f...

Page 56: ...its individual shut off valve must be disconnected from the gas supply piping systems during any pressure testing of that system at test pressures in excess of 1 PSIG 68 9 mbar The air turnover unit m...

Page 57: ...l amount of lift length of suction line and the pump capacity On single air turnover unit installations the return line should be the same size as the suction line On multiple air turnover unit instal...

Page 58: ...ing FIGURE 29 Suntec Two Step Pump FIGURE 30 Webster 3450 RPM Blower Motor Driven Oil Pump 12 3 Pressure Test Ports There are pressure test ports located on the burner s pump The test ports are availa...

Page 59: ...AIR TURNOVER UNITS 47 of 143 FIGURE 32 FM or XL Compliant Manifold for Air Turnover Units with Suntec Pump and High Low Off Burner FIGURE 33 FM or XL Compliant Manifold for Air Turnover Units with We...

Page 60: ...7500 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 48 of 143 FIGURE 34 FM or XL Compliant Manifold for Air Turnover Units with Webster Pump and Fully Modu lating Burner...

Page 61: ...ey share the flame safeguard control and control linkage See Page 49 Figure 35 FIGURE 35 Typical Linkage for a Combination Gas Oil Burner WARNING Explosion Hazard Leak test all components of gas oil p...

Page 62: ...e burner when switching from gas to oil or disconnected when switching from oil to gas Failure to do this can result in pump failure To connect disconnect the pump the connection coupling is located i...

Page 63: ...e burner will energize the appropriate manifold and ignition systems The oil pump mounted remotely from the burner and equipped with its own drive motor does not require manual connection disconnectio...

Page 64: ...60 9 m For longer wire runs consult the factory Care should be used to avoid running the interconnect wiring near large industrial loads or high voltage wire runs as that may further limit the length...

Page 65: ...1 C the high temperature limit switch will open the circuit to the air turnover unit s control system and shut it down Restarting of the burner can only be accomplished after the limit has cooled down...

Page 66: ...nly on oil fired equipment within the burner When a flame signal from the pilot flame is available on gas fired equipment it will allow the main gas valve to open If the pilot flame gas fired or the m...

Page 67: ...SECTION14 ELECTRICAL 55 of 143 FIGURE 38 Wiring Diagram Key...

Page 68: ...SERVICE MANUAL 56 of 143 FIGURE 39 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and On Off Burner with Input Less Than 1 566 MBH 458 9 kW UNIT ON OFF...

Page 69: ...SECTION14 ELECTRICAL 57 of 143 FIGURE 40 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input Less Than 1 566 MBH 458 9 kW...

Page 70: ...ALLATION OPERATION AND SERVICE MANUAL 58 of 143 FIGURE 41 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input Less 1 5...

Page 71: ...9 of 143 FIGURE 42 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input Less Than 1 000 MBH 293 1 kW HIGH LIMIT UNIT ON OFF INTER...

Page 72: ...ERATION AND SERVICE MANUAL 60 of 143 FIGURE 43 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input 1 000 to 1 566 MBH 293 1 458...

Page 73: ...ropeller Fan Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input Less Than 1 000 MBH 293 1 kW UNIT ON OFF INTERLOCKS HIGH LIMIT SECOND STAGE FIRST STAGE CONTROL TWO STAGES...

Page 74: ...NUAL 62 of 143 FIGURE 45 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input 1 000 to 1 566 MBH 293 1 458 9 kW UNIT ON OFF...

Page 75: ...AL 63 of 143 FIGURE 46 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input Less Than 1 000 MBH 293 1 kW UNIT ON OFF IN...

Page 76: ...ON AND SERVICE MANUAL 64 of 143 FIGURE 47 Wiring Diagram for Gas Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input 1 000 to 1 566 MBH 293 1...

Page 77: ...SECTION14 ELECTRICAL 65 of 143 FIGURE 48 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and On Off Burner with Input Less Than 2 500 MBH 732 7 kW...

Page 78: ...ALLATION OPERATION AND SERVICE MANUAL 66 of 143 FIGURE 49 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input Less Than 2 5...

Page 79: ...CTION14 ELECTRICAL 67 of 143 FIGURE 50 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input 2 500 to 5 000 MBH 732 7 1465 4...

Page 80: ...ALLATION OPERATION AND SERVICE MANUAL 68 of 143 FIGURE 51 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input More Than 5 0...

Page 81: ...ECTION14 ELECTRICAL 69 of 143 FIGURE 52 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input Less Than 2 500 MBH 732 7 k...

Page 82: ...ION OPERATION AND SERVICE MANUAL 70 of 143 FIGURE 53 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input 2 500 to 5 000...

Page 83: ...CTION14 ELECTRICAL 71 of 143 FIGURE 54 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input More Than 5 000 MBH 1465 4 k...

Page 84: ...NSTALLATION OPERATION AND SERVICE MANUAL 72 of 143 FIGURE 55 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input Less Than 1 000...

Page 85: ...SECTION14 ELECTRICAL 73 of 143 FIGURE 56 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input 1 000 to 2 500 MBH 293 1 732 7 kW...

Page 86: ...ALLATION OPERATION AND SERVICE MANUAL 74 of 143 FIGURE 57 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input Less Than 1 0...

Page 87: ...CTION14 ELECTRICAL 75 of 143 FIGURE 58 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input 1 000 to 5 000 MBH 293 1 1465 4...

Page 88: ...ALLATION OPERATION AND SERVICE MANUAL 76 of 143 FIGURE 59 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input More Than 5 0...

Page 89: ...ECTION14 ELECTRICAL 77 of 143 FIGURE 60 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input Less Than 1 000 MBH 293 1 k...

Page 90: ...ION OPERATION AND SERVICE MANUAL 78 of 143 FIGURE 61 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input 1 000 to 5 000...

Page 91: ...CTION14 ELECTRICAL 79 of 143 FIGURE 62 Wiring Diagram for Gas Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input More Than 5 000 MBH 1465 4 k...

Page 92: ...NSTALLATION OPERATION AND SERVICE MANUAL 80 of 143 FIGURE 63 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and On Off Burner with Input Less Than 1 566...

Page 93: ...4 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input Less Than 1 566 MBH 458 9 kW SWITCH HIGH LIMIT UNIT ON OFF INTERLOCK...

Page 94: ...LATION OPERATION AND SERVICE MANUAL 82 of 143 FIGURE 65 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input Less Than...

Page 95: ...SECTION14 ELECTRICAL 83 of 143 FIGURE 66 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input Less Than 1 000 MBH 293 1 kW...

Page 96: ...ALLATION OPERATION AND SERVICE MANUAL 84 of 143 FIGURE 67 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input 1 000 to 1 566 MBH...

Page 97: ...SECTION14 ELECTRICAL 85 of 143 FIGURE 68 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input Less Than 1 000 MBH 293 1 kW...

Page 98: ...ATION OPERATION AND SERVICE MANUAL 86 of 143 FIGURE 69 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input 1 000 to 1 566...

Page 99: ...CTION14 ELECTRICAL 87 of 143 FIGURE 70 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input Less Than 1 000 MBH 293 1 k...

Page 100: ...ION OPERATION AND SERVICE MANUAL 88 of 143 FIGURE 71 Wiring Diagram for Oil Fired Single Propeller Fan Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input 1 000 to 1 56...

Page 101: ...SECTION14 ELECTRICAL 89 of 143 FIGURE 72 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and On Off Burner with Input Less Than 2 500 MBH 732 7 kW...

Page 102: ...ALLATION OPERATION AND SERVICE MANUAL 90 of 143 FIGURE 73 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input Less Than 2 5...

Page 103: ...SECTION14 ELECTRICAL 91 of 143 FIGURE 74 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and High Low Off Burner with Input More Than 2 500 MBH 732 7 kW...

Page 104: ...LATION OPERATION AND SERVICE MANUAL 92 of 143 FIGURE 75 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input Less Than 2...

Page 105: ...ECTION14 ELECTRICAL 93 of 143 FIGURE 76 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with FM Compliant Manifold and Fully Modulating Burner with Input More Than 2 500 MBH 732 7 k...

Page 106: ...NSTALLATION OPERATION AND SERVICE MANUAL 94 of 143 FIGURE 77 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input Less Than 1 000...

Page 107: ...SECTION14 ELECTRICAL 95 of 143 FIGURE 78 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and On Off Burner with Input 1 000 to 2 500 MBH 293 1 732 7 kW...

Page 108: ...ALLATION OPERATION AND SERVICE MANUAL 96 of 143 FIGURE 79 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input Less Than 1 0...

Page 109: ...CTION14 ELECTRICAL 97 of 143 FIGURE 80 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and High Low Off Burner with Input 1 000 to 5 000 MBH 293 1 1465 4...

Page 110: ...LATION OPERATION AND SERVICE MANUAL 98 of 143 FIGURE 81 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input Less Than 1...

Page 111: ...ION14 ELECTRICAL 99 of 143 FIGURE 82 Wiring Diagram for Oil Fired Dual Propeller Fans Air Turnover Unit with XL Compliant Manifold and Fully Modulating Burner with Input 1 000 to 5 000 MBH 293 1 1465...

Page 112: ...e main fan motor via the motor controls Burner Indicator Indicates that the air turnover unit has supplied power to open the main fuel shut off valve Flame Failure Indicator The burner control module...

Page 113: ...ir turnover unit this can vary greatly Thoroughly review all documentation for the air turnover unit including the electrical print to familiarize and understand the actual sequence of operation Summe...

Page 114: ...Burners The gas system utilizes an automatic valve to control the on off flow of the fuel A modulating motor controls the modulated positioning of a butterfly type proportioning valve The modulating m...

Page 115: ...SECTION 15 SEQUENCE OF OPERATION 103 of 143 FIGURE 83 Wiring Subbase and Sequence Chart for RM7897 Burner Control Module...

Page 116: ...7500 SERIES INSTALLATION OPERATION AND SERVICE MANUAL 104 of 143 FIGURE 84 Wiring Subbase and Sequence Chart for RM7800 Burner Control Module...

Page 117: ...thermostat is satisfied 15 4 Other Control Options 15 4 1 Exhaust Fan Interlock This option provides an interlock between an exhaust fan and an air turnover unit It includes a break in the control ci...

Page 118: ...by a trained technician only DANGER Failure to follow these instructions can result in death electrical shock or injury Falling Hazard Use proper safety equipment and practices to avoid falling Do not...

Page 119: ...ave alignment as follows 1 Attach a string to the vertical surface next to the blower shaft bearing See Page 107 Figure 85 2 Wrap the string around the fan sheave and across both sheave surfaces as sh...

Page 120: ...and or review all precautions and inspection procedures in previous sections and burner manufacturers literature Close main and manual burner shut off valves Open oil suction line manual valves and ot...

Page 121: ...nal setting can be determined 16 7 1 Recommended Procedure To adjust the low fire setting without energizing the actuator proceed as follows 1 Remove the wiring compartment cover 2 Manually rotate the...

Page 122: ...to increase the pressure and counter clockwise to decrease the pressure to the nozzle Normal nozzle pressure will be 100 to 300 PSI 6894 20684 mbar Refer to the burner s manufacturer s manual packed w...

Page 123: ...the low fire input and counter clockwise will reduce the pressure at the gauge decreasing the low fire input Low fire return pressure will normally be in 60 to 100 PSI 4135 6894 mbar range and at hig...

Page 124: ...ow the low gas pressure switch if supplied to make its circuit 3 Start the burner With the pilot gas cock closed the burner will go through a blower pre purge period after which the pilot ignition tra...

Page 125: ...ircuits have been closed 3 The burner is direct spark ignited Either remove the flame sensor from its sight pipe or electrically disconnect the main oil solenoid valve and start the burner Regardless...

Page 126: ...for oil pump pressure settings 9 Re check all reset switches burner relay lim its pressure cut off switches and if necessary main fan burner motor overload reset but ton s Set the room thermostat and...

Page 127: ...at a minimum annual inspections of your RAPID equipment and perform service where necessary using only replacement parts sold and supplied by Rapid Engineering LLC Falling Hazard Use proper safety eq...

Page 128: ...nit if there is dirt sagging cracking or distortion Remove any carbon deposits or scale using a wire brush If applicable check insulation of vent pipe Repair as required Insulation must have a minimum...

Page 129: ...e Relubrication intervals are specified in the table above After relubricating allow motor to run for 10 minutes before replacing relief hardware NOTE In general it is not recommended to mix greases o...

Page 130: ...ance Filters should be checked for dirt restriction on a monthly basis or as required Replace filters with filters of equal specification when they appear dirty Gain access to the fan s and motor s by...

Page 131: ...s High pressure water 700 psi or less can be used to clean coils with fins at least 0 0095 inches thick IMPORTANT Test the spray pressure on a small area of the coil s to see how well the fins withsta...

Page 132: ...82201020 BUSHING FIXED PULLEY 1 1875 82200660 BUSHING FIXED PULLEY 1 4375 82200680 PULLEY FIXED 1B X 11 0 1 3 16 82105120 PULLEY FIXED 1B X 11 0 PD SDS 14093210 PULLEY FIXED 1B X 12 4 1 3 16 82105140...

Page 133: ...8 82105610 PULLEY VARIABLE 1B x 4 9 5 9 5 8 82107620 PULLEY VARIABLE 1B x 4 9 5 9 7 8 82101610 PULLEY VARIABLE 1B x 5 0 6 5 1 3 8 82105930 PULLEY VARIABLE 1B x 6 0 7 4 1 1 8 82101630 PULLEY VARIABLE...

Page 134: ...ription Part Number ADIABATIC CHAMBER FOR JR15 30 143132 16 ADIABATIC CHAMBER FOR JR50 143132 17 AIRFLOW SWITCH 83100003 ELECTRODE FLAME ROD 14117000 ELECTRODE SPARK JACOB LADDER OIL 2 REQ D 14117101...

Page 135: ...900 MOTORIZED HIGH LOW VALVE BODY 1 5 14043901 MOTORIZED HIGH LOW VALVE BODY 2 10978600 MOTORIZED PROOF OF CLOSURE ACTUATOR 83400301 MOTORIZED PROOF OF CLOSURE VALVE BODY 1 82585171 MOTORIZED PROOF OF...

Page 136: ...TECTOR ROTARY 63 1 AMPS 14320505 MOTOR PROTECTOR ROTARY 1 6 2 5 AMPS 14320507 MOTOR PROTECTOR ROTARY 1 1 6 AMPS 14320506 MOTOR PROTECTOR ROTARY 13 18 AMPS 14320520 MOTOR PROTECTOR ROTARY 17 23 AMPS 14...

Page 137: ...7 12 83100006 BLOWER AIRFLOW PROVING BYPASS TIMER 804 001 02 BULB HOLDER 81100310 CLOGGED FILTER SWITCH 0 17 12 83100006 DOOR GASKET 1 2 X 3 4 10949903 DOOR HANDLE LATCH COMPRESSION SLOTTED 14303506 D...

Page 138: ...SERIES INSTALLATION OPERATION AND SERVICE MANUAL 126 of 143 TOGGLE SWITCH SPDT ON OFF 14217300 TRANSFORMER ISOLATION 40 VA 120 24V 83000020 TRANSFORMER MICRON CONTROL W FUSE BLOCK 200 THRU 480 V 1011...

Page 139: ...lectrical 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 instructions can result...

Page 140: ...s discovered in these initial checks it must be corrected before moving on in the trouble shooting 1 Compare voltage and phase of supply power on site with rating plate information 2 Review wiring bet...

Page 141: ...s but fans do not supply enough air Belts broken or loose Readjust or replace Intake filters dirty Replace or clean Obstruction in intake Check dampers for proper opera tion Clear all intake passages...

Page 142: ...flame cause Defective flame safeguard control replace Defective blower motor Repair or replace Occasional Lockouts for No Apparent Reason Gas pilot ignition failure Refer to pilot adjustment section a...

Page 143: ...s Refer to gas pilot adjustments for correct settings Defective flame safeguard control or plug in purge timing card Replace as required Air flow switch not making circuit Check out electrically and c...

Page 144: ...k and correct Normally open vent valve if supplied not closing when automatic gas valves open Check to see if valve is fully closed when automatic valves are open Replace vent valve if not closing ful...

Page 145: ...for high fire Readjust or replace control Loose wires Verify wiring and tighten all connec tions Flame safeguard control or high fire panel switching relay if supplied defective Verify and correct as...

Page 146: ...put Rate Cannot Be Achieved Nozzle defective or mesh filter dirty Replace or clean mesh Oil supply pressure to nozzle too low Readjust Oil pump defective Replace On Low High Off and Low High Low syste...

Page 147: ...nal If one exists verify that it meets specifications 2 Make sure that the flame amplifier and flame detector are compatible 3 Inspect the main fuel valve s and valve connection s 4 Verify that the fu...

Page 148: ...there is line voltage at terminal 7 when the controller is closed and the fault persists check for a welded or jumpered running interlock or airflow switch Correct any errors 5 If steps 1 through 4 a...

Page 149: ...nd correct any errors 2 Reset and sequence the relay module 3 Use manual motor potentiometer to drive the motor open and closed Verify at motor switch that the end switches are operating properly Use...

Page 150: ...2 Reset and sequence the relay module 3 If fault reappears remove power from the device reapply power then reset and sequence the relay module 4 If the fault does not repeat on the next cycle check f...

Page 151: ...trained technician only DANGER Failure to follow these instructions can result in death electrical shock or injury Falling Hazard Use proper safety equipment and practices to avoid falling Do not use...

Page 152: ...nal Readings Low Fire e r i F h g i H s t l o V Ph Hz Tank Pressure e r i F h g i H s t l o V t i u c r i C l o r t n o C Blower Motor Amps at High Fire Oil Fired High Fire Vacuum Reading Power Supply...

Page 153: ...oming power supply If not contact the RAPID Representative of Rapid Engineering LLC directly Record serial and electrical drawing number from the serial tag on the door of the air make up unit o N g n...

Page 154: ...C Volts Open main shut off valve visually inspect the burner to make sure it is not over firing Adjust the temperature rise to match the serial tag temperature rise e r i f h g i h n o s i t i n u e h...

Page 155: ...plate and or serial number are removed defaced modified or altered in any way The ownership of the RAPID 7500 Series is moved or transferred This warranty is non transferable Rapid Engineering LLC is...

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