Rapid Engineering 2000 Series, Installation, Operation & Service Manual

Page 1: ...MI 49321 Telephone 1 616 784 0500 Fax 1 616 784 0435 www rapidengineering com 2019 Rapid Engineering LLC WARNING FOR YOUR SAFETY If you smell gas 1 Open windows 2 DO NOT try to light any appliance 3...

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Page 3: ...784 0435 www rapidengineering com 2019 Rapid Engineering LLC AVERTISSEMENT POUR VOTRE SECURITE Si vous sentez une odeur de gaz 1 Ouvrir les fen tres 2 N essayer pas d allumer un appareil 3 N utiliser...

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Page 5: ...tions 38 14 1 Inlet Duct Work 38 14 2 Return Duct Work 38 14 3 Discharge Duct Work 38 SECTION 15 Gas Piping 39 15 1 Gas Manifolds 39 15 2 Gas Piping and Pressures 39 15 3 Gas Manifold Venting 39 15 4...

Page 6: ...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...

Page 7: ...rocarbons 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 aer...

Page 8: ...Engineering LLC or your RAPID independent distributor to obtain replacement signs or labels 1 4 California Proposition 65 In accordance with California Proposition 65 require ments a warning label mu...

Page 9: ...ag on a wall near the heater e g thermostat or control system A copy of the wall tag P N 91040118 is illustrated on the back cover For an immediate solution you may affix this copy on the wall near th...

Page 10: ...nsible for supplying or arranging for the appropriate lifting equipment so that the air handler and accessories may be placed in a safe manner The qualified installer or service technician is responsi...

Page 11: ...ent 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 enclosur...

Page 12: ...ended purge card of the appropriate duration to meet this requirement 3 3 Hardware Unless otherwise specified all hardware must be torqued to settings on Page 6 Table 1 Note Inlet hood opening shall n...

Page 13: ...rages must be in accordance with the following codes United States Refer to Standard for Parking Structures NFPA 88A latest revision or the Code for Motor Fuel Dispensing Facilities and Repair Garages...

Page 14: ...as required motor horsepower HP may increase from the specifications given on Page 10 Table 4 FIGURE 1 Vertical Dimensions FIGURE 2 Horizontal Dimensions Fan Burner Section Filter Mix Box Optional Fil...

Page 15: ...70 1 27 8 70 6 12 8 32 5 10 8 27 4 40 5 102 8 4 3 10 9 15 0 38 1 43 1 109 4 2 8 7 1 150 8 383 0 184 8 469 4 44 3 112 5 13 7 34 7 3 2 8 1 20 0 51 0 8 2 20 8 3 4 8 6 45 7 116 1 65 0 165 1 43 25 109 9 2...

Page 16: ...9 1 9 000 15 300 2010 7 5 65 73 79 1 069 875 13 2 32 8 9 2 22 8 10 000 17 000 2010 7 5 66 74 79 1 188 972 16 1 40 1 10 9 27 1 11 000 18 700 2010B 7 5 67 69 73 1 307 1 069 8 2 20 5 6 0 14 9 12 000 20 4...

Page 17: ...0 25 0 62 0 10 0 25 0 05 0 12 18 000 30 000 30 600 51 000 0 40 1 0 0 50 1 25 0 10 0 25 0 05 0 12 2030 27 500 30 000 46 772 51 000 0 35 0 87 0 75 1 87 0 10 0 25 0 05 0 12 32 500 40 000 55 200 68 000 0...

Page 18: ...sories or packages that were shipped on the same skid inside the air handler or inside the control enclosure 3 Inspect the air handler to Verify that there is no damage as a result of shipping Ensure...

Page 19: ...e long axis Lift the air handler off the skid and place it on a flat clean dry surface Step 2 Remove the lifting lugs on the inlet end of the air handler and re install hardware Step 3 Use all four li...

Page 20: ...mm of each other To ensure a weatherproof seal between the air handler 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...

Page 21: ...ide perimeter of roof curb at bolted joints Top Mounting Flange Side Panel End Panel Inlet or Discharge Side panels are split Cross Brace Model Dimensions Weight Weight A B C D E lbs kg lbs kg 2005 in...

Page 22: ...t metal screws supplied by others equally spaced on each side must be used to attach the air handler to the curb After the curb has been installed the air handler may be placed on the curb The install...

Page 23: ...the corner and attach with the previously removed hardware Missing hardware needs to be added at each bolt location The required hardware is a 5 16 18 x 1 grade 5 bolt a 5 16 flat washer and a 5 16 1...

Page 24: ...the top upside down on a flat surface See Page 18 Figure 7 FIGURE 7 Step 1 Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid fa...

Page 25: ...SECTION 9 UPRIGHT INSTALLATION 19 Step 2 Attach the mounting feet to each leg using supplied hardware See Page 19 Figure 8 FIGURE 8 Step 2...

Page 26: ...e upside down insert and attach the first two legs Note All legs are identical and not all the holes will be used on each leg See Page 20 Figure 9 Step 4 Next attach the horizontal support s and repea...

Page 27: ...ler see Page XX Section 10 3 Prior to lifting the air handler apply the foam tape and remove the attaching hardware as described below The 12 7 mm thick double sided urethane foam tape provided by oth...

Page 28: ...bly Crush Hazard Use proper lifting equipment and practices Falling Hazard Use proper safety equipment and prac tices to avoid falling Severe Injury Hazard Use proper lifting practices and equip ment...

Page 29: ...t Air Handlers 10 3 1 Filter Section Installation To install a filter section on an upright air handler that is mounted on legs the filter section must be installed in the leg assembly prior to placin...

Page 30: ...l seams must be caulked provided by others NOTE Check to be sure that all required components are present If any are missing contact your RAPID independent distributor Crush Hazard Use proper lifting...

Page 31: ...ll holes 8 20 3 cm in the flanges of the inlet hood and mount with lag bolts provided by others The following hardware is supplied for the assembly of the inlet hoods 10 TEK self tapping screws 3 8 nu...

Page 32: ...rimeter of the inlet of the air handler with the provided foam gasket tape Step 11 2 2 Mount the upper inlet hood right and left side flanges will be facing out with the bolts and wash ers provided St...

Page 33: ...per inlet hood to the hood using the provided rivets Step 11 2 5 Mount the lower inlet hood right and left side flanges will be facing out with the bolts and wash ers provided and the upper edge of th...

Page 34: ...11 2 6 Attach the bottom filter rail for the lower inlet hood and attach to the left and right side of the hood and to the air handler using the provided TEK screws Step 11 2 7 Attach the lower hood r...

Page 35: ...ifying that the arrow on the side of the filter points in the direction of air flow All of the arrows should be point ing towards the air handler when installed in the proper orientation Once filters...

Page 36: ...d using the TEK screws provided Step 11 3 3 Attach the inlet hood to the filter section using the nuts bolts washers provided Bolt it to each corner of the filter section Use the provided TEK screws t...

Page 37: ...2 If the hood is attached directly to the unit fasten to unit with TEK screws and install blocker piece at the bottom Step 11 4 3 If the unit is equipped with a filter section selected attach the hood...

Page 38: ...tall Mist Limiter media through open face of inlet hood along guide rails Slide the top of the mist limiter all the way into the top rail This will provide clearance to lower the bottom of the limiter...

Page 39: ...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 Wear protective gear during installation...

Page 40: ...inlet of the air handler covering the inlet opening The inlet damper has four outward turned flanges Based on air handler style damper may include upper and lower damper C E C D A B C C F NOTE 1 CONT...

Page 41: ...et metal supplied by others may be required See Page 35 Figure 16 for the three way discharge head available FIGURE 16 Three Way Discharge Head Crush Hazard Use proper lifting equipment and practices...

Page 42: ...anged nut onto each hanger rod Then slip each hanger rod down through a hole located in each corner of the splash plate Next feed a flanged nut onto the rod below the splash plate See Page 36 Figure 1...

Page 43: ...ES 37 FIGURE 18 Mounting Hole Locations A B Blower Discharge Centerline Model A B 2005 in 24 6 22 5 cm 62 5 57 1 2010 in 32 1 34 0 cm 81 5 86 4 2010B in 36 6 36 8 cm 93 0 93 4 2020 in 40 6 40 3 cm 103...

Page 44: ...diameter d round duct inside diameter Hydraulic duct diameter for rectangular ducts in inches Dh 2 H W H W Dh hydraulic diameter H rectangular duct inside height W rectangular duct inside width The ai...

Page 45: ...s This is the responsibility of the installer 15 3 1 Main Gas Regulator Venting The main regulator used on 1 and larger manifolds must be piped to the atmosphere outside the structure This is the resp...

Page 46: ...ff Valve Safety Shut Manual Gas Valve Main Union By Others Alternate Inlet Inlet By Others Vent to Atmosphere Vent to Atmosphere Ps Manual Gas Modulating Valve With Pressure Regulator High Gas Pressur...

Page 47: ...Valve Burner High Gas Pressure Switch Burner LOW GAS PRESSURE SWITCH Low Gas Pressure Switch Pilot Regulator Pilot Solenoid Off Valve With Actuator Block Valve With Actuator Safety Shut Vent Valve Ve...

Page 48: ...et gas pressure and the burner gas pressure during burner setup 15 5 1 Manifold Inlet Gas Pressure The pressure port for measuring manifold inlet pressure is located on the inlet side of the first saf...

Page 49: ...t 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 for...

Page 50: ...terconnection wiring between the remote panel and the air handler control enclosure is run in a single conduit the wire run can be as long as 100 30 m For longer wire runs consult the factory If the i...

Page 51: ...rmits the flame safeguard relay to begin ignition This switch is factory set at 0 32 in wc 0 8 mbar The high velocity pressure switch will open if the airflow across the burner reaches its maximum all...

Page 52: ...Shooting Guide Page 82 Section 23 16 6 5 Discharge Temperature Sensor This device senses the discharge temperature of the air at the blower The discharge temperature sensor reports the discharge temp...

Page 53: ...SECTION16 ELECTRICAL 47 FIGURE 24 Interconect Wiring 2...

Page 54: ...erature limit 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 h...

Page 55: ...y drive enclosure heater and or GFI 16 8 10 Service Receptacle Powered by Others Wired This option provides a service receptacle It includes ground fault interrupter GFI receptacle mounted on the inte...

Page 56: ...is brought into the space to satisfy the pressure setpoint Most installations require a setpoint of 0 02 in wc to 0 03 in wc to achieve adequate pressure control in the building space 5 16 diameter tu...

Page 57: ...dler Configuration Air Flow Air Volume Control Make Up Air MUA 100 Outside Air Constant Fixed Recirculation FR Non adjustable ratio of 20 outside air and 80 return air Constant Air Management AM Adjus...

Page 58: ...ir 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 selection dial The burner...

Page 59: ...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 temperatures on the te...

Page 60: ...gh temperature limit switch and the low and high airflow pressure switches Once the burner control circuit is satisfied then the flame control module will execute the burner ignition sequence Once the...

Page 61: ...nd 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 creating the spark at the...

Page 62: ...n and the flame safeguard will need to be manu ally reset The M4RT1 has a series of 8 jumpers that are used to configure the Purge timing Pilot Trial for Ignition PTFI timing and recycle or non recycl...

Page 63: ...t 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 c...

Page 64: ...of the firing rates WARNING Failure to follow these instructions can result in death electric shock injury or property damage Burn Hazard Allow heater to cool before service Tubing may still be hot a...

Page 65: ...29 Spark 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 or...

Page 66: ...burner and 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 59 Figure 29 NOT...

Page 67: ...an one disconnect switch may be required to disconnect electric from equipment Equipment must be properly grounded Severe Injury Hazard Do not enter equipment while in operation Equipment may start au...

Page 68: ...ated space served by the Process Heater that can be used by personnel to enter the space must have door interlock switch or switches to shut down the Process Heater if in the bake cycle 2 On recircula...

Page 69: ...recirculation air is properly diluted during the bake cycle mode This is accomplished by ensuring the bypass feature of the ventilating air damper is not blocked by the installation or that the minimu...

Page 70: ...instructions 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...

Page 71: ...tions 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 diagram based on...

Page 72: ...cable compare all variable frequency drive VFD programming parameters with specifications provided on electrical drawing 20 4 Airflow The air flow switches are factory calibrated safety devices for bu...

Page 73: ...rily leave the manometer attached to the 1 8 tap It will be used later to check high fire gas pressure 20 5 Gas Piping and Initial Pressure Settings 1 Perform a pressure test on all gas supply lines t...

Page 74: ...unted inside 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...

Page 75: ...If the temperature control system should require field calibration refer to the provided temperature control amplifier product information sheet Table 19 Maximum Temperature Rise SC11 Signal Condition...

Page 76: ...w Fire Adjustment 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 a...

Page 77: ...11 Valve FIGURE 36 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 Regulator Adjustment Be...

Page 78: ...components of 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 instru...

Page 79: ...ust as required See Page 66 Section 20 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 Re check belt tensio...

Page 80: ...aring Lubrication 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 lub...

Page 81: ...se capacity recommen dations as capacities vary by motor Relubrication intervals are specified in the table above After relubricating allow motor to run for 10 minutes before replacing relief hardware...

Page 82: ...as required See Page 66 Section 20 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 the a...

Page 83: ...pers for proper operation See Page 33 Section 12 Filters Filters should be checked for dirt restriction on a monthly basis or as required Replace filters with filters of equal specification when they...

Page 84: ...ly genuine RAPID replacement 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...

Page 85: ...DC 180 in lb 2005 2010 2020 2030 28430 Ignition Control Module 07617 Flame Rod All models 07590 High Temperature Limit Switch 17071 Igniter All models 07640 Relay 15Amp 07165 Relay 8Amp 28560 Relay So...

Page 86: ...17 28718 Starter 33810 33810 33810 33810 33810 33811 33812 33813 33814 33815 33816 33817 33818 Fuse 25128 25091 25092 25093 25094 25095 25096 25097 25099 25100 25101 25103 25106 Fuse Block 25130 25130...

Page 87: ...717 28718 28719 Starter 33812 33813 33813 33815 33817 33818 33819 Fuse 25096 25097 25099 25100 25103 25108 25109 Fuse Block 25130 25130 25131 25131 25132 25906 25906 Description Part Number Descriptio...

Page 88: ...t 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 instructions...

Page 89: ...ate for reversing instructions 23 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 fuse...

Page 90: ...sure 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 Flame c...

Page 91: ...4 Amplifiers are supplied on units equipped with DTC remote panels If problems persist after performing the troubleshooting procedure and the temperature control amplifier troubleshooting procedure co...

Page 92: ...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 holding valve open 14 Plunger jammed...

Page 93: ...ure 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 val...

Page 94: ...emperature 14 Improper TS144 location 15 Incorrect discharge air temperature calibrations G Continuous High Fire electronics ok 16 Foreign material holding valve open 17 Plunger jammed H Continuous Hi...

Page 95: ...air temperature 15 Follow procedures outlined in PRELIMINARY CIRCUIT ANALY SIS Sections IV in Maxitrol product information sheet 14 Move TS144 to location where average temperature can be sensed 15 I...

Page 96: ...ure they are tight OK ____ Loose____ Specify 4 Check sheaves set screws and bearing collars Make sure they are tight OK ____ Loose ____ Specify 5 Compare voltage on unit rating plate to job site volta...

Page 97: ...tting 2 Record burner pressure with inlet manual gas valve off and blowers on ______________ in wc mbar Gas Piping and Initial Pressure Setting Page 42 Section 15 4 1 Perform a pressure test on all ga...

Page 98: ...ory The data plate and or serial number are removed defaced modified or altered in any way The ownership of the RAPID 2000 Series is moved or transferred This warranty is non transferable Rapid Engine...

Page 99: ...SECTION 25 THE RAPID 2000 SERIES WARRANTY 93...

Page 100: ...tion check one o Automotive o Manufacturing o Warehouse o Recreational o Aircraft o Public Building o Of ce o Retail o Agricultural o Other______________ Mail or Fax to Rapid Engineering LLC 1100 Seve...

Page 101: ...All information contained in this document is subject to change without notice...