Rapid 2005 - Figure 80: M611 Valve (2005); Figure 81: Regulator (2005)

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SECTION 19: START-UP PROCEDURES

123 of 147

FIGURE 80: M611 Valve (2005)

FIGURE 81: 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 Below

(High Fire Adjustment Cap)

Gas FlowGas Flow

Table of Contents

Default Chapter5
- Table of Contents5
Table of Contents11
SECTION 1: Air Handler Safety11
- Description of Operation11
- Inspection and Setup11
- Safety Labels and Their Placement12
- California Proposition 6512
- Label Placement13
- Figure 1: 200513
- Figure 2: 2010 and 2010B13
- Figure 3: 2020 and 203014
- Figure 4: 2000-Series Interior15
SECTION 2: Installer Responsibility16
- Wall Tag16
- Corrosive Chemicals16
- National Standards and Applicable Codes17
- Required Equipment17
SECTION 3: Critical Considerations18
- Required Clearances to Combustibles18
- Purge of Supply Duct19
- Hardware19
- Table 1: Recommended Torque Settings19
SECTION 4: National Standards and Applicable Codes20
- Gas Codes20
- Installation Codes20
- Aircraft Hangars20
- Parking Structures and Repair Garages20
- Electrical20
- Venting20
- High Altitude20
SECTION 5: Specifications21
- Figure 5: 2005 Upright Model Dimensions21
- Table 2: 2005 Dimensions21
- Figure 6: 2005 Horizontal Model Dimensions22
- Table 3: 2005 Weights22
- Table 4: Motor Weights22
- Figure 7: 2010, 2010B, 2020 and 2030 Upright Model Dimensions23
- Table 5: 2010, 2010B, 2020 and 2030 Dimensions23
- Figure 8: 2010, 2010B, 2020 and 2030 Horizontal Model Dimensions24
- Table 6: 2010, 2010B, 2020 and 2030 Weights24
- Table 7: Motor Weights24
- Table 8: 2000-Series Selection Guide25
- Table 9: Estimated Pressure Drop of Accessory Components26
SECTION 6: Lifting an Air Handler27
- Lifting an Air Handler27
- Figure 9: Lifting a Horizontal Air Handler27
- Figure 10: Lifting an Upright Air Handler (2005 - 2030)28
SECTION 7: Roof Curb29
- Roof Curb Assembly and Installation29
- Air Handler Mounting to Roof Curb30
- Figure 11: Roof Curb Assembly30
- Figure 12: Curb Mounting31
SECTION 8: Upright Stand32
- Upright Stand Installation32
- Attaching Air Handler to Stand32
- Figure 13: Upright Stand Detail (2005)32
- Figure 14: Upright Stand Detail (2010 - 2030)32
- Figure 15: Stand Shim (2010B - 2030)33
- Figure 16: Upright Stand Mounting Detail33
SECTION 9: Legs34
- Leg Mounting34
- Leg Mounting - Horizontal Air Handler (2005 - 2030)34
- Figure 17: Leg Mounting Holes (2005 - 2030)34
- Figure 18: Stud Positioning35
- Figure 19: Leg Bolt Detail35
SECTION 10: Indoor Suspension Mounting - Horizontal Air Handler36
- Suspension Kit Assembly and Installation36
- Figure 20: Indoor Suspension (2005)37
- Figure 21: Indoor Suspension (2010 and 2010B)38
SECTION 11: Filter Section39
- Filter Section (2005)39
- Filter Section Assembly (2010 and 2010B)40
- Filter Section Assembly (2020 and 2030)44
- Filter Section Support Assembly51
- Figure 22: Filter Section Support Assembly52
- Filter Section Installation - Horizontal Air Handlers53
- Filter Section Installation - Upright Air Handlers53
- Figure 23: Filter Section Installation on Horizontal Air Handler (2010 - 2030)53
SECTION 12: Inlet Hood54
- Inlet Hood Assembly (2005)54
- Figure 24: Inlet Hood Assembly (2005)54
- Inlet Hood Assembly (2010 and 2010B)55
- Inlet Hood Assembly (2020 and 2030)64
- Inlet Hood Installation74
- Figure 25: Inlet Hood Positioning74
SECTION 13: Dampers75
- Discharge Damper76
- Figure 26: Motorized Discharge Damper (2005 - 2030)76
- Inlet Damper77
- Figure 27: Motorized Inlet Damper (2005 - 2010B)77
- Figure 28: Motorized Inlet Damper (2020 and 2030)78
SECTION 14: Discharge Heads and Splash Plates79
- One-Way and Three-Way Discharge Head Installation79
- Figure 29: Three-Way Discharge Head (2005 - 2030)79
- Splash Plate Installation80
- Figure 30: Splash Plate80
- Figure 31: Hole Location (2005 - 2030)81
SECTION 15: Duct Considerations82
- Inlet Duct Work82
- Return Duct Work82
- Discharge Duct Work82
- Table 10: Minimum Recommended Duct Size83
- Table 11: Discharge Duct Size Recommendations to Connect to Heater (for BD/RD)83
SECTION 16: Gas Piping84
- Gas Manifolds84
- Gas Piping and Pressures84
- Gas Manifold Venting84
- Table 12: Gas Manifold Size84
- Figure 32: ANSI/FM/XL-Compliant Manifolds (2005)85
- Figure 33: ANSI-Compliant Manifold (2010 - 2030)85
- Figure 34: FM-Compliant Manifold (2010 - 2030)86
- Figure 35: XL-Compliant Manifold (2010 - 2030)86
- Gas Piping87
- Pressure Test Ports87
- Line Pressure Test - Leak Testing87
- Figure 36: Plug Tapping (2005)87
- Figure 37: Plug Tapping (2010 - 2030)87
SECTION 17: Electrical88
- Wiring and Electrical Connections88
- Remote Panel88
- Motor Current Draw88
- Control Current Draw88
- Safety Systems88
- Table 13: Control Voltage Wiring for All Control Systems88
- Table 14: Full Load Current Draw89
- Table 15: Safety Systems89
- Figure 38: Wiring Diagram Key90
- Figure 39: Basic Remote Wiring Diagram (2005)91
- Figure 40: Standard Discharge Control Remote (SDC) Wiring92
- Figure 41: Deluxe Temperature Control Remote (DTC) Wiring93
- Figure 42: Basic Remote Wiring Diagram (2010 - 2030)94
- Figure 43: Standard Discharge Control Remote (SDC) Wiring Diagram (2010 - 2030)95
- Figure 44: Deluxe Temperature Control Remote (DTC) Wiring Diagram (2010 - 2030)96
- Figure 45: BMS-Ready Control MUA Style (2005)97
- Figure 46: BMS-Ready Control MUA/FR Style Units (2010 - 2030)98
- Additional Control Wiring100
- Figure 48: Additional Control Wiring for VAV Style (2010 and 2010B)100
- Figure 49: Additional Control Wiring for VAV Style (2020 - 2030)101
- Figure 50: BMS-Ready Control for VAV Style (2010 and 2010B)102
- Figure 51: BMS-Ready Control for VAV Style (2020 - 2030)103
- Figure 52: BMS-Ready Control for VAV Style with Inlet Damper (2020 - 2030)104
- Figure 53: Additional Control Wiring for VAV Style with Inlet Damper (2020 - 2030)105
- Figure 54: am Style for 2010 and 2010B106
- Figure 55: am Style for 2020 - 2030106
- Carbon Dioxide Interlocks107
- Control Options107
- Figure 56: CO2 Sensor Interlock for FR and MUA Style107
- Figure 57: CO2 Sensor Interlock for am and VAV Style (2010 and 2010B)107
- Figure 58: CO2 Sensor Interlock for am and VAV Style (2020 and 2030)107
- Figure 59: CO Sensor Interlock for FR and MUA108
- Figure 60: CO Sensor Interlock for am and VAV108
- Figure 61: CO Sensor Interlock for am and VAV with Photohelic108
- Figure 62: CO Sensor Interlock for am with Building Pressure108
- Optional Exhaust Motor Starters, Variable Frequency Drives113
- Figure 63: J-1000 1 Pot 7.5HP or Less113
- Figure 64: V-1000 1 Pot 10-25HP113
- Figure 65: P7 1 Pot 30HP or more114
- Figure 66: J-1000 VFD 7.5HP or Less with Photohelic114
- Figure 67: V-1000 VFD 10 to 25HP with Photohelic115
- Disconnect Fuse Sizing116
- Figure 68: P7 30HP or more with Photohelic116
- Table 16: Minimum and Maximum Fuse Size by Motor Size and Supply Voltage116
- Figure 69: Single Exhaust Starter117
- Figure 70: Two Exhaust Starter117
SECTION 18: Sequence of Operation118
- Air Handler Configuration118
- Figure 71: Air Handler Styles119
- Table 17: Configuration Chart119
- HVAC Remote Panels and Panel Options120
- Basic Air Handler Sequence of Operation122
- Figure 72: Honeywell Safeguard Jumpers122
- Table 18: Factory Preset Schedule on TH8110 Thermostat122
- Table 19: Site-Configuration Jumper Options122
- Figure 73: S8600 Flame Control (2005)123
- Figure 74: RM7890 Flame Control (2010 and 2010B)124
- Figure 75: RM7897 Flame Control (2020 - 2030)125
SECTION 19: Start-Up Procedures126
- Installation of Recirculating Air Handler127
- Mechanical127
- Figure 76: Sheave Alignment127
- Electrical128
- Airflow128
- Figure 77: Belt Tension128
- Table 20: Deflection Force B and BX Belts (in Lbs)128
- Gas Piping and Initial Pressure Settings129
- Figure 78: Honeywell Flame Module129
- Table 21: Motor Sheave Drive Torque Specifications129
- Table 22: Motor and Blower Bushing Torque Specifications129
- Safety Shut off Valve Check131
- Temperature Control System Calibration131
- Table 23: Burner Mode by Amplifier Type131
- Table 24: Maximum Temperature Rise131
- Figure 79: MR 212 Valve (2010 - 2030)132
- Figure 80: M611 Valve (2005)133
- Figure 81: Regulator (2005)133
SECTION 20: Maintenance134
- General135
- Unit Exterior135
- Blower Section135
- Table 25: Motor Lubrication Intervals137
- Manifold and Controls138
- Burner138
- Figure 82: 6" (15.3 CM) Straight Cast Iron139
- Figure 83: 12" (30.5 CM) Straight Cast Iron139
- Figure 84: 12" (30.5 CM) Tee Cast Iron139
- Table 26: Burner Selections139
- Optional Equipment140
SECTION 21: Replacement Parts141
- Figure 85: Control Panel Layouts141
- Figure 86: Power Panel Layout142
- Table 27: Control Panel142
- Table 28: Power Panel143
- Figure 87: Blower Layout144
- Table 29: Manifold Components144
- Table 30: Blower144
- Table 31: Remote Panel145
- Table 32: V-Belt145
SECTION 22: Troubleshooting146
- Initial Checks147
- Motor and Blower147
- Burner148
- Temperature Controls149
- A1014 Amplifier - Field Checklist150
- A44 Amplifier - Field Service Checklist152
SECTION 23: RAPID ® 2000-Series Start-Up Procedures155
SECTION 24: the RAPID ® 2000-Series Warranty157

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