Rapid 2005 - SECTION 23: RAPID 2000-SERIES START-UP PROCEDURES; Receiving Inspection

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SECTION 21: REPLACEMENT PARTS

135 of 147

Table 31: Remote Panel Table 32: V-Belt

Description Remote Panel Part Number

Rocker Switch Center Off

DPDT

SDC & DTC 22038

Rocker Switch DPST All 22039

Remote Temperature Selector DTC 22664

Thermostat with Timer DTC 90425111

Amber Status Light All 18663

Temperature Selector Basic Remote & SDC 07345

Thermostat SDC 83200052

20VA Transformer DTC 90436900

Terminal Block All 91300121

Description Part Number

B78 Belt 04312

B81 Belt 04315

B101 Belt 04318

B105 Belt 04320

B110 Belt 04323

B130 Belt 04328

B118 Belt 04349

BX128 Belt 04352

B130 Belt 04353

BX140 Belt 04355

BX74 Belt 04362

BX78 Belt 04363

BX76 Belt 04364

B74 Belt 04365

BX123 Belt 04510

Main Page

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

Rapid 2005 - SECTION 23: RAPID 2000-SERIES START-UP PROCEDURES; Receiving Inspection

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