Rapid 4044 - Intelligent Control Systems

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4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

92 of 154

Yo ur RAPID

Air Handler may be 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 document.

19.12 Intelligent Control Systems

19.12.1 ICS II

19.12.2 ICS IV

19.12.3 InfinityPro™

Main Page

Default Chapter3
- Table of Contents3
Table of Contents9
SECTION 1: Air Handler Safety9
- Description of Operation9
- Inspection and Setup9
- Temporary Storage10
- Safety Labels and Their Placement10
- California Proposition 6510
- Label Placement11
- Figure 1: 4024 - 404911
- Figure 2: 4054 and 408912
- Figure 3: 4000-Series Interior13
SECTION 2: Installer Responsibility14
- Corrosive Chemicals14
- National Standards and Applicable Codes14
- Required Equipment14
SECTION 3: Critical Considerations16
- Required Clearances to Combustibles16
- Hardware16
- Table 1: Recommended Torque Settings16
SECTION 4: National Standards and Applicable Codes17
- Gas Codes17
- Installation Codes17
- Aircraft Hangars17
- Parking Structures and Repair Garages17
- Electrical17
- Venting17
- High Altitude17
SECTION 5: Specifications18
- Table 2: 4000 am Dimensions19
- Figure 4: 4000 am Vertical Model Dimensions19
- Table 3: 4000 am Approximate Shipping Weights20
- Figure 5: 4000 am Horizontal Model Dimensions20
- Table 4: 4000 MUA Dimensions21
- Figure 6: 4000 MUA Vertical Model Dimensions21
- Table 5: 4000 MUA Approximate Shipping Weights22
- Figure 7: 4000 MUA Horizontal Model Dimensions22
- Table 6: 4000 FR Dimensions23
- Figure 8: 4000 FR Vertical Model Dimensions23
- Table 7: 4000 FR Approximate Shipping Weights24
- Figure 9: 4000 FR Horizontal Model Dimensions24
- Table 8: 4000 VAV Dimensions25
- Figure 10: 4000 VAV Vertical Model Dimensions25
- Table 9: 4000 VAV Approximate Shipping Weights26
- Figure 11: 4000 VAV Horizontal Model Dimensions26
- Table 10: Dimensions27
- Table 11: Leaving Dry Bulb Temperature Drop (Average)27
- Figure 12: Evaporative Cooling27
- Table 12: Air Density Ratio28
- Table 13: Dimensions29
- Table 14: Estimated Tons of Cooling29
- Figure 13: Mechanical Cooling29
- Table 15: Dimensions30
- Figure 14: Energy Recovery30
- Table 16: Energy Recovery31
- Table 17: Fan Selection Chart32
- Table 18: Fan Selection Chart (Continued)33
- Table 19: Static Pressure Drops for Options34
SECTION 6: Lifting an Air Handler (Rigging)35
- Preparing to Lift the Air Handler35
- Lifting a Horizontal Air Handler36
- Figure 15: Lifting a Horizontal Air Handler Filter Section and Options (Model 4024 - 4049)36
- Figure 16: Lifting a Horizontal Air Handler with Options (Model 4054 - 4089)36
- Lifting an Vertical Air Handler37
- Figure 17: Lifting an Vertical Air Handler (All Models)37
- Figure 18: Lifting an Vertical Air Handler with Filter Section and Mixing Box38
- Upright Assembly Alignment39
- Figure 19: Inlet Alignment39
SECTION 7: Air Handler Assembly40
- Caulking the Air Handler41
- Figure 20: Caulking Air Handler Joints41
- Caulking a Horizontal Air Handler42
- Figure 21: Caulking a Standard Horizontal Air Handler42
- Caulking an Vertical Air Handler43
- Figure 22: Caulking a Standard Vertical Air Handler43
- Figure 23: Assembling Optional Discharge / Supply and Return Sleeves44
- Accessory Connections45
- Figure 24: Electrically Connecting Joined Sections45
- Figure 25: Installing Cooling Coil Section45
- Figure 26: Installing Pressure Transmitter Tubing for am and VAV46
- Figure 27: Typical Freeze Protection (Evaporative Cooling Package #1)46
- Figure 28: Conductivity Control and Freeze Protection (Evaporative Cooling Package #2)47
- Figure 29: Protection and Auto-Flush (Evaporative Cooling Package #3)47
- Figure 30: Evaporative Cooling Trap Detail48
SECTION 8: Roof Curb49
- Roof Curb Assembly and Installation49
- Table 20: Roof Curbs (Availability Based on Style)49
- Figure 31: Roof Curb50
- Figure 32: Roof Curb Installation51
- Figure 33: Roof Curb Assembly with Brackets52
- Figure 34: Duct Support Adapter53
SECTION 9: Indoor Suspension Mounting - Horizontal Air Handler54
- Suspension Mounting Assembly and Instructions54
- Figure 35: Indoor Suspension55
SECTION 10: Leg Mounting56
- Figure 36: Assembling Legs for Horizontal Air Handlers57
- Figure 37: Assembly Legs and Rainskirt for Upright Air Handlers58
SECTION 11: Filter Section59
- Figure 38: Filter Section Support Assembly59
SECTION 12: Inlet Hoods60
- Inlet Hood Assembly60
- Figure 39: Inlet Hood Without Filters (4024-4049)60
- Figure 40: Inlet Hood Without Filters (4054-4089)61
- Figure 41: Inlet Hood with Permanent Filters61
- Figure 42: Inlet Hood with Moisture Limiter62
SECTION 13: Service Platform63
- Service Platform63
- Figure 43: Service Platform for an Vertical Air Handler63
- Figure 44: Service Platform for a Horizontal Air Handler64
SECTION 14: Discharge Accessories65
- One-Way, Three-Way and Four-Way Discharge Head Installation65
- Figure 45: Vertical Air Handler with Duct Sleeves and Discharge Head66
- Figure 46: One-Way Discharge Head67
- Figure 47: Three-Way Discharge Head68
- Figure 48: Four-Way Discharge Head69
- Splash Plate Installation71
- Figure 50: Discharge Plate71
SECTION 15: Vibration Isolation72
- Figure 51: Suspended72
- Figure 52: Curb Mounted73
- Figure 53: Platform Mounting on Vibration Isolators74
- Figure 54: Vibration Isolation Platform Locations75
SECTION 16: Cooling Specifications76
- Evaporative Cooling76
- Table 21: Formulas76
- Table 22: Abbreviations76
- Table 23: Evaporation Rate76
- Table 24: Suggested Air Changes Per Hour (Air Change Method)76
- Table 25: Saturation Efficiency at Stated Media Depth76
- Table 26: Static Pressure Drop (in Wc) at Stated Media Depth76
SECTION 17: Duct Considerations77
- Inlet Air Duct77
- Return Air Duct77
- Supply Air Duct Work77
SECTION 18: Gas Piping78
- Gas Manifolds78
- Gas Piping and Pressures78
- Table 27: Manifold Component Identification79
- Figure 55: Standard Gas Manifold79
- Figure 56: FM Gas Manifold80
- Figure 57: XL Insurance Gas Manifold81
- Gas Piping82
- Pressure Test Ports82
SECTION 19: Electrical83
- Disconnect Fuse Sizing84
- Wiring and Electrical Connections84
- Remote Panel84
- Motor Current Draw84
- Table 28: Minimum and Maximum Fuse Size by Motor Size and Supply Voltage84
- Table 29: Control Voltage Wiring for All Control Systems84
- Control Current Draw85
- Safety Systems85
- Table 30: Safety Systems85
- Interlocks87
- Control Options87
- Safety Systems89
- Table 31: Safety Systems89
- Remote Panels90
- Figure 58: Basic Remote90
- Figure 59: Basic Remote (Continued)91
- Figure 60: Standard Discharge Remote92
- Figure 61: Standard Discharge Remote (Continued)93
- Figure 62: Deluxe Room Control Remote94
- Figure 63: Deluxe Room Control Remote (Continued)95
- Figure 64: Standard Room Control Remote96
- Figure 65: Standard Room Control Remote (Continued)97
- DDC-Ready Controls98
- Figure 66: DDC-Ready Controls98
- Figure 67: DDC-Ready Controls (Continued)99
- Intelligent Control Systems100
- Figure 68: Air Handler Styles101
- HVAC Remote Panels and Panel Options102
- Basic Air Handler Sequence of Operation104
- Table 32: Factory Preset Schedule on TH8110 Thermostat104
- FIGURE 69: Fireye M4RT1104
- Table 33: Jumper Settings106
- Figure 70: Jumper Locations106
- Honeywell RM7890 Flame Safeguard108
SECTION 20: Direct Fired Burner120
- Figure 71: Midco HMA-2A Burner121
- Direct Fired Burner Ignition123
- Figure 72: Spark Rod Dimensions123
- Direct Fired Burner Flame Proving (Flame Rod)124
- Figure 73: Maxon NPLE Burner124
- Honeywell UV Flame Detector127
- Honeywell UV Flame Detector (Continued)128
SECTION 21: Start-Up Procedures129
- Installation of Recirculating Air Handler130
- Mechanical130
- Figure 74: Sheave Alignment130
- Electrical131
- Airflow131
- Table 34: Deflection Force B and BX Belts (in Lbs)131
- Figure 75: Belt Tension131
- Gas Piping and Initial Pressure Settings132
- Table 35: Motor Sheave Drive Torque Specifications132
- Table 36: Motor and Blower Bushing Torque Specifications132
- Figure 76: Fireye Flame Module132
- Table 37: Burner Mode by Amplifier Type133
- Safety Shut off Valve Check134
- Temperature Control System Calibration134
- Table 38: Maximum Temperature Rise134
- Figure 77: MR 212 Valve135
- Figure 78: M611 Valve136
- Figure 79: Regulator (2005)136
SECTION 22: Maintenance137
- General138
- Unit Exterior138
- Blower Section138
- Manifold and Controls140
- Burner140
- Table 39: Motor Lubrication Intervals141
- Optional Equipment142
SECTION 23: Replacement Parts143
SECTION 24: Troubleshooting144
- Initial Checks145
- Motor and Blower145
- Burner146
- Temperature Controls147
- A1014 Amplifier - Field Checklist148
- Figure 80: RM7897C Flame Control150
Section 25: Rapid151
- 4000-Series Start-Up Procedures151
Section 26: Rapid156
- 4000-Series Start-Up Procedures Evaporative Cooler156
Evaporative Cooler159
SECTION 27: the RAPID159
- 4000-Series Warranty159

Rapid 4044 - Intelligent Control Systems

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