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4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

152 of 154

Table of Contents

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

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