How it Works
Rapid
Loading...
2020
Installation, Operation & Service Manual
162 pgs9.26 Mb0
Table of contents
Loading...

Rapid 2005, 2010, 2030, 2010B, 2020 Installation, Operation & Service Manual

Download
Page 1
NOT FOR RESIDENTIAL USE
WARNING
Installation must be done by a contractor qualified in the installation and service of gas-fired heating equipment or your gas supplier.
Improper installation, adjustment, alteration, service or maintenance can result in death, injury or property damage. Read the Installation, Operation and Service Manual thoroughly before installing or servicing this equipment.
WARNING
FOR YOUR SAFETY If you smell gas:
1. Open windows.
2. DO NOT try to light any appliance.
3. DO NOT use electrical switches.
4. DO NOT use any telephone in your building.
5. Extinguish any open flame.
6. Leave the building.
7. Immediately call your local gas supplier after leaving the building. Follow the gas supplier’s instructions.
8. If you cannot reach your gas supplier, call the Fire Department.
Fire Hazard
Keep all flammable objects, liquids and vapors the minimum required clear­ances to combustibles away from equipment.
Some objects will catch fire or explode when placed close to equipment.
Failure to follow these instructions can result in death, injury or property damage.

Rapid® 2000-Series

Direct, Gas-Fired, Industrial
Air Handler
Installation, Operation &
Service Manual
2005 2010

2010B

2020

CANADA: 100% OUTSIDE AIR ONLY
© 2015 Rapid Engineering LLC

2030

Installer
Please take the time to read and understand
these instructions prior to any installation.
Installer must give a copy of this manual to the owner.
Owner
Keep this manual in a safe place in order to provide
your service technician with necessary information.
Rapid Engineering LLC
1100 Seven Mile Road NW Comstock Park, MI 49321 Telephone: +1.616.784.0500 Fax: +1.616.784.1910 Toll Free: 800.536.3461
www.rapidengineering.com
P/N RP121100NA Rev C 08/15
Page 2
Page 3
Conçus pour les applications non-résidentielles
Canada: seulement avec
100% d’air externe
ATTENTION
Linstallation doit être effectuée par un installateur éprouvé/contractant qualifié dans linstallation et la maintenance du système de chauffage par infrarouge activé au gaz.
Linstallation, lajustement, laltération, le démarrage ou lentretien inadéquat peuvent causer la mort, des blessures ou des dégâts matériels. Lire entièrement le manuel dinstallation, dopération et dentretien avant linstallation ou l'entretien de cet équipement.
Installateur
Prenez le temps de lire et comprendre ces instructions
avant toute installation.
Linstallateur doit remettre au propriétaire
un exemplaire de ce manuel.
Propriétaire
Gardez ce manuel dans un endroit sûr pour
fournir des informations au réparateur
en cas de besoin.
Rapid Engineering LLC
1100 Seven Mile Road NW Comstock Park, MI 49321 Téléphone: +1.616.784.0500 Fax: +1.616.784.1910 Numéro sans fraís: 800.536.3461
www.rapidengineering.com
AVERTISSEMENT
POUR VOTRE SECURITE
Si vous sentez une odeur de gaz:
1. Ouvrir les fenêtres.
2. N’essayer pas d’allumer un appareil.
3. N’utiliser pas d’interrupteurs électriques.
4. N’utiliser pas de téléphone dans votre bâtiment.
5. Eteindre flamme nue.
6. Quitter le bâtiment.
7. Après avoir quitté le bâtiment, appelez immédiatement votre fournisseur local de gaz. Suivre les instructions du fournisseur de gaz.
8. Si vous ne pouvez pas joindre votre fournisseur de gaz, appeler le service d’incendie.
Risque d’incendie
Garder tous les objets, liquides ou vapeurs inflammables à la distance minimale de l’unité de chauffage requise avec les matériaux combustibles.
Certains objets prendront feu ou exploseront s’ils sont placés à proximité de l’unité de chauffage.
Le non respect de ces instructions peut entraîner la mort, des blessures corporelles ou des dommages matériels.

Rapid® 2000-Series

L’appareil de traitment de l’air à
combustion directe, au gaz pour
les applications industrielles

Manuel d'installation,

d'opération,

et d'entretien

2005 2010

2010B

2020 2030
© 2015 Rapid Engineering LLC
P/N RP121100FC Rev C 08/15
Page 4
Page 5

TABLE OF CONTENTS

SECTION 1: Air Handler Safety..............................................1
1.1 Description of Operation...............................................1
1.2 Inspection and Setup ................................................... 1
1.3 Safety Labels and Their Placement .............................2
1.4 California Proposition 65 ..............................................2
1.5 Label Placement ..........................................................3
SECTION 2: Installer Responsibility .....................................6
2.1 Wall Tag .......................................................................6
2.2 Corrosive Chemicals....................................................6
2.3 National Standards and Applicable Codes ..................7
2.4 Required Equipment .................................................... 7
SECTION 3: Critical Considerations ..................................... 8
3.1 Required Clearances to Combustibles......................... 8
3.2 Purge of Supply Duct...................................................9
3.3 Hardware .....................................................................9
SECTION 4: National Standards and Applicable Codes ... 10
4.1 Gas Codes................................................................. 10
4.2 Installation Codes ...................................................... 10
4.3 Aircraft Hangars ......................................................... 10
4.4 Parking Structures and Repair Garages.................... 10
4.5 Electrical .................................................................... 10
4.6 Venting....................................................................... 10
4.7 High Altitude .............................................................. 10
SECTION 5: Specifications .................................................. 11
SECTION 6: Lifting an Air Handler ......................................17
6.1 Lifting an Air Handler .................................................17
SECTION 7: Roof Curb ......................................................... 19
7. 1 Ro o f C urb Assembly and Installation .........................19
7.2 Air Handler Mounting to Roof Curb ............................20
SECTION 8: Upright Stand...................................................22
8.1 Upright Stand Installation...........................................22
8.2 Attaching Air Handler to Stand...................................22
SECTION 9: Legs ..................................................................24
9.1 Leg Mounting.............................................................24
9.2 Leg Mounting - Horizontal Air Handler
(2005 - 2030)............................................................24
SECTION 10: Indoor Suspension Mounting - Horizontal
Air Handler ..................................................26
10.1 Suspension Kit Assembly and Installation ...............26
SECTION 11: Filter Section ..................................................29
11.1 Filter Section (2005) ................................................. 29
11.2 Filter Section Assembly (2010 and 2010B) ............... 30
11.3 Filter Section Assembly (2020 and 2030)................. 34
11.4 Filter Section Support Assembly...............................41
11.5 Filter Section Installation - Horizontal Air Handlers... 43
11.6 Filter Section Installation - Upright Air Handlers .......43
SECTION 12: Inlet Hood ....................................................... 44
12.1 Inlet Hood Assembly (2005) .................................... 44
12.2 Inlet Hood Assembly (2010 and 2010B)...................45
12.3 Inlet Hood Assembly (2020 and 2030) ....................54
12.4 Inlet Hood Installation ..............................................64
SECTION 13: Dampers .........................................................65
13.1 Discharge Damper................................................... 66
13.2 Inlet Damper ............................................................67
SECTION 14: Discharge Heads and Splash Plates............ 69
14.1 One-Way and Three-Way Discharge Head
Installation ................................................................69
14.2 Splash Plate Installation........................................... 70
SECTION 15: Duct Considerations......................................72
15.1 Inlet Duct Work ........................................................72
15.2 Return Duct Work ....................................................72
15.3 Discharge Duct Work............................................... 72
SECTION 16: Gas Piping.......................................................74
16.1 Gas Manifolds...........................................................74
16.2 Gas Piping and Pressures ........................................74
16.3 Gas Manifold Venting................................................74
16.4 Gas Piping............................................................... 77
16.5 Pressure Test Ports.................................................. 77
16.6 Line Pressure Test - Leak Testing............................ 77
SECTION 17: Electrical......................................................... 78
17.1 Wiring and Electrical Connections............................ 78
17.2 Remote Panel........................................................... 78
17.3 Motor Current Draw.................................................. 78
17.4 Control Current Draw................................................ 78
17.5 Safety Systems......................................................... 78
17.6 Additional Control Wiring .......................................... 90
17.7 Carbon Dioxide Interlocks ........................................ 97
17.8 Control Options ........................................................ 97
17.9 Optional Exhaust Motor Starters, Variable
Frequency Drives.................................................. 103
17.10 Disconnect Fuse Sizing........................................ 106
SECTION 18: Sequence of Operation ............................... 108
18.1 Air Handler Configuration ...................................... 108
18.2 HVAC Remote Panels and Panel Options .............. 110
18.3 Basic Air Handler Sequence of Operation..............112
SECTION 19: Start-up Procedures .....................................116
19.1 Installation of Recirculating Air Handler..................117
19.2 Mechanical .............................................................117
19.3 Electrical .................................................................118
19.4 Airflow .....................................................................118
19.5 Gas Piping and Initial Pressure Settings.................119
19.6 Safety Shut Off Val
ve Check.................................. 121
19.7 Temperature Control System Calibration ............... 121
SECTION 20: Maintenance................................................. 124
20.1 General.................................................................. 125
20.2 Unit Exterior........................................................... 125
20.3 Blower Section....................................................... 125
20.4 Manifold and Controls............................................ 128
20.5 Burner.................................................................... 128
20.6 Optional Equipment............................................... 130
SECTION 21: Replacement Parts ...................................... 131
SECTION 22: Troubleshooting .......................................... 136
22.1 Initial Checks ......................................................... 137
22.2 Motor and Blower .................................................. 137
22.3 Burner.................................................................... 138
22.4 Temperature Controls ............................................ 139
22.5 A1014 Amplifier - Field Checklist ........................... 140
22.6 A44 Amplifier - Field Service Checklist.................. 142
®
SECTION 23: RAPID SECTION 24: The RAPID
2000-Series Start-Up Procedures. 145
®
2000-Series Warranty............. 147
Page 6
© 2015
Rapid Engineering LLC
All rights reserved. No part of this work covered 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 - without the written permission of Rapid Engineering LLC.
Printed in the U.S.A.
Page 7
TABLE OF FIGURES
Figure 1: 2005 ...........................................................................3
Figure 2: 2010 and 2010B ......................................................... 3
Figure 3: 2020 and 2030 ........................................................... 4
Figure 4: 2000-Series Interior ................................................... 5
Figure 5: 2005 Upright Model Dimensions.............................. 11
Figure 6: 2005 Horizontal Model Dimensions ......................... 12
Figure 7: 2010, 2010B, 2020 and 2030 Upright Model
Dimensions ...........................................................13
Figure 8: 2010, 2010B, 2020 and 2030 Horizontal Model
Dimensions............................................................ 14
Figure 9: Lifting a Horizontal Air Handler................................17
Figure 10: Lifting an Upright Air Handler (2005 - 2030)........... 18
Figure 11: Roof Curb Assembly ..............................................20
Figure 12: Curb Mounting .......................................................21
Figure 13: Upright Stand Detail (2005) ...................................22
Figure 14: Upright Stand Detail (2010 - 2030)........................22
Figure 15: Stand Shim (2010B - 2030)....................................23
Figure 16: Upright Stand Mounting Detail ...............................23
Figure 17: Leg Mounting Holes (2005 - 2030) ........................24
Figure 18: Stud Positioning ..................................................... 25
Figure 19: Leg Bolt Detail .......................................................25
Figure 20: Indoor Suspension (2005) .....................................27
Figure 21: Indoor Suspension (2010 and 2010B)....................28
Figure 22: Filter Section Support Assembly............................42
Figure 23: Filter Section Installation on Horizontal Air
Handler (2010 - 2030)...........................................43
Figure 24: Inlet Hood Assembly (2005)...................................44
Figure 25: Inlet Hood Positioning............................................64
Figure 26: Motorized Discharge Damper (2005 - 2030).......... 66
Figure 27: Motorized Inlet Damper (2005 - 2010B) .................67
Figure 28: Motorized Inlet Damper (2020 and 2030) ..............68
Figure 29: Three-Way Discharge Head
(2005 - 2030) ..........................................................................69
Figure 30: Splash Plate........................................................... 70
Figure 31: Hole Location (2005 - 2030) .................................. 71
Figure 32: ANSI/FM/XL-Compliant Manifolds (2005) .............. 75
Figure 33: ANSI-Compliant Manifold (2010 - 2030).................75
Figure 34: FM-Compliant Manifold (2010 - 2030).................... 76
Figure 35: XL-Compliant Manifold (2010 - 2030)..................... 76
Figure 36: Plug Tapping (2005) ..............................................77
Figure 37: Plug Tapping (2010 - 2030) ................................... 77
Figure 38: Wiring Diagram Key ...............................................80
Figure 39: Basic Remote Wiring Diagram (2005)....................81
Figure 40: Standard Discharge Control Remote (SDC) Wiring
Diagram (2005)...................................................... 82
Figure 41: Deluxe Temperature Control Remote (DTC) Wiring
Diagram (2005)...................................................... 83
Figure 42: Basic Remote Wiring Diagram (2010 - 2030) ......... 84
Figure 43: Standard Discharge Control Remote (SDC) Wiring
Diagram (2010 - 2030)........................................... 85
Figure 44: Deluxe Temperature Control Remote (DTC) Wiring
Diagram (2010 - 2030)........................................... 86
Figure 45: BMS-Ready Control MUA Style (2005).................. 87
Figure 46: BMS-Ready Control MUA/FR Style Units (2010 - 2030)
88 Figure 47: BMS-Ready Control AM Style Units (2010 - 2010B)89 Figure 48: Additional Control Wiring for VAV Style (2010 and
2010B)....................................................................90
Figure 49: Additional Control Wiring for VAV Style
(2020 - 2030) ........................................................91
Figure 50: BMS-Ready Control for VAV Style
(2010 and 2010B)................................................ 92
Figure 51: BMS-Ready Control for VAV Style (2020 - 2030) .. 93 Figure 52: BMS-Ready Control for VAV Style with Inlet Damper
(2020 - 2030)......................................................... 94
Figure 53: Additional Control Wiring for VAV Style with Inlet
Damper (2020 - 2030) ........................................... 95
Figure 54: AM Style for 2010 and 2010B................................. 96
Figure 55: AM Style for 2020 - 2030 ....................................... 96
Figure 56: CO2 Sensor Interlock for FR and MUA Style ........ 97
Figure 57: CO2 Sensor Interlock for AM and VAV Style
(2010 and 2010B) ............................................... 97
Figure 58: CO2 Sensor Interlock for AM and VAV Style
(2020 and 2030) ................................................. 97
Figure 59: CO Sensor Interlock for FR and MUA ................... 98
Figure 60: CO Sensor Interlock for AM and VAV ................... 98
Figure 61: CO Sensor Interlock for AM and VAV with
Photohelic ........................................................... 98
Figure 62: CO Sensor Interlock for AM with Building
Pressure ............................................................. 98
Figure 63: J-1000 1 Pot 7.5HP or Less ................................. 103
Figure 64: V-1000 1 Pot 10-25HP ......................................... 103
Figure 65: P7 1 Pot 30HP or More........................................ 104
Figure 66: J-1000 VFD 7.5HP or Less with Photohelic ......... 104
Figure 67: V-1000 VFD 10 to 25HP with Photohelic.............. 105
ure 68: P7 30HP or More with Photohelic........................ 106
Fig
Figure 69: Single Exhaust Starter......................................... 107
Figure 70: Two Exhaust Starter ............................................ 107
Figure 71: Air Handler Styles................................................ 109
Figure 72: Honeywell Safeguard Jumpers ........................... 112
Figure 73: S8600 Flame Control (2005) ................................113
Figure 74: RM7890 Flame Control (2010 and 2010B) ............ 114
Figure 75: RM7897 Flame Control (2020 - 2030)..................115
Figure 76: Sheave Alignment ............................................... 117
Figure 77: Belt Tension ........................................................118
Figure 78: Honeywell Flame Module .................................... 119
Figure 79: MR 212 Valve (2010 - 2030) ................................ 122
Figure 80: M611 Valve (2005)............................................... 123
Figure 81: Regulator (2005).................................................. 123
Figure 82: 6" (15.3 cm) Straight Cast Iron............................ 129
Figure 83: 12" (30.5 cm) Straight Cast Iron.......................... 129
Figure 84: 12" (30.5 cm) Tee Cast Iron ................................ 129
Figure 85: Control Panel Layouts.......................................... 131
Figure 86: Power Panel Layout ............................................. 132
Figure 87: Blower Layout ...................................................... 134
Page 8
Page 9
LIST OF TABLES
Table 1: Recommended Torque Settings................................. 9
Table 2: 2005 Dimensions...................................................... 11
Table 3: 2005 Weights ........................................................... 12
Table 4: Motor Weights .......................................................... 12
Table 5: 2010, 2010B, 2020 and 2030 Dimensions ............... 13
Table 6: 2010, 2010B, 2020 and 2030 Weights ..................... 14
Table 7: Motor Weights .......................................................... 14
Table 8: 2000-Series Selection Guide.................................... 15
Table 9: Estimated Pressure Drop of Accessory
Components ............................................................. 16
Table 10: Minimum Recommended Duct Size ....................... 73
Table 11: Discharge Duct Size Recommendations to
Connect to Heater (for BD/RD)............................. 73
Table 12: Gas Manifold Size .................................................. 74
Table 13: Control Voltage Wiring For All Control Systems..... 78
Table 14: Full Load Current Draw .......................................... 79
Table 15: Safety Systems....................................................... 79
Table 16: Minimum and Maximum Fuse Size by Motor Size
and Supply Voltage............................................. 106
Table 17: Configuration Chart .............................................. 109
Table 18: Factory Preset Schedule on TH8110
Thermostat.......................................................... 112
Table 19: Site-Configuration Jumper Options ...................... 112
Table 20: Deflection Force B and BX Belts (in lbs) .............. 118
Table 21: Motor Sheave Drive Torque Specifications .......... 119
Table 22: Motor and Blower Bushing Torque
Specifications...................................................... 119
Table 23: Burner Mode by Amplifier Type............................ 121
Table 24: Maximum Temperature Rise ................................ 121
Table 25: Motor L
Table 26: Burner Selections ................................................. 129
Table 27: Control Panel........................................................ 132
Table 28: Power Panel ......................................................... 133
Table 29: Manifold Components........................................... 134
Table 30: Blower .................................................................. 134
Table 31: Remote Panel....................................................... 135
Table 32: V-Belt.................................................................... 135
ubrication Intervals ................................... 127
There are references in this manual to various trademarks. All trademarks mentioned herein, whether registered or not, are the property of their respective owners. Rapid Engineering LLC is not sponsored by or affiliated with any of the trademark or registered trademark owners, and makes no representations about them, their owners, their products or services.
Page 10
Page 11

SECTION 1: AIR HANDLER SAFETY

Yo ur Safety is Important to Us! This symbol is used throughout the manual to notify you of possible fire, electrical or burn hazards. Please pay special attention when reading and following the warnings in these
sections. Installation, service and, at a minimum, annual inspection of air handlers must be done by a contractor qualified in the installation and service of gas-fired heating equipment.
Read this manual carefully before installation, operation or service of this equipment.
This air handler is designed for heating non­residential indoor spaces. Do not install in residential spaces. These instructions, the layout drawing, local codes and ordinances and applicable standards that apply to gas piping, electrical wiring, ventilation, etc. must be thoroughly understood before proceeding with the installation.
Protective gear is to be worn during installation, operation and service in accordance to the Occupational Safety and Health Administration (OSHA). Gear must be in accordance to NFPA 70E, latest revision w
hen working with electrical components. Thin sheet metal parts have sharp edges. To prevent injury, the use of work gloves is recommended.
Before installation, check that the local distribution conditions, nature of gas and pressure and adjustment of the appliance are compatible.
The equipment must be applied and operated under the general concepts of reasonable use and installed using the best building practices.
This piece of equipment is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the equipment by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the equipment.
For additional copies of the Installation, Operation and Service Manual, please contact Rapid Engineering LLC.
Gas-fired eq
uipment is not designed for use in atmospheres containing flammable vapors or dust or atmospheres containing chlorinated or halogenated hydrocarbons. Recirculated room air may be
SECTION 1: AIR HANDLER S AFETY
hazardous if containing flammable solids, liquids, and gases; explosive materials; and/or substances which may become toxic when exposed to heat (i.e. refrigerants, aerosols, etc.).

1.1 Description of Operation

This air handler is a direct, gas-fired, fresh-air piece of equipment. It is designed for indoor or outdoor installation with fresh outdoor air delivered to the burner. Air handlers are designed to operate in temperatures as low as -30° F (-34° C). The air handler is factory-tested to fire with natural gas or LPG (check the air handler's rating plate for information on the appropriate gas). The burner flame will modulate to maintain the selected discharge air temperature or room air temperature, depending on the selected controls. See Page 110,
Section 18.2. For maximum temperature rise, See Page 121, Table 24.
The air handler may be provided with several different controls and options to meet various application requirements. Be sure to read this entire manual before installation and start-up.

1.2 Inspection and Setup

The air handler is shipped fully assembled. The air handler was inspected and operated prior to shipment. Immediately upon receipt of the air handler, check the fuel and electrical characteristics of the air handler and verify that they match the fuel and electrical supply available. Verify that the specifications on the air handler rating plate match the order. Check the air handler for any damage that may have occurred during shipment. If any damage is found, file a claim with the transporting agency. Do not refuse shipment. Check the installation location to ensure proper clearances to combustibles. See Page 8, Section 3.1.
Any small options which do not come attached to the air handler (i.e. remote panel) will be found inside the air handler.
Larger accessories (i.e. legs, stand, filter section, inlet hood) may either ship with the air handler or separately. Check the bill of lading for information.
If the air handler must be temporarily stored (i.e. job site is not ready for installation of the air handler), the air handler should be set on 4" x 4" (10 cm x 10 cm) pieces of timber on the ground in a protected area. Cover the air handler to protect it from the environment. Rapid Engineering LLC will not be held responsible for any damages that may occur from
1 of 147
Page 12
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
outdoor storage.

1.3 Safety Labels and Their Placement

Product safety signs or labels should be replaced by product user if they are no longer legible. Please contact Rapid Engineering LLC or your RAPID
®
independent distributor to obtain replacement signs or labels. See Page 3, Figure 1 through Page 4, Figure 3.

1.4 California Proposition 65

In accordance with California Proposition 65 require- ments, a warning label must be placed in a highly visible location on the outside of the equipment (i.e., near equipment's serial plate). See label placement drawing on Page 3, Figure 1 through Page 4, Figure
3 for label location. Avoid placing labels on areas with extreme heat, cold, corrosive chemicals or other
elements. To order additional labels, please contact Rapid Engineering LLC or your RAPID
®
independent
distributor.
2 of 147
Page 13

1.5 Label Placement

AIR FLOW
AIR FLOW
AIR FLOW
AIR FLOW
CONTROL ENCLOSURE
CONTROL ENCLOSURE
1
7
1
7
2
2
4
2
4
3
ON SHRINK WRAP
4
5
5
6
2
4
6
8
ON SHRINK WRAP BY CONTROL ENCLOSURE
9
10
9
10
11
11
12
12
Item Part Number Description
1 91070001 Label Shock Hazard 2 91070002 Label Severe Injury Hazard 3 91070003 Label Crush Hazard 4 91070004 Label Fire Hazard 5 91070005 Label Falling Hazard 6 91070006 Label Burn Hazard 7 19205 Label 2000-Series 8 91010100 Label Manual Location
9 19030 Label Recommended Entry 10 91010427 Label Vent to Outdoors 11 91010431 Label Improper Installation 12 91070015 Label Proposition 65
2
4
6
1
4
5
2
6
7
2
7
2
4
4
x
1
7
x
3
ON SHRINK WRAP
7
AIR FLOW AIR FLOW
AIR FLOW
AIR FLOW
55
5
8
ON SHRINK WRAP BY CONTROL ENCLOSURE
9
10
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
LOCATED OVER THE REGULATOR VENTS
9
10
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
LOCATED OVER THE REGULATOR VENTS
11
11
12
12
Item Part Number Description
1 91070001 Label Shock Hazard 2 91070002 Label Severe Injury Hazard 3 91070003 Label Crush Hazard 4 91070004 Label Fire Hazard 5 91070005 Label Falling Hazard 6 91070006 Label Burn Hazard 7 19205 Label 2000-Series 8 91010100 Label Manual Location
9 19030 Label Recommended Entry 10 91010427 Label Vent to Outdoors 11 91010431 Label Improper Installation 12 91070015 Label Proposition 65

FIGURE 1: 2005

SECTION 1: AIR HANDLER S AFETY

FIGURE 2: 2010 and 2010B

3 of 147
Page 14
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
x
x
4
5
3
ON SHRINK WRAP
7
1
2
4
6
7
1
2
4
6
2
2
4
AIR FLOW
AIR FLOW
AIR FLOW
AIR FLOW
5 5
5
8
ON SHRINK WRAP BY CONTROL ENCLOSURE
9
10
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
LOCATED OVER THE REGULATOR VENTS
9
LOCATED AT THE
BOTTOM CENTER
OF THE CONTROL
ENCLOSURE
10
LOCATED OVER THE REGULATOR VENTS
11
11
12
12
Item Part Number Description
1 91070001 Label Shock Hazard 2 91070002 Label Severe Injury Hazard 3 91070003 Label Crush Hazard 4 91070004 Label Fire Hazard 5 91070005 Label Falling Hazard 6 91070006 Label Burn Hazard 7 19205 Label 2000-Series 8 91010100 Label Manual Location
9 19030 Label Recommended Entry 10 91010427 Label Vent to Outdoors 11 91010431 Label Improper Installation 12 91070015 Label Proposition 65

FIGURE 3: 2020 and 2030

4 of 147
Page 15

FIGURE 4: 2000-Series Interior

5
GROUND LUG ON BURNER END RS PANEL
NOTE:-LABEL 3, 4, AND 10 MUST BE ORIENTATED
SO THAT IT CAN BE READ FROM TOP-LEFT TO BOTTOM-RIGHT WHEN THE AIR HANDLER IS INSTALLED AT THE JOB SITE.
-LABEL 15 IS USED ANY TIME THERE IS A
GFI OUTLET THAT IS POWERED BY OTHERS. TO BE POSITIONED NEXT TO LABEL 8 AND/OR 14.
8 or 14
2005 MOUNT ON ENCL FLOOR UNDER VFD/AUX MOTOR STARTER
15
8 AND/OR 14
2010-2030 SPLASH PLATE MOUNTED ON CONTROL ENCLOSURE BOTTOM PANEL 2005 CONTROL ENCLOSURE FLOOR UNDER VFD/AUX MOTOR STARTER
15
16
1 OR 2
SAFETY SHUTOFF
VALVE
IGNITION
TRANSFORMER
TRANSFORMER
40VA
AMPLIFIER
AIRFLOW SWITCH
0.32IN W.C.
R6
AIRFLOW
SWITCH
1.40IN W.C.
10
7
9
SPLASH PLATE MOUNTED ON CONTROL ENCLOSURE DOOR
CONTROL ENCLOSURE DOOR
11 or 12
13 PLACE INSIDE ITEM #9
2010-2030
7
9
2005 CONTROL ENCLOSURE DOOR
13 PLACE INSIDE ITEM #9
11 or 12
NAMEPLATE
3MOTOR
4
3
BLOWER
HIGH TEMP LIMIT SWITCH
DISCHARGE SENSOR
6
REMOTE BOX RIGHT SIDE
TERMINAL RAIL
REMOTE BOX 10X10 INTERNAL
10
11
REMOTE BOX LEFT SIDE
16
10
TERMINAL RAIL
REMOTE BOX 12x16 INTERNAL
6
REMOTE BOX RIGHT SIDE
11 or 12
REMOTE BOX LEFT SIDE
16
Item Part Number Description Qty.
1 19024 Label - Propane Gas 1 2 19025 Label - Natural Gas 1 3 19162 Label - Rotation 1 4 19161 Label - High Temperature Limit 1 5 19100 Label - Ground 1 6 91070009 Label - Electric Shock Hazard (Mini) 1 7 91010444 Label - 2000-Series Rating Plate 1 8 91010443 Label - 2000-Series Exhaust Fan Motor Control 1 9 90911300 9½" x 13" Clear Pouch 1
10 91010445
Label - 2000-Series Wire Connection Control Panel/ Remote Panel
2
11 91010446 Label - ETL Certification Without Recirculation Z83.4 2 12 91010447 Label - ETL Certification With Recirculation Z83.18 2 13 80XXX Wiring Diagram - Varies by Order 2 14 91040128 Label - Auxiliary Motor Starter 1 15 91010448 Label - Shock Hazard GFI 1
SECTION 1: AIR HANDLER S AFETY
5 of 147
Page 16
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Explosion Hazard
Equipment must have access to uncontaminated air at all times.
Failure to follow these instructions can result in death, injury or property damage.
CAUTION
Product Damage Hazard
Do not use equipment in area containing corrosive chemicals.
Refer to appropriate Material Safety Data Sheets (MSDS).
Failure to follow these instructions can result in product damage.

SECTION 2: INSTALLER RESPONSIBILITY

The installer is responsible for the following:
• To install and commission the air handler, as well as the gas and electrical supplies, in accordance with applicable specifications and codes. Rapid Engineering LLC recommends the installer contact a local building inspector or Fire Marshal for guidance.
•To use the information given in a layout drawing and in the manual together with the cited codes and regulations to perform the installation.
• To install the heater in accordance with the clearances to combustibles.
•To furnish all needed materials not furnished as standard equipment.
• To plan location of supports.
• To provide access to
air handler
for servicing.
• To provide the owner with a copy of this Installation, Operation and Service Manual.
• To never use heater as support for a ladder or other access equipment and never hang or suspend anything from heater.
•To ensure there is adequate air circulation around the air handler and to supply air for combustion, ventilation and distribution in accordance with local codes.
• To assemble or install any accessories or associated duct work using best building practices.
• To properly size supports and hanging materials.
• To ensure heater is placed in an approved application.
6 of 147

2.1 Wall Tag

A laminated wall tag is available for the heater as a permanent reminder of the safety instructions and the importance of the required clearances to combustibles. Please contact Rapid Engineering LLC
®
or your RAPID
independent distributor to obtain the wall tag. Affix the tag 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 the heater.
Know your model number and installed configuration. Model number and installed configuration are found on the rating plate and in the Installation, Operation and Service Manual. See Page 3, Figure 1 through Page 4, Figure 3.

2.2 Corrosive Chemicals

Rapid Engineering LLC cannot be responsible for ensuring that all appropriate safety measures are undertaken prior to installation; this is entirely the responsibility of the installer. It is essential that the contractor, the sub-contractor, or the owner identifies the presence of combustible materials, corrosive chemicals or halogenated hydrocarbons* anywhere in the premises.
* Halogenated Hydrocarbons are a family of chemical compounds characterized by the presence of halogen elements (fluorine, chlorine, bromine, etc.). These compounds are frequently used in refrigerants, cleaning agents, solvents, etc. If these compounds enter the air supply of the burner, the life span of the air handler components will be greatly reduced. The loca­tion of the outside air supply must be carefully chosen to supply outside air, free of these compounds, to the burners whenever the presence of these compounds is suspect. Warranty will be invalid if the air handler is exposed to halogenated hydrocar­bons.
Page 17

2.3 National Standards and Applicable Codes

All equipment must be installed in accordance with the latest revision of the applicable standards and national codes. This refers also to the electric, gas and venting installation. Note: Additional standards for installation in public garages, aircraft hangars, etc. may be applicable.

2.4 Required Equipment

When lifting of the equipment is required, the installing contractor is responsible 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 responsible for having the appropriate equipment for the safe installation and start-up of a direct-fired air handler. Tools required to commission the equipment include, but are not limited to, the following:
• Various screwdriver types and sizes
• Various adjustable wrenches
• Torque wrenches
• Pipe wrenches sized appropriately for the gas train components
• Drill motor and various drills
• U-tube manometer or gas pressure gauge
• Volt meter
• Clamp style ammeter
• Belt tension gau
ge
• Caulk (non-silicone)
SECTION 2: INSTALLER R ESPONSIBILITY
7 of 147
Page 18
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Fire Hazard
Keep all flammable objects, liquids and vapors the minimum required clearances to combustibles away from equipment.
Some objects will catch fire or explode when placed close to equipment.
Failure to follow these instructions can result in death, injury or property damage.

SECTION 3: CRITICAL CONSIDERATIONS 3.1 Required Clearances to Combustibles

Clearances are the required distances that combustible objects must be away from the air handler to prevent fire hazards. Combustibles are materials that may catch on fire and include common items such as wood, paper, rubber, fabric, etc.
Maintain clearances to combustibles at all times for safety.
Check the clearances on each air handler being installed to make sure the product is suitable for your application and the clearances are maintained. Clearances to combustibles for models 2005- 2030 are 12" (30.5 cm) on the control enclosure side and 6" (15.2 cm) on all other surfaces. Read and follow the safety guidelines below:
• Locate the air handler so that the air intakes are not too close to any exhaust fan outlets, gasoline storage, propane tanks or other contaminants that could potentially cause dangerous situations.
WARNING
• Keep gasoline or other combustible materials including flammable objects, liquids, dust or vapors away from this air handler or any other piece of
• Maintain clearances from heat sensitive material, equipment and workstations.
equipment
.
Explosion Hazard
Fresh air supply duct and burner housing must be purged with fresh air four times before every ignition.
Explosive vapors will ignite if not evacuated before ignition attempt.
Failure to follow these instructions can result in death, injury or property damage.
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 enclosure, blower access panel and filter access panel (when equipped).
The stated clearances to combustibles represent a surface temperature of 90° F (50° C) above room temperature (90° F [50° C] plus ambient temperature). Building materials with a low heat tolerance (i.e. plastics, vinyl siding, canvas, tri-ply, etc.) may be subject to degradation at lower temperatures. It is the installer’s/owner’s responsibility to assure that adjacent materials are protected from degradation.
• Maintain clearances from vehicles parked below the
air handler. See Page 10, Section 4.4.
8 of 147
Page 19
SECTION 3: CRITICAL CONSIDERATIONS
8.8
10.9

3.2 Purge of Supply Duct

If this heating unit is to be installed indoors, and its outdoor air supply ducted from outdoors, ANSI Standards Z83.18 and Z83.4 require that all supply duct shall be purged a minimum of four times prior to any ignition attempt. If the volume of the outdoor air supply duct exceeds the heating unit’s ability to complete the required four air changes prior to ignition, you must contact the factory to purchase an extended 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 9, Table 1.
Note: Inlet hood opening shall not be installed with inlet opening facing into the prevailing wind direction in order to help prevent the possibility of moisture entrainment.

Table 1: Recommended Torque Settings

Bolt Head
Grade Marking
Nut Grade
Marking
Bolt Size Grade 2 Grade 5
10-24 27 in•lb 42 in•lb
1/4-20 65 in•lb 101 in•lb
5/16-18 11 ft•lb 17 ft•lb
3/8-16 19 ft•lb 30 ft•lb
Bolt Head
Grade Marking
8.8 10.9
Nut Grade
Marking
Bolt Size Grade 8.8 Grade 10.9
M5 6Nm 9Nm M6 10Nm 15Nm
M8 25Nm 35Nm M10 50Nm 75Nm M12 85Nm 130Nm M16 215Nm 315Nm
9 of 147
Page 20
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 4: NATIONAL STANDARDS AND APPLICABLE CODES

4.1 Gas Codes

The type of gas appearing on the nameplate must be the type of gas used. Installation must comply with national and local codes and requirements of the local gas company.
United States: Refer to NFPA 54/ANSI Z223.1 ­latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1- latest revision, Natural Gas and Propane Installation Code.

4.4 Parking Structures and Repair Garages

Installation in garages 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, NFPA 30A - latest revision.
Canada: Refer to Natural Gas and Propane Installation Code, Standard CSA B149.1 - latest revision.

4.2 Installation Codes

Installations must be made in accordance with the Standard for the Installation of Air­Conditioning and Ventilating Systems, NFPA 90A - latest revision for the installation of air conditioning and ventilating systems.

4.3 Aircraft Hangars

Installation in aircraft hangars must be in accordance with the following codes:
United States: Refer to Standard on Aircraft Hangars, NFPA 409 - latest revision.
Canada: Refer to Natural Gas and Propane Installation Code, Standard CSA B149.1 - latest revision.

4.5 Electrical

Electrical connection to air handler must be in accordance with the following codes:
United States: Refer to National Electrical
®
Code
, NFPA 70 - latest revision. Wiring must
conform to the most current National Electrical
®
Code
, local ordinances, and any special
diagrams furnished.
Canada: Refer to Canadian Electrical Code, CSA C22.1 Part 1 - latest revision.

4.6 Venting

The venting must be installed in accordance with the requirements within this manual and
the following codes:
United States: Refer to NFPA 54/ANSI Z223.1­latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision, Natural Gas and Propane Installation Code.
10 of 147

4.7 High Altitude

These air handlers are approved for installations up to 2000' (609.6 m) (in the US) and 4500' (1371.6 m) (in Canada) without modification. Consult factory if US installation is above 2000 is above 4500
'
(609.6 m) or Canadian installation
'
(1371.6 m).
Page 21
SECTION 5: SPECIFICATIONS

SECTION 5: SPECIFICATIONS

Dimension and estimated weight tables apply to both upright and horizontal units of the same model.
Unless otherwise requested, all direct-fired air handlers are set-up to accept an external static pressure (ESP) of 1 in wc (2.5 mbar). The external static pressure is the sum of all accessories and any attached ductwork. See Page 16, Table 9 for static pressure accessories. If more external static pressure is required, this needs to be requested with the order as required motor horsepower (HP) may increase from the specifications given on Page 15,

FIGURE 5: 2005 Upright Model Dimensions

A
ED
F
E
D
Y
Z
LD or RD
FN
BBAABB
(One Each Corner)
Customer Supplied
Duct Location
(See Page 73, Table 11)
Ta b l e 8 .
The legend below details abbreviations used in this section and applies to Page 11, Figure 5 through Page 14, Figure 8. Return Air (RA) is only for FR (Fixed Recirculation) and AM (Air Management) styles.
Legend
BD = Bottom Discharge OA = Outside Air CE = Control Enclosure RA = Return Air (optional) GC = Gas Connection RD = Right Discharge ED = End Discharge TD = Top Discharge LD = Left Discharge OH = Opposite Hand
C
Lifting Lug
LD
ED
QD
RD
B
G
U
GC-OH
M
CECE-OH
S
GC
Filter Access
K
GC
(OPTIONAL)
FILTER SECTION
OA OA
STAND
(OPTIONAL)
END VIEW
CE
SIDE VIEW
Filter Access

Table 2: 2005 Dimensions

Model CFMABCDEFGKLMNPQSUWXYZAABB
(in)
1,000-
32.3
60.3
28.3
10.4
6.8
11.5
27.0
117.3
1.5
8.0
9.3
1.8
3.1
35.2
30.0
25.0
38.4
2005
(cm)
(in)
(cm)
3,000
4,000
82.0
32.3
82.0
153.2
60.3
153.2
71.9
28.3
71.9
26.4
13.8
35.1
17.3
7.6
19.3
29.2
8.2
20.8
68.6
27.0
68.6
297.9
117.3
297.9
3.8
1.5
3.8
20.3
8.0
20.3
23.6
15.8
40.1
4.6
1.8
4.6
7.9
3.1
7.9
89.4
35.2
89.4
76.2
30.0
76.2
63.5
25.0
63.5
97.5
38.4
97.5
5.3
13.51435.6
7.5
19.01435.6
17.5
44.5
17.5
44.5
7.4
18.7
7.4
18.7
11 o f 14 7
Page 22
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
ED
A
N
F
TD or BD
E
D
F
G
OA
B
OA
ED
P
L
W
C
D
Q
CE
CE-OH
CE
TD
BD
M
X
GC
GC
SIDE
VIEW
PLAN VIEW
FILTER SECTION
(OPTIONAL)
INLET HOOD (OPTIONAL)
Customer Supplied
Duct Location
(See page 73, Table 11)
Filter Access
Filter Access
S
AA
BB
BB
Y
Z
GC-OH

FIGURE 6: 2005 Horizontal Model Dimensions

Table 3: 2005 Weights

Model Air Handler Stand
2005
(lb) 450 75 60 20 100 75 50 40 13 26 50
(kg) 204.1 34.0 27.2 9.1 45.4 34 22.7 18.1 5.9 11.8 22.7

Table 4: Motor Weights

Size
ODP
TEFC
HP
kW
lb kg lb kg
2
1. 5
58
26.3 90
40.8
Inlet
Hood
3
2.2
69
31.3 135
61.2
Splash
Plate
Filter
Section
Roof Curb
Discharge
Head
Dampers
Suspension
Kit
Legs
(each)
Skid
12 of 147
Page 23

FIGURE 7: 2010, 2010B, 2020 and 2030 Upright Model Dimensions

G
B
A
P
M
U
H
H
F
C
J
CE
CE-OH
LD or RD
Lifting Lug
(One Each Corner)
Filter Access
CC
GC
GC
FILTER SECTION
(OPTIONAL)
STAN D
(OPTIONAL)
ED
ED
LD
RD
OA
OA
RA
RA
Filter Access
F
V
D T
DD
KK
EE
Y
NS
SIDE VIEWEND VIEW
CE
NN
E
D
LL
MM
2”
2”
Customer Supplied
Duct Location
(See Page 73, Table 11)
SECTION 5: SPECIFICATIONS

Table 5: 2010, 2010B, 2020 and 2030 Dimensions

Model A B C D E F G H J M N P Q R
2010/
(in) (cm)
(in) (cm)
(in) (cm)
(in) (cm)
(in) (cm)
(in) (cm)
44.2
112.3
56.0
142.2
68.0
172.7
1.6
4.1
1.5
3.8
1.5
3.8
234.4
116.2
295.1
116.2
295.1
2010B
2020
2030
Model S T U V W Y Z AA BB CC DD EE FF GG HH KK LL MM NN 2010/
2010B
2020
2030
92.3
3.0
7.6
3.9
9.9
3.9
9.9
22.0
55.9
31.5
80.0
36.8
93.5
10.0
25.4
26.5
67.3
30.5
77.5
CC
145.3
369.1
164.3
417.3
(Stand Height )
53.0
134.6
72.0
182.9
Model* M
(in) (cm)
2010/ 2010B
(in) (cm)
19.0
10.5
26.7
13.8
35.0
17.0
43.2
56.4
143.2
89.3
226.8
86.9
220.7
11.1
28.2
12.3
31.2
15.6
39.6
37.2
94.5
44.0
111.8
44.0
111.8
48.3
31.5
80.0
36.8
93.5
3.4
8.6
6.0
15.2
6.0
15.2
37.9
96.3
44.3
112.5
56.3
143.0
34.0
86.3
31.0
78.7
31.0
78.7
3.2
8.1
6.0
15.2
6.0
15.2
38.8
98.6
49.7
126.2
64.1
162.8
14.0
35.6**
17.0
43.2
17.0
43.2
28.8
73.2**
52.8
134.1
56.8
144.3
188.2
477.8
188.2
477.8
72.0
182.9
72.0
182.9
29.6
32.7
48.1
75.2
52.6
133.6
56.6
143.8
28.6
72.6
33.0
83.8
33.0
83.8
83.1
56.1
142.5
60.1
152.7
1.5
3.8
2.0
5.1
2.0
5.1
122.2
69.6
176.8
69.6
176.8
1.1
2.8
1.1
2.8
1.1
2.8
35.1
89.2
23.3
59.2
23.3
59.2
41.0
104.1
52.0
132.1
66.4
168.7
0.5
1.3
0.4
1.0
0.4
1.0
6.5
16.5
N/A
N/A
25.3
64.3
35.3
89.5
40.8
103.5
9.5
24.1
10.4
26.4
13.6
34.5
25.3
64.3
35.3
89.5
40.8
103.5
13 of 147
Page 24
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
AA
OA
ED
ED
BD
CE
OA
TD
CE
CE-OH
TD or BD
RA
B
W Z
V U
H
J
D
E
C
F
F
A
Y
R
Q
D
T
GC
SIDE
VIEW
PLAN VIEW
FILTER SECTION
(OPTIONAL)
INLET HOOD (OPTIONAL)
GC
GC-OH
RA
DD
N
P
BB
GG
G
Lifting Lug
(One Each Corner)
Support Brace
Filter Access
Filter Access
H
FF
FF
HH
S
EE
2”
Customer Supplied
Duct Location
(See Page 73, Table 11)
LL
MM
MM
NN

FIGURE 8: 2010, 2010B, 2020 and 2030 Horizontal Model Dimensions

Table 6: 2010, 2010B, 2020 and 2030 Weights

Model Air Handler Stand
(lb) 700 * 40 100 110 120 110 80 26 140 140
(kg) 317.5 * 18.1 45.4 49.9 54.4 49.9 36.3 11.8 63.5 63.5
(lb) 1400 230 60 220 190 210 150 120 26
(kg) 638 104.3 27.2 99.8 86.2 95.3 68 54.4 11.8 154.2
(lb) 1650 300 60 270 240 260 160 160 26
(kg) 748.4 136.1 27.2 122.5 108.9 117.9 72.6 72.6 11.8 165.6
Discharge
(lb) 100 34 4 1 (kg) 72.6 86.2 27.2
(kg) 45.4 15.4 18.6
(lb) 150 46 61
(kg) 68 20.9 27.7
2010/ 2010B
2020
2030
Model
2020
2030

Table 7: Motor Weights

Size
ODP
TEFC
HP kW
(lb)
(kg)
(lb)
(kg)

NOTE:

Dampers
Upper Lower
3
2.2
69
31.3 135
61.2
3.7
34.9 133
60.3
Splash
Plate
Filter
Section
Filtered Moisture Limiter
Inlet 53" 72"
5
77
7. 5
5.6
120
54.4 200
90.7
10
7. 5
164
74 .4
219
99.3
Inlet Hood
Model
2010/ 2010B
11.2
231
104.8 316
143.3
Roof
Discharge
Curb
(lb) 160 190 60
15
20
14.9
269
122.0 395
179.2
Stand*
25
18.6
339
153.8 510
231.3
Head
Dampers
30
22.4
398
180.5 545
247.2
Inlet variation of screen mesh without filters has equal weight as inlet hood with filters. Inlet dampers for MUA style use both the upper and lower dampers for 2020 and 2030. Inlet dampers for FR, AM and VAV styles only use the upper damper for 2020 and 2030. Model 2010/2010B damper weights apply to both discharge and inlet.
Legs
(each)
Suspension
Kit
N/A
N/A
Skid
340
365
14 of 147
Page 25
SECTION 5: SPECIFICATIONS
Table 8: 2000-Series Selection Guide
Motor HP at Noted
Airflow
CFM (m
1,000 (1,700) 2005 2 2 2 2 2 62 66 70 97 76 7 (17.5) 0.75 (19) 2,000 (3,400) 2005 2 2 2 2 2 60 66 70 194 151 7 (17.5) 0.75 (19) 3,000 (5,100) 2005 3 3 3 3 3 60 65 70 292 227 7 (17.5) 0.75 (19) 4,000 (6,800) 2005 3 3 3 3 3 62 65 70 389* 302 7 (17.5) 0.75 (19) 4,000 (6,800) 2010 3 3 3 3 3 59 65 69 432 346 7 (17.5) 1.0 (25) 5,000 (8,500) 2010 3 3 3 3 3 58 63 68 540 432 7 (17.5) 1.0 (25)
6,000 (10,200) 2010 5 5 5 5 5 58 62 67 648 518 7 (17.5) 1.0 (25)
7,000 (11,400) 2010 5 5 5 5 5 59 62 66 756* 605 7 (17.5) 1.0 (25) 8,000 (13,600) 2010 5 5 5 5 5 60 63 66 800* 691 7 (17.5) 1.0 (25) 9,000 (15,300) 2010 7.5 7.5 7.5 7.5 7.5 61 64 67 800* 778 7 (17.5) 1.0 (25)
10,000 (17,000) 2010 7.5 7.5 7.5 7.5 7.5 62 65 68 800* 800 7 (17.5) 1.0 (25)
7,000 (11,900) 2010B 5 5 5 5 5 59 62 66 756 605 7 (17.5) 1.25 (32) 8,000 (13,600) 2010B 5 5 5 5 5 60 63 66 864 691 7 (17.5) 1.25 (32) 9,000 (15,300) 2010B 7.5 7.5 7.5 7.5 7.5 61 64 67 972 778 7 (17.5) 1.25 (32)
10,000 (17,000) 2010B 7.5 7.5 7.5 7.5 7.5 62 65 68 1,080 864 7 (17.5) 1.25 (32) 11,000 (18,700) 2010B 10 10 10 10 10 64 66 68 1,188 950 7 (17.5) 1.25 (32) 12,000 (20,400) 2010B 10 10 10 10 10 66 68 69 1,296 1,037 7 (17.5) 1.25 (32) 13,000 (22,100) 2010B 10 10 10 10 15 67 69 CF 1,404 1,123 7 (17.5) 1.25 (32) 14,000 (23,800) 2010B 10 10 15 15 15 69 CF CF 1,512 1,210 7 (17.5) 1.25 (32) 12,000 (20,400) 2020 7.5 7.5 7.5 7.5 7.5 66 70 73 1,296 1,037 9 (22.5) 1.5 (38) 14,000 (23,800) 2020 10 10 10 10 10 69 70 73 1,512 1,210 9 (22.5) 1.5 (38) 16,000 (27,200) 2020 10 10 10 10 10 70 72 76 1,728 1,382 9 (22.5) 1.5 (38) 18,000 (30,600) 2020 15 15 15 15 15 70 74 77 1,944 1,555 9 (22.5) 1.5 (38) 20,000 (34,000) 2020 15 15 15 15 15 70 74 77 2,160 1,728 9 (22.5) 1.5 (38) 22,000 (37,400) 2020 20 20 20 20 20 71 74 77 2,376 1,901 9 (22.5) 1.5 (38) 25,000 (42,500) 2020 20 20 20 20 20 72 75 77 2,700 2,160 9 (22.5) 1.5 (38) 25,000 (42,500) 2030 15 15 15 15 15 70 72 74 2,700 2,160 11 (27.5) 2.0 (51) 27,500 (46,700) 2030 15 15 15 15 15 71 73 75 2,970 2,376 11 (27.5) 2.0 (51) 30,000 (51,000) 2030 20 20 20 25 25 73 75 76 3,240 2,592 11 (27.5) 2.0 (51) 32,500 (55,200) 2030 20 20 20 20 25 75 76 77 3,510 2,808 11 (27.5) 2.0 (51) 35,000 (59,500) 2030 20 25 25 25 25 77 77 79 3,780 3,024 11 (27.5) 2.0 (51) 37,500 (63,700) 2030 25 25 30 30 30 78 79 79 4,050 3,240 11 (27.5) 2.0 (51) 40,000 (68,000) 2030 30 30 30 30 30 80 CF CF 4,320 3,456 11 (27.5) 2.0 (51)
Model
3
/h)
External Static
Pressure (in wc)
0 0.250.500.751.00 0 0.50 1.00 NG LPG
dBA** at Noted
External Static
Pressure (in wc)
*Temperature rise at this CFM is less than the maximum temperature rise. Heat output is based on heater operation in 100% outside air mode. **dBA is measured at 10' (3 m) from unducted discharge. ***Maximum Inlet Gas Pressure:ANSI - Compliant Manifold = 14 in wc (34.9 mbar)
FM and XL Compliant Manifold = 5 psi (344.7 mbar)
Heat Output @ Max.
Temperature Rise
(Btu/h) x 1000
Minimum Inlet
Gas Pressure
in wc (mbar)***
Manifold Size
in NPT (mm)
15 of 147
Page 26
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Table 9: Estimated Pressure Drop of Accessory Components
Model
2005
2010
2010B
2020
2030
Airflow Range
1,000-2,000 (1,700-3,400) 0.25 0.62 0.25 0.62 - - 0.05 0.12
3,000-4,000 (5,100-6,800) 0.40 1.0 0.50 1.25 - - 0.05 0.12
4,000-6,000 (6,800-10,200) 0.25 0.62 0.25 0.62 0.10 0.25 0.05 0.12 7,000-10,000 (11,400-17,000) 0.40 1.0 0.50 1.25 0.10 0.25 0.05 0.12 7,000-10,000 (11,400-17,000) 0.25 0.62 0.25 0.62 0.10 0.25 0.05 0.12
11,000-14,000 (18,700-23,800) 0.40 1.0 0.50 1.25 0.10 0.25 0.05 0.12
12,000-16,000 (20,400-27,200) 0.25 0.62 0.25 0.62 0.10 0.25 0.05 0.12 18,000-25,000 (30,600-42,500) 0.40 1.0 0.50 1.25 0.10 0.25 0.05 0.12 25,000-30,000 (42,500-51,000) 0.35 0.87 0.75 1.87 0.10 0.25 0.05 0.12 32,500-40,000 (55,200-68,000) 0.40 1.0 0.85 2.12 0.10 0.25 0.05 0.12
CFM (m
3
/h)
Inlet Hood with Filters Filter Section
in wc mbar in wc mbar in wc mbar in wc mbar
Inlet Hood with
Moisture Limiters
Inlet Hood with
Bird Screen
Model
2005
2010
2010B
2020
2030
Airflow Range
1,000-2,000 (1,700-3,400) 0.10 0.25 0.05 0.12 0.10 0.25
3,000-4,000 (5,100-6,800) 0.10 0.25 0.05 0.12 0.10 0.25
4,000-6,000 (6,800-10,200) 0.10 0.25 0.05 0.12 0.10 0.25 7,000-10,000 (11,400-17,000) 0.10 0.25 0.05 0.12 0.10 0.25 7,000-10,000 (11,400-17,000) 0.10 0.25 0.05 0.12 0.10 0.25
11,000-14,000 (18,700-23,800) 0.10 0.25 0.05 0.12 0.10 0.25
12,000-16,000 (20,400-27,200) 0.10 0.25 0.05 0.12 0.10 0.25 18,000-25,000 (30,600-42,500) 0.10 0.25 0.05 0.12 0.10 0.25 25,000-30,000 (42,500-51,000) 0.10 0.25 0.05 0.12 0.10 0.25 32,500-40,000 (55,200-68,000) 0.10 0.25 0.05 0.12 0.10 0.25
CFM (m
3
/h)
Discharge Heads Splash Plate
in wc mbar in wc mbar in wc mbar
Inlet/Discharge
Damper
16 of 147
Page 27
SECTION 6: LIFTING AN AIR H ANDLER
WARNING
Crush Hazard
Use proper lifting equipment and practices.
Failure to follow these instructions can result in death, injury or property damage.
Spreader Bar

SECTION 6: LIFTING AN AIR HANDLER

The air handler must be installed in compliance with all applicable codes. The qualified installer or service technician must use best building practices when installing the air handler and any optional equipment. This piece of equipment requires at least 4 CFM (6.8
3
m
/h) of outside air per 1,000 Btu/h (0.293 kW). Any air handler that recirculates air from the heated space must use the return air opening to prevent any return air from passing over the burner.
Before installation, check that the local distribution condition, nature of gas and gas pressure, and the current state of adjustment of the equipment are compatible. If filters are not installed (via inlet hood or filter section), an air strainer (provided by others) must be installed on the inlet of the air handler with openings less than or equal to 5/8" (16 mm) in diameter. Air inlets must be installed in such a manner that their lowest edge is 19" (500 mm) above any surface. This applies to roof curbs, upright stands and suspended air handlers.

6.1 Lifting an Air Handler

6.1.1 Preparing to Lift the Air Handler

Prior to lifting the air handler, the following steps must be performed:

1. R e m o ve all packaging or banding that attached the air handler to the skid and ensure that the air handler is no longer bound to the skid.

2. Remove all of the accessories or packages that were shipped on the same skid, inside the air handler or inside the control enclosu

3. Inspect the air handler to:

• Verify that there is no damage as a result of shipping.
•Ensure that it is appropriately rated for the utilities available at the installation site.
• Verify that the lifting lugs are intact undamaged and secured to the air handler.
•Ensure factory-installed hardware is torqued as specified.

4. Prepare the installation location to be ready to accept the air handler (i.e. roof curb, mounting stand or legs).

5. Verify the lifting equipment can handle the air handlers weight and the required reach. See
Page 17, Figure 9. For air handlers weight, see Page 12, Table 3 and Page 12, Table 4 for model 2005. See Page 14, Table 6 and Page 14, Table 7 for models 2010 - 2030.

6.1.2 Lifting a Horizontal Air Handler (All Models)

Lift the air handler into place installing appropriate hardware (supplied by others) into all lifting lug holes on the unit base. For model 2005, lifting lug holes are
1.5" (3.81 cm) diameter. For models 2010 - 2030, lifting lug holes are 2.0" (5.1 cm) diameter. Use spreader bars to ensure that the lifting cables clear the sides of the air handler. The air handler must be kept level during the lift to prevent tipping, twisting or falling. If lifted improperly, product damage may occur.
Next, refer to the applicable portions of Page 19, Section 7 through Page 26, Section 10 for specific mounting instructions. For mounting of accessories, refer to the applicable portions of Page 29, Section 11 through Page 69, Section 14.

FIGURE 9: Lifting a Horizontal Air Handler

re.
17 of 147
Page 28
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Step 1
Remove These
Lifting Lugs
Step 2
Step 3
Step 4
Spreader Bar
INLET
INLET
INLET
INLET

6.1.3 Lifting an Upright Air Handler (2005 - 2030)

All air handlers are shipped in the horizontal position.
Prior to lifting an upright air handler, the following steps must be performed (See Page 18, Figure 10):
Step 2: Remove the lifting lugs on the inlet end of the air handler and re-install hardware.
Step 3: Use all four lifting lugs on the discharge end of the air handler to enable the air handler to be lifted into the upright position.
Step 1: The air handler must be lifted using the two lifting lugs on the top of the discharge end and the two lifting lugs on the inlet end, using a spreader bar across the long axis. Lift the air handler off the skid
Step 4: Lift the air handler into upright position.
Step 5: Next, refer to the applicable portions of Page 22, Section 8 for specific mounting instructions.
and place it on a flat, clean, dry surface.

FIGURE 10: Lifting an Upright Air Handler (2005 - 2030)

18 of 147
Page 29

SECTION 7: ROOF CURB

SECTION 7: ROOF CURB
WARNING
Crush Hazard
Use proper lifting equipment and practices.
Failure to follow these instructions can result in death, injury or property damage.

The roof curbs only support the burner and blower sections of the air handler. Roof curbs are shipped unassembled and require field assembly.

NOTE: Before installation, verify that you have the correct roof curb and that all required components are present. If any are missing, contact your RAPID

7.1 Roof Curb Assembly and Installation

Assemble roof curb according to the assembly drawing, on Page 20, Figure 11. Supplied hardware must be torqued to recommended specifications on Page 9, Table 1. Place the curb on the roof in the position in which it will be installed. Check that the diagonal measurements are within 1/8" (3 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 building practices. The curb is self-flashing. Install roofing material as required. NOTE: Check the installation location to ensure proper clearances to combustibles and clearance for access. See Page 8, Section 3.1.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
®
independent distributor.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Equipment and accessories are heavy.
Cut/Pinch Hazard
Wear protective gear during installation, operation and service.
Edges are sharp.
19 of 147
Page 30
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Model Part Number A B C D Weight (lbs) Weight (kg)
2005
(in)
(cm)
77351.201
27.0
68.6
57.5
146.1
23.8
60.5
-75 34
2010 and 2010B
(in)
(cm)
77050.301
42.0
106.7
88.0
223.5
38.8
98.6
-110 49.9
2020
(in)
(cm)
77250.301
53.0
134.6
113 . 0
287.0
49.8
126.5
56.5
143.5
150 68. 0
2030
(in)
(cm)
77532
65.0
165.1
113 . 0
287.0
61.8
157.0
56.5
143.5
160 72. 6

FIGURE 11: Roof Curb Assembly

7.2 Air Handler Mounting to Roof Curb

After the curb has been installed, the air handler may be placed on the curb. See Page 21, Figure 12. After the air handler is in place, the installer must fasten the air handler to the curb. This is accomplished by drilling holes down through the floor of the air handler and into the curb. At least three #12 sheet 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. There must be a 1/8" (.3 cm) x 2" (5.1 cm) neoprene closed cell, adhesive-back gasket (supplied by others) between the top of the curb and the base surface of the air handler to prevent moisture from leaking into the building from either driving rains or melting snow. The installer is responsible for tying the air handler to the curb per all applicable codes.
20 of 147
Page 31

FIGURE 12: Curb Mounting

Air Handler
Roof Curb
Fastening Detail
SECTION 7: ROOF CURB
21 of 147
Page 32
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Foam Tape
Upright Stand
Attaching Locations
Foam Tape
Upright Stand
Attaching Location

SECTION 8: UPRIGHT STAND

WARNING
A stand can be used when an upright air handler is to be installed on a concrete slab or on the floor. The stand for model 2005 is 30" (76.2 cm) tall; stands for models 2010 and 2010B are available at 53" (134.6 cm) or 72" (182.9 cm) tall; stands for models 2020 and 2030 are 72"(182.9 cm) tall. The stand must first be fastened to the concrete slab or floor before the air handler is mounted.

8.1 Upright Stand Installation

To attach the stand to a concrete slab, it must be secured with the use of studs, embedded in the concrete. Four 5/8" studs (minimum) must be installed in the slab, one for each corner of the stand. The stand has four 11/16" (17.4 mm) holes drilled through the stand pads. See Page 23, Figure 16. Fasten the stand to the slab with four 5/8" hex nuts and lock washers (provided by others).

8.2 Attaching Air Handler to Stand

Once the stand is secured to a concrete slab, the air handler may be placed on the stand. Prior to lifting the air handler, apply the foam tape and remove the attaching hardware as described below. The ½" (12.7 mm) thick double-sided urethane foam tape (provided by others) must be applied to the top edge of the stand. The bolts on the air handler that correspond to the attaching location of the mounting stand must be removed and saved for re-installation to sec handler on to the mounting stand. See Page 17, Section 6.1 for safe lifting practices. Once the air handler is placed on the stand, secure it with the attaching hardware that was removed prior to lifting it in to place per recommended torque settings. See
Page 9, Table 1. See Page 22, Figure 13 (2005) and Page 22, Figure 14 (2010 - 2030). After placing the
air handler on the mounting stand, seems between
Crush Hazard
Use proper lifting equipment and practices.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Cut/Pinch Hazard
Wear protective gear during installation, operation and
service. Equipment and accessories are
Edges are sharp. heavy.
Failure to follow these instructions can result in death, injury or property damage.
the mounting stand and the air handler must be properly caulked (caulk provided by others).
NOTE: If using a filter section with an upright air handler and stand, the filter section must be set into the stand before the air handler is mounted on the stand. The 1/2" (12.7 cm) thick double-sided urethane foam tape should be applied between the stand and the filter section. See Page 43, Section
11. 6.

FIGURE 13: Upright Stand Detail (2005)

FIGURE 14: Upright Stand Detail (2010 - 2030)

ure the air handler to the stand. Lift the air
22 of 147
Page 33

FIGURE 15: Stand Shim (2010B - 2030)

NOTE: Quantity 8 required
per stand.
Model Part Number Height A B Weight (lbs) Weight (kg)
2005
(in)
(cm)
94000.3
30.0
76.2
27.1
68.9
22.8
57.8
75.0 34.0
2010 and 2010B
(in)
(cm)
91000.2
53.0
134.6
27.8
70.5
39.3
99.7
160.0 72.6
(in)
(cm)
94000.7
72.0
182.9
27.8
70.5
39.3
99.7
190.0 86.2
2020
(in)
(cm)
92000.3
72.0
182.9
51.1
129.8
51.5
130.8
230.0 104.3
2030
(in)
(cm)
93000.3
72.0
182.9
63.5
161.3
55.8
141.6
300.0 136.1
SECTION 8: UPRIGHT STAND

FIGURE 16: Upright Stand Mounting Detail

A
Non-Control Enclosure Side
Air Handler
Control Enclosure Side
B
Air Handler
23 of 147
Page 34
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 9: LEGS

WARNING
Crush Hazard
Use proper lifting equipment and practices.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
Failure to follow these instructions can result in death, injury or property damage.
Part numbers that end with a “[W]” indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish. To order with a galvanized finish, do not include the "W" at the end of the part number; to order with a painted finish, include the "W" at the end of the part number.

9.1 Leg Mounting

Legs can be used when mounting an air handler on a concrete slab or directly on the floor. Legs are available for all models in the horizontal configuration.

9.2 Leg Mounting - Horizontal Air Handler (2005 - 2030)

The 46" (116.8 cm) legs must first be mounted to the air handler before being mounted to the concrete slab or floor. To attach the legs with the air handler must first be lifted with the provided lifting lugs. See Page 17, Section 6.1 for safe lifting practices. In each corner of the bottom of the air handler, four leg­mounting holes will be found. See Page 24, Figure
17.
The legs can now be mounted one at a time to the inside of the corner by removing the hard
ware that occupies each of the bolt locations. Place the leg on the inside of 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"-18 grade 5 flange nut.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Cut/Pinch Hazard
Wear protective gear during installation, operation and
service. Equipment and accessories are
Edges are sharp. heavy.
On models 2020 and 2030, there is a bracket on the inside of each corner that is held in place by the two bolts closest to the corner. This bracket must be removed when the leg is attached to the air handler. Bracket can be discarded once legs are attached.

FIGURE 17: Leg Mounting Holes (2005 - 2030)

10"
(25.4 cm)
1.5" (3.8 cm)
1.5"
(3.8 cm)
To attach the legs to a concrete slab, the base of each leg is equipped with two 1" holes. Studs capable of accepting 5/8" nuts must be installed in the concrete slab. For stud positioning, See Page 25, Figure 18.
The air handler may now be placed down over the slab studs. The legs should then be bolted down with 5/8" nuts. See Page 25, Figure 19.
10"
(25.4 cm)
24 of 147
Page 35

FIGURE 18: Stud Positioning

Model Part Number A B C Weight* (lbs) Weight* (kg)
2005
(in)
(cm)
77040.301[W]
38.8
98.5
10.8
27.4
9.5
24.1
26.0 11.8
2010 and 2010B
(in)
(cm)
77040.301[W]
71.0
180.3
23.5
59.7
9.5
24.1
26.0 11.8
2020
(in)
(cm)
77040.301[W]
95.0
241.3
35.0
88.9
9.5
24.1
26.0 11.8
2030
(in)
(cm)
77040.301[W]
95.0
241.3
47.0
119 . 4
9.5
24.1
26.0 11.8
B
C
C
C
A C
*NOTE: Weight shown reflects per each leg.
46"
(116.8cm)
14.6"
(37.1 cm)
1.0" (2.5 cm)
10.5"
(26.7 cm)
SECTION 9: LEGS

FIGURE 19: Leg Bolt Detail

25 of 147
Page 36
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Crush Hazard
Check blower assembly per maintenance section.
Lack of blower assembly maintenance can cause excessive vibration.
Excessive vibration can cause support failure.
WARNING
Failure to follow these instructions can result in death, injury or property damage.
Crush Hazard
Hanging hardware must support equipment weight.
Do not hang by lifting lugs.
Crush Hazard
Use proper lifting equip­ment and practices.
WARNING
Failure to follow these instructions can result in death, injury or property damage.
Falling Hazard
Use proper safety equipment and practices to avoid falling.
Severe Injury Hazard
Use proper lifting practices and equipment.
Equipment and accessories are heavy.
Cut/Pinch Hazard
Wear protective gear during installation, operation and service.
Edges are sharp.

SECTION 10: INDOOR SUSPENSION MOUNTING - HORIZONTAL AIR HANDLER

Suspension Kits are available for models 2005 ­2010B. Kits are shipped unassembled and must be assembled prior to installation. Suspension Kits for models 2020 - 2030 are not available.
NOTE: Before installation, verify all required components are present. If any are missing, contact your RAPID

10.1 Suspension Kit Assembly and Installation

After the air handler is in place, the installer must fasten the air handler to the suspension frame. Once the suspension frame is secure, the air handler may be mounted. See Page 17, Section 6 for safe lifting practices.
26 of 147
®
independent distributor.
On model 2005, remove the 1/4" bolts from four corners of base on length of air handler. Slide suspension angle assembly onto both ends of the air handler aligning holes in angle tab with bottom holes. Once completed, reinstall hardware. See Page 27, Figure 20.
On model 2010 and 2010B, drilling holes down through the floor of the air handler and into the suspension frame. At least three #12 sheet metal screws (supplied by others) equally spaced on each angle/side must be used to attach the air handler to the suspension frame. See Page 28, Figure 21.
Page 37

FIGURE 20: Indoor Suspension (2005)

Suspension Support
Suspension End
1/2 X 13 Threaded Rod and
Nuts Supplied by Others
A
B
Suspension End
Single 1/2" Hex Nut
on Top Side of Angle
(to secure unit in position)
Suspension
Angle Clip
Double 1/2" Hex Nuts on
Bottom Side of Angle
(for height adjustment)
5/8" Ø for 1/2" Threaded Rod
1/4" Bolt Clip
to angle and to unit sideskin/floor
Description Part Number Qty. 2005 Suspension Kit 77045.301
Suspension Angle Assembly 77045.201 2 ¼-20x1 Bolt 20813 4 ¼-20 Nut 20630 4 ¼ Washer 20503 4
NOTE: Flush angle to end of unit.
Model A B Weight (lbs) Weight (kg)
2005
in 59.0 36.5
13 5. 9
cm 73.0 84.1
SECTION 10: INDOOR SUSPENSION MOUNTING - HORIZONTAL A IR HANDLER
27 of 147
Page 38
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
A
B
E
C
D
Suspension Sides
Suspension End
Suspension End
B
D
A
Gasket Tape*
Single Nut*
Double Nuts*
E
E
E
B
1/2" x 13 Threaded Rod and Nuts
Not Supplied by manufacturer.
Nuts and bolts provided
*Provided by others
Description Part Number Qty. 2010 and 2010B Suspension Kit 77046.301
Suspension Sides 77047.103 2 Suspension Ends 77047.106 2 1/2"-13 x 1 Bolt HHCS 20524 4 Nut Flange 1/2-13 20493 4 3/4" x 1/8" Gasket Tape 92700017 15' (5 m)
Model A B C D E Weight (lbs) Weight (kg) 2010 and
2010B
(in)
(cm)48121.946116 . 890228.642106.712.5
140 63.5

FIGURE 21: Indoor Suspension (2010 and 2010B)

28 of 147
Page 39

SECTION 11: FILTER SECTION

SECTION 11: FILTER SECTION
WARNING
Crush Hazard
Use proper lifting equipment and practices.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Cut/Pinch Hazard
Wear protective gear during installation, operation and
service. Equipment and accessories are
Edges are sharp. heavy.
Failure to follow these instructions can result in death, injury or property damage.

The 2005 filter section is shipped assembled. The 2010 - 2030 filter sections are shipped unassembled and must be assembled prior to installation.

Part numbers that end with a “[W]” indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish. To order with a galvanized finish, do not include the "W" at the end of the part number; to order with a painted finish, include the "W" at the end of the part number. If the filter section support is necessary, it may be installed prior to attaching the filter section to the air handler. See Page 41, Section 11.4.
NOTE: Check to be sure that all required components are present. If any are missing, contact your RAPID independent distributor.

11.1 Filter Section (2005)

Part Number Description A B C
B
C
77082.301[W]
77083.301[W]
Filter section with permanent alumi- num mesh filters
Filter section with disposable polyes­ter filters
in 28.3 27.0 32.3
cm 71.9 68.6 82.1
Weights
lbs kg
100 45.4
®
A
Filter access through
side access door.
Inlet
Filter
Filter Size Quantity Part Number
in 20 x 25 x 2 cm 50.8 x 63.5 x 5.1 in 20 x 50 x 1 cm 50.8 x 127 x 2.5
2 22628
1 23628
29 of 147
Page 40
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

11.2 Filter Section Assembly (2010 and 2010B)

Filter Section with
Description Part Number
Disposable Polyester Filters 20" x 40" x 1" 23629 4 N/A Permanent Aluminum Mesh Filters 20" x 20" x 1" 20628 N/A 8 Insulated Access Cover 77401.002[W] 1 1 Header Panel 77402.002[W] 1 1 Right Panel 77403.001[W] 1 1 Left Panel 77403.002[W] 1 1 Channel 77404.002 3 3 Support 77405.002 2 2 End Panel 77406.002[W] 1 1 Stiffener 77407.002[W] 1 1 Screw TEK3 #12 x 3/4" Washer HD 13404 38 38 Nut ¼"-20 Speed Grip 20499 4 4 Bolt ¼"-20 x ¾" HHCS 20504 4 4 ¼" Flat Washer 20503 4 4 Fastener Rivnut 3/8"-16 91120106 10 10 3/8" Flatwasher 20515 10 10 3/8"-16 x 1" Bolt Hex Grade 5 20517 10 10
Disposable Polyester Filters
77080.301[W] 77081.301[W] Quantity Quantity
Permanent Aluminum Mesh Filters
Filter Section with
30 of 147
Page 41

Step 11.2.1

Flange
End Panel
Side Panel
Side Panel
Insert Screws
Attach left panel and right panel to the end panel outside mounting flanges. Fasten together with 6 TEK screws on each side as shown.
Description Part Number
Left Panel 77403.002[W] Right Panel 77403.001[W] End Panel 77406.002[W] TEK Screw 13404
Supports
Insert Screws
Insert Screws
Make sure that the bottom flanges are facing out.
Attach supports to top inside of the left and right panels, making sure that the channel portion is facing down into the filter section.
Description Part Number
Supports 77405.002 TEK Screw 13404

Step 11.2.2

SECTION 11: FILTER SECTION
31 of 147
Page 42
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Attach channels to end plate. Make sure top channel is facing down and bottom channels are facing up.
NOTE: Channels "open" to the inside of the filter box.
Description Part Number
Channels 77404.002 TEK screw 13404
Stiffener
Header Panel
Attach header in between the lower portion of the left and right side panels.
Attach stiffener in between top portion of left and right side panels.
Attach loose end of upper filter channel to stiffener; attach loose end of lower filter channels to header piece.
On the inlet of the filter section, rivnuts (P/N 91120106) are factory installed. With additional 3/8" hardware (P/N 20515 and P/N 20517) the filter section can be installed on the inlet of the unit. See Page 43, Section 11.5 for additional information on filter section installation.
NOTE: For easier installation, the filter section may be mounted to the air handler at this point, prior to the addition of filters and access door. Refer to Page 43, Figure 11.5 for installation instructions.
Description Part Number
Header Panel 77402.002[W] Stiffner 77407.002[W] TEK screw 13404

Step 11.2.3

Step 11.2.4

32 of 147
Page 43

Step 11.2.5

Slide filters into channels. Verify proper filter orientation.
For permanent aluminum mesh filters: Verify the arrow on the side
of the filter points in the direction of the airflow.
For disposable polyester filters: Verify the white side is facing the inlet and the blue side is facing the discharge end.
Description Part Number
Permanent Aluminum Mesh Filters 20628 Disposable Polyester Filters 23629
Install cage nuts into each of the four corresponding square holes (two in stiffener, two in header panel) with the cages on the inside of the filter section.
Install insulated access cover and secure with four ¼-20 screws, ¼-20 bolts and ¼" washers.
Description Part Number
Insulated Access Cover 77401.002[W] ¼-20 Screw 20499 ¼-20 Bolt 20504 ¼" Washer 20503

Step 11.2.6

SECTION 11: FILTER SECTION
Filter
Channels
Insulated Access Cover
33 of 147
Page 44
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

11.3 Filter Section Assembly (2020 and 2030)

2020 Filter Section
Permanent Aluminum Mesh Filters Disposable Polyester Filters
Description
Access Door 13205025 1 1 Right Panel 13205026 1 1 Left Panel 13205028 1 1 Top/Bottom Panel 13205029 2 2 Filter Rail 13205030 5 5 Side Filter Rail 13205031 2 2 Screw TEK3 #12 x ¾" Washer HD 13404 64 64 Nut ¼"-20 Speed Grip 20499 3 3 Hinge Butt 3 x 3 Zinc 20500 2 2 ¼" Flat Washer 20503 3 3 Bolt ¼"-20 x ¾" HHCS 20504 3 3 Bolt Retainer Pushnut 1/4 20505 3 3 3/8" Flatwasher 20515 14 14 3/8"-16 x 1 Bolt Hex Grade 5 20517 14 14 10-24 KEPS Nut 20698 12 12 Permanent Aluminum Mesh Filter 20" x 25" x 1" 20629 12 N/A Disposable Polyester Filter 20" x 50" x 1" 23628 N/A 6 Bolt 10-24 x ¾" HHCS 21699 6 6 10-24 x ½" HMS Bolt 27000 6 6 Fastener Rivnut 3/8"-16 91120106 14 14 Spacer Hinge Filter 13205032 8 8 Gasket Door Filter 13205035 11 11
Part
Number
13205022 (Galvanized)
13205023 (Painted)
Quantity Quantity
13205020 (Galvanized)
13205021 (Painted)
2030 Filter Section
Permanent Aluminum Mesh Filters Disposable Polyester Filters
Description
Access Door 13305025 1 1 Right Panel 13305026 1 1 Left Panel 13305028 1 1 Top/Bottom Panel 13305029 2 2 Filter Rail 13305030 7 7 Side Filter Rail 13305031 2 2 Screw TEK3 #12 x ¾" Washer HD 13404 86 86 Nut ¼"-20 Speed Grip 20499 3 3 Hinge Butt 3 x 3 Zinc 20500 2 2 ¼" Flat Washer 20503 3 3 Bolt ¼"-20 x ¾" HHCS 20504 3 3 Bolt Retainer Pushnut 1/4 20505 3 3 3/8" Flatwasher 20515 14 14 3/8"-16 x 1" Bolt Hex Grade 5 20517 14 14 10-24 KEPS Nut 20698 12 12 Permanent Aluminum Mesh Filter 20" x 20" x 1" 20628 16 N/A Permanent Aluminum Mesh Filter 20" x 25" x 1" 20629 8 N/A Disposable Polyester Filter 20" x 60" x 1" 23631 N/A 8 Bolt 10-24 x ¾" HHCS 21699 6 6 10-24 x ½" HMS Bolt 27000 6 6 Fastener Rivnut 3/8"-16 91120106 14 14 Spacer Hinge Filter 13205032 8 8 Gasket Door Filter 13205035 12 12
Part
Number
13305022 (Galvanized)
13305023 (Painted)
Quantity Quantity
13305020 (Galvanized)
13305021 (Painted)
34 of 147
Page 45
SECTION 11: FILTER SECTION
Top Panel
Side (Left) Panel
Top Panel
Side
Panel
For Model 2020: On a flat, clean and dry surface, attach the top panel and side panel of the filter section using five TEK self-tapping screws.
For Model 2030: On a flat, clean and dry surface, attach the top panel and side panel of the filter section using seven TEK self-tapping screws.
Description Part Number
Top Panel 13X05029 Side (Left) Panel 13X05028 TEK Screw 13404
Note: In the instructions, an "X" in a part number indicates a digit that changes based on model. Replace the "X" with a "2" for model 2020; replace the "X" with a "3" for model 2030. For further clarification, reference the individual table of components for each assembly at the begining of the instructions.

Step 11.3.1

35 of 147
Page 46
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
To p
Panel
Side (Left) Panel
Bottom Panel
Side (Right) Panel
Top Panel
Side (Right) Panel
For Model 2020: Attach the bottom panel with five TEK self-tapping screws. Attach the right panel with five TEK self-tapping screws on each side.
For Model 2030: Attach the bottom panel with seven TEK self- tapping screws. Attach the right panel with seven TEK self-tapping screws on each side.
Description Part Number
Bottom Panel 13X05029 Side (Right) Panel 13X05026 TEK Screw 13404

Step 11.3.2

36 of 147
Page 47

Step 11.3.3

Side Filter Rail
Top Panel
Top Panel
Top Panel
2030
2020
OutsideInside
Discharge End
To Unit
Inlet End
For Model 2020: Attach the side filter rail to the top panel
with five TEK self-tapping screws. Line up filter rail holes with provided holes near the discharge end of the filter
section panel.
For Model 2030: Attach the side filter rail to the top panel with six TEK self-tapping screws. Line up with provided holes near the inlet end of the filter section.
Description Part Number
Side Filter Rail 13X05031 TEK Screw 13404
SECTION 11: FILTER SECTION
37 of 147
Page 48
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Discharge End
To Unit
Side Filter Rail
Bottom Panel
Bottom Panel
2030
2020
Outside Inside
Inlet End
Bottom Panel
For Model 2020: Attach the side filter rail to the bottom panel
with five TEK self-tapping screws. Line up filter rail holes with provided holes near the discharge end of the filter section panel.
For Model 2030: Attach the side filter rail to the bottom panel with seven TEK self-tapping screws. Line up with provided holes near the inlet end of the filter section.
Description Part Number
Side Filter Rail 13X05031 TEK Screw 13404

Step 11.3.4

38 of 147
Page 49

Step 11.3.5

Attach the remaining filter rails with four TEK self-tapping screws, two on each side. Ensure that the rails face into the filter section.
NOTE: For easier installation, the filter section may be mounted to the air handler at this point, prior to the addition of filters and access door. Refer to Page 43, Section 11.5 for installation instructions.
Description Part Number
Filter Rail 13X05030 TEK Screw 13404
Load filters into the filter section. Check that each filter in in the proper orientation.
For permanent aluminum mesh filters: Verify the arrow on the side of
the filter points in the direction of the airflow.
For disposable polyester filters: Verify the white side is facing the inlet and the blue side is facing the
discharge end.
The end rows of filters need to be installed first.
NOTE: When the filter section is installed on the air handler, the top of one row of filters will support the bottom of the above row.
Description Part Number
Permanent Aluminum Mesh Filters 20629 and/or 20628 Disposable Polyester Filters 23628/23631
SECTION 11: FILTER SECTION

Step 11.3.6

39 of 147
Page 50
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Door Panel
Gasket
Bolt
Filter Box
Panel
Grip Nut
Door Panel
Filter Section
Panel
Hinge
Gasket
Spacers
Duct Liner
Push Nut
Washer
Hinges
Right Panel
Bolt Holes
On right panel, apply provided gasket material to the filter access opening.
Attach filter access door with two hinges.
Attach the hinges to the door using three 10-24 x 1/2" bolts and 10-24 nuts. Attach the hinge to the filter section right panel using three 10-24 x 3/4" bolts and 10-24 nuts. Use four hinge spacers between the hinge and the right panel to keep the hinge aligned.
Press the ¼-20 grip-nuts into each of the three square cut outs in the filter section right panel on the opposite side of the filter access opening from the hinges.
Place a ¼" washer on a ¼-20 bolt and insert it into one of the three bolt holes on the door panel. Place a push-nut on to the bolt from the inside of the door panel to keep the bolt from being separated from the door panel when it is open. Repeat for the other two bolt holes. Secure the door in the closed position by threading the three bolts in the door panel to the grip-nuts on the filter section right panel.
On the inlet of the filter section, rivnuts (P/N 91120106) are factory installed. With additional 3/8" hardware (P/N 20515 and P/N 20517) the filter section can be installed on the inlet of the unit. See Page 43, Section 11.5 for additional information on filter section installation.
Description Part Number
Gasket Material 13205035 Filter Access Door 13X05025 Hinge 20500 10-24 x ½" Bolt 27000 10-24 Nut 20698 Hinge Spacers 13205032 10-24 X ¾" Bolt 21699 ¼-20 Grip-Nut 20499 ¼" Washer 20503 ¼-20 Bolt 20504 Push-Nut 20505

Step 11.3.7

40 of 147
Page 51
SECTION 11: FILTER SECTION

11.4 Filter Section Support Assembly

The filter section support assembly is used to add additional support to the air handler accessories that are not supported by the roof curb in a horizontal configuration (support leg for use with standard 46" [116.8 cm] legs provided by others). For Models 2010 - 2030, when the air handler has both a filter section and an inlet hood, a filter section support assembly or its equivalent must be used.
Description
Filter Box Suppor t Base 2010 and 2010B 77408001 1 N/A N/A Filter Box Suppor t Base 2020 77408002 N/A 1 N/A Filter Box Suppor t Base 2030 77408003 N/A N/A 1 Filter Box Suppor t Leg LS 2010 - 2030 77408011 1 1 1 Filter Box Suppor t Leg RS 2010 - 2030 77408012 1 1 1 Filter Box Suppor t Ext LS,RS 2010 - 2030 77408021 2 2 2 Filter Box Suppor t Brace 2010 And 2010B 77408031 1 N/A N/A Filter Box Suppor t Brace 2020 77408032 N/A 1 N/A Filter Box Suppor t Brace 2030 77408033 N/A N/A 1 Screw Tek3 #12x3/4 Washer 13404 11 14 16 1/4-20 x 1/2 Bolt Hex Head Cap Screw 20483 8 8 8 1/4-20 Nut Flange 20630 8 8 8 1/4 Flat Washer 20503 8 8 8
Part
Number
2010 and 2010B 2020 2030
77412.001 77412.002 77412.003 Quantity Quantity Quantity
41 of 147
Page 52
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Support Leg Left Side
Support Leg Right Side
Support Base
Extension Arm Left Side
Support Extension
Cross Brace
NOTE: 1) CONTRACTOR/INSTALLER MUST MAKE
APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS.
2) SUPPORT LEG IS REQUIRED WHEN A FILTER SECTION AND INLET HOOD ARE ORDERED.
A
CC
B
FILTER SECTION
3) SUPPORT LEG IS PROVIDED FOR USE WITH STANDARD 19" (50 cm) ROOF CURB. SUPPORT LEG FOR USE WITH STANDARD 46" (116.8 cm) LEGS PROVIDED BY OTHERS.
Model Part Number A Min A Max B C Weight lbs (kg) 2010 and
2010B
77412.001
in 16.0 24.0 38.8 1.5
16 (7.3)
cm 40.5 60.8 98.4 3.7
2020 77412.002
in 16.0 24.0 49.6 1.5
18 (8.2)
cm 40.5 60.8 126.0 3.7
2030 77412.003
in 16.0 24.0 64.1 1.5
20 (9.1)
cm 40.5 60.8 162.7 3.7

11.4.1 Filter Section Support Assembly Installation (2010 - 2030)

It is best to assemble the support base and support arms to the filter section prior to attaching the filter section to the air handler but can also be assembled to a previously installed filter section. Refer to Page 42, Figure 22.

FIGURE 22: Filter Section Support Assembly

Step 1: Place the support base (P/N 7740800X) up to the bottom of the filter section towards the inlet end and line up the pre-drilled holes. Use TEK self-tapping screws (P/N 13404) in the middle of the support base (P/N 7740800X) to secure the support base in place.
Step 2: Line up the pre-drilled holes at the ends of the support base, the filter section and the support legs (P/N 7740900X) and attach the legs to the bottom of the filter section through the support base with TEK self­tapping screws (P/N 13404). Install TEK self-tapping screws (P/N 13404) at each of the remaining hole locations in the support base.

Step 3: Mount the filter section to the air handler as described on Page 43, Section 11.5.

Step 4: Line up the support extension (P/N 77410001) with the left support leg (P/N 77409001) and select the appropriate height alignment. Attach the support extension and left support legs and support brace (P/N 774110X) at the lowest overlap position with one ¼-20 bolt (P/N 20483) and flange nut (P/N 220630) on the front surface. Install a second ¼-20 bolt (P/N 20483) and flange nut (P/N 220630) directly above the first, securing all three parts together. Repeat step 4 on the right side of the su
42 of 147
pport assembly.
Page 53
SECTION 11: FILTER SECTION
Air Handler
Filter Section
11.5 Filter Section Installation - Horizontal Air Handlers

11.5.1 Filter Section Installation (2005)

For installation directly onto the inlet of the air handler, remove the hardware on the inlet surface of the air handler that would prevent the filter section from being mated to the inlet of the air handler. Use the provided shims (one bottom and two sides) to reduce the size of the gap between the air handler and the filter section. Re-install the hardware (that was removed) through the filter section and the shims to mate the air handler to the filter section. Hardware must be torqued to recommended specifications on Page 9, Table 1. Caulk (provided by others) the sides, roof and bottom seams between the filter section and air handler. Apply 3" zip tape (provided by others) over the roof seam. Install the filters in proper orientation (See Page 130, Section
20.6) and attach the filter access door. Secure filter access door in the closed position.

11.5.2 Filter Section Installation (2010 - 2030)

For installation directly onto the inlet of the air handler, foam tape (provided by others) must be applied to the air handler sides and bottom. To place the filter section, the top flange of the filter section will slide up under the top panel (drip edge) of the air handler. Refer to Page 43, Figure 23. All hardware in this top panel drip edge will need to be removed prior to placing the filter section on the air handler. Attach the sides of the filter section to the factory installed riv-nuts on the inlet of the air handler w
ith the supplied hardware. Re-install the hardware from the top panel of the air handler through the top panel and top flange of the filter section. Additional TEK screws may be used along the bottom flange of the filter section to seal the bottom seam. Caulk (provided by others) the side and bottom seams between the filter section and air handler. If the filter section was installed prior to completing the filter section assembly, return to the filter section assembly instructions to complete the assembly. See Page 33,
Figure 11.2.5 for Models 2010 and 2010B or Page 39, Figure 11.3.6 for Models 2020 and 2030.
FIGURE 23: Filter Section Installation on Horizon­tal Air Handler (2010 - 2030)

11.6 Filter Section Installation - Upright Air Handlers

11.6.1 Filter Section Installation (2005)

For installation directly onto the inlet of the air handler, remove the hardware on the inlet surface of the air handler that would prevent the filter section from being mated to the inlet of the air handler. Use the provided shims (one bottom and two sides) to reduce the size of the gap between the air handler and the filter section. Re-install the hardware (that was removed) through the filter section and the shims to mate the air handler to the filter section. Caulk (provided by others) the sides, roof and bottom seams between the filter section and air handler. Install the filters in proper orientation (See Page 130, Section 20.6) and attach the filter access door. Secure filter access door in the closed position.

11.6.2 Filter Section Installation (2010 - 2030)

To install a filter section on an u
pright air handler that is stand mounted, the filter section must be installed in the stand prior to placing the air handler (See Page 22, Section 8 for proper stand mounting). Place the filter section so that the outward flange is on the top side. Set the filter section into the stand. Place ½" foam tape (supplied by others) along the perimeter of the top of the flange. Place the air handler in the stand per the stand mounting instructions.
43 of 147
Page 54
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Filters load from topside, remove the filter cap to access the filters.
Filter Cap
Filter Rail
Filter Rail
Top Panel
Left Panel
Right Panel
Bottom Panel
Description Part Number Qty. 2005 Inlet Hood 77030.301[W]
Top Panel 73031.002[W] 1 Filter Cap 73032.002[W] 1 Left Panel 73033.001[W] 1 Right Panel 73033.002[W] 1 Permanent Filters 20" x 25" x 2"
22628 2
10-24 x 3/4" Hex-Head, Cap-Screw Bolt
21699 18
10-24 Keps Nut 20698 18 TEK Screw 13404 8 Filter Channel 73035.002 2 Bottom Guide 73036.002 1 Bottom Panel 73034.002[W] 1
Note: Inlet hood is also available with screen mesh, no filters (P/N 13405059).

SECTION 12: INLET HOOD

WARNING
Crush Hazard
Use proper lifting equipment and practices.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Cut/Pinch Hazard
Wear protective gear during installation, operation and
service. Equipment and accessories are
Edges are sharp. heavy.
Failure to follow these instructions can result in death, injury or property damage.
Inlet hoods are shipped unassembled and must be assembled prior to installation. The inlet hood may be installed either onto the inlet of the air handler or to an outside wall. After installing an inlet hood, all hardware must be torqued according to recommended specifications on Page 9, Table 1. In addition, all seams must be caulked (provided by others). Part numbers ending with a "[W]" indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish. To order with a galvanized finish, do not include a "W" at the end of the part number; to order with a painted finish, include a "W" at the end of the part number. NOTE: Check to be sure that all required components are present. If any are missing, contact your RAPID
®
independent distributor.

12.1 Inlet Hood Assembly (2005) FIGURE 24: Inlet Hood Assembly (2005)

44 of 147
Page 55
SECTION 12: INLET HOOD

12.2 Inlet Hood Assembly (2010 and 2010B)

Inlet Hood with Permanent
Description
Filter Rail Assembly 13505066 2 2 N/A Top Inner Rail 13505068 1 1 1 Bottom Rail Assembly 13505072 1 1 N/A Top Back Panel 13505075 1 1 1 Top Front Panel 13505076 1 1 N/A Left Panel 13505080 1 1 1 Right Panel 13505081 1 1 1 Upright Mount 13505090 2 2 2 Horizontal Mount 13505091 2 2 2 Drip Rail 13505092 2 2 2 TEK Screw 13404 82 105 92 5/16-18 x 1 Bolt HHCS Grade 5 20507 5 5 5 5/16 Flat Washer 95211600 5 5 5 5/16 Nut Flange 20509 5 5 5 Permanent Filter 20" x 20" x 1" 20628 6 N/A N/A 10-24 KEPS Nut 20698 8 8 N/A A1 Snap Fastener 20900 6 N/A N/A 10-24 x 1/2 HMS Bolt 27000 8 8 N/A Fastener Rivnut 3/8-16 91120106 10 10 10 3/8 Flatwasher 20515 10 10 10 3/8-16 x 1 Bolt Hex Grade 5 20517 10 10 10 Foam Tape 92700017 14ft 14ft 14ft Horizontal Mount for Birdscreen 13505087 N/A 2 N/A Screen 38.75" x 59" 90740051 N/A 1 N/A Fender Washer 1/4 x 1 95211550 N/A 12 N/A Bottom Rail Assembly - ML 13505095 N/A N/A 1 Top Front Panel - ML 13505096 N/A N/A 1 Inner Support Rail - ML 13505097 N/A N/A 1 Outer Suppor t Rail - ML 13505098 N/A N/A 1 Side Cover - ML 13505099 N/A N/A 2 Moisture Limiter Media 12" x 60" x 5.5" 90740001 N/A N/A 3
Part
Number
Aluminum Mesh Filters
13505060 (Galvanized)
13505061 (Painted)
Quantity Quantity Quantity
Inlet Hood Without Filters,
With Birdscreen
13505058 (Galvanized)
13505059 (Painted)
Inlet Hood with
Moisture Limiter
13505062 (Galvanized)
13505063 (Painted)
45 of 147
Page 56
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Air Handler
Air Handler Top Panel
Horizontal Mount
Horizontal Mount
Without Filter Section
Air Handler
With Filter Section
Inlet Hood
Horizontal Mount
Horizontal Mount
Inlet Hood
Filter
Box
Air Handler
Without Filter Section
Without Filter Section
Air Handler
Filter Box
With Filter Section
With Filter Section
External Support
SIDE VIEW SIDE VIEW
TOP VIEW TOP VIEW
Upright Mount
Upright Mount
For an air handler without a filter section:On the inlet of the air handler, install horizontal and upright mounts. The mounts will be installed via angles open towards the outside of the air handler.
For an air handler with a filter section: First, attach the filter section to the air handler. Then, bolt the inlet hood horizontal and upright mounts to the inlet of the filter section with the angles opening towards the inside of the filter section.
Upright mounts (P/N 13505090) are attached with five 3/8-16 bolts (P/N 20517) and flat washers (P/N 20515) each; the receiving riv-nut (P/N 91120106) will be factory installed on the air handler or filter section. Horizontal mounts (P/N 13505091) are attached using five TEK self-tapping screws (P/N 13404).
Prior to installing the mounts, seal the gap between the mating surfaces of the air handler/filter section and the mounts with the provided foam tape (P/N 92700017).
When installing the top horizontal mount directly to the air handler without a filter section, foam tape should NOT be used. In this case, the hardware on the lip of the air handler roof panel should be removed, the mount slid under the lip and hardware re-installed. Foam tape to be used on remaining three sides.
To install inlet hood on an exterior wall, drill holes ev
ery 8" (20.3 cm) in the flanges of the inlet hood and
mount with lag bolts (provided by others).

Step 12.2.1

46 of 147
Page 57

Step 12.2.2

Right Panel
Left Panel
Attach left panel and right to each side flange of the air handler/filter section using five TEK self-tapping screws. Ensure that the flanges on the panels break inward.
Description Part Number
Left Panel 13505080 Right Panel 13505081 TEK Screw 13404
Screws
Bottom Rail
Attach the bottom panel to the bottom attaching flange with five TEK self-tapping screws and to each side panel with two TEK self-tapping screws. Ensure that the side tabs of the bottom panel are to the inside of the side panels.
Description Part Number
Bottom Rail 13505072/13505095 TEK Screw 13404
SECTION 12: INLET HOOD

Step 12.2.3

47 of 147
Page 58
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Top Front
Panel
Attach top front panel to the sidewall panels using four TEK self-tapping screws on each side. Ensure that the side tabs of the top panel are to the outside of the side panels.
Description Part Number
Top Front Panel 13505076/13505096 TEK Screw 13404
Top Front Panel
Top Inner Filter Rail
Top Front Panel
Bottom Rail
Right
Panel
Left
Panel
Top Inner Filter Rail
SIDE VIEW REVERSE INLET VIEW
Attach the top inner filter rail to the inside of the front top panel using four TEK self tapping screws. Ensure that the rail is installed with the ends tight against the flanges of the sidewall panels and the angle opening toward the inside of the inlet hood.
Description Part Number
Top Inner Filter Rail 13505068 TEK Screw 13404

Step 12.2.4

Step 12.2.5

48 of 147
Page 59

Step 12.2.6

Top Back Panel
J-Bend
Attach top back panel with four TEK self- tapping screws on each side, with five TEK self-tapping screws to the top attaching flange and with five 5/16-18 x 1 hex head cap screws, 5/16 washers and 5/16 flange nuts at the J-bend joint. Ensure that the side tabs of the roof panel are to the outside of the side panels and that the J-bend interlocks with the front roof panel.
Description Part Number
Top Back Panel 13505075 TEK Screw 13404 5/16-18 x 1 Hex Head Cap Screw 20507 5/16 Washer 95211600 5/16 Flange Nut 20509
SIDE VIEW
Birdscreen
Horizontal Mount
Install horizontal mounting brackets for birdscreen on to face of inlet hood. Mount birdscreen with brackets and secure with self tapping screws and washers.
Description Part Number
Horizontal mount for birdscreen 13505087 Screen 90740051 TEK Screw 13404
SECTION 12: INLET HOOD
For inlet hoods with permanent aluminum mesh filters, continue to step 12.2.8.
For inlet hoods with birdscreen, no filters, continue to step 12.2.7.
For inlet hoods with moisture limiter, continue to step 12.2.9.

Step 12.2.7

49 of 147
Page 60
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Double Sided
Filter Rail
Filter Clip
Double Sided Filter Rail
Attach the double-sided filter rails horizontally to the face of the inlet hood using two #10-24 x ½" bolts and #10-24 nuts on each side. When attaching the filter rails, insert the bolt from the inside of the filter rail to allow for maximum clearance for the filters. Attach the snap fastener with one TEK self-tapping screw each. (First remove the washer as the washer will restrict the snap fastener, making it difficult to open.)
NOTE: Inlet hood with birdscreen does not require filters or snap fasteners.
Description Part Number
Double-Sided Filter Rails 13505066 #10-24 x 1/2" Bolt 27000 #10-24 Nut 20698 Snap Fastener 20900 TEK Screw 13404
Caulk the seams between the inlet hood and the air handler/filter section and on the open sides of the J-bend that lock the roof panels together.

Step 12.2.8

Step 12.2.9

Caulk
Caulk
50 of 147
Page 61

Step 12.2.10

Drip Rail
Attach drip rail to each side using five TEK self-tapping screws for each drip rail. Ensure that the drip rails are positioned above the filter clips (where applicable), using the provided holes in the sidewall panels. Apply caulk to the drip rails before attaching to the side panels.
NOTE: Double sided filter rails or snap fasteners are not required for inlet hood with moisture limiter.
Description Part Number
Drip Rail 13505092 TEK Screws 13404
Filter
Load filters into the inlet hood, checking to see that each filter is in the proper orientation by verifying that the arrow on the side of the filter points in the direction of air flow. All of the arrows should be pointing towards the air handler when installed in the proper orientation. Once filters are installed, close filter clips installed previously (See Page 50, Step 12.2.8) to hold filters in place.
Description Size Part Number
Permanent Aluminum Mesh Filter
in 20 x 20 x 1
20628
cm 50.8 x 50.8 x 2.5
SECTION 12: INLET HOOD
For inlet hoods with permanent aluminum mesh filters, continue to step 12.2.11.
For inlet hoods with birdscreen, no filters, the instructions end here.
For inlet hoods with moisture limiter, continue to step 12.2.12.

Step 12.2.11

For inlet hoods with permanent alumimum mesh filters the instructions end here.

51 of 147
Page 62
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Moisture Limiter Side Cover
Attach side cover of moisture limiter frame to the left side of the inlet hood rain gutter using eight TEK screws. Attach to the bottom pan assembly with two #10-24 x ½" bolts and #10-24 nuts.
Description Part Number
Side Cover (ML) 13505099 TEK Screw 13404 #10-24 x ½" Bolt 27000 #10-24 Nut 26098
Inner Support
RailMoisture Limiter
Side Cover
Place the moisture limiter inner support rail under the top flange of the moisture limiter frame side cover and to the top of the inlet hood. Attach to the top of the inlet hood using nine #10-24 x ½" bolts and nine #10-24 nuts. Attach to the left side of the frame using two #10-24 x ½" bolts and two #10-24 nuts.
Description Part Number
Inner Support Rail 13505097 TEK Screw 13404 #10-24 x ½" Bolt 27000 #10-24 Nut 26098

Step 12.2.12

Step 12.2.13

52 of 147
Page 63

Step 12.2.14

Moisture Limiter
Media
Insert the 3 pieces of 12" (30.5 cm) x 60" (152.4 cm) moisture limiter media from the right side with the long dimension running top to bottom.
Description Part Number
Moisture Limiter Media 90740001
Moisture Limiter
Side Cover
Outer Support Rail
Place the moisture limiter frame side cover in order to have the flange at the top overlap the top of the frame. Attach to the inlet hood rain gutter using eight TEK screws. Attach to the bottom pan assembly and top with two #10-24 x ½" bolts and #10-24 nuts each. Attach front stiffeners to the left and right side of the moisture limiter frame using four TEK screws for each support.
Description Part Number
Side Cover (ML) 13505099 Outer Suppor t Rail 13505098 TEK Screw 13404 #10-24 x 1/2" Bolt 27000 #10-24 Nut 26098
SECTION 12: INLET HOOD

Step 12.2.15

53 of 147
Page 64
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

12.3 Inlet Hood Assembly (2020 and 2030)

Model
2020
Description
2030
Part
Number
Double Sided Filter Rails 13X05066 4 4 N/A Top Inner Filter Rail 13X05068 1 1 1 Bottom Rail 13X05072 1 1 N/A Top Back Panel #1 13X05075 1 1 1 Top Middle Panel #2 13X05076 1 1 1 Top Front Panel #3 13X05077 1 1 N/A Left Side Panel #1 13X05080 1 1 1 Right Side Panel #1 13X05081 1 1 1 Left Side Panel #2 13X05082 1 1 1 Right Side Panel #2 13X05083 1 1 1 Left Side Panel #3 13X05084 1 1 1 Right Side Panel #3 13X05085 1 1 1 Upright Mount 13X05090 2 2 2 Horizontal Mount 13X05091 2 2020=6 / 2030=2 2 Drip Rail Upper Right 13305092 1 1 1 Drip Rail Upper Left 13305093 1 1 1 Drip Rail Lower Right 13305094 1 1 1 Drip Rail Lower Left 13305095 1 1 1 TEK Screw 13404 150 2020=165 / 2030=175 2020=152 / 2030=162 5/16"-18 x 1 Bolt HHCS Grade 5 20507 26 26 26 3/8" Flatwasher 20515 14 14 14 3/8"-16 x 1 Bolt Hex Grade 5 20517 14 14 14 5/16" Flat Washer 95211600 26 26 26 5/16" Nut Flange 20509 26 26 26 Permanent Aluminum Mesh Filter
20" x 25" x 1" Permanent Aluminum Mesh Filter
20" x 20" x 1" 10-24 KEPS Nut 20698 16 16 16 A1 Snap Fastener 20900 10 N/A N/A 10-24 x 1/2" HMS Bolt 27000 16 16 16 Fastener Rivnut 3/8"-16 91120106 14 14 14 Foam Tape 92700017 20' (6 m) 20' (6 m) 20' (6 m) Birdscreen 9074005X N/A 1 N/A Birdscreen Mount* 13305087* N/A 4* N/A Fender Washer 1/4" x 1" 95211550 N/A 16 N/A Bottom Rail - ML** ######** N/A N/A 1 Left Side Cover - ML 13X05078 N/A N/A 2 Right Side Cover - ML 13X05079 N/A N/A 2 Top Front Panel #3 - ML 13X05096 N/A N/A 1 Inner Rail - ML 13X05097 N/A N/A 1 Outer Rail - ML 13X05098 N/A N/A 1 Moisture Limiter 12" x 96" x 5.5" 90740002 N/A N/A 2020=4 / 2030=5
20629 2020=10 / 2030=5 N/A N/A
20628 2020=0 / 2030=10 N/A N/A
Inlet Hood with Permanent
Aluminum Mesh Filters
13205060 (Galvanized)
13205061 (Painted)
13305060 (Galvanized)
13305061 (Painted)
Quantity Quantity Quantity
Inlet Hood without filters,
with Birdscreen
13205058 (Galvanized)
13205059 (Painted)
13305058 (Galvanized)
13305059 (Painted)
Inlet Hood with
Moisture Limiter
13205062 (Galvanized)
13205063 (Painted)
13305062 (Galvanized)
13305063 (Painted)

*For use on model 2030 Inlet Hoods only. **For model 2020 P/N=13205095; for model 2030 P/N=13305100

Note: In the above chart, an "X" in a part number indicates a digit that changes based on model. Replace the "X" with a "2" for model 2020; replace the "X" with a "3" for model 2030. For further clarification, reference individual chart of components in each step.
54 of 147
Page 65

Step 12.3.1

Air Handler
Air Handler Top Panel
Horizontal Mount
Horizontal Mount
Without Filter Section
Air Handler
With Filter Section
Inlet Hood
Horizontal Mount
Horizontal Mount
Inlet Hood
Filter
Box
Air Handler
Without Filter Section
Without Filter Section
Air Handler
Filter Box
With Filter Section
With Filter Section
External Support
SIDE VIEW SIDE VIEW
TOP VIEW TOP VIEW
Upright Mount
Upright Mount
For an air handler without a filter section:On the inlet of the air handler, install horizontal and upright mounts. The mounts will be installed via angles open towards the outside of the air handler.
For an air handler with a filter section: First, attach the filter section to the air handler. Then, bolt the inlet hood horizontal and upright mounts to the inlet of the filter section with the angles opening towards the inside of the filter section.
Upright mounts (P/N 13X05090) are attached with seven 3/8-16 bolts (P/N 20517) and flat washers (P/N
20515) each; the receiving riv-nut (P/N 91120106) will be factory installed on the air handler or filter section. Horizontal mounts (P/N 13505091) are attached using nine TEK self-tapping screws (P/N 13404).
Prior to installing the mounts, seal the gap between the mating surfaces of the air handler/filter section and the mounts with the provided foam tape (P/N 92700017).
When installing the top horizontal mount directly to the air handler without a filter section, foam tape should NOT be used. In this case, the hardware on the lip of the air handler roof panel should be removed, the mount slid under the lip and hardware re-installed. Foam tape to be used on remaining three sides.
To install inlet hood on an exterior wall, drill holes every 8" (20.3 cm) in the flanges of the inlet hood and mo
unt with lag bolts (provided by others).
SECTION 12: INLET HOOD
55 of 147
Page 66
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Panel 1 Left
Panel 1 Right
Attach an innermost sidewall panel 1 to each side attaching flange using seven TEK self-tapping screws.
NOTE: Flanges face inward.
Description Part Number
Left Side Panel #1 13205080 / 13305080 Right Side Panel #1 13205081 / 13305081 TEK Screws 13404
Bottom Rail
For Model 2020: Attach the bottom panel to the bottom mounting flange with seven TEK self-tapping screws. Attach to each side panel with two TEK self-tapping screws.
For Model 2030: Attach bottom panel to the bottom mounting flange with nine TEK self-tapping screws. Attach to each side panel with two TEK self-tapping screws.
NOTE: Ensure that the side tabs of the bottom panel are to the inside of the side panels.
Description Part Number
Bottom Rail
13205072 / 13305072 /
13205095 / 13305100
TEK Screws 13404

Step 12.3.2

Step 12.3.3

56 of 147
Page 67

Step 12.3.4

Panel 2
Right
Panel 3
Right
Panel 2
Left
Panel 3
Left
Attach the middle sidewall panels (left panel, right panel) with four 5/16"-18 x 1 bolt, 5/16 flat washer, 5/16" flange nut each. Attach outermost sidewall panels (left panel, right panel) to each side of the inlet hood using three 5/16"-18 x 1 bolt, 5/16" flat washer, 5/16" flange nut.
Description Part Number
Left Side Panel #2 13205082 / 13305082 Right Side Panel #2 13205083 / 13305083 Left Side Panel #3 13205084 / 13305084 Right Side Panel #3 13205085 / 13305085 5/16"-18 x 1 Bolt 20507 5/16" Flat Washer 95211600 5/16" Nut Flange 20509
Top Front Panel 3
Attach top front panel to the sidewall panels using four TEK self-tapping screws on each side.
NOTE: Ensure that the side tabs of the top panel are to the outside of the side panels.
Description Part Number
Top Front Panel #3
13205077 / 13305077 /
13205096 / 13305096
TEK Screw 13404
SECTION 12: INLET HOOD

Step 12.3.5

57 of 147
Page 68
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Top Front Panel (Roof)
Top Inner Filter Rail
Top Front Panel
Bottom Rail
Right
Panel
Left
Panel
Top Inner Filter Rail
SIDE VIEW
REVERSE INLET
VIEW
For Model 2020: Attach top inner filter rail to the inside of the top front panel using five TEK self tapping screws.
For Model 2030: Attach top inner filter rail to the inside of the top front panel using six TEK self tapping screws.
NOTE: Ensure the rail is installed with the ends tight against the flanges of the sidewall panels and the angle opening toward the inside of the inlet hood.
Description Part Number
Top Inner Filter Rail 13205068 / 13305068 TEK Screw 13404

Step 12.3.6

58 of 147
Page 69

Step 12.3.7

Attach top middle panel with five TEK self-tapping screws on each side and with six 5/16-18 x 1 bolts, 5/16 washers and 5/16 flange nuts at the J-bend joint.
For Model 2020: Attach top back panel with five TEK self- tapping screws on each side, seven TEK self-tapping screws to the top mounting flange and with six 5/16-18 x 1 bolts, 5/16 washers and 5/16 flange nuts at the J-bend joint.
For Model 2030: Attach top back panel with five TEK self- tapping screws on each side, nine TEK self-tapping screws to the top mounting flange and with six 5/16-18 x 1 bolts, 5/16 washers and 5/16 flange nuts at the J-bend joint.
NOTE: Ensure that the side tabs of the roof panels are to the outside of the side panels and that the J-bends interlock the panel with the roof panel in front of it.
Description Part Number
Top Middle Panel #2 13205076 / 13305076 Top Back Panel #1 13205075 / 13305075 TEK Screw 13404 5/16"-18 x 1 Bolt 20507 5/16" Flat Washer 95211600 5/16" Nut Flange 20509
Top Middle Panel 2
SECTION 12: INLET HOOD
Top Back Panel 1
For inlet hoods with permanent aluminum mesh filters, continue to Step 12.3.9.
For inlet hoods with birdscreen, no filters, continue to Step 12.3.8.
For inlet hoods with moisture limiter, continue to Step 12.3.10.
59 of 147
Page 70
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Birdscreen
Install birdscreen mounts into inlet hood opening. Mount birdscreen into brackets and secure with self tapping screws and washers.
*For Model 2030 only.
Description Part Number
Birdscreen 90740052 / 90740053 Birdscreen Mount 13205091 / 13305087* Fender Washer 95211550 TEK Screw 13404
Double Sided
Filter Rail
Snap Fastener
Screws
Attach the double-sided filter rails horizontally to the face of the inlet hood using two #10-24 x ½" bolts and #10-24 nuts on each side. When attaching the filter rails, insert the bolt from the inside of the filter rail to allow for maximum clearance for the filters. Attach the filter clips with TEK self-tapping screws. (First remove the washer as the washer will restrict the filter clip, making it difficult to open.)
NOTE: Inlet hoods with birdscreen does not require filters or snap fasteners.
Description Part Number
Double-Sided Filter Rails 13205066 / 13305066 #10-24 x ½" Bolt 27000 #10-24 Nut 20698 TEK Screw 13404 A1 Snap Fastener 20900

Step 12.3.8

Step 12.3.9

60 of 147
Page 71

Step 12.3.10

Caulk Caulk
Caulk the seams between the inlet hood and the air handler/filter section and on the open sides of the J-bends that lock the roof panels together.
NOTE: Double-sided filter rails or filter clips are not required for inlet hood with moisture limiter.
Lower
Rail
Upper
Rail
When attaching the drip rail, ensure that the drip rails are positioned above the filter clips, using the provided holes in the sidewall panels. Attach drip rail to right side of inlet hood starting with the lower drip rail using five TEK self-tapping screws. Attach the upper right side rail by sliding it inside the lower drip rail where they overlap use five TEK self-tapping screws. Attach drip rail to left side of inlet hood starting with the lower drip rail using five TEK self-tapping screws. Attach the upper right side drip rail by sliding it inside the lower drip rail where they overlap use five TEK self-tapping screws. Apply caulk to the drip rails before attaching to the side panels.
Description Part No.
Drip Rail Upper Right 13305092 Drip Rail Upper Left 13305093 Drip Rail Lower Right 13305094 Drip Rail Lower Left 13305095 TEK Screw 13404

Step 12.3.11

SECTION 12: INLET HOOD
For inlet hoods with permanent aluminum mesh filters, continue to Step 12.3.12.
For inlet hoods with birdscreen, no filters, the instructions end here.
For inlet hoods with moisture limiter, continue to Step 12.3.13.
61 of 147
Page 72
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Filter
Load filters into the inlet hood, checking to see that each filter is in the proper orientation by verifying that the arrow on the side of the filter points in the direction of air flow. All of the arrows should be pointing towards the air handler when installed in the proper orientation. Once filters are installed, close snap fasteners installed previously (See Page 60, Step 12.3.9) to hold filters in place.
Description Size
Part
Number
Permanent Aluminum Mesh Filter
in 20 x 25 x 1
20629
cm 50.8 x 63.5 x 2.5 in 20 x 20 x 1
20628
cm 50.8 x 50.8 x 2.5
Moisture Limiter Side Cover
Attach side cover of moisture limiter frame to the left side of the inlet hood drip rail using eight TEK screws. Attach to the bottom pan assembly with two #10-24 x ½" bolts and #10-24 nuts.
Description Part Number
Left Side Cover (ML) 13205078 / 13305078 TEK Screw 13404

Step 12.3.12

For inlet hoods with permanent aluminum mesh filters, the instructions end here.

Step 12.3.13

62 of 147
Page 73

Step 12.3.14

Inner Support
Rail
Moisture Limiter
Side Cover
Place the moisture limiter inner support rail under the top flange of the moisture limiter frame side cover and to the top of the inlet hood. Attach to the top of the inlet hood using nine #10-24 x ½" bolts and #10-24 nuts. Attach to the side cover of the frame using two #10-24 x ½" bolts and #10-24 nuts.
Description Part Number
Inner Support Rail 13205097 / 13305097 TEK Screw 13404 #10-24 x 1/2" Bolt 27000 #10-24 Nut 26098
Moisture Limiter
Media
For Model 2020: Insert 4 pieces of 12" (30.5 cm) x 96" (243.8 cm) moisture limiter media from the right side with the long dimension running top to bottom.
For Model 2030: Insert 5 pieces of 12" (30.5 cm) x 96" (243.8 cm) moisture limiter media from the right side with the long dimension running top to bottom.
Description Part Number
Moisture Limiter Media 90740002
SECTION 12: INLET HOOD

Step 12.3.12

63 of 147
Page 74
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Moisture Limiter
Side Cover
Outer Support Rail
Place the moisture limiter frame side cover to the flange at the top overlaps the top of the frame. Attach to the inlet hood drip rail using eight TEK screws. Attach to the bottom pan assembly and top with two #10-24 x ½" bolts and #10-24 nuts each. Attach front stiffeners to the left and right side of the moisture limiter frame using four TEK screws for each support.
Description Part Number
Right Side Cover 13205079 / 13305079 Outer Suppor t Rail 13205098 / 13305098 TEK Screw 13404
Air Handler
Inlet Hood

Step 12.3.13

12.4 Inlet Hood Installation

The inlet hood may be installed either onto the inlet of the air handler or to an outside wall.

12.4.1 Inlet Hood Installation to Wall

Use lagbolts to install the inlet hood to an exterior wall. Once the inlet hood is in place, the edges must be sealed to the wall with the proper sealant. For models 2010 - 2030, assemble the hood prior to mounting, then mount as described below.

12.4.2 Inlet Hood Installation to Air Handler (2005)

First remove the hardware in the top drip edge of the air handler. Tuck the top flange of the hood behind the top drip edge. See Page 64, Figure 25. Replace the hardware, screw together the top drip edge of the air handler, top flange of the inlet hood and the air handler wall panel.
NOTE: After installing the inlet hood, all hardware must be tightened with a torque wrench. The roof, side and bottom seams must be caulked (supplied by others).

12.4.3 Inlet Hood Installation to Air Handler (2010 - 2030)

Inlet hoods are assembled onto the air handler. For Models 2010 and 2010B See Page 46, Step 12.2.1. For Models 2020 and 2030 See Page 55, Step 12.3.1.

FIGURE 25: Inlet Hood Positioning

64 of 147
Page 75

SECTION 13: DAMPERS

SECTION 13: DAMPERS
WARNING
Crush Hazard
Use proper lifting equipment and practices.
Failure to follow these instructions can result in death, injury or property damage.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Equipment and accessories are heavy.
Cut/Pinch Hazard
Wear protective gear
during installation,
operation and
service.
Edges are sharp.
65 of 147
Page 76
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
C
E
C
D
A
B
C
C
F
NOTE:1) CONTRACTOR/INSTALLER MUST MAKE
APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS.
2) NUMBER OF LOUVERS WILL VARY.
3) MOUNTED DOWNSTREAM OF AIR HANDLER IN DUCT WORK. DOES NOT MOUNT DIRECTLY TO AIR HANDLER. FIELD WIRED TO PROVIDED TERMINALS ON CONTROL PANEL.
AIR FLOW
Model Part Number A B C D E F
Weight lbs
(kg)
2005 77014.301
in 21.0 19.0 1.0 19.0 17.0 9.0
40 (18.1)
cm 53.3 48.3 2.5 48.3 43.2 22.9
2010/ 2010B
77018.301
in 27.0 25.0 1.0 23.5 21.5 8.0
60 (27.2)
cm 68.6 63.5 2.5 59.7 54.6 20.3
2020 80922.2
in 37.0 34.0 1.5 36.0 33.0 10.0
100 (45.4)
cm 94.0 86.4 3.8 42.0 83.8 25.4
2030 77537.2
in 42.0 39.0 1.5 42.0 39.0 10.0
150 (68)
cm 106.7 99.1 3.8 106.7 99.1 25.4

13.1 Discharge Damper

Discharge dampers are shipped loose. Discharge dampers are designed to be mounted downstream of the air handler in ductwork. A qualified contractor/installer must make appropriate allowances for duct connections.

To install the discharge damper on an interior wall, drill holes every 8" (20.5 cm) in the flanges on all four sides of the discharge damper to accommodate lag bolts (provided by others).

Discharge dampers are not recommended to be mounted directly to the air handler.

FIGURE 26: Motorized Discharge Damper (2005 - 2030)

66 of 147
Page 77
SECTION 13: DAMPERS
C
E
C
D
A
B
C
C
F
NOTE: 1) CONTRACTOR/INSTALLER MUST MAKE
APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS.
2) NUMBER OF LOUVERS WILL VARY.
3) MOUNTED UPSTREAM OF AIR HANDLER. MOUNTS DIRECTLY TO AIR HANDLER, PRE-INSTALLED.
G
AIR FLOW
Model Part Number A B C D E F G
Weight lbs
(kg)
2005 77019.301
in 21.0 19.0 1.3 25.7 23.4 5.0 3.3
40 (18.1)
cm 53.3 48.3 3.3 65.2 59.5 12.7 8.3
2010/2010B 80900
in 33.3 30.8 1.3 29.0 26.3 5.0 3.3
60 (27.2)
cm 84.5 78.1 3.2 73.7 66.7 12.7 8.3

13.2 Inlet Damper

Inlet dampers are factory mounted to the 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.

FIGURE 27: Motorized Inlet Damper (2005 - 2010B)

67 of 147
Page 78
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
NOTE:1) CONTRACTOR/INSTALLER MUST MAKE
APPROPRIATE ALLOWANCES FOR DUCT CONNECTIONS.
2) NUMBER OF LOUVERS WILL VARY.
3) MOUNTED UPSTREAM OF AIR HANDLER. MOUNTS DIRECTLY TO AIR HANDLER, PRE-INSTALLED.
UPPER DAMPER
LOWER DAMPER
A C
B
D
CA
E
E
E
E
E
E
AIR FLOW
AIR FLOW
Model ABCDE
2020
in 47.3 24.4 2.0 29.5 1.5
cm 120.0 63.0 5.1 74.9 3.8
2030
in 59.3 24.4 2.0 33.5 1.5
cm 150.6 63.0 5.1 85.1 3.8
Model Part Number Style Dampers Used
Weight lbs(kg)
2020 80920
MUA Upper and Lower
75(34)
2030 77530 107(48.1) 2020 80920U
FR/AM/VAV Upper Only
34(15.4)
2030 77530U 46(20.9)

FIGURE 28: Motorized Inlet Damper (2020 and 2030)

68 of 147
Page 79

SECTION 14: DISCHARGE HEADS AND SPLASH PLATES

Model A B C D E
Part
Number
Weight
lbs kg
2005
(in) (cm)
19.0
48.3
40.8
103.5
23.8
60.3
21.0
53.3
2.0
5.1
77349.301 50 22.7
2010 and 2010B
(in) (cm)
22.4
56.9
40.8
103.5
24.0
61.0
19.4
49.3
2.0
5.1
77049.301 80 36.3
2020
(in) (cm)
31.9
81.0
43.3
109.9
21.5
54.6
33.9
86.1
2.0
5.1
77249.201 120 54.4
2030
(in) (cm)
36.9
93.7
48.3
122.6
22.5
57.2
36.9
93.7
2.0
5.1
77549.201 160 72.6
WARNING
SECTION 14: DISCHARGE HEADS AND SPLASH P LATES
Crush Hazard
Use proper lifting equipment and practices.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
Severe Injury Hazard
Use proper lifting practices and equip­ment.
Cut/Pinch Hazard
Wear protective gear during installation, operation and
service. Equipment and accessories are
Edges are sharp. heavy.
Failure to follow these instructions can result in death, injury or property damage.
Part numbers that end with a “[W]” indicate that the part can be ordered with either an unpainted galvanized finish or an acrylic modified alkyd enamel finish. To order with a galvanized finish, do not include the "W" at the end of the part number; to order with a painted finish, include the "W" at the end of the part number.

14.1 One-Way and Three-Way Discharge Head Installation

All discharge heads are shipped assembled. The discharge head is designed for mounting to the face
FIGURE 29: Three-Way Discharge Head (2005 - 2030)
E
of the air handler (covering the discharge opening) or to an interior wall. All discharge heads must be field supported (by others). The discharge head has four
A
B
outward-turned flanges. If the discharge head is to be installed to the face of the air handler, install hardware (provided by others) on all four sides of the discharge head.
To install the discharge head on an interior wall, drill
TOP VIEW
C
E
E
holes every 8" (20.5 cm) in the flanges on all four sides of the discharge heads to accommodate lag bolts (supplied by others). Sheet metal (supplied by
D
others) may be required. See Page 69, Figure 29 for the three-way discharge head available for Models 2005 - 2030.
SIDE VIEW
E
69 of 147
Page 80
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Part NumberModel ABCDE F
G
(min)G(max)
H
Weight
lbs kg
77354.301[W] 2005
(in) (cm)
22.0
55.9
19.5
49.5
0.9
2.2
25.0
63.5
1. 3
3.2
0.6
1. 6
15.0
38.1
20.0
50.8
N/A 20.0 9.1
77053.301[W]
2010/ 2010B
(in) (cm)
44.0
118 . 8
41.5
105.4
0.9
2.2
44.0
111.8
1. 3
3.2
0.6
1. 6
18.0
47.5
27.0
68.6
N/A 40.0 18.1
77253.301[W]
2020
(in) (cm)
54.8
139.1
51.3
130.2
1. 8
4.4
54.8
139.1
1. 8
4.4
0.8
2.0
25.0
63.5
38.0
96.5
N/A
60.0 27.2
2030
(in) (cm)
30.0
76.2
45.0
114 . 3
N/A

14.2 Splash Plate Installation

The splash plate is designed to hang directly from a horizontal air handler with a bottom discharge. Before the splash plate can be installed on the air handler, first drill four holes (2005 - 2030) in the air handler floor. These holes should be approximately 5/8" (15.9 mm) in diameter to accommodate 1/2" hanger rods (supplied by others). These holes should be located as shown in the diagram on Page 71, Figure 31.
To attach all of the hanger rods to the splash plate, start by threading a flanged 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 70, Figure 30. The hanger rods should be attached to the air handler in the same manner as the splash plate, with a flanged nut on both sides of the air handler floor. Adjusting the nuts will level the splash plate. Torque hardware after leveling.

FIGURE 30: Splash Plate

70 of 147
Page 81

FIGURE 31: Hole Location (2005 - 2030)

Model 2005 2010 and 2010B 2020 2030
A
(in) (cm)
19.5
49.5
41.5
105 .4
51.3
130.2
51.25
130.2
B
(in) (cm)
22.5
57.2
41.5
105 .4
51.3
130.2
51.25
130.2
B
SECTION 14: DISCHARGE HEADS AND SPLASH P LATES
A
71 of 147
Page 82
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Cut/Pinch Hazard
Wear protective gear during installation, operation and service.
Edges are sharp.
Falling Hazard
Use proper safety equipment and prac­tices to avoid falling.
WARNING
Failure to follow these instructions can result
in death, injury or property damage.

SECTION 15: DUCT CONSIDERATIONS

The air handler has been designed to operate at the specific air volume and external static pressure that was ordered (air handlers set-up to accept an external static pressure (ESP) of 1 in wc (2.5 mbar). This static pressure is generated by any additional components that are added to the heater (i.e. inlet hood, filter section, dampers, ductwork, discharge heads, etc). Additional static pressure beyond that ordered will affect the performance of the air handler and lessen the air volume that can be delivered.
Proper engineering methods need to be employed when calculating duct and component static pressure (i.e. 2009 ASHRAE Handbook - Fundamentals, Chapter 21). Accessory pressure drops are available on Page 16, Table 9.
The system ductwork must comply with Sheet Metal and Air Conditioning Contractors Nationals Association (SMACNA) or any other recognized standards.
As a general rule, all discharge ducts should have a straight run of at least 3 hydraulic duct diameters after the air handler before adding any fittings, elbows, restrictions, etc. Return ducts should have the same straight r
Hydraulic duct diameter for round ducts in inches:
Dh = d
Dh: hydraulic diameter d: round duct inside diameter Hydraulic duct diameter for rectangular ducts (in
inches):
Dh = (2*H*W)/(H+W)
un before attaching to the unit.
Dh: hydraulic diameter H: rectangular duct inside height W: re ctangular duct inside width
The air handler is not designed to support the weight of ductwork. Ductwork must be constructed in a fashion that is self-supporting. Ductwork should be straight, elbows should be minimal and any transitions should be smooth.
Depending on the options ordered with the air handler, flanges (either external or internal) may be provided to facilitate connection of ductwork. In cases where flanges are not provided, flat surfaces on the exterior skin of the air handler are pro facilitate connection of ductwork.

15.1 Inlet Duct Work

Inlet duct work height and width must be no smaller than the air handler inlet height and width and supply only fresh air to the air handler. (See Page 11, Section 5 for inlet dimensions).

15.2 Return Duct Work

Inlet duct work height and width must be no smaller than the air handler inlet height and width and supply only fresh air to the air handler. (See Page 11, Section 5 for inlet dimensions).

15.3 Discharge Duct Work

Refer to Page 73, Table 10 for minimum discharge duct sizes by model. Refer to Page 73, Table 11 for discharge duct size required for connecting to heater (BD or RD), these dimensions provide clearance for duct flange to blower mounting bolts.
vided to
72 of 147
Page 83

Table 10: Minimum Recommended Duct Size

Model Height Width
2005
2010 and 2010B
2020
2030
(in) (cm)
(in) (cm)
(in) (cm)
(in) (cm)
14
35.6
24
61.0
32
81.3
38
96.5
15.6
39.7
24
61.0
32
81.3
38
96.5

Table 11: Discharge Duct Size Recommendations to Connect to Heater (for BD/RD)

Model Height Width
2005
2010 and 2010B
2020
2030
(in) (cm)
(in) (cm)
(in) (cm)
(in) (cm)
14
35.6
25.3
63.5
40
101.6
47
119 . 4
17.5
44.5
25.3
63.5
35.3
89.5
40.8
103.5
SECTION 15: DUCT CONSIDERATIONS
NOTE: Dimension clearance to clear blower
mounting bolts.
73 of 147
Page 84
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
WARNING
Explosion Hazard
Leak test all components of gas piping before operation.
Gas can leak if piping is not installed properly.
Do not high pressure test gas piping with air handler connected.
Failure to follow these instructions can result in death, injury or property damage.

SECTION 16: GAS PIPING

16.1 Gas Manifolds

All gas piping to the air handler must comply with:
United States: Refer to NFPA 54/ANSI Z223.1 - latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision, Natural Gas and Propane Installation Code.
The air handlers are available with three gas manifold options.
• American National Standards Institute (ANSI) compliant manifold: (
See Page 75, Figure 33
2005.
See Page 75, Figure 32
for 2010 - 2030.
•Factory Mutual (FM)-compliant manifold:
See Page 75, Figure 32
(
Figure 34
for 2010 - 2030.
• XL compliant manifold: ( for 2005.
See Page 76, Figure 35
for 2005.
See Page 76,
See Page 75, Figure 32
for 2010 - 2030.

16.2 Gas Piping and Pressures

The air handler is equipped with a gas manifold suitable for connection to supply pressure of up to:
•14 in wc maximum (34.9 mbar) (2005 - 2030 with
•5 p.s.i. maximum (2005 - 2030 with FM or XL
ANSI-compliant manifold.)
compliant manifold).
When gas supply exceeds the above-listed maximum gas pressures, an additional high pressure gas regulator will be required to assure that the correct
for
gas pressure is supplied to the regulator. Pressure should be measured between the high pressure gas regulator and safety shut off valve. Minimum gas pressure as indicated on data plate must be measured with the burner operating in high fire.

Table 12: Gas Manifold Size

Model Gas NPT Connection
2005 2010 2010B 2020 2030
¾" 1" 1¼" 1½" 2"

16.3 Gas Manifold Venting

Vent valves fitted on XL compliant manifolds must be piped to the atmosphere outside the structure and in accordance with applicable codes. This is the responsibility of the installer.

16.3.1 Main Gas Regulator Venting

The main regulator used on 1¼" and larger manifolds must be piped to the atmosphere outside the structu
re. This is the responsibility of the installer.

16.3.2 Vent Line Installation

The following may be used as a guideline for installation, but all applicable codes and regulations must be followed.
•Natural gas and LPG are toxic and flammable substances. They must be released where they will not cause personal injury or property damage. The end of the vent line must be located where it is safe to release gas.
• Pipe the vent line outside the structure.
• Use as short a vertical run of pipe as possible.
• Do not run pipe from a high point to a lower point to avoid obstacles.
• Use a minimum number of bends.
• Do not downsize the pipe from the origination point (must be same size or larger).
•Make sure vent line is free from obstructions.
• Do not group lines together into a common header.
•The outside termination must have a weatherproof cap or be directed downward for protection from the elements and must be screened to prevent the entry of any objects.
74 o f 147
Page 85

FIGURE 32: ANSI/FM/XL-Compliant Manifolds (2005)

NOTE: Vent valves must be piped to the atmosphere outside the structure and in accordance with
applicable codes.
Alternate
Inlet
Inlet
By Others
Combination Valve
Manual Gas
High Gas Pressure Regulator (Optional)
Burner
Modulating Valve With Pressure Regulator
Manual Gas Valve (Burner)
Valve (Pilot)
Drip Leg
Off Valve
Safety Shut Off Valve
Safety Shut
Manual Gas Valve (Main)
Union
(By Others)
Alternate
Inlet
Inlet
Drip Leg
By Others
High Gas Pressure Regulator (Optional For ANSI-Compliant Manifolds and supplied for FM and XL-Compliant Manifolds)
Regulator With Dual Safety Shut Off Valve
Manual Gas Valve (Main)
Union
(By Others)
Manual Gas Valve (Pilot)
SECTION 16: GAS PIPING
Vent to Atmosphere (FM and XL Manifold)
Modulating Valve
Manual Gas Valve (Burner)
Burner
Combination Valve

FIGURE 33: ANSI-Compliant Manifold (2010 - 2030)

75 of 147
Page 86
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
NOTE: Vent valves must be piped to the atmosphere outside the structure and in accordance with
applicable codes.
Alternate
Inlet
Inlet
By Others
Manual Gas
High Gas Pressure Regulator (Optional)
Valve (Pilot)
Drip Leg
Ps
Modulating Valve With Pressure Regulator
Manual Gas 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
Valv e
Vent to Atmosphere
Vent to Atmosphere
Vent to Atmosphere
Vent to Atmosphere
Manual Gas Valve (Main)
Union
(By Others)
NOTE: Vent valves must be piped to the atmosphere outside the structure and in accordance with applicable codes.

FIGURE 34: FM-Compliant Manifold (2010 - 2030)

Alternate
Inlet
Inlet
Drip Leg
High Gas Pressure Regulator (Optional)
Manual Gas Valve (Main)
Union
(By Others)
Manual Gas
By Others
Valve (Pilot)
Safety Shut
Off Valve
Vent to Atmosphere
Pilot Regulator
Visual Indicator
Pilot Solenoid
Safety Shut
Off Valve
Vent to Atmosphere
Vent to Atmosphere
Modulating Valve With Pressure Regulator
Manual Gas Valve (Burner)
Ps
High Gas Pressure Switch
Burner

FIGURE 35: XL-Compliant Manifold (2010 - 2030)

76 of 147
Page 87
SECTION 16: GAS PIPING
Burner
Modulating Valve
Manual Gas Valve (Burner)
Plugged Taping To Measure Burner Pressure
Burner
Modulating Valve
Manual Gas Valve (Burner)
Plugged Taping

16.4 Gas Piping

The gas manifold extends through the side of the control cabinet for models 2005 - 2030. The factory piping terminates with a female pipe connection in the manual gas valve. The manual main gas shutoff valve is shipped loose for field installation. A union must also be installed (supplied by others) between the supplied manual gas valve main and the first tee pipe. Be sure that the fuel supply pipe connected at this point is large enough to ensure the proper gas flow and line pressure at the inlet of the air handler. The piping must comply with:
United States: Refer to NFPA 54/ANSI Z223.1 - latest revision, National Fuel Gas Code.
Canada: Refer to CSA B149.1 - latest revision, Natural Gas and Propane Installation Code.
Gas supply piping must conform to best building practices and local codes. During installation of the gas piping, be sure that no piping restricts accessibility to the air handler or its removable access doors.
Figure 79.

FIGURE 36: Plug Tapping (2005)

FIGURE 37: Plug Tapping (2010 - 2030)

Lockable manual shut-off val installer in compliance with Occupational Safety and Health Administration (OSHA) regulations.

16.5 Pressure Test Ports

There are 1/8" (3.2 mm) and 1/4" (6.4 mm) pressure test ports located on the manifold. The test ports are available to measure the manifold inlet gas pressure and the burner gas pressure during burner setup.

16.5.1 Manifold Inlet Gas Pressure

The pressure port for measuring manifold inlet pressure is located on the inlet side of the first safety shutoff valve. Refer to the unit rating plate for the acceptable inlet gas pressure.

16.5.2 Burner Gas Pressure

A pressure tap is used to measure negative airflow at the burner and to set high fire gas pressure. On air handlers equipped with a M611 modulating valve (Model 2005), the pressure tap is located on a tee between the M611 valve and the burner. See Page 77, Figure 36 and Page 123, Figure 81. On air handlers equipped with the MR212 modulating valve (Models 2010 - 2030), the pressure tap could be located on the downstream side of the MR212 valve, on a T-fitting coming off the outlet pressure tap on the MR212 valve or between the MR212 valve and the burner. See Page 77, Figure 37 and Page 122,
ve must be added by the

16.6 Line Pressure Test - Leak Testing

The air handler and its individual shut-off valve must be disconnected from the gas supply piping systems during any pressure testing of that system at test pressures in excess of 14 in wc (34.9 mbar). The air handler must be isolated from the gas supply piping system by closing its individual manual gas valv
e that is located immediately upstream of the safety shut-off gas valve.
77 of 147
Page 88
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
DANGER
Electrical Shock Hazard
Disconnect electric before service.
More than one disconnect switch may be required to disconnect electric from equipment.
Equipment must be properly grounded.
Failure to follow these instructions can result in death or electrical shock.

SECTION 17: ELECTRICAL

Each air handler is equipped with a wiring diagram which will vary depending on the type of remote
panel supplied (See Page 80, Figure 38 through Page 86, Figure 44). Depending on the air handler
configuration and optional equipment ordered, an option sheet may also be included. This option sheet overwrites the wiring diagram between the electrical terminals indicated.
Air handlers can also be supplied as building management system (BMS)-ready. In this case, a remote panel is not supplied. See wiring diagrams on Page 87, Figure 45 through Page 89, Figure 47.
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 copper wire only.

17.1 Wiring and Electrical Connections

All electrical wiring and connections, including electrical grounding, must comply with:
United States: Refer to National Electrical Code NFPA 70 - latest revision. Wiring must conform to the most current National Electrical Code
®
, local
ordinances, and any special diagrams furnished.
Canada: Refer to Canadian Electrical Code, CSA C22.1 Part 1 - latest revision.
Check rating plate on air handler for supply voltage and current requirements.
If any of the original control wire supplied with the air handler must be replaced, replace it with type MTW 105°C, 600 V, 16 gauge wire or equivalent, except for
temperature control wiring, which must be a minimum of 20 AWG Type Beldon 5401FE CMR 75C shielded or equivalent.
For all other wires, replace with the equivalent size and type of wire that was originally provided with the air handler.

17.2 Remote Panel

The remote panel must be wired as shown on the electrical schematic. For wire gauge sizes, see Page 78, Table 13. All power supply and motor wiring must be minimu
m type THWN with a 167° F (75° C)
temperature rise.

17.2.1 Remote Panel Mounting Distance

If the interconnection wiring between the remote panel and the air handler control enclosure is ru n in a single conduit, the wire run can be as long as 100' (30 m). For longer wire runs, consult the factory. If the interconnection wiring between the remote panel and the air handler control enclosure is run in two conduits (separating the shielded cable and the 120 V power supply for the remote panel), the wire run can be as long as 200' (60 m). For longer wire runs, consult the factory. Care should be used to avoid running the interconnect wiring near large industrial loads or high voltage wire runs as that may further limit the length of the interconnect wire run.

Table 13: Control Voltage Wiring For All Control Systems

Volts Wire Gauge Max Wire
120 18 150' (45 m) 120 16 250' (75 m) 120 14 35 0' (106 m)
NOTE: Wiring for temperatu
re controls must be run in
shielded cable as indicated on the wiring diagram.

17.2.2 Low Voltage Control Wiring

Low voltage (24 V - AC/DC) control wiring in excess of 100' (30.5 m) in length should be in its own separate conduit run to prevent interference.

17.3 Motor Current Draw

®
,
For current requirements of the motor, refer to Page 79, Table 14. For specific current requirements, see rating plate located on the blower motor. Current draw may be adjusted downward by reducing blower rotations per minute (RPM) or by increasing external static pressure.

17.4 Control Current Draw

The maximum current draw for an air handler’s controls and accessories is 3A.

17.5 Safety Systems

Safety systems are required for proper performance
78 of 147
Page 89
SECTION 17: ELECTRICAL
of the air handler. The air handler shall not be permitted to operate with any safety system disabled. If a fault is found in any of the safety systems, then the system shall be repaired only by a contractor
heating equipment, using only components that are sold and supplied by Rapid Engineering LLC. Refer to Page 79, Table 15 for a brief description of each safety device, its location and its switching voltage.
qualified in the installation and service of gas fired
Table 14: Full Load Current Draw
Electrical Characteristics
230/1/60 12.0 16.0 23.0 31.0 39.0 - - - ­208/3/60 5.9 8.7 14.0 21.7 29.0 41.0 50.0 65.0 77.0 230/3/60 5.6 8.0 13.8 20.0 26.8 38.0 48.0 60.0 72.0 460/3/60 2.8 4.0 6.9 10.0 13.4 19.0 24.0 30.0 36.0 575/3/60 2.2 3.1 5.5 7.7 10.0 16.2 19.2 24.5 29.6
2(1.5) 3(2.2) 5(4.0) 7.5(5.5) 10(7.5) 15(11) 20(15) 25(18.5) 30(22.5)
Motor Size HP(kW)
Table 15: Safety Systems
Safety Controls Location Voltage
Manual Reset High-Temp Limit (All Models) Blower Discharge 120 Pres sure Switches (All Models) Air Handler Control Enclosure 120 Flame Control (2010/2010B/2020/2030) Air Handler Control Enclosure 120 Flame Control (2005) Air Handler Control Enclosure 24 Discharge Temperature Monitor (All Models) Blower Discharge 24 AM Resistor (AM/VAV Style) Air Handler Control Enclosure 24

17.5.1 Manual Reset High Temperature Limit Switch

If for any reason, the temperature of the air at the discharge of the blower reaches the limit set point of 160° F (71.1° C), the high temperature limit switch will open the circuit to the burner system and discontinue all burner functions. Events that could result in excessive discharge air temperatures include if the burner modulation amplifier is defective (i.e. temperature sensor goes open circuit) or if a surge in gas pressure reaches the burner. Restarting of the burner can only be accomplished after the limit has cooled dow
n and the reset button on the switch has been depressed. This switch is located on the blower housing inside the air handler.

17.5.2 Pressure Switches

The low airflow velocity pressure switch monitors the airflow (differential pressure) across the burner. When the airflow across the burner reaches the proper velocity (volume) for combustion, the switch closes. When the switch closes, it permits 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 allowable limit. This switch is factory set at 1.40 in wc (3.5 mbar). The pressure switch is a safety device, which cannot be field-adjusted or tampered with.

17.5.3 Gas Pressure Switches

Gas pressure switches are standard on certain models (FM compliant gas trains above 2,500 MBH and XL compliant gas trains) and are also available
The function of the gas pressure switches is to protect against insufficient, lack of gas pressure and excessive pressure in the system.
On the low gas pressure switch side, this switch opens its internal switch which shuts the burner down and prevents its operation due to insufficient gas pressure.
On the high gas pressure switch side, its internal switch will open, shutting down the burner due to excessive gas pressure passing through the gas train.
The settings of the gas pressure switches are field adjustable. The one monitoring the incoming gas pressure is the low gas pressure switch. The low gas pressu
re switch must be set to the minimum required
gas pressure as indicated on the data plate.
The high gas pressure switch must be set to 1 in w.c. (2.5 mbar) above high fire setting established during commissioning.
If either switch senses a pressure which is lower (low gas pressure switch) or higher (high gas pressure switch) than its set point, then the switch will open and lock out, shutting the burner down. The switch will have to be reset manually, once the condition has been corrected.

17.5.4 Flame Control

This device will check for both pilot flame and main flame within the burner. When a flame signal from the pilot flame is available, it will allow the main gas valve to open.
Models 2005 - 2010B operate with intermittent pilot
as an option on the others.
79 of 147
Page 90
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
Notes:
1. Wire Over 24vac To Be A Minimum Of 16 Awg Flexing Type Mtw, 105c, 600v Or Equivalent Colors 115vac: Phase-red, Neutral-white, Ground-green Colors 24vac: Blue
2. Control Wire To Be A Minimum Of 20 Awg Type Belden 5401fe Cmr 75c Shielded Or Equivalent
3. Power Supply And Motor Wires To Be Sized To Nfpa79, Latest Edition Colors All Voltages: Phase(s)-black, Ground-green
Terminals Located In Control Panel Only
Terminals Located In Control Panel And Connected To The Remote Panel
Terminals Located In Remote Panel Only
Wire(s) Located In Control Panel
Wire(s) Located In Remote Panel
Shielded Wire(s), One End Grounded
M1
CR2
C
No
Nc
Relay / Motor Starter Coil (Associated With M1 Contacts)
Normally Open Contact (Associated With M1 Coil)
Normally Closed Contact (Associated With CR2 Coil)
Air Flow Switch
Indicator Light On Remote Panel
M1
L
(pilot stays lit during burner operation). Models 2020
- 2030 operate with interrupted pilot (pilot turns off after flame is established). The flame sensor observes main flame only.
Model 2005 uses a flame rod to detect the flame (minimum flame current 1µA); Models 2010 - 2030 use an ultraviolet (UV) light scanner (5.0 Vdc flame signal).
If a pilot flame is not present, the electrical signal cannot be sent and the pilot burner gas valve will close. The relay is equipped with a 10-second trial for ignition. If ignition does not occur, the flame safeguard relay will lockout, and must be manually reset. 2005 will reset upon power restoration. (See the Trouble-Shooting Guide - Page 136, Section 22)

17.5.5 Discharge Temperature Sensor

This device senses the discharge temperature of the air at the blower. The discharge temperature sensor

FIGURE 38: Wiring Diagram Key

reports the discharge temperature to the temperature control amplifier which modulates the burner to the temperat
ure set on the remote panel selector. Should this system fail, the manual high temperature limit switch will turn the burner off. BMS-ready air handlers do not come equipped with this sensor and must be field-supplied.

17.5.6 Positive Low Fire Start

This feature forces the burner to start in low fire rather than high fire during the air handler’s start-up sequence of operations. The burner maintains its low fire setting for 10 seconds (as per timer setpoint) before it begins to modulate.
80 of 147
Page 91

FIGURE 39: Basic Remote Wiring Diagram (2005)

TEMPERATURE
1
1
40
MANUAL
RESET
FUSABLE DISCONNECT
HI TEMP
TAS-3
LIMIT
8
1
L1
7
3 AMP
BREAKER
L3
L2
TS114
TEMPERATURE MONITOR
SELECTOR
TD114
1 2
44
TCA-A1014
2
32
43
45
VALVE MRV
REGULATING
MODULATING
7
15
56
48 49
8
T3
24VAC
TEMP CONTROL AMPLIFIER
X1
16
20VA
X2
MTR
250VA
M1
X2
X1
H2H1 H3
H4
T1
4
MOTOR
2
FAN O N
L
M1
MOTOR STARTER
FAN ON
BLOWER
120vac
120VAC
2
M1 OL
M1-OL
9C
MV MV/PV PV GND 24V(GND) 24V SPARK SENSE
CR2
S8600B
SSOV
MV MV
PV
40VA
120VAC
24VAC
X2
X1
2
SAFETY SHUTOFF VALV E
PILOT VALVE
CONTROL
IGNITION
13
SP
FR
L
12
BURNER ON LIGHT
CR2
9C
9C
9
PRIMARY CONNECTION
T1 TRANSFORMER
H4 - COMMON
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
1, 2, 3A, 4, 7, 12
40, 41 (SHIELD)
10
41
TEMP. CONTROL AMPLIFIER
BURNER
OFF
ON
FAN
OFF
ON
18
19
11
14
12A
FLAME
ROD
SPARK
PLUG
9B9A
3A 3B 3C 3D
8A
LOW PRES.
SWITCH
HI PRES.
SWITCH
CNO
CNC
NC
3 PHASE ONLY
BURNER ON RELAY 24VAC
GROUND SHIELDED CABLE AT CONTROL PANEL
BREAKER
SECTION 17: ELECTRICAL
81 of 147
Page 92
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
1, 2, 3A, 4, 7, 12, 24, 25
40, 41 (SHIELD)
TEMPERATURE
1
MANUAL
RESET
HI TEMP
TAS-3
LIMIT
8
1
L1
7
FAN
AUTO
ON
3 AMPBREAKER
L3
L2
TS114
TEMPERATURE MONITOR
SELECTOR
TD114
1 2
44
TCA-A1014
2
43
45
VALVE MRV
REGULATING
MODULATING
7
15
56
48
49
8
T3
24VAC
TEMP CONTROL AMPLIFIER
X1
16
20VA
X2
MTR
250VA
M1
X2
X1
H2H1
H3
3A
H4
T1
4
MOTOR
2
FAN ON
L
M1
MOTOR STARTER
FAN O N
BLOWER
120vac
120VAC
2
M1 OL
M1-OL
9C
MV MV/PV PV GND 24V(GND) 24V SPARK SENSE
CR2
S8600B
SSOV
MV MV
PV
40VA
120VAC
24VAC
X2
X1
2
SAFETY SHUTOFF VALV E
PILOT VALVE
CONTROL
IGNITION
13
SP
FR
L
12
BURNER ON LIGHT
CR2
9C
10
OFF
WINTER
SUMMER
CYCLE STAT
WINTER
3332
TEMP. CONTROL AMPLIFIER
18
19
11
14
12A
FLAME
ROD
SPARK
PLUG
8A
LOW PRES.
SWITCH
HI PRES.
SWITCH
CNO
CNC
NC
9 9A 9B
3B 3C 3D
40 41
3 PHASE ONLY
BURNER ON RELAY 24VAC
L
TD1
TD1
BURNER LOCKOUT
24
TIME DELAY (30S)
CR2
50
LIGHT
L
2
25
FILTERS
CHECK
PRIMARY CONNECTION
T1 TRANSFORMER
H4 - COMMON
BREAKER
1 32
FUSABLE DISCONNECT
GROUND SHIELDED CABLE AT CONTROL PANEL

FIGURE 40: Standard Discharge Control Remote (SDC) Wiring Diagram (2005)

82 of 147
Page 93

FIGURE 41: Deluxe Temperature Control Remote (DTC) Wiring Diagram (2005)

SECTION 17: ELECTRICAL
L3
L2
L1
FUSABLE DISCONNECT
1
8
CHECK
FILTERS
2
CR2
BREAKER
CR1
HI TEMP
LIMIT
TAS-3
MANUAL
RESET
LOW PRES.
SWITCH
CNO
NC
25
L
HI PRES.
SWITCH
CNC
3 PHASE ONLY
H2H1
3 AMP
X1
FAN
31
AUTO
ON
OFF
33
7
8A
9A
9
9B
H3
120vac
H4
X2
SUMMER
WINTER
9C
BREAKER
T1 250VA
3A
IGNITION CONTROL
S8600B
MV MV/PV PV GND 24V(GND) 24V SPARK SENSE
M1 OL
TH8110
3B 3C 3D
M1
4
9C
18
19
11
X1
24VAC
X2
14
12A
12
BLOWER
MTR
MOTOR
T4
24VAC R
G
CR1
50
TD1
CR2
TIME DELAY (30S)
13
10
40VA
120VAC
SSOV
MV
20VA
C
M1
FAN O N
24
PV
CR2
L
L
SP
MV
M1-OL
L
TD1
FLAME
ROD
FR
SPARK
PLUG
2
2
THERMOSTAT TH8110R 1008/U
THERMOSTAT CONTROL RELAY 8
MOTOR STARTER
FAN O N
BURNER LOCKOUT LIGHT
PILOT VALVE
SAFETY SHUTOFF VALV E
BURNER ON RELAY 24VAC
BURNER ON LIGHT
TCA-A1044C
1
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
1, 2, 3A, 4, 7, 12, 24, 25
40, 41 (SHIELD)
44
TEMPERATURE
1
MONITOR
46
2453
TS144C
GROUND SHIELDED CABLE AT CONTROL PANEL
32
40
41
4 5
TEMPERATURE SELECTOR T244A
54
9C
67
48 49
MODULATING REGULATING VALVE MRV
120VAC
15
24VAC
X1
8
9
TEMP CONTROL AMPLIFIER
T3
2
20VA
X2
16
T1 TRANSFORMER
PRIMARY CONNECTION
H1 - 460 USE 1.6 AMP BREAKER H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER H4 - COMMON
83 of 147
Page 94
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
RM7890A
49
TD114
TEMPERATURE
SELECTOR
1
2
3
44
MONITOR
TEMPERATURE
TS114
1
45
40
2
4841
2
TCA-A1014
TEMP CONTROL
AMPLIFIER
13546
SCANNER
UV
14
13
87
16
VALVE MRV
REGULATING
MODULATING
BURNER ON
IGNITION TRANSFORMER
PILOT VALVE
VALV E
SAFETY SHUTOFF
CONTROL
IGNITION
X1
15
20VA
24VAC
X2
T3
9
2
F
G
12
10
6
8
3
SP
11
SSOV
BURNER ON
A
T2
PV
FUSABLE DISCONNECT
M1
1
L1
BURNER
ON
OFF
4
H1
FAN
OFF
ON
H3
H2
X1
X2
H4
T1 250VA
L3
L2
M1
FAN ON
MOTOR STARTER
FAN O N
A
3A
M1
M1-OL
2
MOTOR
BLOWER
OL
MTR
120 VAC
FUSES BY OTHERS
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
1, 2, 3A, 4, 7, 12, 40, 41 (SHIELD)
H4 - COMMON
PRIMARY CONNECTION
T1 TRANSFORMER
7
HI TEMP
LIMIT
HLS
MANUAL
RESET
88A9
LOW PRES.
SWITCH
0.3" W.C.
HI PRES.
SWITCH
1. 4 " W. C.
CNO CNC
NC
3B 3C 3D
7
9A 9B 9C
20
CLIP JR2
GROUND SHIELDED CABLE AT CONTROL PANEL
CONTROL
PRIMARY IGNITION
SCANNER
UV
G
RM7897C
14
9
8
5
F
13
10
2
7
11
10
6
2
12
FOR 2020 AND 2030
CLIP JR2
7
9C
20
3 PHASE ONLY
10
BREAKER
BREAKER
3 AMP
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 42: Basic Remote Wiring Diagram (2010 - 2030)

84 of 147
Page 95

FIGURE 43: Standard Discharge Control Remote (SDC) Wiring Diagram (2010 - 2030)

H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
SUMMER
WINTER
1
TD114
SELECTOR
TEMPERATURE
44
2
1
FUSABLE DISCONNECT
L1
1
WINTER
CYCLE STAT
R B
33
3 AMP
OFF
31
AUTO
ON
L3
L2
12
3
TS114
TEMPERATURE MONITOR
1 2
TCA-A1014
TEMP CONTROL
40
45
2 3
AMPLIFIER
41
4
48
5
REGULATING VALVE MRV
MODULATING
49
6
7158
CLIP JR2
SCANNER
UV
G
RM7890A
14
9
8
3
F
13
10
2
6
11
24VAC
X1
T3
16
20VA
X2
BURNER ON
SSOV
A
SP
T2
PV
CONTROL
SAFETY SHUTOFF
BURNER ON
VALV E
PILOT VALVE
TRANSFORMER
IGNITION
IGNITION
3A
250VA
M1
X1
X2
H1 H2
H3
H4
T1
4
M1 OL
MTR
MOTOR
FAN O N
A
M1
M1-OL
2
MOTOR STARTER
FAN ON
BLOWER
120vac
T1 TRANSFORMER
PRIMARY CONNECTION
H4 - COMMON
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
1, 2, 3A, 4, 7, 12, 24, 25
40, 41 (SHIELD)
7
HI TEMP
LIMIT
HLS
MANUAL
RESET
88A9A
LOW PRES.
SWITCH
0.3" W.C.
HI PRES.
SWITCH
1. 4" W. C.
CNO CNC
NC
25
CLOGGED FILTER
A
2
4
BURNER LOCKOUT
A
2
24
3B 3C 3D
9 9B 9C
20
7
CONTROL
PRIMARY IGNITION
SCANNER
UV
G
RM7897C
14
9
8
5
F
13
10
2
7
11
10
6
2
12
FOR 2020 AND 2030
CLIP JR2
7
9C
20
3
24
GROUND SHIELDED CABLE AT CONTROL PANEL
FUSES BY OTHERS
3 PHASE ONLY
10
BREAKER
BREAKER
SECTION 17: ELECTRICAL
85 of 147
Page 96
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
WINTER
TEMPERATURE
SELECTOR
41
TS144C
TEMPERATURE
MONITOR
1 2443
4
5
45 46
40
TCA-A1044C
21354
TEMP CONTROL
89
VALVE MRV
REGULATING
MODULATING
4948
AMPLIFIER
67
X1
X2
24VAC
20VA
T3
SCANNER
UV
G
CLIP JR2
14
13
9
F
12
SSOV
A
SAFETY SHUTOFF VALV E
BURNER ON
BURNER ON
3
6
2
10
SP
8
11
PILOT VALVE
T2
IGNITION TRANSFORMER
CONTROL
IGNITION
PV
PRIMARY CONNECTION
T1 TRANSFORMER
MOTOR
AUTO
32
CR1
SUMMER
M1
OFF
ON
3A
FUSABLE DISCONNECT
L1
1
31
X2
X1
H1
3 AMP
H3
H2
H4
FAN ON
M1
4
A
FAN O N
M1-OL
MOTOR STARTER
T1 250VA
H4 - COMMON
2
L3
L2
BLOWER
OLM1
MTR
120vac
FUSES BY OTHERS
T244A
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
1, 2, 3A, 4, 7, 12, 24, 25
40, 41 (SHIELD)
7
HI TEMP
LIMIT
HLS
MANUAL
RESET
88A9
LOW PRES.
SWITCH
0.3" W.C.
HI PRES.
SWITCH
1. 4" W. C.
CNO CNC
NC
25
CLOGGED FILTER
A
2
4
BURNER LOCKOUT
A
2
24
3B 3C 3D
24VAC
20VA
T4
TH8110
R
C
G
CR1
THERMOSTAT TH8110R 1008/U
THERMOSTAT CONTROL RELAY
15
16
RM7890A
CONTROL
PRIMARY IGNITION
G
RM7897C
9
8
5
F
10
2
7
11
10
6
2
12
FOR 2020 AND 2030
CLIP JR2
7
9C
20
3
24
20
7
9A 9B 9C
GROUND SHIELDED CABLE AT CONTROL PANEL
3 PHASE ONLY
10
33 34
35
BREAKER
BREAKER
SCANNER
UV
14
13

FIGURE 44: Deluxe Temperature Control Remote (DTC) Wiring Diagram (2010 - 2030)

86 of 147
Page 97

FIGURE 45: BMS-Ready Control MUA Style (2005)

MANUAL
RESET
FUSABLE DISCONNECT
HI TEMP
TAS -3
LIMIT
8
1
L1
7
L3
L2
15
T3
24VAC
X1
16
20VA
X2
MTR
350VA
M1
X2
X1
H2H1
H3
H4
T1
4
MOTOR
2
M1
MOTOR STARTER
BLOWER
120vac
120VAC
2
M1 OL
M1-OL
9C
MV MV/PV PV GND 24V(GND) 24V SPARK SENSE
CR2
S8600B
SSOV
MV MV
PV
40VA
120VAC
24VAC
X2
X1
2
SAFETY SHUTOFF VALVE
PILOT VALVE
CONTROL
IGNITION
13
SP
FR
13
9C
9C
9
WIRE CONNECTIONS
REMOTE TO MAIN PANEL
42, 43, 44, 45, 46, 47
40, 41 (SHIELD)
10
18
19
11
14
12A
FLAME
ROD
SPARK
PLUG
9B9A
3A 3B 3C 3D
8A
LOW PRES.
SWITCH
HI PRES.
SWITCH
CNO
CNC
NC
3 PHASE ONLY
BURNER ON RELAY 24VAC
WIRES GROUNDED AT CONTROL PANEL
PRIMARY CONNECTION
T1 TRANSFORMER
H4 - COMMON
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
3 AMP
BREAKER
BREAKER
49
40
48
41
2
SC11-B
TEMP CONTROL AMPLIFIER
1
354
6
VALVE MRV
REGULATING
MODULATING
4-20MA Input
Signal
R1
R2
COIL CONN BY OTHERS
COIL CONN BY OTHERS
RELAY R1 AND R2 VOLTAGE IS
OR 0-10VDC
Signal
SET DIP SWITCH
BEFORE CONNECTING POWER!
BURNER LOCKOUT CONTACT
CONN BY OTHERS
R3
ON OFF
1
2
3
O
O
O
THREE POSITION DIP
SWITCH ON SC11-B
4-20mA
ALL POSITIONS
ON
OFF
ALL POSITIONS
0-10 VDC
42 43
44 45
46 47
SPECIFIED BY CONTRACTOR CAN BE 120VAC, 24VAC, OR 24VDC
R1
R2
TD1
BURNER LOCKOUT
TIME DELAY (30S)
50
RELAY
TD1 CR2
R3
24
FAN
BURNER
SECTION 17: ELECTRICAL
87 of 147
Page 98
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
RM7890A
49
40
48
41
2
SC11-B
TEMP CONTROL AMPLIFIER
1
354
6
UV
CONTROL
IGNITION
PRIMARY
SCANNER
14
13
16
VALVE MRV
REGULATING
MODULATING
IGNITION TRANSFORMER
PILOT VALVE
VALV E
SAFETY SHUTOFF
CONTROL
IGNITION
X1
15
20VA
24VAC
X2
T3
12
10
SP
SSOV
T2
PV
M1
1
L1
BURNER
7
3A
H1
3 AMP
H3
H2
X1
X2
H4
T1 250VA
L3
L2
M1
MOTOR STARTER
3C
M1
M1-OL
2
MOTOR
BLOWER
OL
MTR
120vac
4-20MA Input
Signal
FAN
R2
R1
OR 0-10VDC
Signal
SET DIP SWITCH
BEFORE CONNECTING POWER!
4
ON OFF
1
2
3
O
O
O
THREE POSITION DIP
SWITCH ON SC11-B
4-20mA
ALL
POSITIONS
ON
OFF
ALL POSITIONS
0-10 VDC
R3
HI TEMP
LIMIT
HLS
MANUAL
RESET
88A9
LOW PRES.
SWITCH
0.3" W.C.
HI PRES.
SWITCH
1. 4" W. C.
CNO CNC
NC
9A 9B 9C
3B 3D
9
2
F
G
10
6
8
3720
4
BURNER LOCKOUT LIGHT (FLAME FAILURE)
120VAC
3 PHASE ONLY
24
CLIP JR2
11
R1
R2
COIL CONN BY OTHERS
COIL CONN BY OTHERS
RELAY R1 AND R2 VOLTAGE IS
BURNER LOCKOUT CONTACT
CONN BY OTHERS
R3
42
43
44
45
46
47
SPECIFIED BY CONTRACTOR CAN BE 120VAC, 24VAC, OR 24VDC
CONTROL
PRIMARY IGNITION
SCANNER
UV
G
RM7897C
9
8
5
F
10
2
7
11
10
6
2
12
FOR 2020 - 2030
CLIP JR2
7
9C
20
3
24
14
13
H4 - COMMON
PRIMARY CONNECTION
T1 TRANSFORMER
WIRE CONNECTIONS
DDC CONTROL TO CONTROL PANEL
1, 1A, 40, 41
42, 43, 44, 45
46, 47
1A
BREAKER
BREAKER
FUSABLE DISCONNECT
FUSES BY OTHERS

FIGURE 46: BMS-Ready Control MUA/FR Style Units (2010 - 2030)

88 of 147
Page 99
SECTION 17: ELECTRICAL
H2 - 230 USE 3.0 AMP BREAKER H3 - 208 USE 4.0 AMP BREAKER
H1 - 460 USE 1.6 AMP BREAKER
H4 - COMMON
PRIMARY CONNECTION
T1 TRANSFORMER
WIRE CONNECTIONS
DDC CONTROL TO CONTROL PANEL
1, 1A, 40, 41
CONTROL
PRIMARY IGNITION
SCANNER
UV
G
RM7897C
9
8
5
F
10
2
7
11
10
6
2
12
FOR 2020 - 2030
CLIP JR2
7
9C
20
RM7890A
49
40
48
41
2
S C11- B
TEMP CONTROL AMPLIFIER
1
354
6
UV
CONTROL
IGNITION
PRIMARY
SCANNER
14
13
16
VALVE MRV
REGULATING
MODULATING
IGNITION TRANSFORMER
PILOT VALVE
VALV E
SAFETY SHUTOFF
CONTROL
IGNITION
X1
15
20VA
24VAC
X2
T3
12
10
SP
SSOV
T2
PV
M1
1
L1
BURNER
7
3A
H1
3 AMP
H3
H2
X1
X2
H4
T1 250VA
L3
L2
M1
MOTOR STARTER
3C
M1
M1-OL
2
MOTOR
BLOWER
OL
MTR
120vac
4-20MA Input
Signal
FAN
R2
R1
R1
R2
COIL CONN BY OTHERS
COIL CONN BY OTHERS
RELAY R1 AND R2 VOLTAGE IS
OR 0-10VDC
Signal
SET DIP SWITCH
BEFORE CONNECTING POWER!
BURNER LOCKOUT CONTACT
CONN BY OTHERS
R3
4
ON OFF
1
2
3
O
O
O
THREE POSITION DIP
SWITCH ON SC11-B
4-20mA
ALL POSITIONS
ON
OFF
ALL POSITIONS
0-10 VDC
R3
HI TEMP
LIMIT
HLS
MANUAL
RESET
88A9
LOW PRES.
SWITCH
0.3" W.C.
HI PRES. SWITCH
1.4" W.C.
CNO CNC
NC
9A 9B 9C
3B 3D
42 43
44 45
46 47
9
2
F
G
10
6
8
3720
4
BURNER LOCKOUT LIGHT (FLAME FAILURE)
120VAC
3 PHASE ONLY
24
CLIP JR2
11
3
24
42, 43, 44, 45
SPECIFIED BY CONTRACTOR CAN BE 120VAC, 24VAC, OR 24VDC
14
13
COM
T2
T1
I+
60
DM
61
MODULATING DAMPER MOTOR M9184D1021
2
MODULATING DAMPER MOTOR ADJUSTING OUTSIDE/ RETURN AIR RATIO
WITH Q7230A INTERFACE
V+ OR
USE V+ WHEN 0-10VDC SIGNAL IS REQUIRED
USE I+ WHEN 4-20MA SIGNAL IS REQUIRED
"+" SIGNAL
"-" SIGNAL
46, 47, 60, 61
1A
BREAKER
BREAKER
FUSABLE DISCONNECT
FUSES BY OTHERS

FIGURE 47: BMS-Ready Control AM Style Units (2010 - 2010B)

89 of 147
Page 100
B-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL
PHOTOHELIC (1) LOCATED INSIDE CONTROL ENCLOSURE CONTROLS DIFFERENTIAL PRESSURE ACROSS BURNER
2
RELAY
R1
MOTOR
OL
VFD
AIR HANDLER
MOTOR
T1
T2
T3
S1
B
C
L1
L2
L3
A
OL
OL
TO FUSABLE
DISCONNECT
3D
50
52
51
50
52
53
50
53
52 50
VARIABLE AIR VOLUME CONTROLLED BY THE DDC
P/N VAV - DDC
PRESET AT 0.75 (LOW) AND 0.90 (HIGH)
OVERLOAD AND M1 AUXILIARY CONTACT IS REPLACED WITH RM1 RELAY.
RM1
RM1
2
4
3D
3A
VFD PROGRAM PARAMTERS 25HP OR LESS
S4
SC
S3
S5
SN
S3
UP TO 25HP
30HP AND UP
B
C
A
VFD TERMINALS
VFD PROGRAM PARAMTERS 30HP OR MORE
B1-02=1, C1-01=25, C1-02=25 D2-02=50, D4-01=1 E1-01=VOLTS, E2-01=AMP H1-03=10, H1-05=11
C1-01=20 ACCEL TIME (SEC) C1-02=20 DECEL TIME (SEC) d2-02=50% MINIMUM HZ (50%=30HZ) H1-03=10, H1-04=11, H1-05=0F H1-07=0F (V1000 ONLY) L2-01=1, L5-01=5
ACCEL
DECEL
ACCEL/DECEL
CONTACTS WIRED BY
OTHERS
1
2
4
(L1)
(L2)
HIGH
LOW
B
60
120V
61
W
R
62
2
MODU­LATING DAMPER MOTOR
NOTE: MOTOR STARTER,
L1
L2
T1
T2
20VA
MODULATING REGULATING VALVE
REDUCED FLOW SWITCH
49A
48
R4B
49
NC
C
29
2
R4B
1
Damper Switch
DM2
0
1.0
1.0
PHOTOHELIC
PROFILE PLATE PRESSURE
PROFILE PLATE
BEFORE
AFTER
PHOTOHELIC PNEUMATIC DIAGRAM
+
-
BURNER
Part Number Description Models
VAV VAV Control Wiring 2010 and 2010B

17.6 Additional Control Wiring

Depending on the style of the air handler (MUA, FR, AM or VAV), there may be additional control wiring that will be factory installed when the air handler is ordered. Any additional control wiring that is added to the air handler will be on the supplemental option sheet. On the MUA style, there are no additional controls unless an optional feature is added. The FR style air handler uses a fixed damper and also does not require additional control wiring unless an optional feature is added.
The VAV style air handler controls a floating damper and a variable frequency drive (VFD) and requires additional control wiring. For additional VAV style
wiring for models 2010 and 2010B, See Page 90, Figure 48 and Page 92, Figure 50. For additional VAV style wiring for models 2020 and 2030, See Page 91, Figure 49 and Page 93, Figure 51 through Page 95, Figure 53.
The AM style air handler controls a floating damper and requires additional control wiring. For additional AM style wiring for models 2010 and 2010B, See Page 96, Figure 54. For additional AM style wiring for models 2020 and 2030, See Page 96, Figure 55.

FIGURE 48: Additional Control Wiring for VAV Style (2010 and 2010B)

90 of 147
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use