Rapid 4044, 4049, 4036, 4054, 4060 Installation, Operation & Service Manual

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® 4000-Series

Direct-Fired Air Handler

Installation, Operation &

Service Manual

4024
4036
4040
4044
4049

4054
4060
4066
4073
4080
4089

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.

CANADA: 100% OUTSIDE AIR ONLY

© 2018 Rapid Engineering LLC

Rapid Engineering LLC

1100 Seven Mile Road NW
Comstock Park, MI 49321
Telephone: [phone]
Fax: [phone]

www.rapidengineering.com

P/N RP140000NA Rev A 03/18

TABLE OF CONTENTS

© 2018

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.

SECTION 1: Air Handler Safety..............................................1

1.1 Description of Operation...............................................1

1.2 Inspection and Setup ................................................... 1

1.3 Temporary Storage.......................................................2

1.4 Safety Labels and Their Placement .............................2

1.5 California Proposition 65 ..............................................2

1.6 Label Placement ..........................................................3

SECTION 2: Installer Responsibility .....................................6

2.1 Corrosive Chemicals....................................................6

2.2 National Standards and Applicable Codes ..................6

2.3 Required Equipment .................................................... 6

SECTION 3: Critical Considerations ..................................... 8

3.1 Required Clearances to Combustibles......................... 8

3.2 Hardware .....................................................................8

SECTION 4: National Standards and Applicable Codes .....9

4.1 Gas Codes...................................................................9

4.2 Installation Codes ........................................................9

4.3 Aircraft Hangars ...........................................................9

4.4 Parking Structures and Repair Garages...................... 9

4.5 Electrical ......................................................................9

4.6 Venting......................................................................... 9

4.7 High Altitude ................................................................9

SECTION 5: Specifications .................................................. 10

SECTION 6: Lifting an Air Handler (Rigging)......................27

6.1 Preparing to Lift the Air Handler.................................27

6.2 Lifting a Horizontal Air Handler ..................................28

6.3 Lifting an Vertical Air Handler ....................................29

6.4 Upright Assembly Alignment......................................31

SECTION 7: Air Handler Assembly...................................... 32

7. 1 Ca ulking the Air Handler............................................. 33

7. 2 Ca ulking a Horizontal Air Handler...............................34

7. 3 Ca ulking an Vertical Air Handler.................................35

7.4 Accessory Connections..............................................37

SECTION 8: Roof Curb .........................................................41

8.1 Roof Curb Assembly and Installation.........................41

SECTION 9: Indoor Suspension Mounting -

Horizontal Air Handler ....................................46

9.1 Suspension Mounting Assembly and Instructions ..... 46

SECTION 10: Leg Mounting .................................................48

SECTION 11: Filter Section ..................................................51

SECTION 12: Inlet Hoods .....................................................52

12.1 Inlet Hood Assembly ................................................ 52

SECTION 13: Service Platform.............................................55

13.1 Service Platform ......................................................55

SECTION 14: Discharge accessories..................................57

14.1 One-Way, Three-Way and Four-Way Discharge

Head Installation......................................................57

14.2 Splash Plate Installation........................................... 63

SECTION 15: Vibration Isolation..........................................64

SECTION 16: Cooling Specifications..................................68

16.1 Evaporative Cooling.................................................68

SECTION 17: Duct Considerations......................................69

17.1 Inlet Air Duct ............................................................. 69

17.2 Return Air Duct .........................................................69

17.3 Supply Air Duct Work ............................................... 69

SECTION 18: Gas Piping...................................................... 70

18.1 Gas Manifolds.......................................................... 70

18.2 Gas Piping and Pressures ....................................... 70

18.3 Gas Piping................................................................74

18.4 Pressure Test Ports...................................................74

SECTION 19: Electrical......................................................... 75

19.1 Disconnect Fuse Sizing .......................................... 76

19.2 Wiring and Electrical Connections........................... 76

19.3 Remote Panel .......................................................... 76

19.4 Motor Current Draw ................................................. 76

19.5 Control Cu rrent Draw ............................................... 77

19.6 Safety Systems........................................................ 77

19.7 Interlocks ................................................................. 79

19.8 Control Options........................................................ 79

19.9 Safety Systems........................................................ 81

19.10 Remote Panels ...................................................... 82

19.11 DDC-Ready Controls ............................................. 90

19.12 Intelligent Control Systems .................................... 92

19.13 HVAC Remote Panels and Panel Options ............. 94

19.14 Basic Air Handler Sequence of Operation............. 96

19.15 Honeywell

SECTION 20: Direct Fired Burner.......................................112

20.1 Direct Fired Burner Ignition.....................................115

20.2 Direct Fired Burner Flame Proving (Flame Rod) ....116

20.3 Honeywell UV Flame Detector ...............................119

20.4 Honeywell UV Flame Detector (Continued)........... 120

SECTION 21: Start-up Procedures .................................... 121

21.1 Installation of Recirculating Air Handler ................. 122

21.2 Mechanical ............................................................. 122

21.3 Electrical ................................................................ 123

21.4 Airflow .................................................................... 123

21.5 Gas Piping and Initial Pressure Settings................ 124

21.6 Safety Shut Off Valve Check .................................. 126

21.7 Temperature Control System Calibration................ 126

SECTION 22: Maintenance................................................. 129

22.1 General.................................................................. 130

22.2 Unit Exterior........................................................... 130

22.3 Blower Section...................................................... 130

22.4 Manifold and Controls............................................ 132

22.5 Burner................................................................... 132

22.6 Optional Equipment............................................... 134

SECTION 23: Replacement Parts ...................................... 135

SECTION 24: Troubleshooting .......................................... 136

24.1 Initial Checks ......................................................... 137

24.2 Motor and Blower ................................................. 137

24.3 Burner................................................................... 138

24.4 Temperature Controls ........................................... 139

24.5 A1014 Amplifier - Field Checklist .......................... 140

SECTION 25: RAPID
SECTION 26: RAPID

Evaporative Cooler ............................................................. 148

SECTION 27: The RAPID® 4000-Series Warranty............. 151

®

RM7890 Flame Safeguard................ 100

®

4000-Series Start-Up Procedures. 143

®

4000-Series Start-Up Procedures

Printed in
the U.S.A.

LIST OF TABLES

Table 1: Recommended Torque Settings................................. 8

Table 2: 4000 AM Dimensions ............................................... 11

Table 3: 4000 AM Approximate Shipping Weights ................. 12

Table 4: 4000 MUA Dimensions............................................. 13

Table 5: 4000 MUA Approximate Shipping Weights .............. 14

Table 6: 4000 FR Dimensions ................................................ 15

Table 7: 4000 FR Approximate Shipping Weights.................. 16

Table 8: 4000 VAV Dimensions.............................................. 17

Table 9: 4000 VAV Approximate Shipping Weights ............... 18

Table 10: Dimensions............................................................. 19

Table 11: Leaving Dry Bulb Temperature Drop (Average) ..... 19

Table 12: Air Density Ratio..................................................... 20

Table 13: Dimensions............................................................. 21

Table 14: Estimated Tons of Cooling ..................................... 21

Table 15: Dimensions............................................................. 22

Table 16: Energy Recovery.................................................... 23

Table 17: Fan Selection Chart................................................ 24

Table 18: Fan Selection Chart (continued)............................. 25

Table 19: Static Pressure Drops for Options.......................... 26

Table 20: Roof Curbs (availability based on style) ................. 41

Table 21: Formulas................................................................. 68

Table 22: Abbreviations.......................................................... 68

Table 23: Evaporation Rate.................................................... 68

Table 24: Suggested Air Changes Per Hour

(Air Change Method).............................................. 68

Table 25: Saturation Efficiency at Stated Media Depth.......... 68

Table 26: Static Pressure Drop (in wc) at Stated

Media Depth ........................................................... 68

Table 27: Manifold Component Identification ......................... 71

Table 28: Minimum and Maximum Fuse Size by Motor

Size and Supply Voltage ........................................ 76

Table 29: Control Voltage Wiring For All Control Systems..... 76

Table 30: Safety Systems....................................................... 77

Table 31: Safety Systems....................................................... 81

Table 32: Factory Preset Schedu

Table 33: Jumper Settings...................................................... 98

Table 34: Deflection Force B and BX Belts (in lbs) .............. 123

Table 35: Motor Sheave Drive Torque Specifications .......... 124

Table 36: Motor and Blower Bushing Torque Specifications 124

Table 37: Burner Mode by Amplifier Type............................ 125

Table 38: Maximum Temperature Rise ................................ 126

Table 39: Motor Lubrication Intervals ................................... 133

le on TH8110 Thermostat .. 96

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.

TABLE OF FIGURES

Figure 1: 4024 - 4049................................................................ 3

Figure 2: 4054 and 4089 ........................................................... 4

Figure 3: 4000-Series Interior ................................................... 5

Figure 4: 4000 AM Vertical Model Dimensions....................... 11

Figure 5: 4000 AM Horizontal Model Dimensions................... 12

Figure 6: 4000 MUA Vertical Model Dimensions..................... 13

Figure 7: 4000 MUA Horizontal Model Dimensions ................14

Figure 8: 4000 FR Vertical Model Dimensions........................ 15

Figure 9: 4000 FR Horizontal Model Dimensions ................... 16

Figure 10: 4000 VAV Vertical Model Dimensions.................... 17

Figure 11: 4000 VAV Horizontal Model Dimensions................ 18

Figure 12: Evaporative Cooling...............................................19

Figure 13: Mechanical Cooling................................................21

Figure 14: Energy Recovery ...................................................22

Figure 15: Lifting a Horizontal Air Handler Filter Section and

Options (Model 4024 - 4049) ................................. 28

Figure 16: Lifting a Horizontal Air Handler with Options (Model

4054 - 4089) ..........................................................28

Figure 17: Lifting an Vertical Air Handler (All Models)............. 29

Figure 18: Lifting an Vertical Air Handler with Filter Section and

Mixing Box .............................................................30

Figure 19: Inlet Alignment .......................................................31

Figure 20: Caulking Air Handler Joints.................................... 33

Figure 21: Caulking a Standard Horizontal Air Handler...........34

Figure 22: Caulking a Standard Vertical Air Handler............... 35

re 23: Assembling Optional Discharge / Supply and Return

Figu

Sleeves. .................................................................36

Figure 24: Electrically Connecting Joined Sections ................ 37

Figure 25: Installing Cooling Coil Section ...............................37

Figure 26: Installing Pressure Transmitter Tubing for AM and VAV

38
Figure 27: Typical Freeze Protection (Evaporative Cooling

Package #1)...........................................................38

Figure 28: Conductivity Control and Freeze Protection

(Evaporative Cooling Package #2).........................39

Figure 29: Protection and Auto-Flush (Evaporative Cooling

Package #3)...........................................................39

Figure 30: Evaporative Cooling Trap Detail ............................. 40

Figure 31: Roof Curb...............................................................42

Figure 32: Roof Curb Installation ............................................43

Figure 33: Roof Curb Assembly with Brackets........................44

Figure 34: Duct Support Adapter ............................................ 45

Figure 35: Indoor Suspension .................................................47

Figure 36: Assembling Legs for Horizontal Air Handlers......... 49

Figure 37: Assembly Legs and Rainskirt for Upright Air Handlers

50

ure 38: Filter Section Support Assembly............................51

Fig

Figure 39: Inlet Hood without Filters (4024-4049)................... 52

Figure 40: Inlet Hood without Filters (4054-4089)................... 53

Figure 41: Inlet Hood with Permanent Filters .......................... 53

Figure 42: Inlet Hood with Moisture Limiter.............................54

Figure 43: Service Platform for an Vertical Air Handler ..........55

Figure 44: Service Platform for a Horizontal Air Handler........ 56

Figure 45: Vertical Air Handler with Duct Sleeves and Discharge

Head .......................................................................................58

Figure 46: One-Way Discharge Head .................................... 59

Figure 47: Three-Way Discharge Head..................................60

Figure 48: Four-Way Discharge Head.................................... 61

Figure 49: 120° Discharge Head Horizontal Bottom Supply Air62

Figure 50: Discharge Plate ..................................................... 63

Figure 51: Suspended ............................................................ 64

Figure 52: Curb Mounted........................................................ 65

Figure 53: Platform Mounting on Vibration Isolators............... 66

Figure 54: Vibration Isolation Platform Locations ................... 67

Figure 55: Standard Gas Manifold .......................................... 71

Figure 56: FM Gas Manifold ................................................... 72

Figure 57: XL Insurance Gas Manifold ................................... 73

Figure 58: Basic Remote ........................................................ 82

Figure 59: Basic Remote (Continued)..................................... 83

Figure 60: Standard Discharge Remote.................................. 84

Figure 61: Standard Discharge Remote (Continued).............. 85

Figure 62: Deluxe Room Control Remote .............................. 86

Figure 63: Deluxe Room Control Remote (Continued)........... 87

Figure 64: Standard Room Control Remote ........................... 88

Figure 65: Standard Room Control Remote (Continued) ....... 89

Figure 66: DDC-Ready Controls............................................. 90

Figure 67: DDC-Ready Controls (Continued) ......................... 91

Figure 68: Air Handler Styles.................................................. 93

Figure 69: Fireye

®

M4RT1 ..................................................... 96

Figure 70: Jumper Locations .................................................. 98

Figure 71: Midco HMA-2A Burner..........................................113

Figure 72: Spark Rod Dimensions.........................................115

Figure 73: Maxon NPLE Burner.............................................116

Figure 74: Sheave Alignment ............................................... 122

Figure 75: Belt Tension ........................................................123

Figure 76: Fireye Flame Module........................................... 124

Figure 77: MR 212 Valve....................................................... 127

Figure 78: M611 Valve .......................................................... 128

Figure 79: Regulator (2005).................................................. 128

Figure 80: RM7897C Flame Control..................................... 142

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. Thin sheet metal parts have
sharp edges. To prevent injury, the use of w

ork

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 appliance 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 appliance by a
person responsible for their safety.

Children should be supervised to ensure that they do
not play with the appliance.

For additional copies of the Installation, Operation
and Service Manual, please contact Rapid
Engineering LLC.

Gas-fired appliances are not designed for use in
atmospheres containing flammable vapors or dust or
atmospheres containing chlorinated or halogenated
hydrocarbons. Recirculated room air may be
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.).

SECTION 1: AIR H ANDLER S AFETY

1.1 Description of Operation

This air handler is a direct-fired, electric, steam, hot
water and/or energy recovery heated fresh air
appliance. 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) variable
frequency drive is only approved for applications
15 °F (-9 °C) and above, unless a control enclosure
heater is installed. The air handler is factory-tested
and may be designed to operate using natural gas or
LPG (check the air handler's rating plate for
information on the appropriate gas). The heat will
modulate to maintain the selected supply air
temperature or room air temperature, depending on
the selected controls. See Page 92, Section .

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 may ship in multiple sections based
upon the configuration selected. The air handler was

inspected and operated prior to shipment.
Immediately u

pon receipt of the air handler, check
the fuel and electrical requirements 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 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 on another truck. Check the bill of lading
for information.

1 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

1.3 Temporary Storage

If the air handler must be temporarily stored (ie. job
site is not ready for installation of the air handler), the
following procedure should be performed. After
unloading unit from truck, place on a flat clean
surface in a protected area. The air handler should
be set on 4" x 4" (10 cm x 10 cm) pieces of timber to
elevate unit off the ground. Cover air handler with a
tarp or weatherproof material to ensure protection
from the environment. Manually rotate the fan wheel
every 15 days to eliminate grease from settling in the
fan bearings and creating flat spots on the shaft.

Air handlers built for indoor installation are not
weatherized.

Rapid Engineering LLC will not be held responsible
for any damage that may occur from outdoor storage.

1.4 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 5,
Figure 3.

1.5 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 5, 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 154

1.6 Label Placement

BDBD

OAOA

7

11

7

VERTICAL CONTROL SIDE

VERTICAL OPP. CONTROL SIDE

HORIZONTAL OPP. CONTROL SIDE HORIZONTAL CONTROL SIDE

3

ON SHRINK WRAP

1

1

2

4

4

4

4

5

6

6

2

5

IF USED.

2

5

2

5

Item Part Number Description

1 19305 Label Shock Hazard
2 19304 Label Severe Injury Hazard
3 19307 Label Crush Hazard
4 19308 Label Fire Hazard
5 19309 Label Falling Hazard
6 19306 Label Burn Hazard
7 91040039 Rapid Logo Label
8 91070015 Proposition 65 Label

FIGURE 1: 4024 - 4049

SECTION 1: AIR H ANDLER S AFETY

3 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

BD

BD

OA

LIFTING RINGS

OA

LIFTING RINGS

VERTICAL CONTROL SIDE

VERTICAL OPP. CONTROL SIDE

HORIZONTAL OPP. CONTROL SIDE

HORIZONTAL CONTROL SIDE

ACCESS DOOR

GAS CONNECTION

6 x 2 x 12GA

CHANNEL BASE FRAME

DISCONNECT

RC

Curb Channel

2 x 6

6 x 2 x 12GA

CHANNEL BASE FRAME

ON SHRINK WRAP

IF USED.

Curb Channel
2 x 6

Access Door
(18 x 30)

LA

Elec Conn.

Gas Conn.

RC

Disconnect

Disconnect

INLET

BR

BR

BD

EXH

BD

EXH

3

6

5

4

2

1

1

2

5

4

2

5

4

4

6

2

5

7

7

7

7

BURNER FAN

FAN

BURNER

BURNER

FAN

BURNER

FAN

Item Part Number Description

1 19305 Label Shock Hazard
2 19304 Label Severe Injury Hazard
3 19307 Label Crush Hazard
4 19308 Label Fire Hazard
5 19309 Label Falling Hazard
6 19306 Label Burn Hazard
7 91040039 Rapid Logo Label
8 91040015 Proposition 65 Label

FIGURE 2: 4054 and 4089

4 of 154

FIGURE 3: 4000-Series Interior

1

CONE PLATE

12

13

2

12

MOTOR & MOTOR COOLING DUCT

INSIDE

CONTROL ENCLOSURE

8

9

7

7

9

2

CONTROL ENCLOSURE DOOR

PROP 65 LABEL

RATING TAG

ELECTRICAL PRINT

RH INSIDE WALL
CONTROL ENCLOSURE

LH INSIDE WALL
CONTROL ENCLOSURE

11

10

3

4

5

6

2

Item Part Number Description Qty.

1 Label - Rotation 2
2 Label - High Voltage 2
3 Label - Caution Don’t Overtighten Belt 1
4 Label - Alignment Guide 1
5 Label - Rapid Factory Direct Parts Information 1
6 Label - Bearing Lube Chart 1
7 Label - Gas Type 3
8 Label - Outdoor Temp Sensor 1

9 Label - Min/Max Gas Pressures Required 1
10 Label - Regulator Model Number 1
11 Label - Regulator/Internal Relief Required 1
12 Label - Notice To Installer 1
13 Label - Caution Yellow Wire Not Diffused 1
14 91070015 Proposition 65 Label 1

SECTION 1: AIR H ANDLER S AFETY

5 of 154

4000-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 air handler in accordance with
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 air handler 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 air handler is placed in an approved
application.

6 of 154

• To provide building pressure relief/dampers fans
to prevent over pressurization of a building, if
needed.

2.1 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.

2.2 National Standards and Applicable Codes

All appliances 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 installations in public garages, aircraft hangars,
etc. may be applicable.

2.3 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 an industrial 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 drill bits and runners

• U-tube manometer or gas pressure gauge

• Volt meter

• Clamp style ammeter

• Belt tension gauge

• Thermometer

SECTION 2: INSTALLER R ESPONSIBILITY

7 of 154

4000-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

WARNING

• Locate the air handler so that the air intakes are
not too close to any exhaust fan outlets, gasoline
storage or other contaminants that could
potentially cause dangerous situations.

• Keep gasoline or other combustible materials
including flammable objects, liquids, dust or
vapors away from this air handler or any other
appliance.

• Maintain clearances from heat sensitive material,
equipment and workstations.

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, fan
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 responsibility to
assure that adjacent materials are protected from
degradation.

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.

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 all models are 6"(15.2
cm) on all surfaces. Read and follow the safety
guidelines below:

• Maintain clearances from vehicles parked below the

air handler. See Page 9, Section 4.4.

3.2 Hardware

Unless otherwise specified, all hardware must be
torqued to settings on Page 8, Table 1.

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

8 of 154

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.

SECTION 4: NATIONAL S TANDARDS AND A PPLICABLE C ODES

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.

4.2 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.

4.4 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 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.

4.6 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.

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).

9 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 5: SPECIFICATIONS

Dimension and estimated weight tables apply to both vertical and horizontal units of the same style.
All dimensions are in inches and all weights are in pounds, but are subject to change without notice.
Dimensions apply to both horizontal and vertical units. Filters and legs are shipped loose. Control enclosure
for 3" or smaller manifolds is 57"H x 57"W x 25"D. (B dimension of model 4024 cabinet is approximately 20"
smaller than the control enclosure. Model 4049 control enclosure is 57"H x 57"W x 20"D.) To minimize water
entrainment, an inlet hood with drift eliminator or inlet plenum is recommended. Outdoor duct sizes vary.
Control enclosure can be located on left or right side of unit. (Shown on right side in drawings.) Consult Rapid
Engineering LLC for additional information.
All industrial air handlers are built based on customer specific static pressure.
All ductwork and connections must be sized per SMACNA (Sheet Metal and Air Conditioning Contractors’
National Association).
The legend below details abbreviations used in this section and applies to Page 11, Figure 4 through Page
18, Figure 11.

Legend
OA = Outside Air
CE = Control Enclosure
BD = Bottom Discharge
LD = Left Discharge
RD = Right Discharge
UD = Up Discharge
BR = Bottom Return
RR = Right Return
LR = Left Return
ER = End Return
FJ = Field Joint *
AD1 = Access Door **
AD2 = Access Door ***

* Models 4054 - 4089

** Models 4080 - 4089

*** Models 4024 - 4073

10 of 154

FIGURE 4: 4000 AM Vertical Model Dimensions

F

B

Q

S

SECTION 5: SPECIFICATIONS

A

MK

K

J

BD RD/LD

ELECTRICAL
CONNECTION

BR

GAS
CONNECTION

BR

UD

FAN SECTIONBURNER SECTION

AD2

FJ

AD1

CE

RD

AD2

AD1

CE

BD/UD

FJ

BR

SERVICE

PLATFORM

(OPTIONAL)

FILTER

SECTION

R

(OPTIONAL)

P

L

LD

D

C

E

N

T

R

V

G

OR

V

H

R

(OPTIONAL)

FILTER MIX BOX

T

N

R

BR

P

RAIN SKIRT

OA

RIGHT SIDE VIEW

(STANDARD FOR

OUTDOOR EQUIPMENT)

LEGS

(OPTIONAL)

OA

AA

FRONT VIEW

Table 2: 4000 AM Dimensions

Air Handler

Width

Model

4024 40 40 109 - 4 - 62 62 62 4 5.5 20 29 18 27 32 22 34 4 2 3 10 30 40 60 48 36 40
4036 58 58 120 - 4 - 62 66 77 5 5.5 25 47 26 41 50 32 50 4 2 3 4 30 63 77 72 36 63
4040 63 63 130 - 4 - 81 68 77 6 6.5 33 50 30 41 55 40 53 4 2 3 4 30 63 77 84 36 63
4044 69 69 137 - 4 - 81 70 79 6 6.5 36 56 32 43 61 46 59 4 2 3 4 30 76 84 84 36 76
4049 76 76 140 - 4 - 81 72 80 6 6.5 39 63 34 44 68 53 66 4 2 3 4 30 76 84 84 36 76
4054 85 85 144 86 58 6 - 100 77 90 6 6.5 43 72 39 55 77 55 75 4 2 3 4 30 94 77 96 48 94
4060 94 94 154 90 64 6 - 100 77 85 6 6.5 48 81 38 50 86 65 84 4 2 3 4 30 94 77 96 48 94
4066 104 96 158 94 64 6 - 119 84 100 6 6.5 50 91 45 65 96 67 90 4 2 3 4 30 112 120 96 48 96
4073 112 96 163 94 69 - 3 119 84 107 6 6.5 50 99 44 72 104 64 90 4 2 3 4 30 112 120 96 48 96
4080 131 112 171 75 96 - 4 139 94 112 6 7.5 60 116 48 77 123 76 106 4 2 3 4 30 131 138 96 48 112
4089 131 112 177 81 96 - 4 139 94 112 6 7.5 60 116 48 77 123 76 106 4 2 3 4 30 131 138 96 48 112

Height

ABCDE F G HH1J K L M NN1PP1Q RR1STV X Y ZAABB

Length

Base Frame

Base Frame

Formed Channel

Filter Length

Plenum Width

Structural Angle

Filter Section Width

With Side Return

Filter Mixbox Length

Filter Mixbox Length

Discharge Width

Discharge Length

Return Air Length

Return Air Width

Return Air Height

Return Air Length

Discharge Height

Plenum Length

Inlet Hood Length

Minimum Leg Height

Plenum Height

11 o f 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

OA

B

F

BD

UD

LD/RD

Q

S

ELECTRICAL

CONNECTION

GAS CONNECTION

BR

CE

V

LR

N

RR

T

H & (H1)

G

V

Y

X

Z

A

OA

RD

BD/UD BR BR

A

M

K

K

J

L

D

E

C

N

T

R

CE

R

FJ

N1

R1

S

P1

RR/LR

P

LD

BR

FJ

AD1

AD2

AD1

AD2

PLAN VIEW

RIGHT SIDE VIEW

FAN SECTION

BURNER SECTION

COIL SECTION

(OPTIONAL)

EVAPORATIVE

COOLER

(OPTIONAL)

ENERGY

RECOVERY

SECTION

(OPTIONAL)

FILTER

SECTION

(OPTIONAL)

FILTER MIX BOX

(OPTIONAL)

OR

INLET PLENUM

(OPTIONAL)

INLET HOOD
(OPTIONAL)

OR

See Page 21, Figure 14 Energy recovery section for dimensions

See Page 19,Figure 12 Evaporative cooler section for dimensions

See Page 20, Figure 13 for coil section for dimensions

BB

R

R

P

FIGURE 5: 4000 AM Horizontal Model Dimensions

Table 3: 4000 AM Approximate Shipping Weights

Horizontal Service Platforms

Model

4024

4036

4040

4044

4049

4054

4060

4066

4073

4080

4089

Horizontal

Fan Section

Horizontal

Burner Section

Basic

Add

With

Outside Air

1,254 475 70 190 320 611 80 343 340 1,289
2,110 520 70 205 465 843 135 657 430 2,129
2,427 606 69 209 525 1,012 210 661 470 2,443
2,783 630 70 215 600 1,122 226 866 500 2,816

3,114 650 68 230 640 1,230 248 870 525 3,150
2,383 1,671 675 66 235 685 1,597 370 1,150 580 2,373 1,754
2,673 1,936 710 70 240 760 1,707 395 1,157 600 2,663 2,029
2,961 2,126 735 65 275 875 2,084 410 1,635 620 3,129 2,228
4,219 2,332 760 65 275 1,125 2,220 425 2,052 630 4,553 2,541
3,667 4,790 805 70 310 1,400 2,776 590 2,128 720 4,002 4,924
4,101 4,849 820 70 310 1,400 2,776 590 2,128 720 4,503 4,983

With

Filter Mix Box

Add

Filter Section

Filter Mixbox

Inlet Hood

Inlet Plenum

Vertical

Service Platform

Vertical

Fan Section

Vertical

Burner Section

12 of 154

FIGURE 6: 4000 MUA Vertical Model Dimensions

F

B

N

H

GAS

CONNECTION

R

G

K

M

A

K

J

L

D

C

E

ELECTRICAL

CONNECTION

OA

BD/UD

CE

OA

CE

UD

BD

RD

RD/LD

LD

P

FJ

AD1

AD2

FRONT VIEW

RIGHT SIDE VIEW

FAN SECTIONBURNER SECTION

FILTER

SECTION

(OPTIONAL)

LEGS

(OPTIONAL)

RAIN SKIRT

(STANDARD FOR

OUTDOOR EQUIPMENT)

FJ

AD2

AD1

SECTION 5: SPECIFICATIONS

Table 4: 4000 MUA Dimensions

Air Handler

Width

Model

4024 40 40 109 - 4 - 62 3 4 5.5 20 29 34 36 30 52 60 48 40
4036 58 58 120 - 4 - 62 3 5 5.5 25 47 50 36 30 63 77 72 63
4040 63 63 130 - 4 - 81 3 6 6.5 33 50 53 36 30 76 84 84 63
4044 69 69 137 - 4 - 81 3 6 6.5 36 56 59 36 30 76 84 84 76
4049 76 76 140 - 4 - 81 3 6 6.5 39 63 66 36 30 94 77 84 76
4054 85 85 144 86 58 6 - 100 3 6 6.5 43 72 75 48 30 94 77 96 94
4060 94 94 154 90 64 6 - 100 3 6 6.5 48 81 84 48 30 112 120 96 94
4066 104 96 158 94 64 6 - 119 3 6 6.5 50 91 90 48 30 112 120 96 96
4073 112 96 163 94 69 - 3 119 3 6 6.5 50 99 90 48 30 131 138 96 96
4080 131 112 162 75 87 - 4 139 3 6 7.5 60 116 106 48 30 131 138 96 112
4089 131 112 168 81 87 - 4 139 3 6 7.5 60 116 106 48 30 131 138 96 112

Height

ABCDE F G HJKLMNPRXYZBB

Length

Base Frame

Formed Channel

Base Frame

Structural Angle

Filter Section Width

Plenum Width

Discharge Width

Discharge Length

Discharge Height

Filter Section Length

Minimum Leg Length

Plenum Length

Plenum Height

Inlet Hood Length

13 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

C

D

E

A

M

K

K

J

L

FJ

G

R

Y

X

A

Z

GAS CONNECTION

F

B

N

H

ELECTRICAL
CONNECTION

BD/UD

UD

BD

RD

LD/RD

LD

CE

CE

OA

OA

FJ

AD1AD2

AD1AD2

FAN SECTION BURNER SECTION

COIL SECTION

(OPTIONAL)

EVAPORATIVE

COOLER

(OPTIONAL)

FILTER

SECTION

(OPTIONAL)

INLET PLENUM

(OPTIONAL)

INLET HOOD

(OPTIONAL)

OR

RIGHT SIDE VIEW

PLAN VIEW

ENERGY

RECOVERY

SECTION

(OPTIONAL)

BB

See Page 21, Figure 14 Energy recovery section for dimensions

See Page 19,Figure 12 Evaporative cooler section for dimensions

See Page 20, Figure 13 for coil section for dimensions

FIGURE 7: 4000 MUA Horizontal Model Dimensions

Table 5: 4000 MUA Approximate Shipping Weights

Model

Horizontal

4024

4036

4040

4044

4049

4054

4060

4066

4073

4080

4089

Fan Section

1,325 320 80 452 1,360

2,110 465 135 657 2,129
2,530 525 210 862 2,546
2,783 600 226 866 2,816
3,305 640 248 1,126 3,341

2,518 1,695 685 370 1,150 2,508 1,760
2,808 1,973 760 395 1,627 2,798 2,076
3,036 2,159 875 410 1,635 3,204 2,234
4,525 2,361 1,125 425 2,052 4,859 2,441
3,667 4,790 1,400 590 2,128 4,002 4,624

4,101 5,210 1,400 590 2,128 4,503 5,044

Horizontal

Burner Section

Filter Section

Inlet Hood

Inlet Plenum

Vertical

Fan Section

Vertical

Burner Section

14 of 154

FIGURE 8: 4000 FR Vertical Model Dimensions

B

F

Z

Q

ELECTRICAL

CONNECTION

GAS

CONNECTION

T

S x P

80%

BR

(Optional)

80%

ER

(Optional)

20%

OA

(Optional)

20%

OA

(Optional)

B

H

K

A

M

20%

OA

(Optional)

K

M

K

T

G

E

C

D

L

J

K

AD2

AD1

A

H

BD/UD

BD

LD

CE

UD

RD

RD/LD

CE

Y

FJ

FAN SECTION

BURNER SECTION

FILTER STAND

with BULK FILTER

MEDIA (OPTIONAL)

LEGS

(OPTIONAL)

FRONT VIEW

RIGHT SIDE VIEW

FJ

AD2

AD1

SECTION 5: SPECIFICATIONS

Discharge Length

Discharge Width

Return Ai r Width

Discharge Length

Discharge Height

Inlet Hoot /

Duct Height

Return Air Length

Louver Height

Inlet Hood Length

Minimum Leg Height

Table 6: 4000 FR Dimensions

Air Handler

Width

Model

4024 40 40 109 - 4 - 10 24 4 5.5 20 29 30 32 34 4 18 10 28 21 27 36 3
4036 58 58 120 - 4 - 12 36 5 5.5 25 47 30 50 50 4 26 4 34 30 35 36 3
4040 63 63 130 - 4 - 12 36 6 6.5 33 50 30 55 53 4 30 4 34 32.5 37 36 3
4044 69 69 137 - 4 - 16 36 6 6.5 36 56 30 61 59 4 32 4 45 35.5 39 36 3
4049 76 76 140 - 4 - 16 36 6 6.5 39 63 30 68 66 4 34 4 45 39 42 36 3
4054 85 85 144 86 58 6 - 16 36 6 6.5 43 72 30 77 75 4 39 4 45 43.5 46 48 3
4060 94 94 154 90 64 6 - 20 36 6 6.5 48 81 30 86 84 4 38 4 56 48 50 48 3
4066 104 96 158 94 64 6 - 20 48 6 6.5 50 91 30 96 90 4 45 4 56 49 51 48 3
4073 112 96 163 94 69 - 3 24 60 6 6.5 50 99 30 104 90 4 44 4 68 49 51 48 3
4080 131 112 171 75 96 - 4 24 60 6 7.5 60 116 30 123 106 4 48 4 68 57 57 48 3
4089 131 112 177 81 96 - 4 24 60 6 7.5 60 116 30 123 106 4 48 4 68 57 57 48 3

Height

ABCDE F G HJKLMNPQRSTUWXYZ

Length

Base Frame

Base Frame

Formed Channel

Structural Angle

Outside Air Length

Filter Stand Height

15 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 9: 4000 FR Horizontal Model Dimensions

C

D

J

L

E

S

LD

K

A

M

K

BD/UD

FJ

AD1AD2

BR

CE

R

R

RD

FAN SECTION

BURNER SECTION

UD

Z

Q

B

LD/RD

FJ

CE

AD1AD2

F

BD

ELECTRICAL

CONNECTION

80% (Optional)

BR

Table 7: 4000 FR Approximate Shipping Weights

T

P

W

ER

80%

(Optional)

GAS CONNECTION

X

INLET HOOD
(OPTIONAL)

RIGHT SIDE

VIEW

A

OA

OA

PLAN VIEW

A x U

Louver Duct Louver

A x W

Outdoor Air
Duct Sleeve

N

A x U

N

A x W

Filtered Inlet
Hood

X

FILTERS

Model

4024

4036

4040

4044

4049

4054

4060

4066

4073

4080

4089

Horizontal

Fan Section

1,245 320 80 1,230 95
2,055 465 135 2,054 140
2,354 525 210 2,360 150
2,716 600 226 2,704 160
3,034 640 248 3,017 175

2,383 1,470 685 370 2,373 1,553 320
2,673 1,712 760 395 2,663 1,805 350
2,961 1,847 875 410 3,129 1,949 400
4,219 1,994 1,125 425 4,553 2,203 450
3,667 4,359 1,400 590 4,002 4,493 500

4,101 4,418 1,400 590 4,503 4,552 500

Horizontal

Burner Section

16 of 154

Filter Section

Inlet Hood

Vertical

Fan Section

Vertical

Burner Section

Filter Stand

FIGURE 10: 4000 VAV Vertical Model Dimensions

F

B

SECTION 5: SPECIFICATIONS

A

J

K

M

K

BD

20% to 100% Air

ELECTRICAL

CONNECTION

CONNECTION

GAS

L

FAN SECTIONBURNER SECTION

AD2

FJ

AD1

CE

FILTER

SECTION

(OPTIONAL)

RAIN SKIRT

(STANDARD FOR

OA

OUTDOOR EQUIPMENT)

LEGS

(OPTIONAL)

AD2

AD1

CE

BD

D

FJ

C

E

N

G

OA

H

RIGHT SIDE VIEW

FRONT VIEW

Table 8: 4000 VAV Dimensions

Air Handler

Width

Model

ABCDE F G HJKLMNXYZBB

4024 4059109 - 4 - 1036 4 5.524293040604840
4036 5884120 - 4 - 1236 5 5.532473063777263
4040 6392130 - 4 - 1236 6 6.535503063778463
4044 69102137 - 4 - 1636 6 6.535563076848476
4049 76109140 - 4 - 1636 6 6.540633076848476
4054 85 124 144 86 58 6 - 16 48 6 6.5 40 72 30 94 77 96 94
4060 94 138 154 90 64 6 - 20 48 6 6.5 43 81 30 94 77 96 94
4066 104 140 158 94 64 6 - 20 48 6 6.5 43 91 30 112 120 96 96
4073 112 137 163 94 69 - 3 24 48 6 6.5 43 99 30 112 120 96 96
4080 131 156 171 75 96 - 4 24 48 6 7.5 43 116 30 131 138 96 112
4089 131 156 177 81 96 - 4 24 48 6 7.5 43 116 30 131 138 96 112

Height

Length

Base Frame

Base Frame

Structural Angle

Formed Channel

Filter Section Width

Minimum Leg Height

Discharge Width

Discharge Length

Plenum Width

Filter Section Length

Plenum Length

Plenum Height

Inlet Hood Length

17 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

C

K

A

M

K

J

L

FJ

G

N

X

Y

Z

GAS CONNECTION

F

B

20% to 100%AIR

ELECTRICAL CONNECTION

BD

CE

CE

BD

OA

OA

FJ

AD1AD2

AD1AD2

D

E

A

FAN SECTION

BURNER SECTION

COIL SECTION

(OPTIONAL)

EVAPORATIVE

COOLER

(OPTIONAL)

FILTER

SECTION

(OPTIONAL)

INLET PLENUM

(OPTIONAL)

INLET HOOD
(OPTIONAL)

OR

RIGHT SIDE VIEW

PLAN VIEW

ENERGY

RECOVERY

SECTION

(OPTIONAL)

BB

See Page 21, Figure 14 Energy recovery section for dimensions

See Page 19,Figure 12 Evaporative cooler section for dimensions

See Page 20, Figure 13 for coil section for dimensions

FIGURE 11: 4000 VAV Horizontal Model Dimensions

Table 9: 4000 VAV Approximate Shipping Weights

Model

4024

4036

4040

4044

4049

4054

4060

4066

4073

4080

4089

Horizontal

Fan Section

1,564 320 80 343 1,589

Horizontal

Burner Section

2,585 465 135 657 2,627
2,982 525 210 661 3,033
3,413 600 226 866 3,470
3,804 640 248 870 3,870

2,953 2,061 685 370 1,150 2,943 2,144
3,333 2,396 760 395 1,157 3,323 2,489

3,711 2,626 875 410 1,635 3,879 2,278
4,959 2,842 1,125 425 2,052 5,293 3,051
4,537 5,640 1,400 590 2,128 4,872 5,774
4,971 5,699 1,400 590 2,128 5,373 5,833

Filter Section

Inlet Hood

Inlet Plenum

Vertical

Fan Section

Vertical

Burner Section

18 of 154

FIGURE 12: Evaporative Cooling

LD

SECTION 5: SPECIFICATIONS

66”

BD/UD

AD2

FJ

AD1

CE

RD

FAN SECTION BURNER SECTION

UD

LD/RD

BD

AD2

ELECTRICAL

CONNECTION

FJ

CE

AD1

BR

COIL SECTION

(OPTIONAL)

GAS CONNECTION

A

EVAPORATIVE

COOLER

(OPTIONAL)

B

ENERGY

RECOVERY

SECTION

(OPTIONAL)

FILTER

SECTION

(OPTIONAL)

PLAN VIEW

INLET PLENUM

(OPTIONAL)

OR

INLET HOOD

RIGHT SIDE VIEW

(OPTIONAL)

Table 10: Dimensions

Applicable

Cabinet

Model

550 FPM

Max
CFM

Applicable

Cabinet

Model

750 FPM

Max

CFM

4024 ECM24 4,000 4024 ECM24D 5,800 40 40

4024-4036 ECM36 10,000 4036 ECM36D 13,700 58 58

4036 ECM40 12,000 4036-4040 ECM40D 16,600 63 63

4036 ECM44 14,500 4036-4040 ECM44D 19,600 69 69
4036-4040 ECM49 17,700 4036-4049 ECM49D 24,300 76 76
4036-4049 ECM54 23,000 4044-4054 ECM54D 31,200 85 85
4040-4049 ECM60 28,000 4049-4060 ECM60D 38,500 49 49
4044-4054 ECM66 31,600 4049-4066 ECM66D 43,100 104 96
4044-4054 ECM73 34,100 4054-4066 ECM73D 46,600 112 96

4054-4066 ECM80/ECM89 48,000 4066-4080

ECM80D/

ECM89D

65,300 131 112

Dimensions

AB

NOTE: Evaporative Cooling Section is 42".

Transition section is 24". Total length is 66". Applicable for MUA/AM/VAV styles only.

OA

OA

Table 11: Le av i ng Dry Bulb Temperature Drop (Average)

Wet Bulb

Depression (°F)

4" 6" 8"12"18" 24"

10.0 5.3 6.8 7.9 8.9 9.8 9.9

12.5 6.6 8.5 9.8 11.1 12.2 12.3

15.0 7.9 10.2 11.8 13.3 14.6 14.8

17.5 9.2 11.9 13.8 15.6 17.1 17.3

20.0 10.5 13.6 15.8 17.8 19.5 19.7

22.5 11.8 15.3 17.7 20.0 21.9 22.2

25.0 13.2 17.0 19.7 22.2 24.4 24.7

27.5 14.5 18.7 21.7 24.4 26.8 27.2

30.0 15.8 20.4 23.6 26.7 29.3 29.6

32.5 17.1 22.1 25.6 28.9 31.7 32.1

35.0 18.4 23.8 27.6 31.1 34.1 34.6

37.5 19.7 25.5 29.5 33.3 36.6 37.0

40.0 21.1 27.2 31.5 35.6 39.0 39.5

NOTE: Rapid Engineering LLC's standard media thickness equals 12".

Temperature Drop (°F)

for Stated Media Depth (in)

19 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Table 12: Air Density Ratio

Temperature

(°F)

68° 1.00 0.97 0.93 0.90 0.87 0.84 0.80 0.77 0.75 0.72 0.69
70° 1.00 0.96 0.93 0.90 0.86 0.83 0.80 0.77 0.74 0.71 0.69
72° 1.00 0.96 0.93 0.89 0.86 0.83 0.80 0.77 0.74 0.71 0.69
74° 0.99 0.96 0.92 0.89 0.86 0.83 0.80 0.77 0.74 0.71 0.68
76° 0.99 0.95 0.92 0.89 0.85 0.82 0.79 0.76 0.73 0.71 0.68
78° 0.99 0.95 0.92 0.88 0.85 0.82 0.79 0.76 0.73 0.70 0.68
80° 0.98 0.95 0.91 0.88 0.85 0.82 0.79 0.76 0.73 0.70 0.68

0/

29.92

1,000/

28.86

2,000/

26.82

Density Ratio for Stated Elevation (ft/in HG)

3,000/

26.82

4,000/

25.84

5,000/

24.90

6,000/

23.98

7, 0 0 0 /

23.09

8,000/

22.22

9,000/

21.39

NOTE: Table to be used when calculating total tonnage of cooling adjusted for elevation.

10,000/

20.58

20 of 154

FIGURE 13: Mechanical Cooling

OA

BD

UD

LD/RD

ELECTRICAL

CONNECTION

GAS CONNECTION

BR

CE

OA

RD

BD/UD

CE

FJ

LD

FJ

AD1AD2

AD1AD2

PLAN VIEW

RIGHT SIDE VIEW

FAN SECTION BURNER SECTION

COIL SECTION

(OPTIONAL)

EVAPORATIVE

COOLER

(OPTIONAL)

ENERGY

RECOVERY

SECTION

(OPTIONAL)

FILTER

SECTION

(OPTIONAL)

INLET PLENUM

(OPTIONAL)

INLET HOOD

(OPTIONAL)

OR

DD

CC

EE

SECTION 5: SPECIFICATIONS

Table 13: Dimensions

Compatible

Cabinet

Sizes

100% RA

Available Tons

0% OA/

Airflow - Cubic

Feet per Minute

(CFM)

3,000-7,000 24 8-35 1 13.8 33 x 60 218 509 68 40 72

7,001-10,000 24 18-50 1 18.0 36 x 72 389 556 80 44 72
10,001-20,000 36-40 25-100 2 38.3 27 x 102 261 523 110 65 72
20,001-27,500 36-44 50-138 2 52.5 35 x 108 381 524 116 80 78
27,501-30,000 40-49 69-150 2 61.2 39 x 113 449 490 121 90 78
30,001-35,000 49-60 75-175 2 70.0 41 x 123 428 500 131 96 84
35,001-50,000 60-73 88-250 2 93.8 45 x 150 373 533 154 105 84
50,001-60,000 66-80 125-300 3 106.5 36 x 142 469 563 150 126 102
60,001-65,000 73-89 150-325 3 117.0 36 x 156 513 556 164 126 102

Table 14: Estimated Tons of Cooling

Airflow - Cubic

Feet per Minute

(CFM)

5,000 16 19 22 24 27

7, 5 0 0 2 4 2 8 3 3 3 5 4 1
10,000 32 38 44 47 54
12,500 39 47 55 59 68
15,000 47 56 66 71 81
20,000 63 75 88 95 108
25,000 79 94 110 118 135
30,000 95 113 132 142 162
35,000 110 131 154 165 189
40,000 126 150 176 189 216
45,000 142 169 197 213 243
50,000 158 188 219 236 270
55,000 173 206 241 260 297
60,000 189 225 263 284 324
65,000 205 244 285 308 351

Range of

of Cooling

Quantity

of Coils

25% OA/

75% RA

Square

Feet

Fin Area (L x H)

of Each Coil (in)*

50% OA/

50% RA

Coil Face Velocity Width Height Length

Low HighCCDD EE

75% OA/

25% RA

Estimated tons of cooling required to achieve 55/54 leaving air condition

(chart based on OA conditions 94/74 and RA conditions of 80/67)

100% OA/

0% RA

21 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FJ

GAS CONNECTION

ELECTRICAL
CONNECTION

BD/UD

UD

BD

RD

LD/RD

LD

CE

CE

OA

OA

FJ

AD1AD2

AD1AD2

FAN SECTION BURNER SECTION

COIL SECTION

(OPTIONAL)

EVAPORATIVE

COOLER

(OPTIONAL)

FILTER

SECTION

(OPTIONAL)

INLET PLENUM

(OPTIONAL)

INLET HOOD

(OPTIONAL)

OR

RIGHT SIDE VIEW

PLAN VIEW

ENERGY

RECOVERY

SECTION

(OPTIONAL)

B

A

C

FIGURE 14: Energy Recovery

Table 15: Dimensions

Applicable Model

MUA AM A B C

4024 4024 4,000-7,000 109 58 69 1,000 150 400 150 250 225

4036 4036

4040

4044 4049 30,001-35,000 150 131 123 4,800 300 1,280 275 750 600
4049 4054 35,001-40,000 160 146 123 5,000 350 1,490 300 750 675
4054 4060 40,001-50,000 164 178 123 5,800 350 1,673 300 1,050 800
4060 4066 50,001-60,000 164 212 123 6,400 400 1,924 325 1,300 925

4040 20,001-25,000 137 94 123 2,700 300 800 250 550 475
4044 25,001-30,000 140 108 123 2,900 300 800 250 600 550

Airflow

Cubic Feet per

Minute (CFM)

Dimensions Estimated Weights

Length Width Height

Module

Inlet

Hood

Exhaust

Fan

Exhaust

Hood

Downturn

Section

7,001-15,000 120 85 94 1,900 200 550 200 450 425

15,001-20,000 130 94 96 2,000 200 800 225 450 425

Filter

Housing

22 of 154

Table 16: Energy Recovery

SECTION 5: SPECIFICATIONS

Compatible

Cabinet Size

MUA AM Supply Exhaust Supply Exhaust Supply Exhaust

4024 4024

4036 4036

4040 4040

4040 4044

4044 4049

4049 4054

4054 4060

4060 4066

Supply/Exhaust Air

Cubic Feet

per Minute (CFM)

4,000 0.42 0.45 59% 59% 329.19 / 851.18 367.34 / 889.82
5,000 0.63 0.67 60% 60% 411.49 / 1,064.04 459.17 / 1,112.20
6,000 0.88 0.94 59% 59% 493.79 / 1,276.74 551.01 / 1,334.75
7,000 1.17 1.25 59% 59% 576.09 / 1,489.31 642.84 / 1,557.43

7,001 0.29 0.30 63% 61% 240.04 / 632.20 267.85 / 658.93
8,000 0.37 0.39 63% 61% 274.33 / 722.60 306.12 / 752.99
9,000 0.45 0.48 63% 61% 308.62 / 812.94 344.38 / 847.09

10,000 0.55 0.59 63% 61% 342.91 / 903.25 382.64 / 941.23
11,000 0.66 0.70 63% 61% 377.20 / 993.53 420.91 / 1,035.40
12,000 0.77 0.82 63% 61% 411.49 / 1,083.78 459.17 / 1,129.59
13,000 0.89 0.95 63% 61% 445.78 / 1,174.00 497.44 / 1,223.81
14,000 1.03 1.09 63% 61% 480.08 / 1,264.21 535.70 / 1,318.05
15,000 1.17 1.24 63% 61% 514.37 / 1,354.39 573.97 / 1,412.31
15,001 0.70 0.74 62% 61% 403.43 / 1,021.84 450.17 / 1,065.94
16,000 0.79 0.84 62% 60% 430.32 / 1,089.88 480.18 / 1,137.09

17,000 0.88 0.94 62% 60% 457.22 / 1,157.91 510.19 / 1,208.25
18,000 0.98 1.05 62% 60% 484.11 / 1,225.92 540.20 / 1,279.42
19,000 1.08 1.16 62% 60% 511.01 / 1,293.92 570.22 / 1,350.60
20,000 1.19 1.27 61% 60% 537.90 / 1,361.91 600.23 / 1,421.78
20,001 0.72 0.77 62% 60% 457.22 / 1,130.29 510.19 / 1,179.84
21,000 0.79 0.85 61% 60% 480.08 / 1,186.72 535.70 / 1,238.92
22,000 0.87 0.92 61% 60% 502.94 / 1,243.14 561.21 / 1,297.99
23,000 0.94 1.00 61% 60% 525.80 / 1,299.55 586.72 / 1,356.99
24,000 1.02 1.09 61% 59% 548.66 / 1,355.95 612.23 / 1,415.99
25,000 1.10 1.17 61% 59% 571.52 / 1,412.35 637.74 / 1,474.99
25,001 0.83 0.89 61% 60% 489.87 / 1,218.80 546.64 / 1,272.52
26,000 0.90 0.96 61% 60% 509.47 / 1,267.47 568.50 / 1,323.44
27,000 0.96 1.03 61% 60% 529.06 / 1,316.14 590.37 / 1,374.35
28,000 1.03 1.10 61% 59% 548.66 / 1,364.80 612.23 / 1,425.25
29,000 1.10 1.17 61% 59% 568.25 / 1,413.45 634.10 / 1,476.15
30,000 1.17 1.25 61% 59% 587.85 / 1,462.10 655.96 / 1,527.05
30,000 0.87 0.92 61% 60% 493.79 / 1,243.14 551.01 / 1,297.99
31,001 0.92 0.98 61% 60% 510.25 / 1,284.50 569.38 / 1,341.26
32,000 0.98 1.04 61% 60% 526.71 / 1,325.87 587.74 / 1,384.53
33,000 1.03 1.10 61% 59% 543.17 / 1,367.23 606.11 / 1,427.79
34,000 1.09 1.17 61% 59% 559.63 / 1,408.59 624.48 / 1,471.06
35,000 1.15 1.23 61% 59% 576.09 / 1,449.94 642.84 / 1,514.32
35,001 0.93 0.99 61% 60% 514.37 / 1,289.10 573.97 / 1,346.07
36,000 0.98 1.04 61% 60% 529.06 / 1,325.87 590.37 / 1,384.53
37,000 1.03 1.10 61% 59% 543.76 / 1,362.63 606.77 / 1,422.98
38,000 1.08 1.15 61% 59% 558.46 / 1,399.40 623.16 / 1,461.44
39,000 1.13 1.21 61% 59% 573.15 / 1,436.16 639.56 / 1,499.90
40,000 1.19 1.27 61% 59% 587.85 / 1,472.92 655.96 / 1,538.36
40,001 0.79 0.84 61% 60% 477.09 / 1,184.03 532.38 / 1,236.11
42,000 0.87 0.92 61% 60% 500.95 / 1,243.14 558.99 / 1,297.99
44,000 0.94 1.01 61% 60% 524.80 / 1,302.23 585.61 / 1,359.80
46,000 1.02 1.09 61% 59% 548.66 / 1,361.32 612.23 / 1,421.61
48,000 1.11 1.18 61% 59% 572.51 / 1,420.40 638.85 / 1,483.42
50,000 1.20 1.28 61% 59% 596.37 / 1,479.48 665.47 / 1,545.23
50,001 0.83 0.89 61% 60% 489.87 / 1,218.80 546.64 / 1,272.52
52,000 0.90 0.96 61% 60% 509.47 / 1,267.47 568.50 / 1,323.44
54,000 0.96 1.03 61% 60% 529.06 / 1,316.14 590.37 / 1,374.35
56,000 1.03 1.10 61% 59% 548.66 / 1,364.80 612.23 / 1,425.25
58,000 1.10 1.17 61% 59% 568.25 / 1,413.45 634.10 / 1,476.15
60,000 1.17 1.25 61% 59% 587.85 / 1,462.10 655.96 / 1,527.05

Pressure Drop

(in wc)

Efficiency

Air Velocity Supply

(face/channel) (ft/min)

NOTE: Model sizes apply to MUA style cabinets. Consult factory when selecting energy recovery for AM

style cabinets. All weights are in pounds.

23 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Table 17: Fan Selection Chart

Required Motor Horse Power (HP)

@ Noted External Static Pressure

(in wc)

Minute (CFM)

Model

Discharge Velocity

Feet per

0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 0

Minute (FPM)

Feet per

Airflow Cubic

5,000 4024 1,241 2 2 2 3333CFCF1.11.41.61.92.22.52.8CFCF 65
6,000 4024 1,490 2 2 3 3355551.41.72.02.32.63.03.33.64.0 68
7,000 4024 1,738 2 3 3 3555551.82.12.52.83.13.53.94.24.6 71
8,000 4024 1,986 3 3 5 55557.57.52.22.63.03.33.74.14.54.95.3 74

9,000 4024 2,234 3 5 5 5 5 7.5 7.5 7.5 7.5 2.7 3.1 3.5 4.0 4.4 5.1 5.3 5.7 6.1 76
10,000 4024* 2,483 CF CF 5 5 7.5 7.5 7.5 7.5 10 3.2 3.7 4.2 4.6 5.1 5.6 6.1 6.6 7.0 78
10,000 4036 1,226 3 3 5 CF CF CF CF CF CF 2.1 2.6 3.2 CF CF CF CF CF CF 71
12,500 4036 1,532 5 5 5 5 7.5 7.5 7.5 CF CF 2.8 3.4 4.0 4.6 5.3 6.0 6.6 CF CF 73
15,000 4036 1,838 5 5 7.5 7.5 7.5 10 10 10 15 3.7 4.4 5.0 5.7 6.4 7.2 7.9 8.7 9.5 75
15,000 4040 1,309 5 5 7.5 7.5 7.5 10 10 CF CF 3.4 4.1 4.8 5.5 6.3 7.2 8.0 CF CF 74

17,500 4036 2,145 7.5 7.5 7.5 10 10 10 15 15 15 4.9 5.6 6.3 7.6 7.9 8.6 9.5 10.3 11.2 78

17,500 4040 1,527 5 7.5 7.5 7.5 10 10 10 15 15 4.2 5.0 5.8 6.6 7.5 8.3 9.2 10.2 11.1 76
20,000 4036 2,451 CF 10 10 10 15 15 15 15 15 6.3 7.1 7.9 8.7 10.1 10.4 11.3 12.2 13.1 80
20,000 4040 1,745 7.5 7.5 7.5 10 10 15 15 15 15 5.3 6.1 7.0 7.9 8.8 9.5 10.6 11.7 12.8 78
20,000 4044 1,429 5 7.5 7.5 10 10 15 15 15 15 4.7 5.6 6.5 7.5 8.5 9.5 10.6 11.7 12.8 77
22,500 4036* 2,757 CF CF 15 15 15 15 15 20 20 8.1 9.0 9.8 10.7 11.6 12.5 13.5 14.5 15.5 82
22,500 4040 1,964 7.5 10 10 15 15 15 15 15 20 6.6 7.5 8.4 9.4 10.3 11.4 12.4 13.4 14.5 80
22,500 4044 1,607 7.5 7.5 10 10 15 15 15 15 20 5.6 6.6 7.6 8.6 9.7 10.8 11.9 13.1 14.3 78
22,500 4049 1,319 7.5 7.5 10 10 15 15 15 20 20 5.1 6.1 7.2 8.3 9.5 10.7 12.0 14.7 16.2 71
25,000 4036**
25,000 4040 2,182 CF 10 15 15 15 15 20 20 20 10.3 11.2 12.1 13.1 14.0 15.0 16.0 17.7 18.1 86
25,000 4044 1,786 7.5 10 10 15 15 15 15 20 20 8.2 9.1 10.1 11.1 12.1 13.2 14.3 15.4 16.5 82
25,000 4049 1,465 7.5 10 10 15 15 15 15 20 20 6.7 7.8 8.8 9.9 11.0 12.2 13.4 14.7 15.9 80
27,500 4044 1,964 10 10 15 15 15 15 20 20 20 5.9 7.0 8.2 9.4 10.6 11.9 13.2 14.6 15.9 73
27,500 4049 1,612 7.5 10 10 15 15 15 20 20 20 10.0 11.0 12.1 13.1 14.2 15.4 16.5 17.7 18.9 83
30,000 4040* 2,618 15 15 20 20 20 20 25 25 25 8.1 9.1 10.3 11.4 12.6 13.9 15.1 16.4 17.7 81
30,000 4044 2,143 15 15 15 15 20 20 20 20 25 6.9 8.1 9.3 10.5 11.9 13.2 14.6 16.0 17.4 75
30,000 4049 1,758 10 10 15 15 15 20 20 20 25 12.6 13.7 14.8 15.5 16.6 17.8 19.1 20.3 21.6 86
30,000 4054 1,395 10 10 15 15 15 20 20 20 25 9.6 10.7 11.9 13.1 14.4 15.7 17.0 18.4 19.7 83
30,000 4060 1,111 7.5 10 15 15 15 20 20 25 25 8.0 9.2 10.5 11.9 13.2 14.6 16.1 17.6 19.1 77
32,500 4044 2,322 15 15 15 20 20 20 20 25 25 7.0 8.4 9.8 11.2 12.7 14.3 15.8 17.5 19.2 73
32,500 4049 1,905 10 15 15 15 20 20 20 25 25 11.4 12.6 13.8 15.1 16.4 17.8 19.2 20.6 22.1 84
32,500 4054 1,512 10 10 15 15 15 20 20 20 25 9.3 10.6 11.9 13.3 14.8 16.2 17.7 19.3 20.9 79
35,000 4044* 2,500 15 20 20 20 20 25 25 25 30 8.0 9.4 10.8 12.3 13.9 15.5 17.2 18.9 20.6 75
35,000 4049 2,051 15 15 15 20 20 20 25 25 25 13.4 14.6 16.0 17.3 18.7 20.1 21.6 23.1 24.6 86
35,000 4054 1,628 10 15 15 15 20 20 25 25 25 10.8 12.1 13.5 15.0 16.5 18.0 19.6 21.1 22.8 81
35,000 4060 1,296 10 15 15 20 20 20 25 25 30 9.0 10.5 12.0 13.6 15.2 16.9 18.6 20.4 22.2 77
37,500 4049* 2,198 15 15 20 20 20 25 25 25 30 8.0 9.6 12.9 14.8 16.7 18.7 20.7 22.9 25.0 73
37,500 4054 1,744 15 15 15 20 20 20 25 25 25 12.4 13.8 15.2 16.8 18.3 20.0 21.6 23.3 25.0 82
37,500 4060 1,388 10 15 15 15 20 20 25 25 25 10.2 11.7 13.3 15.0 16.6 18.4 20.2 22.0 23.9 78
40,000 4049* 2,344 20 20 20 25 25 25 30 30 30 8.9 10.6 12.3 14.1 15.9 17.8 19.8 21.8 23.9 75
40,000 4054 1,860 15 15 20 20 20 25 30 30 40 14.2 15.7 17.2 18.8 20.4 22.1 23.8 25.5 27.3 84
40,000 4060 1,481 15 15 15 20 20 25 25 25 30 11.4 13.1 14.7 16.4 18.2 20.0 25.4 27.5 29.5 80
40,000 4066 1,266 15 15 20 20 25 25 30 30 40 9.8 11.6 13.4 15.2 17.1 19.1 21.1 23.2 25.3 76
45,000 4049* 2,637 20 25 25 30 30 30 40 40 40 10.5 12.5 14.6 16.7 19.0 21.3 23.8 26.3 29.0 72
45,000 4054 2,093 20 20 20 25 25 30 30 30 40 18.5 20.1 21.8 23.5 25.2 27.0 28.8 30.7 32.6 87
45,000 4060 1,667 15 15 20 20 25 25 30 30 40 14.5 16.2 18.0 19.8 21.7 23.7 25.7 27.7 29.7 82
45,000 4066 1,424 15 15 20 20 25 25 30 30 30 12.0 13.9 15.8 17.8 19.8 21.9 24.1 26.4 28.6 79
50,000 4054* 2,326 20 25 25 30 30 30 40 40 40 10.6 12.6 14.7 16.9 19.1 21.4 23.8 26.2 26.7 74
50,000 4060 1,852 20 20 20 25 25 30 30 40 40 18.2 20.0 21.9 23.8 25.9 28.0 30.1 32.2 34.4 85
50,000 4066 1,582 15 20 20 25 25 30 30 40 40 14.6 16.6 18.7 20.8 23.0 25.2 27.4 29.8 32.3 81
50,000 4073 1,455 15 15 20 25 30 30 40 40 40 12.5 14.7 16.9 19.2 21.6 24.0 26.5 32.9 35.7 77

Brake Horse Power (HP)

@ Noted External Static Pressure

(in wc)

dBA Decibel @

Noted External

Static Pressure

(in wc)

24 of 154

Table 18: Fan Selection Chart (continued)

Required Motor Horse Power (HP)

@ Noted External Static Pressure

Minute (CFM)

Model

Discharge Velocity

Feet per

0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 0

Minute (FPM)

Feet per

Airflow Cubic

55,000 4060** 2,037 20 25 25 25 30 30 40 40 40 18.1 20.0 21.9 23.9 26.0 28.1 30.1 32.3 34.6 83
55,000 4066 1,741 20 20 20 25 25 30 30 40 40 15.0 17.1 19.2 21.2 23.5 25.7 28.1 30.4 32.8 80
55,000 4073 1,600 20 20 25 25 30 30 30 CF CF 16.1 18.4 20.8 23.2 25.6 28.2 30.8 CF CF 75
60,000 4060** 2,222 25 25 30 30 40 40 40 40 40 22.0 24.1 26.2 28.3 30.5 32.7 35.0 37.3 39.5 85
60,000 4066 1,899 20 25 25 25 30 30 40 40 40 18.1 20.2 22.4 24.7 27.0 29.4 31.8 34.3 36.9 81
60,000 4073 1,745 20 25 25 30 30 40 40 40 40 18.6 21.0 23.5 26.1 28.6 31.3 34.1 36.9 39.7 77
60,000 4080 1,241 20 20 25 25 30 CF CF CF CF 16.5 19.1 21.7 24.5 27.4 CF CF CF CF 72
65,000 4066 2,057 25 25 30 30 40 40 40 40 50 21.6 23.9 26.2 28.6 31.1 33.6 36.1 38.8 41.4 83
65,000 4073 1,891 25 25 30 30 40 40 40 50 50 21.3 23.8 26.5 29.2 31.9 34.7 37.6 40.5 43.5 79
65,000 4080 1,345 20 25 25 30 40 40 CF CF CF 18.5 21.3 24.0 27.0 30.2 33.0 CF CF CF 74
70,000 4066** 2,215 30 30 40 40 40 40 50 50 50 25.5 27.9 30.4 33.0 35.6 38.2 40.9 43.5 46.4 85
70,000 4073 2,036 25 30 30 40 40 40 50 50 50 24.5 27.1 29.8 32.7 35.6 38.5 41.5 44.5 47.6 81
70,000 4080 1,448 25 25 30 30 40 40 40 50 CF 20.7 23.6 26.6 29.5 32.7 35.9 39.1 42.4 CF 76
75,000 4066** 2,374 30 40 40 40 50 50 50 50 60 30.0 32.6 35.2 37.9 40.6 43.4 46.2 49.1 52.0 87
75,000 4073 2,182 30 40 40 40 40 50 50 50 60 27.9 30.7 33.6 36.4 39.5 42.6 45.7 48.9 52.1 83
75,000 4080 1,552 25 30 30 40 40 40 50 50 50 23.2 26.3 29.4 32.5 35.8 39.1 42.4 45.9 49.4 78
75,000 4089 1,552 25 25 30 40 40 CF CF CF CF 21.3 24.5 27.9 31.3 34.8 CF CF CF CF 73
80,000 4066** 2,532 40 40 50 50 50 50 60 60 60 35.1 37.8 40.6 43.4 46.3 49.2 52.1 55.1 58.2 88
80,000 4073 2,327 40 40 40 50 50 50 60 60 60 31.7 34.6 37.6 40.7 43.7 47.0 50.3 53.6 56.9 85
80,000 4080 1,655 30 30 40 40 40 50 50 50 60 26.0 29.0 33.9 35.5 38.9 42.3 45.8 49.4 52.9 79
80,000 4089 1,655 25 30 40 40 40 50 CF CF CF 23.5 26.9 30.3 33.9 37.6 41.3 CF CF CF 75
85,000 4073** 2,473 40 40 50 50 50 60 60 60 75 36.0 39.1 42.3 45.5 48.7 51.9 55.4 58.8 62.4 86
85,000 4080 1,759 30 40 40 40 50 50 50 60 60 29.0 32.2 35.5 38.9 42.4 46.0 49.6 53.2 57.1 81
85,000 4089 1,759 30 30 40 40 50 50 50 60 CF 25.8 29.4 33.0 36.6 40.4 44.3 48.3 52.3 CF 76
90,000 4073** 2,618 50 50 50 60 60 60 75 75 75 40.7 43.9 47.2 50.5 53.9 57.4 60.7 64.3 68.0 87
90,000 4080 1,862 40 40 40 50 50 50 60 60 75 32.4 35.7 39.2 42.6 46.3 50.0 53.8 57.6 61.5 82
90,000 4089 1,862 30 40 40 40 50 50 60 60 60 28.3 32.0 35.8 39.6 43.5 47.5 51.6 55.8 60.0 78
95,000 4073* 2,764 50 50 60 60 60 75 75 75 75 45.9 49.2 52.6 56.1 59.6 63.2 66.8 70.5 74.1 88
95,000 4080 1,966 40 40 50 50 60 60 60 75 75 35.9 39.4 43.0 46.6 50.3 54.2 58.1 62.1 66.1 84

95,000 4089 1,966 40 40 40 50 50 60 60 60 75 31.3 35.0 38.9 42.9 46.9 51.0 55.3 59.5 64.0 79
100,000 4073** 2,909 50 50 50 60 60 75 75 75 75 41.2 44.8 48.5 52.3 56.0 60.0 64.1 68.3 72.5 89
100,000 4080 2,069 40 50 50 60 60 60 75 75 75 39.8 43.5 47.2 51.0 54.9 58.7 62.8 66.9 71.1 85
100,000 4089 2,069 40 40 50 50 60 60 60 75 75 34.3 38.1 42.2 46.2 50.5 54.7 59.0 66.2 68.0 80

110,000 4080 2,279 50 60 60 60 75 75 75 100 100 46.2 50.4 54.4 59.4 64.0 68.7 73.6 78.5 83.5 88
110,000 4089 2,276 50 50 50 60 60 75 75 75 100 41.1 45.2 49.5 53.8 58.3 62.8 67.5 72.2 76.9 83

120,000 4080** 2,483 60 75 75 75 100 100 100 100 100 57.0 61.6 66.1 70.9 75.9 80.9 86.1

120,000 4089** 2,483 50 60 60 75 75 75 100 100 100 49.0 53.4 57.9 62.5 67.1 71.9 76.8 81.9 86.9 85
130,000 4089** 2,690 60 75 75 75 100 100 100 100 100 58.0 62.7 67.5 72.4 77.4 82.2 87.4 92.7 98.0 87

150,000 4089** 3,103 100 100 100 100 125 125 125 125 125 80.0 85.3 90.6 96.0

* MUA configuration only.
** AM requires high velocity return air damper.
¤ Class II wheels
CF= Consult Factory

IMPORTANT NOTES:

Sound levels are in dBA at 5' from the supply air opening. This figure does not account for attenuation,
additional noise or directivity factors. More horsepower required includes both the running horsepower and
the starting torque requirements. Horsepower can be greater than the standard fan curve charts. Brake
horsepower does not include drive losses. For external static pressure greater than 2", contact your local
representative or Rapid Engineering LLC. For operation in altitudes exceeding 2000' above sea level, contact
the factory. The recommended motor horsepowers shown for the Fan Selection Chart in the 0 in. wc external
static pressure column include fan and burner static pressures only (internal equipment static pressure).
Other cabinet options could add static pressure and should be included in the external static pressure used
to select motor horsepower. See the Static Pressure Drops in Table 20, Page 41 for the external static
pressu

res that should be added for selected options.

(in wc)

Brake Horse Power (HP)

@ Noted External Static Pressure

(in wc)

101.5107.1112 .8118 .5124.

SECTION 5: SPECIFICATIONS

dBA Decibel @
Noted External
Static Pressure

(in wc)

91.2

96.5 90

5

4

91

25 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Table 19: Static Pressure Drops for Options

Description in wc

Cooling Coil Section 0.10
Cooling Coil CF
Damper - Inlet 0.05
Damper - Low Leak 0.05
Damper - Discharge 0.10
Damper - Discharge, Low Leak 0.10
Supply Air End CF
Discharge Plate 0.05
Discharge Head - One Way 0.10
Discharge Head - Three Way 0.10
Discharge Head - Four Way 0.05
Horizontal Inlet Hood 0.00
Horizontal Inlet Plenum0.10
Vertical Inlet Plenum Base 0.05
Moisture Limiter For Horizontal Inlet Hood 0.10
Aluminum Mesh Filters For Horizontal Inlet Hood 0.15
Vertical Stand with Polyester Filters (FR) 0.25
Outside Air Filter Section, No Filters 0
Filtered Mixing Box, No Filters 0
Filters - Polyester 0.25
Filters - Aluminum Mesh 0.15
Filters - 30% Pleated 0.25
Custom Filter Options (Bag, Cartridge, HEPA) CF
Evaporative Cooling Section (ECM) 0.25
Evaporative Cooling Section (ECM-D) 0.50

Note:

Calculate the static pressure for selected cabinet options plus any ductwork. Use external static pressure
column found in Page 24, Table 17 through Page 25, Table 18 Fan Selection Charts to determine motor
horsepower.

26 of 154

SECTION 6: LIFTING AN AIR H ANDLER (RIGGING)

SECTION 6: LIFTING AN AIR HANDLER
(RIGGING)

WARNING

Crush Hazard

Use proper lifting equipment and practices.

Failure to follow these instructions can result
in death, injury or property damage.

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 appliance requires at least 4 CFM (6.8
outside air per 1,000 Btu/h (.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.

IMPORTANT: Four eye bolts are provided with each
upright air handler. These eye bolts are to be used
when lifting the air handler for placement on the

provided support legs. DO NOT Install the support
legs prior to lifting the air handler, damage to the legs
and /or air handler may occur.

3

m

/h) of

6.1 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 a skid or truck
bed.

2. Remove all packaging or blockers.

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

4. 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 eye bolts (lifting lugs) are
intact, undamaged and secured to the air
handler.

•Ensure factory-installed hardware is
torqued to appropriate setting.

5. Prepare the installation location to be ready to
accept the air handler (i.e. roof curb or legs).

6. Verify that the lifting equipment can handle the
air handler’s weight and the required reach.

See Page 12, Table 3, Page 14, Table 5, Page
16, Table 7, Page 18, Table 9 and Page 14,
Ta b l e 5 for air handlers weight.

27 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

LIFTING SLINGS

END VIEW

CL CR

CRANE OR HELICOPTER CABLE

FAN

SECTION

BURNER

SECTION

FILTER

SECTION

FILTER MIX BOX

OR

TRANS, EVAP &

FILTER SECTION

INLET

PLENUM

SPREADER BAR

END VIEW

CL CR

FILTER MIX BOX

OR

TRANS, EVAP &

FILTER SECTION

INLET

PLENUM

NOTE: FOR MODELS 4080-4089, ACCESS DOOR IS ON BURNER SECTION.

LIFTING SLINGS

FAN

SECTION

BURNER

SECTION

FILTER

SECTION

6.2 Lifting a Horizontal Air Handler
FIGURE 15: Lifting a Horizontal Air Handler Filter Section and Options (Model 4024 - 4049)

FIGURE 16: Lifting a Horizontal Air Handler with Options (Model 4054 - 4089)

28 of 154

6.3 Lifting an Vertical Air Handler

BA

C

BA

C

BA

C

WOODEN BLOCKS

BASE FRAME

BASE FRAME

NOTE: SHEET METAL CHANNEL
OR ANGLE IRON FRAME MUST BE
ALIGNED ON ALL SECTIONS

INLET

Shipping Position:

1. Attach crane sling hooks to eye bolts A &
B (4 places.)

2. Lift off truck.

3. Place on a clean flat dry surface free from
water, mud, etc.

Turning Position:

4. Remove eye bolts B. (2 places)

5. Attached eye bolts from B to corner C (2
places.)

6. Attach crane sling hook to A eye bolts A
(2 places.)

7. S lo wly raise and rotate 90 degrees.

Vertical Position:

8. Place air handler section on 4" (10.2 cm)
wooden blocks.

9. Attach crane sling hooks to eye bolts A &
C (4 places).

10. Air handler/section is now ready to be
lifted into place.

NOTE: On fan sections lifting lugs are welded on supply air end.

FIGURE 17: Lifting an Vertical Air Handler (All Models)

SECTION 6: LIFTING AN AIR H ANDLER (RIGGING)

29 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

LIFTING LUGS

B

U

RNER

REMOVE LIFTING
EYE BOLTS AFTER
SETTING SECTION

F

IL

T

ER SE

CT.

SE

CT

IO

N

MIX BOX

S

EC

TION

F

A

N

&

FILTE

R

S

ECT.

S

ECTIO

N

MIX B

O

X

SECTIO

N

B

U

RNE

R

SEC

TION

F

A

N

LEGS (4 required)

REMOVE LIFTING
EYE BOLTS AFTER
SETTING SECTION

SHEETMETAL CHANNEL
OR ANGLE IRON FRAME

MUST BE ALIGNED ON

ALL SECTIONS

Model 4024 - 4049 Model 4054- 4089

LIFTING LUGS

SHEETMETAL CHANNEL
OR ANGLE IRON FRAME

MUST BE ALIGNED ON

ALL SECTIONS

REMOVE LIFTING
EYE BOLTS AFTER
SETTING SECTION

LEGS (4 required)

NOTE: Sections may
vary as shown

SEE FIGURE 19,
PAGE 30

SEE FIGURE 19,
PAGE 30

SEE FIGURE 19,
PAGE 30

FIGURE 18: Lifting an Vertical Air Handler with Filter Section and Mixing Box

30 of 154

6.4 Upright Assembly Alignment

ROPE

WALL

EXTERNAL

CAULKING

FIELD JOINT

SECTION VIEW-A

BURNER INLET/FAN DISCH. SECTION

FILTER MIXBOX DISCH./BURNER INLET

ALIGNMENT DETAIL.

(FOR UPRIGHTS MODELS 49-89 ONLY)

5/8 X 2 3/4

THREADED ROD

ALIGNMENT PIN

FAN SECTION INLET FRAME

OR BURNER INLET FRAME

WITH 7/8" CLEARANCE HOLE.

FMB DISCH./BURNER DISCH.

SECTION FRAME

5/8-11 FLANGE NUT TACK

WELDED (2) TO BURNER/FMB

DISCH. FRAME IN OPPOSITE

CORNER FROM ONE ANOTHER.

APPLY ROPE

CAULKING AROUND

PERIMETER OF FRAME.

DETAIL:

PLAN VIEW:

NOTE: THREADED ROD SHIPPED LOOSE. MOUNT IN OPPOSITE CORNERS WITH PROPER WELDED NUT.

FIGURE 19: Inlet Alignment

SECTION 6: LIFTING AN AIR H ANDLER (RIGGING)

31 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 7: AIR HANDLER ASSEMBLY

WARNING

Crush Hazard

Use proper lifting
equipment and
practices.

Failure to follow these instructions can result in death, injury or property damage.

For models 4024 - 4049, the burner and fan sections of the air handler are shipped as one piece. Filter
section and/or filter mix box can be mounted to air handler when requested.

For models 4054 - 4089, the burner and fan sections of the air handler are shipped as two pieces that
require field-assembly. To assemble, use the supplied hardware and bolt the fan section to the burner section
through pre-drilled holes. Supplied hardware must be torqued to recommended specifications on Table 1,
Page 8.

Caulk (provided by others) the sides, roof and bottom seams between the fan section and burner section.
See Page 33, Figure 7.1 through Page 35, Figure 22.

NOTE: After the equipment sections are set together (if shipped separately), connection of the electrical
conductors between the sections is required. The conductors are numbered on both ends. Join the
conductors like numbers. The quantity of conductors supplied varies with the selected options. In addition,
motor-supply conductors must be connected to the fan motor of model sizes 4054-4073. See Page 37,
Section 7.4.

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.

32 of 154

7.1 Caulking the Air Handler

3" (78.7 cm) ROOF TAPE PROVIDED BY MANUFACTURER

(NOT REQUIRED ON VERTICAL AIR
HANDLER OR INDOOR UNITS)

HOUSING SKIN

HOUSING SKIN

CAULK AFTER ASSEMBLY

HOUSING SKIN

3/8" x 3/4" STRIP

CLEAN HOUSING SKIN

3" (78.7 cm) ROOF TAPE

TYPICAL VERTICAL JOINT

PRIOR TO ASSEMBLY.

CAULK EACH VERTICAL JOINT

TYPICAL ROOF JOINT

CAULK EACH HORIZONTAL JOINT

AFTER ASSEMBLY APPLY

TYPICAL ROOF JOINT

PRIOR TO ASSEMBLY.

OF CAULKING

THE 3" (78.7 cm) ROOF TAPE

"A" Type Joint

"B" Type Joint

(CAULK PROVIDED BY OTHERS)

3/8" x 3/4" STRIP OF CAULKING
(PROVIDED BY MANUFACTURER)

TYPICAL VERTICAL JOINT

AFTER ASSEMBLY.

CAULK EACH VERTICAL EXTERIOR JOINT

NOTE: FAILURE TO PROPERLY CAULK THE AIR HANDLER JOINTS WILL ALLOW WATER TO ENTER THE AIR HANDLER.

Instructions for Roof Tape Installation:

1. Wipe surface clean and dry.

2. Peel backing off 3" (78.7cm) roof tape.

3. Apply roof tape over field joint.

4. Press tape firmly to form a tight seal (roll out if possible).

5. 3" (78.7 cm) roof tape NOT required on vertical air handlers.

6. Do not apply roof tape when outside temperature is below 40° F.

7. Roof tape is not required for indoor air handlers.

FIGURE 20: Caulking Air Handler Joints

SECTION 7: AIR H ANDLER A SSEMBLY

33 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

A

P

L

E

N

U

M

INL

ET

A

IN

LET

B

B

U

R

N

E

R

FA

N

S

E

C

T

IO

N

S

EC

T

IO

N

B

HORIZONTAL AIR HANDLER

WITH INLET PLENUM

HORIZONTAL AIR HANDLER
WITH INLET PLENUM AND
OUTSIDE AIR FILTER

HORIZONTAL AIR HANDLER
WITH INLET PLENUM AND
FILTER MIX BOX

APPLY 3" (78.7 cm) ROOF TAPE TO ALL
ROOF JOINTS. COMPONENTS MAY
VARY AS SHOWN BELOW.

A

SEC

T

I

O

N

SE

C

TION

FAN

B

URNE

R

SECTIO

N

F

ILTE

R

B

P

L

E

N

U

M

IN

L

E

T

M

IX

B

OX

SECTIO

N

B

A

B

B

A

IN

L

ET

P

LE

N

U

M

A

IN

LE

T

F

ILT

E

R

S

ECT

ION

BUR

N

E

R

F

A

N

SE

C

T

IO

N

S

E

C

TIO

N

B

B

B

“A” Type Joint (typical both sides):

Seal with a HEAVY bead of calking.
(provided by others)

“B” Type Joint:

Cover with 3" (78.7 cm) Roof Tape.
(provided by manufacturer)

NOTE:

Failure to properly caulk the air
handler joints will allow water to
enter the air handler.

Caulk supply air/return sleeves
as appropriate.

“A” Type Joint : Vertical joint on
multiple-piece air handlers and inlet
hoods. Run a HEAVY bead of caulking (provided by others).

“B” Type Joint : Roof joints on multiple-piece
air handlers and inlet hoods. Cover with
3" (78.7 cm) roof tape (provided by manufacturer).

IN

LE

T

7.2 Caulking a Horizontal Air Handler
FIGURE 21: Caulking a Standard Horizontal Air Handler

Note: Sections may vary as shown.

34 of 154

7.3 Caulking an Vertical Air Handler

SHEETMETAL CHANNEL OR ANGLE IRON FRAME
MUST BE ALIGNED ON ALL SECTIONS.

RAIN SKIRT ON
OUTDOOR AIR HANDLER

"A

Ó

"AÓ

"AÓ

"AÓ

LEGS

"A"

LIFTING LUGS

"A"

"A"

FIELD ATTACHMENT

"A"

"A"

RAIN SKIRT ON
OUTDOOR AIR HANDLER

FIELD ATTACHMENT

SHEETMETAL CHANNEL OR

ANGLE IRON FRAME MUST BE

ALIGNED ON ALL SECTIONS.

LIFTING LUGS

LEGS

"A" TYPE JOINT:
SEAL WITH HEAVY
BEAD OF CALUKING
(PROVIDED BY OTHERS)

FIGURE 22: Caulking a Standard Vertical Air Handler

SECTION 7: AIR H ANDLER A SSEMBLY

NOTE: Sections may vary as shown.

35 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

--

TYPICAL ASSEMBLY

3'-4"

3'-4"

TYPICAL ASSEMBLY

NOTE:DISCHARGE AND RETURN AIR SLEEVE'S ARE A OPTION AND CAN BE PURCHASED
THRU RAPID, SEE CHART FOR ACTUAL OD OF DUCTS IF BEING BUILT AND INSTALLED BY
SERVICE CONTRACTOR.

A OD

X

B OD

SELF TAPPING SCREWS

EVERY 6-8" C.D.

AIR HANDLER

HOUSING

RETURN AIR

SLEEVE

CAULKING

FLANGE

NOTE: TEK SCREW RETURN SLEEVE

TO INSIDE OF AIR HANDLER

RETURN AIR FLANGE.

RETURN AIR
DAMPER

SELF TAPPING SCREWS

EVERY 6-8" C.D.

AIR HANDLER

HOUSING

FLOOR DISCH. FLANGE

LENGTH (MODELS 24-66) = 3.75"

(73-89) = 2"

DISCHARGE SLEEVE

CAULKING

AIR HANDLER
RETURN AIR FLANGE

DISCHARGE
AIR

RETURN

AIR

SEE CHART BELOW

FOR OD DIMENSION OF

DISCHARGE DUCT BEFORE

MAKING WALL PENETRATION.

2" FLANGE ON BOTH ENDS OF
DISCHARGE DUCT

RETURN
AIR

DISCHARGE

AIR

DISCHARGE DUCT

RETURN DUCT

FIGURE 23: Assembling Optional Discharge / Supply and Return Sleeves.

36 of 154

7.4 Accessory Connections

Legend

OA Outside Air
BR Bottom Return
BD Bottom Discharge

LC Left Controls

DUAL PERFORATED

ADJUSTABLE PANEL

ACCESS PANELS:

REMOVE TO BOLT

SECTIONS TOGETHER

COOLING COIL

MANIFOLD

CONNECTIONS

COIL HOUSING ACCESS

¥ MODELS 4024-4049 = 4" FORMED 10 GA GALV CHANNELS
¥ MODELS 4054-4066 = 6" FORMED 10 GA GALV CHANNELS
¥ MODELS 4073 = 3

x 3 x

3/16" ANGLE IRON

¥ MODELS 4080-4089 = 4

x 3 x

1/4" ANGLE IRON

FIGURE 24: Electrically Connecting Joined Sections

SECTION 7: AIR H ANDLER A SSEMBLY

Inlet Hood

OA

LEFT SIDE VIEW

TYPICALLY 6 THHN CONDUCTORS

AND 1 SHIELDED CABLE

1/2" CONDUIT TYP.

CONTROL

CABINET WALL

NOTE:

DETAIL A

Filter

Mixbox

BR

Burner

Section Fan Section

LC

BD

NOTE: TYPICALLY 2
THHN CONDUCTORS
AND 1 SHIELDED
CABLE

DETAIL B

FIGURE 25: Installing Cooling Coil Section

37 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

MODUS

LOHI

PROTECT TUBING

OPENING FROM

THE WIND.

(Installed by others.)

OUTSIDE AIR DUCT

BUILDING WALL

OR ROOF

AIR HANDLER

SUPPLY AIR

NOTE: BUILDING PRESSURE

TRANSDUCER (INSIDE

CONTROL PANEL - TYPICAL)

FIELD INSTALLED
(Supplied by others)

MODUS

LO HI

RETURN AIR DUCT

AIR HANDLER

5/16" (Minimum)

PLASTIC TUBING

(Installed by others)

RETURN AIR

DAMPER BLADE

NOTE: ENSURE OPEN END OF TUBING

IS AWAY FROM ANY AIR FLOW. DO NOT

MOUNT TUBING NEAR SUPPLY AIR

AND RETURN AIR OPENINGS.

INDOOR INSTALLATION

OUTDOOR INSTALLATION

Factory furnished piping & devices.

Field furnished piping & devices.

HEADER

UNION

BLEED-OFF VALVE

WATER LEVEL

Notes

Legend

1)

2)

3)

4)

EVAPORATIVE COOLING MODULE

FLOAT VALVE & MAKE-UP CONN.

MANUAL SHUT-OFF VALVE

OVERFLOWR CONN.

DRAIN CONN.

VACUUM BREAKER

MANUAL DRAIN VALVE

PER CODE

FILL VALVE SOLENOID 1” NORMALLY CLOSED.

SUPPLY LINE DRAIN COLENOID 1” NORMALLY OPEN.

ROOF DRAIN

ROOF

ROOF CURB

RECIRCULATION PUMP

SUMP DRAIN 1 1/2”
BALL VALVE POWERED OPEN & CLOSED.

AIR GAP

All solenoids must be installed
in a line no smaller than the
solenoid orifice.

Pitch drain line minimum 1/8”
per foot towards outlet

Supply & supply line drain solenoids
must be installed in a non-freeze
location.

Makeup line must be installed
with no traps or sages above
the roof line.

WATER FLOW ADJUSTMENT VALVE

FIGURE 26: Installing Pressure Transmitter Tubing for AM and VAV

FIGURE 27: Typical Freeze Protection (Evaporative Cooling Package #1)

38 of 154

SECTION 7: AIR H ANDLER A SSEMBLY

HEADER

EVAPORATIVE COOLING MODULE

FLOAT VALVE & MAKE-UP CONN.

MANUAL SHUT-OFF VALVE

OVERFLOW CONN.

DRAIN CONN.

VACUUM BREAKER

MANUAL DRAIN VALVE

AIR GAP
PER CODE

UNION

WATER LEVEL

RECIRCULATION PUMP

ROOF CURB

ROOF DRAIN

SUPPLY LINE DRAIN SOLENOID 1” NORMALLY OPEN.

FILL VALVE SOLENOID 1” NORMALLY CLOSED.

SUMP DRAIN 1 1/2”
BALL VALVE POWERED OPEN & CLOSED

CONDUCTIVITY CONTROL

Factory furnished piping & devices.
Field furnished piping & devices.

Notes

Legend

1)

2)

3)

4)

All solenoids must be installed
in a line no smaller than the
solenoid orifice.

Pitch drain line minimum 1/8”
per foot towards outlet

Supply & supply line drain solenoids
must be installed in a non-freeze
location.

Makeup line must be installed
with no traps or sages above
the roof line.

WATER FLOW ADJUSTMENT VALVE

Factory furnished piping & devices.
Field furnished piping & devices.

Notes

HEADER

EVAPORATIVE COOLING MODULE

FLUSH SOLENOID NORMALLY CLOSED

MANUAL SHUTOFF VALVE

FLOAT VALVE & MAKE-UP CONN.

MANUAL SHUTOFF VALVE

OVERFLOW CONN.

DRAIN CONN.

VACUUM BREAKER

MANUAL DRAIN VALVE

AIR GAP
PER CODE

UNION

CHECK VALVE

BLEED-OFF VALVE

WATER LEVEL

RECIRCULATION PUMP

ROOF CURB

ROOF

ROOF DRAIN

SUPPLY LINE DRAIN SOLENOID 1” NORMALLY OPEN.

FILL VALVE SOLENOID 1” NORMALLY CLOSED.

SUMP DRAIN 1 1/2”
BALL VALVE POWERED OPEN & CLOSED.

Legend

1)

2)

3)

4)

All solenoids must be installed
in a line no smaller than the
solenoid orifice.

Pitch drain line minimum 1/8”
per foot towards outlet

Supply & supply line drain solenoids
must be installed in a non-freeze
location.

5)

Header orifices serve as vacuum
break for flush solenoid connection
to header.

Makeup line must be installed
with no traps or sages above
the roof line.

WATER FLOW ADJUSTMENT VALVE

FIGURE 28: Conductivity Control and Freeze Protection (Evaporative Cooling Package #2)

FIGURE 29: Protection and Auto-Flush (Evaporative Cooling Package #3)

39 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

FIGURE 30: Evaporative Cooling Trap Detail

40 of 154

SECTION 8: ROOF CURB

SECTION 8: ROOF C URB

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.

The roof curbs that support the air handler and
accessory sections are available for all horizontal air
handlers. See Page 41, Table 20 for roof curb. Roof
curbs are shipped unassembled and require field
assembly. Double check dimensions after assembly
before roof material is installed and compare to the
drawing on Page 40, Figure 30.
NOTE: Before installation, verify that you have the
correct roof curb and all required assembly brackets.
If any components are missing, contact Rapid

®

Engineering LLC or your RAPID

independent

representative.

8.1 Roof Curb Assembly and Installation

Assemble roof curb according to the assembly
drawings in Page 43, Section 32. Supplied hardware
must be torqued to recommended specifications on
Page 8, Table 1.

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.

Table 20: Roof Curbs (availability based on style)

Extended Curb (ADD for each section)

Fan

Style

MUA * * * * * *
FR * * * *
AM * * * * * * *
VAV * * * * *

and

Burner

Inlet

Coil

Mix

BoxOAFilter*

Inlet

Plenum

Evap.
Cooling
Section

and

Transition

External

Fan

Motor

with
Belt

Guard

*Curb add required only when an inlet plenum is
ordered with an outside air filter section.

For pitched curbs, insulated curbs, w

ood nailers or

cub mounted vibration isolation, consult the factory.
NOTE: Check the installation location to ensure

proper clearances to combustibles and clearance for
access. Page 8, Section 3.

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.

41 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

NOTE: Adapter shown for models 4024 through 4089
horizontal AM, FMB and MUA.

FIGURE 31: Roof Curb

42 of 154

FIGURE 32: Roof Curb Installation

COUNTER FLASHING
(BY OTHERS)

ROOFING (BY OTHERS)

CANT STRIP (BY OTHERS)

UNIT CURB ANGLE

¥ MODELS 4024-4049: 4 x 2 Sheetmetal Formed Channel
¥ MODELS 4054-4066: 6 x 2 Sheetmetal Formed Channel

CANT STRIP (BY OTHERS)

ROOFING (BY OTHERS)

COUNTER FLASHING (BY OTHERS)

ROOF INSULATION

BY CONTRACTOR

SILICONE CAULK

(BY OTHERS)

TYPICAL CURB INSTALLATION

ROOF CURB

CHANNEL

UNIT CURB ANGLE

¥ MODEL 4073: 3 x 3 x 3/16 Angle Iron
¥ MODELS 4080-4089: 4 x 3 x 1/4 Angle Iron

LAG BOLT

OPTIONAL

TYPICAL CURB INSTALLATION

1"

2"

4024-4049: 4"
4054-4066: 6"

ROOF INSULATION

BY CONTRACTOR

1"x4" NAILER

(BY OTHERS)

SILICONE CAULK

(BY OTHERS)

ROOF CURB

CHANNEL

1"x4" NAILER

(BY OTHERS)

DO NOT TWIST OR BEND FRAME

SECTION 8: ROOF C URB

43 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

DETAIL 2

DETAIL 1

DETAIL 3

DETAIL 3

DETAIL 3

OVERHEAD PLANVIEW

SUPPLY AIR OR

INLET END

SIDE

SPLICE &

CROSSBRACE

12 BOLTS,

FLAT WASHERS,

LOCK WASHERS,

FLANGE NUTS

INTERMEDIATE

CROSSBRACE

8 BOLTS,
FLAT WASHERS,
LOCK WASHERS,

FLANGE NUTS

CORNER

CONNECTION

7 BOLTS,

FLAT WASHERS,

LOCK WASHERS,

FLANGE NUTS

1. Refer to the assembly drawings shipped with the curb.

2. Curb length can vary by options selected.

3. Verify overall assembly dimensions before roofing.

4. Curb material is 16 GA for models 4024 through
4049 and 14 GA for models 4054 through 4089.

5. All top corners to be flush and perpendicular.

6. All joints must be caulked.

NOTE: All top corners to be flush and perpendicular. All joints must be caulked.

FIGURE 33: Roof Curb Assembly with Brackets

44 of 154

FIGURE 34: Duct Support Adapter

ASM SIZE A

NOTE:
GASKET SPONGE REQUIRED ON TOP SIDE OF FLANGE PERIMETER.
MATERIAL TO BE ALUMINIZED 20ga. STEEL

BOTTOM RETURN DUCT ADAPTER ASM

24 38.00
36 56.00
40 61.00
44 67.00
49 74.00
54 83.00
60 92.00
66 102.00
73 109.00
80 128.00
89

436126
436184

BOTTOM RETURN DUCT ADAPTER

436196
436208
436220
436232
436247
436259
436268
436277
436277

B

24.69C17.81D31.88E3.44F3.44G3.06

31.13 25.81 49.88 1.81 3.50

35.13 29.81 54.88 1.81 3.50

37.13 31.81 60.88 1.81 3.50

39.13 33.81 67.88 1.81 3.50

44.13 38.81 76.88 1.81 3.50

43.13 37.81 85.88 1.81 3.50

50.13 44.81 95.88 1.81 3.50

48.62 43.25 101.88 1.81 3.56 3.56

52.62 47.25 122.88 1.81 3.56 2.56

INLET SIDE

ASM SIZE A

24 38.00
36 56.00
40 61.00
44 67.00
49 74.00
54 83.00
60 92.00
66 102.00
73 109.00
80 128.00
89

436126
436184

BOTTOM DISCHARGE DUCT ADAPTER

436196
436208
436220
436232
436247
436259
436268
436277
436277

B

25.31C20.00D29.00E3.50F1.81G4.50

31.31 25.00 47.00 4.50 1.81 4.50

40.31 33.00 50.00 5.50 1.81 5.50

43.31 36.00 56.00 5.50 1.81

46.31 39.00 63.00 5.50 1.81

50.31 43.00 72.00 5.50 1.81

55.31 48.00 81.00 5.50 1.81

57.31 50.00 91.00 5.50 1.81

57.13 50.63 99.63 4.69 1.81 4.69

67.13 60.63 116.63 4.69 1.81 5.69

BOTTOM DISCHARGE DUCT ADAPTER ASM

INLET SIDE

(AM AND FMB ASSEMBLIES ONLY)

3.06

3.06

3.06

3.06

3.06

3.06

3.06

5.50

5.50

5.50

5.50

5.50

128.00 52.62 47.25 122.88 1.81 3.56 2.56 128.00 67.13 60.63 116.63 4.69 1.81 5.69

A (OD)

B (OD)

C (ID)

D (ID)

E (ID)

F (ID)

G (ID)

G (ID)

A (OD)

B (OD)

DETERMINED

BY INSTALLER

DETERMINED

BY INSTALLER

E (ID)

F (ID)

G (ID)

G (ID)

C (ID)

D (ID)

SECTION 8: ROOF C URB

45 of 154

4000-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 9: INDOOR SUSPENSION MOUNTING - HORIZONTAL AIR HANDLER

9.1 Suspension Mounting Assembly and Instructions

Indoor suspension mounting is available for all models in horizontal orientation. Suspension mounts are
shipped assembled. The exterior frame perimeter includes additional L channel. Holes in the L channel allow
for threaded rod to be used for suspension. Threaded rod is provided by others. Minimum threaded rod size
is ¾".

NOTE: Check to be sure all required components are present. If there are any missing, contact Rapid
Engineering LLC or your RAPID

Once the suspension frame is secure, the air handler may be mounted. See Page 27, Section 6.1 for safe
lifting practices.

46 of 154

®

independent distributor.

FIGURE 35: Indoor Suspension

VIBRATION ISOLATORS
WHEN SPECIFIED

SUPPORT
RODS

AIR HANDLER

CONTROLS RIGHT

INLET END VIEW

APPROXIMATE
GAS PIPE LOCATION

CENTER SUPPORTS

ROD SIZE­4036 – 4089 3/4" Ø
4024 5/8" Ø

INLET

G

G

CONTROLS RIGHT

BURNER
SECTION

FAN

SECTION

Field Joint

Field Joint

(4054-4073 ONLY)

(4080-4089 ONLY)

PLAN VIEW

CONTROLS RIGHT SHOWN

CENTER SUPPORTS

ON 4040 TO 4089 ONLY

NOTES:

1. CONSULT FACTORY FOR DIMENSIONS WHEN USING
A 3V4 OR 4" MANIFOLD.

2. ALL DIMENSIONS & WEIGHTS ARE SUBJECT TO CHANGE
WITHOUT NOTICE & SHOULD NOT BE USED FOR
CONSTRUCTION UNLESS CERTIFIED.

3. ACCESSORIES MAY VARY BY INDIVIDUAL ORDER. CONSULT FACTORY
FOR ADDITIONAL INFORMATION.

4. FOR NUMBER OF SUPPORT RODS CONSULT FACTORY.

Model A B C D E F G
4024 109 40 4 5 103 - - 3
4036 120 58 63 114 - - 3
4040 130 63 68 124 64 60 3
4044 137 69 74 131 67 64 3
4049 140 76 81 134 70 64 3
4054 144 85 90 138 80 58 3
4060 154 94 99 148 84 64 3
4066 158 104 109 152 88 64 3
4073 163 112 117 157 88 69 3
4080 162 131 136 165 75 90 3
4089 168 131 136 171 81 90 3

SECTION 9: INDOOR S USPENSION MOUNTING - HORIZONTAL AIR HANDLER

47 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 10: LEG MOUNTING

WARNING

Crush Hazard

Use proper lifting
equipment and
practices.

Failure to follow these instructions can result in death, injury or property damage.

Vertical MUA, FR, AM and 4024-4049 VAV units require a quantity of four legs. Vertical 4054-4089 VAV units
without an OA filter section require a quantity of six legs (all of the same height). Vertical 4054-4089 VAV
units with an OA filter section require a quantity of six legs (four legs of the same height and two legs at a

height of 30" taller than the first four). Consult Factory if height of additional two legs exceed the standard leg
offerings. Horizontal 4024-4049 require a minimum quantity of four legs. Horizontal 4054-4089 require a
minimum quantity of eight legs. For every additional section (ie. mix box, coil, etc.) beyond the basic
horizontal unit except for inlet hoods and outside air filter sections, an additional four legs must be added.

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.

48 of 154

FIGURE 36: Assembling Legs for Horizontal Air Handlers

CURB ANGLE

A

AIR HANDLER

INTERMEDIATE BOTTOM PLATE
(BOLTS TO 2 CORNER LEGS)

ACCESS

DOOR

1/2"x 1-5/8"
SLOTTED HOLES

CORNER SUPPORT LEGS
4 - REQUIRED

CONTROLS

RIGHT

INTERMEDIATE SUPPORT LEGS
REQUIRED ON ALL CURB ANGLE FIELD JOINTS
(2 CORNER LEGS BOLTED TOGETHER)

CORNER BOTTOM PLATE

(BOLTS TO CORNER LEG)

A

FOR MODEL 4073-4089

(8) - 3/8 X 1" BOLTS
(8) - 3/8 FLANGE NUTS
(8) - 3/8 FLAT WASHERS

MANUFACTURER
PROVIDES

FOR EACH LEG:

(12) - 3/8 X 1" BOLTS

FOR MODEL 4024-4066

(12) - 3/8 FLANGE NUTS
(12) - 3/8 FLAT WASHERS

CURB ANGLE

ON UNIT

SECTION
VIEW A-A

Models 4024-4066

HORIZONTAL LEG

NOTE: Leg mounts to underneath side of channel curb.

LEG

HEIGHT

Formed 10Ga.

Galvanized Channels

Model 4024-4049: 4"

Models 4054-4066: 6"

LEG TOP PLATE

A-A

CURB ANGLE

ON UNIT

SECTION

VIEW A-A

HORIZONTAL LEG

NOTE: Leg mounts to inside of curb angle. Allow top of
leg to rest against curb angle before tightening bolts.

LEG

HEIGHT

Structural Angle

Model 4073: 3"

Models 4080/4089: 4"

NOTE: To shorten legs, consult factory.

Leg

Heights

in cm
24 61
36 91.4
48 121.9
60 152.4
72 182.9
84 213.4
96 243.8

SECTION 10: LEG MOUN TING

49 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Drawing #50010144

LEG

OPTIONAL
SECTION (s)

RAIN SKIRT

(3 PCS.)

NOTE: Rain Skirt With Outdoor Air Handlers Only

TOP AND BOTTOM PLATES
BOLT ON OUTSIDE OF LEG

NOTE -

(12) - 3/8 X 1" BOLTS

(8) - 3/8 FLANGE NUTS

FOR EACH LEG

(12) - 3/8 WASHERS

DIMENSION A

84"

DIM. A

STANDARD LEG SIZES

60"

72"

48"

36"

24"

96"

RAPID PROVIDES

SHEETMETAL CHANNEL OR ANGLE
IRON FRAME TOWARD BUILDING

NOTE: RAIN SKIRT WITH OUTDOOR AIR

HANDLERS ONLY
CAUTION, SHORTENING THE LEGS MAY
RESULT IN HIGH INLET AIR
VELOCITIES, CONSULT THE FACTORY

APPLY CAULKING ON INSIDE FEATHER EDGE
OF RAIN SKIRT BEFORE INSTALLING, USING #10 X

RUBBER CAP TEK SCREWS, SCREW TO THE SIDES OF
AIR HANDLER, REMOVE SCREW IN ROOF BEFORE INSTALLING
RAIN SKIRT TO ROOF PANEL OF AIR HANDLER, RAIN GUTTER
SHOULD BE FLUSH WITH INLET OF UNIT AS ILLUSTRATED.

RAIN SKIRT

UPRIGHT LEG

AIR HANDLER

20540 SCR,TEK #10 X 3/4 W/WASH

FIGURE 37: Assembly Legs and Rainskirt for Upright Air Handlers

50 of 154

SECTION 11: FILTER SECTION

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.

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.

SECTION 11: FILTER S ECTION

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.

All filter sections are shipped assembled. Models 4024-4049 ship attached to the base unit. Models 4054­4089 shipped loose and required field assembly to base unit.

NOTE: Check to be sure that all required components are present. If any are missing, contact Rapid

®

Engineering LLC or your RAPID

independent distributor.

FIGURE 38: Filter Section Support Assembly

51 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Roof
Tape

Field Joint

Properly
Caulk

Notes:

(1) Failure to properly caulk the
field joints will allow water
to enter the air handler
(2) All parts mounted to inlet end
to be attached with 3/8" bolt
and flat washers.
(3) All other parts bolted together
with 5/16" bolts, flat washer,
and lock nut.
(4) All dimensions & weights are
subject to change without
notice & should not be used
for construction unless certified.

Typ. Assembly

Nut Inserts

Rapid recommends assembling

inlet hood parts to the air

handler in the following

sequence by item #:

5, 6, 11, 4, 2, 1, 10

SECTION 12: INLET HOODS

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.
NOTE: Check to be sure that all required components are present. If any are missing, contact Rapid
Engineering LLC or your RAPID

®

independent distributor.

12.1 Inlet Hood Assembly
FIGURE 39: Inlet Hood without Filters (4024-4049)

52 of 154

FIGURE 40: Inlet Hood without Filters (4054-4089)

Roof
Tape

Field Joint

Properly
Caulk

Notes:

(1) Failure to properly caulk the
field joints will allow water
to enter the air handler
(2) All parts mounted to inlet end
to be attached with 3/8" bolt
and flat washers.
(3) All other parts bolted together
with 5/16" bolts, flat washer,
and lock nut.
(4) All dimensions & weights are
subject to change without
notice & should not be used
for construction unless certified.

Typ. Assembly

Nut Inserts

Rapid recommends assembling

inlet hood parts to the air

handler in the following

sequence by item #:

8, 9, 16, 7, 5, 6, 4, 2, 1, 10, 11, 12

10

10

11

FILTER RAILS

TOP FILTER RAIL

DescriptionDetail

12

BOTTOM PAN & RAIL

13

L INLET HOOD GUTTER

14

15

FILTER CLIPS

16

TEK SCREWS

17

RAIL HARDWARE

18

19

FILTER SPACERS

20

R INLET HOOD GUTTER

ISOMETRIC VIEW

FILTER SPACER
REQUIRED ON SOME
MODELS

11

12

13

14

15

16

FILTERS

40600672

4060067381

QtyASM/Part #

40600674 1

40600674 1

40600675 1

20900 4

20541 30

20699 14

20538 14

--

20596 8

MODEL 36

40620618

4062061981

QtyASM/Part #

40620620 1

40620621 1

40620621 1

20900 8

20541 30

20699 14

20538 14

--

20596 4

MODEL 40

40600641

4060064281

QtyASM/Part #

40600643 1

40600644 1

40600644 1

20900 8

20541 30

20699 12

20538 12

--

09701 12

MODEL 44

40504206-7

40504206-8101

QtyASM/Part #

40504206-9 1

40504206-12 1

40504206-12 1

20900 10

20541 50

20699 16

20538 16

40504206 5

20596 20

MODEL 49

40620418-19

40620418-20121

QtyASM/Part #

40620418-21 1

40620418-22 1

40620418-22 1

20900 12

20541 50

20699 22

20538 22

40620418-23 1

20596 24

MODEL 54

40630445

40630446121

QtyASM/Part #

40630447 1

40630448 1

40630449 1

20900 12

20541 50

20699 24

20538 24

--

20596 30

MODEL 60

437345

437346121

QtyASM/Part #

437347 1

437348 1

437349 1

20900 12

20541 50

20699 20

20538 20

--

20596 12

MODEL 66

40501125-7

40501125-851

QtyASM/Part #

40501125-9 1

40501125-12 1

40501125-12 1

20900 12

20541 50

20699 20

20538 20

-1

20596 36

MODEL 73

40600529-12

40600529-13141

QtyASM/Part #

40600529-14 1

40600529-15 1

40600529-16 1

20900 14

20541 50

20699 30

20538 30

-1

77500 49

MODEL 80/89

EXPLODED VIEW

ASSEMBLY INSTRUCTIONS

· ASSEMBLE INLET HOOD PARTS LISTED IN EXPLODED VIEW #7,8,9,14 TO AIR HANDLER WITH

3
8

" FLAT

WASHERS AND

3
8

X 1 BOLTS.

· BUTYL ROPE CAULKING IS SUPPLIED AND SHOULD BE APPLIED BET WEEN EACH SIDE AND ROOF PANELS TO INSURE A WATER TIGHT SEAL, 3" WIDE ZIP
TAPE IS SUPPLIED AND SHOULD BE USED ACROSS EACH ROOF JOINT AS SHOWN.

· BOLT ITEMS #4,5,6 WITH

5

16

" HARDWARE TO ITEM #7,8,9 PREVIOUS MOUNTED.

· ITEMS #1,2 & 3 ARE THEN BOLTED TO ITEMS #4,5 & 6.

· INTERIOR GUSSET ITEMS ARE MOUNTED ON THE INSIDE OF HOOD TO SIDE WALL PANELS #5 & 6 AND #4 ROOF PANEL.

· HORIZONTAL BRACE IS MOUNTED TO #5 & 6 ON INTERIOR OF HOOD FOR CENTER SUPPORT.

· ITEM #13 & 14 RAIN GUT TERS MOUNT TO TAPERED EDGE OF HOOD, MOUNTING FLANGE TO THE INSIDE OF HOOD AND 2" FLANGE WITH BE TO THE
OUTSIDE AS SHOWN.

· ITEM #11 TOP FILTER RAIL MOUNTS TO ROOF OF INLET HOOD ITEM #1 WITH ITEM #16 TEK SCREWS.

· ITEMS #10 DUAL FILTER RAILS MOUNT TO ITEMS #13 & 14 WITH #10-24 HARDWARE.

· ITEMS #15 FILTER CLIP RETAINER ARE FASTENED TO ITEMS #13 & #14 WITH TEK SCREWS.

· SOME MODELS REQUIRE FILTER SPACER ITEM #19 TO COMPLETE ROW OF FILTERS.

7

8

9

5

6

4

1

2

3

14

10

14

13

13

ITEM #11 TEK SCREWS
TO THE OUTSIDE FLANGE
OF ITEM #1

FILTER RAILS ITEMS #10
MOUNT TO ITEMS #13 & 14 WITH
#10-24 HARDWARE

SOME MODELS REQUIRE FILTER
SPACER #19 (SEE CUTTING LIST)

17

FILTER CLIPS ARE
TEK SCREWED TO THE
OUTSIDE FLANGE OF ITEM #13
& #14 ON BOTH SIDE OF HOOD.

3" WIDE ZIP TAPE, SUPPLIED
FOR EACH ROOF JOINT.

EACH VERTICAL AND HORIZONTAL ROOF JOINT SHOULD
BE CAULKED WITH BUTYL TAPE THAT IS SUPPLIED
WITH INLET HOOD, TO INSURE A WATER TIGHT SEAL.

17 18

ASSEMBLY INSTRUCTIONS

· STANDARD INLET HOOD INSTRUCTION #40004504 (PG.17) FOR INSTRUCTIONS ON CAULKING
PRIOR TO ASSEMBLY.

· REFER TO ASSEMBLY DRAWING PACKAGED WITH INLET HOOD.

· INLET HOODS (4024-4049) ARE 6-PIECES & (4054-4089) 12-PIECES

· INLET HOODS 4054-4089 HAVE INTERNAL CORNER BRACES AND HORIZONTAL CROSS MEMBERS.

21

66512 4 66512 8 - - - - - - - - 66512 18 - - - -

40630297

4063029841

QtyASM/Part #

40630299 1

40630301 1

40630300 1

20900 4

20541 10

20699 8

20538 8

40630302 4

20596 4

MODEL 24

--

20 21

FILTERS

RAIL HARDWARE

19

40600671 40620617 40600640 40504207 40620417 40630444 40437344 40501124 -40630296

Models

Assembly Reference

INLET HOOD FILTER HARDWARE, HARDWARE FOR INLET HOOD ASSEMBLY IS NOT LISTED HERE.

20 21

19

80/89 EXAMPLE

BOTTOM PAN VIEW

12

17

14

8

GUSSETS

SECTION 12: INLET H OODS

FIGURE 41: Inlet Hood with Permanent Filters

53 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

C

B

DETAIL B: SCALE: 4x

A

(2) braces front & back on models 4060 thru 4089

(1) brace front & back on models 4024 thru 4054

1

3

6

8

5

4

2

2

1

3

4 5

6

8

Item 4 flush with Inlet Hood drip edge.

C

DETAIL A: SCALE: 4x

2

DETAIL C: SCALE: 2x

Models 4080-4089 only

Center Channel pieces

B

A

Seal perimeter of Inlet Hood and

Moisture Limiter 100% w/ caulking

Tek screw sides & top to Inlet
Hood flanges

On models 4080 & 4089, moisture limited media is stacked two

rows high and separated with sheetmetal channels pop riveted together.

On all other models, moisture limited media is installed with full-lenth rows.

INLET HOOD

Assembly Instructions:

1. Pop rivet items #1 and #3 together and items #4 and
#5 together and center channel piece (see detail C) for
model 4080-4089 only.

2. If inlet hood is currently mounted, remove corner
brackets. Bolt floor (items #1 and #3) to bottom of the
inlet frame and sides of hood.

3. Tek screw one side to inlet hood rain gutter and to floor.

4. Pop rivet back supports (item #6) to inlet hood rain
gutter using notches in side as a guide.

5. Tek screw top (items #4 and #5) to top lip of hood and
to sides.

6. Install Moisture Limiters media.

7. Tek screw the other side to inlet hood rain gutter and
to floor.

8. Tek screw #8 moisture limiter media to front of
inlet hood.

9. Seal all joints of inlet hood and perimeter of mist
eliminator to inlet hood 100% with caulking.

NOTE: 1. Inlet hood framing side (item #2) not shown.

2. All dimensions are in inches.

Model 4024 4036 4040 4044 4049 4054 4060 4066 4073 4080/4089

A 40 58 63 69 76 85 94 104 112 131
B 48 72 84 84 84 96 94 96 96 112

C

35

7

/8831/2955/8993/41045/81191/

2

126

123

1

/21231/21403/

4

Quantity of

Media Pieces

355667899 22

FIGURE 42: Inlet Hood with Moisture Limiter

54 of 154

SECTION 13: SERVICE PLATFORM

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.

Equipment and
accessories are
heavy.

Cut/Pinch Hazard

Wear protective gear
during installation,
operation and
service.

Edges are sharp.

WARNING

Failure to follow these instructions can result in death, injury or property damage.

SERVICE PLATFORM FRAME

SUPPORT CHANNEL

BURNER SECTION

3/8" BOLTS

3/8" BOLTS

3/4" NUTS

¥ MODEL 4073/4089 ANGLE IRON
¥ MODEL 4024/4066 SHTMTL CHANNEL

RAILING

CONTROLS

Side Railing
Field Assembly

ACCESS SIDE RAILING (SIZES 4049 - 4089)

TEK SCREW IN FIELD.

FRONT

GRATING

Two Front Rails on
4080/4089 Models

2

4

8

9

1

3

5

6

10

ACCESS

CHAINS

SIDE RAILING
4 PCS ASSEMBLY

7

OPTIONAL LADDER

(Available from manufacturer)

Assemble in the following order:

1. Bolt support channels to air handler with four ¾” nuts.

2. Bolt service platform frame between support channels with eight 3/8” x 1” bolts and fig nuts.

3. Lay grating inside service platform frame.

4. Bolt from railing to service platform with four 3/8” x 1” bolts and fig nuts.

5. Screw access railing to support channels with three #14 self-tapping screws.

6. Tek screw access railing to air handler roof.

7. Pre-assemble side railing (4 pieces) with four 3/8” x 1” bolts and fig nuts.

8. Bolt side railing to front railing with two 3/8” x 1” bolts and fig nuts.

9. Screw side railing to angle iron frame with three #14 self-tapping screws.

10. Attach safety chains between access side railing and front railing.

SECTION 13: SERVICE PLATFORM

13.1 Service Platform

Ladders are available as an additional accessory for service platforms. Ladders are available with or without
cages at various heights. Service Platforms are available for use with horizontal or vertical units.

FIGURE 43: Service Platform for an Vertical Air Handler

55 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

CONTROLS

RIGHT

3/8" BOLT

FIELD JOINT
WHEN REQUIRED

SERVICE PLATFORM

SUPPORT CHANNEL

3/8" BOLTS

SAFETY CHAIN

FRONT RAILING

SWAY TAB

SUPPORT RODS

DOUBLE NUTTED

LIFTING EYE

AIR HANDLER

SUPPORT CHANNEL

ACCESS SIDE RAILING

SIDE RAILING

FIELD ASSEMBLY

HOLES FOR 3/8" BOLTS

SUPPORT ROD HOLES

(by others)

TEK SCREW IN FIELD.

SPLICE LOCATED ON

4044-4089 MODELS ONLY

SIDE RAILING 4 PCS ASSEMBLY

FRONT

RAILING

INLET VIEW

RIGHT CONTROLS

Detail A: Models 4073 - 4089

Detail A: Models 4024 - 4066

A

FIGURE 44: Service Platform for a Horizontal Air Handler

56 of 154

SECTION 14: DISCHARGE ACCESSORIES

SECTION 14: DISCHARGE ACCESSORIES

WARNING

Crush Hazard

Use proper lifting
equipment and
practices.

Failure to follow these instructions can result in death, injury or property damage.

14.1 One-Way, Three-Way and Four-Way Discharge Head Installation

All discharge heads are shipped assembled. The discharge head is designed for mounting to the face of the
air handler (covering the supply air opening) or to an interior wall. All discharge heads must be field
supported (by others). The discharge head has four 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.

Discharge heads can be installed on horizontal or vertical air handlers. To install the discharge head on an
interior wall, drill holes in the flanges on all four sides of the discharge heads to accommodate lag bolts
(supplied by others). Sheet metal (supplied by others) may be required.

Consult factory for detailed installation instructions based on unit orientation and discharge location.

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.

57 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

(SUPPLY AIR AND

RETURN AIR DUCT

SLEEVES AVAILABLE

FROM MANUFACTURER)

DETAIL A

DETAIL C

AIR HANDLER

DETAIL B

TYPICAL ASSEMBLY

2"

SELF TAPPING

SCREWS

ALTERNATE

SUPPORT BY

OTHERS

SUPPORT

BY OTHERS

INLET

DETAIL A

DETAIL B

DETAIL C

MODELS 4024-4089

AIR HANDLER
HOUSING

RETURN AIR SLEEVE

CAULK JOINT

AFTER ASSEMBLY

AIR HANDLER
HOUSING

SUPPLY AIR SLEEVE

3-3/4" DISCHARGE

COLLAR

SELF-TAPPING

SCREWS

CAULK JOINT PRIOR

TO ASSEMBLY

CAULK JOINT PRIOR

TO ASSEMBLY

SUPPLY AIR
SLEEVE

DISCHARGE

HEAD

1/4-20 x 1" BOLTS
(12" O.C.)

FIGURE 45: Vertical Air Handler with Duct Sleeves and Discharge Head

58 of 154

FIGURE 46: One-Way Discharge Head

CONTROLS

RIGHT

CURB

ANGLE

ACCESS

DOOR

AIR HANDLER

DISCHARGE

HEAD

1-WAY

DISCHARGE

HEAD

1-WAY

INLET

AIR HANDLER

DISCHARGE

HEAD

1-WAY

INLET

A

G

D

G

C

F

30”

E

DETAIL A

TYPICAL ASSEMBLY

2”

SELF TAPPING

SCREWS

AIR HANDLER

HOUSING

DISCHARGE

HEAD

END VIEW

RIGHT SIDE VIEW

Model A C D E F G

4024 40 24.25 33.25 2 40 3.5
4036 58 29.25 51.25 3 58 3.5
4040 63 37.25 54.25 4 63 4.5
4044 69 40.25 60.25 4 69 4.5
4049 76 43.25 67.25 4 76 4.5
4054 85 47.25 76.25 4 85 4.5
4060 94 52.25 85.25 4 94 4.5
4066 104 54.25 95.25 4 96 4.5
4073 112 54.25 103.25 4 96 4.5
4080 131 64.25 120.25 4 112 5.5
4089 131 64.25 120.25 4 112 5.5

SECTION 14: DISCHARGE ACCESSORIES

59 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

F

D

(TYPICAL)

B

A

C

E

G

G

PLAN VIEW

FRONT VIEW

SIDE VIEW

Model A B C D E F G

4024 44 25 24.4 14 20.3 29.3 2.1
4036 62 30 29.4 22 25.3 47.3 2.1
4040 65 31 37.4 23 33.3 50.3 2.1
4044 71 32 40.4 26 36.3 56.3 2.1
4049 78 34 43.4 28 39.3 63.3 2.1
4054 82 37 47.4 32 43.3 72.3 2.1
4060 96 40 52.4 36 48.3 81.3 2.1
4066 106 43 54.4 40 50.3 91.3 2.1
4073 114 45 54.4 40 50.3 99.3 2.1
4080 131 48 60.4 50 60.3 116.3 2.1
4089 131 48 60.4 50 60.3 116.3 2.1

FIGURE 47: Three-Way Discharge Head

60 of 154

FIGURE 48: Four-Way Discharge Head

E

INLET

AIR HANDLER

C

ROOF CURB

A

ACCESS DOOR

CONTROLS

RIGHT

AIR HANDLER DUCT
NOT SUPPLIED BY
RAPID ENGINEERING LLC.

ROOF

B

D

F

F

F F

AIR HANDLER

12"

TYPICAL

12"

TYPICAL

RIGHT SIDE VIEW END VIEW

Model A B C D E F

4024 40 40 46 24.3 33.3 2
4036 58 58 46 29.3 51.3 2
4040 63 63 46 37.3 54.3 2
4044 69 69 46 40.3 60.3 2
4049 76 76 46 43.3 67.3 2
4054 85 85 58 47.3 76.3 2
4060 94 94 58 52.3 85.3 2
4066 96 104 58 54.3 95.3 2
4073 96 112 58 54.3 103.3 2
4080 112 131 58 64.3 120.3 2
4089 112 131 58 64.3 120.3 2

SECTION 14: DISCHARGE ACCESSORIES

61 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Model A C D E F G H J K Disch ID Weight (lbs)

4024 40 20 1/4 24 1/4 3 7/8 40 5 3/8 19 47 30 24 x 29 75
4036 58 25 1/4 32 1/4 4 7/8 58 5 3/8 26 83 48 32 x 47 105
4040 63 33 1/4 35 1/4 5 7/8 63 6 3/8 31 73 39 35 x 50 140
4044 69 36 1/4 35 1/4 5 7/8 69 6 3/8 33 73 36 35 x 56 180
4049 76 39 1/4 40 1/4 5 7/8 76 6 3/8 33 78 36 40 x 63 190
4054 85 43 1/4 40 1/4 5 7/8 85 6 3/8 39 89 39 40 x 72 210
4060 94 48 1/4 43 1/4 5 7/8 94 6 3/8 44 92 39 43 x 81 250
4066 104 50 1/4 43 1/4 5 7/8 96 6 3/8 44 97 37 43 x 91 290
4073 112 50 1/4 43 1/4 5 7/8 96 6 3/8 41 136 64 43 x 99 380
4080 131 60 1/4 43 1/4 5 7/8 112 7 3/8 44 121 44 43 x 116 480
4089 131 60 1/4 43 1/4 5 7/8 112 7 3/8 44 145 63 43 x 116 480

FIGURE 49: 120° Discharge Head Horizontal Bottom Supply Air

62 of 154

SECTION 14: DISCHARGE ACCESSORIES

Model A B C D

E

(min.)E(max.)

Weight

(lbs)
4024 42 54 3 - 25 38 80
4036 47 72 3 - 36 54 110
4040 55 75 3 - 42 64 130
4044 58 81 3 - 46 70 140
4049 61 88 3 - 50 75 160
4054 65 97 3 - 56 84 180
4060 70 106 3 53 64 96 230
4066 72 116 3 58 70 105 250
4073 72 124 3 62 75 112 260
4080 82 140 4 70 88 132 330
4089 82 140 4 70 88 132 330

14.2 Splash Plate Installation

The splash plate is designed to hang, supported by
suspension rods (rods provided by others) directly
below the bottom discharge opening of a horizontal
air handler. The center point of the splash plate must
be located at the center point of the discharge
opening and be positioned below the air handler
within the range of dimensions show below as E
(min) & E (max.). For model sizes 60-89, center
support rods will be required (see illustration below).

FIGURE 50: Discharge Plate

RIGHT SIDE VIEW

FAN SECTION

NOTE: Be sure to inclu de provisions in the structure
suspending the discharge plate that will prevent
sway/movement of the plate when the supply fan is in
operation.

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.
Adjusting the nuts will level the splash plate. Torque
hardware after leveling.

SUPPORT RODS

(BY OTHERS)

DISCHARGE PLATE

A

C

CENTER HOLES
ON 60 THRU 89

13

/16” HOLES

D

E

B

2”
TYPICAL

D

2”

1¾” TYPICAL

4 CORNERS

63 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

“D” HOLE DIA

SUPPORT ROD

TO STEEL-WORK

BY OTHERS

ISOLATOR

SUPPORT ROD

TO UNIT

BY OTHERS

L

A

H

NOTE:
ALL DIMENSIONS AND WEIGHTS
ARE SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD
NOT BE USED FOR CONSTRUCTION
UNLESS CERTIFIED.

TYPE

L

WH

A

D

RH2
RH3

RH4

3
3 3/4
4 1/2

2 1/4
3 1/4

4

4 1/4
6 1/4

8 3/16

1 3/8
2
2

11/16
7/8

13/16

ISOLATORS REQ’D FOR

AIR HANDLER W/

SERVICE PLATFORM

AIR HANDLER (AM)

W/ FILTER MIX BOX

AIR HANDLER (AM) W/

FILTER MIX BOX &

SERVICE PLATFORM

AIR HANDLER

SIZE

VENDOR #

4024
4036
4040
4044
4049
4054
4060
4066
4073
4080
4089

RH – 2, GRAY
RH – 3, GREEN
RH – 3, GREEN
RH – 3, GRAY
RH – 3, GRAY
RH – 4, GREEN

RH – 4, GREEN
RH – 4, GREEN
RH – 4, GREEN
RH – 4, GREEN

RH – 4, GREEN

4
4
4
4
4
6
6
6
6
6
6

6
6
9
9
9
9
9
9
9
9
9

6
6
6
6
6
8
8
8
8
8
8

9
9
12
12
12
12
12
12
12
12
12

29875
20888
20888
20817
20817
46212
46212
46212
46212
46212
46212

SECTION 15: VIBRATION ISOLATION

WARNING

Crush Hazard

Use proper lifting
equipment and
practices.

Failure to follow these instructions can result in death, injury or property damage.

FIGURE 51: Suspended

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.

64 of 154

FIGURE 52: Curb Mounted

Roof Curb

Roof Curb

SECTION 15: VIBRATION I SOLATION

65 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

NOTE:
ALL DIMENSIONS AND WEIGHTS ARE SUBJECT TO
CHANGE WITHOUT NOTICE AND SHOULD NOT BE
USED FOR CONSTRUCTION UNLESS CERTIFIED.

TYPE

AB

CD

E

H
R – 3
R – 4

3 3/8
4 1/4

5 1/2
6 1/2

4 1/8

5

9/16

9/16

1/2
5/8

1 3/4

1 3/4

H

B

C

D = DIA.

2 PL.

E = NC TAP

A

ISOLATORS

REQ’D FOR

MODEL

VENDOR #

AIR HANDLER

AIR HANDLER

(AM) W/ FILTER

4024 R – 3, RED

R – 3, GREEN
R – 3, GREEN
R – 3, GRAY
R – 3, GRAY
R – 4, BLACK
R – 4, BLACK
R – 4, BLACK
R – 4, RED
R – 4, RED
R – 4, RED

4036
4040
4044
4049
4054
4060
4066

4073
4080
4089

4
4
4
4
4
6
6
6
6
6
6

6
6
6
6
6
8
8
8
8
8
8

FIGURE 53: Platform Mounting on Vibration Isolators

66 of 154

FIGURE 54: Vibration Isolation Platform Locations

A2

NOTE:
ALL DIMENSIONS AND WEIGHTS
ARE SUBJECT TO CHANGE
WITHOUT NOTICE AND SHOULD
NOT BE USED FOR CONSTRUCTION
UNLESS CERTIFIED.

NOTE:
FOR MUA, EXCLUDE MIX BOX

MODEL

A2

BC EFG

HD

A1

H

H

4024
4036
4040
4044
4049
4054
4060
4066
4073
4080
4089

171
186
198
207
212
221
231
242
247
265
271

40
58
63
69
76
85
94

104
112

131
131

A1

109
120
130
137
140
144
154
158
163
171
177

103
114
124
131
134
138
148
152
157
165
171

3
3
3
3
3
3
3
3
3
3
3

62
66
68
70
72
77
77
84
84
94
94

58

-

-

-

-

-

-

-

-

-

-

64
64

69
90
90

80
84
88

88
75
81

37 3/8
55 3/8
60 3/8
66 3/8
73 3/8
82 3/8
91 3/8
101 3/8
114 1/2
133 1/2
133 1/2

SEC A – A

END VIEW

VIBRATION ISOLATORS

AIR HANDLER

CONTROLS

RIGHT

APPROXIMATE
GAS PIPE LOCATION

INLET

SECTION VIEW A – ASECTION VIEW A – A

MODELS 4024 – 4066

MODELS 4073 – 4089

PLAN VIEW

CONTROLS RIGHT SHOWN

CENTER ISOLATOR
ON 4054 – 4089 ONLY

CONTROLS

RIGHT

MIX–BOX
SECTION

BURNER

SECTION

(4054–4073 ONLY)

Field Joint

Field Joint

(4080 – 4089 ONLY)

FAN

SECTION

B

G

F

E

D

C

SECTION 15: VIBRATION I SOLATION

67 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

SECTION 16: COOLING SPECIFICATIONS

16.1 Evaporative Cooling
Table 21: Formulas

Formulas

1 Leaving Dry Bulb = ODB – [SE* x (ODB - OWB)]

Leaving Wet Bulb = Entering Wet Bulb (actually, it’s slightly less

2

than the entering wet bulb, but is normally considered equal.)
3Wet Bulb Depression = ODB – OWB
4Evaporation Rate (GPH) = CFM x WBD x SE/8050
5 Bleed-off Rate = approximately 20% of evaporation rate*
6Recirculation Rate = approximately 3 times evaporation rate*

* Bleed-off and recirculation rates will vary with
locale, water quality and chemical treatment
program. These values are only for approximation.

NOTE: Refer to saturation efficiency table below.

Table 23: Evaporation Rate

Wet Bulb

Depression (°F)

5 0.50 0.51 0.52 0.53 0.55 0.56 0.57 0.58 0.60 0.61
10 0 . 9 9 1. 0 2 1.0 4 1. 0 7 1. 0 9 1. 1 2 1.1 4 1. 1 7 1. 1 9 1.2 2
15 1. 4 9 1.5 3 1.5 6 1.6 0 1.6 4 1.6 8 1. 7 1 1. 7 5 1. 7 9 1. 8 3
20 1.99 2.04 2.09 2.14 2.19 2.23 2.28 2.33 2.38 2.43
25 2.48 2.55 2.61 2.67 2.73 2.79 2.86 2.92 2.98 3.04
30 2.98 3.05 3.13 3.20 3.28 3.35 3.43 3.50 3.58 3.65
35 3.48 3.56 3.65 3.74 3.82 3.91 4.00 4.08 4.17 4.26
40 3.97 4.07 4.17 4.27 4.37 4.47 4.57 4.67 4.77 4.87
45 4.47 4.58 4.69 4.80 4.92 5.03 5.14 5.25 5.36 5.48

0.800.820.840.860.88 0.90 0.92 0.94 0.96 0.98

Gallons per Hour (GPH) Per 1,000 Cubic Feet per Minute (CFM) at Stated Saturation Efficiency

Table 22: Abbreviations

Abbreviations

CFM Cubic Feet Per Minute
GPH Gallons Per Hour
IDB Indoor (Design) Dry Bulb Temperature
LDB Leaving Dry Bulb Temperature
LWB Leaving Wet Bulb Temperature
ODB Outdoor (Design) Dry Bulb Temperature
OWB Outdoor (Design) Wet Bulb Temperature
SE Saturation Efficiency of the Evaporative Media
WBD Wet Bulb Depression

• Heat of vaporization = 1043 BTU/lb

• Weight of water = 8.34 lb./Gallon

• GPH = CFM x WBD x SE x 1.08/1043/8.34 = CFM x WBD x SE/8050

Table 24: Suggested Air Changes Per Hour (Air
Change Method)

Leaving Air

Tem perature

(°F DB)

78° 20° 30 - 60
76° - 78° 15° - 20° 20 - 40
74° - 76° 10° - 15° 15 - 30
72° - 74° 5° - 15° 12 - 20

< 72° < 10° 10 - 15

Indoor Air

Temperature Above

Ambient (°F)*

Air Changes/Hour**

* For existing buildings: Average amount indoor
temperature exceeds ambient outdoor temperature
when evaporative cooling is not in use.

** Experience has shown that significant benefit can
be achieved with 10-15 Air Changes per Hour (AC/
Hr) through the lowest 12' of the facility. For a 24'

Table 25: Saturation Efficiency at Stated Media
Depth

Airflow

Feet per

Minute (FPM)

400 0.71 0.81 0.90 0.98 0.99
500 0.68 0.79 0.89 0.98 0.99
600 0.66 0.77 0.88 0.97 0.99
700 0.64 0.75 0.87 0.97 0.98

Table 26: Static Pressure Drop (in wc) at Stated
Media Depth

Airflow

Feet per

Minute (FPM)

400 0.06 0.09 0.14 0.19 0.24
500 0.09 0.14 0.21 0.30 0.39
600 0.13 0.20 0.30 0.42 0.55
700 0.23 0.31 0.44 0.62 0.80

high building, this would mean 5-6 Air Changes per
Hour (AC/Hr) for the entire volume. This will v
application.

ary by

NOTE: Moisture limiter pressure drop is added for
face velocities greater than 600 Feet per Minute
(FPM). Rapid Engineering LLC's standard media
thickness equals 12".

6" 8"12"18" 24"

6" 8"12"18" 24"

68 of 154

SECTION 17: DUCT CONSIDERATIONS

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.

The air handler has been designed to operate at the
specific air volume and external static pressure that
was originally specified. Static pressure is increased
by any additional components that are added to the
air handler (i.e. inlet hood, filter section, dampers,
ductwork, discharge heads, etc) Additional static
pressure beyond original intention (or time of order)
will affect the performance of the air handler and
reduce 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).
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 ducting should have a straight
run of at least 3 duct diameters immediately before
and after the air handlers mechanical accessories.
No duct fittings, elbows or transitions with restrictions
can be placed within 3 duct diameters.

SECTION 17: DUCT C ONSIDERATIONS

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 gradual.
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 provided to
facilitate connection of ductwork.
Neither the flanges nor exterior skin of the air handler
are capable of supporting the load of the ductwork.
Ductwork support must come from the structure itself
that the air handler is serv
is recommended that ductwork be supported every 6
ft (1.8 m) for ductwork that has a cross section of 10 ft
(3 m) or less and every 4 ft (1.2 m) for ductwork
which has a cross section of greater than 10 ft (3 m).
On vertical runs, it is recommended that ductwork be
supported every 10 ft (3.0 m). On both cases,
supporting members should be sized to carry the
weight load.

17.1 Inlet Air Duct

Inlet duct work height and width must be no smaller
than the air handler inlet height and width and supply
only uncontaminated air to the air handler. (See
Page 10, Section 5 for return air dimensions).

17.2 Return Air Duct

Return air duct work height and width must be no
smaller than the air handler return air opening height
and width. (See Page 10, Section 5 for return air
dimensions).

17.3 Supply Air Duct Work

Supply air duct work sizes sho
the application requirements of the system. Supply
air ductwork must be smaller than supply air
opening. See Page 10, Section 5 for dimensions.

icing. On horizontal runs, it

uld be determined by

Duct diameter for round ducts (in inches):

Dh = d

Duct diameter for rectangular d

Dh:diameter
d:round duct inside diameter

Dh = (2*H*W)/(H+W)

Dh:diameter
H:rectangular duct inside height
W:rectangular duct inside width

ucts (in inches):

69 of 154

4000-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 18: GAS PIPING

Minimum gas pressure as indicated on data plate
must be measured with the burner operating in high
fire.

Minimum inlet gas pressure is determined by gas
train size and BTU/h rating.

18.1 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: (

•Factory Mutual (FM)-compliant manifold:
(

See Page 72, Figure 56

•XL Insurance (former IRI)-compliant manifold:
(

See Page 73, Figure 57

18.2 Gas Piping and Pressures

The air handler is equipped with a gas manifold
suitable for connection to supply pressure of up to 5
p.s.i. maximum for all manifold types.

When gas supply exceeds the above-listed maximum
gas pressures, an additional high pressure gas
regulator will be required to assure that the correct
gas pressure is supplied to the air handler.

Outlet pressure from the regulator / inlet pressure to
air handler should be measured at the inlet of the air
handler gas manifold.

See Page 71, Figure 55

).

).

).

70 of 154

Table 27: Manifold Component Identification

ALTERNATE

INLET

INLET

B

OUTSIDE

C

VENT

E

H

P

J

BY OTHERS

D

A

M

L

BY OTHERS

VENT LIMITER

N

* INTEGRAL VENT LIMITER

G

VENT LIMITER

ALL VENT PIPING TO
OUTSIDE BY OTHERS

Item Component Identification

A Leg Trap (by others)
B Lockable Manual Shut-Off Valve (by others)

High Gas Pressure Regulator (by others)

C

if gas pressure is over 5 P.S.I.

D Pilot Gas Cock

EPrimary Safety Shut Off Valve and Actuator

F Vent Valve and Piping
GBlock Valve and Actuator
HPlug Cock

JModulator Valve / Gas Pressure Regulator

KLow Gas Pressure Switch

L Pilot Valve Solenoid (normally closed)
M Pilot Regulator
N High Gas Pressure Switch

PBurner
Q­R Union (by others)

S ¼" FPT Pressure Tap with Plug (by others)

NOTE: Items vary by manifold type. All items may not apply.

FIGURE 55: Standard Gas Manifold

SECTION 18: GAS P IPING

71 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

VENT OUTSIDE

A

ALTERNATE

INLET

INLET

BY OTHERS

D

M

B

C

K

E

G

H

J

N

P

R

S

L

BY OTHERS

* INTEGRAL VENT LIMITER

* INTEGRAL VENT LIMITER

VENT LIMITER

VENT LIMITER

ALL VENT PIPING TO

OUTSIDE BY OTHERS

FIGURE 56: FM Gas Manifold

72 of 154

FIGURE 57: XL Insurance Gas Manifold

ALL VENT PIPING TO
OUTSIDE BY OTHERS

VENT OUTSIDE

F

VENT OUTSIDE

A

ALTERNATE

INLET

INLET

BY OTHERS

D

B

C

K

E

G

H

J

N

P

R

S

M L

BY OTHERS

* INTEGRAL VENT LIMITER

* INTEGRAL VENT LIMITER

VENT LIMITER

VENT LIMITER

SECTION 18: GAS P IPING

73 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

18.3 Gas Piping

The gas manifold connection extends through the
side of the control enclosure for vertical equipment
and through the bottom for horizontal equipment. The
factory piping terminates with a male pipe connection
in the primary gas valve. Be sure that the fuel supply
pipe connected at this point is large enough to
ensure the proper volume 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 piping does not restrict
accessibility to the air handler or its removable
access doors.

Lockable manual shut-off valve must be added by the
installer in compliance with Occupational Safety and
Health Administration (OSHA) regulations.

.4 Pressure Test Ports

18

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.

18.4.1 Manifold Inlet Gas Pressure

The pressure test 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.

18.4.2 Burner Gas Pressure

A pressure tap is used to measure negative pressure
at the burner (fan only, gas valves closed) and to set
high fire gas pressure regulating (gas valves open).
Air handlers are equipped with a modulating/
regulating valve (MRV). The pressure tap is located
on the downstream side of the MRV.

74 o f 154

SECTION 19: ELECTRICAL

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.

Each air handler is equipped with a wiring diagram
which will vary depending on the type of remote
panel and/or options supplied.

SECTION 19: ELECTRICAL

Air handlers can also be supplied as building
management system (BMS)-ready. In this case, a
remote panel is not supplied.

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.

75 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

19.1 Disconnect Fuse Sizing

The fuse classification must be determined by the service disconnect rating plate and all applicable codes.
Fuse sizing is determined by the motor size, control current and supply voltage. Fuses that are being
replaced must be replaced with the same type, size and class of fuse that was supplied with the air handler.
For additional information or to confirm original fuse specifications, consult the factory.

Table 28: Minimum and Maximum Fuse Size by Motor Size and Supply Voltage

Electrical Characteristics

Motor Size HP(kW) 208/3/60 230/3/60 460/3/60 575/3/60 230/1/60

2(1.5) 7.3-10.2 6.9-9.6 3.4-4.8 2.6-3.6 13.3-18.6
3(2.2) 10.1-14.2 9.3-13.0 4.6-6.5 3.7-5.2 17.3-24.2
5(3.7) 15.4-21.6 15.1-21.1 7.5-10.6 6.1-8.5 24.3-34.0

7.5(5.6) 23.1-32.4 21.3-29.8 10.6-14.9 8.3-11.6 32.3-45.2
10(7.5) 30.4-42.6 28.1-39.3 14.0-19.7 10.6-14.8 40.3-56.4

15(11.2) 42.4-59.4 39.3-55.0 19.6-27.5 16.8-23.5 ­20(14.9) 51.4-72.0 49.3-69.0 24.6-34.5 19.8-27.7 ­25(18.6) 66.4-93.0 61.3-85.8 30.6-42.9 24.5-34.3 ­30(22.4) 78.4-109.8 73.3-102.6 36.6-51.3 29.6-41.4 ­40(29.8) - - 47.6-66.7 38.0-52.6 ­50(37.3) - - 59.5-83.3 48.1-66.7 -

19.2 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.

NOTE: The controls referenced in this manual are
applicable to non-DDC equipped air handlers. If your
air handler is equipped with one of our DDC control
options, please consult the separate DDC Control
Operator's manual that accompanies this document.

19.3 Remote Panel

The remote panel mu

st be wired as shown on the
electrical schematic. For wire gauge sizes, see Page
76, Table 29. All power supply and motor wiring must
be minimum type THWN with a 167° F (75° C)

temperature rise.

19.3.1 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 29: Control Voltage Wiring For All Control
Systems

Volts Wire Gauge Max Wire

120 18 150' (45 m)
120 16 250' (75 m)
120 14 350' (106 m)

NOTE: Wiring for temperature controls must be run in
shielded cable as indicated on the wiring diagram.

19.3.2 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.

19.4 Motor Current Draw

For specific current requirements, see rating plate

76 of 154

SECTION 19: ELECTRICAL

located on the blower motor. Current draw may be
adjusted downward by reducing blower rotations per
minute (RPM) or by increasing external static
pressure.

19.5 Control Current Draw

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

19.6 Safety Systems

Safety systems are required for proper performance
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
qualified in the installation and service of gas fired
heating equipment, using only components that are
sold and supplied by Rapid Engineering LLC. Refer
to Page 81, Table 31 for a brief description of each
safety device, its location and its switching voltage.

Table 30: Safety Systems

Safety Controls Location Voltage

Manual Reset High­Temp Limit (All Models)

Pres sure Switches
(All Models)

Flame Control
(2010/2010B/2020/2030)

Flame Control (2005)

Discharge Temperature
Monitor (All Models)

AM Resistor
(A M /VAV S t yle)

Blower Discharge 120

Air Handler Control

Enclosure

Air Handler Control

Enclosure

Air Handler Control

Enclosure

Blower Discharge 24

Air Handler Control

Enclosure

120

120

24

24

19.6.1 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. E

vents 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 down and the reset button on the switch has
been depressed. This switch is located on the blower
housing inside the air handler.

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 s

witch 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.

19.6.3 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
as an option on the others.

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 w

ill 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
pressure 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.

The switch will have to be reset manually, once the
condition has been corrected.

19.6.2 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

77 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

19.6.4 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.

Yo ur air handler may equipped with either a flame rod
or UV scanner type of flame detection. Consult your
parts list / electrical diagram to confirm and for flame
rod sensors See Page 115 and Page 116. For UV
scanners See Page 119 and Page 120

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, it will reset upon power
restoration. (See the Trouble-Shooting Guide - Page
136, Section 24)

19.6.5 Discharge Temperature Sensor

This device senses the discharge temperature of the
air at the blower. The discharge temperature sensor
reports the discharge temperature to the temperature
control amplifier

which modulates the burner to the
temperature 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.

Yo ur Rapid

®

direct fired air handler was built custom
to meet your needs. For details on interconnect
wiring or any other wiring questions, please consult
the specific wiring diagrams provided with your air
handler.

NOTE: A laminated wiring diagram can be found
permanently affixed inside the unit control enclosure.

78 of 154

SECTION 19: ELECTRICAL

19.7 Interlocks

19.7.1 Carbon Dioxide Interlocks

All air handlers that recirculate air from the heated
space require either a control to limit the temperature
rise in proportion to the amount of outdoor air or the
use of a room carbon dioxide sensor. The carbon
dioxide sensor is field provided and set to maintain a
CO2 concentration below 5,000 ppm.

19.7.2 Carbon Monoxide Interlocks

Carbon Monoxide Detector is a ship loose sensor
that monitors the CO levels in the space. It can either
sound an alarm and/ or force the air handler into
100% outside air if its threshold set point is
exceeded.

19.8 Control Options

19.8.1 Mild Weather Outside Air Stat

This option is designed to turn the burner off when
the incoming outside air is at or above the
temperature setpoint. The blower is allowed to run for
continued ventilation. The mild weather outside air
stat is located in the control enclosure. It has an
adjustable setting between -20° F (-29° C) and
100° F (38° C).

19.8.2 Low Temperature Limit with Override Timer

This option is designed to turn the unit off when air is
discharged below the temperature setpoint for a
period in excess of timer setpoint. The low
temperatu

re limit switch is located in the air handler’s
control enclosure. The low temperature limit switch
has an adjustable setting between -20° F (-29° C)
and 100° F (38° C). The timer by-passes the low
temperature limit switch for the first 5 minutes to allow
the burner to establish a flame when the air handler
is turned on. If the air handler’s discharge
temperature falls to the predetermined low
temperature limit setpoint, after the 5 minute
establishing period, the air handler’s blower will be
turned off. To reset the low temperature limit switch,
set the fan switch to off and then on again. The air
handler will return to the normal sequence of
operations.

19.8.3 MUA / Exhaust Failsafe Interlock

This option incorporates the low temperature limit
with override timer and an exhaust fan airflow switch

monitor. The exhaust fan airflow switch is field
provided and field w

ired as per the option sheet
supplied with the unit. When the air handler is turned
on there is a 5 minute establishing period for the low
temperature limit switch and the exhaust fan
interlock. If the air handler’s discharge temperature
falls to the predetermined low temperature limit

setpoint, after the 5 minute establishing period, the
air handler fan will be turned off. If there is a failure of
the exhaust fan to activate the field supplied airflow
switch, after the 5 minute establishing period, the air
handler fan will be turned off. To reset the
MUA/exhaust failsafe interlock, set the fan switch to
off and then on again. The air handler will return to
the normal sequence of operations.

19.8.4 Motorized Inlet Damper

The motorized inlet damper covers the outside air
inlet of the air handler. When the air handler blower is
turned on, the damper motor is energized and opens
the damper. The damper motor has an auxiliary
switch that prevents the blower from starting until that
damper has opened sufficiently to allo

w the required

air volume to pass through the air handler.

19.8.5 Motorized Discharge Damper

The motorized discharge damper is mounted in the
duct downstream from the discharge opening of the
air handler. When the air handler fan is turned on the
damper motor is energized and opens the damper.
The damper motor has an auxiliary switch that
prevents the blower from starting until that damper
has opened sufficiently to allow the required air
volume to pass through the air handler.

19.8.6 Control Enclosure Heater

The control enclosure heater is an electric heater that
keeps the temperature in the control enclosure within
the range for the control components. This option is
intended for extremely cold climates, but
recommended for installations below 15° F (-9° C).
The air handler controls are rated to perform at
temperatures as low as -30° F (-34° C). In
environments where the air handler may be exposed
to lower temperatures, a control enclosure heater
may be required.

19.8.7 Auxiliary Relay

An auxiliary relay may be added to an air handler for
either an interlock or a customer defined pu

rpose.
Refer to the option sheet supplied with the air handler
to indicate whether the relay is wired for an intended
purpose or left unwired for a future interface. Each
relay will be double pole double throw (DPDT) type.
Maximum switching capacity on the normally open
contact is 8A, and for the booth light relay, 15A.

19.8.8 Smoke Detector

A smoke detector interlock allows for the air handler
to operate (either off or on) based on signal input
from the fire alarm.

79 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

19.8.9 Service Receptacle Powered by Others
(Wired)

This option provides a service receptacle. It includes
ground-fault interrupter (GFI) receptacle mounted on
the interior or exterior of the control enclosure. Power
to the receptacle is supplied by the installer.

19.8.10 Room Override Stat

For use with Standard Discharge Control remote.
This option provides additional thermostat capability
based on room temperature. The thermostat senses
room temperature, and resets the discharge air to a
higher temperature whenever the temperature falls
below settings indicated on the temperature selection
dial (located on remote panel). Override temperature
can be set 0° F to 40° F above the temperature
selection dial on the remote panel.

80 of 154

SECTION 19: ELECTRICAL

19.9 Safety Systems

Safety systems are required for proper performance 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 qualified in the installation and service of gas fired heating equipment,
using only components that are sold and supplied by Rapid Engineering LLC. Refer to Page 81, Table 31 for
a brief description of each safety device, its location and its switching voltage.

Table 31: 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 (All Models) Air Handler Control Enclosure 120
Supply Air Temperature Monitor (All Models) Blower Discharge 24

81 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

1

5 MIN.

LLS

R W

C

NC

TR

1

LOW TEMP
BY-PASS TIMER

HLS

LO

T-1 CONTROL TRANS.

H1 H2

AFS1

PS-1

HIGH

GAS PRS.

SWITCH

FEEDER PROTECTION

REF: N.E.C. TABLE 430-152

SIZING BY OTHERS.

G

LPJ-50SP

POWER SUPPLY

____V___PH___HZ

____FLA

460

L2

L1

L3

60

35.1

3

F1

F1

DISC SW

F1

34.0

1800

25

SUPPLY FAN

MOTOR

____HP

____FLA

____RPM

MTR

T3

T2

1

T1

AA

FAN ON
LIGHT

LT

MOTOR FLA TAKEN FROM N.E.C
REFER TO NAMEPLATE FOR ACTUAL FLA

H3 H4

460VAC

HI

AFS2

RESET

MANUAL

LIMIT

HIGH TEMP

AIRFLOW

AIRFLOW

2

11

30

31

33

35

18

16

10

54

54

34

15

32

54

3A

CB-2

5A

CB-3

X4

120V

X1

X2X3

24VAC

T-4

DAMPER(s)

DAMPER L.S.

DM

1

INLET / SUPPLY

19

21

FAN

OFF

ON

ON

OFF

BURNER

SW-2

SW-1

M1

M1

MOL-1

START

MOTOR

M1

OL

350VA.

FAN RUNNING
86

CR39CR

PS-2

GAS PRS.

LOW

SWITCH

TH-3

OA STAT

BU R

19.10 Remote Panels

19.10.1 Basic Remote
FIGURE 58: Basic Remote

82 of 154

FIGURE 59: Basic Remote (Continued)

MRV

1

W

2

B

UV

T3

LOW VOLTAGE

TRANSFORMER

AMPLIFIER

SP

T2

TRANSFORMER

IGNITION

G

F

9

8

L2

76

FR-1

10

5

SOL.-1

VALVE

BURNER ON

FLAME RELAY

PILOT VALVE
SOLENOID

PRIMARY SHUT-OFF

20

AA

LT

VALVES OPEN

52

52

2

41

43

45

44

49

46

35

36

18

24VAC

40VA

80

81

6

5

TM

1

1
2
3

8

7

W

B

3
4

1

2

321

SEL

SERIES 14A

TCA

BASIC REMOTE

84

85

VENT VALVE

SOL.-2

V1

V2

L

1

1

21

SECTION 19: ELECTRICAL

83 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

19.10.2 Standard Discharge Control Remote
FIGURE 60: Standard Discharge Remote

FEEDER PROTECTION
SIZING BY OTHERS.

REF: N.E.C. TABLE 430-250

L1

L2

L3

G

POWER SUPPLY

460

____V___PH___HZ

DISC SW

F1

F1

F1

LPJ-25SP

1

3

15.1

____FLA

60

M1

OL

CB-2

3A

T-1 CONTROL TRANS.

X4

CB-3

460VAC

H3 H4

H1 H2

5A

X1

X2X3

120V

MOTOR FLA TAKEN FROM N.E.C
REFER TO NAMEPLATE FOR ACTUAL FLA

T1

SUPPLY FAN

MTR

MOTOR

1

____HP

10

____RPM

1800

____FLA

14.0

T2

T3

2

JUMPER

5 MIN.

ON

OFF

AUTO

SW-1

6

5

R B

TH-1

CYCLE STAT

SUMMER

8

WINTER

SW-2

18

HIGH TEMP

LIMIT

RESET

MANUAL

HLS

30

C

10

R W

16

TR

1

NC

LLS

M1

JUMPER

T-4

19

DM

1

24VAC

21

11

15

MOL-1

HIGH GAS

PRS. SWITCH

31

35

PS-1

JUMPER

MANUAL

RESET

32

34

AIRFLOW

AFS1-LO

AIRFLOW

AFS2-HI

M1

LT-1

AA

33

LOW TEMP
BY-PASS TIMER

INLET/DISCHARGE

DAMPER(s)

DAMPER L.S.

MOTOR
START

FAN ON
LIGHT

54

84 of 154

54

54

FIGURE 61: Standard Discharge Remote (Continued)

MRV

1

W

2

B

UV

T3

LOW VOLTAGE

TRANSFORMER

AMPLIFIER

SP

T2

TRANSFORMER

IGNITION

G

F

9

8

L2

76

FR-1

10

5

SOL.-1

VALVE

BURNER ON

FLAME RELAY

PILOT VALVE
SOLENOID

PRIMARY SHUT-OFF

20

AA

LT-2

VALVES OPEN

52

52

2

41

43

45

44

49

46

35

52

18

24VAC

51

52

V1

V2

L

1

52

1

6

5

TM

1

1
2
3

8

7

W

B

3
4

1

2

321

SEL

53

54

SECTION 19: ELECTRICAL

85 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

1

HLS

T-1 CONTROL TRANS.

H1 H2

AFS1-LO

PS-1

HIGH GAS

PRS. SWITCH

RESET

MANUAL

FEEDER PROTECTION

REF: N.E.C. TABLE 430-250

SIZING BY OTHERS.

G

LPJ-30SP

POWER SUPPLY

____V___PH___HZ

____FLA

460

L2

L1

L3

60

22.1

3

F1

F1

DISC SW

F1

21.0

1800

15

SUPPLY FAN

MOTOR

____HP

____FLA

____RPM

MTR

T3

T2

1

T1

AA

FAN ON
LIGHT

LT-1

MOTOR FLA TAKEN FROM N.E.C
REFER TO NAMEPLATE FOR ACTUAL FLA

H3 H4

460VAC

AFS2-HI

RESET

MANUAL

LIMIT

HIGH TEMP

AIRFLOW

AIRFLOW

2

11

30

31

33

35

18

16

54

54

34

15

32

54

5A

CB-3

X4

120V

X1

X2X3

JUMPER

JUMPER

JUMPER

M1

M1

MOL-1

M1

OL

START

MOTOR

350VA

3A

CB-2

TH-1

SW-2

SUMMER

ON

SW-1

OFF

R B

CYCLE STAT

TC26

TC26

AUTO

6

7
8

WINTER

TC

TIME CLOCK

26

5 MIN.

LLS

R W

C

NC

TR

1

LOW TEMP
BY-PASS TIMER

10

19.10.3 Deluxe Room Control Remote
FIGURE 62: Deluxe Room Control Remote

86 of 154

FIGURE 63: Deluxe Room Control Remote (Continued)

MRV

1

W

2

B

UV

T3

LOW VOLTAGE

TRANSFORMER

AMPLIFIER

SP

T2

TRANSFORMER

IGNITION

G

F

9

8

L2

76

FR-1

10

5

SOL.-1

VALVE

BURNER ON

FLAME RELAY

PILOT VALVE
SOLENOID

PRIMARY SHUT-OFF

20

AA

LT-2

VALVES OPEN

52

52

41

43

45

44

49

46

52

24VAC

51

52

1

18

35

2

V1

V2

L

52

52

B

W

R

8
9

3

4
5

1

2

321

1

TM

TCA

S
E

E

S

L

N

6
7

55

56

57

SECTION 19: ELECTRICAL

87 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

1

HLS

T-1 CONTROL TRANS.

H1 H2

AFS1-LO

PS-1

HIGH GAS

PRS. SWITCH

RESET

MANUAL

FEEDER PROTECTION

REF: N.E.C. TABLE 430-250

SIZING BY OTHERS.

G

LPJ-125SP

POWER SUPPLY

____V___PH___HZ

____FLA

460

L2

L1

L3

60

79.7

3

F1

F1

DISC SW

F1

77.0

1800

60

SUPPLY FAN

MOTOR

____HP

____FLA

____RPM

MTR

T3

T2

1

T1

AA

FAN ON
LIGHT

LT-1

MOTOR FLA TAKEN FROM N.E.C
REFER TO NAMEPLATE FOR ACTUAL FLA

H3 H4

460VAC

AFS2-HI

RESET

MANUAL

LIMIT

HIGH TEMP

AIRFLOW

AIRFLOW

2

11

30

31

33

35

18

16

54

54

5

34

15

32

54

5A

CB-3

X4

120V

X1

X2X3

12

JUMPER JUMPER

SD

SMOKE DETECTOR
DISCHARGE

SD22

23

CR

22

23

CR

5

60

M1

M1

MOL-1

M1

OL

START

MOTOR

AFS3

AA

CLOGGED FILTER
LIGHT

70

500VA.

3A

CB-2

PS-2

LOW GAS

PRS. SWITCH

RESET

MANUAL

TH-3

OA STAT

BU R

TH-1

SW-2

SUMMER

ON

SW-1

OFF

R B

CYCLE STAT

AUTO

6

8

WINTER

5 MIN.

LLS

R W

C

NC

TR

1

LOW TEMP
BY-PASS TIMER

10

19.10.4 Standard Room Control Remote
FIGURE 64: Standard Room Control Remote

88 of 154

FIGURE 65: Standard Room Control Remote (Continued)

MRV

1

W

2

B

UV

T3

LOW VOLTAGE

TRANSFORMER

AMPLIFIER

SP

T2

TRANSFORMER

IGNITION

G

F

9

8

L2

76

FR-1

10

5

SOL.-1

VALV E

BURNER ON

FLAME RELAY

PILOT VALVE
SOLENOID

PRIMARY SHUT-OFF

20

AA

LT-2

VALVES OPEN

52

52

2

41

43

45

44

49

46

35

52

18

24VAC

51

52

SOV1

SOV2

1

52

47

B
W
R

8
9

3

4
5

1

2

321

1

TM

TCA

S
E

E

S

L

N

6
7

86

87

88

SECTION 19: ELECTRICAL

89 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

T-1 CONTROL TRANS.

X4

120VAC

X1

H1

500VA

H4

FEEDER PROTECTION

REF: N.E.C. TABLE 430-152

SIZING BY OTHERS.

G

LPJ-40SP

POWER SUPPLY

____V___PH___HZ

____FLA

460

L2

L1

L3

60

29.7

3

F1

F1

DISC SW

F1

27.0

1800

20

SUPPLY FAN

MOTOR

____HP

____FLA

____RPM

MTR

T3

T2

1

T1

MOTOR FLA TAKEN FROM N.E.C
REFER TO NAMEPLATE FOR ACTUAL FLA

H3 H2

FAN START/STOP

INTERLOCK

BURNER START/STOP

INTERLOCK

CR98

CR93

1

2

12

16

18

15

X3 X2

54

54

21

24

22

21

1

CR-23

5

JUMPER

460VAC

L2L3

M1

M1

MOL-1

M1

OL

MOTOR STARTER/

MOTOR

INLET

TRANS.

TRANS.

OVERLOAD RELAY

DM

1

INLET DAMPER

24VAC

T-4

INLET DAMPER

DAMPER L.S.

T-6

120VAC

120VAC

40VA

40VA

INLET DAMPER

OA/RA DAMPER

BLK

RED

3

DM2

BY OTHERS

CONTROL

24VAC

(-) COMMON

OA/RA

W

DAMPER

(+) 0 -10 VDC

3A

CB-2

5A

CB-3

8

9

2

18

19.11 DDC-Ready Controls
FIGURE 66: DDC-Ready Controls

90 of 154

FIGURE 67: DDC-Ready Controls (Continued)

W

B

V3/MRV

2 1

UV

50

51

LOW VOLTAGE

TRANSFORMER

AMPLIFIER

SP

T-2

TRANSFORMER

IGNITION

G

F

9

8

L2

67

FR-1

10

5

SOL.-1

VALV E

BLOCK VALVE

FLAME RELAY

PILOT VALVE
SOLENOID

PRIMARY SHUT-OFF

20

HLS

LO

AFS1

PS-1

HIGH

GAS PRS.

SWITCH

HI

AFS2

LIMIT

HIGH TEMP

AIRFLOW

AIRFLOW

RM7897C

BU R

TH-2

OA STAT

CR93

24 VAC COIL

(YELLOW WIRE)

POWERED BY OTHERS

FAN START/STOP

INTERLOCK

CR98

24 VAC COIL

(YELLOW WIRE)

POWERED BY OTHERS

BURNER START/STOP

INTERLOCK

10 AMPS MAX

BURNER FAILURE

INTERLOCK

3

CR67

SAFETIES

BURNER FAILURE
RELAY

30

31

33

32

34

40

41

42

43

44

45

46

64

65

JUMPER

49

110

111

112

113

114

115

53

53

MANUAL

RESET

MANUAL

RESET

MANUAL

RESET

CR67

(YELLOW WIRE)

POWERED BY OTHERS

24VAC

T-3

120VAC

40VA

PS-2

GAS PRS.

LOW

SWITCH

SOV1

SOV2

48

4-20mA/0-10VDC MODULATION

INPUT

CONDITIONER

SIGNAL

1

2

3

4

-

+

6

5

B

R

SC-1

18

2

SECTION 19: ELECTRICAL

91 of 154

4000-SERIES INSTALLATION, OPERATION AND SERVICE MANUAL

Yo ur RAPID

®

Air Handler may be equipped with one
of the following DDC control offerings. If so, a
separate manual providing wiring, operation and
trouble shooting information, specific to that control
offering, will also accompany this document.

19.12 Intelligent Control Systems

19.12.1 ICS II

19.12.2 ICS IV

19.12.3 InfinityPro™

92 of 154