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RAPID® InfinityPro™ Manual

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2. 25 SECTION 2 Sequence of Operation 2 1 Air Handler Model Configurations 2 2 Select Operating 2 3 Outdoor Air nennen nnn enne 2 4 Flush 2 5 Heating Control Type Occupied Period 4 2 6 Heating Mode Unoccupied Setback nennen nennen 5 2 7 Heating amp m vell PALS EG 0 c4 ERES SECTION 3 User Instructions EE 3 2 Keypad Screen Brightness 8 3 3 Standby 6 10 3 4 11 3 5 SCION uice dd nic oe es 12 3 6 Setting PME 13 3 7 Nime Glock d 15 3 8 Status Scree a 21 GRECI CE 23 S310 Cali ratio trm 24 3 11 Manual
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5. sees 19 Figure 11 GIocK Set 5 hee REED LU ERREUR RR Ue dA 20 Fig re t2 Status Screen ed gr e ER ee ee ie 22 Figure t3 Alarm Screen zio eee aee PIU OH TT 23 Fig re 14 Calibration Screen xiii tete Ret pe eet 24 Figure 15 Manual Overrides Technician Use Only sse 25 Figure 16 Configuration Technician Use 27 Figure 17 Keypad Scteen rice Dieter t t d e eels 28 Figure 18 MUA FR with Forced Supply Air Heating 29 Figure 19 MUA FR with Room Air Temperature Control sese 30 Figure 20 MUA FR with Outdoor Air Room Temperature Control sse 31 Figure 21 AM VAV with Forced Supply Air 32 Figure 22 AM VAV with Room Air Temperature 33 Figure 23 AM VAV with Outdoor Air Room Temperature Control seen 34 Figure 24 Basic Wiring Diagram Part 35 Figure 25 Basic Wiring Diagram Part 0 36 Figure 26 Basic Wiring Diagram Part 37 Figure 27 RAPID InfinityPro Networking Software 38 Fig re 28 Control Board uiis cetero oet 39 Figure 2
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7. 1 25 2 HRS ERE 26 3 13 Model Flow 29 SECTION 4 WANG 35 SECTION 5 Web Control Software Front End Communication eene 38 5 1 General Informatioh eiecit Eee texere ciere ein R aie 38 5 2 System 38 DS oe done E N 38 5 4 Setting Up 39 5 5 Installing Web Control 39 5 6 Software Installation Complete 40 5 7 Establishing a 40 SECTION 6 User Integration Points 46 6 1 User Integration 46 SECTION 7 Troubleshoolting ica uro neuen usn cu nn ea ne eant aan si sm nan Dx 50 em 50 72 General Troubleshooting 51
8. 00 500 xoeqies 00 2 SONILI3S sbumes epon 200 duie pidey 4N33H2S Aue JO 00 duie BuueeuiBu3 pidey LINVAAG ony epo 8unejedo 5199195 4020 9 oiny YIO Q 104340 YUM T3GOW 30 of 61 USER INSTRUCTIONS SECTION 3 ue4 001 AJO SIH INHVTV MUA FR with Outdoor Air Room Temperature Control FIGURE 20 ed L ped eainog poueg HO andino 00 00 Andino Ud 200 HO sniels 18 00 eunjejeduue Ajddng 500 eunyejeduue 58715 snes ony epoyy HO 4 00 195 00 9 195 95 40019 9990 smeis
9. Engineering RAPID InfinityPro Control System for 4000 Series A WARNING 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 Installation must be done by an electrician qualified in the installation and service of control systems for heating equipment C UL US LISTED 1090 2015 Rapid Engineering LLC industrial Air Handler User Operation amp Troubleshooting Manual Installer Please take the time to read and understand these instructions prior to any installation Installer must give a copy of this manual to the owner Owner Keep this manual in a safe place in order to provide your service technician with necessary information Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park MI 49321 Telephone 1 616 784 0500 Fax 1 616 784 1910 Toll Free 800 536 3461 Service Telephone 1 616 784 6800 Service Fax 1 616 785 0375 Service Toll Free 800 968 0500 www rapidengineering com P N RP140005NA Rev A 03 15 TABLE OF CONTENTS jzeglebHiuceuuuunm M 1 ct E ue 1 1 2 What is a RAPID InfinityPro 1 Electrical Requirernernits renti eo EIE
10. 00 e oqy JO 200 xen Ajddns 000 duie 00 30 200 xoeqieg 00 2 SONILLAS sbumes epow 200 oJgAyuygu 4N33H92S 3INOH Aue usng JO smeis ue4 00 erg pidey 8 ony ees 42019 YIO D uo 5 YUM AVA WV 3dAL 5199105 33 of 61 OPERATION AND SERVICE MANUAL INFINITYPRO USER FIGURE 23 RAPID Wes ue4 qi 001 A401SIH with Outdoor Air Room Temperature Control eainog 000 000 JoopinQ O M 40070 Bumes O M 0070 ensseJg einsseJg 9 Bunejedo 1eziuouoo3 HO andino 00 00 U
11. Contact Rapid Engineering LLC with any additional questions at 800 968 0500 42 of 61 WEB CONTROL SOFTWARE FRONT END COMMUNICATION SECTION 5 tyPro ini Sensor Network Cable for Infi FIGURE 33 IVLSNI INNON 71 8 NIG vc 0c uQW 898 14405 u3MOd 986 IVLSNI INNOW NIC 80140587 898 83173434 v96cc IVLSNI NN3d 153M 81 3182 YOSNAS QVdA3 V N IVLSNI VS01 013 5 38IM N3138 318V2 YYOMLIN V N 1978 80123 02 LAN Y 318V2 QVdA3 996 1978 QVdA33 97000 NOLLO3NNOO 13 3 HOSN3S WOO 00121 19478 331104 303 NIG 1161980 19 333045731 TIVM OSr vc ns vM 14405 YIMOd LL8CC Idv dL SW OL di 19u5 V8 SVE 6 01 d3riddns 5 9 YASWNN 1 01993 Jauuosiad 5 5494401 2 aui Aq dn jas 1 Jausa U y TH LOQ9M 01 5952 ut Dd Jo 38s 15e BY Jo uondeoxe BU 01195 aq IM 5 dI Dd 91 89689161 IIM 1201 BU 20 d si Jd J 830N 1euJa1u Jema PHOM ul Dd Auy Jo pueu 1se OL pue 6 Way ajqe gt xjoweu 291 Ul La 936212 0 JO Sjlun UBYM Y 0002
12. OL 88 S W3TIOMINOO OL ATILO3MIO MOSN3S 309 PUY WOLLOG OL 193NNOO VSEO VAVE SLIOA 021 et ANH IOON HSM 37 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL SECTION 5 WEB CONTROL SOFTWARE FRONT END COMMUNICATION 5 1 General Information Rapid Engineering LLC supplied optional networking software is available to allow the user to visually con nect with and operate each air handler for proper operation and troubleshooting 5 2 System Requirements Web Control desktop computers should have at least a dual core processor 1 5 GB RAM and a communication link of 10 Mbps or higher It will work on slower computer with slower links but results may vary For desktop browser requirements see Page 38 Table 9 For tablet requirements consult factory Table 9 Desktop Computer Requirements Computer with this operating system Web Browser Google Chrome v23 0 or later Windows Internet Explorer v8 v9 v10 or v11 Desktop Mozilla Firefox v21 0 or later Google Chrome v23 0 or later Linux Mozilla Firefox v21 0 or later Safari v6 or later Mac OS X Apple Mac only Google Chrome v23 0 or later Mozilla Firefox v21 0 or later 5 3 Graphics Visual graphic screens help the user to change parameters with ease An example of the main graphics screen
13. See Page 52 Section 73 1 BV 9 R Fan Contactor On When Should Off See Page 52 Section 73 2 BV 10 R S Peatair Net See Page 52 Section 73 3 11 See Page 53 Section 73 4 BV 12 R Closed Burner Lockout or Safety SW Not Made See Page 53 Section 73 5 BV 13 R Low Supply Air Temp Shutdown See Page 56 Section 73 6 BV 14 R Dirty Filters See Page 57 Section 73 7 BV 15 R Low Building Pressure See Page 58 Section 73 8 BV 16 R 48 of 61 6 1 7 Auto Discovery SECTION 6 USER INTEGRATION POINTS Display Name bea Units zs Reference Name ET Select Schedule Source R W nounits 1 sched source AV 5 Select Occ Unocc Period On Off R W Inactive 0 enable bas BV 1 Select Operating Mode R W units 0 op_mode_select AV 7 Select Damper Control HW 1 setdampct 5 2 Select Economizer Type R W 1 econ type MSV 1 Status Schedule Cntrl Source R no units status sch Source 19 Status Occ Unoccupied R occ_status BV 2 Status Operating Mode R no units status_op_mode AV 17 Status Fan On R status_fan_on BV 7 Status Output to VFD R vfd_spd AV 18 Status Active Heating Setpt R F eff htg stpt AV 11 Status Heat Off Stpt status heat off AV 12 Status DA Temp H status da temp AV 20 Status Cooling Stpt R
14. rrow 4 b Buttons Number Buttons 9 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 3 Standby Screen When the handheld keypad is connected to the DDC Controller the first screen to appear will be the Standby Screen See Page 10 Figure 2 User will be able to easily identify room temperature and fan status based on information shown in main viewing window on line 3 For convenience date and time are also shown on line 2 Within standby screen parameters information is fixed room temperature and fan status In order to implement changes push any key and follow directions based on subsequent screens If inactivity takes place for one minute this screen will be displayed This is the factory default setting User can change inactivity time duration in the Configuration Screen A special button sequence is required to access the Configuration Screen See Page 26 Section 3 12 FIGURE 2 Standby Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE Rapid Engineering InfinityPro V0 0 MM DD YYYY 55 Room Temp 00 0 Fan Status Off Push any key to begin 10 of 61 SECTION 3 USER INSTRUCTIONS 3 4 Home Screen On the Home Screen See Page 11 Figure 3 the user can easily identify heat cool set
15. F eff clg stpt AV 10 Status Room Temperature H no units status room temp AV 22 Status OA Temperature R F status_oa_temp AV 8 Status Heat On_Off R heat_enable BV 8 Status Heat Output R status_burn_output AV 13 Status Damper Control R no units status_damp_ctrl AV 14 Status Manual Damper Position SP R status man damp sp AV 15 Status Total OA Peret R AV 21 Status Building Pressure H in H2O eff bldg pres AV 9 Status Economizer On Off R status econ active BV 3 Status Cooling Stage R status clg stg BV 4 Stpt Occupied Htg R W F 70 occ_htg_stp AV 2 Stpt Unoccupied Htg R W F 55 unocc_htg_stp AV 1 Stpt Heat Off range 2 20 degrees R W F 3 burn_off delta AV 26 StptCooling __ RNW F 74 occclg stp AV 4 Bldg Static Pressure inH2O 001 bldg press stpt AV 23 Stpt Manual Damper Position R W 50 fxd dmpr pos AV 28 Stpt Max Supply Air Temp R W F 95 max_dat_stpt AV 29 Stpt Min Supply Air Temp R W F 60 min_dat_stpt AV 30 Stpt Forced Supply Air Temp R W F 70 DA_Temp_Sp AV 25 Stpt OA Heat Disable R W F 95 oa_heat_disable AV 32 Stpt OA Heat Enable R W F 50 oa_heat_en_sp AV 31 Temp Shutdown HW F 40 Low Temp Shutdown AV 27 Stpt OA Limit R W F 65 OA Econ Limit Stpt AV 24 ME Supply Damper LS Did R heat damp BV 9 Alarm Energy Alert H low pressure BV 10 Alarm Fan Contactor Hand Mode H fan forced BV 11 Alarm Filters Dirty H
16. b Inspect all terminations and plug connections make sure that they are making good electrical con tact 2 The sensor is defective a Replace the sensor For burner equipped direct fired air handlers which circulate room air if the room or discharge air tempera ture sensors are defective the RAPID InfinityPro logic for temperature rise control will allow the burner to light but it will remain at low fire Replace the defective sensor in order to restore proper operation 58 of 61 Table 10 Thermistor Performance SECTION 7 TROUBLESHOOTING Temperature Temperature Fahrenheit Celsius one 0 85 350 17 5 84 106 5 72 910 15 0 72 910 10 62 480 12 5 62 523 15 53 640 10 0 55 408 20 46 230 7 5 48 453 25 39 910 5 0 42 438 30 34 560 2 5 37 235 35 30 000 0 0 32 736 40 26 100 2 5 28 830 45 22 760 5 0 25 432 50 19 900 7 5 22 474 55 17 440 10 0 19 900 60 15 310 12 5 17 686 65 13 480 15 0 15 736 70 11 880 17 5 14 029 75 10 500 20 0 12 520 80 9 298 22 5 11 190 85 8 250 25 0 10 019 90 7 331 27 5 8 984 95 6 532 30 0 8 066 100 5 826 32 5 7 251 105 5 209 35 0 6 532 110 4 663 37 5 5 897 115 4 182 40 0 5 332 120 3 757 42 5 4 827 125 3 381 45 0 4 374 NOTE This table is applicable for the standard RAPID temperature sensor which is a thermistor The purpose of this table is to assist a service technician in diagnosing sensor relat
17. The burner requires maintenance a See RAPID 4000 Series Industrial Air Handler Installation Operation and Service Manual RP140000NA Maintenance Section and drill burner orifices out with the correct size drill bit b Check burner gas pressure and compare it to the unit rating tag adjust if needed 3 The manual gas valve is closed or there is a blockage in the gas line a Open the valve or open the dirt leg cap and remove any blockage 4 The discharge sensor its cable or its connection to the control module is off or defective a Verify proper discharge sensor operation and cable connections and repair as necessary 5 The connection from the control module to the modulating valve is defective or off a Repair the connector or cable as necessary 6 Low limit set point is set too high Factory default is 40 degrees Fahrenheit a Adjust the low limit set point to an appropriate value 7 The modulating gas valve does not open to allow high fire The valve should modulate progressively more open as the voltage from the controller rises above 5 volts DC and continue opening until the volt age exceeds 15 19 volts DC a Repair or replace the valve and adjust high and low fire flames as needed 8 Ignition did not occur 56 of 61 SECTION 7 TROUBLESHOOTING a The igniter spark plug is defective fouled or shorting against the burner end plate Check that it is properly installed has a clean no carbon gap of about 3 32 2 5
18. Thermistor 59 There are references in this manual to various trademarks All trademarks mentioned herein whether regis tered or not are the property of their respective owners Rapid Engineering LLC is not sponsored by or affili ated with any of the trademark or registered trademark owners and makes no representations about them their owners their products or services SECTION 1 INTRODUCTION SECTION 1 INTRODUCTION This manual is to be used in conjunction with the RAPID9 4000 Series Industrial Air Handler Installation Operation and Service Manual P N RP140000NA 1 1 Safety Your 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 the controller and its associated heating cooling equipment must be done by an electrician qualified in the installation and service of control systems for heating equipment using only replacement parts sold and supplied by Rapid Engineering LLC Installation service and at a minimum annual inspection of the heater must be done by a contractor qualified in the installation and service of gas fired heating equipment using only replacement parts sold and supplied by Rapid Engineering LLC Read this manual carefully before installation operation
19. USER OPERATION AND SERVICE MANUAL FIGURE 34 95015 91909 uepijeg 5529 G8r VI3 a u ASNW 21097 so g J0 emod 3 sn 3 oneri a 4 86 INOZ uo HO did Licioeyes 4941 JV NYG 992021 1405 jd 40 48 48S SPDAUUOD 197 44 of 61 SECTION 5 WEB CoNTROL SOFTWARE FRONT END COMMUNICATION pue eui 10 9 483490 ajnpou Aud puo pue ajnpou BuiuuiBao 10 020 eq snu pesn saedunf 6Bulzoulwuey 4I 4o Ul 83050 AyyovidAy uon 2eulp Ul ZNO J 21005 HUOMPSU AY y uo sjun 26 USYL S 44 0002 5 3 gt 242 pauinbau 51 y for Use with Multiple Air Handlers LN gt 4aypuou O4 319923 re Qdul42 NU 49Uu430 0 y ujor ics A UO 484nos y UO Pulda JS 247 puo 450 ay 01 pe42a8uuo2 5126 24 ay 19
20. catch fire or explode when placed close to equipment Failure to follow these instructions can result in death injury or property damage 71 Initial Checks When encountering any abnormal operation or fault conditions of the equipment all the troubleshooting should start with the following initial checks If a problem is discovered in these initial checks it must be cor rected before moving on in the troubleshooting 1 The air handler may have any number of possible heat sources electric gas hot water or steam or none at all Several cooling options are also available evaporative DX chilled water 50 of 61 SECTION 7 TROUBLESHOOTING 2 If the air handler does not include a feature as described in this Troubleshooting Guide disregard infor mation provided for that feature As indicated above in item 1 some features are optional and not included with every air handler 3 The following voltages are used for the control circuitry 120 volts AC 24 volts AC 5 volts DC 0 20 VDC and 0 10 VDC 4 Refer to the air handler wiring diagram for aid in locating the error 5 The Maxitrol modulating regulating valve direct fired models and its associated circuitry is powered by a 0 20 VDC signal The RAPID InfinityPro controller provides a 0 10 VDC signal to a signal condi tioner which then converts the signal to 0 20 VDC 72 General Troubleshooting 1 Compare voltage and phase of power supply on site with rating
21. 73 e adenine Se dence neces 51 SECTION 8 The RAPID InfinityPro 61 2015 Rapid Engineering LLC All rights reserved No part of this work covered by the copyrights herein may be reproduced or copied in any form or by any means graphic electronic or mechanical including photocopying recording taping or information storage and retrieval systems without the written permission of Rapid Engineering LLC Printed in U S A TABLE OF FIGURES Figure 1 Basic Screen 9 Figure 2 Standby Screen icio Ga e PU RUE ERA BENE RR MESSER 10 Fig re 3 Home Screen csv sh a er pee to aether rt 11 Fig re 4 Mode nti ed iie anne e e ie c ecd dc eh n o des 12 Fig re 5 Setting sd acie ett etre dad tena i t re c eati ds 14 Fig re 6 Time Clock Screen caddie ed die Ie Ee 15 Figure 7 Daily Schedule 16 Figure 8 Holiday Schedule 17 Figure 9 Override Schedule 18 Figure 10 24 Hours a Day 7 Days a Week 24 7
22. Not Made Burner Control Safety Lockout The Honeywell 7800 Series burner control defaults into safety lockout during certain conditions The Honey well 7897 burner control features an LED blink pattern when in lockout condition The fast blinks identify the tens portion of the fault code 3 fast blinks is 30 while the slow blinks identify the units portion of the fault code 2 slow blinks is 2 For a complete list of fault codes refer to the Honeywell burner control literature 1 No flame signal present during the trial for ignition period a Check that the supply gas pressure meets that air handler specifications b Make sure all of the manual shut off valves are open c Check the pilot line gas pressure at the in the pilot line down stream of the pilot solenoid and the pilot regulator Typical pilot line gas pressure is approximately 2 w c differential resulting in a pilot flame about the size of a baseball If no pressure is present either the pilot regulator or pilot solenoid valve may be defective 55 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL d Check the igniter clean or replace if needed e Remove and clean the lens of the UV scanner with a soft cloth f Check the UV scanner by holding a flame in front of the UV scanner lens Look for the flame LED light on the burner control to come on If it does not come on the UV scanner has most likely failed 9 Check the ignition transformer make
23. UN 25 26 27 28 29 30 S 55 5 t 5 5 5 5 B 8 9l S 8 v FEEDER PROTECTION SIZING BY OTHERS REF N E C TABLE 430 152 POWER SUPPLY 208 230 460 575 VOLT DISC SW 460VAC 1 3 75 120 TO LINE 133 JUMPER JUMPER MANUAL RESET SECTION 4 WIRING MOTOR FLA TAKEN FROM N E C REFER TO NAMEPLATE FOR ACTUAL FLA M1 MOL 1 n SUPPLY FAN MOTOR DM2 OUTSIDE RETURN I A BURNER INITIATE AIR DAMPER BELAY FAN INITIATE RELAY 39 DAMPER INITIATE RELAY INLET DAMPER MOTOR INLET DAMPER LIMIT SWITCH 139 QA SUPPLY FAN MOTOR CONTACTOR OVERLOAD MANUAL RESET HIGH TEMP LOW GAS PRS HIGH GAS PRS LO HLS PS2 PSI AFS 1 SAFETIES 35 of 61 Rapip INFINITYPRO USER OPERATION AND SERVICE MANUAL FIGURE 25 Basic Wiring Diagram Part Two BURNER INITIATE CR27 89 9588 2 REUS PRIMARY SHUT OFF VALVE ER VALVES 4 FBR TO LINE 134 00 MODULATING TO LINE 135 75 76 7 78 79 09 1 H LN n TO LINE 133 TO LINE 132 M zc PJ3 PJ5 PRESSURE TRANSDUCER CONFIGURATION JUMPERS 8892 887988 36 of 61 WIRING SECTION4 Part Three iagram D ic W Bas FIGURE 26 300W HSM og INN OL INN OL te
24. different types of heating controls available Room Air Temperature Control Force Supply Air Heating and Outdoor Air Room Control When changing a temperature heating type control careful consideration should be taken 4 of 61 SECTION 2 SEQUENCE OF OPERATION 2 5 1 Room Air Temperature Control The heating setting is activated if the room temperature falls below the Occupied Heating setting The heat is dynamically modulated to maintain the supply air temperature between the minimum and maxi mum supply air temperature settings as needed to maintain the Occupied Heating setting f the room temperature continues to increase reaching the Heat Off Setting the heat is deactivated The heat will remain off until the room temperature drops below Occupied Heating setting 2 5 2 Forced Supply Air Heating f the room temperature drops below the Occupied Heating Setting the heat will start and modulate as needed to maintain the Forced Supply Air Heating setting f the room temperature continues to increase reaching the Heat Off Setting the heat is deactivated The heat will remain off until the room temperature drops below the Occupied Heating setting 2 5 3 Outdoor Air Room Control f the outdoor air temperature drops below the Outdoor Air Heat On setting the heating function is acti vated When the heat is on the supply air temperature is controlled as detailed on Page 5 Section 2 5 1 Room Temperature Control The heat
25. fillers dirty BV 12 Alarm Gas Valve LS Did Not Make H gas valve BV 13 Alarm Low Temp Shutdown H low temp BV 14 Alarm Supply Damper LS Did Not Open H heat damp force BV 15 Alarm Supply Fan Fail H fan fail BV 16 Keypad Schedule Enable R W Inactive 0 enable keypad BV 17 49 of 61 RaPID INFINITYPRO USER OPERATION AND SERVICE MANUAL SECTION 7 TROUBLESHOOTING Electrical Shock Hazard Severe Injury Hazard Disconnect electric before service Do not enter equipment while in operation More than one disconnect switch may be Equipment may start automatically required to disconnect electric from equipment Do not operate with door open Equipment must be properly grounded Installation operation and service must be done by a trained technician only Failure to follow these instructions can result in death electrical shock or injury WARNING Explosion Hazard Fire Hazard Falling Hazard Burn Hazard Cut Pinch Hazard Turn off gas Keep all Use proper safety Allow equipment Wear protective supply to flammable equipment and to cool before gear during equipment before objects liquids practices to avoid service installation service and vapors the falling operation and minimum required Internal compo service clearances to Do not use any nents of combustibles part of equipment equipment may Edges are sharp away from as support still be hot after equipment operation Some objects will
26. manually set the damper position Select Damper Control 2 Pressure dampers modulate to maintain Auto Room MSV 2 R W Pressure 1 Handheld Keypad Select Schedule Source 2 Building Management Automation System AV 5 R W 3 WebCTRL This point is used by the controls integrator to put the air handler into Select Occ Unocc Peri the occupied period when the schedule source is via the e BV 1 R W od On Off building management system 0 Unoccupied 1 Occupied Use this point to enable the economizer control Select Economizer Type 1 No Economizer MSV 1 R W 2 Economizer 6 1 2 Operating Status mu 5 Read Point Name Description Point Type ID Write R t the stat f th t tion ff Aut Status Operating Mode e status of the current operation On Off Auto or 17 R Status Damper Control Reports the status of the dampers Auto or Manual 14 R Status Schedule Reports the status of the Schedule Source Handheld Source pad Building Management BAS System or WebCTRL AV 19 Status Occ Unoccu Reports current status of operation Occupied Unoccu BV 2 R pied pied onze On Reports status of Economizer On or Off BV 3 R Off 46 of 61 6 1 3 Heat Settings SECTION 6 USER INTEGRATION POINTS drive based on unit operation Point Name Description Point Type ID Read Write During the occupied period burner starts
27. mode of operation selected and is adjustable by the user In order to change operating mode use arrow keys to navigate around main viewing window and enclose ON OFF AUTO text Once ON OFF AUTO is properly bracketed press enter on keypad The text OK CANCEL DECR and INCR will then appear in line 4 Using a combination of the arrow buttons and INCR or DECR navigation buttons the mode can be altered Use the CANCEL button to terminate the command and use the OK button to accept the command See Page 12 Table 1 for opera tion modes with descriptions Table 1 Mode Commands Mode of Operation Description The fan and heat will not run unless overridden by flush or forced occupied command The OEF air handler is turned off The fan runs continuously the available heating and cooling functions respond to maintain ON their occupied settings The time clock schedule is not in use The fan will run continuously in the occupied period and turns off in the unoccupied period unless the room temperature falls below the unoccupied heat setting The heat cycles on and off based on the heat setting During scheduled occupied periods the air handler AUTO operates in the occupied sequence of operation During scheduled unoccupied periods the air handler operates in the unoccupied sequence of operation The air handler oper ates based on the scheduling that is entered into the controller or as directed by the hand held keypad
28. plate information 2 Review wiring diagram Do the electrical connections match the supplied wiring diagram 3 Compare the gas type and supply pressure on site with rating plate information 4 Check for proper blower rotation on air handler Blowers paired with a three phase motor can be reversed by swapping any two incoming power legs For blowers powered by a single phase motor refer to the motor rating plate for reversing instructions 5 For additional information on supplemental temperature sensor information See Page 58 Section 73 9 7 2 1 Fuses Overloads Tripping Frequent tripping of the electrical safety devices often indicate an electrical or duct design problem Investigate carefully to determine the underlying cause consulting the National Electrical Code as neces sary Possible causes for tripping include 1 The voltage supply to the air handler is too low Check the transformer taps Check wire size and length for excessive voltage drop 2 The feeder breaker or fuses are undersized Correct the improper component 3 Air handler CFM is too high causing excessive current draw This occurs when the actual static pres sure is significantly less than expected and specified Consult Rapid Engineering LLC if additional assistance is required 7 2 2 Flame Relay The Honeywell flame relay RM7897C 1000 is equipped with an interrupted pilot The pilot is extinguished after the main flame is established A Test Run switch
29. sure the wiring to the igniter is good and not grounded out 2 The flame signal is lost during the main flame establishing period or during the run period a Make sure the burner orifices are clean See RAPID 4000 Series Industrial Air Handler Installa tion Operation and Service Manual RP140000NA Maintenance Section and drill burner orifices out with the correct size drill bit b Remove and clean the lens of the UV scanner with a soft cloth c Check the burner low fire setting The flame length at a minimum firing rate must be long enough for the UV scanner to see the flame d Make sure the primary and block gas valves are opening during the main flame establishing period Optimum low fire flame length setting is 1 2 Ensure that there is a continuous ribbon of flame with no gaps Gaps are most likely to occur at T intersections on the burner 7 3 6 Alarm Description Low Supply Air Temp Shutdown This alarm occurs when the supply air temperature drops below the Fan Off If Supply Air Temp Below setting for more than 5 minutes and there is a call for heat 1 Heat system failure a The control module detects problems with other areas of operation it will not allow the burner to light This in turn may allow the supply air to fall below the low temperature set point for 5 min utes b Check the Alarms log to see if another code has preceded it by 5 minutes and follow that alarm code s explanation of possible trouble 2
30. the potential for an excessively high building pressure relief dampers can be installed in the space 2 8 3 Mechanical Cooling The 20 burner supply air damper on Air Management and Variable Air Volume models is closed at all times during the cooling operation with the exception of Evaporative Cooling Mechanical Cooling is available in both Auto Room Pressure and Manual Percent Outside Air setting 2 8 4 Time Clock The air handler can be controlled by more than one schedule but not at the same time The schedule source must be selected by the operator Selecting the schedule source is accomplished via the configuration screen See Page 26 Section 3 12 using the handheld keypad a building management automation sys tem or WebCTRL software See Page 8 Section 3 for more information on keypad screens and Page 15 Table 3 for schedule options 6 of 61 SECTION 2 SEQUENCE OF OPERATION 2 9 Options 2 9 1 Energy Alert Control AM amp VAV Models This control function is only active during occupied periods and when the air hander is in the Auto Room Pressure setting When activated this control function monitors the room pressure If for any reason the room pressure remains 0 01 w c below the Auto Room Pressure setting for ten consecutive minutes the energy alert control reverts back to the Unoccupied Setback Temp setting The dampers are then forced to the mini mum outside air position 20 outdoor air 80 return air This cond
31. turning it ON or OFF Economizer Setting Defines the maximum outdoor temperature allowed for Economizer cooling Outdoor Air Control Auto Room Pressure Pressure the dampers modulate automatically to maintain Auto Room Pressure Manual the dampers are fixed at a user defined setting Defines the setting when Pressure is selected The dampers modulate automatically to maintain Auto Room Pressure Manual Percent Outdoor Air Defines the setting when Manual is selected The dampers remain fixed until the setting is changed 13 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL FIGURE 5 Setting Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE Heatings Settings Occupied Heating 00 Unoccupied Setback 00 gt Home 5Time Clock 14 of 61 SECTION 3 UsER INSTRUCTIONS 3 7 Time Clock The air handler can be controlled by more than one schedule but not at the same time The schedule source must be selected by the user the default is handheld keypad Selecting the schedule source is done using the handheld keypad from the Configuration menu or by the 3rd party front end Table 3 Schedules Schedule Options Description Daily Typical daily schedul
32. will shut off when the outdoor air temperature is above the Heat Off If Outdoor Air Above setting 2 5 4 Heating Function Notes The heat is disabled if the outdoor air temperature is greater than the Heat Off If Outdoor Air Above set ting for all of the temperature controls listed above The factory default setting is 95 F This function is available in all three heating types as described on Page 5 Section 2 5 1 through Page 5 Section 2 5 3 f the heat fails and the supply air temperature drops below the Fan Off If Supply Air Temp Below setting the fan will shut off and generate an alarm See Page 23 Section 3 9 The fan and heat operation are disabled in the unoccupied period 2 6 Heating Mode Unoccupied Setback During an unoccupied setback period the fan and heat will only run when the room temperature falls below the Unoccupied Setback Temp setting Cooling is disabled during unoccupied periods 2 6 1 Room Air Temperature Control amp Forced Supply Air Heating If the room temperature falls below the Unoccupied Setback Temp setting the fan and heat will start The heat will remain on until the room temperature reaches the Heat Off Setting 2 6 2 Outdoor Air Room Control When this function is selected the fan and heat operation are disabled in the unoccupied period 2 7 Heating Types 2 7 1 Direct Fired Gas Burner The burner is controlled by an analog output from the RAPIDS InfinityPro controller and will operat
33. 04 AVA WY T300W 32 of 61 USER INSTRUCTIONS SECTION 3 AM VAV with Room Air Temperature Control FIGURE 22 Wes ue4 1u82281 001 A401SIH dA 6 000 40070 einssejg 00 0 eunsseJg poueg peidnooo 1eziuouoo3 HO andino 00 00 00 eunjejeduue HO 5 18 5 00 199 000 200 200 aunyesodway snes 5041 snes olny ueJ 00 195 00 9 19 hes 42015 ned Live fAepioH rea 0 snjeis 120712 000 1 O M 00 0 e1nssejg einsseid 200 Bumes 1eziuiouo23 1eziuouo 23 00 000 Ajddng 4O
34. 9 Getting to Know the 41 Figure 302 Configure E 41 31 Download oo ctt ted ci dee eb a ferte etie tra pde etes ice aero cen 42 Figure 32 Air Handler Network 42 Figure 33 Sensor Network Cable for 43 Figure 34 Cabling and Network Specifics for Use with One 44 Figure 35 Cabling and Network Specifics for Use with Multiple Air Handlers 45 LIST OF TABLES Table 1 Mode Commands dee tp Ee nr PLE ec tiger aD ecu d ecd 12 Tabl 2 Setting Commands cu A ERREUR URS 13 Table 3 Schedules eec ee 15 Table 4 Schedule Examples uc ce dca Wiad ain in 16 T bl 5 Status Conditions Ee io E e ic cei eic rd cra 21 6 EE e RR RI Pre D EU TREE ER 23 Table 7 Calibration Adjustment ssi 4 odore eid fter c idet y 24 Table 8 Configuration Status dicunt tee ei ice eg eed e Dye 26 Table 9 Desktop Computer 38 Table 10
35. DECR amp INCR to hide or show the days Press the OK to accept the change To activate the schedule it must be turned on by selecting YES next to the word Use There are three daily schedules two holiday schedules two override schedules and one 24 7 schedule available Operation is limited to 24 hour clock astronomical time Each day s schedule may not be set to stop later than 23 59 PM If you want the schedule to run past midnight two schedules must be established to cover the occupied period An example of a schedule to run from 7 00 AM to 2 00 AM Monday through Saturday is as follows Table 4 Schedule Example Example Start Stop Days Daily Schedule 1 07 00 23 59 MTWTF Daily Schedule 2 00 00 02 00 TWTFS FIGURE 7 Daily Schedule Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE DAILY SCH 1 Use YES Stat OFF 24hr Start Time 00 00 Stop Time 00 00 DAYS MON TUE WED THU FRI SAT SUN gt Next gt Home 16 of 61 SECTION 3 USER INSTRUCTIONS 3 72 Holiday Schedule The holiday schedule forces the air handler to the unoccupied mode See Page 5 Section 2 6 FIGURE 8 Holiday Schedule Screen HOLIDAY SCH 1 Use YES Stat OFF 24hr Start Time 00 00 St
36. G8r VI3 04 185 aq 8 94 2409 403 2 SSUDTIMS dio S oe Ave 57579 3 Dai pa D uuod ag SNU 2 ZO puo 29 Cabling and Network Spec FIGURE 35 95015 21990 uepjeg 5229 488u snu 9 a31nus IWATE 03 3 041 4 305 48 48S 4128uuo2 192 45 of 61 RaPID INFINITYPRO USER OPERATION AND SERVICE MANUAL SECTION 6 USER INTEGRATION POINTS 6 1 User Integration Points 6 1 1 Operating Types NOTE Default values are represented in bold ode Read Point Name Description Point Type ID Write 0 Off Select Operating Mode 1 AV 7 R W 2 Auto 1 Manual
37. II 00 eunjejeduue HO SNIS 00 eunyejeduue Ajddng 200 5119185 snes ue4 00 195 00 9 195 hes 2019 ned Live rea dooo snjeis 12012 INIL eui 000 JoopinQ 1u9218g O M 00 0 e1nssejg AINSSAld 200 1eziuouo23 UO 3 000 6 00 Ajddng 4O ue 000 e oqy HO 78H 000 JoopinO 00 xen Ajddns 00 duue 000 2 sBumes SONILLAS sbumes 00 duie pidey 4N33H2S 3INOH Aue usng smeis 00 duie pidey 043005 aJn3ejeduue AVA WV ony 99 96 ees eAnoy 0010 2200 13800 34 of 61 SECTION 4 WIRING FIGURE 24 Basic Wiring Diagram Part One OO UO
38. INSTRUCTIONS SECTION 3 3 13 Model Flow Charts Heating Ir MUA FR with Forced Supply A FIGURE 18 001 Alo sIH ed L 1e pueH 954 S9A poueg peidnooo ony HO andino 00 00 3ndino 00 HO 9 15 200 eunye1eduue Ajddng 00 JO H 00 9 00 e1nye1eduue snes 51715 snes hes 49019 rea eq dooo snieis 432019 INIL 00 2 5 00 dwa Ajddng 4O 00 e oqy JO 29H 400 Aiddng 00 e oqy H 00 xoeqies 000 peidnooo SONILLAS sBumes gt ony 00 00 9 19 00 195 BuueeuiBu3 pidey 4N33H2S 3INOH Aue usng snreig 00 duie
39. R button then use the DECR or INCR buttons at the bottom of the display to make the change Push the ENTER or OK button to accept the change Pushing the DST button will enable the operator to shift the controller to daylight savings time FIGURE 11 Clock Set Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE This sample system screen may look different on actual handheld keypad _ Set Current Time Date 24 hr clock Time hh mm ss Date dd mmm yy Nav angs 2Prev 25DST 20 of 61 3 8 Status Screen SECTION 3 UsER INSTRUCTIONS On the Status Screen See Page 22 Figure 12 users are able to view all current conditions with heating cooling and outdoor air status Within screen parameters results displayed are fixed In order to change air handler status advance to appropriate setting screen based on desired changes This screen has a show hide feature that automatically displays applicable status conditions See Page 21 Table 5 for a complete list of status conditions available Depending on the model and features of the air han dler not all status conditions will be displayed at one time on the handheld keypad At the end of line 3 when arrow is visible use arrow buttons to scroll up down for a
40. RANTY READ YOUR USER OPERATION AND TROUBLESHOOTING MANUAL If you have questions about your equipment contact your installing professional Should you need Replacement Parts or have additional questions call or write Rapid Engineering LLC 1100 Seven Mile Road NW Comstock Park MI 49321 Telephone 1 616 784 0500 Fax 1 616 784 1910 Toll Free 800 536 3461 www rapidengineering com Rapid Engineering LLC s liability and your exclusive remedy under this warranty or any implied warranty including the implied warranties of merchantability and fitness for a particular purpose is limited to providing replacement parts during the term of this warranty Some jurisdictions do not allow limitations on how long an implied warranty lasts so this limitation may not apply to you There are no rights warranties or conditions expressed or implied statutory or otherwise other than those contained in this warranty Rapid Engineering LLC shall in no event be responsible for incidental or consequential damages or incur liability for damages in excess of the amount paid by you for the RAPID InfinityPro Some jurisdictions do not allow the exclusion or limitation of incidental or consequential damages so this limitation or exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from jurisdiction to jurisdiction Rapid Engineering LLC shall not be responsible for failu
41. Schedule Source Temperature Ctrl Handheld keypad BAS WebCTRL Room Temp Ctrl OA Rm Temp Ctrl Forced Supply Air Selects the schedule source Handheld keypad BAS building automation system or WebCtrl can be used for factory provided software See Page 4 Section 2 5 Lock DA Temp to 30 above Locks the supply air maximum temp to 30 above the heating Damper 26 of 61 Htg SP setting Select Yes if the unit has mechanical cooling The 20 burner Mech Cooling No Yes 4 supply air damper will close when the cooling mode Evaporative Clg No Yes Select Yes if unit equipped with evaporative cooling Coil Heat Source No Yes Select Yes if the heat source is steam hot water or electric Energy Alert No Yes Select Yes to enable feature See Page 7 Section 2 9 1 Model Type AM VAV or MUA FR Defines the model of the air handler and the features available MUA W VFD No Yes Select Yes if the air handler is an MUA with a factory installed variable frequency drive MUA W No Inlet or Supply No Yes Select Yes if the air handler is an MUA with no inlet or supply air damper SECTION 3 USER INSTRUCTIONS FIGURE 16 Configuration Technician Use Only To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pr
42. TYPRO USER OPERATION AND SERVICE MANUAL 6 1 4 Cooling Settings Point Name Description Point Type ID When the room temperature reaches the Cooling setting the first stage of cooling is enabled The Cooling set point cannot set below the Heating Off Setting plus one CUN Default value is 74 F Stpt OA Limit p the setting for Economizer cooling Default Valve is AV 24 R W Status Cooling Stpt Reports current cooling setpoint 10 R Status Cooling Stage Reports current condition of cooling On or Off BV 4 R 6 1 5 Damper Control Point Name Description Point Type ID dioi 4 Stot Manual Damper When in the Manual Percent Outdoor Air setting the damp P Positi P ers will bring in the amount of outside air defined by this 28 R W osition setting When in the Auto Room Pressure setting the dampers will oe 2 2 modulate open and closed to control the room pressure to AV 23 R W this setting For AM and VAV models with inlet dampers Reports mix 5 og ing damper position plus the burner supply air damper AV 21 R position to give you the total outside air in a percentage Status Manual Damper Reports current setpoint percentage for manual outside 15 R Position air setting Status uu pres Reports current building pressure differential pressure AV 9 R 6 1 6 Alarms Point Name Description Point Type ID 4 Fan Contactor Not
43. The operator names and passwords listed above have been created by Rapid Engineering LLC The operator has full privileges with complete access to the software This includes the ability to change passwords and create new users The has basic privileges that includes read only capabilities Users are able to view information but not change anything NOTE Use caution when changing user names and passwords Once changed Rapid Engineering LLC is unable to reset the password to factory default Additionally lost or forgotten passwords other than unchanged factory default are unable to be retrieved 5 7 Establishing a Connection a Once logged in a connection will need to be established with the air handler s See Page 41 Figure 29 to help navigate around the screen 40 of 61 SECTION 5 WEB CoNTROL SOFTWARE FRONT END COMMUNICATION FIGURE 29 Getting to Know the Interface Geographic tree Network tree Schedule Groups tree System Configuration tree Back button Print button System wide alarms button Action buttons Help button Click to display menu gt Buong Performanca Systeme Intagrstion gt gt GB Outside Air Prestige gt Parking Lot Lighting gt Q Wall Wash Ughtng Click an drag to adjust width of tree Action pane Navigation P Menu Indicates Click to show hide Navigation menu b To establish a connection click on the System Configuration Tree locat
44. USER OPERATION AND SERVICE MANUAL SECTION 3 USER INSTRUCTIONS A WARNING Electrical Shock Hazard Explosion Hazard Burn Hazard Cut Pinch Hazard Disconnect electric Turn off gas supply to Allow heater to cool Wear protective gear before service heater before service before service during installation operation and service Tubing may still be hot after operation Edges are sharp Heater must be connected to a grounded electrica Source Failure to follow these instructions can result in death electric shock injury or property damage 3 1 Overview The handheld keypad allows the user to adjust setpoint values and receive data directly from an individual air handler s RAPID InfinityPro controller To operate as a remote control device the handheld keypad requires connection to the bottom of the room temperature sensor For the handheld keypad to be used as a service tool it can be directly connected to the air handler mounted RAPID InfinityPro controller In either case the handheld keypad provides the user with access to all available controller setpoints and reported status conditions The main viewing window has four lines of text available See Page 9 Figure 1 When navigating through the various screens text will change as needed to reflect the air handler settings or status conditions appropriate for the currently active screen Text on line 1 will indicate the air handler oper
45. and service of this equipment The appliance must be applied and operated under the general concepts of reasonable use and installed using 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 optimum heater performance and safe heating conditions inspect and maintain heater before every heating season as necessary Also know and maintain heater clearances to combustibles see heater Installation Operation and Service Manual for further details If you require additional manuals contact Rapid Engineering LLC This air handler is designed for heating non residential 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 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 my be hazardous if containing flammable solids liquids and gases explosive materials a
46. ating setting or status condition Based on active screen items can be changed or monitored Text on line 2 and line 3 provide additional information on the features represented Within active screen an arrow may appear all the way to the right of line 3 The presence of an arrow on this line represents the viewing area of the screen may be scrolled up or down to access additional features or settings On line 4 in the main viewing window bracketed text appears above any of the four navigation buttons Using the navigation buttons the user is able to switch screens based on selected bracketed text Based on selected screen temperatures are displayed as a variable setting or status condition Tempera tures indicated are in Fahrenheit 3 2 Keypad Screen Brightness Adjustment The contrast of the screen can be adjusted by rotating the adjusting screw with a screwdriver The adjust ment screw is located on the left side of the top edge of the handheld keypad Rotate it counter clock wise CCW to make it brighter and clock wise CW to make it dimmer 8 of 61 SECTION 3 USER INSTRUCTIONS FIGURE 1 Basic Screen Overview eue To adjust Moda Settings Time Clock buttons position brackets 1 press ENTER Basic Operation V ed DECR e INCR te change value pees ENTER or OK conim Instructions To reset alarm first press and hold FN button while pressing Main Viewing Window Navigation Buttons A
47. based on desired room temperature when heating control type selected is Stpt Occupied Hig Room Air Temperature Control or Forced Supply Air Heat 2 R W ing Default value is 70 F During the unoccupied period the fan and burner will start if the room temperature drops below this setting and the Stpt Unoccupied Htg temperature select type is Room Air Temperature Control DUM FM or Forced Supply Air Heating Default value is 55 F During the occupied and unoccupied period the heat shuts off when the room temperature reaches the Heat Off Set Stpt Heat Off range ting when operating in the Room Air Temperature Control AV 26 R W 2 20 degrees and Forced Supply Air Heating The Heat Off Setting is defined by entered value which is then added to Heat Set ting Current Default value is 3 F Limits the minimum supply air temperature to this setting Stpt Supply Air when the heat is on Applies to Room Air Temperature Con AV 30 R W emp trol and Outdoor Air Room Control Default value is 60 F Limits the maximum supply air temperature to this setting Stpt Supply Air when the heat is on Applies to Room Air Temperature Con AV 29 R W emp trol and Outdoor Air Room Control Default value is 95 F Applies when the Forced Supply Air Heating is selected Stpt Supply Air The heat modulates to control the supply air at this setting AV 25 R W emp regardless of the room temperature Default value is 70 F Applies to all heat
48. d to avoid possible damage to the equipment when enabling this feature The burner output lock has a timer that will shut off this feature after one minute To access push and hold the FN button and then push number 8 button FIGURE 15 Manual Overrides Technician Use Only To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE ssdasssssMsnunallNSc uS5ssidsasssssha ssS SEE Caution Enabling the following points will override normal operation Space Temp Lock Enable Off Stpt 000 Heat Percent Output Lock Enable Enable Off Percent Out 000 gt Home MUTE FN 1 2 3 4 5 6 7 8 9 0 B ENTER 4 NOTE Image is larger than handheld screen Shown for reference only 25 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 12 Configuration This screen See Page 27 Figure 16 is used to configure the air handler for specific options The controls are pre configured from the factory prior to shipping The default schedule source is handheld keypad If the time clock is controlled by a BAS See Page 46 Section 6 or Webctrl software See Page 38 Section 5 it may need to change in the field To access push and hold the FN button and then push number 9 Table 8 Configuration Status Text Status Description
49. dditional status options Table 5 Status Conditions Status Description Room Air Temperature Displays current room temperature Heat Setting Current Displays current heat setting for either occupied or unoccupied period deter mined by time clock Heat Off Setting Displays current heat off setting for either occupied or unoccupied period Supply Air Temperature Displays current supply air temperature Heat Status Displays if the heat is ON or OFF Outdoor Air Temperature Displays current outdoor air temperature Percent Heat Output Displays the current output percent to the heat source Cooling Setting Cooling Output Displays the current cooling setting Displays if the cooling output is ON or OFF Economizer Active Displays if the economizer is active by YES or NO Operating Mode Occupied Period Displays the current mode of operation ON OFF AUTO or FLUSH Displays YES if occupied and NO if unoccupied Outdoor Air Control Displays current outdoor air control Pressure or Manual Room Pressure Room Pressure Setting Displays current room pressure Displays current setting for room pressure Percent Outdoor Air Displays the current percent of outdoor air Percent Outdoor Air Setting Percent Output to Displays the current manual outdoor air setting Displays current output to variable frequency drive Schedule Source Displays the sche
50. dule source Handheld keypad BAS or WebCTRL Air Handler Type Displays the air handler type MUA VAV AM FR 21 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL FIGURE 12 Status Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE Heating Status Room Air Temperature 00 0 Heat Setting Current 00P Heat 00 Supply Air Temperature 000 Heat Status Off Outdoor Air Temperature 000 Percent Heat Output 000 Cooling Status Gooling 007 Cooling Output Off Economizer Active Yes Operating Mode AUTO Occupied Period YES Outdoor Air Control PRESSURE Room Pressure 00 00 Ww C Bek Percent Outdoor Air 000 Percent Outdoor Air Setting 000 Precent Output to VFD 000 Schedule Source KEYPAD Air Handler Type AM VAV gt Home 1 2 3 4 5 MUTE FN 6 7 8 9 0 4 C NOTE Image is larger than handheld screen Shown for reference only 22 of 61 SECTION 3 USER INSTRUCTIONS 3 9 Alarm When an alarm is triggered the red alarm light will illuminate on the handheld keypad To clear the alarm light the fault must be corrected The alarm screen stores the last 100 alarms Alarms are time stamped and stored in or Retu
51. e as described in Heating Mode occupied period on Page 4 Section 2 5 through Page 5 Section 2 6 5 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 2 7 2 Electric Hot Water or Steam Coils Heat output modulation of the coils is performed via an analog output from the RAPIDS InfinityPro control ler Upon a call for heat fan operation is delayed for 60 seconds to allow for coil warm up When in the heat ing mode the controller will modulate the heating coil as described on Page 4 Section 2 5 through Page 5 Section 2 6 For electric hot water or steam as a heat source configure the controller as per Page 26 Sec tion 3 12 2 8 Cooling Types RAPIDS InfinityPro controller provides a single output for cooling control The cooling output activates an evaporative cooling module or mechanical cooling coil initiation only For multiple stages of mechanical cooling consult the factory 2 8 1 Economizer AM amp VAV Models The Economizer is a selectable feature and must be selected ON with the settings screen See Page 13 Section 3 6 in order to function Outdoor air for cooling is used when the outdoor air temperature is below a user specified value for the Economizer Setting Whenever the outdoor air temperature is above the Econo mizer Setting the air handler will operate with the amount of outdoor air determined by the Outdoor Air Con trol setting When selected the Economizer functions as if there is
52. e defined by normal occupied period The Holiday schedule forces the air handler to the unoccupied mode overriding the daily Holiday schedule for all periods defined as a Holiday Override schedule forces the air handler to the occupied mode overriding all other Override schedules for the periods defined as Override 24 7 Forces the air handler to occupied mode 24 hours a day 7 days a week Use this feature to update the time and date of the air handler controller to which the hand Clockset held keypad is connected FIGURE 6 Time Clock Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE UNIT SCHEDULES Status UnnOccp DAY DD MON YYYY 24 55 Daily 5Holiday 5Override 224 7 gt Home 5Prev 15 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 71 Daily Schedule Using the arrow buttons move the brackets between the start and stop times Press the ENTER button to change the start and stop times The text OK CANCEL DECR and INCR will appear at the bottom of the screen Change the values to the desired settings Next using the arrow buttons move the brackets and select the days you want the air handler to operate Press the ENTER button and use the
53. eck for voltage 120 volts at the contactor coil If there is voltage and the contactor does not pull in the energizing coil is defective If the contactor pulls in but does not start the fan the contacts are defective Replace the contactor 7 An interlock smoke detector or access door limit switch is open and power to the control circuit has been interrupted a Check appropriate interlock 7 3 2 Alarm Description Fan Contactor On When It Should Be Off This alarm occurs when input 5 at the controller is on when it should be off It indicates the supply fan con tactor has been activated before the fan has been commanded on or after the fan has been commanded off Since this contactor should not be powered when the fan is not commanded to be on an alarm is reported 1 The auxiliary contact to the starter is jumped and or shorted a Remove jumper or replace auxiliary contact on starter 2 The M1 motor contactor has failed closed a Replace the contactor 3 The fan motor initiate relay is wired incorrectly or defective a Verify the wiring is connected to the relay coil and contacts as is illustrated on the wiring diagram Rewire relay if necessary b If the normally open contacts on the relay have failed closed replace the fan motor initiate relay 4 The fan relay on output relay is wired incorrectly or has failed closed a Verify the wiring is connected to the relay coil and contacts as is illustrated in air handler wiri
54. ed on the top of the Navigation Menu c Within System Configuration Tree select Connections Select Configure Tab and at the top of the screen Select BACnet IP Connection Once highlighted green click the Start button to begin See Page 41 Figure 30 FIGURE 30 Configure Connections My Settings System Settings Operators Privilege Sets BACnet Local Access Operator Groups b comes 2 onfiguration Services License Administration Update Hierarchical Servers Disconnect d Switch to Network Tree See Page 41 Figure 29 in the Navigation Menu to download air han dler s See Page 42 Figure 31 Within the action buttons click Downloads if not already selected e Expand the network to reveal air handler s available Click Start button to begin downloading 41 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL FIGURE 31 Download AM 4 amp amp BACnet_MS TP gt Kj Zone 583 old Add Move to Ud 17 Select all Location f Once download is complete switch to Geographic Tree See Page 41 Figure 29 in the Naviga tion Menu See Page 42 Figure 32 Select the site to list all air handlers on the network Within the action buttons verify Graphics is selected FIGURE 32 Air Handler Network Tree g Select specific air handler AHU to receive view graphics h Navigate within the interface to complete actions reference Help menu if needed
55. ed problems Without precision temperature measurement and a clear understanding of the accuracy specifications for these sensors it will be impossible to exactly duplicate the table data Normal service test equipment however used in conjunction with the table should indicate whether the sensor is operating properly 59 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 60 of 61 SECTION 8 THE RAPID INFINITYPRO WARRANTY RAPID ENGINEERING LLC WILL PAY FOR Within 24 months from date of purchase by buyer or 27 months from date of shipment by Rapid Engineering LLC whichever occurs first replacement parts will be provided free of charge for any part of the product which fails due to a manufacturing or material defect Rapid Engineering LLC will require the part in question to be returned to the factory Rapid Engineering LLC will at its sole discretion repair or replace after determining the nature of the defect and disposition of part in question RAPID Replacement Parts are warranted for the later of 12 months from date of shipment from Roberts Gordon LLC or the remaining RAPIDS InfinityPro warranty RAPID ENGINEERING LLC WILL NOT PAY FOR Service trips service calls and labor charges Shipment of replacement parts Claims where the total price of the goods have not been paid Damage due to Improper installation operation or maintenance Misuse abuse neglect or modification of the RAPIDS Infi
56. energized and de energized Replace relay if necessary 5 The heat air damper motor is defective a If the motor fails to open when power is applied and the damper operation is not restricted replace the motor 6 An interlock smoke detector or access door is open and power to the control circuit has been interrupted a Check appropriate interlock 7 3 4 Alarm Description Damper for Heat Air Not Closed This alarm occurs when input number 4 on the controller remains open and the heat air inlet damper should be closed The damper for the heat inlet air fails to close when the fan is shut off The damper remains open when fan is off The heat air damper actuator is a power open spring return actuator 1 A mechanical problem is preventing the damper from closing a Check for and remove any obstructions ice formations that may be preventing the damper from opening when powered b Disconnect the linkage and manually operate the damper to determine the cause of binding Clean lubricate adjust and repair as necessary 2 The heat air damper limit switch is defective or needs adjustment a The damper is closed but the limit switch in the actuator is still made b Adjust the switch or replace the actuator as needed 3 The heat air damper output relay has failed a Check proper contact operation as damper should open and close when relay is energized and de energized Replace relay if necessary 7 3 5 Alarm Description Burner L
57. essing MUTE B CONFIGURATION SCREEN Warning changing the unit configeration will change operating sequence it is intended for authorized personal use Schedule Source BACview Temperature Ctrl Forced Supply Air Lock DA Temp to 30 above Htg SP Off Mechanical Cooling Yes Close 20 Damper Evaporative Clg Yes Steam Hot Water Htg Yes Energy Alert Yes Model MUA FR MUA W VFD Yes MUA W No Inlet or Supply Damper Yes Home 2KEYPAD More 1 2 3 4 5 MUTE FN 6 7 8 9 0 4 NOTE Image is larger than handheld screen Shown for reference only 27 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 12 1 Keypad Configuration From this screen inactivity timeout can be adjusted Increasing the inactivity timeout will delay the amount of time before the screen reverts back to the Standby Screen when the handheld keypad sits idle The range available is 1 255 minutes Changes can be made via number or arrow buttons FIGURE 17 Keypad Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE This sample system screen may look different on actual handheld keypad Keypad Configuration Inactivity Timeout 10 minutes BACnet Write Priority 0 5Prev 28 of 61 USER
58. fire gas pressure is set to high a Compare the actual high fire gas pressure to the rating plate on the air handler Adjust the actual gas pressure as needed 2 The utility gas pressure exceeded 5psig overpowering the modulating regulating valve s pressure reg ulator a Install an additional pressure regulator to reduce the incoming pressure to below 5psig 3 The modulating regulating valve s pressure regulator has failed a Replace the regulator 4 The high gas pressure switch is set too low a Adjust the gas pressure switch setting to 1 5 w c above the high fire setting 5 The high gas pressure switch is defective a Measure gas pressure at switch Determine if gas pressure is actually lower than the high gas pressure switch set point Replace the switch if necessary 54 of 61 SECTION 7 TROUBLESHOOTING 3 Possible Cause of Lockout or Safety SW Not Made Low Gas Pressure Switch The low gas pressure switch is a normally closed switch that opens on a pressure fall to protect equipment from under firing and potentially deliver unburned fuel to the conditioned space Consult the equipment data plate for the proper setting FM manifolds are manual reset type XL and ANSI manifolds are automatic reset type 1 The manual gas valve is closed a Open manual gas valve 2 The utility inlet gas pressure dropped lower than the minimum inlet supply gas pressure required for the air handler a Investigate causes for low supply gas
59. ibration Screen is used to calibrate input sensors if needed Move the brackets around the number for the sensor to be calibrated press ENTER and then use the arrow buttons or DECR and INCR to increase or decrease Press ENTER or OK to save the changes To access push and hold the FN button then push number 7 Table 7 Calibration Adjustments Text Status Description Build Press Offset 00 0 Room Temp Offset 00 0 Increase or decrease the offset change the actual reading OA Temp Offset 00 0 DA Temp Offset 00 0 NOTE OA Outside Air DA Discharge Air FIGURE 14 Calibration Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE CALIBRATION SCREEN Build Press Offset 00 00 Actual 00 00 Room Temp Offset 00 0 Actual 00 0 gt Home 24 of 61 SECTION 3 USER INSTRUCTIONS 3 11 Manual Overrides A CAUTION Product Damage Hazard Do not override burner output lock timer Verify normal heater operation after one minute Failure to follow these instructions can result in product damage This screen is intended for use by qualified personal only When needed the field start up technician can lock the burner output to 10096 in order to set up the gas fired burner Caution must be exercise
60. ing types When the outside air tempera Stpt OA Heat Disable ture reaches this set point the burner will shut off regard AV 32 R W less of room temperature Default value is 95 F Applies when the Outdoor Air Room Control is selected Stpt OA Heat Enable The burner will turn on when the outside air temperature AV 31 R W falls below this set point Default value is 50 F If in the heating mode and the supply air temperature is UE Temp below this set point for more than 5 minutes the operating 27 R W mode is switched to Off Default value is 40 F Value is 0 to 100 Output from the controller to the mod Status Output ulating heat source AV 13 R Status Active Heating The Heat Setting Current is determined by the time clock Set Point and occupied unoccupied heat settings AV 11 R Status Fan On Reports the status of fan On or Off BV 7 R Reports the status of the heat source On or Off Heat Status Heat On_Off Source options Direct Fired Burner Electric Steam or Hot BV 8 R Water Status Heat Off Stpt Reports the setpoint at which the heat source turns off AV 12 R Status OA Temperature Reports current outside air temperature AV 8 R Status DA Temp Reports current discharge air temperature AV 20 R Satis Mooni Reports current temperature in the building AV 22 R Temperature R t t t tput t iable f Status Output to eports current percentage output to variable frequency AV 18 R 47 of 61 RAPID INFINI
61. is provided on these relays The relay remains in the original mode before it was placed in the Test position If the flame relay appears to be stuck it may be attempting to operate in the Test position For normal operation the Test Run switch should always be in the Run position 7 3 Alarm Description There are a number of safety features included with the air handler If a problem occurs during normal oper ation a red alarm light on the handheld keypad will illuminate and an alarm description will appear This is an indication to the user there is an alarm condition To reset the alarm light push and hold the FN button then press MUTE To permanently clear an alarm light the fault must be corrected Based on information below fault can properly be corrected 51 of 61 RaPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 73 1 Alarm Description Fan Contactor Not On This alarm occurs if input number 5 on the controller fails to activate while the fan is commanded to start and the unit is in the occupied period a Reset the overloads If the overloads continue to trip check motor running amperage against motor name plate full load amperage If greater than full load rating determine cause of over amperage e g low service voltage excessive voltage drop 4 The auxiliary contact is defective a Replace the fan contactor built in 5 Check for loose wiring between terminals 6 Defective contactor M1 a Ch
62. is shown on Page 38 Figure 27 below See Page 43 Figure 33 for sensor network cabling and Page 45 Figure 35 for networking specifics FIGURE 27 RAPID InfinityPro Networking Software Outdoor Air Control BUTGPTESSUTE w Run Conditions Econo 2 Off Heat On Fan Off if gt Auto Flush Current Mode Auto Burner Damper Open Filter Clean Economizer Active Off od Occupied 38 of 61 SECTION 5 WEB CONTROL SOFTWARE FRONT END COMMUNICATION 5 4 Setting Up Communication a Install the specified network cable to each air handler and router in the network Connect the router and computer as shown in drawings on Page 43 Figure 33 through Page 45 Figure 35 b Set the address on the controllers using the rotary address switches Address can be set from 1 99 and must be different for each controller on each network Cycle power if address is changed while the controller is powered See Page 39 Figure 28 c Set the baud rate to 76 8 and communication protocol to BACnet MS TP using the dip switches Cycle power if dip switches are changed during normal operation FIGURE 28 Control Board Rotary Address switches DIP switch d Ensure router is powered with power supply provided The router was downloaded with the IP address provided by the customer prior to shipping 5 5 Installing Web Control Software a Load CD labeled Data Base License and copy license on to desktop Once completed remo
63. ition will be maintained for 20 minutes or until the room under pressure condition has been corrected Once either of these events occur the Occu pied Heating setting is restored and modulation of the dampers is returned to Auto Room Pressure control NOTE Each time the energy alert control reverts to the Unoccupied Setback Temp an alarm is activated to alert low building pressure 2 9 2 Make Up Air Units with Variable Frequency Drive When a variable frequency drive is installed on a make up air unit the fan modulates between the minimum and maximum air delivery capacity of the air handler vs the Auto Room Pressure setting to control building pressure Auto Room Pressure setting can be adjusted within the setting screen See Page 13 Section 3 6 with the handheld keypad or by using head end software See Page 38 Section 5 Burner air velocity is controlled by a profile damper A pressure transducer compares static building pressure to the static pres sure outdoors or to the pressure in another part of the building 2 9 3 Forced Occupied When the air handler is equipped with a room sensor RS Plus or RS Pro the unit can be forced to occupied mode by pushing the manual on button located on the face of the room sensor Each time this button is pushed it adds 30 minutes to occupied period up to a total of four hours Holding the manual on button in for three seconds cancels the Forced Occupied period 7 of 61 RaPID INFINITYPRO
64. ly to Air Management and Variable Air Volume model configuration Whenever the fan is operating the mixing dampers are fixed at the Manual Air setting 2 3 2 Auto Room Pressure This is applicable only to Air Management and Variable Air Volume model configuration A pressure trans ducer compares the pressure inside the building to the pressure outside the building or can be used to com pare pressure from a particular room to an adjacent room Whenever the fan is operating the dampers are automatically positioned to maintain the Auto Room Pressure setting except during the following conditions 1 Economizer is active See Page 6 Section 2 8 1 2 Evaporative Cooling is operating See Page 6 Section 2 8 2 3 Flush mode is activated See Page 4 Section 2 4 2 4 Flush Mode Flush mode provides 100 outdoor air to the building space It is applicable to many model configuration styles Air Management Variable Air Volume and Make Up Air Even if the air handler is in the unoccupied period or Off mode the fan will start when Flush mode is triggered The temperature controls respond as needed to maintain the heating and cooling set points This forced fresh air condition overrides both Manual Percent Outdoor Air See Page 4 Section 2 3 1 and Auto Room Pressure See Page 4 Section 2 3 2 damper operations 2 5 Heating Control Type Occupied Period During an occupied period the fan runs continuously and heat is provided There are three
65. mm and no cracks in the ceramic Clean the electrode with a wire brush if necessary b The ignition transformer is not receiving power or putting out the proper 6000V voltage Deter mine the cause and repair c If spark is present in the test above air may be present in the gas line Purging of air in a new line may be required An LP system may need purging if the tank ran out of gas before refilling 9 The flame verification signal ultraviolet light is not present Possible causes include a Dirty UV scanner Clean the scanner with a soft cloth b Plugged UV scanner sight tube Remove the obstructions c UV scanner not secured firmly to the sight tube Screw the scanner on firmly but only finger tight d Defective UV scanner Replace the scanner e Loose or defective UV scanner wiring Determine the location of the problem and repair f A defective flame relay or UV amplifier Replace the defective component 10 Pilot manual valve is closed a Open valve 11 Pilot solenoid valve is defective a Replace solenoid 12 Low pilot flame a Increase pilot gas pressure by adjusting pilot regulator The outlet pressure at the pilot regulator should be about 2 w c resulting in a pilot flame about the size of a baseball 13 The airflow switch setting is too low causing frequent flame relay power cycling a Set the switch properly per the Service Technician Manual 14 Wires on flame relay terminals are disconnected or loose a Re
66. move the relay from its base and check 15 wire is broken or grounded against unit a Repair the wire or isolate from ground 16 The primary block or vent valve actuator is defective a Replace the faulty actuator NOTE Honeywell 7800 flame relays are designed to allow remote resetting The burner is reset every time the air handler is turned off and then returned to the On or Auto mode 7 3 7 Alarm Description Dirty Filters 1 The filters are dirty or the belts are loose a Change the filters b Check the fan belts replace or tighten per the maintenance manual 2 Motor or fan sheaves are worn a Replace the worn sheaves with new Confirm replacement sheaves are the correct size consult factory if necessary 3 The clogged filter switch has failed a Verify the pressure drop across the filters and compare it to the set point of the clogged filter switch to determine if the switch is working correctly 57 of 61 RaPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 7 3 8 Alarm Description Low Building Pressure This alarm occurs when there is a call for heat and the air handler is operating in the Occupied Heating set ting with Auto Room Pressure heating type The air handler has been unable to maintain a positive building pressure within 01 w c of the pressure set point for 10 consecutive minutes As a result the program has placed the outside air dampers in the minimum outside air position and the air handle
67. mperature that is maintained during unoccupied periods Heat Off Above Heating Setting This setting is added to the Occupied and Unoccupied heat setting to define the tempera ture at which the heat turns off This is referred to as the Heat Off Setting on the Status screen of the handheld keypad See Page 27 Table 5 Forced Supply Air Defines the supply air temperature when the temperature controls selected are Forced Heating Supply Air Supply Air Min Tem Defines the supply air minimum temperature when temperature controls selected are P Room Air Temperature Control and Outdoor Air Room Control Supply Air Tem Defines the supply air maximum temperature when the temperature controls selected are P Room Air Temperature Control and Outdoor Air Room Control Supply Air Max Temp This setting is displayed when the unit is configured with a 30 plus heat setting lock It is Locked not adjustable Outdoor Air Heat When enabled the heat will turn on based on this setting AE The heat will shut off if outdoor air temperature raises above this setting Fan Off If Supply Air The fan will shut down if supply air temperature falls below this setting for more than 5 min Temp Below utes The setting that starts the cooling sequence if available The cooling set point cannot be Cooling set below Heating Off Setting plus one Economizer Enables or disables the Economizer by
68. nd or substances which may become toxic when exposed to heat i e refrigerants aerosols etc 1 2 What is a RAPIDO InfinityPro Controller The RAPID InfinityPro is a control system for use with a RAPID 4000 Series air handler It includes DDC direct digital control controller containing 8 outputs 5 digital 3 analog and 6 universal inputs An optional handheld keypad remote control device is available to be used on site as a start up troubleshooting device It may also be permanently mounted to a column or wall and cabled to the DDC controller for use as a remote control device If desired the DDC controller allows the air handler to communicate with a building management system The handheld keypad allows the end user to adjust settings schedules operating modes as well as receive data independent of the building management system Optional off site communication capability is available 1 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 1 3 Electrical Requirements A 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 Failure to comply with the installation instructions will invalidate the limited warranty set out on Page 61 Sec tion 8 The RAPIDS InfinityPro mus
69. ng dia gram Rewire relay if necessary b If the normally open contacts on the relay have failed closed replace the fan relay on output relay 7 3 3 Alarm Description Damper for Heat Air Not Open This alarm occurs when the end switch in the heat air damper fails to close on input number 4 at the control ler 1 A mechanical problem is preventing the damper from opening a Check for and remove any obstructions ice formations that may be preventing the damper from opening when powered b Disconnect the linkage and manually operate the damper to determine the cause of binding Clean lubricate adjust and repair as necessary 2 The wiring for the heat air damper or the limit switch is loose or defective a Trace the voltage from the output relay to the motor and back to the input relay and repair the prob lem 52 of 61 SECTION 7 TROUBLESHOOTING 3 The heat air damper limit switch is defective or needs adjustment a Observe the limit switch response to successively energizing and de energizing the damper motor Adjust the limit switch for appropriate response to operation of the motor If the switch is unable to be adjusted properly replace the motor 4 The heat air damper output relay or limit switch input relay are defective a Verify wiring is connected to the relay coil and contacts as is illustrated in air handler wiring dia gram b Check proper contact operation as damper should open and close when relay is
70. nityPro in any way Use of the RAPIDS InfinityPro for other than its intended purpose Incorrect gas or electrical supply accident fire floods acts of God war terrorism or other casualty Improper service use of replacement parts accessories not specified by Rapid Engineering LLC Failure to install or maintain the RAPID InfinityPro as directed in the User Operation and Troubleshooting Manual e Relocation of the RAPIDS InfinityPro after initial installation Use of the RAPIDS InfinityPro in a corrosive atmosphere containing contaminants Use of the RAPIDS InfinityPro in the vicinity of a combustible or explosive material Any defect in the RAPID InfinityPro arising from a drawing design or specification supplied by or on behalf of the consumer Damage incurred during shipment Claim must be filed with carrier WARRANTY IS VOID IF The RAPID InfinityPro is not installed by an contractor qualified in the installation and service of gas fired heating equipment You cannot prove original purchase date and required annual maintenance history The data plate and or serial number are removed defaced modified or altered in any way The ownership of the RAPID InfinityPro is moved or transferred This warranty is non transferable Rapid Engineering LLC is not permitted to inspect the damaged equipment and or component parts SECTION 8 THE RAPID INFINITYPRO WAR
71. no call for heat A condition in which there is no call for heat is if the outdoor air temperature falls below the Economizer Setting and the room air temperature is above the Cooling Setting If all of these conditions are met the Economizer control brings in up to 10096 out door air to maintain the Cooling Setting When the room air temperature falls below the Cooling setting the air handler will resume damper modulation determined by the Outdoor Air Control setting While bringing in additional outdoor air for cooling the room pressure may rise above the Room Pressure Setting To minimize the potential for an excessively high building pressure relief dampers can be installed During Economizer operation if the supply air temperature falls below the Supply Air Min Temp setting the dampers will modulate to maintain the Supply Air Min Temp setting 2 8 2 Evaporative Cooling Evaporative Cooling overrides the Economizer control The dampers are forced to 100 outside air on AM amp VAV models when the room temperature rises above the Cooling Setting A digital output from the controller will enable the Evaporative Cooler When the Cooling Setting is satisfied the air handler will resume damper modulation based on the previously selected Auto Room Pressure or Manual Percent Outside Air setting While bringing in additional outdoor air during evaporative cooling operation the room pressure may rise above the Auto Room Pressure setting To minimize
72. nting adequate airflow a Replace the filters 3 Airflow switch tubing is plugged preventing it from closing a Clear the tubing 4 Fan rotation is reversed a Turn off disconnect switch and reverse two power wires preferably at the line side of the discon nect High importance for pony motor drives or two speed motors The wires on the load side of the disconnect may be reversed for single speed single motor air handlers NOTE The wide edge of the fan blades should be the leading edge 5 Airflow switch is defective and has failed to close a Measure the pressure drop across the burner and compare it to the set point of the airflow switch to determine if the switch is bad Replace switch if necessary 6 Supply or discharge damper is not open a Check linkage and repair 7 Access door is open a Close the door 8 Fan is overloaded a Verify and compare the actual external static installed ductwork to design external static ESP to make sure the fan is not overloaded b Consult Rapid Engineering LLC for additional information 2 Possible Cause of Burner Lockout or Safety SW Not Made High Gas Pressure Switch The high gas pressure switch is a normally closed switch that opens on a pressure rise to protect the equip ment from over firing The factory set point is 1 5 w c above the high fire gas pressure set point FM mani folds are manual reset type XL and ANSI manifolds are automatic reset type 1 The burner high
73. ockout Or Safety SW Not Made This alarm occurs when input number 6 on the controller drops out or is not made when there is a call for heat Prior to generating this alarm the normal start up sequence includes a time delay of 120 seconds from the time the heat start relay output 3 is energized There are a number of safety devices wired in series with each other if any of them open during a call for heat the burner is de energized and this alarm is generated See below for possible causes 1 Possible Cause of Burner Lockout or Safety SW Not Made Airflow An airflow switch on the air handler measures the pressure drop across the burner to ensure proper air velocity for combustion The switch is pre set to open if the airflow is low and the pressure drops fall below 0 2 w c The switch additionally includes a pre set to open if the airflow is too high and the pressure drop across the burner exceeds 1 35 w c The target standard operating pressure drop is 0 9 w c This can be measured by connecting a monometer to airflow switch pitot tubes 53 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 1 Belts are loose sheaves are worn a Tighten or replace belts per Rapid Engineering LLC specifications and belt manufacturer s recom mendations NOTE Never replace only one belt in a set as belts will elongate Replace entire set if necessary b Check for worn drive sheaves and replace as needed 2 Filters are dirty preve
74. op Time 00 00 Prev gt Next gt Home 17 of 61 RaPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 7 3 Override Schedule The Override Schedule forces the air handler to the occupied mode overriding all other schedules FIGURE 9 Override Schedule Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE OVERRIDE SCH 1 Use YES Stat OFF 24hr Start Time 00 00 Stop Time 00 0 Boneh OOO E BER 2Prev gt Next gt Home 18 of 61 SECTION 3 USER INSTRUCTIONS 3 7 4 24 7 Schedule The 24 7 schedule forces the air handler into occupied mode 24 hours a day 7 days a week FIGURE 10 24 Hours a Day 7 Days a Week 24 7 Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE Force Air Handler to Run Fan 24 7 Occupied Mode Yes Prev gt Home 19 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 7 5 Clock Set To change the time and date use the arrow buttons to move the brackets over the desired time or date Push the ENTE
75. pressure Possible causes could be a valve closed down stream or insufficient pipe sizing to air handler b Close manual gas valve and remove any obstructions found in gas line 3 The switch is not set properly a The switch should be set to the minimum inlet gas pressure setting as indicated on the air handler rating plate 4 The low gas pressure switch is defective a Verify the supply inlet gas pressure is higher than switch set point If switch will not close replace it 4 Possible Cause of Lockout or Safety SW Not Made High Temperature Limit Switch Tripped The supply air high temperature limit switch is a normally closed switch factory set at 150 degrees Fahren heit The switch opens when the supply air exceeds the set point of the switch The high temperature limit switch is a manual reset The purpose of the high temperature limit switch is to prevent damage to the air handler fan motor and drive 1 The maximum discharge temperature set point is set to high a Set the maximum discharge air temperature set point to 95 degrees Fahrenheit 2 The modulating regulating valve high fire gas pressure regulator is set to high a Setup the modulating regulating valve to meet the factory specifications for the air handler 3 The high temperature limit switch is set too low a Set the switch for 150 degrees Fahrenheit 4 The high temperature limit switch is defective a Replace the switch 5 Possible Cause of Lockout or Safety SW
76. r in the Unoccupied Setback Temp setting This setting will be maintained until the situation causing the lack of building pressure has been corrected or after a maximum of 20 minutes Once either of these conditions has occurred the pro gram will then return the air handler to the Occupied Heating setting with Auto Room Pressure heating type The cycle will restart again in 10 minutes if the situation that caused the building pressure drop has not been corrected This alarm occurs only if the heating control type has been configured for the Low Building Pres sure option This alarm is a report of the Low Building Pressure condition there is no problem with the soft ware or hardware 1 Determine why the building pressure is less then set point a Most common cause is open over head garage doors b Close the doors 7 3 9 Supplemental Temperature Sensor Information The thermistor temperature sensors change resistance to the Control Module proportionally to the tempera ture with 10 000 ohms representing 77 F Each 1 F drop in temperature causes an approximately 250 ohm increase The simplest way to check their performance is by using the temperature resistance chart on Page 59 Table 10 The display may indicate that a temperature sensor is seeing a very cold temperature that is much colder than the actual temperature 1 The sensor wiring is damaged or connected improperly a Inspect all cabling for the sensor and repair as necessary
77. re to perform under the terms of this warranty if caused by circumstances out of its control including but not limited to war fire flood strike government or court orders acts of God terrorism unavailability of supplies parts or power No person is authorized to assume for Roberts Gordon LLC any other warranty obligation or liability LIMITATIONS ON AUTHORITY OF REPRESENTATIVES No representative of Rapid Engineering LLC other than an Executive Officer has authority to change or extend these provisions Changes or extensions shall be binding only if confirmed in writing by Rapid Engineering LLC s duly authorized Executive Officer 61 of 61
78. ring LLC or handheld keypad if connected See Page 38 Section 5 for additional information on Rapid Engineering LLC provided front end software 3 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 2 2 1 Off In this mode of operation the fan and burner are off and all outdoor air dampers are closed The air handler continues to report status conditions and other settings based on operating conditions 2 2 2 On In this mode of operation the Time Clock Schedule is not in use The fan runs continuously the available heating and cooling functions respond to maintain their occupied settings 2 2 3 Auto In this mode of operation the air handler is controlled by the Time Clock During occupied periods the fan runs continuously Heating and cooling functions respond as needed to maintain their respective settings During unoccupied periods the fan and heat will both cycle on and off as needed to maintain the unoccupied setback temperature setting Any available cooling functions are not active during unoccupied time periods 2 3 Outdoor Air Control Reference RAPID 4000 Series Industrial Air Handler Installation Operation and Service Manual RP140000NA Installer Responsibility section for building pressure damper relief information Installer is responsible to provide building pressure relief damper fans to prevent over pressurization of a building if needed 2 3 1 Manual Percent Outdoor Air This is applicable on
79. rn to Normal is part of the alarm screen and can be viewed if scrolled down If alarm is reset it is not stored in RTN To reset alarm see information below Alarms run newest to oldest within alarm screen Real time run info is available in the status screen See Page 21 Section 3 8 To reset the alarm light push and hold the FN button then push MUTE Table 6 Alarm Description Description of Alarm Reference Fan Contactor Not On See Page 52 Section 73 1 Fan Contactor On When Should Be Off See Page 52 Section 73 2 Damper for Heat Air Not Open See Page 52 Section 73 3 Damper for Heat Air Not Closed See Page 53 Section 73 4 Burner Lockout or Safety SW Not Made See Page 53 Section 73 5 Low Supply Air Temp Shutdown See Page 56 Section 73 6 Dirty Filters See Page 57 Section 73 7 Low Building Pressure See Page 58 Section 73 8 FIGURE 13 Alarm Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE This sample system screen may look different on actual handheld keypad Module Event History 100 most recent ACTIVE ALARMS None in buffer 23 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 10 Calibration This screen should be used by qualified personal only The Cal
80. t be installed and electrically grounded in accordance with the following United States Refer to National Electrical Code 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 1 4 Communication The InfinityPro has built in protocol support for BACnet amp Modbus and N2 Lonworks open communication protocol is also available as an option Front end air handling system software is available from Rapid Engineering LLC See Page 38 Section 5 2 of 61 SECTION 2 SEQUENCE OF OPERATION SECTION 2 SEQUENCE OF OPERATION AWARNING Electrical Shock Hazard Carbon Monoxide Hazard Disconnect electric before service Do not recirculate air from the heated space over burner More than one disconnect switch may be required to disconnect electric from equipment Air supply to burner must be from outside Failure to follow these instructions can result in death or injury Equipment must be properly grounded Failure to follow these instructions can result in death or electrical shock 2 1 Air Handler Model Configurations Based on the air handler application the air handler may be configured in any of the four models described in the upcoming sections 2 1 1 Air Management AM The air handler provides a variable outside air re
81. tings room tempera ture fan status and mode of operation Within screen parameters information is fixed room temperature fan status and mode of operation In order to implement changes advance to appropriate primary screen based on desired changes See Page 29 Section 3 13 From the Home Screen the user can navigate to each subsequent primary screen Mode Settings Status and Alarm The navigation buttons under the bracketed corresponding text once selected advance user to the next screen Screen advances are gt Mode gt Settings gt Status or gt Alarm For Mode infor mation See Page 12 Section 3 5 For Setting information See Page 13 Section 3 6 For Status informa tion See Page 21 Section 3 8 For Alarm information See Page 23 Section 3 9 FIGURE 3 Home Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE Rapid Engineering InfinityPro V0 0 Heating Set 00 F Cooling Set 00 F Room Temp 00 0 Fan Off Mode AUTO 4Mode 5Settings Status ALARM 11 of 61 RAPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 3 5 Mode Screen On the Mode Screen See Page 12 Figure 4 the air handler mode of operation can be selected ON OFF and AUTO are the three modes available On line 3 bracketed text represents
82. turn air ratio within the range of 100 outdoor air 0 return air to 2096 outdoor air 80 return air during the heating seasons and up to 100 return air during the cooling season The unit controls the amount of outdoor air delivered into the building by modulating out door air and return air dampers Supply air volume is fixed 2 1 2 Variable Air Volume VAV The air handler provides 10096 outdoor air with a variable supply air volume from 20 100 with use of bypass section This air handler has no return air capabilities The unit controls the amount of outdoor air delivered into the building by modulating dampers 2 1 3 Make Up Air MUA The air handler provides a fixed supply air volume of 10096 outdoor air to a building This air handler has no return air capabilities An optional variable frequency drive is available to modulate the total air volume when desired 2 1 4 Fixed Recirculation FR The air handler provides a fixed 2096 outdoor air and 80 return air to a building Supply air volume is fixed in both heating and cooling seasons 2 2 Select Operating Modes Each air handler is capable of operating in one of three different modes Off On or Auto mode can be selected Flush mode is also available but forced via building sensor such as carbon dioxide or carbon mon oxide Setting commands See Page 13 Table 2 or status conditions See Page 21 Table 5 can be viewed via front end software available from Rapid Enginee
83. ue HO snyeys 200 e1npe1eduue 00 YO 00 Bumes 200 108281 001 AJO SIH 50415 314815 hes 49019 rea 9000 smeis S31003H98 4390719 INIL 40019 euin 000 uly 1u9218g enue 00 0 enssejg einsseJg 1 500 1eziuouoo3 4 00 00 dwa Ajddng 4O ue4 000 JO 000 Ajddng peo104 00 e oqy YO 1eeH 000 duie oeqies peidnooouf 200 peidnooo SONILLAS sbumes gt JO Ue4 00 000 195 00 195 pidey 4N33H2 Aue usng JO smeis ue4 200 duie pidey 3 8 eAnoy 40019 uo Kjddng 21
84. ve CD from driver and set aside b Load CD labeled WebCTRL and start to run software c Follow instructions on screen during installation Welcome Il Accept License Agreement Product License NOTE Browse for license as saved on desktop and select appropriate file IV Select Destination Directory NOTE Default C AWebCTRL for OEMs 6 0 V WebApps Network Diagnostic Utility VII Select Start Menu Folder VIII Installation Summary 39 of 61 RaPID INFINITYPRO USER OPERATION AND SERVICE MANUAL 5 6 Software Installation Complete Run a Once the software is loaded a folder is created on the hard drive named WebCTRL for OEMs Within this folder locate the webroot folder b Re insert the CD labeled Data Base License and copy the database job specific labeled into the webroot folder c Go to the START menu on the PC and view all programs Select and open program WebCTRL OEM Server to initialize server After the server has initialized it will disappear into an icon on the tool bar This is normal d Open Internet Explorer and type in the address bar the IP address for the local host 127 0 0 1 NOTE Running Internet Explorer 10 0 or higher you must use compatibility mode You must also disable pop up blockers in Internet Explorer for WebCTRL to function properly e Log into WebCTRL User Name Password Privileges Operator 1100 Full User 7831 Basic Read Only
85. web control or BAS FIGURE 4 Mode Screen To adjust Mode Settings Time Clock use arrow buttons to position brackets press ENTER Press DECR or INCR to change value press ENTER or OK to confirm change To reset alarm first press and hold FN button while pressing MUTE ON Time Clock Overridden AUTO Clock Active See Settings Operating Mode Auto HOME 12 of 61 3 6 Setting Screen SECTION 3 USER INSTRUCTIONS On the Setting Screen See Page 14 Figure 5 various heating and cooling commands are available in addi tion to outdoor air control adjustments Each setting is adjustable based on desired user operation This screen has a show hide feature that automatically displays applicable setting commands based on air handler features See Page 13 Table 2 for a complete list of setting commands available Not all settings will be displayed at one time on the handheld keypad At the end of line 3 See Page 9 Figure 7 for reference when arrow is visible use arrow buttons to scroll up down for additional settings Settings can be changed with the handheld keypad via number buttons to define settings Table 2 Setting Commands Setting Description of Temperature and Outdoor Air Settings Occupied Heating This setting is used to specify the desired room temperature that is maintained during occupied periods Unoccupied Setback Temp This setting is used to specify the desired room te

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