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So just because you're an expert in reloading a light crossbow does not make you an expert in other types of crossbows.
What's he's done is legal, but it doesn't even optimize the weapon (which is sub-optimal to begin with).
If he chose light crossbow when he chose Rapid Reload he's going to be eating AoO's reloading a heavy crossbow as a free action with Crossbow Mastery.
So Crossbow Mastery makes him a master of all crossbows, but he's still has the greatest level of expertise with the Light Crossbow, hence no AoO's when reloading.
This is fine rules & fluff wise. Sub-optimal yes, but still totally fine.
He still needs point-blank master to avoid AoO's when firing. Which is nuts. They should have just rolled that into Crossbow Mastery as far as I'm concerned.