Daikin 90 Plus AFUE Installation & Commissioning Download Page 37 | Manualshive

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background image

36

©

2014

Daikin

North

America,

LLC



Suspension,

Leveling,

Filters,

Return

Options



Condensate

Drain

Trap,

Drain

Pan,

and

Lines



Horizontal

Right

Side

Down



Horizontal

Left

Side

Down



Venting



Gas

Valve

and

Connections



Electrical

Connections



24

Volt

Thermostat

Wiring



ComfortNet



Furnace

Start

Up



Temperature

Rise

and

Blower

Speed

Adjust



Duct

Static

Agenda

©

2014

Daikin

North

America,

LLC

ComfortNet

System



The

ComfortNet system

is

one

that

includes

a

ComfortNet

compatible

furnace,

an

air

conditioner

or

heat

pump,

with

a

CTK04

thermostat

.



A

valid

ComfortNet system

could

also

be

a

compatible

furnace,

CTK04

thermostat,

and

non

‐

compatible,

single

stage

air

conditioner

.



Indoor

unit,

outdoor

unit,

and

thermostat

interact/

communicate

digitally

with

one

another.



Two

‐

way

communication

ComfortNet

control

system

recommended

for

furnace

models:

DM97MC

DC97MC

DM96VC

DC96VC

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Summary of Contents for 90 Plus AFUE

Page 1: ...90 Plus AFUE Furnace Install Commissioning Participant Guide ...

Page 2: ... Leveling Filters Return Options Condensate Drain Trap Drain Pan and Lines Horizontal Right Side Down Horizontal Left Side Down Venting Gas Valve and Connections Electrical Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda ...

Page 3: ...ce Installation Horizontal Right Upflow Downflow Horizontal Right Horizontal Left Horizontal Left 2014 Daikin North America LLC Suspension from rafters or joists Use 3 8 threaded rod 2 x2 x1 8 angle iron Crawl space installation Suspended from floor joists Supported by concrete pad Never install on ground under home as it could be exposed to water Furnace Suspension ...

Page 4: ... end for proper flue pipe drainage Level end to end 2014 Daikin North America LLC Furnace Leveling Install the furnace with a slight tilt from back to front with the access doors downhill from the back panel Tilt approximately 1 2 to 3 4 inches Allows the condensate from the secondary heat exchanger to flow forward to the recuperator coil front cover and into drain trap ...

Page 5: ...ters Filters must be used with this furnace Filters are not shipped with this furnace but must be provided sized and installed externally by the installer If the furnace is installed without filters the warranty will be voided NOTE Change filters before occupants take ownership of a new home Filter Sizing Chart Model Minimum Filter Size DM96VC0403B 20 x 24 DM96VC0603B 20 x 25 DM96VC0803B 18 x 36 D...

Page 6: ...ound the perimeter of the opening using a pair of seamer pliers or seamer tongs WARNING Sharp edges Gloves required 2014 Daikin North America LLC Bottom Return Air Opening Airflow area will be reduced by approximately 18 if duct flanges are not unfolded This could cause performance issues and noise issues Press Out by Hand Scribe Lines Outlining Duct Flanges Cut Using Tin Snips Cut Four Corners Af...

Page 7: ... your opening NOTE An undersized opening will caused reduced airflow 2014 Daikin North America LLC Suspension Leveling Filters Return Options Condensate Drain Trap Drain Pan and Lines Horizontal Right Side Down Horizontal Left Side Down Venting Gas Valve and Connections Electrical Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static...

Page 8: ...pace Must cover the entire area under the furnace Secondary containment for trap Under furnace and evaporator coil when applicable 2014 Daikin North America LLC Drain Pan Trap and Lines Condensate drain trap is secured to furnace side panels in horizontal applications A minimum clearance of 5 5 below the furnace must be provided for trap installation 9 Min 5 5 ...

Page 9: ...oth sides of the drain trap with water Importance of drain trap priming Ensures proper furnace drainage upon startup Prohibits the possibilities of flue gases escaping through the drain system 2014 Daikin North America LLC Drain Trap Installed in Vertical Upflow Furnace Drain Exiting Left Side Drain Exiting Right Side ...

Page 10: ...rain Trap Drain Pan and Lines Horizontal Right Side Down Horizontal Left Side Down Venting Gas Valve and Connections Electrical Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda 2014 Daikin North America LLC Video ...

Page 11: ...s period of instruction Upflow model installed horizontally with right side down Upflow model installed horizontally with left side down Condensate Drain Trap Conversion 2014 Daikin North America LLC Remove the clamps from both ends of the drain hoses Remove the two screws holding the drain trap to the blower deck Remove the trap and two hoses from the blower deck Horizontal Right Side Down Remove...

Page 12: ...ide of the cabinet through the cabinet drain hole nearest the top of the furnace Cut C Remove Plugs 2014 Daikin North America LLC Horizontal Right Side Down Secure hose 5 to the barbed fitting in the elbow with a red clamp Install the non grommet end of hose 11 from the outside of the cabinet through the bottom drain hole Install on collector box and secure with a silver clamp Secure w clamp Secur...

Page 13: ...r to the Field Supplied Drain section in the manual for instructions on field supplied installed drain on outlet of furnace trap Secure drain trap 2014 Daikin North America LLC Suspension Leveling Filters Return Options Condensate Drain Trap Drain Pan and Lines Horizontal Right Side Down Horizontal Left Side Down Venting Gas Valve and Connections Electrical Connections 24 Volt Thermostat Wiring Co...

Page 14: ... Upflow model is installed horizontal left side down Downflow model is installed horizontal right side down Pressure Tube 2014 Daikin North America LLC Front Cover Pressure Switch Tube Step 1 Remove factory installed 6 square tubing that connects the front cover pressure switch and the top collector box cover port Remove tube ...

Page 15: ...over Pressure Switch Tube Step 2 Remove rubber plug from the bottom collector box port Remove Plug 2014 Daikin North America LLC Front Cover Pressure Switch Tube Step 3 Install rubber plug on top collector box port Plug Top Collector Box Port ...

Page 16: ...hipped with furnace Install one end on the front cover pressure switch and the other end onto the bottom lower collector box port Attach to lower collector box port 2014 Daikin North America LLC Front Cover Pressure Switch Tube Step 5 Cut off access tubing and tuck access hose into the furnace compartment close to the inducer draft motor ...

Page 17: ...LLC D M 9 7 M C 0 8 0 3 B N A A 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Brand Minor Revision D Daikin A Initial Release B 1st Revision Configuration M Upflow Horizontal C Downflow Horizontal Major Revision A Initial Release AFUE B 1st Revision 97 97 AFUE Gas Valve NOx M Modulating N Low NOx V 2 Stage H Convertible 2 Stage S Single Stage Cabinet Width A 14 Motor B 17 5 C Variable Speed ECM ComfortNet C 21...

Page 18: ...move Plug 2014 Daikin North America LLC Horizontal Left Side Down Place hose 6 on the vent drain elbow side port and secure with a silver clamp Remove black drain cap near the lower collector box port and place on barbed fitting Secure with a red clamp Attach to vent drain elbow side port Black cap secured with red clamp ...

Page 19: ...using the 100 degree elbow in drain assembly bag and secure with two red clamps Cut 3 from the non gromett end 100 degree elbow 2014 Daikin North America LLC Horizontal Left Side Down Drain the collector box Install the non grommet end of hose 11 from the inside of the cabinet into the cabinet hole closest to the top air discharge end of the furnace Install on collector box and secure with a silve...

Page 20: ...p Temperature Rise and Blower Speed Adjust Duct Static Agenda 2014 Daikin North America LLC All furnaces are dual certified and built with a 2 vent intake pipe and connectors Transitioning from 2 to 3 PVC pipe should be done as close to the furnace as possible Do not connect to Type B BW or L vent or any vent connector metal Must not be vented to any portion of a factory built or masonry chimney e...

Page 21: ...mum of 12 above the top of the chimney Direct Venting 2014 Daikin North America LLC Requires vent flue pipe only PVC may run horizontally and exit through the side of the building or run vertically and exit through the roof of building PVC may be run through and existing unused chimney PVC must extend a minimum of 12 above the top of the chimney The space between the vent pipe and the chimney must...

Page 22: ...5 90 85 60 000 2 or 2 1 2 95 90 85 80 75 70 65 60 80 000 B 2 or 2 1 2 75 70 65 60 55 50 45 40 80 000 B 3 200 193 186 179 172 165 158 151 80 000 C 2 or 2 1 2 25 20 15 10 5 N A N A N A 80 000 C 3 200 193 186 179 172 165 158 151 100 000 2 or 2 1 2 25 20 15 10 5 N A N A N A 100 000 3 200 193 186 179 172 165 158 151 120 000 2 or 2 1 2 45 40 35 30 25 20 15 10 120 000 3 95 90 85 80 75 70 65 60 Pipe Lengt...

Page 23: ...nces Vent Terminations 3 Min Forced Air Inlet 4 Min 12 Min No Terminations Above Walkway Non Direct Non Direct Direct Direct Non Direct 2014 Daikin North America LLC Vent Terminations Direct Vent Terminations Must terminate at least 12 from any opening through which flue gases may enter a building door window or gravity fed inlet A vent pipe run vertically through a roof must terminate at least 12...

Page 24: ...on should not terminate in an area which is frequently dusty or dirt 12 Min to Grade or Highest Anticipated Snow Level Vent Flue Pipe Tee Optional Combustion Air Intake Optional 10 24 2014 Daikin North America LLC Side Wall Vent Kit Concentric Vent Terminations side wall Used with 2 or 3 direct vent systems May be installed with the intake and exhaust pipes located side by side or with one pipe ab...

Page 25: ...cations Down venting is for upflow model furnaces only Applicable for homes with crawlspaces and basements Vent Pipe Slope per foot min Combustion Air Pipe Drain Tee on Vent Pipe Condensate Disposal Condensate trapped to prevent flue gas from escaping 2014 Daikin North America LLC Venting Rubber Coupling Direct Vent Non Direct Vent ...

Page 26: ...Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda 2014 Daikin North America LLC 24 volt gas valve controlled by the integrated control module Manual ON OFF control located on the valve itself The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and length of...

Page 27: ...0 560 80 43 90 170 350 530 90 40 84 160 320 490 100 38 79 150 305 460 BTUH Furnace Input Heating Value of Gas BTU Cubic Foot CFH 2014 Daikin North America LLC Gas Connections Piping may enter the left or right side of cabinet The installer must supply rigid pipe long enough to reach the outside of the cabinet to seal the grommet cabinet penetration A semi rigid connector to the gas piping can be u...

Page 28: ...es Manifold Burners 2014 Daikin North America LLC Propane L P Kits Available Manufacturer s propane gas conversion kits are available The 24 volt gas valve is field convertible for use with propane gas by replacing the regulator spring with a propane gas spring from the appropriate propane gas conversion kit Consult the furnace specification sheet for a listing of appropriated kits All gas to prop...

Page 29: ... DM96VC DC96VC DM96VE DM96HS DC96HS DM92SS DC92SS 2014 Daikin North America LLC Suspension Leveling Filters Return Options Condensate Drain Trap Drain Pan and Lines Horizontal Right Side Down Horizontal Left Side Down Venting Gas Valve and Connections Electrical Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda ...

Page 30: ...at least 105 degree C Must also be a copper conductor 2014 Daikin North America LLC 115 Volt Line Connections Check furnace data plate before installing electrical connections Power supply to the furnace must be NEC Class 1 and must comply with all applicable codes Use a SEPARATE fused branch electrical circuit containing properly sized wire and fuse or circuit breaker An electrical disconnect mus...

Page 31: ... vent applications the cabinet opening to the junction box must be sealed air tight Line polarity must be observed when making field connections Line voltage connections can be made through either the right or left side panel 2014 Daikin North America LLC Checking For Line Polarity Hot Leg L1 Common Neutral Leg L1 to ground reading 119VAC Neutral to ground reading 0 3VAC ...

Page 32: ...d one of the burners Resistance should be 10 ohms or less 2014 Daikin North America LLC 115 Volt Line Connection of Accessories Line voltage accessory terminals for controlling power to an optional field supplied humidifier and or electronic air cleaner Follow the humidifier or air cleaner manufacturers instructions for locating mounting grounding and controlling these accessories The accessory lo...

Page 33: ...ral Humidifier Electronic Air Cleaner 2014 Daikin North America LLC Suspension Leveling Filters Return Options Condensate Drain Trap Drain Pan and Lines Horizontal Right Side Down Horizontal Left Side Down Venting Gas Valve and Connections Electrical Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda ...

Page 34: ...tage cooling 24 Volt Thermostat Wiring 2014 Daikin North America LLC 24 Volt Thermostat Wiring For single stage cooling applications a jumper may be required between Y1 and Y2 at the furnace control in order to achieve the desired single stage cooling airflow Use of ramping profiles and dehumidification features require a jumper between Y1 and O Single Stage Heating with Single Stage Cooling C G R...

Page 35: ... C G R Y C O NEU HOT DE HUM W1 W2 W1 W2 Remote Condensing Unit Single Stage Cooling Dehumidistat Optional Furnace Integrated Control Module Y2 Y1 2014 Daikin North America LLC 24 Volt Dehumidistat Wiring The optional usage of a dehumidistat allows the furnace s circulator blower to operate at a slightly lower speed 85 of desired speed during a combined thermostat call for cooling and dehumidistat ...

Page 36: ...t wire to the terminal marked R on the furnace integrated control module 24 Volt Dehumidistat Installation OFF ON 1 2 DEHUM TRIM ENABLE S5 2014 Daikin North America LLC Dual Fuel Applications This furnace can be used in conjunction with a heat pump in a dual fuel application A dual fuel application refers to a combined gas furnace and heat pump installation Strictly follow the wiring guidelines in...

Page 37: ...st Duct Static Agenda 2014 Daikin North America LLC ComfortNet System The ComfortNet system is one that includes a ComfortNet compatible furnace an air conditioner or heat pump with a CTK04 thermostat A valid ComfortNet system could also be a compatible furnace CTK04 thermostat and non compatible single stage air conditioner Indoor unit outdoor unit and thermostat interact communicate digitally wi...

Page 38: ... connect to 1 and 2 R is 24VAC hot C is 24VAC common Size of page image ComfortNet System 24AC Hot 24AC Common Data lines 2014 Daikin North America LLC ComfortNet System A removable plug connector is provided with the control It is STRONGLY recommended that you do not connect multiple wires into a single terminal Minimum 18 AWG wire no longer than 100 max length between all components 100 b t indo...

Page 39: ... North America LLC ComfortNet System Two Wire Outdoor Four Wire Wiring Two wires can be utilized between the indoor and outdoor units For this wiring scheme only the data lines 1 2 are needed between the indoor and outdoor units A 40VA 208 230 VAC to 24VAC transformer must be installed in the outdoor unit to provide 24VAC power to the outdoor units electronic control CTK0 Thermostat ComfortNet Com...

Page 40: ...system configuration the Y1 terminal on the integrated furnace control becomes an output rather than an input The Y1 connection to the outdoor unit is made using both 4 position thermostat connections in the CTK0 kit ComfortNet System C Net Compatible Furnace w Non C Net Compatible Single Stage AC C G Y2 2 1 R W1 O ComfortNet Compatible Furnace Integrated Control Module DE HUM W2 C 2 1 R Y C CTKO ...

Page 41: ...ctrical Connections 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda 2014 Daikin North America LLC Gas Piping Leak Checks Leak test before placing unit into operation Use approved chloride free soap and water solution electronic combustible gas detector or other approved testing methods WARNING Never use a match or open flame to test...

Page 42: ...ntrol will force a high capacity demand at this time 2014 Daikin North America LLC Gas Pressure Test Cont The Ft will flash until the furnace has reached 100 Solid FT once 100 capacity is achieved A 5 minute timer has just started The line pressure supplied to the gas valve must be within the range specified below Supply pressure can be measured at the gas valve inlet pressure tap The supply press...

Page 43: ...Model 36J54 Connected to Manometer Measuring Gas Supply Pressure On Off Switch Outlet Pressure Boss Inlet Pressure Boss Gas Pressure Gauge 2014 Daikin North America LLC Measuring Gas Supply Pressure Measure furnace gas supply pressure with burners firing Supply pressure must be within the range specified in the Inlet Gas Supply Pressure Table If supply pressure differs from table make the necessar...

Page 44: ...alve Turn on gas and power to furnace Close thermostat R and W1 contacts to call for low stage heat Measure the gas manifold pressure with burners firing Outlet Pressure Barb 2014 Daikin North America LLC Gas Manifold Pressure Measurement and Adjust Remove regulator cover screw from the low LO outlet pressure regulator Adjust tower and turn screw clockwise to increase pressure or counterclockwise ...

Page 45: ... pressure regulator Adjust tower and turn screw clockwise to increase pressure or counterclockwise to decrease pressure Replace regulator cover screw Turn off power and gas to furnace 2014 Daikin North America LLC Gas Manifold Pressure Measurement and Adjust Natural Gas Propane Gas Low Stage High Stage Low Stage High Stage Range w c 1 6 2 2 3 2 3 8 5 7 6 3 9 7 10 3 Nominal w c 1 9 3 5 6 0 10 0 Man...

Page 46: ...t Up Temperature Rise and Blower Speed Adjust Duct Static Agenda 2014 Daikin North America LLC Temperature Rise Temperature rise must be within the range specified on the unit rating plate An incorrect temperature rise may result in condensing or overheating of the heat exchanger An airflow and temperature rise table is provided in the Specification Sheet applicable to your model Determine the tem...

Page 47: ...ine the air temperature rise 2014 Daikin North America LLC Temperature Rise Measurement Adjust temperature rise by adjusting the circulator blower speed Increase the blower speed to reduce temperature rise Decrease the blower speed to increase temperature rise Refer to the Startup Procedure and Adjustment Circulator Blower Speeds section of your furnace manual for instructions on how to adjust blo...

Page 48: ...No 3 4 A OFF OFF B ON OFF C OFF ON D ON ON Indicates factory setting Switch Bank S3 Cooling Speed Taps DIP Switch No 3 4 A OFF OFF B ON OFF C OFF ON D ON ON Indicates factory setting 2014 Daikin North America LLC Setting Variable Speed Blower Switches OFF ON 1 2 3 4 Switch Bank S4 Heating Airflow DIP Switch No 3 4 A OFF OFF B ON OFF C OFF ON D ON ON Indicates factory setting Airflow speed adjustme...

Page 49: ...CFM the LED display will indicate a 14 for 1400 CFM Blower Speed Adjust 2014 Daikin North America LLC Blower Speed Adjust Determine the tonnage of the cooling system installed with the furnace If the cooling capacity is the BTU hr divide it by 12 000 to convert the capacity to tons So if your cooling capacity requirement is 42 000 BTU hr then 42 000 12 000 3 5 tons Determine the proper air flow fo...

Page 50: ...ge cooling air flow charts in the furnace specification sheet applicable to your model Look up the cooling air flow determined in example 3 above and find the required cooling speed and adjust the setting 2014 Daikin North America LLC Blower Speed Adjust Model Tap Low Stage Cool High Stage Cool Low Stage Heat High Stage Heat DM96VC0403BN A B C D 403 527 675 803 596 796 974 1192 422 471 521 574 494...

Page 51: ...928 868 810 743 670 614 560 505 Y 870 658 548 469 413 349 293 N A OFF OFF ON Ylo 928 868 810 743 670 614 560 505 Y 885 821 755 684 621 557 508 461 OFF ON ON Ylo 874 697 612 533 470 414 361 303 Y 1146 1097 1049 1002 941 895 846 787 ON OFF ON Ylo 885 821 755 684 621 557 508 461 Y 1146 1097 1049 1002 941 895 846 787 ON ON ON Ylo 885 821 755 684 621 557 508 461 Y 874 697 612 532 470 414 361 303 2014 D...

Page 52: ... 2 3 Y ON OFF OFF Ylo ON OFF OFF Use the Y setting only for single stage air conditioners 2014 Daikin North America LLC Setting Multi Speed Blower Off Delay OFF ON 1 2 3 4 Switch Bank S1 Off Delay Seconds DIP Switch No 3 4 90 OFF OFF 120 OFF ON 150 ON OFF 180 ON ON Indicates factory setting The integrated control module furnace board provides a selectable heat off delay function The 3rd and 4th di...

Page 53: ...ions 24 Volt Thermostat Wiring ComfortNet Furnace Start Up Temperature Rise and Blower Speed Adjust Duct Static Agenda 2014 Daikin North America LLC Checking Duct Static Refer to your furnace rating plate for the maximum ESP external duct static rating Too much external static pressure will result in insufficient air that can cause excessive temperature rise This can cause limit switch tripping an...

Page 54: ... static readings through test holes in ducts and tape up holes once your test is complete 2014 Daikin North America LLC Checking Duct Static Supply Air Inclined Manometer Measure Negative Static Return Air Steps to determine total external static pressure Inspect replace filter in furnace Install an inclined manometer magnehelic or digital manometer into return duct of furnace closest to blower bu...

Page 55: ...supply duct at the outlet of the furnace Total Static Example Negative static pressure 4 w c Positive static pressure 2 w c Total external static pressure would be 6 w c The difference between the two numbers is the total external static pressure on the system 2014 Daikin North America LLC QUESTIONS ...

Page 56: ...nce are needed for the trap to be installed properly A 6 5 inches B 5 0 inches C 4 5 inches D 5 5 inches 4 The condensate drain trap on the Daikin 90 Plus furnace must be primed prior to furnace start up A True B False 5 In a horizontal right side down drain trap conversion hose number 5 is cut at line ___ A E B G C D D C 6 In a horizontal left side down drain trap conversion hose number 6 is cut ...

Page 57: ... A direct vent termination must terminate at least ___ feet from any opening through which flue gases may enter a building A 6 Feet B 10 5 Feet C 12 Feet D 10 Feet 10 The gas piping supplying the furnace must be properly sized based on the gas flow required specific gravity of the gas and the _____________ A Model number on the furnace B Length distance of the run C Serial number on the furnace D ...

Page 58: ...ehumidification features require a jumper between Y1 and ____ on the integrated control module A O B R C G D Y2 15 The first step taken when installing a dehumidistat to the integrated control module is to turn off power to the Daikin 90 Plus furnace A True B False 16 When installing a ComfortNet system for Daikin 90 plus furnace 18 gauge thermostat wiring should be no longer than ____ feet betwee...

Page 59: ...s furnace can be adjusted by the blower speed Decrease the blower speed to _____ temperature rise A Monitor B Decrease C Reduce D Increase 21 The airflow quantity is displayed on the LED display adjacent to the dip switches on the integrated control module If the furnace airflow being delivered is 1255 CFM the LED display will indicate a 12 on the screen A True B False rounded up to 1300 so it wil...

Page 60: ...manometer magnehelic or digital manometer B Turn the furnace on to fan on C Inspect replace filter in the furnace D Turn the furnace to the highest heat setting 25 The positive static pressure should be measured at outlet of the furnace after the evaporator coil A True B False Measure at outlet of furnace before the evap coil ...

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