background image

15

C

B

VL & VM

NOTE:

Do 

NOT 

operate sheave with flange projecting beyond

the hub end.

GAS SYSTEM CHECK

Pre-Operation Checks

1. Close the manual gas valve external to the unit.
2. Turn off the electrical power supply to the unit.
3. Set the room thermostat to its lowest possible setting.
4. Remove the heat exchanger door on the side of the unit

by removing screws.

5. This unit is equipped with an ignition device which

automatically lights the main burner. DO NOT try to light
burner by any other method.

6. Move the gas control valve switch to the OFF position. Do

not force.

7. Wait five minutes to clear out any gas.
8. Smell for gas, including near the ground. This is important

because some types of gas are heavier than air. If you have
waited five minutes and you do smell gas, immediately
follow the warnings on page 3 of this manual. If having
waited for five minutes and no gas smell is noted, move
the gas control valve switch to the ON position.

9. Replace the heat exchanger door on the side of the unit.

10. Open the manual gas valve external to the unit.
11. Turn on the electrical power supply to the unit.
12. Set the thermostat to desired setting.

G

AS

 S

UPPLY

 P

RESSURES

 & R

EGULATOR

 A

DJUSTMENTS

S

HOULD

 

OVERHEATING

 

OCCUR

 

OR

 

THE

 

GAS

 

SUPPLY

 

FAIL

 

TO

 

SHUT

 

OFF

TURN

 

OFF

 

THE

 

MANUAL

 

GAS

 

SHUTOFF

 

VALVE

 

EXTERNAL

 

TO

 

THE

 

UNIT

 

BEFORE

 

TURNING

 

OFF

 

THE

 

ELECTRICAL

 

SUPPLY

.

WARNING

T

O

 

AVOID

 

PROPERTY

 

DAMAGE

PERSONAL

 

INJURY

 

OR

 

DEATH

DO

 

NOT

 

FIRE

 

GAS

 

UNIT

 

WITH

 

FLUE

 

BOX

 

COVER

 

REMOVED

.

WARNING

NOTE:

Except during brief periods when gas pressures are  being

measured by qualified service personnel, the furnace access panel
must always be secured in place when the furnace is in operation.
An inspection port in the access panel is provided to monitor the
flame.

The first step in checking out the gas-fired furnace is to test the
gas supply piping to the unit for tightness and purge the system of
air using methods outlined in the latest edition of the National
Fuel Gas Code ANSI Z223.1.  Verify that the disconnect switch is in
the “OFF” position.  A soapy water solution should be used to check
for gas leaks. Since the unit is subject to considerable jarring dur-
ing shipment, it is extremely important that all gas connections
and joints be tested for tightness. Gas piping downstream from
the unit inlet should be checked for leaks during the subsequent
sequence check.

The supply gas pressure should be adjusted to 7.0" w.c. on natural
gas and 11.0" on LP gas with the gas burners operating. If there is
more than one unit on a common gas line, the pressures should
be checked with all units under full fire. A supply pressure tap is
provided on the upstream side of the gas valve. A manifold pres-
sure tap is provided on the gas valve. The normal manifold pres-
sure for full input is 3.5" w.c. on natural gas and 9.5" w.c. for pro-
pane gas. Low fire  natural gas 2.0” w.c., 6.0”  low fire propane gas.
Minimum gas supply pressure is 5.5" w.c. for natural gas and 11.0"
for propane gas. In order to obtain rating, gas supply pressure must
be 11.0" w.c. for propane gas.

The pressure regulator on LP gas models is adjusted for 9.5" w.c.
manifold pressure and is intended to prevent over-firing only. Do
not attempt adjustment of the built-in pressure regulator unless
the supply pressure is at least 7.0" w.c. on natural gas or 13.0" w.c.
on propane gas. Check the location of  the  ignition electrode and
the flame sensor for correct gap setting.

FLAME

SENSOR

Flame Sensor and Ignition Electrode Location

Summary of Contents for DCG Series

Page 1: ...MERCIAL PACKAGED GAS UNIT 3 to 6 TON 2013 2016 5151 San Felipe St Suite 500 Houston TX 77056 www daikincomfort com Our continuing commitment to quality products may mean a change in specifications wit...

Page 2: ...FIED IN THIS MANUAL OR ATTEMPTING TO INSTALL ADJUST SERVICE OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER TRAINING MAY RESULT IN PRODUCT DAMAGE PROPERTY DAMAGE PERSONAL INJURY OR DEA...

Page 3: ...ould be greater than or equal to the design heating and cooling loads of the area to be conditioned The loads should be calculated by an approved method or in accordance with ASHRAE Guide or Manual J...

Page 4: ...ial and industrial processes may also be sources of chlorine fluorine compounds To avoid possible illness or death of the building occupants do NOT locate outside air intake device economizer manual f...

Page 5: ...l perimeter curbs include duct connection frames to be assembled with the curb Cantilevered type curbs are not available from the factory Curb insulation cant strips flashing and general roofing mater...

Page 6: ...S 42 TO PREVENT DAMAGE TO THE UNIT HOWEVER 48 IS RECOMMENDED CAUTION Provisions for forks have been included in the unit base frame No other fork locations are approved WARNING TO PREVENT POSSIBLE EQU...

Page 7: ...WIRING OF THESE UNITS ARE FACTORY INSTALLED AND HAVE BEEN THOROUGHLY TESTED PRIOR TO SHIPMENT CONTACT YOUR LOCAL REPRESENTATIVE IF ASSISTANCE IS REQUIRED WARNING TO PREVENT DAMAGE TO THE WIRING PROTE...

Page 8: ...ING Areas Without Convenience Outlet It is recommended that an independent 115V power source be brought to the vicinity of the roof top unit for portable lights and tools used by the service mechanic...

Page 9: ...m Value Shown in Table Above The minimum supply pressure should not vary from that shown in the table above because this could prevent the unit from having dependable ignition In addition gas input to...

Page 10: ...line by loosening the ground joint union until pure gas is expelled Tighten union and wait for five minutes until all gas has been dissipated in the air Be certain there is no open flame in the vicini...

Page 11: ...If the gas pressure at the unit is greater than 10 5 w c the contractor must furnish and install an external type positive shut off service pressure regulator The unit will not function satisfactorily...

Page 12: ...MACHINERY HAZARD TO PREVENT POSSIBLE PERSONAL INJURY OR DEATH DISCONNECT POWER TO THE UNIT AND PADLOCK IN THE OFF POSITION BEFORE SERVICNG FANS WARNING This unit is equipped with an electronic igniti...

Page 13: ...pply voltage will be main tained within the utilization range under all system conditions check and calculate if an unbalanced condition exists between phases Calculate percent voltage unbalance as fo...

Page 14: ...tor and bearing failure will occur Check you belt drive for adequate run in belt tension by measuring the force required to deflect the belt at the midpoint of the span length Belt tension force can b...

Page 15: ...when the furnace is in operation An inspection port in the access panel is provided to monitor the flame The first step in checking out the gas fired furnace is to test the gas supply piping to the u...

Page 16: ...R W1 and W2 on TB1 Place jumper wire between R W1 and W2 to engage high stage heat note on 045 kbtu hr units W2 is not used only jumper R to W1 2 See Figure in input rating section for gas valve adjus...

Page 17: ...EVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE THE GAS MANIFOLD PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE ONLY MINOR ADJUSTMENTS SHOULD BE MADE BY ADJUSTING THE GAS VALVE PRESSURE REGULAT...

Page 18: ...ing 2 Turn off the electrical power supply to the unit 3 Remove the heat exchanger door on the side of the unit by removing screws 4 Move the gas control valve switch to the OFF position Do not force...

Page 19: ...1 or M2 Black High Speed Blue Medium Speed Red Low Speed EEM Motor Adjust the CFM for the unit by changing the position of the low voltage leads on the motor terminal block White is for fan only and g...

Page 20: ...ly matted on the entering air face of the coil and can be removed by brushing 3 Lubricate motor bearings 4 Align or replace belts as needed 5 Replace filters as needed see below 6 Check for blockage o...

Page 21: ...ng the heating season make a visual check of the burner flames NOTE This will involve removing and reinstalling the heat exchanger door on the unit which is held by two screws If you are uncertain abo...

Page 22: ...n the gas valve is deenergized the circulator blower heat off cycle begins and the induced draft blower remains on The diagnostic fault code is two flashes Pressure Switch Stuck Closed 3 FLASH CODE A...

Page 23: ...EXTERNAL STATIC PRESSURE ESP in w c STANDARD CFM AMPS WATTS RPM 0 10 1293 1 72 364 715 0 20 1235 1 67 354 759 0 30 1173 1 62 342 803 0 40 1124 1 58 330 841 0 50 1056 1 54 316 880 0 60 978 1 47 298 913...

Page 24: ...SPEED TAP EXTERNAL STATIC PRESSURE ESP in w c STANDARD CFM AMPS WATTS RPM 0 10 1612 2 60 554 789 0 20 1548 2 49 532 832 0 30 1484 2 38 510 875 0 40 1400 2 27 486 904 0 50 1316 2 16 462 933 0 10 1846...

Page 25: ...626 1008 0 70 1688 5 05 642 1039 0 10 2106 5 14 650 924 0 20 2050 5 26 670 951 0 30 1993 5 32 678 969 0 40 1960 5 47 696 1001 0 50 1920 5 54 706 1021 0 60 1880 5 61 726 1041 0 70 1810 5 73 736 1072 0...

Page 26: ...4 58 582 940 0 70 1782 4 72 602 968 0 10 2224 4 73 592 832 0 20 2165 4 79 612 860 0 30 2123 4 91 630 891 0 40 2079 5 01 642 913 0 50 2029 5 14 666 946 0 60 1978 5 26 676 969 0 70 1926 5 38 698 1001 0...

Page 27: ...M BHP 0 2 2210 0 91 2041 0 76 1869 0 63 1739 0 52 1565 0 40 0 4 2197 0 98 2021 0 82 1841 0 67 1660 0 54 1521 0 44 1339 0 32 0 6 2002 0 88 1822 0 72 1635 0 58 1445 0 44 1288 0 35 0 8 1799 0 77 1610 0 6...

Page 28: ...OWN SHOT CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP 0 6 2262 1 16 2051 0 95 1851 0 76 1657 0 60 0 8 2277 1 27 2070 1 05 1852 0 84 1646 0 66 1 0 2304 1 39 2089 1 15 1872 0 93 1647 0 72 1 2 2104 1...

Page 29: ...CFM BHP CFM BHP CFM BHP 0 2 2460 0 96 2251 0 80 2073 0 65 1862 0 51 0 4 2408 1 00 2206 0 84 1982 0 68 1808 0 55 1572 0 41 0 6 2402 1 08 2173 0 89 1943 0 72 1701 0 55 1511 0 43 0 8 2153 0 95 1917 0 77...

Page 30: ...M BHP CFM BHP CFM BHP CFM BHP CFM BHP 0 6 2219 0 95 1970 0 75 0 8 2215 1 04 1956 0 82 1697 0 62 1 0 2240 1 15 1957 0 90 1681 0 67 1 2 2260 1 26 1983 1 00 1683 0 74 1 4 2288 1 38 2009 1 10 1711 0 84 1...

Page 31: ...0 7 6 BD STD STATIC 1 0 3 8 460 60 3 414 506 1 7 76 52 0 1 1 4 0 80 BD STD STATIC 1 0 1 9 575 60 3 518 633 1 5 71 38 9 1 1 4 0 60 BD STD STATIC 1 5 2 3 208 230 60 3 187 253 1 19 123 1 1 3 1 92 BD STD...

Page 32: ...6 1 4 4 7 8 DRAIN THRU CURB LOCATION EMBOSS FOR THRU THE BASE UTILITIES BOTTOM VIEW OF UNIT 8 3 16 5 7 8 19 7 16 27 3 8 47 1 2 4 1 2 7 1 2 SUPPLY RETURN 73 1 4 47 1 2 74 1 16 48 3 16 38 13 16 6 Ton 4...

Page 33: ...YL 208 240 1 60 SEE NOTE 5 RD YL RD IIC C RD YL L2 C T2 L1 T1 BK BK PU RD OR YL SEE NOTE 8 GREEN JUMPER ALS PS RS PLF YL YL NOTE 4 GAS VALVE MV PU W R GAS VALVE PU ALT HONEYWELL BL BR PU PU PU BK R G...

Page 34: ...898 A HPS LPS HPS HIGH PRESSURE SWITCH HIGH VOLTAGE FACTORY WIRING OPTIONAL HIGH VOLTAGE LOW VOLTAGE FIELD WIRING LINE VOLTAGE LOW VOLTAGE BL RD Y1 YL W BL G R W NO ECONOMIZER G YL RD Y1 PK WH W R RD...

Page 35: ...EE NOTE 5 RD YL RD IIC C RD YL L2 C T2 L1 T1 BK BK PU RD OR YL SEE NOTE 8 GREEN JUMPER ALS GR PS RS PLF YL YL NOTE 4 GAS VALVE MV BL W R GAS VALVE PU ALT HONEYWELL BR PU PU PU BK BR R G Y1W1 OR RD C M...

Page 36: ...GEND COMP ALS TB1 TR TRANSFORMER 208 240 1 60 0140L02900 A HPS LPS HPS HIGH PRESSURE SWITCH HIGH VOLTAGE FACTORY WIRING OPTIONAL HIGH VOLTAGE LOW VOLTAGE FIELD WIRING LINE VOLTAGE LOW VOLTAGE BL RD Y1...

Page 37: ...NOTE 5 RD YL R D IIC C RD RD L2 C T2 L1 T1 BK BK PU YL OR YL SEE NOTE 8 GREEN JUMPER ALS GR PS RS PLF YL YL NOTE 4 GAS VALVE MV BL W R GAS VALVE PU ALT HONEYWELL BR PU PU PU BK BR R G Y1 W1 OR RD C M...

Page 38: ...0 3 60 0140L02899 A HPS HIGH PRESSURE SWITCH HIGH VOLTAGE FACTORY WIRING OPTIONAL HIGH VOLTAGE LOW VOLTAGE FIELD WIRING LINE VOLTAGE LOW VOLTAGE BL RD Y1 YL W BL G R W NO ECONOMIZER G RD Y1 PK WH W R...

Page 39: ...K PU YL OR YL RD RD RD BK SEE NOTE 8 GREEN JUMPER BL BK YL YL PU BR BL RD PU WH GR BL ALS GR PS RS PLF YL YL NOTE 4 GAS VALVE MV 2 1 4 5 YL BL W R GAS VALVE PU ALT HONEYWELL 3 6 YL BR PU PU PU BK BR O...

Page 40: ...IGN IIC EM L2 L3 COMPRESSOR COMPONENT LEGEND COMP ALS TR TRANSFORMER C CM T3 T3 T2 FC C T1 T1 C T2 208 240 3 60 0140L02902 A HPS LPS HPS HIGH PRESSURE SWITCH HIGH VOLTAGE FACTORY WIRING OPTIONAL HIGH...

Page 41: ...NOTE 8 NOTE 8 POWER SUPPLY 240 1 60 BL L2 C T2 L1 T1 NOTE 2 COMP CM VMR C 24V TR LS NOTE 6 SEE ALS PS RS GAS VALVE MV 2 1 4 5 W R GAS VALVE ALT HONEYWELL 3 6 1 2 3 MV GV GV TB1 LPS HPS 1 5 EM Y2Y1 GND...

Page 42: ...VICEMAN STATUS LIGHT 3 BLINKS 6 BLINKS 2 BLINKS 4 BLINKS 5 BLINKS OFF ON 1 BLINK OPEN AUX LIMIT FALSE FLAME SENSED OUTPUT DELAY OPEN LIMIT SWITCH COMPRESSOR WITHOUT INDUCER ON PRESSURE SWITCH SWITCH O...

Page 43: ...C T2 T3 L3 L1 T1 BK BK PU YL COMP BK PU CM BR VMR OR YL RD RD YL YL PU RD BL RD ALS GR PS RS PLF YL YL NOTE 4 BR WH PU PU BK YL GR TB1 WH YL NOTE 3 7 1 5 3 2 1 RD RD LS 208 TR BL 24V C BL PK 240 BL N...

Page 44: ...3 60 SUPPLY VOLTAGE CM CONDENSER MOTOR NOTE 6 FS IIC L2 VM 1 VMR L3 LS LIMIT SWITCH VENT MOTOR RELAY VENT MOTOR PRESSURE SWITCH TERMINAL BLOCK 24V SIGNAL ROLLOUT SWITCH VMR VM PS PLF TB1 RS NOTES FAN...

Page 45: ...1 240 2 3 C BK OR RD OR BL GR SEE NOTE 3 FS IGN BK VM OR RD FC RD BR RD T2 T3 T1 C BC BK 208 L3 L2 L1 WH YL HPS LPS PK TB1 YL PK BL PK GR RD TO THERMOSTAT 3 1 2 F C OR OR SEE NOTE 4 BK BK BK GND T3 RD...

Page 46: ...LUE PU PURPLE PK PINK WH WHITE BK BLACK RD RED BR BROWN OR ORANGE YL YELLOW VM 5 FOR 208 VOLT TRANSFORMER OPERATION MOVE BLACK WIRE FROM TERMINAL 3 TO TERMINAL 2 ON TRANSFORMER INSTALLER SERVICEMAN FA...

Page 47: ...Y YL BK 208 240 3 60 YL IIC T1 T2 BK PU YL BK RD C L1 L2 BL BL RD RD BK PU COMP CM BR BK RD RD LS WH GR BL PU RD RD YL RD YL GR YL PU YL PU PS NOTE 2 PLF YL ALS OR RD BK OR EM WH VMR BL 24V TR BL BL 1...

Page 48: ...ALS PS 10 3 6 8 12 11 9 IIC 7 TR 1 4 208 240 3 60 0140L02894 A LPS HPS LPS LOW PRESSURE SWITCH HPS HIGH PRESSURE SWITCH BC BC 3 L1 AND L2 ON IIC CONTROL IS 24V INPUT USE NEC CLASS 2 WIRE 2 ACCESSORY E...

Page 49: ...60 SEE NOTE 4 POWER SUPPLY GR YL PK BL PK OR WH BK OR L3 L2 L1 LPS HPS OR RD BK BC C T3 T1 T2 PK RD BR BR RD FC RD OR VM BK IGN FS NOTE 3 SEE YL OR BK 460 575 TR 240 C 460 BL BL TR 24V BL VMR 3 1 2 W...

Page 50: ...n the unit for the most up to date wiring HIGH VOLTAGE DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT MULTIPLE POWER SOURCES MAY BE PRESENT FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE PE...

Page 51: ...R RD FC RD BR SMOKE FIRE DETECTOR REPLACES JUMPER WIRE HPS BL PK GND T3 RD OR L3 YL BK GR YL IIC T1 T2 BK PU YL BK RD C L1 L2 BL BL RD OR BK BK PU COMP CM BR BK RD RD LS WH GR BL PU RD RD RD WH BR YL...

Page 52: ...TAGE FIELD WIRING HIGH VOLTAGE OPTIONAL HIGH VOLTAGE ALS COMP COMPONENT LEGEND COMPRESSOR EM IIC IGN GND FS GV C F FUSE FC EVAPORATOR MOTOR FLAME SENSOR EQUIPMENT GROUND IGNITOR GAS VALVE CONTACTOR FA...

Page 53: ...M 2 STAGE COMP BL CC BC1 BC2 CS PU PK AUX B AUX A 8 18 7 Y Y R B SENSOR 2 Y Y R B SEN2 PK OPTIONAL SMOKE DETECTOR Y Y R B 24V AC DC SENSOR 1 9 10 Y Y R B 16 6 17 SEN1 RD BR BL 5 BL C R 1 S 2 S RD BK R...

Page 54: ...FLAME SENSER GAS VALVE GAS PRESSURE GAS FLOW REPLACE CONTROL CHECK FUSE ON CONTROL CHEC K INPUT POWER DELAY COMPRESSOR OUTPUT FALSE FLAME SENSED OPEN LIMIT SWITCH WITHOUT INDUCE R ON PRESSU RE SW ITCH...

Page 55: ...OMPRESSOR OUTPUT FALSE FLAME SENSED OPEN LIMIT SWITCH WITHOUT INDUCER ON PRESSUR E SW ITCH CLOSED PRESSURE SWITCH OPEN OPEN AUX LIMIT SWITCH OPEN ROLLOUT SWITCH IGNITION FAILURE INTERNAL CONTROL NO PO...

Page 56: ...56 WIRING DIAGRAMS FOR MODELS WITH DDC CONTROLS ARE LOCATED IN SUPPLEMENT IOD S1004 For complete information and installation instructions for models with DDC controls see manual DK DDC TGD 01A...

Page 57: ...tension and alignment per installation instructions Check refrigerant piping for rubbing and leaks Repair if necessary Check unit wiring to ensure it is not in contact with refrigerant piping or sharp...

Page 58: ...Amps Blower Amps Condenser Fan Amps ELECTRICAL Total External Static Pressure Blower Wheel RPM TEMPERATURES Outdoor Air Temperature Return Air Temperature Cooling Supply Air Temperature Discharge Cir...

Page 59: ...59 THIS PAGE LEFT INTENTIONALLY BLANK...

Page 60: ...60 2013 2016 5151 San Felipe St Suite 500 Houston TX 77056 www daikincomfort com Our continuing commitment to quality products may mean a change in specifications without notice...

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