Daikin DC80TN, Service Instructions Manual

Page 1: ...PROPRIATE SERVICE MANUAL BEFORE BEGINNING REPAIRS Only personnel that have been trained to install adjust service or repair hereinafter service the equipment specified in this manual should service the equipment The manufacturer will not be responsible for any injury or property damage arising from improper service or service procedures If you service this unit you assume responsi bility for any i...

Page 2: ...er servicing WARNING FIRE EXPLOSION OR CARBON MONOXIDE POISONING HAZARD Failure to replace with proper control could result in fire explosion or carbon monoxide poisoning This appliance uses NEGATIVE PRESSURE REGULATED gas control Replace ONLY with the same model number or as specified by the manufacturer WARNING RISQUE D ÉLECTROCUTION D INCENDIE OU D EXPLOSION Si les consignes de sécurité ne sont...

Page 3: ...National Fuel Gas Code ANSI Z223 1 WARNING If not installed operated and maintained in accordance with the manufacturer s instructions this product could expose you to substances during fuel combustion which can cause death or serious illness This product contains fiberglass insulation No almacene ni use gasolina u otros vapores y líquidos inflamables cerca de este o cualquier otro aparato PARA SU...

Page 4: ...10259 216 El monóxido de carbono puede causar enfermedades severas como daño cerebral permanente ó muerte Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo B10259 216 RISQUE D EMPOISONNEMENT AU MONOXYDE DE CARBONE Le monoxyde de des carbone peut causer des maladies graves telles que dommages permanents au cerveau et meme la mort au CO pouva...

Page 5: ... Initial Release B 1st Revision Configuration M Upflow Horizontal Major Revision C Downflow Horizontal A Initial Release B 1st Revision Nox AFUE 80 80 AFUE 92 92 AFUE 96 96 AFUE 97 97 AFUE Cabinet Width A 14 Gas Valve B 17 5 T 2 Stage C 21 S 1 STAGE D 24 5 MOTOR Maximum CFM N Nine Speed ECM 3 1200 CFM 4 1600 CFM 5 2000 CFM MBTU h 030 30 000 BTU h 080 80 000 BTU h 040 40 000 BTU h 100 100 000 BTU h...

Page 6: ...ed in accordance with local codes or in their absence with the latest edition of The National Electric Code ANSI NFPA 70 and or The Canadian Electric Code CSA C22 1 An electrical disconnect must be provided at the furnace location NOTE Line polarity must be observed when making field connections Connect hot neutral and ground wires as shown in the wiring diagram located on the unit s blower door M...

Page 7: ...w to high fire 1 Auto 2 Fixed Time Press the Left or Right menu switches to get to the A H S menu The menu will display these options no 10 20 30 60 AUt Fixed time options are expressed in minutes on the display as 10 20 30 60 If AUt Automatic is selected the actual timing for the transition to 2nd stage heat will be calculated by the control board based on length of run time of previous heating c...

Page 8: ...cating mounting grounding and controlling these accessories Accessory wiring connections are to be made through the 1 4 quick connect terminals provided on the furnace integrated control module The humidifier and electronic air cleaner hot terminals are identified as HUM H and EAC H The humidifier and electronic air cleaner neutral terminals are identified as NEUTRAL All field wiring must conform ...

Page 9: ...r blower is energized When the thermostat is satisfied The gas valve is de energized The inducer remains energized for the post purge period 15 seconds The indoor blower runs for the selected off delay period 90 seconds by default adjustable from 30 180 seconds Call for 2nd Stage Heat During 1st Stage Heat Operation The control board receives a 24 VAC signal on the W2 terminal The inducer motor is...

Page 10: ...er the thermostat is satisfied the compressor is de energized and the Cool Mode Fan Off Delay period begins Following the Cool Mode Fan Off Delay period the cool circulator and air cleaner relay are de energized Cooling Mode Speed Selection To change the main blower speed in COOLING mode follow the following steps Press the left or right switch until LED displays AC1 for single stage COOLING or AC...

Page 11: ...NACE BEFORE CHANGING SPEED TAPS WARNING CIRCULATING AIR AND FILTERS DUCTWORK AIR FLOW Duct systems and register sizes must be properly designed for the C F M and external static pressure rating of the furnace Ductwork should be designed in accordance with the recommended methods of Air Conditioning Contractors of America manual D A duct system should be installed in accordance with Standards of th...

Page 12: ...1500 1459 1419 1387 1349 1317 1286 F01 1036 985 940 895 848 799 751 705 F02 1391 1352 1314 1278 1241 1209 1175 1140 F03 710 646 580 515 432 367 314 274 F04 1138 1091 1045 1001 959 920 876 832 F05 1209 1166 1124 1083 1045 1005 964 923 F06 977 931 880 836 785 734 683 626 F07 1298 1255 1216 1178 1140 1102 1067 1028 F08 1456 1414 1376 1341 1302 1270 1238 1200 F09 1533 1488 1452 1415 1383 1350 1317 128...

Page 13: ...1156 1103 1037 982 932 878 F05 1811 1769 1730 1686 1649 1610 1572 1525 F06 1541 1487 1440 1395 1353 1310 1251 1203 F07 1587 1545 1494 1451 1409 1367 1316 1266 F08 1703 1659 1613 1579 1537 1495 1451 1401 F09 1892 1850 1805 1774 1735 1692 1658 1621 F01 1589 1539 1498 1459 1417 1377 1334 1293 F02 2153 2119 2073 2044 2003 1971 1939 1907 F03 1034 745 642 550 462 374 329 287 F04 1579 1525 1483 1443 1400...

Page 14: ...1544 1500 1459 1419 1387 1349 1317 1286 F01 1036 985 940 895 848 799 751 705 F02 1391 1352 1314 1278 1241 1209 1175 1140 F03 710 646 580 515 432 367 314 274 F04 1138 1091 1045 1001 959 920 876 832 F05 1209 1166 1124 1083 1045 1005 964 923 F06 977 931 880 836 785 734 683 626 F07 1298 1255 1216 1178 1140 1102 1067 1028 F08 1456 1414 1376 1341 1302 1270 1238 1200 F09 1533 1488 1452 1415 1383 1350 131...

Page 15: ...207 1156 1103 1037 982 932 878 F05 1811 1769 1730 1686 1649 1610 1572 1525 F06 1541 1487 1440 1395 1353 1310 1251 1203 F07 1587 1545 1494 1451 1409 1367 1316 1266 F08 1703 1659 1613 1579 1537 1495 1451 1401 F09 1892 1850 1805 1774 1735 1692 1658 1621 F01 1589 1539 1498 1459 1417 1377 1334 1293 F02 2153 2119 2073 2044 2003 1971 1939 1907 F03 1034 745 642 550 462 374 329 287 F04 1579 1525 1483 1443 ...

Page 16: ...419 1387 1349 1317 1286 F01 1036 985 940 895 848 799 751 705 F02 1391 1352 1314 1278 1241 1209 1175 1140 F03 710 646 580 515 432 367 314 274 F04 1138 1091 1045 1001 959 920 876 832 F05 1209 1166 1124 1083 1045 1005 964 923 F06 977 931 880 836 785 734 683 626 F07 1298 1255 1216 1178 1140 1102 1067 1028 F08 1456 1414 1376 1341 1302 1270 1238 1200 F09 1533 1488 1452 1415 1383 1350 1317 1286 F01 1104 ...

Page 17: ... 294 F04 1260 1207 1156 1103 1037 982 932 878 F05 1811 1769 1730 1686 1649 1610 1572 1525 F06 1541 1487 1440 1395 1353 1310 1251 1203 F07 1587 1545 1494 1451 1409 1367 1316 1266 F08 1703 1659 1613 1579 1537 1495 1451 1401 F09 1892 1850 1805 1774 1735 1692 1658 1621 F01 1589 1539 1498 1459 1417 1377 1334 1293 F02 2153 2119 2073 2044 2003 1971 1939 1907 F03 1034 745 642 550 462 374 329 287 F04 1579 ...

Page 18: ...74 928 F05 1588 37 1539 39 1494 40 1447 41 1401 42 1358 1313 1267 F01 1420 29 1359 31 1301 32 1254 33 1206 34 1152 1100 1044 F03 826 N A 744 N A 661 N A 573 N A 485 N A 399 339 N A F04 1623 N A 1567 N A 1516 N A 1468 N A 1423 N A 1374 1328 1281 F02 1825 32 1769 33 1718 34 1673 35 1629 36 1584 1540 1497 F04 1623 37 1567 38 1516 39 1468 40 1423 42 1374 1328 1281 F05 1697 35 1644 36 1596 37 1551 38 1...

Page 19: ...160 F01 1176 1105 1020 935 864 797 729 673 F02 1513 1459 1400 1335 1253 1182 1122 1067 F03 1022 813 674 585 511 431 334 282 F04 1640 1595 1540 1489 1436 1367 1307 1254 F05 1843 1786 1747 1690 1643 1575 1497 1435 F06 1580 1534 1495 1459 1429 1390 1356 1324 F07 1753 1713 1677 1642 1611 1576 1549 1518 F08 1523 1483 1438 1403 1370 1336 1299 1266 F09 1643 1599 1562 1525 1491 1462 1431 1394 F01 1176 110...

Page 20: ...196 1160 F01 1176 1105 1020 935 864 797 729 673 F02 1513 1459 1400 1335 1253 1182 1122 1067 F03 1022 813 674 585 511 431 334 282 F04 1640 1595 1540 1489 1436 1367 1307 1254 F05 1843 1786 1747 1690 1643 1575 1497 1435 F06 1580 1534 1495 1459 1429 1390 1356 1324 F07 1753 1713 1677 1642 1611 1576 1549 1518 F08 1523 1483 1438 1403 1370 1336 1299 1266 F09 1643 1599 1562 1525 1491 1462 1431 1394 F01 117...

Page 21: ...1302 1267 1232 1196 1160 F01 1176 1105 1020 935 864 797 729 673 F02 1513 1459 1400 1335 1253 1182 1122 1067 F03 1022 813 674 585 511 431 334 282 F04 1640 1595 1540 1489 1436 1367 1307 1254 F05 1843 1786 1747 1690 1643 1575 1497 1435 F06 1580 1534 1495 1459 1429 1390 1356 1324 F07 1753 1713 1677 1642 1611 1576 1549 1518 F08 1523 1483 1438 1403 1370 1336 1299 1266 F09 1643 1599 1562 1525 1491 1462 1...

Page 22: ...7 N A 636 N A F04 1309 32 1261 33 1218 34 F02 1393 43 1348 44 1308 45 F04 1309 45 1261 47 1218 49 F05 1459 41 1414 42 1371 43 F01 1176 35 1105 38 1020 41 F03 1022 N A 813 N A 674 N A F04 1640 N A 1595 N A 1540 N A F02 1513 39 1459 41 1400 42 F04 1640 36 1595 37 1540 38 F05 1843 32 1786 33 1747 34 F01 1628 32 1571 33 1521 34 F03 956 N A 777 N A 675 N A F04 1561 33 1499 35 1441 36 F02 2159 34 2116 3...

Page 23: ...1 N A 402 349 300 F04 1182 35 1142 36 1103 1064 1025 F02 1270 47 1230 48 1196 1158 1123 F04 1182 50 1142 52 1103 1064 1025 F05 1336 44 1297 46 1264 1229 1193 F01 935 44 864 48 797 729 673 F03 585 N A 511 N A 431 334 282 F04 1489 N A 1436 N A 1367 1307 1254 F02 1335 44 1253 47 1182 1122 1067 F04 1489 40 1436 41 1367 1307 1254 F05 1690 35 1643 36 1575 1497 1435 F01 1472 35 1425 36 1380 1337 1291 F03...

Page 24: ...e in 7 Secs increments from 0 to 35 Secs Cool Off Delay Delay Seconds Default set at 65 Secs Adjustments can be made in 5 Secs increments from 0 to 120 Secs Blower Speed for 1st Stage Gas Heat Mode xx xx Blower Speed Number F01 F02 Blower Speed for 2nd Stage Gas Heat Mode xx xx Blower Speed Number F01 F02 Gas Heat On Delay Delay Seconds Default set at 30 Secs Adjustments can be made in 5 Secs incr...

Page 25: ...SYSTEM OPERATION 25 2 Stage Status Codes Status Menu Idle Continous Fan Compressor Cooling Low Stage Compressor Cooling High Stage Gas heat Low Stage Gas heat High Stage OEM test Mode Mode Main Menu ...

Page 26: ...ICAL COMPONENTS ARE CONTAINED IN BOTH COMPARTMENTS TO AVOID ELECTRICAL SHOCK INJURY OR DEATH DO NOT REMOVE ANY INTERNAL COMPARTMENT COVERS OR ATTEMPT ANY ADJUSTMENT CONTACT A QUALIFIED SERVICE AGENT AT ONCE IF AN ABNORMAL FLAME APPEARANCE SHOULD DEVELOP Periodically during the heating season make a visual check of the burner flames Turn the furnace on at the thermostat Wait a few minutes since any...

Page 27: ...82 164 327 655 1636 37 97 195 486 12 75 150 300 600 1500 38 23 47 95 189 474 13 69 138 277 555 1385 39 92 185 462 14 64 129 257 514 1286 40 22 45 90 180 450 15 60 120 240 480 1200 41 176 439 16 56 113 225 450 1125 42 21 43 86 172 429 17 53 106 212 424 1059 43 167 419 18 50 100 200 400 1000 44 41 82 164 409 19 47 95 189 379 947 45 20 40 80 160 400 20 45 90 180 360 900 46 78 157 391 21 43 86 171 343...

Page 28: ...the gas valve turn downward clockwise to increase pressure and input and upward counterclockwise to decrease pressure and input A properly operating unit must have the BTU per hour input and CFM of air within the limits shown to prevent short cycling of the equipment As the external static pressure goes up the temperature rise will also increase Consult the proper tables for temperature rise limit...

Page 29: ...cking Auxiliary Limit Control 34 S 302 Checking Flame Rollout Control 35 S 303 Induced Draft Blower Motor 36 S 304 Checking Gas Valve Redundant 36 S 305 Checking Main Burners 36 S 306 Checking Orifices 36 S 307 Checking Gas Pressure 37 S 308 Checking Hot Surface Ignitor 39 S 309 Checking For Flashback 39 S 310 Checking Pressure Switch 39 S 311 High Altitude Application Usa 40 S 312 Checking For De...

Page 30: ...ately 144 volts out of phase reverse low voltage wires NOTE For flame rectification the common side of the secondary voltage 24 V is cabinet grounded If you were to bench test a transformer the primary neutral and secondary common must be connected together for testing purposes Some transformers will display phasing symbols as shown in the illustration to the left to assist in determining proper t...

Page 31: ...cking Thermostat And Wiring DISCONNECT ALL POWER BEFORE SERVICING WARNING 1 Remove the blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module terminals 2 Remove the thermostat low voltage wires at the furnace control panel terminal board 3 Jumper terminals R to W or W1 and W2 for two stage models on the integrated ignition contro...

Page 32: ... T1 T5 wires on the control board Green ground wire connected to cabinet ground The control harness has The nine speed ECM motor requires a line voltage power supply black connected to CIRC H and white connected to neutral on the control board as well as a signal on one of the speed taps T1 T5 The speed tap voltage is 3 15 D C and can vary depending speed selection The voltage reading from any one...

Page 33: ...furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger SUPPLY AIR RETURN AIR Checking Temperature Rise 3 Subtract the return air temperature from the supply air temperature to determine the air temperature rise Allow adequate time for thermometer readings to stabilize 4 Adjust temperature rise by adjusting the circulator blower speed Increas...

Page 34: ...ash ELEVEN times If the limit circuit opens and does not close within fifteen minutes the control assumes the manual rollout or fuse has opened and the RED LED will flash FIVE times The control will enter a one hour lockout and the inducer will run continuously In an open limit condition the red LED will flash as described above but the error code will not be stored in memory until the limit reset...

Page 35: ...out occur An over firing condition or flame impingement on the heat shield may also cause the control to open If the rollout control opens the air circulation blower will run continuously 1 Remove the burner compartment door to gain access to the rollout switch es mounted to burner bracket 2 Reset the manual roll out switch 3 Remove wires from roll out switch 4 Using an ohmmeter check for continui...

Page 36: ...is used The valve provides control of main burner gas flow pressure regulation and 100 percent safety shut off Two stage gas valves always require 24 volts between common and low fire main coil to open Also the furnace front cover pressure switch is wired in series with the low main solenoid of the gas valve In the event of a non functioning gas valve always check the front cover pressure switch S...

Page 37: ...te Rodgers Model 36J54 Connected to Manometer 3 5 White Rodgers Model 36J54 Connected to Manometer 1 Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace 2 Connect a calibrated manometer or appropriate gas pressure gauge at either the gas valve inlet pressure tap or the gas piping drip leg See White Rodgers 36J54 gas valve figure for location of inlet pressure tap Natura...

Page 38: ...e outlet pressure tap White Rodgers 36J54 valve Turn outlet pressure test screw in to seal pressure port clockwise 7 in lb mini mum 14 Turn on electrical power and gas supply to the system 15 Close thermostat contacts R and W1 W2 to ener gize the valve Range Nominal Natural Low Stage 1 6 2 2 w c 1 9 w c High Stage 3 2 3 8 w c 3 5 w c Propane Low Stage 5 7 6 3 w c 6 0 w c High Stage 9 7 10 3 w c 10...

Page 39: ...ur at the moment of ignition after a burner heats up or when the burner turns off The latter is known as extinction pop Since the end results of flashback and delayed ignition can be the same burning in the burner venturi a definite attempt should be made to determine which has occurred If flashback should occur check for the following 1 Improper gas pressure adjust to proper pressure 2 Check burn...

Page 40: ...he electrical panel Proper grounding can be confirmed by disconnecting the electrical power and measuring resistance between the neutral white connection and the burner closest to the flame sensor Resistance should be less than 2 ohms The ignition control is a combination electronic and electromechanical device and is not field repairable Complete unit must be replaced LINE VOLTAGE NOW PRESENT WAR...

Page 41: ...at Correct short at flame sensor or in flame sensor wiring Short to ground in flame sense circuit Lingering burner flame Slow closing gas valve Open fuse Replace fuse Short in low voltage wiring Locate and correct short in low voltage wiring Induced draft blower and circulator blower runs continuously No furnace operation Check for lingering or lazy flame Verify proper operation of gas valve No fu...

Page 42: ...rated control board Furnace fails to operate No 115 power to furnace or no 24 volt power to integrated control module Restore high voltage power to furnace and integrated control module Blown fuse or tripped circuit breaker Correct condition which caused fuse to open replace fuse Integrated control module is non functional Replace non functional integrated control module Furnace fails to operate G...

Page 43: ...ING OF AT LEAST 105 C USE COPPER CONDUCTORS ONLY 4 UNIT MUST BE PERMANENTLY GROUNDED AND CONFORM TO N E C AND LOCAL CODES 5 TO RECALL THE LAST 6 FAULTS MOST RECENT TO LEAST RECENT DEPRESS SWITCH FOR MORE THAN 2 SECONDS WHILE IN STANDBY NO THERMOSTAT INPUTS COLOR CODES PK PINK BR BROWN WH WHITE BL BLUE GY GRAY RD RED YL YELLOW OR ORANGE PU PURPLE GN GREEN BK BLACK 1 2 3 4 5 6 7 8 9 10 11 12 READ CO...

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