Daikin DC92SS, Installation Instructions Manual

Page 1: ...ZE THIS SYMBOL AS A SAFETY PRECAUTION TABLE OF CONTENTS Safety Considerations 3 Shipping Inspection 4 Electrostatic Discharge ESD Precautions 5 To The Installer 5 Product Application 5 Location Requirements Considerations 6 Clearances and Accessibility 7 Existing Furnace Removal 8 Thermostat Location 9 Combustion Ventilation Air Requirements 9 Installation Positions 10 Horizontal Applications Cons...

Page 2: ... 26 High Altitude Derate 26 Propane Gas Conversion 26 Gas Piping Connections 26 Gas Piping Checks 29 Propane Gas Tanks and Piping 29 Circulating Air Filters 29 Duct work Air Flow 29 Checking Duct Static 30 Bottom Return Air Opening Upflow Models 30 Filters Read This Section Before Installing The Return Air Duct work 31 Upright Installations 31 Startup Procedure Adjustment 31 Furnace Cabinet 31 Dra...

Page 3: ... gas fired furnace for installation in a residential garage must be installed as specified in the LOCATION REQUIREMENTS AND CONSIDERATIONS section of this manual This furnace may be used as a construction site heater only if certain conditions are met These conditions are listed in the PRODUCT APPLICATION section of this manual AVERTISSEMENT WARNING FIRE OR EXPLOSION HAZARD Failure to follow the s...

Page 4: ...ctrical shock the furnace must be located to protect the electrical components from water Drain trap must be primed at time of installation Trap is internally partitioned add water to both inlet ports until water appears at both sides of the outlet opening Failure to prime trap at time of installation may have a negative effect on combustion quality and pressure switch action B10259 216 CO can cau...

Page 5: ...with static electricity i e do not move or shuffle your feet do not touch ungrounded objects etc If you come in contact with an ungrounded object repeat step 2 before touching control or wires 4 Discharge your body to ground before removing a new control from its container Follow steps 1 through 3 if installing the control on a furnace Return any old or new controls to their containers before touc...

Page 6: ...o and the service area around the unit must have flooring To ensure proper furnace operation install operate and maintain the furnace in accordance with these installation and operation instructions all local building codes and ordinances In their absence follow the latest edition of the National Fuel Gas Code NFPA 54 ANSI Z223 1 and or CAN CSA B149 1 15 Installation Codes local plumbing or waste ...

Page 7: ...e above substances This protects the non direct vent furnace from airborne contaminants To ensure that the enclosed non direct vent furnace has an adequate supply of combustion air vent from a nearby uncontaminated room or from outdoors Refer to the Combustion and Ventilation Air Requirements for details If the furnace is used in connection with a cooling coil unit install the furnace upstream or ...

Page 8: ...enting system may be too large to properly vent the remaining attached appliances POSITION SIDES REAR FRONT BOTTOM FLUE TOP Upflow 0 0 3 C 0 1 Horizontal 6 0 3 C 0 6 C If placed on combustible floor floor MUST be wood only DM92SS MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS INCHES CARBON MONOXIDE POISONING HAZARD Failure to follow the steps outlined below for each appliance connected to the venting...

Page 9: ...é pendant l un des essais décrits ci dessus des correctifs doivent être apportés au système de ventilation conformément au National Fuel Gas Code ANSI Z223 1 NFPA 54 et ou au Code d installation du gaz naturel et du propane CSA B149 1 9 Une fois qu il a été déterminé que chaque appareil raccordé au système de ventilation fonctionne correctement au moyen des essais décrits ci dessus les portes les ...

Page 10: ...ntal counterflow furnaces return ductwork must be attached to the basepan top end of the blower compartment NOTE Ductwork must never be attached to the back of the furnace Contact your distributor for proper airflow requirements and number of required ductwork connections Refer to Recommended Installation Positions figure for appropriate installation positions ductwork connections and resulting ai...

Page 11: ...rgy content difference between natural and propane gas High Stage Low Stage Natural None 45 3 5 w c 1 9 w c None Propane LPM 07 1 1 25mm 10 0 w c 6 0 w c None Gas Altitude Kit Orifice Manifold Pressure Pressure Switch Change 0 7000 1 LPM 07 supports both Honeywell and White Rodgers 1 stage valves NOTE In Canada gas furnaces are only certified to 4500 feet For furnace being converted to LP gas it i...

Page 12: ...Materials and Joining Methods Two three inch nominal diameter PVC Schedule 40 pipe meeting ASTM D1785 PVC primer meeting ASTM F656 and PVC solvent cement meeting ASTM D2564 specifications must be used Fittings must be DWV type fittings meeting ASTM D2665 and ASTM D3311 Carefully follow the manufacturer s instructions for cutting cleaning and solvent cementing of PVC The use of Schedule 40 PVC cell...

Page 13: ...hes above ground level or the anticipated snow level Vent terminations non direct and direct vent must terminate at least 3 feet above any forced air inlet located within 10 feet NOTE This provision does not apply to the combustion air intake termination of a direct vent application The vent termination of a non direct vent application must terminate at least 4 feet below 4 feet horizontally from ...

Page 14: ... pipe Secure vent flue pipe directly into the furnace fitting with the appropriate glue Alternately a small section of 2 pipe may be glued in the furnace socket and a rubber coupling installed to allow removal for future service Combustion Air and Vent piping should be routed in a manner to avoid contact with refrigerant lines metering devices condensate drain lines etc If necessary clearances may...

Page 15: ...cer outlet 5 Install cut end of the flanged section and connect to inducer with rubber coupling supplied with furnace Install screws removed in step 1 securing flange to cabinet MODEL PIPE SIZE 1 2 3 4 5 6 7 8 2 75 70 65 60 55 50 45 40 3 114 107 100 93 86 79 72 65 2 145 140 135 130 125 120 115 110 3 168 161 154 147 140 133 126 119 2 55 50 45 40 35 30 25 20 3 127 120 113 106 99 92 85 78 2 30 25 20 ...

Page 16: ... per material manufacturers specifications to prevent separation and flue gas leaks Figure 11 Insert flange Cut 2 long R 000142 F Figure 9 CUT HERE Figure 10 Vent Flue Pipe Cuts Upflow Horizontal models only When using the alternate venting location either in a horizontal left side down installation or a vertical installation using down venting an alternate combustion air opening can be used A loc...

Page 17: ...e secured to the combustion air intake to prevent inadvertent blockage The tee used in the vent flue termination must be included when determining the number of elbows in the piping system Vent Flue Pipe Terminations NOTE If either a 90 degree or 45 degree elbow is used for termination it must be pointed downward The vent flue pipe may terminate vertically as through a roof or horizontally as thro...

Page 18: ...for specific details on termination construction For details concerning connection of pipes to the furnace refer to the Vent Flue Pipe and Combustion Pipe Standard Furnace Connections or Alternate Furnace Connections 90 ELBOWS 12 MIN ABOVE HIGHEST ANTICIPATED SNOW LEVEL 3 24 BETWEEN PIPES Combustion Air Intake may also be snorkeled to obtain 12 min ground clearance Alternate Vent Termination Above...

Page 19: ...pecifications Condensate Drain Lines Drain Trap Acondensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point where condensation takes place The condensate must be collected in the furnace drain trap and routed to an appropriate drain location in compliance with local and national codes Follow the bullets listed below when installing ...

Page 20: ...ay be added in the area shown in Figure 21 Any unused cabinet opening must be sealed Do not allow drain hose to sag or trap water Figure 21 Drain Exiting Right Side 1 Locate and Install the 45º pipe hose drain coupling from the outside of the cabinet barbed end goes in the cabinet through hole in the right side of the cabinet and secure with two field supplied 8 self tapping screws see Figure 22 2...

Page 21: ... the top mounting tabs of the trap into the two predrilled holes in the side of the cabinet 9 Refer to Field Supplied Drain section for instructions on field supplied installed drain on outlet of furnace trap Hose 11 Hose 2 Figure 23 Upflow Model Installed Horizontally with Left Side Down Minimum 5 clearance is required for the drain trap beneath the furnace Also see Front Cover Pressure Switch Tu...

Page 22: ...the non grommet end Discard the section without the grommet 5 Insert the cut end of tube 5 through the lower cabinet drain hole 6 Insert 100 degree elbow in the cut end of hose 5 7 Locate hose 6 Using red clamps connect between the coupling and 100 degree elbow cutting off excess tubing 8 Draining the Collector Box Remove cap from left side collector box drain port bottom in horizontal left positi...

Page 23: ...oses needed for installation and install per the following directions 1 Remove the drain trap and factory installed drain tube assemblies 2 Remove two 1 plugs from right side of cabinet 3 Draining the Collector Box From outside the cabinet insert the non grommet end hose 7 into the back drain hole and secure to collector box drain port using a silver clamp 4 Draining the Vent Elbow Insert the stra...

Page 24: ...n hole 12 Insert 100º elbow in hose 5 and secure with a red clamp 13 Locate hose 4 and cut a cut off a 4 straight section and discard the radius end 14 Connect the 4 straight section of hose 4 to the 100º elbow and the PVC pipe and secure with red clamps 15 Connect the hoses to the trap inlets and secure with silver clamps drain trap outlet must point to the original bottom of the furnace 16 Using...

Page 25: ...elow NOTE Wire routing must not to interfere with circulator blower operation filter removal or routine maintenance Junction Box Relocation WARNING HIGH VOLTAGE To avoid personal injury or death due to electrical shock disconnect electrical power before servicing or changing any electrical wiring CAUTION To prevent unreliable operation or equipment damage the gas manifold pressure must be as speci...

Page 26: ...st not be exceeded to prevent unit overfiring High Altitude Derate When this furnace is installed at high altitude the appropriate High Altitude orifice kit must be applied This is required due to the natural reduction in the density of both the gas fuel and combustion air as altitude increases The kit will provide the proper design certified input rate within the specified altitude range High alt...

Page 27: ... 1 8 NPT pipe plug fitting accessible for test gauge connection immediately upstream of the gas supply connection to the furnace Always use a back up wrench when making the connection to the gas valve to keep it from turning The orientation of the gas valve on the manifold must be maintained as shipped from the factory Maximum torque for the gas valve connection is 375 in lbs excessive over tighte...

Page 28: ...cation Gas Valve Burners Manual Shut Off Valve upstream from ground joint pipe union Drip Leg Grommet in Standard Gas Line Hole Ground Joint Pipe Union Ground Joint Pipe Union NOTE Union may be inside furnace cabinet where allowed by local codes Manifold Upflow Figure 31 Alternate Gas Line Location Plug in Alternate Gas Line Hole Gas Valve Burners Manual Shut Off Valve upstream from ground joint p...

Page 29: ...ode NSCNGPIC CAN CSA B149 1 15 For satisfactory operation propane gas pressure must be 10 WC at the furnace manifold with all gas appliances in operation Maintaining proper gas pressure depends on three main factors 1 Vaporization rate depending on temperature of the liquid and wetted surface area of the container or containers 2 Proper pressure regulation Two stage regulation is recommended for b...

Page 30: ... an air conditioner coil or Electronic Air Cleaner is used in conjunction with the furnace the readings must also include theses components as shown in the following drawing 4 Consult proper tables for the quantity of air If the total external static pressure exceeds the maximum listed on the furnace rating plate check for closed dampers registers undersized and or oversized poorly laid out duct w...

Page 31: ...he furnace The installation of a centrally installed air cleaner cabinet or a return duct filter installation may offer more practicality Clean Comfort brand MERV 11 air cleaners have 5 media filters and are available in the following configurations Consult your distributor for information on our complete line of IAQ Clean Comfort products Upright Installations Depending on the installation and or...

Page 32: ...ht angle 2000 CFM 20 in X 25 in x 5 AM11 2025 5RA AM11 5RA Bottom return platform 2000 CFM 20 in X 25 in x 5 AM11 2832 5PP Bottom return platform 2000 CFM 20 in X 25 in x 5 AM11 2843 5PP AM11 5 2 X 1600 CFM 2 16 in X 25 in x 5 AM11 3225 5 AM11 3225 AM11 5PP AM11 5 AM11 5RA AM11 5PP Family Family Family FILTER AIR FLOW CENTRAL RETURN GRILLE FILTER SIDE RETURN EXTERNAL FILTER RACK KIT EITHER SIDE F ...

Page 33: ...iances on the same gas supply line 4 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 necessary adjustments to pressure regulator gas piping size etc and or consult with local gas utility 5 Turn OFF gas to furnace at the manual shutoff valve and disconnect...

Page 34: ...upplier if additional input rate adjustment is required 4 Turn ON gas to and relight all other appliances turned off in step 1 Be certain that all appliances are functioning properly and that all pilot burners are operating OUTLET INLET White Rodgers Model 36J22 Connected to Manometer Figure 40B Mode Measuring Inlet Gas Pressure Alt Method Figure 41 Temperature Rise Temperature rise must be within...

Page 35: ...nals 4 Connect all unused blower motor leads to the PARK terminals on the integrated control module Any leads not connected to the PARK terminals must be taped 5 Turn ON power to furnace 6 Verify proper temperature rise as outlined in the Temperature Rise section of Startup Procedure and Adjustment In general lower heating speeds will reduce electrical consumption lower operating sound levels of t...

Page 36: ...s heat exchanger compartment temperatures It is a normally closed electrically automatic reset temperature activated sensor The limit guards against overheating as a result of insufficient conditioned air passing over the heat exchanger Auxiliary Limit Theauxiliarylimitcontrols arelocatedonornearthecirculator blower and monitors blower compartment temperatures They are a normally closed electrical...

Page 37: ...s following a one hour lockout period 2 Manual power interruption Interrupt 115 volt power to the furnace 3 Manual thermostat cycle Lower the thermostat so that there is no longer a call for heat for 1 20 seconds then reset to previous setting NOTE If the condition which originally caused the lockout still exists the control will return to lockout Refer to the Troubleshooting Chart for aid in dete...

Page 38: ... condensate drainage Check drain system for hose connection tightness blockage and leaks Clean or repair as necessary Flame Sensor Qualified Servicer Only Under some conditions the fuel or air supply can create a nearly invisible coating on the flame sensor This coating acts as an insulator causing a drop in the flame sense signal If the flame sense signal drops too low the furnace will not sense ...

Page 39: ...s Loose or improperly connected wiring Pressure switch circuit not closed Induced draft blower isoperating Induced draft blower runs continuously with no further furnace operation Integrated control module diagnostic LED is flashing THREE 3 flashes 3 3 FLASHES Turn power OFF prior to repair Replace pressure switch with proper replacement part Fault Description s Possible Causes Associated LED Code...

Page 40: ...operation Rollout limit open Integrated control module fuse is blown Check burners for proper alignment Check flue and air inlet piping for blockage proper length elbows and termination Correct as necessary Check rollout limit Replace if necessary Check induced draft blower for proper performance Replace if necessary Tighten or correct wiring connection Turn power OFF prior to repair See Vent Flue...

Page 41: ... N A 1203 N A 1158 N A 1111 1058 932 HIGH 5 0 2235 38 2166 39 2110 40 2021 42 1956 44 1855 1740 1618 MED 4 0 1955 44 1921 44 1860 46 1808 47 1746 49 1645 1572 1461 MED LO 3 5 1658 51 1634 52 1590 54 1549 55 1494 57 1432 1359 1266 LOW 3 0 1418 60 1374 62 1348 63 1297 NA 1265 N A 1219 1152 1106 HIGH 5 0 2489 N A 2420 35 2330 37 2250 38 2183 39 2091 1963 1803 MED 4 0 2102 41 2050 42 2005 42 1944 44 1...

Page 42: ...BOX 1 TO115 VAC 1 60HZ OR ID BLOWER PRESSURE SWITCH HEAT H GND WH RD WH GND BURNER COMPARTMENT BLOWER COMPARTMENT N O COOL H BK HI BR BR CAPACITOR YL WH CONTROL PRIMARY LIMIT AUTO RESET BL PU MANUAL RESET ROLLOUT LIMIT CONTROL S RD OR PK BK WH WH BLOWER INDUCED DRAFT AUXILIARY LIMIT CONTROLS C CIRCULATOR BLOWER FS LIMIT CONTROLS AUXILIARY HEAT H COOL IGNITER HOT SURFACE IND IGN BLWR CIRCULATOR BLW...

Page 43: ...inimum height of eight 8 feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment The sign shall read in print size no less than one half 1 2 inch in size GAS VENT DIRECTLY BELOW KEEP CLEAR OF ALL OBSTRUCTIONS 4 INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall no...

Page 44: ...ise DB F Delta T Difference between Supply and Return Temperatures DB F GAS PRESSURES Gas Inlet Pressure IN W C Gas Manifold Pressure Low Fire IN W C Gas Manifold Pressure High Fire IN W C Gas Type NG Natural Gas LP Liquid Propane Additional Checks Check wire routings for any rubbing Check for kinked pressure switch tubing Check flue elbow for alignment and clamp tightness Check screw tightness on...

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Page 48: ...he protec on of the standard warranty registering your product is a rela vely short process and en tles you to addi onal warranty protec on except that failure by California and Quebec residents to register their product does not diminish their warranty rights For Product Registra on please register by following this link h ps daikincomfort com owner support product registra on You can also scan t...