Daikin DCC Series, Installation Instructions Manual

Page 1: ... 3 Clearances 4 Roof Curb Post Installation Checks 5 Roof Top Duct Connections 5 Rigging Details 5 Electrical Wiring 6 Circulating Air and Filters 8 Condensate Drain Connection 8 Startup Adjustments and Checks 9 Air Flow Adjustments 10 INSTALLATION INSTRUCTIONS WARNING PROP 65 WARNING FOR CALIFORNIA CONSUMERS Cancer and Reproductive Harm www P65Warnings ca gov 0140M00517 A ONLY PERSONNEL THAT HAVE...

Page 2: ...d performance is achieved after 72 hours of operation Rated performance is delivered at the specified airflow See product specification sheet for light commercial models Specification sheets can be found at www daikinac com for Daikin brand products Within the website please select the commercial products menu and then select the submenu for the type of product to be installed such as air conditio...

Page 3: ...pt of any visible damage to shipment or container 2 Notify carrier promptly and request an inspection 3 In case of concealed damage carrier should be notified as soon as possible preferably within 5 days 4 File the claim with the following supporting documents a Original Bill of Lading certified copy or indemnity bond b Original paid freight bill or indemnity in lieu thereof c Original invoice or ...

Page 4: ...de on any surface as this may damage unit base The unit must be stored on a flat level surface Protect the condenser coil because it is easily damaged Roof Curb Installations Only Curb installations must comply with local codes and should be done in accordance with the established guidelines of the National Roofing Contractors Association Proper unit installation requires that the roof curb be fir...

Page 5: ...ET UNIT ON CURB CAUTION Horizontal Discharge To convert to horizontal discharge remove the covers over the horizontal duct connections save washered screws Refer to IOD 7006 included in the literature pack for install ing horizontal duct covers to the downflow duct connections Flexible duct connectors between the unit and ducts are rec ommended Insulate and weatherproof all external ductwork and j...

Page 6: ...an tilever curb is used care should be taken to center the unit Check for proper alignment and orientation of supply and return openings with duct Rigging Removal Remove spreader bars lifting cables and other rigging equipment ELECTRICAL WIRING For unit protection use a fuse or hacr circuit breaker that is in excess of the circuit ampacity but less than or equal to the maximum overcurrent protecti...

Page 7: ...e absence of local codes with the latest edition of the National Electrical Code ANSI NFPA 70 A ground lug is provided for this purpose Size grounding conductor in accordance with Table 250 95 of the National Electrical Code Do not use the ground lug for connecting a neutral conductor Remove plug in panel located at the condenser end of unit and route conduit to control box Remove plug in control ...

Page 8: ...the thermostat 3 Use 18 AWG wire for 24V control wiring runs not ex ceeding 75 feet Use 16 AWG wire for 24V control wir ing runs not exceeding 125 feet Use 14 AWG wire for 24V control wiring runs not exceeding 200 feet Low volt age wiring may be National Electrical Code NEC Class 2 where permitted by local codes 4 Route thermostat wires from sub base terminals to the unit Control wiring should ent...

Page 9: ...a step by step sequence which if followed will assure the proper startup of the equipment in the minimum amount of time Air balancing of duct system is not considered part of this procedure However it is an important phase of any air conditioning system startup and should be performed upon completion of the Startup Adjustments and Checks proce dure The Startup Adjustments and Checks procedure at o...

Page 10: ... 4 3 Percent Voltage Unbalance 100 x 1 8 Percent voltage unbalance MUST NOT exceed 2 4 216 400 216 100 X AIR FLOW ADJUSTMENTS NOTE For 2 speed models airflow adjustments must be made on high speed i e 2nd stage cooling or in heat mode Refer to Motor Sheave Adjustments section When the final adjustments are complete the current draw of the motor should be checked and compared to the full load curre...

Page 11: ...RCE lbs SHEAVE DIAMETER in TYPE New V belts will drop rapidly during the first few hours of use Check tension frequently during the first 24 hours of operation Tension should fall between the minimum and maximum force To determine the deflection distance from a normal position measure the distance from sheave to sheave using a straightedge or a cord This is your refer ence line On multiple belt dr...

Page 12: ...G After the cooling mode is checked out turn the thermo stat system switch to OFF 10 Turn the thermostat system switch to HEAT and fan switch to AUTO 11 Slowly raise the heating temperature setting When the heating first stage makes contact stop raising the tem perature setting The compressor blower and fan should now be running with the reversing valve in the de ener gized heating position After ...

Page 13: ...ature of the refrigerant in the outdoor coil must be below the tempera ture of the outdoor air in order to extract heat from the air Thus the greater the difference in the outdoor temperature and the outdoor coil temperature the greater the heating capacity of the heat pump This phenomenon is a char acteristic of a heat pump It is a good practice to provide supplementary heat for all heat pump ins...

Page 14: ...ENCY OR EQUIPMENT DAMAGE DUE TO DUST AND LINT BUILD UP ON INTERNAL PARTS NEVER OPERATE UNIT WITHOUT AN AIR FILTER INSTALLED IN THE RETURN AIR SYSTEM Cabinet Finish Maintenance Use a fine grade automotive wax on the cabinet finish to maintain the finish s original high luster This is especial ly important in installations with extended periods of direct sunlight Clean Outside Coil Qualified Service...

Page 15: ... shift a Undercharged check for leaks b Valve Body Damaged Replace valve c Unit Properly Charged If it is on the heating cycle raise the discharge pressure by restricting airflow through the indoor coil If the valve does not shift tap it lightly on both ends with a screwdriver handle DO NOT TAP THE VALVE BODY If the unit is on the cooling cycle raise the discharge pressure by restricting airflow t...

Page 16: ...representsdry coil without filter to compensate for filter add 0 08 to measured E S P SCFM correction for wet coil 4 CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP 0 6 2793 1 64 2603 1 39 2450 1 18 2270 0 97 0 8 2903 1 87 2696 1 57 2369 1 23 2236 1 05 1987 0 82 1 0 2776 1 86 2682 5 1 69 2445 1 38 2196 1 12 1968 0 90 1 2 2599 1 71 2539 1 57 2310 1 29 1932 0 96 1 4 2424 1 57 2305 1 40 2032 1 11 1 6...

Page 17: ...ORIZONTAL INCLUDES 2 SPEED MOTOR ON HIGH SPEED CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP CFM BHP 0 6 2746 1 38 2515 1 12 0 8 2721 1 47 2494 1 21 2261 0 97 1 0 2689 1 56 2500 1 32 2255 1 06 1994 0 83 1 2 2752 1 74 2473 1 40 2252 1 15 1996 0 91 1 4 2802 1 88 2487 1 53 2286 1 27 2037 1 02 1 6 2553 1 67 2308 1 40 1997 1 08 1 8 2355 1 51 2014 1 19 2 2055 1 29 NOTES Table representsdry coil without filter...

Page 18: ... 30 4 35 EHK4 20 24 0 3 3 37 9 40 EHK4 25 30 1 3 3 45 5 50 14 3 20 EHK4 10 12 0 18 6 20 EHK4 15 18 0 26 1 30 EHK4 20 24 0 33 6 35 EHK4 25 30 1 41 3 45 3 3 17 6 25 EHK4 10 12 0 3 3 22 8 25 EHK4 15 18 0 3 3 30 3 35 EHK4 20 24 0 3 3 37 8 40 EHK4 25 30 1 3 3 45 4 50 12 3 15 EHK7 10 10 0 15 4 20 EHK7 15 15 1 21 8 25 EHK7 20 20 0 27 9 30 EHK7 25 25 1 34 3 35 2 6 14 9 20 EHK7 10 10 0 2 6 18 6 20 EHK7 15 ...

Page 19: ... 41 8 45 EHK4 20 24 0 3 3 49 3 50 EHK4 25 30 1 3 3 57 0 60 14 3 20 EHK4 10 12 0 29 3 30 EHK4 15 18 0 36 8 40 EHK4 20 24 0 44 3 45 EHK4 25 30 1 52 0 60 3 3 17 6 25 EHK4 10 12 0 3 3 32 6 35 EHK4 15 18 0 3 3 40 1 45 EHK4 20 24 0 3 3 47 6 50 EHK4 25 30 1 3 3 55 3 60 12 3 15 EHK7 10 10 0 24 8 25 EHK7 15 15 1 31 1 35 EHK7 20 20 0 37 3 40 EHK7 25 25 1 43 6 45 2 6 14 9 20 EHK3 10 10 0 2 6 27 4 30 EHK3 15 ...

Page 20: ...DEL NUMBER MINIMUM CFM EHK 10 2100 EHK 15 2100 EHK 20 2100 EHK 25 2100 MINIMUM AIR FLOW FOR ELECTRIC HEAT 6 TON ATTENTION INSTALLING PERSONNEL Use only the heater kit specified for each model as dictated by the table above ...

Page 21: ...URN SUPPLY 12 17 7 3 8 11 25 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 NOTE Refer to IOD 7006 included in the literature pack for installing horizontal duct covers ...

Page 22: ...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 PERSONAL INJURY OR DEATH APPENDIX D WIRING DIAGRAMS DCC072 208 230 460 575 3 60 1 SPEED ...

Page 23: ...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 PERSONAL INJURY OR DEATH 23 WIRING DIAGRAMS DCH072 208 230 3 60 1 SPEED ...

Page 24: ...ring diagram on 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 PERSONAL INJURY OR DEATH 24 DCH072 460 575 3 60 1 SPEED ...

Page 25: ...NAL USE COPPER CONDUCTORS ONLY 2 IF OPTIONAL ECONOMIZER IS INSTALLED REMOVE ECON SHRT PLM AND CONNECT ECON PLM TO ECON PLF 3 TB3 LOW VOLTAGE TERMINAL BLOCK 4 TERMINALS FOR 24VAC PWR RD BR WIRE AND 6 TERMINALS FOR 24VAC COM BL WIRE 4 CONNECTIONS SHOWN ARE FOR 1 STAGE HEAT OPERATION WHEN 2 STAGE OPERATION IS REQIRED REMOVE JUMPER WIRE CONNECTING W2 TO W1 ON TB1 5 IF OPTIONAL SMOKE DETECTOR S ARE INS...

Page 26: ...T1 T2 T3 CC OR RD BK OR RD YL BK T1 T3 COMP T2 EM BR OR RD BK WH OR BL GY BL YL GY BL YL GR RD BK 2 3 4 24V CNTL VOLTAGE LINE VOLTAGE TR1 LOW VOLTAGE FIELD WIRING HIGH VOLTAGE Y2 2ND STAGE COOL CALL OUTPUT Y1 1ST STAGE COOL CALL OUTPUT W2 2ND STAGE HEAT CALL OUTPUT W1 1ST STAGE HEAT CALL OUTPUT G C R TB1 CONNECTION 24VAC PWR INPUT THERMOSTAT IN OUT 24VAC COM INPUT FAN CALL OUTPUT THERMOSTAT CO NNE...

Page 27: ...P T2 EM OR RD BK WH OR BL GY BL YL GY BL YL GR RD BK 2 3 4 24V CNTL VOLTAGE LINE VOLTAGE TR1 LOW VOLTAGE FIELD WIRING HIGH VOLTAGE Y2 2ND STAGE COOL CALL OUTPUT Y1 1ST STAGE COOL CALL OUTPUT W2 2ND STAGE HEAT CALL OUTPUT W1 1ST STAGE HEAT CALL OUTPUT G C R TB1 CONNECTION 24VAC PWR INPUT THERMOSTAT IN OUT 24VAC COM INPUT FAN CALL OUTPUT THERMOSTAT CONNECTIONS YELLOW PINK STRIPE YELLOW YL PK BL PK B...

Page 28: ... TO ECON PLF 3 TB3 LOW VOLTAGE TERMINAL BLOCK 4 TERMINALS FOR 24VAC PWR RD BR WIRE AND 6 TERMINALS FOR 24VAC COM BL WIRE 4 CONNECTIONS SHOWN ARE FOR 1 STAGE HEAT OPERATION WHEN 2 STAGE OPERATION IS REQIRED REMOVE JUMPER WIRE CONNECTING W2 TO W1 ON TB1 5 IF OPTIONAL SMOKE DETECTOR S ARE INSTALLED REMOVE JUMPER WIRE CONNECTING S1 TO S2 ON TB1 WIRE CONNECTIONS FROM ACCESSORY KIT CONNECT RD WIRE TO TB...

Page 29: ...2 L3 T1 T2 T3 CC OR RD BK OR RD YL BK T1 T3 COMP T2 EM OR RD BK WH OR BL GY BL YL GY BL YL GR RD BK 2 3 4 24V CNTL VOLTAGE LINE VOLTAGE TR1 LOW VOLTAGE FIELD WIRING HIGH VOLTAGE Y2 2ND STAGE COOL CALL OUTPUT Y1 1ST STAGE COOL CALL OUTPUT W2 2ND STAGE HEAT CALL OUTPUT W1 1ST STAGE HEAT CALL OUTPUT G C R TB1 CONNECTION 24VAC PWR INPUT THERMOSTAT IN OUT 24VAC COM INPUT FAN CALL OUTPUT THERMOSTAT CONN...

Page 30: ...30 WIRING DIAGRAMS FOR MODELS WITH DDC CONTROLS FOR COMPLETE INFORMATION AND INSTALLATION INSTRUCTIONS FOR MODELS WITH DDC CONTROLS SEE MANUAL DK DDC TGD XXX ...

Page 31: ...3 60 SEE NOTE 2 BI7 CFS PK BL PK RD YL GR 1 4 HEATER PLF BK BK PU PU RD OR RD BK RD BK BC CC DAT AI1 GND AGND 24VAC AI4 AI5 AI6 AI7 AI8 AI2 AI3 BK BR GR BL BL BL RD 24V RD RD BL BL SEE NOTE 4 YL RD PK RD OR BK RD YL BK RD GR WH RD BL BL BL GR YL BR WH WH WH BR 2 3 5 6 7 8 9 BK BK RD BL AG C PU T5 T4 T3 T2 T1 TB2 TB1 RD SEE NOTE 5 CS PS ES XS RD BK PU BL OAT HGRH EXF ALRM AGND T3 GR AO3 AO2 AO1 COM...

Page 32: ... PROVING SWITCH CONTACTOR COMPRESSOR CONTACTOR COMPRESSOR CONTACTOR RELAY CONDENSOR FAN CONDENSOR FAN CONTACTOR CLOGGED FILTER SWITCH CRANKCASE HEATER CRANKCASE HEATER SWITCH CONDENSER MOTOR COMMON C ON TB2 COMPRESSOR COM1 AND SMOKE DETECTOR DEFROST THERMOSTAT ECONOMIZER EVAPORATOR MOTOR ECON COM3 8 BI1 AND SMOKE DETECTOR EXHAUST FAN EQUIPMENT GROUND HOT GAS REHEAT HIGH PRESSURE SWITCH LOAD SHEDDI...

Page 33: ...TER PLF C L2 BR BK BK DFT RD RD BK BK GR F C PU BK PU RD BK RD OR RD BK RD BK RCCF BK BC CFC CC DAT AI1 GND AGND 24VAC AI4 AI5 AI6 AI7 AI8 AI2 AI3 BK BR GR BL CHS RVC BL BL RD 24V RD RD BL BL RD SEE NOTE 4 YL RD PK RD OR BK RD YL BK RD RD BK RD RD BK RD GR WH RD BL BL BL GR BK YL BR WH WH WH OR BR OR BK RD BK BK RD 2 3 5 6 7 8 9 T2 T1 L1 BK BK RD BL BL BL AG C PU T5 T4 T3 T2 T1 TB2 TB1 RD SEE NOTE...

Page 34: ...RY INPUTS BLOWER LOW SPEED BLOWER PROVING SWITCH COMPRESSOR CONTACTOR COMPRESSOR CONTACTOR RELAY CLOGGED FILTER SWITCH CRANKCASE HEATER CRANKCASE HEATER SWITCH CONDENSER MOTOR COMMON C ON TB2 COMPRESSOR COM1 AND SMOKE DETECTOR DEFROST THERMOSTAT ECONOMIZER EVAPORATOR MOTOR ECON COM3 8 AND SMOKE DETECTOR EXHAUST FAN EQUIPMENT GROUND HOT GAS REHEAT HIGH PRESSURE SWITCH LOAD SHEDDING LOW PRESSURE SWI...

Page 35: ...BL PK 6 4 9 8 7 3 2 1 BI4 BI5 BI6 BI7 GND GND COM3 8 RL8 AO4 COM2 AO3 AO2 AO1 COM3 8 RL7 RL6 RL5 RL4 RL3 RL2 RL1 COM1 BL HGRH EXF ALRM RD YL PU BK T3 T2 T1 L2 L1 OR RD BK BL BL BL OR RD RD BK BL BL RD BK BK RD RD WH PK BK BK L3 T3 T2 T1 L2 L1 BK RD C BK PU RD RD YL BK BK RD SEE NOTE 4 575 C 460 BL 24V RD BL 24V SEE NO TE 5 RD RD TB1 RD BK PU PU PK YL PK BK PK AI1 BK BR GR BL DAT OAT BI8 AI2 AI3 AI...

Page 36: ...Y EQUIPPED WHEN REQUIRED OR ORANGE AGND AO AI ALRM BC BCC BHS BI BLS BPSW CC CCR CFS CH CHR CHS CM COM COMP CS DFT ECON EM ES EXF GND HGRH HPS LDS LPS OAT OARH PLF PS RCCF RL RSS RVC SAT DAT SMK EMG SPCTEMP SPCRH T1 T5 TB1 2 TR1 2 XS DC GROUND FOR ANALOG SENSORS AG ON TB2 4 ANALOG OUTPUTS 8 ANALOG INPUTS ALARM BLOWER CONTACTOR BLOWER CONTACTOR COIL BLOWER HIGH SPEED 8 BINARY INPUTS BLOWER LOW SPEE...

Page 37: ... 24VAC AI4 AI5 AI6 AI7 AI8 AI2 AI3 BK BR GR BL BL RD 24V RD RD BL BL SEE NOTE 4 YL RD PK BK GR WH RD BL BL GR GR YL BR BR WH WH 2 3 5 6 7 8 9 BK AG C PU T5 T4 T3 T2 T1 TB2 TB1 RD SEE NOTE 5 CS PS ES XS RD BK PU BL OAT HGRH EXF ALRM AGND GR AO3 AO2 AO1 COM3 8 RL7 RL6 RL5 RL4 RL3 RL2 RL1 COM1 BK 240 575 208 460 BL BL BPSW GR BK YL PK BL PK BL PK HPS LPS YL YL PK YL RD WH WH WH BK GR CO2 VOUT DC GND ...

Page 38: ...VING SWITCH COMPRESSOR CONTACTOR COMPRESSOR 2ND STAGE SOLENOID CONDENSOR FAN CONDENSOR FAN CONTACTOR COIL CLOGGED FILTER SWITCH CRANKCASE HEATER CRANKCASE HEATER SWITCH CONDENSER MOTOR COMMON C ON TB2 COMPRESSOR DEFROST THERMOSTAT ECONOMIZER EVAPORATOR MOTOR ECON COM3 8 BI1 AND SMOKE DETECTOR EXHAUST FAN EQUIPMENT GROUND HOT GAS REHEAT HIGH PRESSURE SWITCH LOAD SHEDDING LOW PRESSURE SWITCH OUTDOOR...

Page 39: ...AI2 AI3 BK BR GR CHS RVC BL BL RD 24V RD RD BL BL RD SEE NOTE 4 YL RD PK RD RD RD WH RD BL BL GR BK YL BR WH WH WH OR BR OR BK RD BK BK RD 2 3 5 6 7 8 9 T2 T1 L1 BL AG C PU T5 T4 T3 T2 T1 TB2 TB1 SEE NOTE 5 CS PS ES XS RD BK BL OAT HGRH EXF ALRM AGND GR AO3 AO2 AO1 COM3 8 RL7 RL6 RL5 RL4 RL3 RL2 RL1 COM1 BK BL BL 208 240 3 60 0140L06609 A GND VOUT DC OARH SPCRH STPT OFFSET GND TEMP SPCTEMP VOUT DC...

Page 40: ... 2 COM1 RL1 RL2 COM2 COM3 8 AI3 RL3 RL4 RL5 CC RL6 CFC RL7 RL8 RVC 24VAC GND ECON PLF SMK EMG AO1 AO2 AO3 AO4 DDC BI4 2 2 208 240 3 60 208 240 3 60 SWITCH PRESS OVERCURRENT PROT DEVICE TERMINAL PLUG CONNECTION FIELD GROUND IGNITER JUNCTION INTERNAL TO INTEGRATED CONTROL SCHEMATIC SYMBOL SEE NOTE 5 HGRH EXF ALRM 0140L06610 A OARH CO2 SPC TEMP COM SENSOR OFFSET SPCRH SEE NOTE 4 CS BC1 AGND AO AI ALR...

Page 41: ...6 RL5 RL4 RL3 RL2 RL1 COM1 BL HGRH EXF ALRM RD YL PU BK T3 T2 T1 L2 L1 BC2 RD BK BL BL OR RD BK BL BL RD BK RD WH PK BK BK L3 T3 T2 T1 L2 L1 BK RD C BK PU RD RD YL BK BK RD SEE NOTE 7 575 C 460 BL 24V RD BL 24V SEE NOTE 8 RD RD TB1 RD BK PU PU PK YL PK BK PK AI1 BK BR GR BL DAT OAT BI8 AI2 AI3 AI4 AI5 AI6 AI7 AI8 GND AGND 24VAC AGND AG C GR RD BK BL BL BL BR WH OR BR WH OR BK RD BK BL BPSW YL PK B...

Page 42: ... BI BPSW CC CFS CH CHR CHS CM COM COMP DFT ECON EM ES EXF GND HGRH HPS LDS LPS OAT OARH PLF PS RCCF RL RSS RVC SAT DAT SMK EMG SPCTEMP SPCRH T1 T5 TB1 2 TR1 2 XS SD CS CFC TB1 T3 PM DC GROUND FOR ANALOG SENSORS AG ON TB2 4 ANALOG OUTPUTS 8 ANALOG INPUTS ALARM HIGH SPEED CONTACTOR LOW SPEED CONTACTOR 8 BINARY INPUTS BLOWER PROVING SWITCH COMPRESSOR CONTACTOR CLOGGED FILTER SWITCH CRANKCASE HEATER C...

Page 43: ...ty service maintenance and proper unit operation Verify proper weatherproofing of all ductwork roof curbs and electrical connections Check that the flue screen is in place Check gas piping for leaks Verify gas pressure to the unit is within the range specified on the serial plate Check to ensure that all fans pulleys and wheels are secure Check for proper belt tension and alignment per installatio...

Page 44: ...Condenser Fan Amps ELECTRICAL Total External Static Pressure Blower Wheel RPM TEMPERATURES Outdoor Air Temperature Return Air Temperature Cooling Supply Air Temperature Discharge Circuit 1 Heating Supply Air Temperature PRESSURES Gas Inlet Pressure Gas Manifold Pressure Suction Circuit 1 Suction Circuit 2 Discharge Circuit 2 Superheat Orifice System Superheat Orifice System Subcooling TXV System S...

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Page 48: ...K Daikin is very interested in all product comments Please fill out the feedback form on the following link https daikincomfort com contact us You can also scan the QR code on the right to be directed to the feedback page ...