background image

9

3. Use #18 AWG wire for 24V control wiring runs not

exceeding 75 feet. Use #16 AWG wire for 24V control wiring
runs not exceeding 125 feet. Use #14 AWG wire for 24V
control wiring runs not exceeding 200 feet. Low voltage
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 enter through the condenser
panel opening or through curb indicated in “Electrical
Entrance” figure. Connect thermostat and any accessory
wiring to low voltage terminal block TB1 in the main control
box.

NOTE:

Field-supplied conduit may need to be installed depending

on unit/curb configuration. Use #18 AWG solid conductor wire
whenever connecting thermostat wires to terminals on sub-base.
DO NOT use larger than #18 AWG wire. A transition to #18 AWG
wire may be required before entering thermostat sub-base.

NOTE: Refer to unit wiring diagrams for thermostat hookups.

GAS SUPPLY PIPING

 

T

O

 

PREVENT

 

PERSONAL

 

INJURY

 

OR

 

DEATH

 

DUE

 

TO

 

IMPROPER

 

INSTALLATION

ADJUSTMENT

ALTERATION

SERVICE

 

OR

 

MAINTENANCE

REFER

 

TO

 

THIS

 

MANUAL

. F

OR

 

ADDITIONAL

 

ASSISTANCE

 

OR

 

INFORMATION

CONSULT

 

A

 

QUALIFIED

 

INSTALLER

SERVICE

 

AGENCY

 

OR

 

THE

 

GAS

 

SUPPLIER

.

WARNING

IMPORTANT NOTE: 

This unit is factory set to operate on natural

gas at the altitudes shown on the rating plate.

T

O

 

AVOID

 

PROPERTY

 

DAMAGE

PERSONAL

 

INJURY

 

OR

 

DEATH

 

WHEN

 

EITHER

 

USING

 

PROPANE

 

GAS

 

ALONE

 

OR

 

AT

 

HIGHER

 

ALTITUDES

OBTAIN

 

AND

 

INSTALL

 

THE

 

PROPER

 

CONVERSION

 

KIT

(

S

). F

AILURE

 

TO

 

DO

 

SO

 

CAN

 

RESULT

 

IN

 

UNSATISFACTORY

 

OPERATION

 

AND

/

OR

 

EQUIPMENT

 

DAMAGE

. H

IGH

 

ALTITUDE

 

KITS

 

ARE

 

FOR

 U.S. 

I

NSTALLATIONS

 

ONLY

 

AND

 

ARE

 

NOT

 

APPROVED

 

FOR

 

USE

 

IN

 C

ANADA

.

WARNING

The rating plate is stamped with the model number, type of gas
and gas input rating. Make sure the unit is equipped to operate on
the type of gas available. Conversion to propane (LP) gas is permit-
ted with the use of the factory authorized conversion kit (see the
unit Technical Manual for the appropriate kit). For High Altitude
derates, refer to the latest edition of the National Fuel Gas Code
NFPA 54/ANSI Z223.1.

NATURAL

Min.    5.0"  W.C.,  Max. 10.0" W.C.

PROPANE

Min. 11.0" W.C., Max. 14.0" W.C.

INLET GAS PRESSURE

Inlet Gas Pressure Must Not Exceed the Maximum 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 the burners must
not exceed the rated input shown on the rating plate. Overfiring
of the unit could result in premature heat exchanger failure.

P

IPING

IMPORTANT NOTE: 

To avoid possible unsatisfactory operation or

equipment damage due to under firing of equipment, do not un-
dersize the natural/propane gas piping from the meter/tank to the
unit. When sizing a trunk line, include all appliances on that line
that could be operated simultaneously.

The rating plate is stamped with the model number, type of gas
and gas input rating. Make sure the unit is equipped to operate on
the type of gas available.  The gas line installation must comply
with local codes, or in the absence of local codes, with the latest
edition of the National Fuel Gas Code NFPA 54/ANSI Z223.1.

Natural Gas Connection

1/2

3/4

1

1  1/4

1  1 /2

10

132

278

520

1050

1600

20

92

190

350

730

1100

30

73

152

285

590

980

40

63

130

245

500

760

50

56

115

215

440

670

60

50

105

195

400

610

70

46

96

180

370

560

80

43

90

170

350

530

90

40

84

160

320

490

100

38

79

150

305

460

Pressure= .50 PSIG or less and Pressure Drop of 0.3" W.C.
(Based on 0.60 Specific Gravity Gas)

Natural Gas Capacity of Pipe

in Cubic Feet of Gas Per Hour (CFH)

Nominal Black Pipe Size (inches)

Length of

Pipe in Feet

Heating Value of Gas (BTU/Cubic Foot

CFH = 

BTUH Furnace Input

Refer to the Proper Piping Practice drawing for the general layout
at the unit. The following rules apply:

1. Use black iron pipe and fittings for the supply piping.  The

use of a flex connector and/or copper piping is permitted
as long as it is in agreement with local codes.

2. Use pipe joint compound on male threads only. Pipe joint

compound must be resistant to the action of the fuel used.

3. Use ground joint unions.
4. Install a drip leg to trap dirt and moisture before it can

enter the gas valve. The drip leg must be a minimum of
three inches long.

5. Use two pipe wrenches when making connection to the

gas valve to keep it from turning.

6. Install a manual shut-off valve in a convenient location

(within six feet of unit) between the meter and the unit.

7. Tighten all joints securely.
8.  The unit must be connected to the building piping by one

of the following methods:

• Rigid metallic pipe and fittings

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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