Daikin RoofPak RPS Series Installation And Maintenance Manual
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Daikin RoofPak RPS Series Installation And Maintenance Manual

Roof mounted singlezone heating and cooling units with microtech iii unit controllers
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Installation and Maintenance Manual
RoofPak
Roof Mounted
®
Singlezone Heating and Cooling Units
RPS/RDT/RFS/RCS
Models 015C–105C
with MicroTech
III Unit Controllers
®
IM 926-3
Group: Applied Air Systems
Part Number: IM 926
Date: October 2018

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Summary of Contents for Daikin RoofPak RPS Series

  • Page 1 Installation and Maintenance Manual IM 926-3 Group: Applied Air Systems Part Number: IM 926 Date: October 2018 RoofPak Roof Mounted ® Singlezone Heating and Cooling Units RPS/RDT/RFS/RCS Models 015C–105C with MicroTech III Unit Controllers ®...

  • Page 2: Table Of Contents

    Table of Contents Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Unit Options .

  • Page 3: Introduction

    This manual provides general information about the “C” vintage Unit Nameplate Daikin RoofPak applied rooftop unit, models RPS, RDT, RFS, and RCS. In addition to an overall description of the unit, it The unit nameplate is located on the outside lower right corner includes mechanical and electrical installation procedures, of the main control box door.

  • Page 4: Hazard Identification Information

    Introduction Hazard Identification Information DANGER Capacitor hazardous voltage! Failure to disconnect power and discharge capacitors before servicing will result in serious injury or death. WARNING Warnings indicate potentially hazardous situations, which can result in property damage, severe personal injury, or death if not avoided.
  • Page 5 Introduction Figure 3: Typical Component Locations—RPS Units Bottom return air opening Bottom discharge air opening Top View Outside and return air dampersa Power and control entrances Side View Exhaust Discharge plenum Supply air fan Filter section Evaporator coil hood (main control panel) Optional back Return air Return air...

  • Page 6: Condenser Fan Arrangement

    Introduction Condenser Fan Arrangement Table 2 shows the condenser fan numbering conventions and locations for each unit size. Table 2: Condenser Fan Arrangement Unit size Refrigerant circuit Arrangement Unit size Refrigerant circuit Arrangement C O N D A H U 015C 060C 018C...

  • Page 7: Refrigeration Piping

    Introduction Refrigeration Piping This section presents the unit refrigeration piping diagrams for the various available configurations. Figure 5: Circuit Schematic Legend A - Compressor (1, 2, or 3 per circuit)† B - Discharge line † C - Condenser coil † D - Evaporator coil* E - Manual shutoff valve†...
  • Page 8 Introduction Figure 7: Air Handler Piping (Flat DX) C i r c u i t # 2 C i r c u i t # 1 C o n d e n s e r S e c t i o n L i q u i d L i n e C i r c u i t # 1 L i q u i d L i n e...

  • Page 9: Control Locations

    Introduction Control Locations Figure 9 (RPS Units) and Figure 10 (RDT Units) show and the wiring diagram legend, which is included in Wiring the locations of the various control components mounted Diagrams on page 63. Components mounted in the blow- throughout the units.

  • Page 10: Control Panel

    Introduction Control Panel The unit control panels and their locations are shown in the following figures. These figures show a typical unit configuration. Specific unit configurations may differ slightly from these figures depending on the particular unit options. Figure 11: Control Panel Locations Supply fan section Prop exhaust/Return Fan...
  • Page 11 Introduction Figure 13: Typical Main Control Panel, 036C - 040C, 208 Volt Figure 14: Typical Main Control Panel, 045C - 075C, 460 Volt www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 12 Introduction Figure 15: Typical Main Control Panel, 080C - 105C, 460 Volt Figure 16: Typical Gas Heat Panel, 1000 MBH Figure 17: Typical Prop Exhaust Panel, 3 Fans, 460 Volt TD10 Figure 18: Figure 18: VFD Bypass Panel, 40 HP, 460 Volt) LR10, 20 MMP30, 40 M30, 40...
  • Page 13 Introduction Figure 19: RCS Control Panel with MicroTech III, 015C - 040C GFR4 PVM4 REC2 CS1 CS2 S2 M12 M11 PS1 PS2 CCB1 CCB2 Resistor R1 R2 GFS2 Sensor MMP1 MMP2 MMP 11 F1A F1B F1C TB6, GND LUG DS4 TB8, remaining seven...
  • Page 14 Introduction Figure 22: Electric Heat Panel, Sizes 015C - 040C Figure 24: Electric Heat Panel, Sizes 080C - 105C FB33 FB32 FB31 FB44 FB34 FB33 FB32 FB31 FB43 FB42 FB41 TB11 FB43 FB42 FB41 TB11 GLG3 Figure 25: Harness Plug Connector Detail Figure 23: Electric Heat Panel, Sizes 045C - 075C RATS DATS...

  • Page 15: Controls, Settings, And Functions

    Introduction Controls, Settings, and Functions Table 3 lists all of the unit control devices and associated information. Table 3: Controls, Settings, and Functions Symbol Description Function Reset Location Setting Range Differential Part No . Switch (toggle), refrigerant Shuts off compressor control CS1 &...
  • Page 16 Introduction FanTrol The FanTrol, provided on all units, is a method of head pressure control that automatically cycles the condenser fans in response to ambient air temperature. This feature maintains head pressure and allows the unit to run at low ambient air temperatures.

  • Page 17: Mechanical Installation

    Low head 26 on page 18. Also, Daikin recommends providing a roof pressure may lead to poor, erratic refrigerant feed control at walkway to the rooftop unit as well as along two sides of the the thermostatic expansion valve.

  • Page 18: Overhead Clearance

    Mechanical Installation Figure 26: Service Clearances 72" (1829 mm) 60" (1524 mm) 60" 60" 96" (1524 mm) (1524 mm) (2438 mm) Legend: Roof walkway Varies with unit arrangement A = Return air section To roof Refer to certified drawing & note. B = Filter section access location...

  • Page 19: Roof Curb Assembly And Installation

    Mechanical Installation Roof Curb Assembly and Installation Install the curb and unit level to allow the condensate drain to WARNING flow properly and allow service access doors to open and close Mold can cause personal injury. Some materials such as without binding.
  • Page 20 Mechanical Installation RPS/RDT Assembly instructions 1. Set curbing parts A through K per dimensions shown 6. Weld curbing in place. Caulk all seams watertight. over roof opening or on a level surface (see Figure 29). Remove backing from 0.25" (6 mm) thick × 1.50" (38 Note location of return and supply air openings.

  • Page 21: Ibc Seismic Compliant Units

    IBC Seismic Compliant Units Roof Curb Arrangement CAUTION 1. Set the rooftop unit on the roof curb (Daikin Rooftop units When welding unit to the curb, do not damage wiring (control panel side). Weld ONLY in the specified zone in the acceptable are designed to overhang from the roof curb).
  • Page 22 Mechanical Installation Figure 31: Welding of Hold Down Brackets—Unit Base, Cross-Sectional View Unit control wiring Unit power wiring (by factory) (by factory) Unit base Field attachment weld Weld .50" zone High temp Insulation Acceptable weld zone Seismic hold down bracket Roof curb Figure 32: Shim Spacers on Hold Down Brackets Unit power wiring...

  • Page 23: Post And Rail Arrangement

    Mechanical Installation Post and Rail Arrangement 1. Set the rooftop unit on the rails. The rails should run CAUTION lengthwise and support the entire unit base. When welding unit to the curb, do not damage wiring (control 2. Weld both sides of the unit directly to each rail as shown panel side).
  • Page 24 Mechanical Installation Figure 35: Typical Power Wire Entrance, Curb View (RPS/RFS 015C - 040C Shown, Refer to Submittal Drawings) 20.0 RPS only 97.0 76.0 OPNG OPNG See Detail A 2 Typ 4 Typ Unit length minus 6.4 Detail A 12.1 0.9 Dia.

  • Page 25: Rigging And Handling

    Mechanical Installation Rigging and Handling Figure 37 shows an example of the rigging instruction label WARNING shipped with each unit. Use all lifting points. Improper lifting can cause severe personal injury and property damage. Figure 37: Rigging and Handling Instruction Label Rigging and Handling Instructions CAUTION Lifting points may not be symmetrical to the center of gravity...
  • Page 26 Mechanical Installation Lifting Points Refer to Figure 38 Figure 39 and the following calculations Figure 38: Unit Type RPS/RDT Lifting Points to determine wheterh a four or six point lift is required. “X” X = distance from the entering air end of the unit (or shipping section) to the first lifting lug in the direction of air flow.
  • Page 27 Mechanical Installation Figure 40: Unit Type RCS Figure 42: RPS Factory Split at Supply Fan Section Figure 41: Unit Type RCS or Condenser Section from RPS/ RDT Factory Split at Condenser 4 lifting points 045C – 060C: B (min.) = 57" (1448 mm) C: B (min.) = 93"...

  • Page 28: Reassembly Of Split Units

    Mechanical Installation Reassembly of Split Units RPS/RDT Factory Split at Fan Although RoofPak units typically ship from the factory as complete units, they may be split at the factory in one of three Field reassembly of an RPS/RDT unit that shipped split at the possible configurations.
  • Page 29 Mechanical Installation Figure 43: Set Sections—Steps 1–4, RPS Factory Split at Supply Fan Figure 44: Re-Assemble Cabinet Reinstall top cap saved in step 1 Caulk ends of splice cap Splice cover, provided #10 screws, Caulk provided vertical seam See detail Nut clip-on, provided Install screws...
  • Page 30 Mechanical Installation Phase III. Reconnect power and control wiring Figure 45: Electrical Connections and Raceway Cover Installation CAUTION Connect the power block correctly and maintain proper If applicable, install as shown phasing. Improper installation can cause severe equipment with provided fasteners. damage.
  • Page 31 Mechanical Installation RPS/RDT Factory Split at Condensing Unit 10. After condenser unit is set in place, install the top cap CAUTION saved Do not damage piping components while setting condensing 11. Caulk (watertight) ends of splice cap and vertical seam. unit in place.
  • Page 32 Mechanical Installation Figure 47: RPS/RDT Split at Condensing Unit Reassembly, Steps 1–6 Step 3: Loosen piping clamps and move pipes to prevent piping Step 1: Remove top cap interference during and save for step 10. reassembly (suction, liquid, and hot gas condensing bypass lines).
  • Page 33 Mechanical Installation Figure 49: Setting Condender in Place, Steps 8 and 9 R C S U n i t F I R S T  l o w e r c o n d e n s i n g u n i t u n t i l n e a r l y l e v e l w i t h m a i n u n i t .
  • Page 34 Mechanical Installation Figure 51: RFS/RCS 015 to 030 Refrigerant Piping Connections NOTE: RFS units with front discharge do NOT include refrigerant piping to the DX coil. Field piping is required. NOTE: RFS units with front discharge do NOT include refrigerant piping to the DX coil. Field piping is required. Figure 52: RFS/RCS 036 and 040 Refrigerant Piping Connections NOTE: RFS units with front discharge do NOT include refrigerant piping to the DX coil.
  • Page 35 Mechanical Installation Figure 53: RPS/RDT (Split)/RFS/RCS 045 to 105 Refrigerant Piping Connections NOTE: RFS units with front discharge do NOT include refrigerant piping to the DX coil. Field piping is required. NOTE: RFS units with front discharge do NOT include refrigerant piping to the DX coil. Field piping is required. Table 8: RFS/RCS 015–040 Connection Sizes and Locations, Figure 51 Figure 52...
  • Page 36 Mechanical Installation Phase III. Reconnecting power and control wiring The wire harnesses are coiled in the condenser section base Figure 54: Connecting Power/Control Wiring (015C - 040C) rail (see Figure 54). The power wires into the lower base rail raceway and the control wires into the upper raceway. 1.
  • Page 37 The RFS unit includes a factory Although conflicting piping recommendations can be found in installed filter-drier, solenoid valve, and sightglass in each different sources, Daikin offers the following recommendations liquid line, upstream of the thermostatic expansion valve. for these controversial issues.
  • Page 38 Note and report this to the To service liquid line components, the manual shutoff valve Daikin sales representative and freight carrier (if the loss is due is closed and refrigerant is pumped into the condenser. The to shipping damage).
  • Page 39 Mechanical Installation Table 11: Approximate R-22 Refrigerant Charge Per Circuit, 015C - 040C Additional charge for heat section Condenser Base charge lbs . per circuit (less DX coil) EVAP .coil (lbs/CKT/ additional length Unit size pumpdown coil row) capacity* (lbs) Circuit #1 Circuit #2 Circuit #1...
  • Page 40 Mechanical Installation Table 14: Approximate R-407C Refrigerant Charge Per Circuit, 045C - 105C Base charge lbs . per circuit (less DX coil) DX coil charge lbs per circuit per coil row Condenser Unit size pumpdown DX=S* DX=L* capacity** (lbs) Circuit #1 Circuit #2 Circuit #1 Circuit #2...
  • Page 41 Mechanical Installation Charging the System This is especially true with R-407C because the charge must CAUTION be drawn from the liquid portion of the tank. Adding refrigerant to the suction always risks liquid-related damage to the compressor. Table 17: Acceptable Refrigerant Oils CAUTION Polyolester [POE] oils Copeland ULtra 22 CC...

  • Page 42: Unit Piping

    Mechanical Installation Refrigeration Service Valves • Where the cooling coils have intermediate condensate pans on the face of the evaporator coil, copper tubes The unit is shipped with all refrigeration service valves closed. near both ends of the coil provide drainage to the main RDT, RPS and RCS units have the following: drain pan.
  • Page 43 Some products have higher freezing points in their natural state than when mixed with water. The freezing of coils is not the responsibility of Daikin Applied. Refer to Winterizing Water Coils on page 108.
  • Page 44 Mechanical Installation Steam Piping Recommendations Steam Coil Freeze Conditions 1. Be certain that adequate piping flexibility is provided. If the air entering the steam coil is below 35°F (2°C), note the Stresses resulting from expansion of closely coupled following recommendations: piping and coil arrangement can cause serious damage.

  • Page 45: Damper Assemblies

    Mechanical Installation Damper Assemblies The optional damper assemblies described in this section Figure 61: Damper Adjustment normally are ordered with factory-installed actuators and O p t i o n a l R e t u r n A i r F a n O u t s i d e A i r linkages.
  • Page 46 Mechanical Installation Intake Hood Damper Figure 63: Intake Hood Damper Adjustment 0% to 100% outside air Units requiring 100% outside air are provided with a rain hood and dampers that can be controlled by a single actuator. The Airflow actuator provides two-position control for opening the dampers fully during unit operation and closing the dampers during the off cycle.

  • Page 47: Ductwork

    Table 18: Rated Airflow access to plenum-mounted components is difficult. Unit AHRI Rated Airflow On bottom-supply/bottom-return units, if a Daikin roof curb 3750 is not used, the installing contractor should make an airtight 4375 connection by attaching field-fabricated duct collars to the 5000 bottom surface of either the roof curb’s duct flange or the unit’s...
  • Page 48 Static pressu re and reference pressure (LO) taps, or tag the tubes. tubing Daikin recommends 1/4" plastic tubing. 3. Locate the duct pressure (HI) tap near the end of a long duct to ensure that all terminal box take-offfs along the run have adequate static pressure.
  • Page 49 Mechanical Installation Installing Building Static Pressure Sensor Taps Lab Pressurization Applications CAUTION 1. Install a “T” fitting with a leak-tight removable cap in each Fragile sensor fittings. If you must remove tubing from a tube near the sensor fitting. This facilitates connecting a pressure sensor fitting, use care.

  • Page 50: Electrical Installation

    Electrical Installation Electrical Installation Field Power Wiring Figure 67: RPS/RDT and RFS Power Wiring Connections DANGER Hazardous voltage. Can cause severe injury or death. Disconnect electric power before servicing equipment. More than one disconnect may be required to de-energize the unit. Electric heat CAUTION control panel...
  • Page 51 Electrical Installation All Units The minimum circuit ampacity (wire sizing amps) is shown on Figure 70: RCS 015C - 030C Power Wiring Connections the unit nameplate. Refer to Table 20 for the recommended number of power wires. Copper wire is required for all conductors. Size wires in accordance with the ampacity tables in Article 310 of the Conduit and hub National Electrical Code.
  • Page 52 Electrical Installation Table 19: Multiple Point Power Connection Options Number of electrical circuits Disconnect designation Load Location (see Figure 3 on page 4) Supply and return fan motors plus controls Main control panel Balance of unit Main control panel Electric heat Electric heat control panel Balance of unit Main control panel...

  • Page 53: Field Control Wiring

    Electrical Installation Field Control Wiring RFS/RCS Units DANGER Electrical shock hazard. Can cause severe injury or death. The RCS unit receives 115-volt and 240-volt control circuit Connect only low voltage NEC Class II circuits to terminal power and a number of control signals from the RFS unit. block TB5.

  • Page 54: Preparing Unit For Operation

    Preparing Unit for Operation Preparing Unit for Operation Spring Isolated Fans Releasing Spring Mounts Figure 76: Spring Mounted Hold-Down Fasteners, All Units WARNING This bracket is added, Moving machinery hazard. Can cause severe injury or death. Before servicing equipment, disconnect power and and these 3/8"...
  • Page 55 Preparing Unit for Operation Adjusting Spring Mounts Adjusting Scroll Dampers Two sets of scroll dampers are provided in the housing of CAUTION the twin 15" × 6" supply fan to allow control of air volume to Do no use impact tools for field spring mount adjustments as each fan wheel.
  • Page 56 Preparing Unit for Operation Adjusting Supply Fan Thrust Restraints Thrust restraints are provided when housed double-width Figure 79: Thrust Restraint Adjustment fans are mounted on springs. After the spring mounts are adjusted for level operation when the fan is running, check See Detail A the thrust restraints.

  • Page 57: Sequences Of Operation

    Sequences of Operation Sequences of Operation The following sequences of operation are for a typical “C” Fan Operation vintage applied rooftop unit equipped with MicroTech III, an economizer, 4-compressor/4-stage cooling, 3 to 1 turn down When the main control board (MCB) commands the supply and burner, variable frequency drives (VFD), a return air fan and return fans to start, the unit enters the Startup operating state.

  • Page 58: Economizer Operation

    Sequences of Operation Economizer Operation Compressors are staged by 115 V (ac) power supplied to the following: Refer to Figure 90 on page 76. When the outdoor air is • Frost protect FP1 to CCB1-BI8 (line 812, not shown)— suitable for free cooling, the switch in enthalpy sensor OAE is Optional when no hot gas bypass is ordered on the unit in position “3”...

  • Page 59: Microtech Iii Controller Operation

    “down” arrow to indicate there are pages Figure 81: Password Main Page “below” the currently displayed items or an “up/down” arrow Daikin AHU to indicate there are pages “above and below” the currently displayed page. Enter Password...

  • Page 60: Navigation Mode

    MicroTech III Controller Operation Navigation Mode Edit Mode In the Navigation Mode, when a line on a page contains no The Editing Mode is entered by pressing the navigation wheel editable fields all but the value field of that line is highlighted while the cursor is pointing to a line containing an editable field.

  • Page 61: Menu Structure

    Menu Structure Menu Structure Figure 83: Keypad Accessible Menu Structure www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 62 Menu Structure Figure 83 continued: Keypad Accessible Menu Structure IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...

  • Page 63: Wiring Diagrams

    Wiring Diagrams Wiring Diagrams Description Standard location Legend Circuit breaker, return/exhaust CB20 Main control box General Notes Circuit breaker, energy CB60 Main control box recovery wheel Field wiring Compressor control boards, CCB1, 2 Main control box refrig. circuits Circuit board, main, micro Main control box Factory wiring controller...
  • Page 64 Wiring Diagrams Description Standard location Description Standard location Hi-limits, pwr, elec heaters Manual motor protector, HL11–20 Heat section, electric MMP60 Main control box (bot. bank) energy recovery wheel HL22 Hi-limits, gas heat (pre-filters) Supply fan section Manual motor protector, sump MMP64 Main/RCE control box pump...
  • Page 65 Wiring Diagrams Description Standard location Description Standard location Relay, smoke detector, return TB25, 26, Terminal block, split unit Main control box Junction box, split unit 27, 28 junction box Relay, supply fan, enable Main control box TC12, 13, 14 Temperature controls, Fantrol Condenser section Relay, return fan, enable Main control box...
  • Page 66 Wiring Diagrams Figure 84: VAV Fan Power (With SAF and RAF VFDs and Unit Powered Outlet/Light Circuit) IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 67 Wiring Diagrams Figure 84 continued: VAV Fan Power (With SAF and RAF VFDs and Unit Powered Outlet/Light Circuit) www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 68 Wiring Diagrams Figure 85: Constant Volume Fan Power (SAF and RAF) IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 69 Wiring Diagrams Figure 85 continued: Constant Volume Fan Power (SAF and RAF), Continued www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 70 Wiring Diagrams Figure 86: RPS 75 Condensing Unit Power (With SpeedTrol and Scroll Compressors) IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 71 Wiring Diagrams Figure 87: VFD Control (SAF and RAF) www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 72 Wiring Diagrams Figure 88: VAV Control Inputs IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 73 Wiring Diagrams Figure 88 continued: VAV Control Inputs www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 74 Wiring Diagrams Figure 89: HTD Gas Burner Schematic IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 75 Wiring Diagrams Figure 89 continued: HTD Gas Burner Schematic www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 76 Wiring Diagrams Figure 90: Electric Heat Control IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 77 Wiring Diagrams Figure 90 continued: Electric Heat Control www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 78 Wiring Diagrams Figure 91: RPS 60 Condensing Unit Control (with Scroll Compressors) IM 926-3 • ROOFPAK APPLIED SYSTEMS www.DaikinApplied.com...
  • Page 79 Wiring Diagrams Figure 91 continued: RPS 60 Condensing Unit Control (with Scroll Compressors) www.DaikinApplied.com IM 926-3 • ROOFPAK APPLIED SYSTEMS...
  • Page 80 Wiring Diagrams Figure 92: CV Fan Control (SAF and RAF) 115VAC_GF/1 T3_24V T3_COM T1_N jprs 24V SRC 401A SUPPLY FAN SOURCE 9-16 WIRED INTERNAL jprs TO MOTHERBOARD 24V SRC 404A RETURN FAN MMP10 MMP20 426A 426B 426C 11(31) 12(32) 11(31) 12(32) 431A IM 926-3 •...
  • Page 81 Wiring Diagrams Figure 93: Light and Receptacle Power (Field Power) FIELD SUPPLIED 115V/60/1 REC1 1003A 1003B 1004B G1004 1005A 1005B LT10 PL31 PL31 H1006-1 H775 H1006-2 REC10 H775 H776 G1009 LT11 PL32 PL32 H1010-1 H775 H1010-2 REC11 H775 H776 G1012 www.DaikinApplied.com IM 926-3 •...

  • Page 82: Unit Options

    Unit Options Unit Options Control Actuators The actuators are controlled by an analog signal from the unit controller. Damper actuators utilize a 0-10VDC analog signal while modulating heating/cooling valve actuators utilize a 2-10VDC signal. Spring-return actuators are used for the 0 - 30% outdoor air and economizer dampers.

  • Page 83: Ground Fault Protection

    Unit Options Ground Fault Protection Hot Gas Bypass The ground fault protection is designed to protect motors CAUTION from destructive arcing ground faults. The system consists of Do not touch gas liner during valve checkout. The hot a ground fault relay and a ground fault current sensor. The gas line can become hot enough in a short time to cause ground fault relay employs solid state circuits that will instantly personal injury.

  • Page 84: Smoke And Fire Protection

    D14. This Daikin optionally offers factory installed outdoor air, return input in wired to TB2 and the supply air smoke detector can be...

  • Page 85: Speedtrol

    An optional freezestat is available on units with MicroTech III control that have hot water, chilled water, or steam heating Daikin’s SpeedTrol system of head pressure control operates coils. The sensing element is located on the downstream in conjunction with FanTrol by modulating the motor speed side of the heating coil in the heating section of the unit.

  • Page 86: External Time Clock

    Unit Options External Time Clock External Time Clock or Tenant Override You can use an external time clock as an alternative to (or in addition to) the MicroTech III controller’s internal scheduling There are several methods of switching the rooftop unit function.

  • Page 87: Field Output Signals

    Unit Options Field Output Signals VAV Box Signal/Fan Operation Signal The following outputs may be available for field connections to a suitable device. Digital Output #10 (MCB-DO10) may be selected as either the Entering Fan Temperature Sensor Fan Operation output or the VAV output via the keypad. The VAV/Fan Op selection can be selected by accessing the Unit The entering fan temperature (EFT) sensor and an associated Setup menu in the Extended Menu section.

  • Page 88: Designflow ™ Outdoor Air Damper Option

    Unit Options DesignFlow Outdoor Air Damper Option ™ DesignFlow airflow measurement stations are located inside 1. Verify that power is supplied to the unit’s MicroTech III the louvered outdoor air intake doors between the intake control system. The DesignFlow startup procedure cannot louver and outside air dampers.
  • Page 89 Unit Options Figure 102: Tape Fulcrum Alignment Plate to Vane 13. Rest the leveling weight assembly on the fulcrum, as shown in Figure 102, so that: a. Bottom two thumbscrews rest on the top edge of V a n e the fulcrum.
  • Page 90 Unit Options Making Level Adjustments Figure 103: Place Leveling Weight on Fulcrum The DesignFlow unit is mounted so that it pivots at the top when three lock nuts are loosened, two at the top and one at the bottom of the assembly (see Figure 104).
  • Page 91 Unit Options Figure 104: DesignFlow Frame Figure 105: Remove Covers From Access Opening Top lock nuts Vane Pivot point Access opening Bottom lock nut Cover Figure 106: Leveling Adjustment T h r e a d e d A d j u s t e r A s s e m b l y L o n g A d j u s t e r N u t L o c k n u t...

  • Page 92: Propeller Exhaust Fan Option

    Unit Options Propeller Exhaust Fan Option Economizer units may include propeller exhaust or centrifugal The adjustable motor pulley is preset at the factory for the return fan options. This section covers maintenance and specified fan RPM. Fan speed can be increased by closing operating instructions for the propeller exhaust option.

  • Page 93: Exhaust Fan On/Off Control

    Unit Options Exhaust Fan ON/OFF Control Check belt tension two times during the first 24 hours of operation and periodically thereafter. To adjust belt tension, The exhaust fans are turned on and off based on building simply loosen four fasteners (two on each side of the motor static pressure, outdoor air damper position, and discharge plate) and slide the motor plate away from the fan shaft until fan capacity.

  • Page 94: Bearings

    Unit Options Bearings Ultraviolet Lights Option Bearings are the most critical moving part of the fan and WARNING should be inspected at periodic intervals. Locking collars and UVC exposure is harmful to the skin and eyes. Looking at set screws, in addition to fasteners attaching the bearings to an illuminated bulb can cause permanent blindness.

  • Page 95: Convenience Receptacle/Section Lights

    Unit Options Figure 113: Typical Ultraviolet Light Wiring Schematic Convenience Receptacle/Section Variable Frequency Drive Lights Operation A Ground Fault Circuit Interrupter (GFCI) convenience Refer to the vendor instructions supplied with the unit. receptacle is provided in the main control box on all units. One of the following is required: 1.

  • Page 96: Check, Test, And Start Procedures

    Setscrews on page 111. Registration on page 122, and return it to Daikin Applied. 12. Verify that the evaporator drain is trapped and that the A representative of the owner or the operator of the equipment drain pan is level.
  • Page 97 Check, Test, and Start Procedures Fan Start-Up 17. Before closing (connecting) the power disconnect switch, open (disconnect) the following unit control 1. Verify all duct isolation dampers are open. Unit mounted circuit switches: isolation dampers may be mounted in the supply or a.
  • Page 98 Check, Test, and Start Procedures Economizer Start-Up Compressor Startup CAUTION CAUTION Adjust dampers properly. Improper adjustment can damage Low ambient temperature hazard. Can cause compressor the dampers. damage. When an economizer is ordered without an actuator, the Do not attempt to start up and check out the refrigeration linkage requires a 3.14"...
  • Page 99 Check, Test, and Start Procedures Scroll Compressor Rotational Direction 5. When the outdoor air damper has fully opened and the CAUTION time delay has expired, liquid line solenoid valve SV1 Venting refrigerant to atmosphere is not allowed per most should open and compressor #1 should start. If this does local laws and/or codes.
  • Page 100 Check, Test, and Start Procedures Expansion Valve Superheat Adjustment 10. Check the oil level in the compressor sightglass. If low oil is observed, it is possible that liquid refrigerant It is very important that the expansion valve superheat setting is returning to the compressor. Check the suction be adjusted to be between 10°F (-12°C) and 13°F (-11°C).

  • Page 101: Heating System Start-Up

    Check, Test, and Start Procedures Heating System Start-up Air Balancing General WARNING Moving machinery hazard. Can cause severe personal injury 1. At the keypad, set the heating setpoints high enough or death. so that the controller will call for heating. The value in Do not use a mechanically driven tachometer to measure the Temperature \ Zone Heating \ Occ Htg Spt= will need to be speed of return fans on this fan arrangement.

  • Page 102: Drive Belt Adjustment

    Check, Test, and Start Procedures Drive Belt Adjustment Sheave Alignment General Rules of Tensioning Mounting and Adjusting Motor Sheaves 1. The ideal tension is the lowest tension at which the belt Mounting: will not slip under peak load conditions. 1. Verify both driving and driven sheaves are in alignment 2.
  • Page 103 Check, Test, and Start Procedures VM and VP Variable Pitch Sheaves Mounting: Adjusting: 1. Mount all sheaves on the motor shaft with setscrew A 1. Slack off all belt tension by moving the motor toward the toward the motor (see Figure 117).
  • Page 104 Check, Test, and Start Procedures LVP Variable Pitch Sheaves Mounting: Adjusting: 1. For single-groove sheaves, slide the sheave onto the 1. Slack off all belt tension by moving the motor toward the motor shaft so that the side of the sheave with setscrew driven shaft until the belts are free from the grooves.
  • Page 105 Check, Test, and Start Procedures MVP Variable Pitch Sheaves 3. Adjust the sheave to the desired pitch diameter by CAUTION turning the outer locking ring with a spanner wrench. Any Do not loosen any screws other than the two locking screws pitch diameter can be obtained within the sheave range.

  • Page 106: Final Control Settings

    Lock=. Do not set it below 50°F (10°C) unless the unit is equipped for low ambient operation. Daikin recommends that the MicroTech III controller’s setpoints 6. Set the high ambient heat lockout temperature setpoint, and parameters be recorded and saved for future reference. If Temperature \ Zone Heating \ OAT Htg Lock= as required.

  • Page 107: Maintenance And Service

    Maintenance and Service Maintenance and Service Servicing Control Panel Planned Maintenance Components Preventive maintenance is the best way to avoid unnecessary expense and inconvenience. Have this system inspected at regular intervals by a qualified service technician. The required WARNING frequency of inspections depends upon the total operating time Moving machinery and electrical power hazards.

  • Page 108: Unit Storage

    Location Cooling Circuits The steps below are necessary only if the unit has been The Daikin Rooftop Packaged System Unit is an outdoor started. unit. However, the schedule may dictate storage either on the ground or in its final position at the site. If the unit is stored on 1.
  • Page 109 For information on maintenance of the gas furnace, refer to for intermittent operation. For a relubrication schedule, see 685. Table 24. For any applications that are not in the ranges of the table, contact Daikin. Bearing Lubrication CAUTION CAUTION Bearing overheating potential. Can damage the equipment.
  • Page 110 Maintenance and Service Bearing Replacement BOA Concentric Inserts 1. Be sure that BOA Concentric collar is fitted square and The following instructions must be read in entirety before snug against the shoulder on the inner ring. attempting installation or removal. The procedures indicated should be carefully followed.
  • Page 111 Maintenance and Service Propeller Exhaust Setscrews For information, see Propeller Exhaust Fan Option on page Setscrews are used to lock bearings, sheaves, locking collars, and fan wheels to their shafts. They must be checked periodically to see that they have not loosened. If this is not Vibration Levels done, severe equipment damage could occur.
  • Page 112 Maintenance and Service Supply Fan Wheel-to-Funnel Alignment Figure 123: 24" DWDI Backward Curved Wheel-to-Funnel (036C, 040C) If the unit is equipped with an airfoil or backward curved supply . 1 8 " W h e e l . 1 8 " fan, the fan wheel-to-funnel alignment must be as shown in Figure 122,...

  • Page 113: Refrigerant Charge

    . There is no need, except in the Servicing Refrigerant Sensors or Switches case of critically charged systems, to replace the entire charge The Daikin Rooftop unit includes the following refrigerant after a leak. Add charge per instructions on page sensors or switches.

  • Page 114: Control Panel Component

    Maintenance and Service Control Panel Component Manual Motor Protector (MMP) Circuit Breaker WARNING Circuit breakers are installed upstream of all VFDs to provide short circuit protection. These breakers are not adjustable. If an overload or a fault current interruption occurs, check circuits to determine the cause of the interruption.
  • Page 115 Maintenance and Service Disconnect Switch 3. Recommended method to “lock off” power while the DANGER disconnect is OFF: Hazardous voltage. Will cause severe injury or death. a. Rotate the handle to the “Reset Lock” position. Disconnect electric power before servicing equipment. More b.
  • Page 116 Maintenance and Service Terminal Connectors Phase Voltage Monitor (PVM) The terminals are spring clamp type. They only require The phase voltage monitor (see page 83) is designed to inserting (see #1 in Figure 130) and clamping the wire to protect three-phase loads from damaging power conditions. be stripped, which offers several advantages over screw A microprocessor-based voltage and phase sensing circuit terminals.
  • Page 117 Maintenance and Service Pressure Sensors The MicroTech III controller uses 0 to 5" W.C. static pressure If a second sensor (SPS2) is installed, make sure the 2nd transducers for measuring duct static pressure. As the duct DSP Sensor= parameter in the Unit Configuration menu of the static pressure varies from 0-5"...

  • Page 118: Replacement Parts List

    Replacement Parts List Replacement Parts List Table 33: Replacement Parts List Component Designation Description Daikin Part Number Main Control Board 060006101 CCB1 Auxiliary Cooling Control Board (DX Circuit #1 or generic condenser) 112026101 (replaces 106102701) CCB2 Auxiliary Cooling Control Board (DX Circuit #2)

  • Page 119: Service And Warranty Procedure

    Service and Warranty Procedure Service and Warranty Procedure Replacement Parts When writing to Daikin for service or replacement parts, provide the model number, serial number, and unit part number of the unit as stamped on the serial plate attached to the unit. For questions regarding wiring diagrams, it will be necessary to provide the number on the specific diagram.
  • Page 120 All parts shall be returned to the factory designated on availability. the return goods tag, transportation charges prepaid. 2. Send a completed parts order form to the Daikin Parts The return of the part does not constitute an order for Department.

  • Page 121: Limited Product Warranty (North America)

    Conditioning, AAF Air Conditioning, AAF HermanNelson and Daikin Service, and used in the United States or Canada, 2. Refrigerants, fluids, oils and expendable items such as proves defective in material or workmanship within twelve (12) filters are not covered by this warranty.

  • Page 122: Rooftop Equipment Warranty Registration

    Rooftop Equipment Warranty Registration Form To comply with the terms of Daikin Applied Warranty, complete and return this form within 10 days to the Warranty Department of Daikin Applied. Check, test, and start procedure for Rooftop roof mounted air conditioners with or without heat recovery and roof mounted air handlers.
  • Page 123 Rooftop Equipment Warranty Registration Rooftop Equipment Warranty Registration Form (continued) Select Yes or No. If not applicable to the type of unit, select N/A. I. INITIAL CHECK A. Is any shipping damage visible? ........Yes B.
  • Page 124 Rooftop Equipment Warranty Registration Rooftop Equipment Warranty Registration Form (continued) Select Yes or No. If not applicable to the type of unit, select N/A. III. START-UP COMPRESSOR OPERATION A. Do compressors have holding charges? Circuit #1........... . Yes Circuit #2.
  • Page 125 Rooftop Equipment Warranty Registration Rooftop Equipment Warranty Registration Form (continued) Select Yes or No. If not applicable to the type of unit, select N/A. Q. At what suction pressure does the hot gas bypass valve open?..Circuit 1 __________ psig Circuit 2 __________ psig R.
  • Page 126 Rooftop Equipment Warranty Registration Rooftop Equipment Warranty Registration Form (continued) Select Yes or No. If not applicable to the type of unit, select N/A. N. Flame failure shutoff (seconds): ......... _________________ O.
  • Page 127 AAH.Wty_WAR_forms@daikinapplied.com Please fill out the Daikin Applied “Quality Assurance Survey Report” and list any additional comments that could affect the operation of this unit; e.g., shipping damage, failed components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a separate sheet, attach it to the Survey Report and return it to the Warranty Department of Daikin Applied with the completed Equipment Warranty Registration form.

  • Page 128: Quality Assurance Survey Report

    Poor 10. How would you rate the overall quality of the product? Excellent Good Fair Poor 11. How does the quality of Daikin Applied products rank in relation to competitive products? Excellent Good Fair Poor Comments _______________________________________________________________________________________ Please list any additional comments which could affect the operation of this unit; i.e., shipping damage, failed components, adverse installation applications, etc. If additional comment space is needed, write the comment(s) on a separate sheet, attach the sheet to this completed Quality Assurance Survey Report, and return it to the Warranty Department with the completed preceding “Equipment Warranty Registration Form”.
  • Page 130 Daikin Applied Training and Development Now that you have made an investment in modern, efficient Daikin equipment, its care should be a high priority. For training information on all Daikin HVAC products, please visit us at www.DaikinApplied.com and click on Training, or call 540-248-9646 and ask for the Training Department.

This manual is also suitable for:

Roofpak rcs seriesRoofpak rdt seriesRoofpak rfs series

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