Daikin Rebel DPS Series Installation And Maintenance Manual
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Daikin Rebel DPS Series Installation And Maintenance Manual

Commercial packaged rooftop systems
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Installation and Maintenance Manual
Rebel
Commercial Packaged
®
Rooftop Systems
Heating and Cooling
Models DPS 003 – 028A
R-410A Refrigerant
MicroTech
III Unit Controller
®
Energy Recovery Wheel
3–6 tons
16–28 tons
Shown with Energy Recovery
IM 1125-13
Group: Applied Air Systems
Part Number: IM 1125
Date: July 2021
7–15 tons
Shown with Energy Recovery

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Summary of Contents for Daikin Rebel DPS Series

  • Page 1 Installation and Maintenance Manual IM 1125-13 Group: Applied Air Systems Part Number: IM 1125 Date: July 2021 Rebel Commercial Packaged ® Rooftop Systems Heating and Cooling Models DPS 003 – 028A R-410A Refrigerant MicroTech III Unit Controller ® Energy Recovery Wheel 3–6 tons 7–15 tons Shown with Energy Recovery...

  • Page 2: Table Of Contents

    Daikin Tubular Heater Series . . . . . . . . . . . . . . . . . .

  • Page 3: Introduction

    This manual provides general information about the “A” The unit nameplate is located on the outside of the main vintage Daikin Rebel Commercial Packaged Rooftop Unit, control box door. It includes the unit model number, serial model DPS. In addition to an overall description of the unit, number, electrical characteristics, and refrigerant charge.

  • Page 4: Mechanical Installation

    Allow service clearances as approximately indicated in Figure 1. Also, Daikin recommends providing a roof walkway to the 1 . Unit(s) surrounded by screens or solid walls must have rooftop unit as well as along each side of the unit that provides no overhead obstructions over any part of the unit.
  • Page 5 Mechanical Installation Figure 1: Service Clearances Small Cabinet Medium Cabinet 003—006 007—015 Exhaust Exhaust 50.00 50.00 Fan Access Fan Access (1270 mm) (1270 mm) Outdoor Air Outdoor Air 17.00 (431 mm) 21.00 (533 mm) Hood Hood Filter Filter Access Access 60.00 36.00 60.00...

  • Page 6: Steel Rail Installation

    The unit must be supported to condenser section. prevent bending or twisting of the machine. Daikin does allow welding of the base of the unit directly to the If building construction allows sound and vibration into structural steel supports.
  • Page 7 Mechanical Installation Figure 2: Roof Curb Assembly (DPS 003—006) LEFT SIDE BACK SIDE 28.69 INSIDE 9.84 INSIDE 28.76 INSIDE 9.64 INSIDE 44.24 61.50 RIGHT SIDE FRONT SIDE NOTE: 1. Check submittal drawing for gas/water/electrical/supply/return air opening 2. Horizontal above the roof gas connection only 3.
  • Page 8 Mechanical Installation Figure 3: Roof Curb Assembly (DPS 007–015) BACK SIDE LEFT SIDE SUPPLY RETURN RIGHT SIDE FRONT SIDE NOTE: 1. Check submittal drawing for gas/water/electrical/supply/return air opening 2. Horizontal above the roof gas connection only 3. All dimensions in inches Standard Roof Curb –...
  • Page 9 Mechanical Installation Figure 4: Roof Curb Assembly (DPS 016–028) BACK SIDE LEFT SIDE SUPPLY RETURN RIGHT SIDE FRONT SIDE NOTE: 1. Check submittal drawing for gas/water/electrical/supply/return air opening 2. Horizontal above the roof gas connection only 3. All dimensions in inches Standard Roof Curb –...
  • Page 10 Mechanical Installation Figure 6: Rigging and Handling Figure 5: Roof Curb Assembly (DPS 007, 011, 015—021) with CORE ERV WARNING CORE Roof Curb – Medium Cabinet (DPS 007 – 015) Only trained and qualified personnel should be allowed to rig loads or operate load rated cranes and/or hoist assemblies.
  • Page 11 Mechanical Installation flooding of the equipment. Figure 10: Rebel with CORE 007–015 4 . Provide adequate protection from vandalism, mechanical LIFT ONLY AS SHOWN contact, etc. 5 . Securely close the doors. 6 . Cover the supply and return air openings. NOTE: Only DPS 003–015 without CORE have the ability to be forklift moved.
  • Page 12 Mechanical Installation Table 2: Physical Data—Standard Units DPS 003 through 028 Small cabinet Medium cabinet Large cabinet Model Cooling only performance Gross cooling capacity (tons) 7 .5 15 .5 17 .5 20.1 27 .5 Nominal airflow (cfm) 1125 1500 1875 2100 2450 3500...
  • Page 13 Mechanical Installation Table 3: Physical Data—Unit Weights DPS 003 through 028 Small cabinet Medium cabinet Model Electrical 208/230V or 460V 208/230V, 460V, or 575V Dimensions (inches) Standard (with OA) 87” x 85” x 41” 87” x 85” x 41” 97” x 107” x 56” With ERW and OA 87”...

  • Page 14: Unit Piping - Condensate Drain Connection

    Mechanical Installation Unit Piping - Condensate Drain Connection Damper Assemblies The optional damper assemblies described in this section WARNING are ordered with factory-installed actuators and linkages. Warning indicates potentially hazardous situations for PVC (Polyvinyl The following sections describe the operation and linkage Chloride) and CPVC (Clorinated Polyvinyl Chloride) piping in chilled water adjustment of the factory option.

  • Page 15: Cabinet Weather Protection

    On vertical-supply/vertical-return units, if a Daikin roof curb 5 . Use a static pressure tip (Dwyer A302 or equivalent) or is not used, the installing contractor should make an airtight the bare end of the plastic tubing for the duct tap. (If the connection by attaching field fabricated duct collars to the duct is lined inside, use a static pressure tip device.)
  • Page 16 Mechanical Installation Installing Building Static Pressure Sensor Taps Figure 14: Typical Wiring Chase, Size 007–015 shown Field CAUTION Wiring Block Fragile sensor fittings. If you must remove tubing from a pressure Behind sensor fitting, use care. Do not use excessive force or wrench the tubing Panel back and forth to remove or the fitting can break off and damage sensor.
  • Page 17 Mechanical Installation Discharge Air Temperature Sensor Lab Pressurization Applications The discharge air temperature sensor must be installed in the 1 . Install a “T” fitting with a leak-tight removable cap in each discharge air duct, downstream of the rooftop unit. Locate the tube near the sensor fitting.

  • Page 18: Electrical Installation

    Electrical Installation Electrical Installation All Units DANGER Wiring must comply with all applicable codes and ordinances. Hazardous voltage. Can cause severe injury or death. The warranty is voided if wiring is not in accordance with these Disconnect electric power before servicing equipment. More than one specifications.
  • Page 19 (1) 600 mcm farthest from the average value must not be more than 2% #4-500 mcm (1) 600 mcm away.) Daikin suggests contacting the local power company for #4-300 mcm (2) 3/0 correction of improper voltage or phase imbalance. #6-2/0...
  • Page 20 A proper start-up requires the following: voltmeter, performed by Daikin trained technicians who are familiar with manometer or gauges with ranges for both manifold pressure working on live equipment. A representative of the owner or the and inlet gas pressure.
  • Page 21 Electrical Installation Table 8: DPS 003–015 Electric Heat Data Table 9: DPS 016–028 Electric Heat Data Voltage Amps Voltage Amps 16 .7 27.8 14 .4 24 .1 7 .2 12.0 — — 9 .6 33 .3 55 .5 28.9 48.1 14 .4 24 .1 —...
  • Page 22 Electrical Installation Table 10: Amp Draw Data Condenser Fan Compressor RLA Compressor LRA FLA Each Unit Compressor 1 - Variable Compressor 2 - Fixed Compressor 1 Compressor 2 Size (Tons) Voltage Voltage Voltage Voltage Qty 208 230 460 7 .7 3 .5 —...

  • Page 23: Refrigeration System

    Refrigeration System Refrigeration System Piping System The Rebel piping system varies significantly between the multiple possible configurations; heat pump, cooling only, and modulating hot gas reheat. In spite of this multiplicity there are some consistent characteristics. All units have a single circuit with a single or tandem compressor.
  • Page 24 Refrigeration System Figure 18: Typical Refrigeration Circuit for Heat Pump Unit with Modulating Hot Gas Reheat (DPS 007–015 shown) Piping Schematic: Rebel 7.5T MOD-Hot Gas Reheat REC. ¼” ” 5/16 ” ” ” ” Item Description Indoor coil electronic expansion valve Outdoor coil electronic expansion valve Check Valve, size 3-15 only...

  • Page 25: Dps Component Description

    Refrigeration System DPS Component Description Compressor Compartment Variable Speed Compressor Prior to start-up, verify all shipping brackets are removed and A variable speed compressor (COMP1) is used on all DPS(H) the compressor foot bolts are secured. 003–015. On small cabinet units (3–6 Tons) the variable speed compressor will be the only one present.
  • Page 26 Refrigeration System Receiver Oil Separator Only Rebel Heat Pump units will have a receiver. Different All DPS(H) 003–015 and 016–020 heat pumps units will have volumes of refrigerant are required inside the system during an oil separator on the discharge line of the compressor. This Mechanical Cooling (or defrost) and Mechanical Heating.
  • Page 27 Refrigeration System Check Valve High Pressure Switch All DPS 003–015 will have check valves on each of the All Rebel Units will have a high pressure switch on each compressor discharge lines. On medium cabinet units compressor. Medium cabinet units (7–15 Tons) will have an (7–15 Tons), two valves, one on each compressor, prevent HP1 switch on the variable speed compressor (COMP1) and a recirculation of refrigerant during part load conditions.
  • Page 28 Refrigeration System Four-Way Valve By-Pass Solenoid Valve The Four-Way Valve (4WV) also known as a Reversing Valve The By-Pass Solenoid Valve (SVB) is used to “short-circuit” is a component only used on Heat Pumps. This device is used the high pressure compressor discharge to the low pressure to direct the discharge gas from the compressor into the indoor suction side during start-up.
  • Page 29 Refrigeration System Indoor Expansion Valve Suction Pressure Transducer The Indoor Expansion Valve (EVI) is a 12 VDC stepper motor The Suction Pressure Transducer (PTS) is a refrigerant driven valve, used in heating and cooling mode. In cooling pressure sensor that screws onto a Schrader fitting on the mode EVI is used to expand the refrigerant entering the Indoor suction line of the compressor deck.
  • Page 30 Refrigeration System Outdoor Refrigerant Temperature Heating (DPS 003–015 only) The unit’s heating mode of operation is determined by the control temperature and the heating setpoint temperature. The Only Rebel Heat Pumps units will have an Outdoor Refrigerant unit enters the heating mode of operation by comparing the Temperature Sensor (ORT).

  • Page 31: Dps 016-028 Ton Component Description

    Refrigerant should never be added or removed from the system based on the desire to achieve an arbitrary subcooling value. It will always be Daikin's recommendation that unit’s suspected of being over/under charged have all of their refrigerant removed, leak tested with nitrogen, and then re-charged based on the unit name plate.
  • Page 32 Refrigeration System Indoor Expansion Valve Figure 35: High Pressure Switch The Indoor Expansion Valve (EVI) is a 12 VDC stepper motor driven valve. In cooling mode EVI is used to control the superheat and expand the refrigerant entering the Indoor Coil, operating as an evaporator, in much the same way as a TXV on a conventional air conditioner.

  • Page 33: Vfd Compressor Operation

    Refrigeration System VFD Compressor Operation Suction Pressure Transducer (DPS 016–028 only) The Suction Pressure Transducer (PTS) is a refrigerant pressure sensor that screws onto a Schrader fitting on the VFD compressor modulation is controlled by a Mobus signal ® suction line of the compressor deck. On single compressor from the unit controller.
  • Page 34 Refrigeration System VFD Compressor Control Dehumidification Transition During Cooling State Control of the VFD compressor is accomplished with a digital When dehumidification operation becomes active while the output enable signal and Modbus control signal. unit is in the Cooling operating state, The VFD compressor is ramped to its maximum capacity.
  • Page 35 Refrigeration System VFD Compressor Protection Unloading Control If the oil balance mode fails to resolve the low oil condition, or the fixed speed compressor was not running when the low There are several modulating control functions that adjust the oil indication occurred, or the VFD compressor was not part speed control range of the VFD compressor to protect it from of a tandemized compressor set, when the low oil indication damage under abnormal operating conditions.
  • Page 36 Refrigeration System High Discharge Line Temperature Unloading Control High Superheat A compressor discharge temperature sensor (Thermistor) is If the VFD compressor discharge superheat rises to 85°F for 15 installed on the VFD compressor as standard. The temperature consecutive minutes, the VFD compressor speed is reduced by is used to measure discharge temperature and superheat 10 rps increments down to a 40 rps operating speed.

  • Page 37: Variable Speed Scroll Compressor

    Guidelines. Under all circumstances, the EN378 (or other applicable local safety regulations) requirements must be fulfilled. Daikin units with variable speed inverter compressor are engineered with fixed speed compressor in such a way that the unit delivers only the required energy to satisfy space conditions and provides you with exceptional energy savings.
  • Page 38 Refrigeration System Oil Injection Control Optical Oil Level Sensor The VFD compressor contains an oil injection valve and An optical oil sensor is used to monitor oil level in VFD solenoid (SV11) as standard. The oil injection valve provides compressor sump. The sensor is mounted directly to a fitting lubrication to the scroll set under low speed/low refrigerant on the VFD compressor shell and can be removed without velocity situations.
  • Page 39 Refrigeration System Variable Frequency Drive for VFD Compressor Basic Operation of Compressor Drive: WARNING Start= Connect terminals 12 & 18 for minimum of 5 secs, Never bypass the compressor drive or directly connect the VFD compressor connect terminals 12 &27 and terminals 13 &37 to the main power supply.

  • Page 40: Optional Modulating Hot Gas Reheat

    Optional Modulating Hot Gas Reheat Optional Modulating Hot Gas Reheat Modulating Hot Gas Reheat The reheat coil option comes complete with an aluminum micro channel coil and modulating hot gas valves for leaving air temperature control. On a call for dehumidification, the unit will enable the supply to be over-cooled by the DX coil.
  • Page 41 Optional Modulating Hot Gas Reheat Figure 45: Ideal for Neutral Air Ventilation Control • The rooftop mainly dehumidifies the required ventilation air • Terminal units provide additional sensible cooling as required Dehumidification Initiation Dehumidification Termination An analog sensor is mounted in the return duct, the space, or Dehumidification is terminated if the selected variable, Relative outdoors to sense Relative Humidity.
  • Page 42 Optional Modulating Hot Gas Reheat Control & Arrangement In conjunction with dehumidification, MHGRH is used to raise • In the reheat mode, the minimum position for the reheat the temperature of the cooled air to a desirable value. MHGRH valves is 1% (1.0 Vdc). The controller will modulate the is comprised of a parallel coil arrangement, with dual reheat reheat valves from this starting position.

  • Page 43: Optional Electric Heat

    Optional Electric Heat Optional Electric Heat Electric Heater Design If the 10th digit in the model number is an “E”, the rooftop unit was furnished with a factory installed electric furnace (Example, DPS010AHCE). The Rebel rooftop units are available with 4-stage heat output (see capacities in Table 28 .

  • Page 44: Optional Gas Heat

    Optional Gas Heat Optional Gas Heat Daikin Tubular Heater Series Package Heater Module NOTICE DAT heater series modules are a recognized furnace component design ANSI Z83.8-2013/CSA 2.6-2013 certified by Intertek Testing Services (ETL). WARNING For outdoor installation and installation downstream from refrigeration FIRE OR EXPLOSION HAZARD systems in cabinet applications.

  • Page 45: Gas Furnace Design

    Optional Gas Heat Hooded and screened openings for combustion air have been provided in the furnace(s) access door. The air opening provides unrestricted combustion air to the burners and sized such that a minimum free area is maintained. The minimum free area is defined as 1 in (625 mm ) per 4000 BTUH (2.345 kW).

  • Page 46: Gas Heating Capacity Data

    Optional Gas Heat Gas Heating Capacity Data Table 15: DPS 003-015 Gas Heating Capacities Unit Size Data 003 - 006 007 - 015 Low Heat Med Heat High Heat Low Heat Med Heat High Heat Heating Input (MBh) Heating Output (MBh) Steady State Efficiency Number of Stages Turndown...
  • Page 47 Optional Gas Heat Figure 49: Typical Modulating Furnace Assembly (003–007 shown) Item Description Furnace Inducer Combustion Blower Inducer Orifice Plate Transformer Spark Igniter Ignition Control Gas Safety Valve Gas Modulating Valve (Not Shown) VB1285 Gas Modulating Control or VB1287 Gas Staged Control In-Shot Burner Flame Roll Out Switch Flame Sensor...
  • Page 48 Optional Gas Heat Figure 51: Typical Chimney Flue Assembly Ventilation & Flue Pipe Requirements NOTE: A cabinet – Ships Factory Installed B cabinet – Refer to Figure above. Note that section B must be affixed to The Rebel rooftop unit is equipped with an outdoor air hood to cabinet before installing sections A &...
  • Page 49 Optional Gas Heat Electrical DANGER The Daikin burner receives power and sequencing from the main The spark ignitor and ignition control are high voltage. Keep hands and unit control panel. No additional power wiring must be routed tools away to prevent electrical shock. Shut off electrical power before to the burner.
  • Page 50 Optional Gas Heat Auxiliary Limit Switch Function DPS Modulating Burner Setup for VB1200 Burner Controllers. The auxiliary limit switch is a manually resetable switch and is DPS have two variations of burners 5-1 and 10-1. 10-1 burners designed to trip in the event of a supply fan failure. It should not have a split manifold where one side is modulating and the trip during any other conditions.

  • Page 51: Maxitrol Exa Star Controller

    Optional Gas Heat Maxitrol EXA Star Controller Figure 55: VB-1200 Modulating Control Operation 1 . Remove the two screws holding the cover. 2 . Connect switched OFF 24V (AC/DC) power source to Terminals 3 and 4. 3 . Set DIP switches to match available control signal. 4 .
  • Page 52 Optional Gas Heat High Fire Setting – Button 1 Low Fire Setting – Button 2 To enter the high fire setting mode, press and hold button #1 To enter the high fire setting mode, press and hold button #2 until the LED lights solid red. Release. The valve is now in until the LED lights solid red.
  • Page 53 Optional Gas Heat Gas Piping Routing Into Unit On-The-Roof Piping 1 . Remove knockout on upright (refer to Figure Figure Figure 60: Rebel C Cabinet 016–028 Gas Piping 59 or Figure 60). Field Piping . Piping to Field Piping . Piping to 2 .
  • Page 54 Optional Gas Heat DPS 016–028 Gas Pipe Manifold Pressure Adjustment For Two Stage Furnace Figure 62: Honeywell VR8305Q Gas Safety Control Valve for Both Staged and Modulating Furnaces 1 . Read gas pressure at the Inlet Pressure Tap of the Honeywell VR8305Q Gas Safety Control Valve (Figure High Pressure Adjustment...
  • Page 55 Optional Gas Heat Figure 64: White Rodgers Control Valve Maxitrol www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...

  • Page 56: Dps 003-015 Sequence Of Operation

    This unit is equipped at the factory for use with natural gas only. Conversion to LP gas requires a special kit supplies by Daikin Parts. Failure to use NOTE: For units built before February 2020, use kits the proper conversion kit can cause fire, carbon monoxide poisoning, Table 20 .

  • Page 57: Dps 016-028 Sequence Of Operation

    This unit is equipped at the factory for use with natural gas only. Conversion For units built after August 2020, use kits in Table to LP gas requires a special kit supplies by Daikin Parts. Failure to use 23 . the proper conversion kit can cause fire, carbon monoxide poisoning, explosion, personal injury, property damage, or death.
  • Page 58 910191276 Altitude Conversion 910191280 For elevations up to 2000 feet, rating plate input ratings apply. For high altitudes (elevations over 2000 ft) contact Daikin Applied Parts . See Table 24 for part numbers. Or contact local gas supplier to confirm gas heating value has been devalued for applicable elevations.

  • Page 59: Start-Up Procedures

    . It is highly recommended that the initial start-up and future service be performed by Daikin trained technicians who are familiar with working on live equipment. A representative of the owner or the operator of the equipment should be present during start-up to receive instructions in the operation, care and adjustment of the unit.

  • Page 60: Operating Procedures

    Optional Gas Heat Operating Procedures Set the controller to the lowest setting. WARNING 5 . Turn off all electric power to the appliance. FIRE OR EXPLOSION HAZARD 6 . This appliance is equipped with an ignition device which LOCKOUT/TAGOUT all power sources prior to installing the gas furnace. automatically lights the burner.
  • Page 61 Optional Gas Heat Monthly Check cabinet air filters and replace if dirty. After heavy snowfall verify that combustion air intakes are not blocked by snow. Periodically check during periods of snow accumulation as drifting may also lead to combustion air intake blockage. Twice Yearly 1 .
  • Page 62 Optional Gas Heat DPS 003–015 (only) Ignition Control Module for Staged Gas Furnace Figure 65: Rebel 3-6 Ton 5:1 Staged Gas Furnace Electrical Schematic with Sensor IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 63 Optional Gas Heat Figure 66: Rebel 3-6 Ton Twp Stage Gas Furnace Electrical Schematic with Sensor www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 64 Optional Gas Heat Figure 67: Rebel 7-15 Ton Modulating Gas Furnace Electrical Schematic with Sensor IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 65 Optional Gas Heat Figure 68: Rebel 7-15 Ton Staged Gas Furnace Electrical Schematic with Sensor Figure 69: www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 66 Optional Gas Heat Figure 70: Rebel 7-16 Ton Two Stage Gas Furnace Electrical Schematic with Sensor IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 67 Optional Gas Heat Figure 71: Typical Staged Gas Furnace Electrical Schematic with Sensor Ignition Control Module LED Diagnostics The following LED indicators can be used to diagnose faults associated with the staged gas furnace. Table 26: LED Indicator and Fault Conditions Indicator Fault Condition Steady Off...

  • Page 68: Gas Furnace

    Optional Gas Heat DPS 003–015 (only) Ignition Control Module for Modulating Gas Furnace Figure 73: Typical Modulating Gas Furnace Electrical Schematic with Sensor IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...

  • Page 69: Dps 003-015 (Only) Gas Furnace Ignition And Control

    DPS 003–015 (only) Gas Furnace Ignition and Control Troubleshooting Variable Furnace Controller Modulating Furnace Diagnostics Daikin’s furnace controller is an electronic device that delivers The Rebel furnace control that operates the furnace has full control of the modulating furnace. Control includes built-in, self-diagnostic capability.
  • Page 70 Optional Gas Heat Table 29: Functional Alerts — DPS 003–015 only Display Information Alert Description Possible Cause Solution The flame could not be established during the trial for ignition period. Failed ignition attempt This alert indicates the See “E 0 1” in the See “E 0 1”...
  • Page 71 Optional Gas Heat Table 29 continued: Functional Alerts Display Information Alert Description Possible Cause Solution 1. Insure gas supply is connected to furnace A. Low gas line pressure and check for proper line pressure . 1. Check for faulty gas valve wiring.
  • Page 72 Optional Gas Heat Table 30: Lockout Errors — DPS 003–015 only Display Information Alert Description Possible Cause Solution 1. Check 24-volt transformer for correct output . 2. Check connections and A . Faulty transformer wiring to control board and other components connected to the 24 volt source.
  • Page 73 Optional Gas Heat Table 30 continued: Lockout Errors Display Information Alert Description Possible Cause Solution 1. Check filter / replace if dirty . 2. Check for improperly sized duct system. A. Improper circulating airflow 3. Check for faulty blower motor . 4.
  • Page 74 Optional Gas Heat Table 30 continued: Lockout Errors Display Information Alert Description Possible Cause Solution 1. Perform Modulating System A. Modulating actuator / ball Gas Valve Alignment valve not properly aligned procedure as defined in the service manual. 1 . Insure line pressure is properly adjusted for the B.

  • Page 75: Dps 016-028 Gas Furnace Ignition Troubleshooting

    Optional Gas Heat DPS 016–028 Gas Furnace Ignition Troubleshooting Table 31: 300/450/600 MBH Staged Ignition Control Troubleshooting Guide (UTEC 1016 Ignition Board) LED Indicator System Status Fault Description Possible Causes and Corrective Action Steady ON System Normal 1. Check 120V is being supplied to heater transformer. LED OFF Lockout LED is OFF...
  • Page 76 Switch Switch Spark Igniter TS02 TS01 SI01 620A 620D 620B 620C (Daikin P/N 910172859; includes ignitor and wire) remotely mounted Inducer Fan Motor IFM01 602C 623A 602D LED Diagnostic Information Steady Off: No power or Control hardware fault Steady On: Power applied, Control OK...
  • Page 77 Switch Switch Spark Igniter TS02 TS01 SI01 620D 620A 620B 620C (Daikin P/N 910172859; includes ignitor and wire) remotely mounted Inducer Fan Motor IFM01 602C 623A 602D LED Diagnostic Information Steady Off: No power or Control hardware fault Steady On: Power applied, Control OK...
  • Page 78 616A Flame Sensor FS01 619A 619B Spark Igniter 1R-1 S101 622A 622B 622C (Daikin P/N 910172859; includes ignitor and wire) Inducer Fan Motor IFM01 602C 625A 602D Ignition Module #2 Gas Safety Shutoff Valve #2 IM02 GSSV02 UTEC 1016-578 610D...
  • Page 79 616B 618A 618E TB10 2R-1 Flame Sensor FS01 621A 621B 621C Spark Igniter S101 624A 624B (Daikin P/N 910172859; includes ignitor and wire) Inducer Fan Motor 1R-1 (Hi speed) IFM01 627B 627A 627C 603C 1R-2 629A 618A TB10 633B (Low speed)

  • Page 80: Optional Hot Water Heat

    Follow instructions for mixing antifreeze solution. Some products have higher freeze points in natural state than when mixed with water. The freezing of coils is not the responsibility of Daikin Applied. If the 10th digit of the model number is a “W”, the rooftop unit was furnished with a factory installed hot water coil (Example: DPS010AHCW).

  • Page 81: Optional Energy Recovery Wheel

    Wheel Construction Enthalpy wheel - A generic name for an energy conservation Your Daikin enthalpy wheel is delivered completely assembled wheel. The term “enthalpy” refers to an air stream’s total and ready to run. The wheel is built to provide many years of energy (temperature and humidity level).
  • Page 82 Optional Energy Recovery Wheel Figure 81: Wheel Construction (Side-by-Side) (1) Currently, only the Over-Under configuration is offered on Daikin rooftop systems and air handlers. Purge and Pressurization Drive Motor Pressurization is critical to minimize crossover from exhaust to The enthalpy wheel comes standard with a constant speed drive supply and to allow the purge to operate.
  • Page 83 Optional Energy Recovery Wheel Variable Speed Frequency Control Constant Speed Frost Prevention When there is a threat of frost on the enthalpy wheel, the wheel A variable frequency drive is included with the frost protection is jogged so that less enthalpy transfer occurs and frosting option and it controls the speed of the enthalpy wheel.

  • Page 84: Core ® Construction

    Construction ® Defrost Control Your Daikin enthalpy heat exchanger is delivered completed assembled and ready to run. The core is built to provide With this method the enthalpy core’s outdoor air is bypassed many years of trouble free service with minimal maintenance around the heat exchanger periodically for a defrost time following proper installation and commissioning.

  • Page 85: Optional Outdoor Air Monitor

    Optional Outdoor Air Monitor Optional Outdoor Air Monitor Thermal Dispersion Airflow Measurement Technology Connecting to MicroTech III Controllers Thermal dispersion technology relates the velocity of the air to the power and rise in temperature of a heated element in a Wiring moving airstream.
  • Page 86 Optional Outdoor Air Monitor Figure 90: MicroTech III Controller Figure 91: Transmitter and Connector Detail Transmitter Connector IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 87 When all characters of the flow rate units are displayed in lower case (for example cfm) the transmitter is operating in the Field Calibration Wizard mode. Daikin users do not need to use this function. LCD Blinks ** LOW ALARM **, ** HIGH ALARM ** or **...
  • Page 88 Optional Outdoor Air Monitor Table 36: General Troubleshooting Problem Possible Cause Remedy Power switch not in the "ON" position. Move the power switch to the "ON" position. Ensure that 24VAC power is connected to L1 and L2 Improper supply voltage to the power input terminal of the POWER terminal block and that the voltage No LCD display indication and the green Transmitter block.
  • Page 89 Differential pressure is only available from transmitters If a differential pressure measurement is required, There is no value for the differential pressure point that have a Bi-directional Bleed Airflow Sensors contact your local Daikin Representative about a Bi- connected. directional Bleed Airflow Sensor. www.DaikinApplied.com...

  • Page 90: Ecm Motor

    ECM Motor Addressing Return Or Exhaust ECM ECM Motor Rebel (size 003–015) SAFs and all EAFs utilize ECM [electronically commutated external rotor] motors. ECM motor 1 . Close the MMP or shut the circuit breakers to the speed is controlled by unit mounted, MicroTech III, static supply and energy recovery drives to keep modbus pressure and temperature controls to reliably maintain comfort communication enabled only at the return/exhaust ECM.
  • Page 91 ECM Motor ECM Smoke Purge or Ventilation Override 12 . Click on the “Modbus Status” menu Microtech III has been configured via modbus to perform a ventilation override if terminals Din2 and GND at Terminal strip 3 on the ECM are made. Install an isolation relay that would make a dry NO contact across the return/exhaust fan Din2 and GND per Detail A on page...

  • Page 92: Unit Options

    Unit Options Unit Options Economizer Enthalpy Control Figure 93: Pressure Tubing Diagram The economizer can be ordered with the optional differential enthalpy control. With this option a solid-state humidity and temperature sensing device is located in the return and outdoor airstreams. These devices are labeled RAE and OAE respectively.

  • Page 93: Convenience Receptacle (Field Powered)

    Unit Options Convenience Receptacle (Field Powered) Convenience Receptacle (Unit Powered) A Ground Fault Circuit Interrupter (GFCI) convenience A Ground Fault Circuit Interrupter (GFCI) convenience receptacle is provided in the main control box on all units. To receptacle is provided in the main control box on all units. The use this receptacle, connect a separate field-supplied 115 V receptacle shall be powered by a factory installed and wired power wiring circuit to the outlet.

  • Page 94: Wiring Diagrams

    Wiring Diagrams Wiring Diagrams Figure 95: Typical CAV_VAV 208-230 VAC Wiring (1 of 4) — DPS 003–006 shown 208V, 3 Phase, 60Hz 208V, 3 Phase, 60Hz 208V, 3 Phase, 60Hz 208V, 3 Phase, 60Hz 103B CUSTOMER 104B SUPPLIED POWER 105A Wire for CW phase monitor MMP1...
  • Page 95 Wiring Diagrams Figure 95 continued: Typical CAV_VAV 208-230 VAC Wiring (2 of 4) — DPS 003–006 shown (160) (160) 120V_H 120V_N 159A 155B 120V CLASS 2 75VA 207A 207B 207B 207A G-24V 207B GO-24C TIME CLOCK OR TENNANT OVERIDE 207B R3-4 T_CLOCK 207A...
  • Page 96 Wiring Diagrams Figure 95 continued: Typical CAV_VAV 208-230 VAC Wiring (3 of 4) — DPS 003–006 shown (160) (160) 120V_H 120V_N R-HP1 HP1-I HP1-I 155B 159A 303A R-CCH1 DO1B 159A 305A 155B R-HP1 HP3-I HP3-I DO2B 159A 307A 307B 307C 155B (303) R5-6...
  • Page 97 Wiring Diagrams Figure 95 continued: Typical CAV_VAV 208-230 VAC Wiring (4 of 4) — DPS 003–006 shown www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 98 Wiring Diagrams Figure 96: Typical CAV_VAV 460 VAC Wiring (1 of 4) — DPS 003–006 shown 460V, 3 Phase, 60Hz 460V, 3 Phase, 60Hz 460V, 3 Phase, 60Hz 460V, 3 Phase, 60Hz 103B CUSTOMER 104B SUPPLIED POWER 105A Wire for CW phase monitor MMP1 T4-I...
  • Page 99 Wiring Diagrams Figure 96 continued: Typical CAV_VAV 460 VAC Wiring (2 of 4) — DPS 003–006 shown (160) (160) 120V_H 120V_N 159A 155B 120V CLASS 2 75VA 207A 207B 207B 207A G-24V 207B GO-24C TIME CLOCK OR TENNANT OVERIDE 207B R3-4 T_CLOCK 207A...
  • Page 100 Wiring Diagrams Figure 96 continued: Typical CAV_VAV 460 VAC Wiring (3 of 4) — DPS 003–006 shown (160) (160) 120V_H 120V_N R-HP1 HP1-I HP1-I 155B 159A 303A R-CCH1 DO1B 159A 305A 155B R-HP1 HP3-I HP3-I DO2B 159A 307A 307B 307C 155B (303) R5-6...
  • Page 101 Wiring Diagrams Figure 96 continued: Typical CAV_VAV 460 VAC Wiring (4 of 4) — DPS 003–006 shown www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 102 Wiring Diagrams Figure 97: Typical 575 Volt Wiring (1 of 4) — DPS 007–015 shown with 460 to 575 Transformer (106) 22kVA T12-1I HEAT1575-PI T12-2E T12-2E T12-1I 347/575V, 3 Phase, 60Hz 347/575V, 3 Phase, 60Hz 347/575V, 3 Phase, 60Hz 347/575V, 3 Phase, 60Hz F12A F13A HEAT1...
  • Page 103 Wiring Diagrams Figure 97 continued: Typical 575 Volt Wiring (2 of 4) — DPS 007–015 shown with 460 to 575 Transformer (160) (160) 120V_H 120V_N PVM1 160A 204A 155A (123) 120V CLASS 2 75VA GF1-I GF1-I GFR1 207A 207B (117) 209A 207B T1-G...
  • Page 104 Wiring Diagrams Figure 97 continued: Typical 575 Volt Wiring (3 of 4) — DPS 007–015 shown with 460 to 575 Transformer (160) (160) 120V_H 120V_N R-HP1 HP1-I HP1-I 155A 160A 303A R-CCH1 DO1B 160A 305A 155A R-HP1 HP3-I HP3-I DO2B 160A 307A 307B...
  • Page 105 Wiring Diagrams Figure 97 continued: Typical 575 Volt Wiring (4 of 4) — DPS 007–015 shown with 460 to 575 Transformer www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 106 Wiring Diagrams Figure 98: Typical 460V DPS 016–028 with Gas Heat IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 107 Wiring Diagrams Figure 98 continued: Typical 460V DPS 016–028 with Gas Heat www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 108 Wiring Diagrams Figure 98 continued: Typical 460V DPS 016–028 with Gas Heat IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 109 Wiring Diagrams Figure 98 continued: Typical 460V DPS 016–028 with Gas Heat www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 110 Wiring Diagrams Figure 98 continued: Typical 460V DPS 016–028 with Gas Heat IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 111 Wiring Diagrams Figure 99: Typical 575V DPS 016–028 with Electric Heat, Dual Power, and Energy Recovery Wheel www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 112 Wiring Diagrams Figure 99 continued: Typical 575V DPS 016–028 with Electric Heat, Dual Power, and Energy Recovery Wheel ( IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 113 Wiring Diagrams Figure 99 continued: Typical 575V DPS 016–028 with Electric Heat, Dual Power, and Energy Recovery Wheel www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 114 Wiring Diagrams Figure 99 continued: Typical 575V DPS 016–028 with Electric Heat, Dual Power, and Energy Recovery Wheel IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 115 Wiring Diagrams Figure 100: Typical 575V DPS 016–028 with Gas Heat www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 116 Wiring Diagrams Figure 100 continued: Typical 575V DPS 016–028 with Gas Heat IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 117 Wiring Diagrams Figure 100 continued: Typical 575V DPS 016–028 with Gas Heat www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 118 Wiring Diagrams Figure 100 continued: Typical 575V DPS 016–028 with Gas Heat IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...
  • Page 119 Wiring Diagrams Figure 100 continued: Typical 575V DPS 016–028 with Gas Heat www.DaikinApplied.com IM 1125-13 • REBEL ROOFTOPS...
  • Page 120 Wiring Diagrams Figure 100 continued: Typical 575V DPS 016–028 with Gas Heat IM-1125-13 • REBEL ROOFTOPS www.DaikinApplied.com...

  • Page 121: Sequence Of Operation

    Sequence of Operation Sequence of Operation Operating States Fan Only The transition from any operating state to another is graphically represented in Figure 101 . The outside air damper will modulate to the minimum position and based upon the sensor inputs, the unit will go into one of Figure 101: Operating State Diagram the four running states - “Heating,”...

  • Page 122: Mechanical Cooling

    Sequence of Operation Mechanical Cooling The unit goes into the cooling mode of operation when the control temperature (return temperature) is above the change- Constant Volume (Space Comfort Controller) over setpoint by more than ½ the deadband. The control temperature for a CAV unit is typically the space Example - If the change over temperature is 70.0°F and the temperature.

  • Page 123: Preparing The Unit For Start Up

    Adjusting Spring Mounts Daikin Applied. During operation all fans should ride level. Level the fan A representative of the owner or the operator of the equipment...

  • Page 124: Servicing Control Panel Components

    16 . Inspect the outside and inside of the unit for any signs of damage or rough handling. Excessive air leakage would be one possible, unacceptable consequence. If any problems are found, contact the local Daikin representative for instructions. IM-1125-13 • REBEL ROOFTOPS...

  • Page 125: Check, Test And Start Procedures

    Check, Test and Start Procedures Check, Test and Start Procedures Economizer Start-Up Perform the Following Procedure: 1 . Check whether the outdoor air is suitable for free cooling. NOTICE 2 . At the keypad, set the cooling setpoint low enough so the controller calls for cooling.

  • Page 126: Set Up For Optimum Control

    Check, Test and Start Procedures Set Up for Optimum Control Air Balancing The Outdoor air sensor must be calibrated. WARNING • Compare the MicroTech III OAT reading to an external Moving machinery hazard. Can cause severe personal temperature measuring device . See Appendix, Figure injury or death .

  • Page 127: Energy Recovery Wheel

    Check, Test and Start Procedures Energy Recovery Wheel Prestartup Checks CORE Set-Up 1 . Attain outdoor air hoods. 1 . By hand, turn wheel clockwise (as viewed from the pulley side) to verify wheel turns freely through 360° rotation. 2 . Verify bypass damper moves freely. 2 .

  • Page 128: Final Control Settings

    Final Control Settings Final Control Settings Maintaining Control Parameter Records Daikin recommends that the MicroTech III controller’s setpoints Controller Settings for Normal Operation and parameters be recorded and saved for future reference. When all start-up procedures are completed, set the controls If the microprocessor control board requires replacement, this and program the MicroTech III controller for normal operation.

  • Page 129: Maintenance

    Maintenance Maintenance Performing Service Maintenance Planned Maintenance Installation and maintenance must be performed only by Preventive maintenance is the best way to avoid unnecessary qualified personnel who are experienced with this type of expense and inconvenience. Have this system inspected at equipment and familiar with local codes and regulations.

  • Page 130: Periodic Service And Maintenance

    Once a month, open a door on each section and verify that no moisture or debris is accumulating in the unit. Control Compartment 1 . Daikin Applied recommends that the electronic control equipment in the unit be stored in a 5% to 95% RH (non- condensing) environment.

  • Page 131: Refrigerant Charge

    Maintenance Refrigerant Charge MicroTech III keypad instructions for charging and/ The Rebel unit has many configurable options that can affect or evacuation the refrigerant charge. Actual unit charge is given on the unit’s data plate found on the inside of the control panel. The Rebel Evacuating the charge: unit uses electronic expansion valves that maintain peak •...

  • Page 132: Servicing Refrigerant Sensors Or Switches

    Maintenance Servicing Refrigerant Sensors or Switches Phase Voltage Monitor (PVM) The phase voltage monitor (Figure 106) is designed to CAUTION protect three-phase loads from damaging power conditions. A microprocessor-based voltage and phase sensing circuit Severe loss of charge may occur if the high refrigerant constantly monitors the three-phase voltages to detect harmful pressure switch is replaced before reclaiming the power line conditions.

  • Page 133: Cleaning Option E Coated Coils

    Maintenance Cleaning Option E Coated Coils Routine Quarterly Cleaning of Option E Coated Coil WARNING Surfaces Quarterly cleaning is essential to extend the life of an Option Prior to cleaning the unit, turn off and lock out the main power switch to the E Coated Coil and is required to maintain warranty coverage.

  • Page 134: Service And Warranty Procedures

    Any miswiring of the MicroTech III controller that damages it 2 . Send a completed parts order form to the Daikin Parts in any way, such as blown internal fuse, will not be covered Department.

  • Page 135: Warranty Registration Form

    Warranty Registration Form 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 136 Warranty Registration Form Rebel 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 137 Warranty Registration Form Rebel Equipment Warranty Registration Form (continued) Select Yes or No. If not applicable to the type of unit, select N/A. IV. PERFORMANCE DATA (Unit to run at steady state for 15 minutes) A. Discharge pressure, one compressor: .
  • Page 138 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 139: 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 140: Appendix - Keypad Display Menu Structure

    Appendix - Keypad Display Menu Structure Appendix - Keypad Display Menu Structure The following is a description of the MicroTech III menu structure. These menus and items can all be displayed with the keypad/ display. Menu items displayed will change based on the selected unit configuration. Figure 107: Main Menu –...
  • Page 141 Appendix - Keypad Display Menu Structure Commission Unit Manual Control Service Menus Trending Unit Maintenance BMS Communications ► ► ► Unit Set-Up Manual Control= Normal Timer Settings Trending Ena= No Operating Hours LON Set-Up ► ► ► Timer Settings Supply Fan= Off Operating Hours Apply Chgs= No BACnet MSTP Set-Up...
  • Page 142 Appendix - Keypad Display Menu Structure Figure 108: View/Set Unit – Keypad/Display Menu Structure View/Set Unit ► Unit Status/Settings ► Occupancy ► Temperatures ► Flow Status ► SAF Spd Control ► RF/EF Control ► Cooling ► Economizer ► Min OA Damper ►...
  • Page 143 Appendix - Keypad Display Menu Structure Cooling Economizer Min OA Damper Heating Dehumidification Date/Time/Schedules Occ Clg Spt= 72.0°F OAD/Econo Pos= XXX% Min OA Pos= XXX% Occ Htg Spt= 68.0°F Dehum Status= ________ Time= hh:mm:ss Unocc Clg Spt= 85.0°F DAT Clg Spt= 55.0°F Vent Limit= 20% Unocc Htg Spt= 55.0°F Rel Humidity= XXX%...
  • Page 144 Appendix - Keypad Display Menu Structure Figure 109: Commission Unit – Keypad/Display Menu Structure Commission Unit ► Unit Set-Up ► Timer Settings ► SAF Set-Up ► RF/EF Set-Up ► Htg/Clg ChgOvr Set-Up ► Cooling Set-Up ► Unit Set-Up Timer Settings SAF Set-Up INV Cmp Set-Up ►...
  • Page 145 Appendix - Keypad Display Menu Structure 1, 2 See Figure 110, page 146 for the expansion information RF/EF Set-Up Htg/Clg ChgOvr Set-Up Cooling Set-Up INV Cmp Set-Up RF/EF Ctrl= None Ctlr Temp Src= RAT Clg Stage Time= 5min COMPRESSOR STATUS COMPRESSOR SETUP Clg State= ____________ Clg Lo OAT Lk= 55°F...
  • Page 146 Appendix - Keypad Display Menu Structure Figure 110: Service Menu – Keypad/Display Menu Structure Service Menus ► Timer Settings ► Operating Hours ► Save/Restore Settings ► Active Alarms ► Alarm Log ► Alarm Configuration ► Analog Input Status ► Universal I/O Status ►...
  • Page 147 Appendix - Keypad Display Menu Structure Alarm Log Alarm/Event Analog Input Status Universal I/O Status Digital Input Status Digital Output Status ► Configuration Log Count: xx Clr Log= No MCB Al1= XXXXXXXX MCB X1= XXXXXXXX MCB DI1= ____________ MCB DO1= __________ ►...
  • Page 148 Appendix - Keypad Display Menu Structure Figure 111: BMS Communications – Keypad/Display Menu Structure BMS Communications ► LON Set-Up ► BACnet MSTP Set-Up ► BACnet IP Set-Up ► D-Net Set-Up ► Network Unit Set-Up IM 918 IM 917 IM 916 LON Set-Up BACnet MSTP Set-Up BACnet IP Set-Up...
  • Page 149 Appendix - Keypad Display Menu Structure Figure 113: Optional Outdoor Air Monitor – Changing the System of Units Press and release ↑/↓ during normal operation to select Enter ↑/↓ (Select) Enter (Move →) Enter (Move →) (Action, Move →→) During Esc (Move ←) Esc (Move ←) Normal Operation...
  • Page 150 Appendix - Keypad Display Menu Structure Figure 114: Optional Outdoor Air Monitor – Set Up Menu Press and release ↑/↓ during normal operation to select Enter (Move →) Enter (Move →) Enter (Move →) Enter (Action, Move →→) Esc (Normal Operation) Esc (Move ←) Esc (Move ←) Esc (Move ←←)
  • Page 151 Appendix - Keypad Display Menu Structure 1 . Factory default/current setting 2 . If a selection is made that requires SW1 to be set, the LCD displays “Set SW1 on Board”. 3 . If a selection is made that requires SW2 to be set, the LCD displays “Set SW2 on Board”.
  • Page 152 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.

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