Daikin DCG Series Installation And Maintenance Manual
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Daikin DCG Series Installation And Maintenance Manual

Light commercial packaged gas units 15–20 tons
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See also: Instruction and Installation Manual
Installation and Maintenance Manual
Light Commercial Packaged Gas Units
DCG Series
15–20 Tons
IM 1213
Group: Applied Air Systems
Part Number: IM 1213
Date: January 2014

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  • Page 1 Installation and Maintenance Manual IM 1213 Group: Applied Air Systems Part Number: IM 1213 Date: January 2014 Light Commercial Packaged Gas Units DCG Series 15–20 Tons...
  • Page 2 This Forced Air Central Unit Design Complies With Requirements Embodied In The American National Standard / National Standard of Canada Shown Below. ANSI Z21.47 • CSA-2.3 Central Furnaces Our continuing commitment to quality products may mean a change in specifications without notice. ©2013 Daikin Company, L.P. 5151 San Felipe St., Suite 500, Houston, TX 77056 www.daikincomfort.com...

  • Page 3: Table Of Contents

    Index Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Startup, Adjustments, and Checks .

  • Page 4: Replacement Parts

    WHICH MAY CAUSE SERIOUS ILLNESS OR DEATH AND WHICH ARE CONSUMER AFFAIRS KNOWN TO THE TATE OF ALIFORNIA TO CAUSE CANCER BIRTH DAIKIN NORTH AMERICA LLC DEFECTS OR OTHER REPRODUCTIVE HARM 7401 SECURITY WAY HOUSTON, TEXAS 77040 855-770-5678 WARNING SAFETY INSTRUCTIONS...

  • Page 5: General Information

    Specification sheets Carefully inspect the unit for damage including damage to the can be found at www.daikincomfort.com for Daikin brand prod- cabinetry. Any bolts or screws which may have loosened in transit ucts. Within the website, please select the residential or com- must be re-tightened.

  • Page 6: Unit Location

    d. Copy of the inspection report issued by carrier swimming pool chemicals and chlorine bleaches, paint representative at the time damage is reported to the stripper, adhesives, paints, varnishes, sealers, waxes (which carrier. The carrier is responsible for making prompt are not yet dried) and solvents used during construction inspection of damage and for a thorough investigation and remodeling.
  • Page 7 • Minimum horizontal clearance of 48” from the furnace LIFT OVER APPROXIMATE CENTER OF UNIT flue discharge to any electric meters, gas meters, regulators SPREADER BARS and relief equipment is required. MUST BE USED WITH LIFTING STRAPS THAT ARE LESS THAN 16 FEET LONG RECAUTIONS •...

  • Page 8: Clearances

    • Sufficient structural support must be determined prior to locating and mounting the curb and package unit. • Ductwork must be constructed using industry guidelines. The duct work must be placed into the roof curb before mounting the package unit. Our full perimeter curbs include duct connection frames to be assembled with the curb.
  • Page 9 CAUTION CAUTION O NOT LIFT UNITS TWO AT A TIME ROVISIONS FOR FORKS HAVE BEEN HEN UNIT IS SUSPENDED BOARDS AND SHIPPING BRACE WILL DROP WHEN , STAND CLEAR. 72” INCLUDED IN THE UNIT BASE FRAME INIMUM FORK LENGTH IS SCREWS ARE REMOVED O PREVENT PERSONAL INJURY PREVENT DAMAGE TO THE UNIT...

  • Page 10: Electrical Wiring

    Main power wiring should be sized for the minimum wire ampacity IGGING EMOVAL shown on the unit’s database. Size wires in accordance with the ampacity tables in Article 310 of the National Electrical Code. If CAUTION long wires are required, it may be necessary to increase the wire O PREVENT DAMAGE TO THE UNIT DO NOT ALLOW CRANE HOOKS AND size to prevent excessive voltage drop.

  • Page 11: Gas Supply Piping

    3. Use #18 AWG wire for 24V control wiring runs not WARNING exceeding 75 feet. Use #16 AWG wire for 24V control wiring runs not exceeding 125 feet. Use #14 AWG wire for 24V AILURE OF UNIT DUE TO OPERATION ON IMPROPER LINE VOLTAGE OR control wiring runs not exceeding 200 feet.
  • Page 12 5. Use two pipe wrenches when making connection to the INLET GAS PRESSURE gas valve to keep it from turning. NATURAL Min. 5.0" W.C., Max. 10.0" W.C. 6. Install a manual shut-off valve in a convenient location (within six feet of unit) between the meter and the unit. PROPANE Min.

  • Page 13: Propane Gas Installations

    NOTE: The unit gas supply entrance is factory sealed with plugs. All propane gas equipment must conform to the safety standards Keep plugs in place until gas supply is ready to be installed. Once of the National Board of Fire Underwriters (See NBFU Manual 58). ready, replace the plugs with the supplied grommets and install Line pressure 11.3 - 14”...

  • Page 14: Circulating Air And Filters

    2. All units are furnished with standard female NPT pipe 7. There must be no obstruction to prevent the flow of connections. Connection pipe size is 3/4" NPT. The size of combustion and ventilating air. A vent stack is not required the gas supply piping to the unit must be based on length and must never be used.

  • Page 15: Startup, Adjustments, And Checks

    STARTUP, ADJUSTMENTS, AND CHECKS ONTRACTOR ESPONSIBILITY The installing contractor must be certain that: WARNING • All supply and return air ductwork is in place, properly HIGH VOLTAGE! sealed, and corresponds with installation instructions. O AVOID PERSONAL INJURY OR DEATH DUE TO •...

  • Page 16: Air Flow Adjustments

    Utilization Voltage - The voltage of the line terminals of the equip- VAPORATOR OTATION HECK ment at which the equipment must give fully satisfactory perfor- Check that fan rotates clockwise when viewed from the drive side mance. Once it is established that supply voltage will be main- of unit and in accordance with rotation arrow shown on blower tained within the utilization range under all system conditions, housing.

  • Page 17: Motor Sheave Adjustments

    NOTE: Future adjustments should be made by loosening the belt tension and increasing or decreasing the pitch diameter of the sheave by half or full turns as required. Readjust belt tension before starting drive. *Apply force to the center of the span. t = Span length, inches C = Center distance, inches VL &...
  • Page 18 MAXIMUM NUMBER GAS ORIFICES WARNING MAXIMUM INPUT BTUH/BURNER NATURAL PROPANE (LP) (BTUH) BURNERS O AVOID PROPERTY DAMAGE PERSONAL INJURY OR DEATH DO NOT FIRE GAS UNIT WITH FLUE BOX COVER REMOVED 350,000 50,000 400,000 50,000 NOTE: Except during brief periods when gas pressures are being measured by qualified service personnel, the furnace access panel HEAT EXCHANGER AND BURNER ORIFICE SPECIFICATIONS must always be secured in place when the furnace is in operation.
  • Page 19 To adjust the pressure regulator, remove the adjustment screw or Pressure Regulator Outlet Pressure cover on the gas valve. Turn out (counterclockwise) to decrease Adjustment pressure, turn in (clockwise) to increase pressure. Only small varia- (Under Cap Screw) tions in gas flow should be made by means of the pressure regula- tor adjustment.

  • Page 20: Normal Sequence Of Operation - Heating

    4. Relight all other appliances turned off in step 1. Be sure all 6. When the burners are ignited, a minimum four (4) micro- pilot burners are operating. amp DC current will flow through the flame between the sensor electrode and the grounded burner. Main Burner Flame Check 7.

  • Page 21: Normal Sequence Of Operation - Cooling

    (RS) ANUAL ESET LAME OLLOUT ONTROL TART ROCEDURE AND HECKLIST FOR PEED ODELS Located in the burner compartment at the top of the burner as- Models with a V in the 11th position of the model number. sembly, it senses high temperature that could occur if the heat exchanger tubes were plugged and the flame was rolling out in- For 2 speed models, the indoor blower will operate on low speed stead of entering the tubes.

  • Page 22: Maintenance

    4. The belt drive blower contactor closes its contacts L1, L2 EFRIGERATION ERFORMANCE HECK and L3 to T1, T2 and T3 to provide power to the supply fan Under normal summertime (full load) operating conditions, super- motor. heat should be between 10 +/- 3° F and sub-cooling measured at 5.
  • Page 23 Preventive maintenance is the best way to avoid unnecessary ex- UBRICATION pense and inconvenience. Have this system inspected at regular The fan shaft bearings and the supply fan motor have grease fit- intervals by qualified service personnel, at least twice a year. Rou- tings that should be lubricated during normal maintenance checks.

  • Page 24: Troubleshooting

    Flames should be stable, soft and blue (dust may cause orange tips BNORMAL PERATION EATING ODES but must not be yellow). The flames must extend directly outward External Lockout (1 FLASH CODE) from the burner without curling, floating or lifting off. An external lockout occurs if the integrated ignition control deter- mines that a measurable combustion cannot be established within three (3) consecutive ignition attempts.
  • Page 25 • Check flame sensor Flame Detected with Gas Valve Closed (5 FLASH CODE) A drop in flame signal can be caused by nearly invisible If flame is detected with the gas valve deenergized, the combus- coating on the sensor. Remove the sensor and carefully tion and air circulator blowers are energized.

  • Page 26: Appendix A Blower Performance Data

    APPENDIX A BLOWER PERFORMANCE DATA BELT DRIVE - STANDARD DCG180 STANDARD BELT DRIVE (includes 2 speed models at high speed) TURNS OPEN ESP, In H 0.00 6827 2.67 6394 2.28 5982 1.94 7079 3.20 6623 2.76 6161 2.34 5706 1.98 5271 1.66 6903...

  • Page 27: Appendix B Electrical Data

    APPENDIX B ELECTRICAL DATA ELECTRICAL DATA VOLTAGE 2 SPEED COMPRESSOR (ea) OD FAN MOTORS (ea) ID FAN MOTOR LIMITATIONS ID FAN MOTOR VOLTAGE MODELS MOTOR (NAMEPLATE) APPL BD STD 208/230-60-3 25.0 164.0 2.40 12.7 14.0 STATIC BD STD 15 TON 460-60-3 12.2 100.0...

  • Page 28: Appendix C Unit Dimensions

    APPENDIX C UNIT DIMENSIONS Model 15 Ton 88-7/32" 50-9/32" 5-5/32" 133-1/2" 20 Ton 21” 60” 7” 48” 22” VERTICAL DISCHARGE (TOP VIEW)

  • Page 29: Appendix D Wiring Diagrams

    APPENDIX D WIRING DIAGRAMS...
  • Page 30 DCG1803503B* & DCG2404003B* THREE PHASE 208-230/60 HZ BELT DRIVE WIRING DIAGRAM POWER SUPPLY SEE NOTE 4 208V / 240V - 3 ph - 60Hz GRND GRND CCH2 COMP COMP CCH1 COMP 2 2 2 4 4 4 CCHR2 CCHR1 CCHR1 LPS2 LPS2 HPS2...
  • Page 31 DCG1803503B* & DCG2404003B* THREE PHASE 208-230/60 HZ BELT DRIVE WIRING DIAGRAM SUPPLY VOLTAGE 208-240/3/60 NOTE 3 NOTE 3 5. FOR TWO STAGE OPERATION REMOVE W1 TO W2 WIRE JUMPER. HPS2 LPS2 ECON NOTE 2 CHECK STATUS LIGHT EQUIPMENT STATUS ------ NORMAL OPERATION CHECK INPUT POWER NO POWER OR...
  • Page 32 DCG1803504B*/7B & DCG2404004B*/7B* THREE PHASE 460-575/60 HZ BELT DRIVE WIRING DIAGRAM POWER SUPPLY 460V / 575 - 3 ph - 60 SEE NOTE 4 CCH2 COMP CCH1 COMP NOTE 6 OR APPROPRIATE CCHR2 INPUT VOLTAGE NOTE 2 LPS2 LPS2 HPS2 LPS1 LPS1 HPS1...
  • Page 33 DCG1803504B*/7B & DCG2404004B*/7B* THREE PHASE 460-575/60 HZ BELT DRIVE WIRING DIAGRAM NOTE 3 5. FOR TWO STAGE OPERATION REMOVE W1 TO W2 WIRE JUMPER. LPS2 ECON INSTALL ER/SERVIC EMAN THE STATUS LIGHT ON THE FURNACE CONTROL MAY BE USED AS A GUID E TO TROUBLESHOOTING THIS APPLIANCE.
  • Page 34 DCG1803503V*& DCG2404003V* THREE PHASE 208/230/60 HZ BELT DRIVE WIRING DIAGRAM CCH1 CCHR1 COMP CCH2 CCHR2 POWER SUPPLY SEE NOTE 4 208V / 240V - 3 ph - 60Hz COMP GRND GRND HIGH SPEED HIGH SPEED CCR1 CCR2 UNUSED UNUSED HEAT HEAT COOL COOL...
  • Page 35 DCG1803503V*& DCG2404003V* THREE PHASE 208/230/60 HZ BELT DRIVE WIRING DIAGRAM SUPPLY VO LTAGE 2 08- 2 40/3 /60 2 4 V 5 . F OR TW O STAGE OPERAT IO N REM OVE W 1 TO W2 W IR E JUM PER . AL S HPS2 LP S2...
  • Page 36 DCG1803504V*/7V*& DCG2404004V*/7V* THREE PHASE 460/575/60 HZ BELT DRIVE WIRING DIAGRAM CCH1 CCHR1 COMP CCH2 CCHR2 POWER SUPPLY SEE NOTE 4 460V / 575V - 3 ph - 60Hz COMP GRND GRND HIGH SPEED HIGH SPEED OR APPROPRIATE INPUT VOLTAGE CCR1 CCR2 UNUSED UNUSED...
  • Page 37 DCG1803504V*/7V*& DCG2404004V*/7V* THREE PHASE 460/575/60 HZ BELT DRIVE WIRING DIAGRAM NOTE 3 5. FO R TW O STAG E OPER ATIO N R EMO VE W 1 T O W 2 WIRE JUMP ER. LPS2 E CON STATU S LIGHT EQ UIPMEN T STATU S CH EC K NO RM AL OP ERATION...
  • Page 38 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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