Daikin DM97MC Service Instructions Manual
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Daikin DM97MC Service Instructions Manual

Modulating gas furnaces, up to 98% afue 34.5" chassis dm97mc, dc97mc & accessories
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Service Instructions
Modulating Gas Furnaces, up to 98% AFUE
34.5" Chassis DM97MC, DC97MC
& Accessories
RSD6612009r5
This manual is to be used by qualified, professionally trained HVAC technicians only. Daikin does not
assume any responsibility for property damage or personal injury due to improper service
September 2016
procedures or services performed by an unqualified person.
Copyright © 2014-2016
1

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  • Page 1 34.5" Chassis DM97MC, DC97MC & Accessories RSD6612009r5 This manual is to be used by qualified, professionally trained HVAC technicians only. Daikin does not assume any responsibility for property damage or personal injury due to improper service September 2016 procedures or services performed by an unqualified person.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS OPERATIONAL CHECKS ...... 49 - 50 IMPORTANT INFORMATION ...... 2-4 MAINTENANCE ........51 PRODUCT IDENTIFICATION ....5 - 8 SERVICING TABLE OF CONTENTS ....52 ACCESSORIES ........9 - 11 SERVICING ........53 - 61 LIGHTING INSTRUCTIONS ......12 TROUBLESHOOTING ......

  • Page 3: Important Information

    IMPORTANT INFORMATION To locate an authorized servicer, please consult your telephone book or the dealer from whom you purchased this product. For further assistance, please contact: CONSUMER INFORMATION LINE DAIKIN BRAND PRODUCTS TOLL FREE 1-855-770-5678 (U.S. only) email us at: customerservice@daikincomfort.com...
  • Page 4 IMPORTANT INFORMATION CO can cause serious illness including permanent brain damage or death. B10259-216 Advertencia especial para la instalación de calentadores ó manejadoras de aire en áreas cerradas como estacionamientos ó cuartos de servicio. Las emisiones de monóxido de carbono pueden circular a través del aparato cuando se opera en cualquier modo.

  • Page 5: Product Identification

    PRODUCT IDENTIFICATION PRODUCT FURNACE TYPE TYPE: MAJOR D: Daikin M: Modulating REVISION V: 2-Stage CABINET A: Initial Release WIDTH B: 17-1/2" C: 21" D: 24-1/2" MINOR REVISION A: Initial Release NOMINAL INPUT AFUE 060: 60,000 Btuh 97: 97% 080: 80,000 Btuh...
  • Page 6 PRODUCT IDENTIFICATION MODEL: DM97MC REV AA Equipment Type Daikin Brand Residential Gas Furnace Heating Stages Modulating (35% - 100% of rated input) Cooling Stages Control Type ClimateTalk ™ or Conventional 24 Volt Blower Motor Type 4 Wire Variable Speed ECM...
  • Page 7 Communicating Thermostat Kit- Digitally communicating thermostat, a necessary part of any communicating system. Designed for use with compatible Daikin Air Handlers or Furnaces and outdoor split AC or Heat Pump units. The CTK02** thermostat features full color, high definition display, advanced programming options...
  • Page 8 DESCRIPTION DCVK-20 Concentric Vent Kit. For use with Daikin Modulating furnace models. This kit is designed to allow terminations (CVENT-2) of a direct vent furnace to be "concentrically" vented through a wall or roof. This kit allows a single penetration to support terminations for both the vent/flue and the combustion air intake pipe.

  • Page 9: Accessories

    ACCESSORIES 97% Mod Furnace Accessories DM9 7 MC0 6 0 3 BN* * DM9 7 MC0 8 0 3 BN* * DM9 7 MC0 8 0 4 CN* * DM9 7 MC10 0 5 CN* * DM9 7 MC12 0 5 DN* * DC9 7 MC0 6 0 3 BN* * DC9 7 MC0 8 0 3 BN* * DC9 7 MC0 8 0 4 CN* *...
  • Page 10 ACCESSORIES EXTERNAL FILTER RACK (EFR02) Used on 97% Upflow Modulating Furnaces SLOTS IN FILTER CLEAR SCREWS ON UNIT BLOWER DECK SCREWS UNIT SIDE PANEL FRONT OF UNIT FILTER RACK ASSEMBLY (FACE FILTER OPENING BASE TOWARDS FRONT OF UNIT OF UNIT) RETURN AIR CUTOUT AREA LOWER EDGE...
  • Page 11 LP gas. To con- with 2” - 3” vent systems. This kit is NOT intended for vert a DM97MC or DC97MC furnace to operate on LP gas, use with single pipe (non-direct vent) installations.

  • Page 12: Lighting Instructions

    LIGHTING INSTRUCTIONS WARNING:...

  • Page 13: Product Design

    PRODUCT DESIGN Adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating the furnace. To ensure proper installation and operation, thoroughly read this manual for specifics pertaining to the installation and application of this product. WARNING WARNING O PREVENT PERSONAL INJURY OR DEATH DUE TO IMPROPER O PREVENT POSSIBLE PROPERTY DAMAGE...
  • Page 14 PRODUCT DESIGN Our 34.5" modulating furnace is one of the products in our WARNING newly redesigned line of shorter chassis furnaces. It comes in two models: an up flow / horizontal model and a down HOULD OVERHEATING OCCUR OR THE GAS SUPPLY FAIL TO SHUT OFF flow / horizontal model.
  • Page 15 Direct vent (dual pipe) central forced air furnace in which 1. Modulating furnace alone all combustion air supplied directly to the furnace burn- 2. Modulating furnace with Daikin communicating split ers through a field installed combustion air pipe. A/C or H/P unit (no separate dual fuel control is re-...
  • Page 16 PRODUCT DESIGN • Ensure adequate combustion air is available for the fur- To ensure proper furnace operation, install, operate and nace. Improper or insufficient combustion air can ex- maintain the furnace in accordance with the installation pose building occupants to gas combustion products that manual shipped with the furnace as well as all local build- could include carbon monoxide.
  • Page 17 PRODUCT DESIGN exchanger sections are joined by a 441 stainless steel header For vertical (upflow or downflow) applications, the plate. Flue gas condensation takes place in the secondary minimum cooling coil width shall not be less than fur- heat exchanger as latent heat is transferred from the flue nace width minus 1”.
  • Page 18 PRODUCT DESIGN verts it to a three phase supply to operate the draft inducer jumper is installed between these two terminals. As an op- at the desired speed. The windings of the induced draft tion; the jumper may be removed and the terminals wired motor will have equal resistance +/- 5%.
  • Page 19 PRODUCT DESIGN Fault Recall This feature allows the service person to check Installations must adhere to the clearances to combustible ma- for any fault history. The board memory is capable of re- terials to which this furnace has been design certified. The cording and storing 10 fault codes.
  • Page 20 Installation Positions DM97MC models may be installed up flow or horizontally with left or right side down. DC97MC models may be in- stalled down flow or horizontally with left or right side down.
  • Page 21 PRODUCT DESIGN Propane Gas/High Altitude Installations ONNECTIONS Return duct must not be connected to the back of any fur- nace. Up flow furnaces installed vertically may have return WARNING air duct connections on either side or the furnace bottom. When airflow requirements are greater than 1,800 CFM for OSSIBLE PROPERTY DAMAGE PERSONAL INJURY OR DEATH MAY heating or cooling, both sides or a bottom return must be...
  • Page 22 PRODUCT DESIGN PREFERRED Direct Vent (2 - Pipe) and Non-Direct Vent (1- Pipe) Number of Elbows Model Pipe Size 2 or 2 1/2 DM97MC0603BNA* 2 or 2 1/2 DM97MC0803BNA* 2 or 2 1/2 DM97MC0804CNA* 2 or 2 1/2 DM97MC1005CNA* 2 or 2 1/2 DM97MC1205DNA* ACCEPTABLE 2 or 2 1/2...
  • Page 23 PRODUCT DESIGN DIRECT VENT TERMINAL CLEARANCES Canadian Installations U.S. Installations Canadian Installations U.S. Installations Clearance to service 3 ft. (91 cm). A= Clearance above grade, 12 in. (30 cm) 12 in. (30 cm) regulator vent outlet. veranda, porch, deck or balcony.
  • Page 24 PRODUCT DESIGN Condensate Drain Lines & Drain Trap Electrical Connections A condensing gas furnace achieves its high level of efficiency by extracting heat from the products of combustion to the point WARNING where condensation takes place. The condensate must be col- lected in the furnace drain trap and routed to an appropri- HIGH VOLTAGE ! ate drain location in compliance with local and national codes.

  • Page 25: Operation

    OPERATION Line voltage connections can be made through either the right 115 V ONNECTIONS or left side panel. The furnace is shipped configured for a Before proceeding with electrical connections, ensure that the right side electrical connection. To make electrical connec- supply voltage, frequency, and phase correspond to that speci- tions through the opposite side of the furnace, the junction fied on the unit rating plate.
  • Page 26 OPERATION When installed with a non-communicating thermostat, the IMPORTANT NOTE furnace integrated control module provides terminals for both “W1” and “W2”, and “Y1” and “Y2” thermostat connections. O APPLY A SINGLE STAGE EATING HERMOSTAT THE THERMOSTAT This allows the furnace to support the following system applica- MUST SELECTOR SWITCH ON THE NTEGRATED...
  • Page 27 OPERATION 1. Humidification Options are ON / OFF with the CTK03. OSSIL PPLICATIONS When “On” is selected, the humidification relay on the This furnace can be used in conjunction with a heat pump in a furnace control board will function during a heat call if a fossil fuel application.
  • Page 28 OPERATION All field wiring must conform to applicable codes. Connections should be made as shown in the following figure. CAUTION O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE INLET GAS SUPPLY PRESSURE MUST BE AS SPECIFIED ON THE UNIT RATING PLATE WITH ALL OTHER HOUSEHOLD GAS FIRED APPLIANCES OPERATING Inlet gas supply pressures must be maintained within the ranges specified in the following table.
  • Page 29 OPERATION • Tighten all joints securely. Natural Gas Capacity of Pipe In Cubic Feet of Gas Per Hour (CFH) • Connect the furnace to the building piping by one of Length of Nominal Black Pipe Size the following methods: Pipe in Feet 1/2"...
  • Page 30 OPERATION ROPANE ANKS AND IPING Sizing Between First and Second Stage Regulator* Maximum Propane Capacities listed are based on 2 psig pressure drop at 10 psig setting. Capacities in 1,000 BTU/hour. Pipe or Nominal Pipe Size WARNING Tubing Tubing Size, O.D. Type L Schedule 40 Length Feet...
  • Page 31 OPERATION If the total external static pressure exceeds the maximum A closed return duct system must be used, with the return duct listed on the furnace rating plate, check for closed damp- connected to the furnace. NOTE: Ductwork must never be at- ers, registers, undersized and/or oversized poorly laid out tached to the back of the furnace.
  • Page 32 OPERATION AIR FLOW CUT USING TIN SNIPS CENTRAL PRESS OUT BY HAND RETURN GRILLE SIDE RETURN EXTERNAL FILTER RACK KIT (EITHER SIDE) CUT FOUR CORNERS AFTER REMOVING SHEET METAL SCRIBE LINES OUTLINING DUCT FLANGES Duct Flange Cut Outs When a cooling coil is installed with the furnace, it must be installed in the supply air to avoid condensation from Possible Upright Upflow occuring in the heat exchanger.
  • Page 33 OPERATION Upon power up, all segments in the dual seven segment After a successful Light Off Sequence and expiration of the display will illuminate briefly and then display ON, indicat- Ignition Stabilization Period: ing the furnace is standing by & ready to receive commands •...
  • Page 34 OPERATION Call for 2nd-Stage Heat satisfied; Call for 1st-Stage Heat remains. 10 MINS. • The IFC remains at the current firing rate until the 8 MINS. 1st-Stage call for heat is satisfied. IGNITION (80%) CTK01 T EATING PERATION WITH HERMOSTAT OMMUNI CATING •...
  • Page 35 OPERATION 1. Turn OFF gas to furnace at the manual gas shutoff UPPLY RESSURE EASUREMENT valve external to the furnace. 2. Connect a calibrated water manometer (or appropri- CAUTION ate gas pressure gauge) at either the gas valve inlet O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE pressure boss or the gas piping drip leg.
  • Page 36 OPERATION URNACE ANIFOLD RESSURES Gas Line NATURAL GAS L.P. GAS Shutoff Valve .5" WC 1.2" WC .9" WC 2.5" WC 1.25" WC 3.7" WC 1.70" WC 5.0" WC Gas Line To Furnace 2.20" WC 6.5" WC 2.80" WC 8.0" WC 100% 3.50"...
  • Page 37 OPERATION 1. Turn OFF the gas supply to all other gas-burning ap- 4. Adjust temperature rise by adjusting the circulator pliances except the furnace. blower speed. Increase blower speed to reduce tem- perature rise. Decrease blower speed to increase 2. While the furnace is operating, time and record one temperature rise.
  • Page 38 C also has a one (1) minute 100% OFF delay. 1000 CFM. Looking at the cooling speed chart for DM97MC, find the air flow closest to 1000 CFM. A cooling airflow of 1000 CFM can be attained by select- 100% CFM ing the cooling speed “C”...
  • Page 39 OPERATION using a two stage outdoor unit, move this switch to the ON DIP S WITCHES position and wire Y1 from the room stat to Y1 on the IFC, There are 18 DIP switches on the modulating furnace IFC. wire Y2 on the room stat to Y2 on the IFC. This switch is Switches are located in 3 rows, each having 6 switches.
  • Page 40 DIP Switches...
  • Page 41 OPERATION fan operation, the thermostat sends a fan request along transformer is included with the CTK01AA, CTK03 and CTK04 with the continuous fan demand to the furnace. The fur- kits. See kit instructions for mounting and wiring instructions. nace, in turn, sends the demand to the ECM motor. The If using a CTK02 or CTK01BA, an accessory transformer is ECM motor delivers the requested continuous fan airflow.
  • Page 42 OPERATION • Close the humidifier relay contacts OOLING PERATION WITH A OMMUNICATING HERMOSTAT AND • Energize the circulator at the circulation speed (G ONVENTIONAL INGLE TAGE speed) unless the circulator is commanded to a dif- • The call for cooling will be communicated via the ferent speed by a heat demand.
  • Page 43 OPERATION High High ComfortNet System Model Stage Stage Stage Stage VERVIEW Cool Cool Heat Heat NOTE: DIP switch #13 MUST be set to match thermostat type. To use the CTK01 communicating thermostat, DIP 1059 DM97MC0603BN** switch #13 must be set to ON position. This is also the 1007 1158 correct setting for a non-communicating 2-stage thermo-...
  • Page 44 OPERATION Before beginning a calibration routine, the IFC will check OMFORT OMPATIBLE URNACE WITH OMFORT that both pressure switches are in the open position. INGLE TAGE ONDITIONER · The IFC powers the draft inducer at a predetermined Four wires are required between the furnace and thermostat. speed and checks to see if the LPS has closed.
  • Page 45 OPERATION • Ignition Activation Period (IAP): The period between • Heat Fan On Delay: The period between proof of the energizing the main gas valve and deactivation of supervised main burner flame and the activation of the ignition source prior to the end of TFI. the blower motor at the low heat speed.
  • Page 46 OPERATION • The inducer will run for the Post-purge period at its Ignition Retries: current speed When flame is not sensed during the • If the circulator fan is on it will run for the normal fan Trial for Ignition Period: off delay at the current heat speed.
  • Page 47 OPERATION H Fitting Heat mode through the Post-purge and perform the Calibration routine immediately (error code “E9” is flashed until calibration routine is successful). • High Pressure Switch check takes place during the Calibration routine. If the switch is stuck open or The H-fitting closed calibration will not be completed and the ap- “conditions”...

  • Page 48: Service And Operation

    SERVICE & OPERATION • The orange button of the diagnostic tool sends a sig- nal to the UltraTech motor to rotate when pressed. ® 3 Wire There may be a five second delay between the time Motor-to-Control Harness the button is pressed and the motor begins to rotate. 3 Pin Connector If the orange button does not illuminate when pressed, the tool is not connected to a 24 volt supply or it is...

  • Page 49: Operational Checks

    OPERATIONAL CHECKS LED Status Indication Possible Causes Corrective Action(s) • Normal condition • None • None 2 Flashes • Out-of-box reset • Control power up • None Communications • Learn button depressed Rapid Flashing • Normal network traffic • Control is “talking” on •...
  • Page 50 OPERATIONAL CHECKS 6. Make sure there are no cabinet air leaks allowing sup- 5. Furnace control board will display “OP” or ‘ON” (depend- ply air to affect combustion ing on board part number). 6. Check operation. 7. If heat exchanger integrity is uncertain, follow proce- dures in Service Bulletin SF-041 7.

  • Page 51: Maintenance

    MAINTENANCE Troubleshooting • Flue pipe system. Check for blockage and/or leakage. Check the outside termination and the connections at and internal to the furnace. WARNING • Heat exchanger. Check for corrosion and/or buildup HIGH VOLTAGE ! within the heat exchanger passageways. O AVOID PERSONAL INJURY OR DEATH DUE TO •...

  • Page 52: Servicing Table Of Contents

    SERVICING SERVICING CHECKING VOLTAGE ........53 S-305 CHECKING MAIN BURNERS ......57 CHECKING WIRING ........53 S-306 CHECKING ORIFICES ........57 S-3A THERMOSTAT AND WIRING ......53 S-307 CHECKING GAS PRESSURE ......57 S-3B HEATING ANTICIPATOR/ CYLCE RATE ....54 S-308 CHECKING HOT SURFACE IGNITOR ....

  • Page 53: Checking Voltage

    SERVICING S-1 CHECKING VOLTAGE 3. If any wires must be replaced, replace with AWM, 105°C. 2/64 thick insulation of the same gauge or its equiva- lent. WARNING CHECKING THERMOSTAT, WIRING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR AND ANTICIPATOR CHANGING ANY ELECTRICAL WIRING. ULTIPLE POWER SOURCES MAY BE PRESENT.

  • Page 54: S-3B Heating Anticipator/ Cylce Rate

    SERVICING S-300 CHECKING PRIMARY LIMIT CONTROL S-3B HEATING ANTICIPATOR/ CYCLE RATE All modulating furnaces use a nonadjustable, automatic Older heating thermostats may have an adjustable antici- reset, bi-metal type limit control. The primary limit con- pator. This is a wire wound adjustable heater which is en- trol is located on the front panel of the furnace between ergized during the "ON"...

  • Page 55: Checking Flame Rollout Control

    SERVICING S-303 INDUCED DRAFT BLOWER MOTOR Induced Draft Blower (IDB) AUXILIARY LIMIT All modulating furnace models use a three phase induced CONTROL draft blower to draw flue gases through the heat exchanger. The inducer uses ball bearings and is permanently lubricated.

  • Page 56: S-304A Checking Inductor Coil

    SERVICING 12. If manifold pressure is found to be lower than accept- Inlet Gas Supply Pressure able (less than .9" wc for natural gas, less than 2.6" WC for LP gas) turn the fine adjustment screw coun- Natural Gas Minimum 4.5" w.c. Maximum 10"...

  • Page 57: Checking Main Burners

    CHECKING ORIFICES the range specified below. The supply pressure can be mea- A fixed gas orifice is used in all Daikin furnaces. That is sured at the gas valve inlet pressure tap or at a hose fit- an orifice which has a fixed bore and position as shown in ting installed in the gas piping drip leg.

  • Page 58: Checking Hot Surface Ignitor

    SERVICING GAS LINE M anifold Gas Pressure Natural Gas 3.5" w.c. GAS SHUTOFF VALVE Propane Gas 10.0" w.c. GAS LINE S-308 CHECKING HOT SURFACE IGNITOR TO FURNACE Modulating furnaces use a 115 volt silicon nitride hot sur- face igniter. This is the familiar and reliable 0131F00008S OPEN TO igniter with 17 second warm up time.

  • Page 59: High Altitude Application

    SERVICING If switch reads as above proceed to Step 4, otherwise S-313 CHECKING INTEGRATED IGNITION CON- replace control. TROL BOARDS 4. Remove the pressure control hose from the control NOTE: Failure to earth ground the furnace, reversing the and interconnect with an inclined manometer as shown neutral and hot wire connection to the line (polarity), or a in the following figure.

  • Page 60: Checking Flame Sensor

    SERVICING Flame signal is continuously monitored by the IFC. The S-314 CHECKING FLAME SENSOR flame rod, flame rod wire, and proper grounding are all A flame sensing device is used in conjunction with the ig- critical to proving the presence of flame. Because of the nition control module to prove combustion.
  • Page 61 SERVICING DM97MC / DC97MC Pressure Switch Trip Points And Usage Chart Coil Cover ID Blower Set Point on Max Make Pressure Low Fire Low Fire High Fire High Fire Low / High Model Pressure Fall Pressure On Switch Set Point on...

  • Page 62: Troubleshooting

    Troubleshooting...
  • Page 63 Troubleshooting...
  • Page 64 Troubleshooting...
  • Page 65 Troubleshooting...
  • Page 66 Troubleshooting...

  • Page 67: Status Codes

    Status Codes NO POWER NORMAL OPERATION INDICATES AIRFLOW, FOLLOWED BY CFM BLOWER MOTOR NOT RUNNING BLOWER COMMUNICATION ERROR BLOWER HP MIS-MATCH BLOWER MOTOR OPERATING IN POWER, TEMPERATURE, OR SPEED LIMIT BLOWER MOTOR CURRENT TRIP OR LOST ROTOR BLOWER MOTOR LOCKED ROTOR BLOWER OVER/UNDER VOLTAGE TRIP OR OVER TEMPERATURE TRIP INCOMPLETE PARAMETERS SENT TO MOTOR LOW INDOOR AIRFLOW...

  • Page 68: Wiring Diagram

    Wiring Diagram DM97MC_A* / DC97MC_A* DOOR SWITCH JUNCTION BOX INDUCTOR COIL (ON SOME MODELS) INDOOR CIRCULATOR BLWR LINE NEUTRAL ELECTRONIC AIR CLEANER OPTIONAL 3 ID BLWR NEUTRAL HUMIDIFIER OPTIONAL NEUTRAL HOT SURFACE IGNITER NEUTRAL LINE DIAGNOSTIC LED’S 40 VA FUSE 3A TRANSFORMER TR (5) 24 VAC...

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