Daikin DM92SN Service Instructions Manual
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Daikin DM92SN Service Instructions Manual

Daikin DM92SN Service Instructions Manual

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DM92SN, DM96SN & DC96SN MODELS
Only personnel that have been trained to install, adjust,
service or repair(hereinafter, "service") the equipment
specified in this manual should service the equipment. The
manufacturer will not be responsible for any injury or
property damage arising from improper service or service
procedures. If you service this unit, you assume responsi-
bility for any injury or property damage which may result.
In addition, in jurisdictions that require one or more
licenses to service the equipment specified in this manual,
only licensed personnel should service the equipment.
Improper installation, adjustment, servicing or repair of
the equipment specified in this manual, or attempting to
install, adjust, service or repair the equipment specified in
this manual without proper training may result in product
damage, property damage, personal injury or death.
Copyright © 2021
Service Instructions
WARNING
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
procedures or services performed by an unqualified
person.
The material in this manual does not supersede
manufacturers installation and operation instructions.
RSD6612021
July 2021

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  • Page 1 This manual is to be used by qualified, professionally trained HVAC technicians only. WARNING Daikin does not assume any responsibility for property Only personnel that have been trained to install, adjust, damage or personal injury due to improper service service or repair(hereinafter, “service”) the equipment specified in this manual should service the equipment.
  • Page 2 IMPORTANT INFORMATION IMPORTANT INFORMATION Pride and workmanship go into every product to provide our customers with quality products. It is possible, however, that during its lifetime a product may require service. Products should be serviced only by a qualified service technician who is familiar with the safety procedures required in the repair and who is equipped with the proper tools, parts, testing instruments and the appropriate service manual.
  • Page 3 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 fax us at: (713) 856-1821 (Not a technical assistance line for dealers.)
  • Page 4 IMPORTANT INFORMATION RR V E RR V E "O " "O " R V E N" LE E N"...

  • Page 5: Product Identification

    The model and manufacturing number are used for positive identification of component parts used in manufacturing. Please use these numbers when requesting service or parts information. Brand Minor Revision D - Daikin A - Initial Release B - 1st Revision Configuration...

  • Page 6: Installation Considerations

    INSTALLATION CONSIDERATIONS Safety WARNING Please adhere to the following warnings and cautions when installing, adjusting, altering, servicing, or operating Possible property damage, personal injury or death due to the furnace. fire, explosion, smoke, soot, condensation, electrical shock or carbon monoxide may result from improper installation, WARNING repair operation, or maintenance of this product.

  • Page 7: Gas Supply And Piping

    This includes any must be maintained to prevent unreliable ignition. The conversion kits required for alternate fuels and/or high maximum must not be exceeded to prevent unit overfiring. altitude. DM92SN & DM96SN MINIMUM CLEARANCES TO COMBUSTIBLE MATERIALS POSITION SIDES REAR FRONT...

  • Page 8: Propane Gas Tanks And Piping

    Inlet gas supply pressures must be maintained within the Propane Gas Tanks and Piping ranges specified below. The supply pressure must be constant and available with all other household gas fired WARNING appliances operating. The minimum gas supply pressure must be maintained to prevent unreliable ignition. The Propane gas is heavier than air and any leaking gas can maximum must not be exceeded to prevent unit overfiring.

  • Page 9: Electrical Connections

    ELECTRICAL CONNECTIONS WARNING Wiring Harness Edges of sheet metal holes may be sharp. Use gloves as a The wiring harness is an integral part of this furnace. precaution when removing hole plugs. Wires are color coded for identification purposes. Refer to the wiring diagram for wire routings.

  • Page 10: Junction Box Relocation

    The integrated control module humidifier terminal 120V Junction Box Relocation HUM-H is energized with 115 volts whenever the induced Line voltage connections can be made through either the draft blower is energized. This terminal can also be used right or left side panel. The furnace is shipped configured to provide 115 volt power to a humidifier transformer.
  • Page 11 Thermostat Wiring Diagrams Twinning Two furnaces of the same model may be twinned. The integrated control board has a 3/16” terminal labeled “TWIN” ROOM THERMOSTAT located beside the low voltage thermostat connection strip. Twinning allows simultaneous operation of two furnaces and forces the indoor blower motors of each furnace to INTEGRATED FURNACE Y/Y1...

  • Page 12: System Operation

    SYSTEM OPERATION Inlet gas supply pressures must be maintained within the the LP gas supply pressure is too low to support proper ranges specified in the following table. The supply pressure combustion. must be constant and available with all other household gas fired appliances operating.
  • Page 13 SYSTEM OPERATION • Always use a back-up wrench when making the The gas piping may enter the left or right side of the furnace connection to the gas valve to keep it from turning. cabinet. The installer must supply rigid pipe long enough to The orientation of the gas valve on the manifold must reach the outside of the cabinet to seal the grommet cabinet be maintained as shipped from the factory.
  • Page 14 SYSTEM OPERATION Gas Piping Checks Manual Shut Off Valve (upstream from Before placing unit in operation, leak test the unit and gas Alternate ground joint pipe union) connections. Union Location Check for leaks using an approved chloride-free soap and Drip Leg water solution, an electronic combustible gas detector, or Grommet in other approved testing methods.

  • Page 15: Circulating Air & Filters

    SYSTEM OPERATION Install the duct system in accordance with Standards of the National Board of Fire Underwriters for the Installation 5 to 15 PSIG First Stage (20 PSIG Max.) of Air Conditioning, Warm Air Heating and Ventilating Regulator Continuous 11" W.C. Systems.

  • Page 16: Bottom Return Air Opening [Upflow Models]

    SYSTEM OPERATION NOTE: Both readings may be taken simultaneously and read directly on the manometer if so desired. If an CUT USING TIN SNIPS air conditioner coil or Electronic Air Cleaner is used in PRESS OUT BY HAND conjunction with the furnace, the readings must also include theses components, as shown in the following drawing.
  • Page 17 SYSTEM OPERATION Filter Sizing Charts Clean Comfort™ brand MERV 11 air cleaners have 5¼” media filters and are available in the following Filter Sizing Chart configurations. Consult your distributor for information on Model Minimum Recommended Filter Size our complete line of IAQ Clean Comfort™ products. DM92SN0403AN 1 - 16 X 25 Side or 1 - 14 X 24 Bottom Return DM92SN0603BN...

  • Page 18: Startup Procedure & Adjustment

    SYSTEM OPERATION STARTUP PROCEDURE & ADJUSTMENT Furnace must have a 115 VAC power supply properly connected and grounded. Proper polarity must be maintained for correct operation. In addition to the following start-up and adjustment items, refer to further information in Operational Checks section. Furnace Cabinet Check that all furnace cabinet sealing components are in place (plugs, grommets, gaskets).
  • Page 19 SYSTEM OPERATION 7. If you smell gas after five minutes, immediately follow 2. The control shall rotate available speed number every the safety instructions in the Safety Considerations time Left/Right switches are pressed. Table below on page 2 of this manual. If you do not smell gas shows the available speeds for Low &...

  • Page 20: Furnace Shutdown

    SYSTEM OPERATION   Cooling Mode Sequence of Operation Low Stage Cooling Mode Sequence: THERMOSTAT CALL  AVAILABLE SPEEDS    On a call for low stage cooling, the Y/Y1 or Y/Y1 and G thermostat contacts close signaling the furnace control F01  board with 24 VAC on Y/Y1 or Y/Y1 and G terminals. F02 ...
  • Page 21 ACCESSORIES EXTERNAL FILTER RACK KIT (EFR02) 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 SCREW EFR02 EXTERNAL FILTER RACK KIT 90% Upflow Model Furnaces...
  • Page 22 ACCESSORIES CONCENTRIC VENT CONVERSION KIT (DCVK-20 / CVENT-2) (DCVK-30 / CVENT-3) Vent Maintain 12" (18" for Canada) minimum clearance above highest The DCVK-20 (2") or the DCVK-30 (3") is a concentric vent anticipated snow level. Maximum of 24" above roof. kit approved with furnaces listed in this manual.

  • Page 23: Side Wall Vent Kit

    ACCESSORIES SIDE WALL VENT KIT (0170K00000S / 0170K00001S) Description These side wall only vent kits are to be used with 2” - 3” vent systems. These kits are NOT intended for use with single pipe (indirect vent) installations. These vent kits must terminate outside the structure and may be installed with the intake and exhaust pipes located side-by-side or with one pipe above the other.
  • Page 24 SERVICING *NOTE: For flame rectification the common side of As more and more electronic's are introduced to the Heating Trade, Polarization of incoming power and phasing the secondary voltage (24 V) is cabinet grounded. of primary to secondary voltage on transformers becomes If you were to bench test a transformer the more important.

  • Page 25: Condensate Drainage

    SERVICING Combustion Quality GAS RATE -- CUBIC FEET PER HOUR Combustion quality can be affected by several factors. Size of Test Dial Seconds for Major factors are venting and draining. Revolution cu/ft cu/ft cu/ft cu/ft cu/ft Venting 1800 The venting system should be planned and installed with 1636 the following in mind: 1500...

  • Page 26: Troubleshooting

    TROUBLESHOOTING Unsatisfactory Service Problem No Heat Heat POSSIBLE CAUSE Test Method DOTS IN ANALYSIS Remedy GUIDE INDICATE "POSSIBLE CAUSE" • Pow er Failure Test Voltage • Blow n Fuse Test Voltage • Loose Connection Check Wiring • Shorted or Broken Wires Check Wiring S-3A •...

  • Page 27: Checking Transformer And Control Circuit

    SERVICING SERVICE NUMBERS 4. With ample voltage at line voltage connectors, energize the furnace blower motor by jumpering terminals R to G on the integrated ignition control. Checking Voltage..........27 5. With the blower motor in operation, the voltage should Checking Wiring............27 be 115 volts ±...

  • Page 28: S-10B Capacitance Check

    SERVICING S-16A Checking Air Circulator Blower Motor 1. Remove blower compartment door to gain access to the thermostat low voltage wires located at the furnace integrated control module. WARNING 2. Remove the thermostat low voltage wires at the furnace integrated control module terminals. Disconnect ALL power before servicing.
  • Page 29 SERVICING S-200 Checking Duct Static S-201 Checking Temperature Rise The maximum and minimum allowable external static The more air (CFM) being delivered through a given pressures are found in the specification section. These furnace, the less the rise will be; so the less air (CFM) tables also show the amount of air being delivered at a being delivered, the greater the rise.

  • Page 30: S-301 Checking Auxiliary Limit Control

    SERVICING PRIMARY LIMIT CONTROL VOLT / OHM METER Primary Limit Control Location (90% Upflow Furnace Shown, Counterflow COLOR Similar) IDENTIFYING The following drawing illustrates the style of limit switches Testing Primary Limit Control used on the 90% furnaces. (90% Furnaces) 4.

  • Page 31: Checking Flame Rollout Control

    SERVICING The control is designed to open should a flame roll out occur. An over firing condition or flame impingement on the heat shield may also cause the control to open. If the rollout control opens, the air circulation blower will run continuously.

  • Page 32: Induced Draft Blower Motor

    SERVICING S-303 Induced Draft Blower Motor The main burners are used to provide complete combustion of various fuels in a limited space, and transfer WARNING this heat of the burning process to the heat exchanger. Proper ignition, combustion, and extinction are primarily due to burner design, orifice sizing, gas pressure, primary HIGH VOLTAGE Disconnect ALL power before servicing or in-...

  • Page 33: Checking Gas Pressure

    SERVICING 1. After turning off gas to furnace at the manual gas shutoff valve external to the furnace, remove burner WARNING compartment door to gain access to the gas valve. 2. Connect a calibrated water manometer (or appropriate Disconnect ALL Gas and Electric Power Supply. gas pressure gauge) at either the gas valve inlet 1.

  • Page 34: Gas Manifold Pressure Measurement And Adjustment

    SERVICING WARNING WARNING HIGH VOLTAGE Line Voltage now present. Disconnect ALL power before servicing or in- 3. Turn ON the gas and electrical power supply and stalling this unit. Multiple power sources may be present. Failure to do so may cause proper- operate the furnace.
  • Page 35 SERVICING Remove regulator cover screw from the Manifold Gas Pressure outlet pressure regulator adjust tower and turn screw clockwise to increase pressure or Rate Range Nominal counterclockwise to decrease pressure. Replace High Stage 9.7 to 10.3" w.c. 10.0" w.c. Propane Gas regulator cover screw.

  • Page 36: Natural Gas

    S-308A Checking Hot Surface Ignitor shown in the following figures. 120V Silicon Nitride Igniter - Daikin Brand model furnaces 4. With an ohm meter connected across the pressure use a 120V silicon nitride igniter for ignition. The normal switch terminals;...

  • Page 37: Checking Integrated Ignition Control Boards

    SERVICING 1. Improper gas pressure - adjust to proper pressure No voltage, check for loose connection in the 2-pin (See S-307 Checking Gas Pressure). connector or replace ignition control. 2. Improper burner positioning - burners should be in 4. If voltage is present in Steps 1 through 3 and the locating slots, level front to rear and left to right.

  • Page 38: Maintenance

    MAINTENANCE WARNING WARNING HIGH VOLTAGE HIGH VOLTAGE Disconnect ALL power before servicing or in- Disconnect ALL power before servicing, stalling this unit. Multiple power sources may removing the filter or performing any other be present. Failure to do so may cause proper- maintenance.

  • Page 39: Flame Sensor (Qualified Servicer Only)

    MAINTENANCE Condensate Drainage System (Qualified Servicer Only) The drain tubes, standpipe, and field supplied drain line must be checked annually and cleaned as often as necessary to ensure proper condensate drainage. Check the Burner Flames for: Flame Sensor (Qualified Servicer Only) 1.
  • Page 40 - 1.48 0130F00477 DC96SN1205DNAA - 0.10 ± .05 - 0.25 - 0.85 ± .05 - 1.00 0130F00476 DM92SN Pressure Switch Trip Points And Usage Chart COIL COVER COIL COVER ID BLOWER ID BLOWER ID BLOWER Set Point on Max Make...

  • Page 41: Menu Description

    1 STAGE STATUS CODES LED Display Menu Description Notes Main Option Menu Menu ( xx: code numbers ) Active Alaram menu   xx ( xx: code numbers ) Last 6 Faults  xx Code Release Number CR Number  yes, no Reset to Factory Default ...

  • Page 42: Status Menu

    1 STAGE STATUS CODES STATUS MENU Main Mode Menu Idle  Continous Fan  Compressor Cooling, Low  Stage Compressor Cooling, High  Stage Gas heat - Single Stage  Control OEM test Mode  ...

  • Page 43: Troubleshooting Chart

    1 STAGE TROUBLESHOOTING CODES TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions Status Normal operation Normal operation None   Locate and correct gas interruption Replace or realign igniter Furnace lockout due to an excessive number Check flame sense signal, clean sensor if coated or of ignition “retries”...
  • Page 44 1 STAGE TROUBLESHOOTING CODES TROUBLESHOOTING CHART Symptom Fault Description Corrective Actions Status Flame sense micro amp signal is minimal Clean flame sensor if coated or oxidized Inspect for proper Flame sensor is coated/oxidized flame sensor alignment Flame sensor incorrectly positioned in burner Normal furnace operation ...
  • Page 45 AIRFLOW CHARTS - DC96SN LOW STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL F04^ DC96SN0403B* Y/Y1 1106 1076 1044 1010 1156 1125 1096 1063 1028 1237 1205 1174 1145 1115 1081 1050 1016 1334 1306 1275 1249...
  • Page 46 Airflow Charts - DC96SN HIGH STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL DC96SN0403B* F05^ 1106 1076 1044 1010 1156 1125 1096 1063 1028 1237 1205 1174 1145 1115 1081 1050 1016 1334 1306 1275 1249 1220...
  • Page 47 Airflow Charts - DC96SN CIRCULATION AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL DC96SN0403B* 1106 1076 1044 1010 1156 1125 1096 1063 1028 1237 1205 1174 1145 1115 1081 1050 1016 1334 1306 1275 1249 1220 1194 1163 1136...
  • Page 48 Airflow Charts - DC96SN HEATING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT TEMP MODEL TAP # CALL RANGE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM F01^^ 632 F02^ DC96SN0403B* W/W1 35-65 F01^^ 771 F02^ 1197 1150 1102...
  • Page 49 Airflow Charts - DM92SN LOW STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL F04^ DM92SN0403A* Y/Y1 1038 1003 1106 1072 1041 1011 1215 1180 1151 1121 1095 1066 1043 1017 1238 1210 1180 1153...
  • Page 50 Airflow Charts - DM92SN LOW STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1754 1707 1673 1640 1604 1568 1538 1509 1648 1620 1586 1552 1515 1480 1449 1412 F04^ 1558 1517 1479 1441...
  • Page 51 Airflow Charts - DM92SN HIGH STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL DM92SN0403A* F05^ 1038 1003 1106 1072 1041 1011 1215 1180 1151 1121 1095 1066 1043 1017 1238 1210 1180 1153 1126...
  • Page 52 Airflow Charts - DM92SN HIGH STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1754 1707 1673 1640 1604 1568 1538 1509 1648 1620 1586 1552 1515 1480 1449 1412 1558 1517 1479 1441 1403...
  • Page 53 Airflow Charts - DM92SN CIRCULATION AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL DM92SN0403A* 1038 1003 1106 1072 1041 1011 1215 1180 1151 1121 1095 1066 1043 1017 1238 1210 1180 1153 1126 1099 1073 1047...
  • Page 54 Airflow Charts - DM92SN CIRCULATION AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1754 1707 1673 1640 1604 1568 1538 1509 1648 1620 1586 1552 1515 1480 1449 1412 1558 1517 1479 1441 1403 1366 1330...
  • Page 55 Airflow Charts - DM92SN HEATING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT TEMP MODEL TAP # CALL RANGE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM F01^^ 610 559 N/A 513 N/A 467 N/A...
  • Page 56 Airflow Charts - DM96SN LOW STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1079 1055 1027 F04^ DM96SN0403A* Y/Y1 1135 1106 1078 1049 1021 1189 1163 1138 1111 1085 1059 1032 1001 1266 1243 1218 1197 1172...
  • Page 57 Airflow Charts - DM96SN LOW STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1029 1814 1766 1722 1679 1637 1595 1555 1511 1893 1844 1803 1763 1723 1685 1641 1604 F04^ 1738 1680 1637 1596 1554 1510...
  • Page 58 Airflow Charts - DM96SN HIGH STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1079 1055 1027 DM96SN0403A* F05^ 1135 1106 1078 1049 1021 1189 1163 1138 1111 1085 1059 1032 1001 1266 1243 1218 1197 1172 1148...
  • Page 59 Airflow Charts - DM96SN HIGH STAGE COOLING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1029 1814 1766 1722 1679 1637 1595 1555 1511 1893 1844 1803 1763 1723 1685 1641 1604 1738 1680 1637 1596 1554 1510 1469...
  • Page 60 Airflow Charts - DM96SN CIRCULATION AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1079 1055 1027 DM96SN0403A* 1135 1106 1078 1049 1021 1189 1163 1138 1111 1085 1059 1032 1001 1266 1243 1218 1197 1172 1148 1123 1099 1313...
  • Page 61 Airflow Charts - DM96SN CIRCULATION AIRFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT MODEL TAP # CALL 1029 1814 1766 1722 1679 1637 1595 1555 1511 1893 1844 1803 1763 1723 1685 1641 1604 1738 1680 1637 1596 1554 1510 1469 1420 DM96SN0805C*...
  • Page 62 Airflow Charts - DM96SN HEATING AIFLOW EXTERNAL STATIC PRESSURE, (INCHES WATER COLUMN) THERMOSTAT TEMP MODEL TAP # CALL RANGE CFM RISE CFM RISE CFM RISE CFM RISE CFM RISE CFM CFM CFM F01^^ 705 N/A 661 N/A 617 N/A 564 N/A 509 N/A 455 F02^ 1079 1055...

  • Page 63: Wiring Diagram

    WIRING DIAGRAM DM92SN, DM96SN, & DC96SN POWER BEFORE PROPERLY POLARIZED 40 VA TRANSFORMER TH (3) RLI (12) HLO (1) PS1(5) READ CODES FROM LEFT TO RIGHT HLI (8) MV (10) MVC (11) TR (7) W/W1 R Y/Y1 Y2 ECM MTR...

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