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Daikin 80% Single Stage Gas Furnaces
O
NLY PERSONNEL THAT HAVE BEEN TRAINED TO INSTALL
(
, "
OR REPAIR
HEREINAFTER
SERVICE
MANUAL SHOULD SERVICE THE EQUIPMENT
BE RESPONSIBLE FOR ANY INJURY OR PROPERTY DAMAGE ARISING FROM
IMPROPER SERVICE OR SERVICE PROCEDURES
YOU ASSUME RESPONSIBILITY FOR ANY INJURY OR PROPERTY DAMAGE
. I
WHICH MAY RESULT
N ADDITION
MORE LICENSES TO SERVICE THE EQUIPMENT SPECIFIED IN THIS MANUAL
ONLY LICENSED PERSONNEL SHOULD SERVICE THE EQUIPMENT
,
,
INSTALLATION
ADJUSTMENT
SERVICING OR REPAIR OF THE EQUIPMENT
,
SPECIFIED IN THIS MANUAL
OR ATTEMPTING TO INSTALL
OR REPAIR THE EQUIPMENT SPECIFIED IN THIS MANUAL WITHOUT PROPER
TRAINING MAY RESULT IN PRODUCT DAMAGE
.
PERSONAL INJURY OR DEATH
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 supercede manufacturers installation and operation instructions.
Service Instructions
DM80SE, DC80SE
& Accessories
,
ADJUST
")
THE EQUIPMENT SPECIFIED IN THIS
. T
HE MANUFACTURER WILL NOT
. I
F YOU SERVICE THIS UNIT
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IN JURISDICTIONS THAT REQUIRE ONE OR
. I
,
ADJUST
,
PROPERTY DAMAGE
Our continuing commitment to quality products may mean a change in specifications without notice.
©2019
19001 Kermier Rd., Waller, TX 77484
www.daikincomfort.com
FOR CALIFORNIA CONSUMERS
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SERVICE
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MPROPER
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PROP 65 WARNING
Cancer and Reproductive Harm
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0140M00517-A
RSD6621006r1
December 2019
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Summary of Contents for Daikin DM80SE
- Page 1 PERSONAL INJURY OR DEATH 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.
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Page 2: Table Of Contents
TABLE OF CONTENTS IMPORTANT INFORMATION ......2 - 4 POLARIZATION and PHASING ......23 PRODUCT IDENTIFICATION ......5-7 MAINTENANCE ...........24 - 25 ACCESSORIES ..........8-9 SERVICING ..........26 - 41 OPERATING INSTRUCTIONS ......13 SERVICING TABLE OF CONTENTS ....28 PRODUCT DESIGN .......... 18 SCHEMATICS ............ -
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 PRODUCTS TOLL FREE 1-877-254-4729 (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 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. CO can cause serious illness including permanent brain El monóxido de carbono puede causar enfermedades severas damage or death.
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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. 0 6 0 7 8 9 Brand Minor Revision D - Daikin A - Initial Release B - 1st Revision Configuration M - Upflow/Horizontal Major Revision... - Page 6 PRODUCT IDENTIFICATION MODEL # 80% GAS FURNACES DM80SE0403A* DAIKIN 80% SINGLE STAGE GAS FURNACE, FOR INSTALLATION IN UPFLOW / HORIZONTAL DM80SE0603A* LEFT OR RIGHT. SILICON NITRIDE IGNITER. MULTISPEED ECM BLOWER MOTOR, STAINLESS DM80SE0604B* STEEL TUBULAR HEAT EXCHANGER. COMES IN 4 CHASSIS SIZES "A" = 14" , "B" = 17.5" , "C" = DM80SE0803B* 21"...
- Page 7 White-Rodgers and Honeywell single stage valves. The conversion from natural gas (as shipped from the factory) to propane gas require Masonry Vent Kit. For use with Daikin 80% AFUE, 33" tall "H" and "S" model furnaces installed in the MVK-01A upflow position only and will only be used with interior masonry chimneys.
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Page 8: Accessories
ACCESSORIES DAIKIN DM80SE DC80SE Model Furnace Accessories MODEL NUMBER · · · · · DM8 0 S E0 4 0 3 AX ** (2 ) · · · · · DM8 0 S E0 6 0 3 AX ** (2 ) ·... - Page 9 ACCESSORIES EXTERNAL FILTER RACK KIT ( EFR01 ) 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 EFR01 EXTERNAL FILTER RACK KIT...
- Page 10 ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 24VAC POWER SUPPLY P1-8 +VDC INPUT POWER +5VDC FURNACE DEMAND P1-7 W1-FURN...
- Page 11 ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. FURNACE TWINING KIT - FTK04 (UTEC Control Board) This wiring diagram is for reference only.
- Page 12 ACCESSORY WIRING DIAGRAMS HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. JACKSON SYSTEMS THERMOSTAT GAS / ELECTRIC UNIVERSAL TWINNING KIT SWITCH MUST BE SET IN THE ELECTRIC POSITION PATENT PENDING...
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Page 13: Operating Instructions
OPERATING INSTRUCTIONS FOR YOUR SAFETY READ BEFORE OPERATING WARNING : Improper installation, adjustment, alteration, service or maintenance can cause injury WARNING : If you do not follow these instructions or property damage. Refer to the user’s information manual provided with this furnace. For assistance exactly, a fire or explosion may result causing property or additional information consult a qualified damage, personal injury or loss of life. - Page 14 Daikin 80% furnaces are ETL certified appliances and are Safety appropriate for use with natural or propane gas. (NOTE: If Please adhere to the following warnings and cautions when using propane gas, a propane conversion kit is required). installing, adjusting, altering, servicing, or operating the fur- IMPORTANT NOTE: The 80% furnace cannot be installed nace.
- Page 15 Propane Gas and/or High Altitude Installations GAS VALVE This unit is equipped with a 24 volt gas valve controlled dur- ing furnace operation by the integrated control module. As WARNING shipped, the valve is configured for natural gas. The valve is field convertible for use with propane gas by using the ap- OSSIBLE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH MAY OCCUR IF propriate propane gas conversion kit.
- Page 16 NOTE: Wire routing must not interfere with circulator blower ELECTRICAL CONNECTIONS operation, filter removal, or routine maintenance. WARNING WARNING O AVOID THE RISK OF ELECTRICAL SHOCK, WIRING TO THE UNIT MUST BE O AVOID THE RISK OF ELECTRICAL SHOCK, INJURY, OR DEATH, THE PROPERLY POLARIZED AND GROUNDED.
- Page 17 5. Heating speed can be adjusted by adjusting S2-1, S2-2 DM80SE MODELS (see Heating airflow Chart). DM80SE furnaces require installer provision of a return air 6. Circulation / Continuous Fan speed can be adjusted by filter located on the side or bottom of the furnace or a cen- adjusting S2-3, S2-4 (see Circulation airflow Chart).
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Page 18: Product Design
PRODUCT DESIGN NORMAL SEQUENCE OF OPERATION continuously. 6. R and Y thermostat contacts open, completing the OWER call for cool. 1. 115 VAC power applied to furnace. 7. Outdoor fan and compressor are de-energized. 2. Integrated ignition control module performs internal checks. 8. -
Page 19: System Operation
SYSTEM OPERATION HEATING - Abnormal Operation disconnected hose to the pressure switch, faulty pres- sure switch or wiring, or restricted air intake or flue The following presents the probable causes of question- piping. able furnace operation and how to fix them. Look through 5. -
Page 20: Troubleshooting
TROUBLESHOOTING PCBBF145(S) CONTROL BOARD ROUBLESHOOTING HART Associated Symptoms of Abnormal Operation Fault Description(s) Possible Causes Corrective Action Cautions and Notes LED Code • Furnace fails to operate. • No 115 volt power • Manual disconnect • Assure 115 and 24 volt •... - Page 21 TROUBLESHOOTING PCBBF145(S) CONTROL BOARD ROUBLESHOOTING HART Associated Symptoms of Abnormal Operation Fault Description(s) Possible Causes Corrective Action Cautions and Notes LED Code • Induced draft blower runs • Pressure switch circuit • Pressure switch hose • Inspect pressure switch • Turn power OFF prior continuously with no further not closed.
- Page 22 TROUBLESHOOTING PCBBF145(S) CONTROL BOARD ROUBLESHOOTING HART Associated Symptoms of Abnormal Operation Fault Description(s) Possible Causes Corrective Action Cautions and Notes LED Code • Furnace not operating. • Igniter Relay Fault •Improperly connected •Check and correct • Turn power OFF prior •...
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Page 23: Polarization And Phasing
POLARIZATION AND PHASING INCOMING POWER As more and more electronic's are introduced to the Heat- METER READS METER READS ing Trade, Polarization of incoming power and phasing 120 VOLTS 0 VOLTS of primary to secondary voltage on transformers becomes more important. VOLT / OHM VOLT / OHM Polarization has been apparent in the Appliance industry... -
Page 24: Maintenance
MAINTENANCE INDUCED DRAFT AND CIRCULATION BLOWERS CAUTION The bearings in the induced draft blower and circulator blower motors are permanently lubricated by the manufac- F YOU MUST HANDLE THE ITNITOR, HANDLE WITH CARE. OUCHING turer. No further lubrication is required. Check motor wind- THE IG NITOR BODY WITH BARE FINGERS, ROUG H HANDLING, OR ings for accumulation of dust which may cause overheat- VIBRATIO N COULD RESULT IN EARLY IGNITO R FAILURE. - Page 25 MAINTENANCE HEATING PERFORMANCE TEST The dissipation of the heat transferred to the heat exchanger Before attempting to diagnose an operating fault, run a heat- is now controlled by the amount of air circulated over its ing performance test and apply the results to the Service surface.
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Page 26: Servicing
SERVICING CUBIC FEET GAS RATE -- CUBIC FEET PER HOUR Size of Test Dial Size of Test Dial Seconds for Seconds for cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft cu/ft Revolution Revolution 1800 1636 1500 1385 1286 1200 1125 1059 1000... - Page 27 SERVICING Uns atis factor y Se r vice Pr oble m No He at He at POSSIBLE CAUSE Te st Me thod DOTS IN ANALYSIS Re m e dy GUIDE INDICATE "POSSIBLE CAUSE" • Pow er Failure Test V oltage •...
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Page 28: Servicing Table Of Contents
SERVICING SERVICE NUMBERS CHECKING VOLTAGE ..........................29 CHECKING WIRING ............................ 29 S-3A THERMOSTAT AND WIRING ........................29 S-3B HEATING ANTICIPATOR ..........................29 CHECKING TRANSFORMER AND CONTROL CIRCUIT ................30 S-16 CHECKING AIR CIRCULATOR BLOWER MOTOR ................30 S-200 CHECKING DUCT STATIC ........................... 31 S-201 CHECKING TEMPERATURE RISE ...................... -
Page 29: Checking Voltage
SERVICING S-1 CHECKING VOLTAGE CHECKING THERMOSTAT, WIRING AND ANTICIPATOR WARNING S-3A THERMOSTAT AND WIRING HIGH VOLTAGE WARNING ISCONNECT POWER BEFORE SERVICING OR CHANGING ANY ELECTRICAL WIRING. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE ISCONNECT POWER BEFORE SERVICING. PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. -
Page 30: Checking Transformer And Control Circuit
SERVICING S-16 CHECKING AIR CIRCULATOR BLOWER system is restarted. A properly sized anticipator should main- tain room temperature within 1 1/2 to 2 degrees. MOTOR (MULTI-SPEED ECM) The anticipator is fixed in the subbase and is not to be re- placed. -
Page 31: S-200 Checking Duct Static
SERVICING 2. Measure the static pressure of the supply duct. (Posi- Heat Off Delay (S1-4) tive Pressure) S1-4 Units 3. Add the two (2) readings together for total external *150 Seconds static pressure. Seconds NOTE: Both readings may be taken simultaneously and * = DEFAULT SETTING read directly on the manometer if so desired. -
Page 32: S-300 Checking Primary Limit Control
SERVICING S-300 CHECKING PRIMARY LIMIT CONTROL All use a nonadjustable, automatic reset, bi-metal type limit control. Refer to the following drawing for the location of the SUPPLY primary limit. Location of Primary Limit RETURN Checking Temperature Rise 3. Subtract the return air temperature from the supply air temperature to determine the air temperature rise. -
Page 33: Checking Auxiliary Limit Control
SERVICING VOLT / OHM METER RESET BUTTON COLOR IDENTIFYING Testing Primary Limit Control Testing Auxiliary Limit Control S-301 CHECKING AUXILIARY LIMIT CONTROL WARNING O AVOID POSSIBLE FIRE, ONLY RESET THE AUXILIARY LIMIT CONTROL ONCE. F IT SHOULD OPEN A SECOND TIME, A QUALIFIED SERVICER MUST DETERMINE WHY THE AUXILIARY LIMIT OPENED BEFORE BLOWER HOUSING RESETTING AGAIN. -
Page 34: S-303 Induced Draft Blower Motor
SERVICING not the other it indicates the control is open. Flame Rollout Switch Location c. If voltage is measured on both sides of the control (80% Upflow Furnace Shown, Downflow Similar) the wiring to gas valve or valve is at fault. 3. -
Page 35: S-305 Checking Main Burners
SERVICING S-305 CHECKING MAIN BURNERS The main burners are used to provide complete combustion of various fuels in a limited space, and transfer 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 STREAM B and secondary air, vent and proper seating of burners. - Page 36 SERVICING NOTE: At either location, a hose fitting must be installed Gas Manifold Pressure Measurement and Ad- prior to making the hose connection. justment NOTE: Use apapter kit #0151K00000S to measure gas pres- sure on White-Rodgers 36J22. n a c e CAUTION GAS LINE O PREVENT UNRELIABLE OPERATION OR EQUIPMENT DAMAGE, THE...
- Page 37 SERVICING 8. Turn on electrical power and verify proper unit operation. b. Attach a hose and manometer to the outlet pressure outlet pressure boss. Gas Valve c. Turn ON the gas supply. On/Off d. Turn on power and close thermostat “R” and “W” con- Selector Inlet Pressure Switch...
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Page 38: S-308 Checking Hot Surface Ignitor
SERVICING S-308 CHECKING HOT SURFACE IGNITOR S-310 CHECKING PRESSURE SWITCH 120V Mini Igniter Single Stage - furnaces use a 120V car- The pressure switch a safety device to prevent the combus- bide mini igniter for ignition. The normal operating tempera- tion cycle from occurring with inadequate venting caused by a ture is approximately 2550°F - 2876°F. -
Page 39: S-311 High Altitude Application (Usa)
SERVICING S-311 HIGH ALTITUDE APPLICATION (USA) The ground wire must run from the furnace all the way back to the electrical panel. Proper grounding can be confirmed The furnace as shipped requires no change to run between by disconnecting the electrical power and measuring resis- 0 - 5500 feet. -
Page 40: S-314 Checking Flame Sensor
SERVICING Control & Flame Sensor Probe (80% Upflow Model Shown, Counterflow Similar) WARNING HIGH VOLTAGE ISCONNECT POWER BEFORE SERVICING OR INSTALLING THIS UNIT. ULTIPLE POWER SOURCES MAY BE PRESENT. AILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1. - Page 41 SERVICING DM80SE / DC80SE Pressure Switch Trip Points And Usage Chart ID BLOWER Set Point on Max Make MODEL Pressure Pressure Fall (PF) Pressure On Rise Switch Part# W.C. W.C. DM80SE0403A* -0.70 ±0.06 -0.85 0130F00505 DM80SE0603A* -0.75 ±0.07 -0.90 0130F00506 DM80SE0604B* -0.75 ±0.07...
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Page 42: Schematics
IGNITOR VALVE PRESSURE SWITCH TYPICAL SCHEMATIC DM80SE * MODEL FURNACES WR 50T55-289 INTEGRATED IGNITION CONTROL This schematic is for reference only. Not all wiring is as shown above. Always refer to the appropriate wiring diagram for the unit being serviced. -
Page 43: Wiring Diagrams
WIRING DIAGRAMS PCBBF145 CONTROL BOARD HIGH VOLTAGE! DISCONNECT ALL POWER BEFORE SERVICING OR INSTALLING THIS UNIT. MULTIPLE POWER SOURCES MAY BE PRESENT. FAILURE TO DO SO MAY CAUSE PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. Wiring is subject to change, always refer to the wiring diagram on the unit for the most up-to-date wiring.